Electric workover rig electrical control device and control method thereof

Abstract

The invention discloses an electric control device of an electric workover rig and a control method thereof, and relates to the technical field of electric workover rigs, the device comprises a charger, a high-voltage battery module, a PLC module and a DC / AC group module; the PLC module controls the charger to start and stop based on the operation data of the charger, the operation data of the high-voltage battery module and the operation data of the DC / AC group module; the input end of the charger is used for inputting three-phase alternating current; when the charger is started, three-phase alternating current is converted into direct current to charge the high-voltage battery module; after the high-voltage battery module is saturated, the charger stops; and the DC / AC group module is used for converting the direct current output by the high-voltage battery module into three-phase alternating current to supply power to the power motor. According to the invention, the charger and the PLC module are arranged, so that charging can be completed on the premise of no shutdown.

Description

Technical Field

[0001] The present application relates to the technical field of electric workover rigs, and in particular to an electrical control device for an electric workover rig and a control method thereof. Background Art

[0002] Electric workover rigs are a type of workover equipment used in the oil and gas industry. Their main function is to replace traditional diesel-driven workover rigs to improve operational efficiency and environmental performance. With the global focus on renewable energy and clean technology, the oil and gas industry has also begun to explore more sustainable technical solutions. Against this background, electric workover rigs have emerged as a powerful alternative to traditional workover equipment. Modern workover operations are increasingly inclined to intelligence and automation to improve operational safety and efficiency. Electric workover rigs do not directly emit exhaust gas, which can significantly reduce the emission of greenhouse gases and harmful substances, and help promote the green transformation of the industry. The noise level of electric motors is significantly lower than that of diesel engines, which helps to reduce the impact on the surrounding environment, especially in operations in ecologically sensitive areas. The cost of electricity for electric workover rigs is usually lower than that of diesel, and the maintenance requirements of electric motors are lower, which can reduce maintenance costs. The high energy conversion efficiency of electric motors can use energy more efficiently and avoid energy loss in diesel engines. Electric workover rigs provide stable torque output and can maintain good performance and fast response under various working conditions. Electric motors have a simple mechanical structure and a small number of components. They are generally more reliable, have a low failure rate, and have a long maintenance cycle. Electric workover rigs are usually equipped with advanced electronic control systems to support intelligent operations, enabling more precise control and real-time monitoring. Electric workover rigs can be used flexibly in different operating environments, including remote areas, with only an appropriate power supply or efficient batteries. Electric workover rigs are relatively safer without diesel leaks and potential fire risks. Modern electric workover rigs can be equipped with advanced safety monitoring systems to improve the safety of the work site, timely alarm and automatic shutdown.

[0003] Electric workover rigs need to provide power output equivalent to or even higher than that of diesel engines to cope with various operational requirements. How to design an efficient electric drive system is a challenge. The performance, heat dissipation and efficiency of electric motors under high load conditions need further research and optimization. With the increasing demand for automation and intelligence, how to achieve efficient and accurate control algorithms and ensure the real-time responsiveness of the system is an important technical issue. Using sensors to collect operating data, how to quickly process and analyze data to achieve better operating status monitoring and fault warning requires a complete technical solution. The durability of electric workover rigs in harsh environments (such as high temperature, low temperature, high humidity, etc.) needs to be enhanced to ensure that the equipment can operate reliably under various conditions. Good dust and water proof design is essential for the long-term use of equipment, especially in outdoor working environments. How to establish an effective maintenance system so that electric workover rigs can detect and handle faults in time during use to avoid downtime losses. Operators need to receive special training to adapt to the operation and maintenance of electric equipment and improve overall operating efficiency. Summary of the invention

[0004] The purpose of the present application is to provide an electrical control device and a control method for an electric workover rig, which can complete charging without stopping the rig.

[0005] To achieve the above objectives, this application provides the following solutions:

[0006] In a first aspect, the present application provides an electrical control device for an electric workover rig, comprising: a charger, a high-voltage battery module, a PLC module, and a DC / AC group module;

[0007] The PLC module is connected to the charger, the high-voltage battery module and the DC / AC group module respectively; the output end of the charger is connected to the high-voltage battery module; the DC / AC group module is connected to the load; the load is the power motor in the electric workover rig;

[0008] The PLC module is used to obtain the operating data of the charger, the operating data of the high-voltage battery module and the operating data of the DC / AC group module, and control the start and stop of the charger based on the operating data of the charger, the operating data of the high-voltage battery module and the operating data of the DC / AC group module;

[0009] The input end of the charger is used to input three-phase alternating current; when the charger is turned on, the three-phase alternating current is converted into direct current to charge the high-voltage battery module; when the high-voltage battery module is saturated with electricity, the charger stops;

[0010] The DC / AC group module is used to convert the direct current output by the high-voltage battery module into three-phase alternating current to power the power motor.

[0011] Optionally, the high-voltage battery module comprises: a high-voltage box and a battery pack;

[0012] The high-voltage box is on a high-voltage box branch; the high-voltage box branch is connected in parallel with the charger;

[0013] The battery pack is connected in parallel with the high voltage box;

[0014] The high voltage is also connected to the PLC module; the high voltage box is used to charge the battery pack using the direct current converted by the charger;

[0015] The battery pack is used to supply power to the load.

[0016] Optionally, the battery capacities of the multiple batteries in the battery pack are different.

[0017] Optionally, a first branch fuse is provided on the high voltage box branch.

[0018] Optionally, the electric workover rig electrical control device further comprises: a main fuse;

[0019] The main fuse is arranged between the charger and the high-voltage box branch.

[0020] Optionally, the DC / AC group module includes a plurality of DC / AC branches;

[0021] The plurality of DC / AC branches are connected in parallel with the high-voltage battery module;

[0022] The plurality of DC / AC branches are respectively connected to corresponding loads;

[0023] A plurality of the DC / AC branches are connected to the PLC module;

[0024] The DC / AC branch is used to convert the direct current output by the high-voltage battery module into three-phase alternating current to power the power motor.

[0025] Optionally, the DC / AC branch includes: a second branch fuse and a DC / AC converter connected in series.

[0026] Optionally, the PLC module includes: a PLC and a touch screen;

[0027] The PLC is connected to the touch screen, the charger, the high-voltage battery module and the DC / AC group module respectively;

[0028] The PLC is used to obtain the operating data of the charger, the operating data of the high-voltage battery module and the operating data of the DC / AC group module, and control the start and stop of the charger based on the operating data of the charger, the operating data of the high-voltage battery module and the operating data of the DC / AC group module.

[0029] In a second aspect, the present application provides a control method for an electric workover machine electrical control device, the control method for an electric workover machine electrical control device is applied to the electric workover machine electrical control device, and the control method for an electric workover machine electrical control device includes:

[0030] Get the real-time power of the power motor;

[0031] When the real-time power reaches the power threshold, controlling the charger and the high-voltage battery module to charge the power motor simultaneously;

[0032] When the real-time power does not reach the power threshold, the charger is controlled to charge the high-voltage battery module.

[0033] Optionally, the control method of the electric workover rig electrical control device further includes:

[0034] Get the real-time power of the battery pack in the high-voltage battery module;

[0035] When the real-time power level is lower than the power safety threshold, the battery pack in the high-voltage battery module is controlled to stop discharging.

[0036] According to the specific embodiments provided in this application, this application discloses the following technical effects:

[0037] The present application provides an electrical control device for an electric well repair machine and a control method thereof. The PLC module controls the start and stop of the charger based on the operating data of the charger, the operating data of the high-voltage battery module and the operating data of the DC / AC group module; the input end of the charger is used to input three-phase AC power; when the charger is turned on, the three-phase AC power is converted into DC power to charge the high-voltage battery module; after the high-voltage battery module is saturated with power, the charger stops; the DC / AC group module is used to convert the DC power output by the high-voltage battery module into three-phase AC power to power the power motor. By collecting real-time data of the battery pack, charger, power motor, etc., the charging voltage and charging current output by the charger are controlled. When the power motor needs to run, the battery pack and the charger supply power to the power motor together. When the power motor power is reduced or stops running, the charger charges the battery pack with equal current, so that the power of the battery pack is always kept within the safe power range of the battery pack, without stopping to wait for charging. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0039] Figure 1 Schematic diagram of the structure of an electrical control device for an electric workover rig in one embodiment of the present application. DETAILED DESCRIPTION

[0040] The following will be combined with the drawings in the embodiments of the present application to clearly and completely describe the technical solutions in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0041] In order to make the above-mentioned objects, features and advantages of the present application more obvious and easy to understand, the present application is further described in detail below with reference to the accompanying drawings and specific implementation methods.

[0042] Conventional energy storage system: uses battery packs and supercapacitors to store energy. When the power motor is running, the power of the battery pack and supercapacitor will be lower and lower. When the power drops to a certain level, the system must be shut down to recharge the battery pack. The process of charging the battery pack from the minimum power to full power requires 2-4 hours, and some require longer time, due to the different battery capacities. The waiting process for charging causes the equipment to be idle, which has an impact on costs, personnel, and company operations.

[0043] In order to make up for the idle period of the charging waiting process, in an exemplary embodiment, as Figure 1As shown, an electrical control device for an electric well repair machine is provided, comprising: a charger, a high-voltage battery module, a PLC module and a DC / AC group module; the PLC module is connected to the charger, the high-voltage battery module and the DC / AC group module respectively; the output end of the charger is connected to the high-voltage battery module; the DC / AC group module is connected to the load; the load is a power motor in the electric well repair machine; the PLC module is used to obtain the operating data of the charger, the operating data of the high-voltage battery module and the operating data of the DC / AC group module, and control the start and stop of the charger based on the operating data of the charger, the operating data of the high-voltage battery module and the operating data of the DC / AC group module; the input end of the charger is used to input three-phase alternating current; when the charger is turned on, the three-phase alternating current is converted into direct current to charge the high-voltage battery module; the charger stops after the high-voltage battery module is saturated; the DC / AC group module is used to convert the direct current output by the high-voltage battery module into three-phase alternating current to power the power motor.

[0044] The high-voltage battery module includes: a high-voltage box and a battery pack; the high-voltage box is on the high-voltage box branch; the high-voltage box branch is connected in parallel with the charger; the battery pack is connected in parallel with the high-voltage box; the high voltage is also connected to the PLC module; the high-voltage box is used to charge the battery pack with the DC power converted by the charger; the battery pack is used to power the load. The battery capacities of multiple batteries in the battery pack are different.

[0045] The high voltage box branch is provided with a first branch fuse. The electric well repair machine electrical control device also includes: a main fuse; the main fuse is provided between the charger and the high voltage box branch.

[0046] The DC / AC group module includes multiple DC / AC branches; multiple DC / AC branches are connected in parallel with the high-voltage battery module; multiple DC / AC branches are connected to corresponding loads respectively; multiple DC / AC branches are connected to the PLC module; the DC / AC branch is used to convert the DC power output by the high-voltage battery module into three-phase AC power to power the power motor. The DC / AC branch includes: a second branch fuse and a DC / AC converter connected in series.

[0047] The PLC module includes: a PLC and a touch screen; the PLC is connected to the touch screen, the charger, the high-voltage battery module and the DC / AC group module respectively; the PLC is used to obtain the operating data of the charger, the operating data of the high-voltage battery module and the operating data of the DC / AC group module, and control the start and stop of the charger based on the operating data of the charger, the operating data of the high-voltage battery module and the operating data of the DC / AC group module.

[0048] This device consists of a charger, a high-voltage battery module, a PLC module and a DC / AC module. The charger converts three-phase AC power into stable DC power and charges the battery pack through the high-voltage box. When the battery pack is saturated, the charger stops charging the battery pack. When the load needs to be powered, the battery pack discharges to the DC / AC through the DC bus, and the DC / AC converter converts DC power into three-phase AC power to supply the power motor, thereby driving the mechanical system to operate.

[0049] The electric workover rig electrical control device provided in this embodiment has an overall architecture design, including an integrated solution of hardware and software. The hardware includes a charger, a high-voltage battery module, a PLC module, and a DC / AC group module, etc.; the software includes a control program for hardware such as a PLC control system, a charger, a high-voltage battery module, and a DC / AC module, and a unified two-way communication is performed through the CAN2.0 protocol to realize the unified control of the PLC control system on the charger, the high-voltage battery module, and the DC / AC module. The charger realizes the energy replenishment of the system DC bus and the battery; the high-voltage battery module realizes the energy storage of the system; the DC / AC module realizes the precise speed and torque control of each motor of the workover rig, thereby realizing the operation process control of the electric workover rig. The communication scheme between different modules includes a data transmission protocol, a signal processing mechanism, etc. The electric workover rig is innovative in improving energy efficiency and extending the service life of the equipment. Set working procedures and safety protection measures to improve the safety and efficiency of operation. Real-time monitoring of system abnormalities, providing alarm functions, setting overcurrent, overvoltage, overheating and other protection measures to ensure equipment safety.

[0050] When the motor is under high load, the main problem involved is the heat dissipation of the motor and its supporting controller, which can be effectively solved by the thermal management unit. Under high temperature conditions, such as 45°C, the temperature control system of the thermal management unit is tested and reaches the cooling temperature threshold set by the system. The compressor in the thermal management unit starts, and the refrigeration system starts working. A closed loop is formed through temperature feedback, and the temperature of the motor and its supporting controller is effectively controlled within the range of 0-30°C, ensuring the reliable operation of the system; under low temperature conditions, such as -30°C, the temperature control system of the management unit is tested and reaches the heating temperature threshold set by the system. The PTC heating component in the thermal management unit starts to start, and a closed loop is formed through temperature feedback, effectively controlling the temperature of the motor and its supporting controller within the range of 0-30°C, ensuring the reliable operation of the system.

[0051] In another embodiment, a control method for an electric workover machine electrical control device is provided. The control method for the electric workover machine electrical control device is applied to the electric workover machine electrical control device. The control method for the electric workover machine electrical control device includes:

[0052] Step 1: Get the real-time power of the power motor.

[0053] Step 2: When the real-time power reaches the power threshold, the charger and the high-voltage battery module are controlled to charge the power motor at the same time.

[0054] Step 3: When the real-time power does not reach the power threshold, the charger is controlled to charge the high-voltage battery module.

[0055] Step 4: Get the real-time power of the battery pack in the high-voltage battery module.

[0056] Step 5: When the real-time power level is lower than the power safety threshold, the battery pack in the high-voltage battery module is controlled to stop discharging.

[0057] The technical features of the above embodiments may be combined arbitrarily. To make the description concise, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0058] This article uses specific examples to illustrate the principles and implementation methods of this application. The description of the above embodiments is only used to help understand the method and core ideas of this application. At the same time, for those skilled in the art, according to the ideas of this application, there will be changes in the specific implementation methods and application scope. In summary, the content of this specification should not be understood as limiting this application.

Claims

1. An electrical control device for an electric workover rig, characterized in that: include: Charger, high-voltage battery module, PLC module and DC / AC group module; The PLC module is connected to the charger, the high-voltage battery module and the DC / AC group module respectively; the output end of the charger is connected to the high-voltage battery module; the DC / AC group module is connected to the load; the load is the power motor in the electric workover rig; The PLC module is used to obtain the operating data of the charger, the operating data of the high-voltage battery module and the operating data of the DC / AC group module, and control the start and stop of the charger based on the operating data of the charger, the operating data of the high-voltage battery module and the operating data of the DC / AC group module; The input end of the charger is used to input three-phase alternating current; when the charger is turned on, the three-phase alternating current is converted into direct current to charge the high-voltage battery module; when the high-voltage battery module is saturated with electricity, the charger stops; The DC / AC group module is used to convert the direct current output by the high-voltage battery module into three-phase alternating current to power the power motor.

2. The electric control device for an electric workover rig according to claim 1, characterized in that: The high-voltage battery module includes: a high-voltage box and a battery pack; The high-voltage box is on a high-voltage box branch; the high-voltage box branch is connected in parallel with the charger; The battery pack is connected in parallel with the high voltage box; The high voltage is also connected to the PLC module; the high voltage box is used to charge the battery pack using the direct current converted by the charger; The battery pack is used to supply power to the load.

3. The electric control device for an electric workover rig according to claim 2, characterized in that: The battery capacities of the plurality of batteries in the battery pack are different.

4. The electric control device for an electric workover rig according to claim 2, characterized in that: The high voltage box branch is provided with a first branch fuse.

5. The electric control device for an electric workover rig according to claim 2, characterized in that: The electric workover rig electrical control device further comprises: a main fuse; The main fuse is arranged between the charger and the high-voltage box branch.

6. The electric control device for an electric workover rig according to claim 2, characterized in that: The DC / AC group module includes a plurality of DC / AC branches; The plurality of DC / AC branches are connected in parallel with the high-voltage battery module; The plurality of DC / AC branches are respectively connected to corresponding loads; A plurality of the DC / AC branches are connected to the PLC module; The DC / AC branch is used to convert the direct current output by the high-voltage battery module into three-phase alternating current to power the power motor.

7. The electric control device for an electric workover rig according to claim 6, characterized in that: The DC / AC branch includes: a second branch fuse and a DC / AC converter connected in series.

8. The electric control device for an electric workover rig according to claim 1, characterized in that: The PLC module includes: a PLC and a touch screen; The PLC is connected to the touch screen, the charger, the high-voltage battery module and the DC / AC group module respectively; The PLC is used to obtain the operating data of the charger, the operating data of the high-voltage battery module and the operating data of the DC / AC group module, and control the start and stop of the charger based on the operating data of the charger, the operating data of the high-voltage battery module and the operating data of the DC / AC group module.

9. A control method for an electric control device of an electric workover rig, characterized in that: The control method of the electric workover rig electrical control device is applied to the electric workover rig electrical control device according to any one of claims 1 to 8, and the control method of the electric workover rig electrical control device comprises: Get the real-time power of the power motor; When the real-time power reaches the power threshold, controlling the charger and the high-voltage battery module to charge the power motor simultaneously; When the real-time power does not reach the power threshold, the charger is controlled to charge the high-voltage battery module.

10. The control method of the electric control device of the electric workover rig according to claim 9, characterized in that: The control method of the electric workover rig electrical control device also includes: Get the real-time power of the battery pack in the high-voltage battery module; When the real-time power level is lower than the power safety threshold, the battery pack in the high-voltage battery module is controlled to stop discharging.

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