Water injection pump leakage pressure detection and control device and system based on industrial vision

Abstract

The invention provides a water injection pump leakage pressure detection and control device based on industrial vision. The device comprises an industrial visual pressure detection module and a PLC control module. The image source module is used for setting shooting basic parameters and shooting leaked water of the water injection pump in real time; the rapid matching module establishes a corresponding picture template when water leaked by the water injection pump is a water drop or a water column; the condition detection module detects whether each picture obtained by photographing is matched with a picture template or not; a first variable calculation module counts the total number N of pictures shot in real time within a period of time; the first variable calculation module counts the number NOK matched with the picture templates; the second variable calculation module calculates the number NNG which is not matched with the picture templates and the qualified rate R which is matched with the picture templates; the consumed time statistics module counts total consumed time T; a third variable calculation module calculates the qualified rate R1 in unit time; and when the qualification rate R1 is within a preset range, the PLC control module controls the water injection pump to continuously operate, and otherwise, the PLC control module controls the water injection pump to stop operating. The technical blank of pressure detection of the leakage rate of the water injection pump in a non-contact mode is filled.

Description

Technical Field

[0001] The present invention relates to the technical field of water injection pump detection, and in particular to a water injection pump leakage pressure detection and control device based on industrial vision. Background Art

[0002] Water drive production technology is a widely used technology in oil production. Its principle is to increase the wellhead pressure by injecting water with a certain pressure into the oil layer, so as to promote the migration of oil from the oil layer to the wellhead, thereby achieving the purpose of facilitating production. Since the water injection pressure is generally around 10 MPa, the water injection pressure is high, and water will seep out of the mechanical seal of the water injection pump. The amount of water leaking from the plunger pump is an objective existence, but the amount of water leakage determines the working condition of the water injection pump. Too little water leakage is not good for the plunger pump, and too much water leakage also indicates that there is a problem with the seal of the plunger pump. If the water seepage is within a reasonable leakage range, the oilfield system will think that the water injection pump is in good working condition. How to detect the amount of water leakage has become a difficult problem for the oilfield water injection system.

[0003] However, the existing pressure detection of water injection pump leakage is mostly carried out using contact sensors. The main problems with this method are: (1) The injected water contains some impurities. If they are directly dropped onto the sensor surface, contact measurement may cause corrosive damage to the sensor, thereby affecting the life cycle of the entire detection system. (2) The mass of the water droplet is about 50 mg, and the measurement accuracy of general sensors does not meet the use requirements. Summary of the invention

[0004] The present invention aims to solve at least one of the technical problems existing in the prior art or related art.

[0005] To this end, the purpose of the present invention is to provide a water injection pump leakage pressure detection and control device based on industrial vision.

[0006] In order to achieve the above-mentioned purpose, the technical solution of the present invention provides a water injection pump leakage pressure detection and control device based on industrial vision, including: an industrial vision pressure detection module and a PLC control module; the industrial vision pressure detection module includes an image source module, a fast matching module, a condition detection module, a first variable calculation module, a second variable calculation module, a time consumption statistics module, and a third variable calculation module; the image source module is used to set the basic parameters for taking pictures and take real-time pictures of the water leaking from the water injection pump; the fast matching module is used to establish a corresponding picture template when the water leaking from the water injection pump is a water drop or a water column; the condition detection module is used to Detect whether each picture obtained by taking pictures matches the picture template; when it is detected that any picture matches the picture template corresponding to the water leaked by the water injection pump as a water column, send information to control the water injection pump to stop running to the PLC control module; otherwise, send the detection result to the first variable calculation module; the first variable calculation module is used to count the total number N of pictures taken in real time within a period of time after the image source module starts working, and send the total number N to the second variable calculation module; the first variable calculation module is also used to receive the detection result, and count the number N that matches the picture template according to the detection result OK , and the number N OK Sent to the second variable calculation unit; the second variable calculation module is used to receive the total number N and the number N OK , according to the total number N and the number N OK Calculate the number N that does not match the image template NG , and the qualified rate R that matches the picture template during the working time period, and sending the qualified rate R to the third variable calculation module; the time-consuming statistical module is used to count the total time T consumed from the first picture taken by the image source module to the Nth picture taken, and send the total time T to the third variable calculation module; the third variable calculation module, according to the number N OK And the time consumed T, calculate the pass rate per unit time R 1 The qualified rate R 1 Sent to the PLC control module; the PLC control module is used to receive the pass rate R 1 , and judge the pass rate R 1 Is it within the preset range? 1 When the qualified rate R is within the preset range, the water injection pump is controlled to continue to operate; 1 When it is not within the preset range, the water injection pump is controlled to stop running; the PLC control module is also used to control the water injection pump to start or stop running when receiving the start and stop information of the water injection pump.

[0007] Preferably, the water injection pump leakage pressure detection and control device based on industrial vision also includes: an HMI module; the HMI module is used to receive the water injection pump leakage pressure control parameters of the water injection site input by the user, and display the water injection pump leakage pressure control parameters; the HMI module is also used to send the water injection pump leakage pressure control parameters to the PLC control module; the PLC control module is also used to receive the water injection pump leakage pressure control parameters, and calculate the preset range according to the water injection pump leakage pressure control parameters.

[0008] Preferably, the PLC control module is also used to 1 The actual leakage pressure parameter of the water injection pump at the water injection site is calculated, and the actual leakage pressure parameter of the water injection pump is fed back to the HMI module; the HMI module is also used to display the actual leakage pressure parameter of the water injection pump.

[0009] Preferably, the industrial visual pressure detection module, PLC control module, and HMI module are distributed in the same network segment and are uniformly connected to an industrial gateway; the industrial gateway is connected to a remote server.

[0010] Preferably, the industrial visual pressure detection unit is implemented by an industrial camera.

[0011] Preferably, the basic parameters include: the format of the picture taken by the camera, the exposure time of the camera, the frame rate of the camera, and the trigger mode of the camera.

[0012] The technical solution of the present invention also provides an injection pump leakage pressure detection and control system based on industrial vision, including: an injection pump leakage pressure detection and control device based on industrial vision as described in any of the above technical solutions; a cloud platform; a user site terminal; the cloud platform is used to receive all control signals and control parameters of the water injection site sent by the industrial vision pressure detection module, PLC control module, and HMI module; the user site terminal is used to receive instructions input by the user to query all control information and control parameters of the water injection site, and display the query results.

[0013] Beneficial effects of the present invention:

[0014] (1) The water injection pump leakage pressure detection and control device based on industrial vision provided by the present invention performs pressure detection based on industrial vision and does not come into contact with the leaked water, so that the working time of the entire device is long, thereby greatly extending the service life of the entire device. At the same time, the pressure detection of the water injection pump leakage amount is highly accurate.

[0015] (2) The water injection pump leakage pressure detection and control system based on industrial vision provided by the present invention integrates industrial vision, industrial Internet, PLC control technology, HMI technology and cloud computing, and realizes remote monitoring based on the remote monitoring technology of the cloud platform, which is easy to realize unmanned management and greatly saves human resource costs.

[0016] (3) The present invention can also be applied to other fluid pressure detection fields.

[0017] Additional aspects and advantages of the invention will become apparent from the following description, or may be learned by practice of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 The overall network architecture diagram of a water injection pump leakage pressure detection and control system based on industrial vision according to an embodiment of the present invention is shown;

[0019] Figure 2 A schematic diagram showing an interface of an image source module according to an embodiment of the present invention is shown;

[0020] Figure 3 A schematic diagram showing an interface of a quick matching module according to an embodiment of the present invention is shown;

[0021] Figure 4 A schematic diagram of an interface of a condition detection module according to an embodiment of the present invention is shown;

[0022] Figure 5 A schematic diagram of an interface of a first variable calculation module according to an embodiment of the present invention is shown;

[0023] Figure 6 A schematic diagram of an interface of a second variable calculation module according to an embodiment of the present invention is shown;

[0024] Figure 7 A schematic diagram of an interface for calculating the qualified rate R by a second variable calculation module according to an embodiment of the present invention is shown;

[0025] Figure 8 A schematic diagram of an interface of a time-consuming statistics module according to an embodiment of the present invention is shown;

[0026] Fig. 9 A schematic diagram of an interface of a third variable calculation module according to an embodiment of the present invention is shown;

[0027] Fig.10 A schematic flow chart of a water injection pump leakage pressure detection and control system based on industrial vision according to an embodiment of the present invention is shown. DETAILED DESCRIPTION

[0028] In order to more clearly understand the above-mentioned objectives, features and advantages of the present invention, the present invention is further described in detail below in conjunction with the accompanying drawings and specific embodiments. It should be noted that the embodiments of the present application and the features in the embodiments can be combined with each other without conflict.

[0029] In the following description, many specific details are set forth to facilitate a full understanding of the present invention. However, the present invention may also be implemented in other ways different from those described herein. Therefore, the protection scope of the present invention is not limited to the specific embodiments disclosed below.

[0030] Figure 1 The overall network architecture diagram of the water injection pump leakage pressure detection and control system based on industrial vision according to an embodiment of the present invention is shown. Figure 1 As shown, the water injection pump leakage pressure detection and control system includes: a water injection pump leakage pressure detection and control device based on industrial vision; a cloud platform; a user field terminal (PC terminal); the cloud platform is used to receive the industrial vision pressure detection module, the PLC control module (i.e. Figure 1 PLC in), and HMI module (i.e. Figure 1 The HMI (human-machine interface) in the water injection site sends all control signals and control parameters; the user site terminal (PC terminal) is used to receive the user's input instructions for querying all control information and control parameters of the water injection site, and display the query results.

[0031] The leakage pressure detection and control device of the water injection pump based on industrial vision includes: an industrial vision pressure detection module and a PLC control module; the industrial vision pressure detection module includes an image source module, a fast matching module, a condition detection module, a first variable calculation module, a second variable calculation module, a time consumption statistics module, and a third variable calculation module; the image source module is used to set the basic parameters for taking pictures and take real-time pictures of the water leaking from the water injection pump; the fast matching module is used to establish a corresponding picture template when the water leaking from the water injection pump is a water drop or a water column; the condition detection module is used to detect whether each picture obtained by taking pictures matches the picture template; when it is detected that any picture matches the picture template corresponding to the water leaking from the water injection pump as a water column, the information for controlling the water injection pump to stop running is sent to the PLC control module; otherwise, the detection result is sent to the first variable calculation module; the first variable calculation module is used to count the total number N of pictures taken in real time within a period of time after the image source module starts working, and send the total number N to the second variable calculation module; the first variable calculation module is also used to receive the detection result, and count the number N matching the picture template according to the detection result. OK , and the number N OKSent to the second variable calculation unit; the second variable calculation module is used to receive the total number N and the number N OK , according to the total number N and the number N OK Calculate the number N that does not match the image template NG , and the qualified rate R that matches the picture template during the working time period, and sending the qualified rate R to the third variable calculation module; the time-consuming statistical module is used to count the total time T consumed from the first picture taken by the image source module to the Nth picture taken, and send the total time T to the third variable calculation module; the third variable calculation module, according to the number N OK And the time consumed T, calculate the pass rate per unit time R 1 The qualified rate R 1 Sent to the PLC control module; the PLC control module is used to receive the qualified rate R 1 , and judge the pass rate R 1 Is it within the preset range? 1 When the qualified rate R is within the preset range, the water injection pump is controlled to continue to operate; 1 When it is not within the preset range, the water injection pump is controlled to stop running; the PLC control module is also used to control the water injection pump to start or stop running when receiving the start and stop information of the water injection pump.

[0032] Furthermore, the industrial visual pressure detection unit is implemented by an industrial camera, and the visual software is embedded in the industrial camera, which can realize the corresponding functions of the image source module, the fast matching module, the condition detection module, the first variable calculation module, the second variable calculation module, the time consumption statistics module, and the third variable calculation module. The industrial camera matches the high-precision lens and light source to take real-time photos of the water droplets (or water columns) leaking from the water injection pump.

[0033] Furthermore, the water injection pump leakage pressure detection and control device based on industrial vision also includes: an HMI module (HMI, human-machine interface); the HMI module is used to receive the water injection pump leakage pressure control parameters at the water injection site input by the user and display the water injection pump leakage pressure control parameters; the HMI module is also used to send the water injection pump leakage pressure control parameters to the PLC control module; the PLC control module is also used to receive the water injection pump leakage pressure control parameters and calculate the preset range according to the water injection pump leakage pressure control parameters. The PLC control module is also used to calculate the preset range according to the qualified rate R 1The actual leakage pressure parameter of the water injection pump at the water injection site is calculated and fed back to the HMI module; the HMI module is also used to display the actual leakage pressure parameter of the water injection pump. In a specific embodiment, the leakage pressure control parameter of the water injection pump at the water injection site and the actual leakage pressure parameter of the water injection pump fed back by the PLC control module are completed by the TP700 Comfort human-machine interface (i.e., HMI module) of Siemens.

[0034] Furthermore, the industrial visual pressure detection module (ie, industrial camera), PLC control module, and HMI module are distributed in the same network segment and are uniformly connected to the industrial gateway; the industrial gateway is connected to the remote server.

[0035] In this embodiment, if Figure 2 As shown in the figure, the image source module is mainly used to set the basic parameters for taking photos and take real-time photos of the water leaking from the water injection pump. Figure 3 As shown in the figure, the quick matching module is mainly used to establish the corresponding image template when the water leaked by the water injection pump is a water drop or a water column. The part with a green line in the upper right corner of the figure is the template of the captured water drop. Figure 4 As shown, the condition detection module is used to detect whether the photos captured on site match the picture template; when no picture is detected that matches the picture template corresponding to when the water leaking from the water injection pump is a water column, it means that there must be several pictures that match the picture template corresponding to when the water leaking from the water injection pump is water droplets, and the detection result is sent to the first variable calculation module. When it is detected that any picture matches the picture template corresponding to when the water leaking from the water injection pump is a water column, it means that the actual leakage pressure parameter of the water injection pump must exceed the upper limit value, which means that the working condition of the water injection pump at this time is not very good and is in an abnormal state, and the information to control the water injection pump to stop running is sent to the PLC control module. Figure 5 As shown, the first variable calculation module is used to count the total number N of pictures taken in real time within a period of time after the image source module starts working (i.e., Figure 5 The name n in the real-time calculation is performed, and the running program automatically adds 1 to automatically calculate the total number of the last real-time pictures taken), and the total number N is sent to the second variable calculation module; the first variable calculation module is also used to receive the detection results, and count the number N that matches the picture template according to the detection results OK (The template at this time corresponds to the picture template corresponding to the case where the water leaking from the water injection pump is water droplets, the number N OK That is Figure 5 The value corresponding to the name OK in the OK Sent to the second variable calculation unit. Figure 6 As shown, the second variable calculation module is used to receive the total number N and the number N OK, according to the total number N and the number N OK Calculate the number N that does not match the image template NG (Number N NG That is Figure 6 The value corresponding to the name NG in the working time period, and the qualified rate R that matches the image template during the working time period (the qualified rate R is the value corresponding to the name NG in the working time period). Figure 6 The qualified rate R is sent to the third variable calculation module. Figure 7 As shown, the pass rate R ( Figure 7 The value of rate) is the number N OK The ratio of the total number N. Figure 8 As shown, the time-consuming statistics module is used to count the total time T consumed from the first picture taken by the image source module to the Nth picture taken, and send the total time T to the third variable calculation module. The start time node and the end time node of the time-consuming statistics can be changed. Fig. 9 As shown, the third variable calculation module, according to the number N OK And the time consumed T, calculate the pass rate per unit time R 1 The pass rate R 1 Sent to PLC control module. 1 (right Fig. 9 The value of the name var0) in the OK The ratio of the time T consumed.

[0036] In this embodiment, the industrial camera, PLC control module, and HMI module are distributed in the same network segment and are uniformly connected to the industrial gateway; the industrial gateway is connected to the remote server. Information communication can be carried out between the industrial camera, PLC control module, and HMI module. Fig.10 As shown in the figure, the PLC control module is the core of the entire water injection pump leakage pressure detection and control system based on industrial vision: on the one hand, it controls the operation of the industrial vision system (i.e., industrial camera, with visual software embedded inside the industrial camera) to obtain visual detection data; on the other hand, it controls the operation process to realize logical control tasks such as water injection pump start and stop control, water injection pump pressure setting, and system communication. After receiving the data detected by the industrial camera, the PLC control module makes a logical judgment on the data to determine whether the actual leakage pressure parameters of the water injection pump meet the preset requirements, and then sends the data to the cloud platform. The industrial vision system is responsible for taking real-time photos of the water leaking from the water injection pump, and uploading the calculated data to the PLC control module. The PLC control module controls the operation of the water injection pump by analyzing the data.

[0037] In this embodiment, the top layer of the entire system is the cloud platform (server side). All control signals and parameters of the water injection site can be uploaded to the cloud platform through the gateway, which is convenient for the remote host (PC side) to read the parameters and implement monitoring and control of the site. The cloud platform can perform information monitoring, predictive maintenance, quality improvement, and fault debugging, thereby collecting, querying, and sharing big data. At the same time, it can perform real-time analysis and edge computing based on cloud models.

[0038] The water injection pump leakage pressure detection and control device based on industrial vision provided by the present invention performs pressure detection based on industrial vision and does not come into contact with leaked water, so that the working time of the entire device is long, thereby greatly extending the service life of the entire device. At the same time, the pressure detection of the water injection pump leakage amount is highly accurate.

[0039] The water injection pump leakage pressure detection and control system based on industrial vision provided by the present invention integrates industrial vision, industrial Internet, PLC control technology, HMI technology and cloud computing, and realizes remote monitoring based on the remote monitoring technology of the cloud platform, which is easy to realize unmanned management and greatly saves human resource costs.

[0040] In one embodiment of the present invention, the basic parameters for taking pictures include: the format of the picture taken by the camera, the exposure time of the camera, the frame rate of the camera, and the trigger mode of the camera.

[0041] In this embodiment, the format of the pictures taken by the camera is set, which can facilitate the user to store and process the pictures taken by the camera later. The exposure time of the camera refers to the length of time that the camera's photosensitive element receives light, and the unit can be milliseconds. When setting the exposure time of the camera, the user needs to make different choices based on the reflected light of the object being photographed. Too short an exposure time will cause the image to be dim, and too long an exposure time will cause the image to be overexposed. The frame rate of the camera refers to the number of times the camera takes an image per second. When setting the frame rate of the camera, the user needs to make a choice based on actual needs and system performance. The higher the frame rate, the lower the corresponding resolution. The trigger mode of the camera refers to the working mode of the camera, which has two modes: soft trigger and hard trigger. Soft triggering refers to controlling the camera's shooting through computer software, while hard triggering refers to the camera triggering shooting based on external signals.

[0042] Through on-site calculations and laboratory tests, it can be known that when the working condition of the water injection pump is very good, the leakage of the water injection pump under a certain pressure is within a certain fixed range (that is, the number of water droplets falling is fixed); when the water leaking from the water injection pump under a certain pressure is a water column, it means that the actual leakage pressure parameter of the water injection pump must exceed the upper limit value, which further indicates that the working condition of the water injection pump at this time is not very good and is in an abnormal state. Therefore, the water injection pump leakage pressure detection and control device and system based on industrial vision provided by the present invention can accurately detect the leakage of the water injection pump, solve the technical drawbacks of the existing water injection pump leakage pressure detection that mostly uses contact sensors for detection, and fill the technical gap of using non-contact methods to detect the leakage of water injection pumps.

[0043] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A water injection pump leakage pressure detection and control device based on industrial vision, characterized in that: include: Industrial visual pressure detection module and PLC control module; the industrial visual pressure detection module includes an image source module, a fast matching module, a condition detection module, a first variable calculation module, a second variable calculation module, a time-consuming statistics module, and a third variable calculation module; The image source module is used to set basic parameters for taking photos and take real-time photos of water leaking from the water injection pump; The quick matching module is used to establish a corresponding image template when the water leaking from the water injection pump is water droplets or water columns; The condition detection module is used to detect whether each picture obtained by taking pictures matches the picture template; when it is detected that any picture matches the picture template corresponding to the water leaked by the water injection pump as a water column, the information for controlling the water injection pump to stop running is sent to the PLC control module; otherwise, the detection result is sent to the first variable calculation module; The first variable calculation module is used to count the total number N of pictures taken in real time within a period of time after the image source module starts working, and send the total number N to the second variable calculation module; The first variable calculation module is further configured to receive the detection result and count the number N of images that match the image template according to the detection result. OK , and the number N OK Send to the second variable calculation unit; The second variable calculation module is used to receive the total number N and the number N OK , according to the total number N and the number N OK Calculate the number N that does not match the image template NG , and the qualified rate R that matches the picture template during the working time period, and sending the qualified rate R to the third variable calculation module; The time-consuming statistics module is used to count the total time T consumed from the first picture taken by the image source module to the Nth picture taken, and send the total time T to the third variable calculation module; The third variable calculation module, according to the number N OK and the consumed time T, calculate the qualified rate R1 within the unit time and send the qualified rate R1 to the PLC control module; The PLC control module is used to receive the qualified rate R1 and determine whether the qualified rate R1 is within a preset range; when the qualified rate R1 is within the preset range, control the water injection pump to continue running; when the qualified rate R1 is not within the preset range, control the water injection pump to stop running; The PLC control module is also used to control the water injection pump to start or stop operation when receiving the water injection pump start and stop information.

2. The water injection pump leakage pressure detection and control device based on industrial vision according to claim 1 is characterized in that: Also includes: HMI module; The HMI module is used to receive the water injection pump leakage pressure control parameter at the water injection site input by the user and display the water injection pump leakage pressure control parameter; The HMI module is also used to send the water injection pump leakage pressure control parameter to the PLC control module; The PLC control module is further used to receive the water injection pump leakage pressure control parameter and calculate the preset range according to the water injection pump leakage pressure control parameter.

3. The water injection pump leakage pressure detection and control device based on industrial vision according to claim 2 is characterized in that: The PLC control module is further used to calculate the actual leakage pressure parameter of the water injection pump at the water injection site according to the qualified rate R1, and feed back the actual leakage pressure parameter of the water injection pump to the HMI module; The HMI module is also used to display the actual leakage pressure parameters of the water injection pump.

4. The water injection pump leakage pressure detection and control device based on industrial vision according to any one of claims 1 to 3, characterized in that: The industrial visual pressure detection module, PLC control module, and HMI module are distributed in the same network segment and are uniformly connected to an industrial gateway; the industrial gateway is connected to a remote server.

5. The water injection pump leakage pressure detection and control device based on industrial vision according to any one of claims 1 to 3, characterized in that: The industrial visual pressure detection unit is implemented by using an industrial camera.

6. The water injection pump leakage pressure detection and control device based on industrial vision according to claim 5 is characterized in that: The basic parameters include: the format of the picture taken by the camera, the exposure time of the camera, the frame rate of the camera, and the trigger mode of the camera.

7. A water injection pump leakage pressure detection and control system based on industrial vision, characterized in that: include: The water injection pump leakage pressure detection and control device based on industrial vision as described in any one of claims 1 to 6; Cloud platform; User on-site terminal; The cloud platform is used to receive all control signals and control parameters of the water injection site sent by the industrial visual pressure detection module, the PLC control module, and the HMI module; The user site terminal is used to receive the instruction input by the user to query all the control information and control parameters of the water injection site, and display the query result.

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