Submersible servo controller

Abstract

The invention discloses a submersible servo controller, and relates to the technical field of controllers. Comprising a controller body, the controller body comprises a controller shell and a driving assembly arranged in the controller shell, the driving assembly comprises a radiator, one end of the radiator is provided with a capacitor support, the radiator is provided with an integrated mainboard, and the integrated mainboard is provided with a power module. Two sealing rings and redundancy design are adopted, and three-proofing treatment is combined, so that the failure rate of equipment in a 3000-meter deep well, 150-DEG C high-temperature and 30-MPa high-pressure environment is reduced to be lower than that of traditional equipment, the service life of a sealing system is greatly prolonged, the strict requirements of offshore oil fields and unconventional oil and gas development are met, and on the basis of a three-level closed-loop control system and a self-adaptive PWM modulation technology, the service life of the equipment is greatly prolonged. The torque fluctuation of the permanent magnet synchronous motor is greatly reduced, the speed control error is smaller, the DC bus voltage utilization rate is improved, and the energy loss caused by underground load fluctuation is remarkably reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of controllers, and particularly to a submersible servo controller. Background Art

[0002] A servo driver, also known as a "servo controller" or "servo amplifier", is a controller used to control a servo motor. Its function is similar to that of a frequency converter acting on an ordinary AC motor and belongs to a part of the servo system. The submersible servo controller is applied to downhole equipment such as submersible screw pumps and reciprocating pumps.

[0003] Traditional submersible drive systems have multiple technical bottlenecks in complex downhole environments: on the one hand, the high-temperature and high-pressure environment leads to a high failure rate of electronic components and easy damage to the sealing system; on the other hand, the control accuracy of conventional drivers is insufficient, and it is impossible to perform real-time optimization and adjustment according to the changing characteristics of downhole fluids, resulting in low energy utilization efficiency and shortened equipment service life. The failure rate of traditional submersible drive equipment in deep wells over 3000 meters and environments with temperatures exceeding 150°C is as high as 30%. Each repair results in an average production stoppage of 5 - 7 days, and the direct economic loss exceeds 500,000 yuan per time. Summary of the Invention

[0004] To achieve the above object, the present invention provides the following technical solution: a submersible servo controller, including a controller main body, the controller main body includes a controller housing and a driving component disposed inside the controller housing. The driving component includes a radiator, one end of the radiator is provided with a capacitor bracket, an integrated main board is arranged on the radiator, a power module is arranged on the integrated main board, and a capacitor body is arranged inside the capacitor bracket.

[0005] As a preferred technical solution of the present invention, an installation groove is provided on one side of the radiator, and the bottom of the power module is embedded inside the installation groove.

[0006] As a preferred technical solution of the present invention, a plurality of heat dissipation fins are provided on the side of the radiator away from the installation groove, and a plurality of heat dissipation holes are arranged inside the radiator.

[0007] As a preferred technical solution of the present invention, a capacitor board is arranged inside the controller housing, the capacitor body is arranged on the capacitor board, a plurality of assembly holes are arranged inside the capacitor bracket, and the top of the capacitor body extends into the assembly holes.

[0008] As a preferred technical solution of the present invention, connection heads are arranged at both ends of the radiator, docking heads are arranged at both ends of the capacitor bracket, and the radiator and the capacitor bracket are locked and connected by cooperation of the connection heads and the docking heads with screws.

[0009] As a preferred technical solution of the present invention, baffles are provided inside both ends of the capacitor bracket, and wire passing hole plugs are provided inside the baffles.

[0010] As a preferred technical solution of the present invention, one end of the capacitor bracket away from the radiator is connected to a fixing plate through a docking head, and an end cover is provided at one end of the fixing plate away from the capacitor bracket.

[0011] As a preferred technical solution of the present invention, a housing rear plug and a housing front plug are respectively provided at both ends of the controller housing.

[0012] As a preferred technical solution of the present invention, double-sealed rings are nested at one ends of the housing rear plug and the housing front plug extending into the controller housing.

[0013] As a preferred technical solution of the present invention, one end of the housing rear plug extending into the controller housing is connected to one end of the radiator away from the capacitor bracket through a connecting head, and an I / O interface plug is provided at one end of the housing rear plug away from the radiator.

[0014] Compared with the prior art, the present invention provides a submersible servo controller, which has the following beneficial effects: This submersible servo controller adopts double-sealed rings and redundant design, combined with three-proof treatment, which reduces the failure rate of the equipment in the environment of 3,000-meter deep well, 150 °C high temperature and 30 MPa high pressure to below that of traditional equipment, greatly improves the service life of the sealing system, meets the stringent requirements of offshore oilfields and unconventional oil and gas development. Based on the three-level closed-loop control system and adaptive PWM modulation technology, it greatly reduces the torque fluctuation of the permanent magnet synchronous motor, has a smaller speed control error, improves the utilization rate of the DC bus voltage, and significantly reduces the energy loss caused by the load fluctuation underground. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a schematic structural diagram of a submersible servo controller proposed by the present invention; Figure 2 It is an exploded view of the controller housing structure of a submersible servo controller proposed by the present invention; Figure 3 It is a schematic structural diagram of a drive assembly of a submersible servo controller proposed by the present invention; Figure 4 It is an exploded view of the drive assembly structure of a submersible servo controller proposed by the present invention; Figure 5 It is a sectional view of the structure of a submersible servo controller proposed by the present invention.

[0016] In the figure: 1. Controller main body; 11. Controller housing; 111. Rear plug of the housing; 112. Front plug of the housing; 113. Double-channel sealing ring; 114. Plug for I / O interface; 12. Driving component; 121. Radiator; 1211. Connector; 1212. Heat dissipation holes; 1213. Heat dissipation fins; 1214. Installation groove; 122. Integrated main board; 123. Power module; 124. Capacitor bracket; 1241. Docking head; 1242. Baffle; 1243. Plug for wire passing hole; 125. Assembly hole; 126. Capacitor board; 127. Capacitor main body; 128. Fixed plate; 129. End cover. Detailed implementation manners

[0017] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0018] Please refer to Figures 1-5 , a submersible servo controller, including a controller main body 1, the controller main body 1 includes a controller housing 11 and a driving component 12 arranged inside the controller housing 11, the driving component 12 includes a radiator 121, one end of the radiator 121 is provided with a capacitor bracket 124, an integrated main board 122 is arranged on the radiator 121, a power module 123 is arranged on the integrated main board 122, and a capacitor main body 127 is arranged inside the capacitor bracket 124.

[0019] As a specific technical solution of this embodiment, an installation groove 1214 is arranged on one side of the radiator 121, and the bottom of the power module 123 is embedded inside the installation groove 1214.

[0020] In this implementation manner, the capacitor board 126 is electrically connected to the integrated main board 122. The integrated main board 122 is composed of a power board and a control board. The integrated main board 122 adopts a three-level closed-loop control system and PWM digital modulation technology. The three-level closed-loop control system includes a three-level closed-loop control architecture of a current loop (stable torque), a speed loop (optimize dynamic response), and a position loop (ensure positioning accuracy). Current loop: The sampling period is less than 10 μs. By real-time monitoring and adjusting the motor phase current, the stability of torque output is guaranteed, and the influence of downhole load fluctuation is effectively suppressed; Speed loop: The sampling period is 100 - 500 μs. Based on the feedback of a high-precision encoder, smooth acceleration and deceleration control are realized, and mechanical impact is reduced; Position loop: The sampling period is 1 - 5 ms. For application scenarios that require precise position control, such as precise stroke control of reciprocating pumps.

[0021] The PWM digital modulation technology realizes the precise control of the permanent magnet synchronous motor through 16-bit high-precision duty cycle adjustment. Carrier frequency: adjustable range 4 - 16 kHz, adaptively optimized according to different well depths and load conditions; Dead time: can be precisely adjusted to the 50 ns level, effectively avoiding the risk of shoot-through of the bridge arm; Overmodulation strategy: adopts space vector PWM (SVPWM) technology to improve the utilization rate of the DC bus voltage and expand the speed regulation range.

[0022] As a specific technical solution of this embodiment, a plurality of heat dissipation fins 1213 are provided on one side of the radiator 121 away from the installation groove 1214, a plurality of heat dissipation holes 1212 are provided inside the radiator 121, a capacitor board 126 is provided inside the controller housing 11, the capacitor body 127 is arranged on the capacitor board 126, and a plurality of assembly holes 125 are provided inside the capacitor bracket 124, and the top of the capacitor body 127 extends into the assembly holes 125.

[0023] In this implementation scheme, the cooperation of the heat dissipation fins 1213 and the heat dissipation holes 1212 ensures the heat dissipation efficiency of the integrated main board 122 and the power module 123. All components in the drive assembly 12 meet the working temperature range of -40°C to 120°C, and key components are selected as military-grade products; Three-proof treatment: The integrated main board 122 and the capacitor board 126 are treated with three-proof paint, effectively preventing moisture, salt spray, and mildew; Redundant design: Key sensors and control units adopt redundant design to ensure that a single-point failure does not affect the normal operation of the system.

[0024] It is widely applicable to conventional oilfield deep well oil production, unconventional oil and gas development, offshore oilfield development, and high-temperature and high-pressure oil reservoir development.

[0025] Conventional oilfield deep well oil production: Particularly suitable for deep well operation environments above 3000 meters; Unconventional oil and gas development: Such as exploitation under complex geological conditions such as shale oil and tight oil; Offshore oilfield development: Meeting the high-reliability requirements in the marine environment; High-temperature and high-pressure oil reservoir development: Can effectively cope with environments with temperatures exceeding 150°C and pressures of 30 MPa.

[0026] As a specific technical solution of this embodiment, connection heads 1211 are provided at both ends of the radiator 121, docking heads 1241 are provided at both ends of the capacitor bracket 124, and the radiator 121 and the capacitor bracket 124 are connected by screwing and locking with each other through the connection heads 1211 and the docking heads 1241. Baffles 1242 are provided inside both ends of the capacitor bracket 124, and wire passing hole plugs 1243 are provided inside the baffles 1242. One end of the capacitor bracket 124 away from the radiator 121 is connected with a fixing plate 128 through the docking head 1241, and an end cover 129 is provided at one end of the fixing plate 128 away from the capacitor bracket 124.

[0027] As a specific technical solution of this embodiment, a housing rear plug 111 and a housing front plug 112 are respectively provided at both ends of the controller housing 11, and double-sealed rings 113 are nested at one ends of the housing rear plug 111 and the housing front plug 112 extending into the controller housing 11.

[0028] In this implementation scheme, both ends of the controller housing 11 are sealed with double-sealed rings 113, effectively preventing oil stains from entering the inside of the controller housing 11.

[0029] As a specific technical solution of this embodiment, one end of the housing rear plug 111 extending into the controller housing 11 is connected with one end of the radiator 121 away from the capacitor bracket 124 through the connection head 1211, and an I / O interface plug 114 is provided at one end of the housing rear plug 111 away from the radiator 121.

[0030] In this implementation scheme, an I / O interface is provided on the integrated main board 122, the I / O interface plug 114 is opposite to the I / O interface, and the I / O interface belongs to the communication and interface module, supporting multiple field buses (such as CAN, Modbus) and wireless communication protocols.

[0031] In summary, this submersible servo controller adopts double-sealed rings 113 and redundant design, combined with three-proof treatment, reducing the failure rate of the equipment in the environment of 3000-meter deep well, 150 °C high temperature and 30 MPa high pressure to below that of traditional equipment, greatly improving the service life of the sealing system, meeting the stringent requirements of offshore oilfields and unconventional oil and gas development. Based on the three-level closed-loop control system and adaptive PWM modulation technology, the torque fluctuation of the permanent magnet synchronous motor is greatly reduced, the speed control error is smaller, and the utilization rate of the DC bus voltage is improved, significantly reducing the energy loss caused by the load fluctuation underground.

[0032] It should be noted that in this text, terms such as "including", "comprising", or any other variants thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or device that includes a series of elements not only includes those elements but also includes other elements not explicitly listed, or further includes elements inherent to such process, method, article, or device. Without further limitation, an element defined by the statement "including one..." does not exclude the existence of additional identical elements in the process, method, article, or device that includes the said element.

[0033] Although the embodiments of the present invention have been shown and described, it will be understood by those of ordinary skill in the art that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the present invention, and the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A submersible servo controller, comprising a controller body (1), characterized in that: The controller body (1) comprises a controller housing (11) and a drive assembly (12) arranged inside the controller housing (11); the drive assembly (12) comprises a radiator (121); a capacitor bracket (124) is arranged at one end of the radiator (121); an integrated mainboard (122) is arranged on the radiator (121); a power module (123) is arranged on the integrated mainboard (122); and a capacitor body (127) is arranged inside the capacitor bracket (124).

2. A submersible servo controller according to claim 1, characterized in that: A mounting groove (1214) is provided on one side of the heat sink (121), and the bottom of the power module (123) is embedded in the mounting groove (1214).

3. A submersible servo controller according to claim 1, characterized in that: A plurality of heat dissipation fins (1213) are arranged on a side of the heat sink (121) away from the mounting groove (1214), and a plurality of heat dissipation holes (1212) are arranged inside the heat sink (121).

4. A submersible servo controller according to claim 1, characterized in that: A capacitor plate (126) is arranged inside the controller housing (11), the capacitor body (127) is arranged on the capacitor plate (126), a plurality of assembly holes (125) are arranged inside the capacitor bracket (124), and the top of the capacitor body (127) extends to the inside of the assembly hole (125).

5. A submersible servo controller according to claim 1, characterized in that: Both ends of the radiator (121) are provided with connectors (1211), and both ends of the capacitor bracket (124) are provided with docking joints (1241); the radiator (121) and the capacitor bracket (124) are connected by screw locking via the connectors (1211) and the docking joints (1241).

6. A submersible servo controller according to claim 1, characterized in that: Baffles (1242) are provided inside both ends of the capacitor support (124), and wire hole plugs (1243) are provided inside the baffles (1242).

7. A submersible servo controller according to claim 1, characterized in that: One end of the capacitor support (124) away from the radiator (121) is connected to a fixing plate (128) via a docking joint (1241); and one end of the fixing plate (128) away from the capacitor support (124) is provided with an end cover (129).

8. A submersible servo controller according to claim 1, characterized in that: A housing rear plug (111) and a housing front plug (112) are respectively provided at both ends of the controller housing (11).

9. A submersible servo controller according to claim 8, characterized in that: A double-pass sealing ring (113) is embedded on one end of the housing rear plug (111) and the housing front plug (112) extending into the interior of the controller housing (11).

10. A submersible servo controller according to claim 8, characterized in that: One end of the housing rear plug (111) extending into the interior of the controller housing (11) is connected to one end of the radiator (121) away from the capacitor bracket (124) via a connector (1211); an I / O interface plug (114) is provided at one end of the housing rear plug (111) away from the radiator (121).

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