Modular drive system for electric fracturing sled

Abstract

The application discloses a modular drive system for electric fracturing pry, which is used for driving the electric fracturing pry and comprises a vehicle controller, a plurality of control units and the same number of drive motors as the control units, the vehicle controller synchronously starts the corresponding control units according to the required driving power of the current electric fracturing pry and preset selection rules, so that the motor driver of the control unit drives the drive motor connected therewith, the drive motors in operation run at the same speed and transmit torque through a gear set, and then drive the electric fracturing pry. The modular drive system for electric fracturing pry is linked through a flange, a control unit and a drive motor, the controller and the drive motor are connected through a cable, a drive system for fracturing pry is formed, and the number of the drive motors and the controller needs to be adjusted according to different application scenarios.

Description

Technical Field

[0001] This invention belongs to the field of fracturing skid drive technology, specifically relating to a modular drive system for an electric fracturing skid. Background Technology

[0002] Traditional fracturing skids use diesel engines for their drive systems, which generate tremendous noise and emit large amounts of exhaust gas during operation, causing serious pollution to human health and the environment.

[0003] With the development of new energy sources, electric-driven fracturing skids are becoming increasingly popular in the market due to their advantages such as less pollution and lower noise. However, the size requirements for fracturing equipment vary depending on the scale of oil and gas exploration. Equipment with different power ratings requires different drive motors, ultimately leading to incompatibility of parts. Each set of equipment requires redesigned mounting flanges and recalibration, significantly increasing manufacturing costs and efficiency.

[0004] Therefore, further improvements will be made to address the aforementioned issues. Summary of the Invention

[0005] The main objective of this invention is to provide a modular drive system for electric fracturing skids. This system is interconnected through a flange, a control unit, and a drive motor. The controller is connected to the drive motor via a cable to form a fracturing skid drive system. Depending on the application scenario, only the number of drive motors and controllers needs to be adjusted. Furthermore, when the drive motor malfunctions, the faulty motor can be directly removed from the mounting flange and replaced with a working one, thus improving after-sales efficiency.

[0006] To achieve the above objectives, the present invention provides a modular drive system for an electric fracturing skid, used to drive the electric fracturing skid, comprising a vehicle controller, several control units, and a number of drive motors equal to the number of control units, wherein:

[0007] The vehicle controller synchronously starts the corresponding control unit according to the driving power required by the electric fracturing skid and according to the preset selection rules, so that the motor driver of the control unit drives the drive motor connected to it. Each working drive motor runs at the same speed and transmits torque through the gear set, thereby driving the electric fracturing skid.

[0008] The preset selection rules are implemented as follows:

[0009] Before formally selecting a control unit, a self-test is performed on each drive motor. The vehicle controller sends a self-test command to each control unit so that the motor driver of all control units drives the drive motor connected to them and feeds back each feedback signal to the vehicle controller. The vehicle controller then determines whether each control unit is controlling the drive motor normally based on the feedback signal. If it is, it outputs a drive qualified signal; otherwise, it outputs a drive fault signal and alarms, and then replaces the faulty drive motor.

[0010] After confirming that there are enough drive motors to be started to meet the driving power of the current electric fracturing skid, the vehicle controller retrieves the cumulative working time of each drive motor to be started, and sorts the drive motors according to the cumulative working time, prioritizing the drive motors with shorter cumulative working time, until the number of selected drive motors meets the driving power of the current electric fracturing skid (to ensure that the cumulative working time of each drive motor is balanced as much as possible, thereby improving the service life of all drive motors).

[0011] As a further preferred technical solution to the above technical solution, each of the drive motors can be detachably installed on the flange. When a drive motor fails, the faulty drive motor is removed from the flange and replaced with a qualified drive motor.

[0012] As a further preferred technical solution to the above technical solution, a threshold for the continuous operating time of the drive motor is set, wherein:

[0013] When the continuous working time of the active drive motor reaches the continuous working time threshold, the vehicle controller stops the drive motor and sorts the remaining inactive drive motors according to their cumulative working time, thereby automatically replacing the drive motor that has reached the continuous working time threshold with the drive motor with the shortest cumulative working time, thus realizing automatic rotation of drive motors.

[0014] As a further preferred technical solution to the above technical solution, an idle time for the drive motor is set. If the drive motor is not started for a long time and reaches the idle time, the vehicle controller sends a short-term operation command to the control unit connected to the drive motor, so that the motor controller can briefly drive the drive motor (to prevent the drive motor from rusting due to prolonged inactivity).

[0015] As a further preferred technical solution to the above technical solution, the modular drive system for electric fracturing skids also includes an alarm indicator light and a buzzer. When the drive motor fails, the vehicle controller drives the alarm indicator light and buzzer to work. Attached Figure Description

[0016] Figure 1This is a schematic diagram of a modular drive system for an electric fracturing skid according to the present invention. Detailed Implementation

[0017] The following description is intended to disclose the present invention and enable those skilled in the art to implement it. The preferred embodiments described below are merely examples, and other obvious variations will occur to those skilled in the art. The basic principles of the invention defined in the following description can be applied to other embodiments, modifications, improvements, equivalents, and other technical solutions that do not depart from the spirit and scope of the invention.

[0018] In the preferred embodiments of the present invention, those skilled in the art should note that the electric fracturing skid and the like involved in the present invention can be considered as prior art.

[0019] Preferred embodiment.

[0020] This invention discloses a modular drive system for an electric fracturing skid, used to drive the electric fracturing skid, comprising a vehicle controller, several control units, and a number of drive motors equal to the number of control units, wherein:

[0021] The vehicle controller synchronously starts the corresponding control unit according to the driving power required by the electric fracturing skid and according to the preset selection rules, so that the motor driver of the control unit drives the drive motor connected to it. Each working drive motor runs at the same speed and transmits torque through the gear set, thereby driving the electric fracturing skid.

[0022] The preset selection rules are implemented as follows:

[0023] Before formally selecting a control unit, a self-test is performed on each drive motor. The vehicle controller sends a self-test command to each control unit so that the motor driver of all control units drives the drive motor connected to them and feeds back each feedback signal to the vehicle controller. The vehicle controller then determines whether each control unit is controlling the drive motor normally based on the feedback signal. If it is, it outputs a drive qualified signal; otherwise, it outputs a drive fault signal and alarms, and then replaces the faulty drive motor.

[0024] After confirming that there are enough drive motors to be started to meet the driving power of the current electric fracturing skid, the vehicle controller retrieves the cumulative working time of each drive motor to be started, and sorts the drive motors according to the cumulative working time, prioritizing the drive motors with shorter cumulative working time, until the number of selected drive motors meets the driving power of the current electric fracturing skid (to ensure that the cumulative working time of each drive motor is balanced as much as possible, thereby improving the service life of all drive motors).

[0025] Specifically, each of the drive motors can be detached and installed on the flange. When a drive motor fails, the faulty drive motor is removed from the flange and replaced with a qualified drive motor.

[0026] More specifically, a threshold for the continuous operating time of the drive motor is set, where:

[0027] When the continuous working time of the active drive motor reaches the continuous working time threshold, the vehicle controller stops the drive motor and sorts the remaining inactive drive motors according to their cumulative working time, thereby automatically replacing the drive motor that has reached the continuous working time threshold with the drive motor with the shortest cumulative working time, thus realizing automatic rotation of drive motors.

[0028] Furthermore, the idle time of the drive motor is set. If the drive motor is not started for a long time and reaches the idle time, the vehicle controller sends a short-run command to the control unit connected to the drive motor so that the motor controller can briefly drive the drive motor (to prevent the drive motor from rusting due to long-term inactivity).

[0029] Furthermore, the modular drive system for electric fracturing skids also includes an alarm indicator light and a buzzer. When the drive motor fails, the vehicle controller activates the alarm indicator light and buzzer.

[0030] Preferably, for equipment with different power ratings, the number and combination of drive motors can be adjusted to meet different needs. For example, the power of a single motor P1 can be used to obtain the final equipment power kP1 according to the requirements. Adjusting k can yield fracturing skid equipment with different power levels to meet the needs of different scenarios.

[0031] Preferably, according to the number k of drive motors, the same number k controllers (MCUs) are matched, and the vehicle controller (VCU) controls the multiple motor controller MCUs synchronously to achieve synchronous speed operation of multiple motors and realize the modularization of motor controllers.

[0032] It is worth mentioning that the technical features such as the electric fracturing skid involved in this patent application should be regarded as prior art. The specific structure, working principle, and possible control methods and spatial arrangement of these technical features can be adopted using conventional choices in the field, and should not be regarded as the inventive point of this patent. This patent will not be further elaborated in detail.

[0033] For those skilled in the art, modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this invention should be included within the protection scope of this invention.

Claims

1. A modular drive system for an electric fracturing sled for driving an electric fracturing sled, characterized in that, It includes a vehicle controller, several control units, and a number of drive motors equal to the number of control units, wherein: The vehicle controller synchronously starts the corresponding control unit according to the driving power required by the electric fracturing skid and according to the preset selection rules, so that the motor driver of the control unit drives the drive motor connected to it. Each working drive motor runs at the same speed and transmits torque through the gear set, thereby driving the electric fracturing skid. The preset selection rules are implemented as follows: Before formally selecting a control unit, a self-test is performed on each drive motor. The vehicle controller sends a self-test command to each control unit so that the motor driver of all control units drives the drive motor connected to them and feeds back each feedback signal to the vehicle controller. The vehicle controller then determines whether each control unit is controlling the drive motor normally based on the feedback signal. If it is, it outputs a drive qualified signal; otherwise, it outputs a drive fault signal and alarms, and then replaces the faulty drive motor. After confirming that there are enough drive motors to be started to meet the driving power of the current electric fracturing skid, the vehicle controller retrieves the cumulative working time of each drive motor to be started, and sorts the drive motors according to the cumulative working time, prioritizing the drive motors with shorter cumulative working time, until the number of selected drive motors meets the driving power of the current electric fracturing skid. Set the threshold for the continuous operating time of the drive motor, where: When the continuous working time of the working drive motor reaches the continuous working time threshold, the vehicle controller stops the drive motor and sorts the remaining non-working drive motors according to their cumulative working time, thereby automatically replacing the drive motor that has reached the continuous working time threshold with the drive motor with the shortest cumulative working time, thus realizing automatic rotation of drive motors. The idle time of the drive motor is set. If the drive motor is not started for a long time and reaches the idle time, the vehicle controller sends a short-run command to the control unit connected to the drive motor so that the motor controller can briefly drive the drive motor.

2. A modular drive system for an electric fracturing pry according to claim 1, wherein, Each of the drive motors can be detached and installed on the flange. When a drive motor fails, the faulty drive motor is removed from the flange and replaced with a qualified drive motor.

3. A modular drive system for an electric fracturing pry according to claim 2, wherein, The modular drive system for electric fracturing skids also includes an alarm indicator light and a buzzer. When the drive motor fails, the vehicle controller drives the alarm indicator light and buzzer to operate.

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