Power consumption statistics and power regulation control method for electrically driven slurry pump

Abstract

The invention discloses an electric drive slurry pump power consumption statistics and power regulation control method, and relates to the technical field of non-excavation electric drive slurry pumps, the electric drive slurry pump power consumption statistics and power regulation control method comprises a display, a vehicle control unit and a motor controller, the display is connected with the vehicle control unit through a bus, and the vehicle control unit is connected with the motor controller through a bus. According to the method, the real-time current and voltage of electric control of the motor are collected in a millisecond level through a bus message by a vehicle control unit, then millisecond level power is accumulated, the accumulated power consumption value is sent to a vehicle display through a bus message to be read by a client, and due to the design, an additional current transformer and a power meter are not added, and the cost is reduced. Harm to human bodies caused by disconnection, open circuit and high voltage of the current transformer is safely avoided.

Description

Technical Field

[0001] The invention relates to the technical field of trenchless electric-driven mud pumps, and in particular to a method for counting power consumption and regulating power of an electric-driven mud pump. Background Art

[0002] Trenchless technology is widely used in pipeline laying in the fields of oil and gas transportation, water supply, sewage, electricity, communications, etc. It can greatly alleviate many problems caused by traditional excavation operations, such as traffic congestion, ground damage, construction noise, etc. With the development of the economy, the electric-driven mud pumps supporting trenchless drilling rigs will play an increasingly important role in infrastructure construction. The electric-driven mud pumps in the trenchless field are new products developed in the past two years and use green electricity as power.

[0003] However, there is no mature reference for iterative application of power consumption statistics and regulation control technology for this product. Therefore, the present invention designs a power statistics and regulation control system based on the special requirements of electric-driven mud pumps in the trenchless field: strong mobility, compact equipment space, digital control of permanent magnet synchronous motors, and power supply from AC power or generators. Summary of the invention

[0004] In view of the deficiencies in the prior art, the present invention provides a method for statistically analyzing power consumption and regulating power of an electric-driven mud pump, which solves the problems raised in the background technology.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solutions: a method for power consumption statistics and power regulation control of an electric-driven mud pump, comprising a display, a vehicle controller and a motor controller, the display is connected to the vehicle controller through a bus, and the vehicle controller is connected to the motor controller through a bus;

[0006] Preferably, the method is as follows:

[0007] S1. Establishment of communication bottom layer: CODESYS programming is required to accurately establish the communication bottom layer; during power-on initialization, the system will execute a series of steps including hardware detection, firmware check, configuration loading, system setting, safe startup, and module initialization to ensure stable operation of the system; S2. Power consumption statistics and power regulation: For the vehicle controller, it is necessary to realize the function of calculating instantaneous power at millisecond level and accurately accumulating the power consumption of the whole vehicle; the data acquisition system monitors the output frequency and current of the inverter in real time to calculate the power consumption;

[0008] S3.PID closed-loop control: PID closed-loop control algorithm is used to adjust the output power of the electric-driven mud pump; the PID controller dynamically adjusts the output of the inverter according to the given request speed and maximum torque value to meet the working requirements of the mud pump; improves the response speed and stability of the system to ensure that the output power of the mud pump matches the actual working conditions; S4. Stability analysis of the control system: When designing the control system, the stability of the DC motor control system needs to be considered, including the analysis and improvement of the interference of the given signal of the handwheel in the control room, the stability of the PLC program design, the stability of the DC drive control system, and the interference factors of the communication cable;

[0009] S5. Selection and matching of inverter and motor: Select the appropriate inverter and motor matching system, select the motor with appropriate rated power and torque according to the displacement and maximum input power of the mud pump, and ensure that the inverter can provide sufficient output to drive the motor; S6. System integration and debugging: After the electric drive system is integrated, debugging is required to ensure that the various components work together to achieve stable operation of the mud pump, including the connection of power lines, control lines and communication lines, as well as solving the problems of room structure, MCC cabinet and inverter cabinet installation and communication interference.

[0010] Preferably, the specific steps for power-on initialization in CODESYS are as follows:

[0011] Hardware detection: The system checks whether the hardware connection is correct, including the connection of CPU, I / O modules, and memory components; Firmware check: The system will confirm whether the firmware version is the latest; if there is an update, the system prompts the user to update the firmware to ensure that the system runs the latest version of the firmware to obtain the best performance and security; Configuration loading: If there is a predefined configuration file, the system loads the configuration at startup and configures it as the default configuration or a user-defined configuration to quickly enter the working state; System settings: Perform basic time, date, and network parameter settings; Secure startup: Ensure that no unauthorized code is executed; including checking signatures and authorization information to ensure the security of the system; Module initialization: Initialize the functional modules on the controller according to the configuration, such as PLC programs, device drivers, and communication modules; Operation preparation: After completing all necessary initialization, the system enters the operation mode, at which time the system waits for user interaction or executes predefined tasks, ready to start normal working procedures.

[0012] Preferably, the calculation of power consumption in S2 requires data collection, which is accomplished by connecting sensors and using a data acquisition system to obtain accurate current and voltage values, wherein power calculation: the instantaneous power calculation formula is as follows:

[0013] P(t)=V m ×I m ×cos(ωt+αv )×cos(ωt+α i )

[0014] Where P(t) is the instantaneous power, V m is the maximum voltage, I m is the maximum current, ω is the angular frequency, t is the time, α v and α i are the phase angles of voltage and current respectively.

[0015] Preferably, the millisecond-level calculation in S2 needs to ensure that the frequency of data acquisition and processing is high enough to ensure that power calculation can be performed at the end of each time interval (such as 1 millisecond), where the sampling frequency should be at least twice the signal frequency. When the highest signal frequency is 600Hz, the sampling frequency is set to ≥1400Hz.

[0016] Preferably, the vehicle power consumption in S2 is obtained by integrating the instantaneous power or accumulating the power consumption within a certain time interval. When the integration method is adopted, it is calculated by the following formula:

[0017] E total =∫P(t)dt

[0018] If time interval accumulation is used, a millisecond timer is set to add the power consumption in each time interval Δt to the total power consumption:

[0019]

[0020] Among them, E total It represents the total power consumption of the vehicle, usually in joules (J) or kilowatt-hours (kWh), calculated based on the results of accumulation or integration. P(t) represents the instantaneous power at time t, usually in watts (W), and dt represents a small time interval; P(t i ) represents the instantaneous power at the end of the i-th time interval, Δt represents the time interval for accumulating power consumption in milliseconds, and n represents the total number of time intervals considered in the accumulation process.

[0021] Preferably, in S2, in order to further realize millisecond-level calculation, an efficient data processing algorithm is used to reduce data processing time and ensure that data can be quickly received and calculated by the processor, including using a fast Fourier transform (FFT) algorithm to analyze the spectral characteristics of the signal. The fast Fourier transform (FFT) algorithm can quickly convert from a time domain signal to a frequency domain. For a time domain signal x[n] with a length of N, its discrete Fourier transform (DFT) expression is:

[0022]

[0023] Where X[k] is the kth sample in the frequency domain, x[n] is the nth sample in the time domain, i is the imaginary unit, N is the size of the FFT (i.e., the number of samples in the signal), and k is the index in the frequency domain.

[0024] Preferably, the PID control algorithm in S3 controls the controlled object through a linear combination of proportional, integral, and derivative links; in the control of the electric drive mud pump, the PID controller adjusts the output power according to the given requested speed and maximum torque value, wherein the PID control algorithm formula is:

[0025] Proportional term (P): P = K p ×e(t)

[0026] Integral term (l): Differential term (D): Where, e(t) is the deviation between the set value and the actual value, K p , K i , K d They are the control coefficients of proportion, integration and differentiation respectively. The output of PID controller is the sum of these three items, which is used to adjust the output of the inverter to control the speed and torque of the mud pump. The output formula of the controller is:

[0027]

[0028] Preferably, the signal given by the handwheel in the driver's room in S4 may be interfered with, which will affect the stability and precise control of the motor; in order to reduce this interference, signal filtering and isolation technology can be used to ensure the clarity and accuracy of the signal, wherein the signal filtering is performed by Gaussian weighted moving average filtering: a filtering method based on weighted average, in which the weights are calculated according to the Gaussian distribution, and the closer to the center point, the larger the weight, which is used to remove Gaussian noise while retaining the main features of the signal.

[0029] The present invention provides a method for power consumption statistics and power regulation control of an electric-driven mud pump, which has the following beneficial effects:

[0030] This is a method for power consumption statistics and power regulation control of an electric-driven mud pump. The method uses a vehicle controller to collect the real-time current and voltage of the motor electronic control through a bus message at the millisecond level, and then accumulates the power at the millisecond level. The accumulated power consumption value is sent to the vehicle display through a bus message for the customer to read. This design does not add additional current transformers and power meters, and safely avoids the harm to the human body caused by the current transformer breaking and opening the circuit. The data acquisition accuracy of the high-performance and high-frequency controller of the vehicle is high. The vehicle controller collects the real-time value of the motor controller speed and current through the bus to calculate the current load power and compare it with the rated power of the motor. The PID closed-loop adjustment request speed and maximum torque value are used to limit the load power to operate within the rated power value of the motor. This control method saves 15% of the use cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 It is a schematic diagram of the process of the present invention;

[0032] Figure 2 It is a schematic diagram of the module of the present invention. DETAILED DESCRIPTION

[0033] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0034] See also Figure 1-2 , an embodiment of the present invention provides a technical solution: a method for power consumption statistics and power regulation control of an electric-driven mud pump, comprising a display, a vehicle controller and a motor controller, the display is connected to the vehicle controller via a bus, and the vehicle controller is connected to the motor controller via a bus;

[0035] The method is as follows:

[0036] S1. Establishment of communication bottom layer: CODESYS programming is required to accurately establish the communication bottom layer; during power-on initialization, the system will perform a series of steps including hardware detection, firmware check, configuration loading, system settings, safe startup, and module initialization to ensure stable operation of the system;

[0037] S2. Power consumption statistics and power regulation: For the vehicle controller, it is necessary to realize the function of calculating instantaneous power in milliseconds and accurately accumulating the power consumption of the whole vehicle; through the real-time monitoring of the inverter output frequency and current through the data acquisition system, the power consumption can be calculated;

[0038] S3.PID closed-loop control: The PID closed-loop control algorithm is used to adjust the output power of the electric-driven mud pump. The PID controller dynamically adjusts the output of the inverter according to the given request speed and maximum torque value to meet the working requirements of the mud pump. It improves the response speed and stability of the system and ensures that the output power of the mud pump matches the actual working conditions.

[0039] S4. Stability analysis of the control system: When designing the control system, the stability of the DC motor control system needs to be considered, including the analysis and improvement of the interference of the handwheel given signal in the control room, the stability of the PLC program design, the stability of the DC drive control system, and the interference factors of the communication cable;

[0040] S5. Selection and matching of inverter and motor: Select the appropriate inverter and motor matching system, select the motor with appropriate rated power and torque according to the displacement and maximum input power of the mud pump, and ensure that the inverter can provide sufficient output to drive the motor;

[0041] S6. System integration and debugging: After the electric drive system is integrated, debugging is required to ensure that all components work together to achieve stable operation of the mud pump, including the connection of power lines, control lines and communication lines, as well as solving the problems of room structure, MCC cabinet and frequency conversion cabinet installation and communication interference.

[0042] The specific steps for power-on initialization in CODESYS are as follows:

[0043] Hardware detection: Check whether the hardware connection is correct through the system, including the CPU, I / O modules, and memory component connections;

[0044] Firmware check: The system will confirm whether the firmware version is the latest; if there is an update, the system prompts the user to update the firmware to ensure that the system runs the latest version of the firmware to obtain the best performance and security; Configuration loading: If there is a predefined configuration file, the system loads the configuration at startup, and configures it as the default configuration or the user-defined configuration to quickly enter the working state;

[0045] System settings: set basic time, date, and network parameters;

[0046] Secure boot: Ensures that no unauthorized code is executed; includes checking signatures and authorization information to ensure system security;

[0047] Module initialization: Initialize the functional modules on the controller according to the configuration, such as PLC program, device driver, and communication module;

[0048] Run Ready: After completing all necessary initialization, the system enters the run mode, at which point the system waits for user interaction or performs predefined tasks, ready to start the normal work process.

[0049] Calculating power consumption in S2 requires data collection, which is accomplished by connecting sensors and using a data acquisition system to obtain accurate current and voltage values. The power calculation formula is as follows:

[0050] P(t)=V m ×I m ×cos(ωt+α v )×cos(ωt+α i )

[0051] Where P(t) is the instantaneous power, V m is the maximum voltage, I m is the maximum current, ω is the angular frequency, t is the time, α v and α i are the phase angles of voltage and current respectively.

[0052] The millisecond-level calculation in S2 requires ensuring that the frequency of data acquisition and processing is high enough to ensure that power calculation can be performed at the end of each time interval (such as 1 millisecond). The sampling frequency should be at least twice the signal frequency. When the highest signal frequency is 600 Hz, the sampling frequency is set to ≥1400 Hz.

[0053] The vehicle power consumption in S2 is obtained by integrating the instantaneous power or accumulating the power consumption within a certain time interval. When the integration method is adopted, it is calculated by the following formula:

[0054] E total =∫P(t)dt

[0055] If time interval accumulation is used, a millisecond timer is set to add the power consumption in each time interval Δt to the total power consumption:

[0056]

[0057] Among them, E total It represents the total power consumption of the vehicle, usually in joules (J) or kilowatt-hours (kWh), calculated based on the results of accumulation or integration. P(t) represents the instantaneous power at time t, usually in watts (W), and dt represents a small time interval; P(t i ) represents the instantaneous power at the end of the i-th time interval, Δt represents the time interval for accumulating power consumption in milliseconds, and n represents the total number of time intervals considered in the accumulation process.

[0058] In order to further achieve millisecond-level calculations in S2, an efficient data processing algorithm is used to reduce data processing time and ensure that data can be quickly received and calculated by the processor, including using the fast Fourier transform (FFT) algorithm to analyze the spectral characteristics of the signal. The fast Fourier transform (FFT) algorithm can quickly convert from time domain signals to frequency domain. For a time domain signal x[n] with a length of N, its discrete Fourier transform (DFT) expression is:

[0059]

[0060] Where X[k] is the kth sample in the frequency domain, x[n] is the nth sample in the time domain, i is the imaginary unit, N is the size of the FFT (i.e., the number of samples in the signal), and k is the index in the frequency domain.

[0061] The butterfly operation is needed to reduce the number of multiplications and additions. The formula of the butterfly operation is as follows:

[0062]

[0063] in, is the rotation factor, X cven [k] and X odd [k] are the DFT results for even and odd indices respectively.

[0064] The PID control algorithm in S3 controls the controlled object through a linear combination of proportional, integral, and derivative. In the control of the electric mud pump, the PID controller adjusts the output power according to the given requested speed and maximum torque value. The PID control algorithm formula is:

[0065] Proportional term (P): P = K p ×e(t)

[0066] Integral term (l): Differential term (D): Where, e(t) is the deviation between the set value and the actual value, K p , K i , K d They are the control coefficients of proportion, integration and differentiation respectively. The output of PID controller is the sum of these three items, which is used to adjust the output of the inverter to control the speed and torque of the mud pump. The output formula of the controller is:

[0067]

[0068] The parameters of the PID controller need to be adjusted according to the response characteristics of the system to achieve the best control effect. The parameters K can be adjusted manually or automatically (such as PID self-tuning). p , K i and K d .

[0069] The signal given by the handwheel in the driver's room of S4 may be disturbed, which will affect the stability and precise control of the motor. In order to reduce this interference, signal filtering and isolation technology can be used to ensure the clarity and accuracy of the signal. The signal filtering is performed by Gaussian weighted moving average filtering: a filtering method based on weighted average, in which the weights are calculated according to the Gaussian distribution. The closer to the center point, the larger the weight, which is used to remove Gaussian noise while retaining the main features of the signal.

[0070] In summary, this method uses the vehicle controller to collect the real-time current and voltage of the motor electronic control through the bus message at the millisecond level, and then accumulates the power at the millisecond level. The accumulated power consumption value is sent to the vehicle display through the bus message for the customer to read. This design does not add additional current transformers and power meters, and safely avoids the harm to the human body caused by the high voltage of the current transformer being broken and open-circuited.

[0071] The above shows and describes the basic principles and main features of the present invention and the advantages of the present invention. It is obvious to those skilled in the art that the present invention is not limited to the details of the above exemplary embodiments, and the present invention can be implemented in other specific forms without departing from the spirit or basic features of the present invention. Therefore, no matter from which point of view, the embodiments should be regarded as exemplary and non-restrictive. The scope of the present invention is defined by the attached claims rather than the above description, and it is intended that all changes falling within the meaning and scope of the equivalent elements of the claims are included in the present invention. Any figure mark in the claims should not be regarded as limiting the claims involved.

[0072] In addition, it should be understood that although the present specification is described according to implementation modes, not every implementation mode contains only one independent technical solution. This description of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment may also be appropriately combined to form other implementation modes that can be understood by those skilled in the art.

Claims

1. A method for counting power consumption and regulating power of an electric-driven mud pump, characterized in that: It includes a display, a vehicle controller and a motor controller. The display is connected to the vehicle controller via a bus, and the vehicle controller is connected to the motor controller via the bus.

2. According to claim 1, a method for counting power consumption and regulating power of an electric-driven mud pump is characterized in that: The method is as follows: S1. Establishment of communication bottom layer: CODESYS programming is required to accurately establish the communication bottom layer; during power-on initialization, the system will perform a series of steps including hardware detection, firmware check, configuration loading, system settings, safe startup, and module initialization to ensure stable operation of the system; S2. Power consumption statistics and power regulation: For the vehicle controller, it is necessary to realize the function of calculating instantaneous power in milliseconds and accurately accumulating the power consumption of the whole vehicle; through the real-time monitoring of the inverter output frequency and current through the data acquisition system, the power consumption can be calculated; S3.PID closed-loop control: The PID closed-loop control algorithm is used to adjust the output power of the electric-driven mud pump. The PID controller dynamically adjusts the output of the inverter according to the given request speed and maximum torque value to meet the working requirements of the mud pump. It improves the response speed and stability of the system and ensures that the output power of the mud pump matches the actual working conditions. S4. Stability analysis of the control system: When designing the control system, the stability of the DC motor control system needs to be considered, including the analysis and improvement of the interference of the handwheel given signal in the control room, the stability of the PLC program design, the stability of the DC drive control system, and the interference factors of the communication cable; S5. Selection and matching of inverter and motor: Select the appropriate inverter and motor matching system, select the motor with appropriate rated power and torque according to the displacement and maximum input power of the mud pump, and ensure that the inverter can provide sufficient output to drive the motor; S6. System integration and debugging: After the electric drive system is integrated, debugging is required to ensure that all components work together to achieve stable operation of the mud pump, including the connection of power lines, control lines and communication lines, as well as solving the problems of room structure, MCC cabinet and frequency conversion cabinet installation and communication interference.

3. According to claim 2, a method for counting power consumption and regulating power of an electric-driven mud pump is characterized in that: The specific steps of power-on initialization in CODESYS are as follows: Hardware detection: Check whether the hardware connection is correct through the system, including the CPU, I / O modules, and memory component connections; Firmware check: The system will confirm whether the firmware version is the latest; If an update is available, the system prompts the user to update the firmware to ensure that the system is running the latest version of the firmware for optimal performance and security; Configuration loading: If there is a predefined configuration file, the system loads the configuration at startup. The configuration is the default configuration or the user-defined configuration, so as to quickly enter the working state; System settings: set basic time, date, and network parameters; Secure boot: Ensures that no unauthorized code is executed; includes checking signatures and authorization information to ensure system security; Module initialization: Initialize the functional modules on the controller according to the configuration, such as PLC program, device driver, and communication module; Operation preparation: After completing all necessary initialization, the system enters the operation mode. At this time, the system waits for user interaction or executes predefined tasks, and is ready to start the normal working process.

4. According to claim 2, a method for counting power consumption and regulating power of an electric-driven mud pump is characterized in that: The calculation of power consumption in S2 requires data collection, which is completed by connecting sensors and using a data acquisition system to obtain accurate current and voltage values. The power calculation formula is as follows: P(t)=V m ×I m ×cos(ωt+α v )×cos(ωt+α i ) Where P(t) is the instantaneous power, V m is the maximum voltage, I m is the maximum current, ω is the angular frequency, t is the time, α v and α i are the phase angles of voltage and current respectively.

5. According to claim 2, a method for counting power consumption and regulating power of an electric-driven mud pump is characterized in that: The millisecond-level calculation in S2 needs to ensure that the frequency of data acquisition and processing is high enough to ensure that power calculation can be performed at the end of each time interval (such as 1 millisecond), where the sampling frequency should be at least twice the signal frequency. When the highest signal frequency is 600 Hz, the sampling frequency is set to ≥1400 Hz.

6. According to claim 2, a method for counting power consumption and regulating power of an electric-driven mud pump is characterized in that: The vehicle power consumption in S2 is obtained by integrating the instantaneous power or accumulating the power consumption within a certain time interval. When the integration method is adopted, it is calculated by the following formula: E total =∫P(t)dt If time interval accumulation is used, a millisecond timer is set to add the power consumption in each time interval Δt to the total power consumption: Among them, E total It represents the total power consumption of the vehicle, usually in joules (J) or kilowatt-hours (kWh), calculated based on the results of accumulation or integration. P(t) represents the instantaneous power at time t, usually in watts (W), and dt represents a small time interval; P(t i ) represents the instantaneous power at the end of the i-th time interval, Δt represents the time interval for accumulating power consumption in milliseconds, and n represents the total number of time intervals considered in the accumulation process.

7. The method for counting power consumption and regulating power of an electric-driven mud pump according to claim 2, characterized in that: In order to further realize millisecond-level calculation, S2 uses an efficient data processing algorithm to reduce data processing time and ensure that data can be quickly received and calculated by the processor, including using a fast Fourier transform (FFT) algorithm to analyze the spectral characteristics of the signal. The fast Fourier transform (FFT) algorithm can quickly convert from a time domain signal to a frequency domain. For a time domain signal x[n] with a length of N, its discrete Fourier transform (DFT) expression is: Where X[k] is the kth sample in the frequency domain, x[n] is the nth sample in the time domain, i is the imaginary unit, N is the size of the FFT (i.e., the number of samples in the signal), and k is the index in the frequency domain.

8. The method for counting power consumption and regulating power of an electric-driven mud pump according to claim 2, characterized in that: The PID control algorithm in S3 controls the controlled object through a linear combination of proportional, integral, and derivative. In the control of the electric mud pump, the PID controller adjusts the output power according to the given requested speed and maximum torque value. The PID control algorithm formula is: Proportional term (P): P = K p ×e(t) Integral term (l): Differential term (D): Where, e(t) is the deviation between the set value and the actual value, K p , K i , K d They are the control coefficients of proportion, integration and differentiation respectively. The output of PID controller is the sum of these three items, which is used to adjust the output of the inverter to control the speed and torque of the mud pump. The output formula of the controller is:

9. The method for counting power consumption and regulating power of an electric-driven mud pump according to claim 2, characterized in that: The signal given by the handwheel in the driver's room in S4 may be interfered with, which will affect the stability and precise control of the motor. In order to reduce this interference, signal filtering and isolation technology can be used to ensure the clarity and accuracy of the signal, wherein the signal filtering is performed by Gaussian weighted moving average filtering: a filtering method based on weighted average, in which the weights are calculated according to the Gaussian distribution. The closer to the center point, the larger the weight, which is used to remove Gaussian noise while retaining the main features of the signal.

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