Beam pumping unit intelligent brake device, using method and remote control method

Abstract

The application discloses a beam pumping unit intelligent brake device and a use method and a remote control method, and relates to the technical field of oil extraction, in particular to the beam pumping unit intelligent brake device and the use method and the remote control method. The beam pumping unit intelligent brake device comprises a brake part connected with an input shaft of a pumping unit, the brake part is connected with a transmission part, the transmission part is connected with a self-control part, and the self-control part is connected with a multifunctional pumping unit control cabinet. The self-control part adjusts brake starting time through an intelligent brake device closed-loop control system. The multifunctional pumping unit control cabinet is further connected with an information part. The application has information function, remote well opening function, break-in shutdown function and power-off shutdown function, realizes intelligent brake, provides effective application data for the application of a new technology of oil field "two integration", and fills the technical blank of the oil field intelligent brake without well shutdown.

Description

Technical Field

[0001] This invention relates to the field of petroleum equipment, specifically to an intelligent braking device for a beam pumping unit, its usage method, and a remote control method. Background Technology

[0002] The timeliness and stability of the brakes on beam pumping units directly affect the safety of oilfield production and the lives of personnel. Currently, the external braking system widely used in beam pumping units in oilfields consists of components such as a brake handle, brake center seat, lever, locking spring, brake hub, and brake shoes. It connects the brake lever to the brake handle and brake shoes via the brake horn on the brake center seat. When the pumping unit stops, an operator must be on-site, holding the brake handle and pulling it backward. The force, through leverage, is transmitted to the brake shoes and brake hub, generating friction. This friction creates static torque on the input shaft of the gearbox connected to the brake hub, thus braking the pumping unit.

[0003] The braking system has several problems: First, during normal production, if the pumping unit suddenly malfunctions and stops, or experiences a power outage, the wells are scattered across the field, making it difficult for staff to reach the site in time to manually apply the brakes. Second, if external personnel or animals enter the area, the pumping unit may suddenly rotate due to changes in operating conditions, potentially causing serious safety accidents such as injuries or fatalities.

[0004] Secondly, prolonged use of beam pumping units in the field can lead to brake pad wear, slippage, and loosening, reducing friction and increasing the risk of brake failure or insecure braking. During routine maintenance, repairs, wellhead pump contact, and anti-surge adjustment, brake failure or insecure braking frequently results in injuries to workers caused by crushing or crushing of moving parts of the pumping unit. Thirdly, forgetting to brake beam pumping units during well shutdown can cause sudden rotation due to changes in operating conditions, leading to serious safety accidents such as injuries or fatalities.

[0005] Publication No. CN219035394U discloses a braking mechanism for an oilfield pumping unit, including a base plate. A control plate is fixedly connected to the front right end of the base plate. An upper sliding plate and a lower sliding plate are fixedly connected to the top and bottom left ends of the control plate, respectively. The bottom right side of the upper sliding plate and the top right side of the lower sliding plate are slidably connected to both ends of a clamping plate. A slider is slidably connected to the inner wall of the right end of the clamping plate. The top and bottom ends of the slider are fixedly connected to one end of a spring. In this prior art, an electric push rod drives the clamping plate to slide towards a reduction gear, and then a clamping block locks the reduction gear. A compression spring provides buffering. When the slider slides to the stop, the reduction gear is locked. The braking effect is stable and wear is reduced. The movement of the electric push rod is controlled by a remote controller, realizing remote control and reducing the risk of accidents caused by manual braking.

[0006] The existing technology is unable to cope with sudden well malfunctions, sudden power outages, or machine shutdowns, and it is also unable to respond to the intrusion of personnel or animals.

[0007] Publication No. CN116336108A discloses an electrically controlled braking device for a beam pumping unit. It includes a base plate with symmetrically distributed sliding members slidably connected to it. Each sliding member is fixed to a brake disc via a drive shaft. The sliding members are equipped with a braking mechanism for stopping the beam pumping unit. The braking mechanism includes a first ring fixed to the sliding members, a first cavity filled with hydraulic oil for power transmission within the first ring, and a buffer mechanism within the first ring. The sliding members are symmetrically equipped with locking mechanisms. The buffer mechanism controls the resistance to the brake disc by mitigating the resistance experienced by the hydraulic oil during flow, reducing the change in braking speed during the initial braking phase and preventing overload damage to the drive shaft due to excessively short braking time. The locking mechanism locks the brake disc when it stops, improving the stability of the pumping unit during maintenance and providing safety assurance for subsequent maintenance work.

[0008] The existing technology is unable to cope with sudden well failures, power outages, or machine shutdowns, and it is also unable to respond to the intrusion of personnel or animals.

[0009] Publication No. CN115263251A discloses a remote automatic braking device for an oil pumping unit, comprising a base, a reduction gearbox base, a reduction gearbox, a brake clamp, a limit switch base, and an electric push rod base on the side wall of the reduction gearbox base. The electric push rod base has a detachable electric push rod, and the upper part of the electric push rod has a detachable electric brake longitudinal connecting rod. The top of the electric brake longitudinal connecting rod has a detachable double-groove pull rod cam. The base also includes a handbrake base, a handbrake transmission seat, and a manual brake longitudinal connecting rod. This remote automatic braking device for an oil pumping unit effectively solves the problem of remote automatic braking of oil pumping units without changing their structure, principle, performance, and safety factor, further improving the inherent safety of the oil pumping unit and ensuring safe on-site production operation.

[0010] The existing technology is unable to cope with sudden well malfunctions, sudden power outages, or machine shutdowns, and it is also unable to respond to the intrusion of personnel or animals.

[0011] In summary, the technical solutions, technical problems to be solved, and beneficial effects of the above-disclosed technologies are all different from those of the present invention. For more technical features, technical problems to be solved, and beneficial effects of the present invention, the above-disclosed technical documents do not provide any technical inspiration. Summary of the Invention

[0012] To address the aforementioned deficiencies in existing technologies, the purpose of this invention is to provide an intelligent braking system for beam pumping units in oil wells. This system can solve problems such as the inability to brake in time during beam pumping unit malfunctions or sudden power outages, or forgetting to brake during maintenance. This invention controls the braking device through an adaptive closed-loop control system, uses a pressure sensor to provide feedback on the locking pressure, and employs an intelligent pre-control memory system and solar cells to ensure the equipment can operate even in the event of a power outage. This reduces the risk of injury or death caused by sudden rotation of the pumping unit when brakes are not applied or fail, protecting personnel and equipment. The command center can remotely control the braking device and monitor the braking status via an app and intranet platform.

[0013] To achieve the above objectives, the present invention employs the following technical solution:

[0014] The intelligent braking device for a beam pumping unit includes a braking section connected to the input shaft of the pumping unit, the braking section being connected to a transmission section, the transmission section being connected to an automatic control section, and the automatic control section being connected to a multi-functional pumping unit control cabinet; the automatic control section adjusts the braking start time through a closed-loop control system of the intelligent braking device.

[0015] The automatic control unit includes a power supply line installed in the automatic control cabinet, a protection circuit connected to the power supply line, an intelligent control circuit and a manual control circuit connected to the protection circuit respectively, the controlled equipment connected to the control circuit, and also includes a clean energy power supply line.

[0016] The automatic control section includes a power supply line, which includes a terminal block. The power supply line is connected to the protection circuit through the terminal block, and the terminal block also connects the signal lines of various components.

[0017] The protection circuit includes a power switch, a leakage current protector, and a power-off AC contactor arranged sequentially on the line.

[0018] The intelligent control circuit includes a PLC and a delayed start time relay, a timing stop time relay, and a release brake time set relay, which are respectively connected to the PLC. The timing stop time relay and the release brake time set relay are connected to the brake motor of the controlled equipment. The delayed start time relay is also connected to an intermediate relay. The PLC is powered through a power-off AC contactor.

[0019] The manual control circuit includes a manual / automatic switch, which is connected to an intermediate relay, a delayed start time relay, a brake control button, and forward and reverse buttons. The brake control button is connected to a brake release time relay, and the manual / automatic switch is connected to a power-off AC contactor for power supply.

[0020] The power switch is also connected to a clean energy power supply line, which is a solar cell.

[0021] The braking system includes a brake motor, the output shaft of which is connected to a worm gear drive to convert rotation into movement. A manual brake disc is mounted on the worm gear drive, and a horizontal tie rod is connected to the other end of the worm gear drive. The horizontal tie rod is connected to one corner of the steering horn on the intermediate seat, and the other corner of the steering horn on the intermediate seat is connected to a longitudinal tie rod. The steering horn converts lateral movement into longitudinal movement.

[0022] A brake buffer section is provided on the longitudinal tie rod. A first spring is provided at the upper end of the brake buffer section and a second spring is provided at the lower end. A pressure sensor is fixedly connected to the lower end of the first spring.

[0023] It also includes a brake rocker arm, one end of which is connected to a longitudinal tie rod, and the other end of which is provided with a movable fixing pin hole. A connecting pin is provided in the movable fixing pin hole, and the connecting pin fixing part is connected and fixed to the oil pumping unit. A return spring is provided in the stroke part. An arc-shaped rack is fixedly connected to the lower part of the brake rocker arm, and the lower tooth profile of the arc-shaped rack cooperates with the brake gear provided on the input shaft of the reduction gearbox.

[0024] The brake rocker arm is installed on the outside of the original brake hub of the input shaft of the pumping unit gearbox. The front end of the connecting pin is fixed to the pumping unit. The movable fixing pin hole moves back and forth on the connecting pin. The brake rocker arm rotates around the movable fixing pin hole. When the brake is restored, the return spring causes the movable fixing pin hole to return to its original position.

[0025] The multi-functional pumping unit control cabinet is connected to the automatic control cabinet. The multi-functional pumping unit control cabinet is connected to an AC contactor for power supply. The AC contactor is connected to a power-delayed power supply time relay of the control cabinet. The power-delayed power supply time relay of the control cabinet is connected to a brake release time relay. The multi-functional pumping unit control cabinet connects a signal line to a terminal block via a power-off AC contactor. The signal line is connected to a manual / automatic switch at the terminal block. The signal line transmits a shutdown signal while energized when the pumping unit fails to shut down.

[0026] The PLC collects signals from the pressure sensor and the time relay connected to the PLC in real time. By using the data feedback from the pressure sensor and the time set by the relay, a closed-loop control system for the intelligent braking device is formed.

[0027] The closed-loop control system of the intelligent braking device adopts a control algorithm based on PID with neural network adaptive adjustment, wherein the incremental PID formula is as follows:

[0028] (1)

[0029] Where K p For proportional adjustment parameters, K i For integral adjustment parameters, K d K is the differential adjustment parameter, and k is the controller gain parameter. The optimal values ​​of the three parameters are calculated through a neural network. The motor rotation time and locking pressure exhibit obvious nonlinear characteristics. When PID is used to solve linear problems, K... p K i K d An optimal solution exists, but for nonlinear problems, the optimal parameters differ at different times.

[0030] Control quantity net of intelligent braking system i 2 (k) and output O i 2 (k) The formula is:

[0031]

[0032] The deviation between the actual locking pressure and the expected locking pressure of the locking device is e(k) = 0. i -x j The incremental PID control algorithm is used to calculate the value of the PID control quantity u(k), and the result obtained by discretization is shown in equation (3):

[0033]

[0034] Among them, T I and T D The integral and derivative time parameters are respectively; the control increment of the PID is further obtained as shown in equation (4):

[0035] (4)

[0036] BP-PID automatic learning relies on performance evaluation indicators to continuously optimize the nonlinear model that approximates the rotation time and locking pressure of the locking motor.

[0037] The multi-functional oil pumping unit control cabinet is also connected to an information technology component; this component includes the PDM2000, i.e., the production command system, located in the safety production command center of the management area.

[0038] The PDM2000 commands the multi-functional pumping unit control cabinet in the downstream well site, which has a built-in RTU, i.e., remote terminal unit.

[0039] The multi-functional pumping unit control cabinet is also equipped with a remote braking module controlled by the RTU and an automatic stop braking module for entering prohibited areas.

[0040] The remote braking module and the automatic stop braking module for entering prohibited areas are controlled by a PLC to start and stop the brake motor.

[0041] The PLC has a network communication module that uploads braking data to the PDM in real time.

[0042] The operating method of the intelligent braking device for a beam pumping unit includes the following steps.

[0043] S1: Circuit setup steps;

[0044] The delayed start time relay and the control cabinet delayed power supply time relay are open circuit by default. They start timing after startup and turn on after timing is completed.

[0045] The timing stop relay and the release brake time set relay are in the default state of being on. They start timing after being activated and disconnect after timing is completed.

[0046] The intermediate relay execution part is installed on the power line of the pumping unit, so that the pumping unit loses power when it is started.

[0047] S2: Steps for adjusting the brakes;

[0048] When adjusting the brake, set the manual / automatic switch to the manual position. The intermediate relay will start, disconnecting the power supply to the pumping unit and protecting it. Use the reverse stop button, reverse start button, forward stop button, and forward start button as needed to adjust the clearance between the brake rack and gear. After adjustment, set the manual / automatic switch to automatic mode.

[0049] S3: Steps for automatic brake restart after pumping unit malfunction and shutdown;

[0050] When the pumping unit fails and stops, a stop signal is sent from the multi-functional pumping unit control cabinet. The manual / automatic switch is activated to reach the automatic state, the automatic brake is started, and the delayed start time relay starts timing. After a delay of several seconds, the pumping unit comes to a complete stop. The intermediate relay is activated, disconnecting the power supply line to the pumping unit. The delayed start time relay is activated, and the brake motor 201 starts rotating forward. After running for several seconds, the stop time relay is activated after the stop time set by the timing stop time relay. The stop time relay is then deactivated, the brake motor stops, and the braking is completed.

[0051] S4: Release the brake and turn on the machine.

[0052] In automatic mode, pressing the brake start button releases the brake time relay to start timing, the brake motor starts and reverses, running for several seconds until the brake is fully released, the brake time relay disconnects, and the brake motor stops running; after a delay of a few seconds, the power supply delay time relay in the multi-functional pumping unit control cabinet activates the AC contactor, and pressing the well motor start button starts the pumping unit.

[0053] A remote control method for an intelligent braking device of a beam pumping unit, the control method including information function, remote well opening function, intrusion shutdown function and power failure shutdown function;

[0054] The information technology functions are as follows:

[0055] Each time the brakes are applied and released, the program within the remote braking module transmits a braking completion signal / brake release completion signal to the RTU.

[0056] The RTU transmits signals to the safety production command center's backend data acquisition server via the network, and the server displays the data in real time within the PDM2000.

[0057] The PDM system sets alarm values ​​based on big data of the operating status of the pumping unit's brakes and brake release. When the alarm value is exceeded, an alarm sound is issued to prompt the monitoring personnel to promptly grasp the status of the brakes, pumping unit, and production operation information, and take emergency production measures.

[0058] The remote well-opening function is as follows:

[0059] When remote well opening is required, the personnel at the well monitoring post in the safety production command center issue a brake release command. The PDM2000 transmits the command to the well site RTU via the network, and then to the remote brake module. The PLC then initiates the brake release program within the automatic control system to release the brake completely.

[0060] If the brake is not fully released, the intermediate relay in the automatic control system will self-lock for protection, causing the pumping unit motor to lose power and prevent it from starting. At the same time, the brake release status will be verified via the well monitoring video.

[0061] Once the brakes are confirmed to be fully released, the personnel at the well monitoring post in the safety production command center issue a remote well-opening command to open the well.

[0062] The intrusion shutdown function is as follows:

[0063] Using the balance fast rotation displacement axis of the beam pumping unit as the baseline, electronic fences for prohibited areas are set up on both sides of the pumping unit.

[0064] When the pumping unit is running, if outsiders, biological personnel, inspection personnel, or construction personnel touch the electronic fence set by the video surveillance, the automatic shutdown and braking module will immediately initiate the emergency shutdown and emergency braking procedure via the PIC after recognizing the intrusion into the prohibited area.

[0065] The power outage shutdown function is as follows:

[0066] When the oil well motor stops due to power failure or malfunction, the AC contactor in the control cabinet of the multi-functional pumping unit transmits the power failure signal to the AC contactor in the automatic control box. The signal reaches the manual / automatic switch through the wiring terminal, which activates the automatic braking mode and completes the braking.

[0067] It also issues alarm sounds through information technology functions, prompting monitoring personnel to promptly grasp the shutdown and braking production status and take timely emergency production measures.

[0068] Compared with the prior art, the present invention has the following advantages:

[0069] 1) Intelligent braking has been achieved, providing effective application data for the next step of the application of new technologies for the integration of informatization and industrialization in the oilfield, and filling the technological gap of intelligent braking without well shutdown in the oilfield.

[0070] 2) Ensure the brake wheel teeth are fully engaged, making the brakes secure and reliable;

[0071] 3) Information technology makes it easier for monitoring personnel to keep track of production status such as shutdown and braking, and to take timely emergency measures.

[0072] 4) It enables remote braking and remote brake release, saving a significant amount of labor costs and improving labor efficiency;

[0073] 5) The electronic fence function ensures the safety of external personnel, organisms, inspection and construction personnel when the oil pumping unit is running; Attached Figure Description

[0074] Figure 1 This is a simplified structural diagram of the intelligent braking device for the beam pumping unit of the present invention, its usage method, and its remote control method;

[0075] Figure 2 For the present invention Figure 1 Schematic diagram of the automatic control section;

[0076] Figure 3 For the present invention Figure 1 Schematic diagram of the horizontal structure of the central transmission section;

[0077] Figure 4 For the present invention Figure 1 Schematic diagram of the vertical structure of the central transmission section;

[0078] Figure 5 For the present invention Figure 1 Schematic diagram of the middle brake section;

[0079] Figure 6 For the present invention Figure 5 A schematic diagram of the structure of the connecting pin;

[0080] Figure 7 For the present invention Figure 1 Schematic diagram of the information technology component structure;

[0081] Figure 8 This is a schematic diagram of the connection structure of the various parts of the present invention;

[0082] Figure 9 This is a schematic diagram of the transfer function of the intelligent braking part of the present invention.

[0083] In the diagram: 1. Automatic control section; 2. Transmission section; 3. Braking section; 4. Information system section; 5. Multifunctional oil pumping unit control cabinet; 101. Power switch; 102. Residual current device (RCD); 103. Power-off AC contactor; 104. Power-on AC contactor; 105. Terminal block; 106. Delay start relay; 107. Timing stop relay; 108. Brake release relay; 109. Control cabinet delay power supply relay; 110. Manual / automatic switch; 111. Brake start button; 112. Brake emergency stop; 113. Reverse stop button; 114. Reverse start button; 115. Forward stop button; 116. Forward start button; 117. Intermediate relay; 118. 119. Solar cell; 201. PLC (Programmable Logic Controller); 202. Brake motor; 203. Worm gear drive; 204. Manual brake disc; 205. Horizontal tie rod; 206. Intermediate seat; 207. Longitudinal tie rod; 208. Brake buffer; 209. Spring; 210. Pressure sensor; 301. Positioning pin; 302. Brake rocker arm; 303. Movable fixing pin hole; 304. Return spring; 305. Fixing part; 306. Arc rack; 307. Brake gear; 308. Input shaft; 401. Connecting pin; 402. PDM2000 (Production Command Center); 403. RTU (Remote Terminal Unit); 404. Remote braking module; 405. Automatic stop brake module for intrusion into prohibited areas. Detailed Implementation

[0084] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Example 1

[0085] Please see Figure 1The intelligent braking device for the beam pumping unit includes a braking part 3 connected to the input shaft 307 of the pumping unit. The braking part 3 is connected to the transmission part 2, which can control the working state of the braking part 3. The transmission part 2 is connected to the automatic control part 1 and is controlled by the automatic control part 1. The automatic control part 1 is connected to the multi-functional pumping unit control cabinet 5.

[0086] Please see Figure 2 The automatic control unit 1 includes a power supply line installed in the automatic control cabinet, a protection circuit connected to the power supply line, an intelligent control circuit and a manual control circuit connected to the protection circuit respectively, a controlled device connected to the control circuit, and also includes a clean energy power supply line.

[0087] The power supply line includes a terminal block 105, which is connected to the protection circuit. The terminal block 105 also connects the signal lines of various components.

[0088] The protection circuit includes a power switch 101, a leakage current protector 102, and a power-off AC contactor 103 arranged sequentially on the line. The power switch 101 is connected to the terminal block 105 to draw power.

[0089] The intelligent control circuit includes a PLC 119 and a delayed start time relay 106, a timing stop time relay 107, and a release brake time set relay 108, all connected to the PLC 119. The timing stop time relay 107 and the release brake time set relay 108 are connected to the brake motor 201 of the controlled device. The delayed start time relay 106 is also connected to an intermediate relay 117. The PLC 119 is connected to a power-off AC contactor 103 for power supply.

[0090] The manual control circuit includes a manual / automatic switch 110, which is connected to an intermediate relay 117, a delayed start time relay 106, a brake control button, and forward and reverse buttons. The brake control button is connected to a brake release time relay 108, and the manual / automatic switch 110 is connected to a power-off AC contactor 103 for power supply.

[0091] The power switch 101 is also connected to a clean energy power supply line, which is a solar cell 118.

[0092] The delayed start time relay 106 is in an open circuit state by default. It starts timing after startup and turns on after timing is completed.

[0093] The timing stop relay 107 is in the default state of being closed. It starts timing after being activated and disconnects after timing is completed.

[0094] The release brake time set relay 108 is in the default state of being on, and starts timing after being started and disconnects after timing is completed.

[0095] The intermediate relay 117 is installed on the power line of the pumping unit, and causes the pumping unit to lose power when it is started.

[0096] Please see Figure 3 , Figure 4 and Figure 8 The braking unit 2 includes a brake motor 201. The output shaft of the brake motor 201 is connected to a worm gear drive 202, which converts rotation into movement. A manual brake disc 203 is mounted on the worm gear drive 202. The other end of the worm gear drive 202 is connected to a horizontal tie rod 204. The horizontal tie rod 204 is connected to one corner of a yoke on a central seat 205. The other corner of the yoke on the central seat 205 is connected to a longitudinal tie rod 206. The yoke converts lateral movement into longitudinal movement.

[0097] A brake buffer section 207 is provided on the longitudinal tie rod 206. A first spring 208 is provided at the upper end of the brake buffer section 207 and a second spring 211 is provided at the lower end. A pressure sensor 209 is fixedly connected to the lower end of the first spring 208. The PLC 119 can receive and process the signal from the pressure sensor 209.

[0098] Please see Figure 5 , Figure 7 The brake part 3 includes a brake rocker arm 301. One end of the brake rocker arm 301 is connected to the longitudinal tie rod 206. The other end of the brake rocker arm 301 is provided with a movable fixing pin hole 302. A connecting pin 308 is provided in the movable fixing pin hole 302. The fixing part 304 of the connecting pin 308 is connected and fixed to the oil pump. A return spring 303 is provided in the stroke part. An arc-shaped rack 305 is fixedly connected to the lower part of the brake rocker arm 301. The lower tooth profile of the arc-shaped rack 305 cooperates with the brake gear 306 provided on the input shaft 307 of the reduction gearbox.

[0099] The brake rocker arm 301 is installed on the outside of the original brake hub of the input shaft of the pumping unit gearbox. The front end 304 of the connecting pin 308 is fixed to the pumping unit. The movable fixing pin hole 302 moves back and forth on the connecting pin 308. The brake rocker arm 301 rotates around the movable fixing pin hole 302. When the brake is restored, the return spring 303 returns the movable fixing pin hole 302 to its original position.

[0100] Please see Figure 2The multi-functional pumping unit control cabinet 5 is connected to the automatic control cabinet. The multi-functional pumping unit control cabinet 5 is connected to the energized AC contactor 104 for power supply. The energized AC contactor 104 is connected to the control cabinet delayed power supply time relay 109. The control cabinet delayed power supply time relay 109 is connected to the release brake time relay 108. The multi-functional pumping unit control cabinet 5 connects the signal line to the terminal block 105 through the power-off AC contactor 103. The signal line is connected to the manual / automatic switch 110 at the terminal block 105. The signal line transmits a shutdown signal while energized when the pumping unit fails to shut down.

[0101] The control cabinet's delayed power supply time relay 109 is in an open circuit state by default. It starts timing after power is applied and conducts to close the energized AC contactor 104 after the timing is completed. Example 2

[0102] Please see Figure 1 and Figure 7 The multi-functional pumping unit control cabinet 5 is also connected to an information system 4; the information system 4 includes a PDM2000 (production command system) 401 located in the safety production command center of the management area. The PDM2000 (production command system) 401 controls the multi-functional pumping unit control cabinet 5 in the downstream well site, which has a built-in RTU (remote terminal unit) 402. The multi-functional pumping unit control cabinet 5 is also equipped with a remote braking module 403 and an automatic stop braking module 404 for entering prohibited areas, which are controlled by the RTU (remote terminal unit) 402. The remote braking module 403 and the automatic stop braking module 404 for entering prohibited areas can control the start and stop of the brake motor 201 through the PLC 119.

[0103] The PLC 119 has a network communication module that uploads brake data to the PDM2000 (Production Command System) 401 in real time;

[0104] If the locking force exceeds the time limit, a buzzer alarm will sound and the situation will be reported to the command center.

[0105] Working principle of the invention:

[0106] Automatic control section 1:

[0107] When adjusting the brake, switch the manual / automatic selector switch 110 to the manual position, and the intermediate relay 117 will start, disconnecting the power supply line of the pumping unit to protect the pumping unit. Use the reverse stop button 113, the reverse start button 114, the forward stop button 115, and the forward start button 116 as needed to adjust the clearance between the brake rack and the gear. After adjustment, switch the manual / automatic selector switch 110 to automatic mode.

[0108] When the pumping unit fails and stops, the AC contactor in the multi-functional pumping unit control cabinet 5 transmits the power-off signal to the power-off AC contactor 103 in the automatic control box, and then through the wiring terminal 105 to the manual / automatic switch 110. This causes the manual / automatic switch 110 in automatic mode to start the automatic brake, and the delayed start time relay 106 starts timing for a delay of several seconds. At this time, the pumping unit comes to a complete stop. The intermediate relay 117 is activated, disconnecting the power supply line to the pumping unit. The delayed start time relay 106 is activated, and the brake motor 201 starts rotating forward. After running for several seconds, the stop time relay 107 is activated after the stop time is set by the timing stop time relay 107. The stop time relay 107 is then deactivated, and the brake motor 201 stops, completing the braking procedure.

[0109] When the brake is released and the machine is started, press the brake start button 111. The brake release time relay 108 starts timing, the brake motor 201 starts reversing and runs for several seconds. When the brake is fully released, the brake release time relay 108 disconnects and the brake motor 201 stops running. After a delay of xx seconds, the power supply delay time relay 109 in the multi-functional pumping unit control cabinet 5 connects the power-on AC contactor 104. Press the oil well motor start button and the pumping unit starts running.

[0110] Pressure sensor 209 feeds back brake locking pressure signal to PLC 119, which executes control algorithm and interacts with each time relay. After the control is completed, the rotation time of brake motor 201 is written into the time relay.

[0111] Solar-powered backup power supply can precisely brake when all equipment loses power, based on the most recent time of PLC 119's output.

[0112] Intermediate relay 117 de-energizes the pumping unit motor when the brake is locked, preventing it from starting and thus protecting the pumping unit's braking device and electrical equipment from damage.

[0113] Transmission part 2 and brake part 3:

[0114] When the brake is activated, the brake motor 201 starts to rotate forward, and through the worm gear drive 202, the motor's rotational torque is converted into radial tension, which pulls the horizontal tie rod 204 to move radially towards the motor. Through the brake yoke on the brake intermediate seat 205, the longitudinal tie rod 206 moves vertically downward to the ground. The longitudinal tie rod 206 pulls the brake rocker arm 301, which in turn moves the arc-shaped rack 305 below it downward to engage with the brake gear 306 for braking. The brake gear 306 engages with the arc-shaped rack 305 on the brake rocker arm through its gears, thus completing the pumping unit braking.

[0115] When the brake is released, the brake motor 201 reverses and converts the motor's rotational torque into radial thrust through the worm gear drive 202, pushing the horizontal tie rod 204 forward. Through the brake horn on the brake intermediate seat 205, the brake longitudinal tie rod 206 moves vertically upward, pushing the brake rocker arm 301 upward, which in turn drives the arc-shaped rack 305 below it to move upward and disengage from the brake gear 306.

[0116] During braking, a buffer protection mechanism is provided. A brake buffer section 207 is installed and fixed in the middle of the brake longitudinal tie rod 206 to prevent the brake motor from running for too long and damaging the brake device and circuit components. The pressure sensor 209 receives the brake locking force and sends the locking force pressure signal to the PLC 119 to adjust the braking time and achieve precise braking.

[0117] When using the manual disc brake: rotate the manual brake disc 203 with both hands as needed to achieve forward and reverse rotation of the worm gear drive 202;

[0118] When adjusting the brake part 3, when the brake is fully released by manual adjustment, the minimum distance between the tip of the brake arc rack 305 and the tip of the brake gear 306 is maintained at 10mm.

[0119] When the arc-shaped rack 305 of the brake rocker arm and the tooth tip of the brake gear 306 are aligned and cannot engage, the brake rocker arm, under the pull of the longitudinal tie rod 206, overcomes the elastic force of the fixed return spring 303 and moves back and forth around the brake fixing pin 304 until the arc-shaped rack 305 of the brake rocker arm and the tooth tip of the brake gear 306 are misaligned and engage.

[0120] Information Technology Part 4:

[0121] Information Functions: With each braking and release, the program within the remote braking module 403 transmits the braking / release signal to the RTU 402. The RTU 402 then transmits the signal via network to the safety production command center's backend data acquisition server. The server displays the data in real-time in the PDM2000 (production command system) 401. The PDM2000 401 system tracks the braking and release status of the pumping unit, allowing monitoring personnel to promptly grasp the shutdown and braking production status and take timely emergency production measures. When alarm thresholds are exceeded, an alarm sound is emitted, prompting monitoring personnel to promptly grasp the brake release and restart status, and to stay informed about production operation information.

[0122] Remote well opening function: When remote well opening is required, the personnel at the well monitoring post of the safety production command center issue a brake release command. The PDM2000 401 transmits the command to the well site RTU 402 via the network, and then to the remote brake module 403. The PLC 119 starts the brake release program in the automatic control system 1 to release the brake completely. If the brake is not completely released, the intermediate relay 117 in the automatic control system 1 will self-lock for protection, causing the pumping unit motor to lose power and not start. At the same time, the brake release status is verified through the well monitoring video. Once it is confirmed that the brake is completely released, the remote start-up can be initiated. The personnel at the well monitoring post of the safety production command center issue a remote well opening command, and the PDM2000 401 transmits the command to the well site RTU 402 via the network, and then to the remote brake start-up module to realize well opening.

[0123] Intrusion Stop Function: Using the balance fast rotation displacement axis of the beam pumping unit as the baseline, an electronic fence for the prohibited area is set up 50mm outward from both sides of the pumping unit; when the pumping unit is running, when external personnel, biological agents, inspection personnel, and construction personnel touch the electronic fence set by the video monitoring, the intrusion stop braking module 404 recognizes the intrusion and immediately initiates the emergency stop and emergency braking procedure through PIC 119 to ensure the safety of personnel and biological agents;

[0124] Power failure shutdown function: When the oil well motor loses power or fails to shut down, the AC contactor in the multi-functional pumping unit control cabinet transmits the power failure signal to the power failure AC contactor 103 in the automatic control box. The signal reaches the manual / automatic switch 110 through the terminal block 105. During normal operation, the switch 110 is in the automatic position, activating the automatic braking mode to complete the braking. At this time, the program in the remote braking module 403 transmits the braking signal to the well site RTU 402, communicates with the RTU 402, and transmits the data to the background acquisition server of the safety production command center through the wireless network. The data is displayed in real time in the PDM2000 401 system, and the braking status is displayed in the PDM2000 system. An alarm sound is also issued to remind the monitoring personnel to keep abreast of the shutdown and braking production status and take timely emergency production measures.

[0125] Intelligent Braking Function: Pressure sensor 209 is installed at the bottom of the first spring 208. The pressure sensor 209 feeds back a signal to PLC 119 in the control cabinet. PLC 119 executes a control algorithm and interacts with a time relay. After control is complete, the start time of the brake motor 201 is written into the time relay. The start time of the brake motor 201 and the locking pressure have a non-linear relationship with hysteresis, meaning there is a certain delay in the transmission of the motor's rotation to the braking system after passing through the physical device. The closer to the braking objective, the higher the conversion ratio between motor rotation time and locking pressure. This invention uses PID control with neural network adaptive adjustment for more precise control of the locking force. The PLC 119 collects the signal from pressure sensor 209 in real time, and the feedback from pressure sensor 209 forms a closed-loop control system for the intelligent braking device. The transfer function diagram of the intelligent braking device closed-loop control system is shown below. Figure 9 As shown.

[0126] This invention employs a PID-based control algorithm, wherein the incremental PID formula is as follows:

[0127] (1).

[0128] Where K p For proportional adjustment parameters, K i For integral adjustment parameters, K d K is the differential adjustment parameter, and k is the controller gain parameter. The optimal values ​​of the three parameters are calculated through a neural network. The motor rotation time and locking pressure exhibit obvious nonlinear characteristics. When PID is used to solve linear problems, K... p K i K d An optimal solution exists, but for nonlinear problems, the optimal parameters differ at different times.

[0129] Control quantity net of intelligent braking system i 2 (k) and output quantity O i 2 (k) The formula is:

[0130]

[0131] The deviation between the actual locking pressure and the expected locking pressure of the locking device is e(k) = 0. i -x j The incremental PID control algorithm is used to calculate the value of the PID control quantity u(k), and the result obtained by discretization is shown in equation (3):

[0132]

[0133] BP-PID automatic learning relies on performance evaluation indicators to continuously optimize the nonlinear model that approximates the rotation time and locking pressure of the locking motor.

[0134] It should be noted that PDM2000 (Production Command System) and RTU (Remote Terminal Unit) are commonly used management software and equipment in oil fields, and are existing technologies, which are clear to those skilled in the art.

[0135] All components not discussed in detail in this application, as well as the connection methods of these components, are well-known technologies in this field. They can be directly applied and will not be elaborated further.

[0136] In this invention, the term "multiple" refers to two or more unless otherwise explicitly defined. The terms "install," "connect," "link," and "fix" should be interpreted broadly. For example, "connect" can mean a fixed connection, a detachable connection, or an integral connection; "link" can mean a direct connection or an indirect connection via an intermediate medium. Those skilled in the art will understand the specific meaning of these terms in this invention according to the specific circumstances.

[0137] In the description of this invention, it should be understood that the terms "upper," "lower," "left," "right," "front," "rear," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or unit referred to must have a specific orientation or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0138] In the description of this specification, the terms "one embodiment," "some embodiments," "specific embodiment," etc., refer to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0139] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations will be apparent to those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An intelligent braking device for a beam pumping unit, comprising a braking section connected to the input shaft of the pumping unit, the braking section being connected to a transmission section, the transmission section being connected to an automatic control section, and the automatic control section being connected to a multi-functional pumping unit control cabinet; characterized in that, The automatic control unit adjusts the brake start time through a closed-loop control system of the intelligent braking device. The automatic control section includes a power supply line installed in the automatic control cabinet, a protection circuit connected to the power supply line, an intelligent control circuit and a manual control circuit connected to the protection circuit respectively, a controlled device connected to the control circuit, and a clean energy power supply line. The braking system includes a brake motor, the output shaft of which is connected to a worm gear drive to convert rotation into movement. A manual brake disc is mounted on the worm gear drive, and a horizontal tie rod is connected to the other end of the worm gear drive. The horizontal tie rod is connected to one corner of the steering horn on the intermediate seat, and the other corner of the steering horn on the intermediate seat is connected to a longitudinal tie rod. The steering horn converts lateral movement into longitudinal movement. A brake buffer section is provided on the longitudinal tie rod. A first spring is provided at the upper end of the brake buffer section and a second spring is provided at the lower end. A pressure sensor is fixedly connected to the lower end of the first spring. It also includes a brake rocker arm, one end of which is connected to a longitudinal tie rod, and the other end of which is provided with a movable fixing pin hole. A connecting pin is provided in the movable fixing pin hole, and the connecting pin fixing part is connected and fixed to the oil pumping unit. A return spring is provided in the stroke part. An arc-shaped rack is fixedly connected to the lower part of the brake rocker arm, and the lower tooth profile of the arc-shaped rack cooperates with the brake gear provided on the input shaft of the reduction gearbox. The brake rocker arm is installed on the outside of the original brake hub of the input shaft of the pumping unit gearbox. The front end of the connecting pin is fixed to the pumping unit. The movable fixing pin hole moves back and forth on the connecting pin. The brake rocker arm rotates around the movable fixing pin hole. When the brake is restored, the return spring makes the movable fixing pin hole return to its original position. The programmable logic controller (PLC) collects signals from the pressure sensor and the time relay connected to the PLC in real time. By using the data feedback from the pressure sensor and the time setting of the relay, a closed-loop control system for the intelligent braking device is formed. The closed-loop control system of the intelligent braking device adopts a control algorithm based on PID with neural network adaptive adjustment, wherein the incremental PID formula is as follows: （1） Where K p For proportional adjustment parameters, K i For integral adjustment parameters, K d K is the differential adjustment parameter, and k is the controller gain parameter. The optimal values ​​of the three parameters are calculated through a neural network. The motor rotation time and locking pressure exhibit obvious nonlinear characteristics. When PID is used to solve linear problems, K... p K i K d An optimal solution exists, but for nonlinear problems, the optimal parameters differ at different times. Control quantity net of intelligent braking system i 2 (k) and output O i 2 (k) The formula is: The deviation between the actual locking pressure and the expected locking pressure of the locking device is e(k) = 0. i -x j The incremental PID control algorithm is used to calculate the value of the PID control quantity u(k), and the result obtained by discretization is shown in equation (3): Among them, T I and T D The integral and derivative time parameters are respectively; the control increment of the PID is further obtained as shown in equation (4): （4） BP-PID automatic learning relies on performance evaluation indicators to continuously optimize the nonlinear model that approximates the rotation time and locking pressure of the locking motor.

2. The intelligent braking device for a beam pumping unit according to claim 1, characterized in that, The automatic control section includes a power supply line, which includes a terminal block. The power supply line is connected to the protection circuit through the terminal block, and the terminal block also connects the signal lines of various components. The protection circuit includes a power switch, a leakage current protector, and a power-off AC contactor arranged sequentially on the line. The intelligent control circuit includes a PLC and a delayed start time relay, a timing stop time relay, and a release brake time set relay, which are respectively connected to the PLC. The timing stop time relay and the release brake time set relay are connected to the brake motor of the controlled equipment. The delayed start time relay is also connected to an intermediate relay. The PLC is powered through a power-off AC contactor. The manual control circuit includes a manual / automatic switch, which is connected to an intermediate relay, a delayed start time relay, a brake control button, and forward and reverse buttons. The brake control button is connected to a brake release time relay, and the manual / automatic switch is connected to a power-off AC contactor for power supply. The power switch is also connected to a clean energy power supply line, which is a solar cell.

3. The intelligent braking device for a beam pumping unit according to claim 1, characterized in that, The multi-functional pumping unit control cabinet is connected to the automatic control cabinet. The multi-functional pumping unit control cabinet is connected to an AC contactor for power supply. The AC contactor is connected to a power-delayed power supply time relay of the control cabinet. The power-delayed power supply time relay of the control cabinet is connected to a brake release time relay. The multi-functional pumping unit control cabinet connects a signal line to a terminal block via a power-off AC contactor. The signal line is connected to a manual / automatic switch at the terminal block. The signal line transmits a shutdown signal while energized when the pumping unit fails to shut down.

4. The intelligent braking device for a beam pumping unit according to claim 3, characterized in that, The multi-functional oil pumping unit control cabinet is also connected to an information technology component; this component includes the PDM2000, i.e., the production command system, located in the safety production command center of the management area. The PDM2000 commands the multi-functional pumping unit control cabinet in the downstream well site, which has a built-in RTU, i.e., remote terminal unit. The multi-functional pumping unit control cabinet is also equipped with a remote braking module controlled by the RTU and an automatic stop braking module for entering prohibited areas. The remote braking module and the automatic stop braking module for entering prohibited areas are controlled by a PLC to start and stop the brake motor. The PLC has a network communication module that uploads braking data to the PDM in real time.

5. A method of using the intelligent braking device for a beam pumping unit as described in claim 2, characterized in that, Includes the following steps, S1: Circuit setup steps; The delayed start time relay and the control cabinet delayed power supply time relay are open circuit by default. They start timing after startup and turn on after timing is completed. The timing stop relay and the release brake time set relay are in the default state of being on. They start timing after being activated and disconnect after timing is completed. The intermediate relay execution part is installed on the power line of the pumping unit, so that the pumping unit loses power when it is started. S2: Steps for adjusting the brakes; When adjusting the brake, set the manual / automatic switch to the manual position. The intermediate relay will start, disconnecting the power supply to the pumping unit and protecting it. Use the reverse stop button, reverse start button, forward stop button, and forward start button as needed to adjust the clearance between the brake rack and gear. After adjustment, set the manual / automatic switch to automatic mode. S3: Steps for automatic brake restart after pumping unit malfunction and shutdown; When the pumping unit fails and stops, a stop signal is sent from the multi-functional pumping unit control cabinet. The manual / automatic switch is activated to reach the automatic state, and the automatic brake is started. The delayed start time relay starts timing for a certain number of seconds. At this time, the pumping unit comes to a complete stop. The intermediate relay is activated, which disconnects the power supply line to the pumping unit. The delayed start time relay is activated, and the brake motor starts to rotate forward. It runs for a certain number of seconds. After the stop time set by the timing stop time relay is reached, the stop time relay is deactivated, the brake motor stops, and the braking is completed. S4: Release the brake and turn on the machine. In automatic mode, pressing the brake start button releases the brake time relay to start timing, the brake motor starts and reverses, running for several seconds until the brake is fully released, the brake time relay disconnects, and the brake motor stops running; after a delay of a few seconds, the power supply delay time relay in the multi-functional pumping unit control cabinet activates the AC contactor, and pressing the well motor start button starts the pumping unit.

6. A remote control method for the intelligent braking device of a beam pumping unit as described in claim 4, characterized in that, The control method includes information technology functions, remote well opening functions, intrusion shutdown functions, and power failure shutdown functions. The information technology functions are as follows: Each time the brakes are applied and released, the program within the remote braking module transmits a braking completion signal / brake release completion signal to the RTU. The RTU transmits signals to the safety production command center's backend data acquisition server via the network, and the server displays the data in real time within the PDM2000. The PDM system sets alarm values ​​based on big data of the operating status of the pumping unit's brake and release brakes. When the alarm value is exceeded, an alarm sound is issued to prompt the monitoring personnel to promptly grasp the status of the brakes, pumping unit, and production operation information, and take emergency production measures. The remote well-opening function is as follows: When remote well opening is required, the personnel at the well monitoring post in the safety production command center issue a brake release command. The PDM2000 transmits the command to the well site RTU via the network, and then to the remote brake module. The PLC then initiates the brake release program within the automatic control system to release the brake completely. If the brake is not fully released, the intermediate relay in the automatic control system will self-lock for protection, causing the pumping unit motor to lose power and prevent it from starting. At the same time, the brake release status will be verified via the well monitoring video. Once the brake is confirmed to be fully released, the personnel at the well monitoring post in the safety production command center issue a remote well-opening command to open the well. The intrusion shutdown function is as follows: Using the balance fast rotation displacement axis of the beam pumping unit as the baseline, electronic fences for prohibited areas are set up on both sides of the pumping unit. When the oil pumping unit is running, if outsiders, biological personnel, inspection personnel, or construction personnel touch the electronic fence set by the video surveillance, the automatic shutdown and braking module will identify the intrusion into the prohibited area and immediately initiate the emergency shutdown and emergency braking program through the PLC. The power outage shutdown function is as follows: When the oil well motor stops due to power failure or malfunction, the AC contactor in the multi-functional pumping unit control cabinet transmits the power failure signal to the AC contactor in the automatic control box. The signal passes through the wiring terminal to the manual / automatic switch, which activates the automatic braking mode and completes the braking. It also issues alarm sounds through information technology functions, prompting monitoring personnel to promptly grasp the shutdown and braking production status and take timely emergency production measures.

Images