Electro-hydraulic servo closed pump controlled pumping unit with fault monitoring and real-time regulation

Abstract

The present application provides a kind of electro-hydraulic servo closed pump control pumping unit with fault monitoring and real-time regulation, it is related to pumping unit field, it includes pumping unit body, pump control unit, remote control unit and fault monitoring alarm unit;Fault monitoring alarm unit monitors pumping unit body and pump control unit and feeds back fault state signal, remote control unit controls pump control unit based on fault state signal;Fault monitoring alarm unit monitors relevant parameters and constructs nonlinear health assessment model based on dynamic coupling weight to carry out fault monitoring, sends alarm signal to pump control unit when failure occurs, realizes to adjust alarm quickly.Pump control unit combines the speed of oil cylinder with the output of oil production process demand, adjusts the speed and displacement in real time, realizes the double promotion of oil production efficiency and transmission efficiency.Hydraulic pump adopts closed hydraulic circuit design, reduces the throttling loss and heat loss of traditional open system, while pumping unit body structure is simplified, manufacturing cost is low, recovery efficiency is high.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of pumping unit, in particular to an electro-hydraulic servo closed pump control pumping unit with fault monitoring and real-time regulation. BACKGROUND

[0002] In recent years, hydraulic pumping units have been valued for their energy-saving and efficiency advantages. Hydraulic pumping units use accumulators to recover energy for energy saving, and there are also research and development of servo pump driven closed-loop hydraulic systems. However, these systems have some problems, such as large energy loss and low stability of the hydraulic throttling speed regulation system, and high cost and high maintenance cost of the servo pump driven system. The design of the new electro-hydraulic servo closed pump control pumping unit with fault monitoring and real-time regulation aims to overcome the defects of traditional pumping units and existing hydraulic pumping units. This hydraulic pumping unit has significant energy-saving performance. However, there is still no hydraulic pumping unit with good energy-saving effect, and a new electro-hydraulic servo closed pump control pumping unit with fault monitoring and real-time regulation is urgently needed. SUMMARY

[0003] The present application aims to provide an electro-hydraulic servo closed pump control pumping unit with fault monitoring and real-time regulation, which has a high power-to-weight ratio using an electro-hydraulic servo closed pump control unit, and a closed hydraulic circuit design for the hydraulic pump, reducing the throttling loss and heat loss of the traditional open system. At the same time, the pumping unit body structure is simplified, the manufacturing cost is low, and the recovery efficiency is high. At the same time, the fault monitoring and alarm unit monitors the relevant parameters to build a nonlinear health assessment model based on dynamic coupling weight for fault monitoring, and sends an alarm signal to the pump control unit when a fault occurs, realizing rapid alarm adjustment. The pump control unit combines the speed and output of the oil cylinder according to the oil production process requirements, and adjusts the speed and displacement in real time, realizing the double improvement of oil production efficiency and transmission efficiency.

[0004] Specifically, the present application provides an electro-hydraulic servo closed pump control pumping unit with fault monitoring and real-time regulation, which comprises a pumping unit body, a pump control unit, a remote control unit and a fault monitoring and alarm unit; the fault monitoring and alarm unit monitors the pumping unit body and the pump control unit and feeds back the fault state signal to the remote control unit, and the remote control unit remotely controls the pump control unit based on the fault state signal;

[0005] The fault monitoring and alarm unit monitors the load, pressure, flow, temperature, oil level, vibration and electrical parameters and builds a nonlinear health assessment model based on dynamic coupling weight for fault monitoring, and predicts whether a fault occurs, and sends an alarm signal to the pump control unit when a fault occurs;

[0006] The nonlinear health assessment model based on dynamic coupling weight is specifically:

[0007]

[0008] wherein, x = {P 载荷 , P 压力 , Q 流量 , T, L, V 振动 , E 电} is a multi-dimensional monitoring vector, u i , σ i represent the running basic value and standard value of each parameter respectively, P 载荷 , P 压力 , Q 流量 , T, L, V 振动 , E 电 are the monitored load, pressure, flow, temperature, oil level, vibration and electrical parameters respectively, characterizes the parameter change rate, γ i is the adaptive nonlinear order associated with the maximum parameter deviation, η i , τ i are the coupling coefficient and time constant respectively; and α is the weight.

[0009] When Ψ ≥ Ψ th , it is judged that a fault has occurred and a fault state signal is generated, which is characterized by:

[0010]

[0011] Preferably, the pump control unit comprises a controller, a servo driver, a servo motor, a variable pump, a first pressure sensor, a second pressure sensor and a displacement sensor; the controller is in bidirectional communication with the servo driver, the output of the servo driver is connected with the input of the servo motor, the driving end of the servo motor is connected with the variable pump, the first end and the second end of the variable pump are respectively connected with the upper chamber and the lower chamber of the hydraulic cylinder of the pumping unit body, and the first pressure sensor, the second pressure sensor and the displacement sensor are all connected with the input end of the controller.

[0012] Preferably, an encoder is arranged between the servo motor and the variable pump, the output of the encoder is connected with the servo driver, the variable pump is connected with an energy accumulator, and a one-way valve and a safety valve are respectively arranged on the pipeline connecting the first end and the second end of the variable pump with the upper chamber and the lower chamber of the hydraulic cylinder.

[0013] Preferably, the remote control unit is in communication connection with the controller and performs remote control, if a fault occurs, the fault monitoring and alarm unit sends the fault state signal to the remote control unit, the remote control unit analyzes the fault state signal and generates a hierarchical instruction, and adjusts the running parameters of the servo controller or triggers the shutdown protection according to the hierarchical instruction.

[0014] Preferably, the fault monitoring alarm unit comprises a load sensor, a third pressure sensor, a flow meter, a temperature sensor, a liquid level sensor, a vibration sensor, an electrical parameter measurement sensor and a central processor, which accepts the monitored load, pressure, flow, temperature, oil level, vibration and electrical parameters and outputs a fault state signal.

[0015] Preferably, the pumping unit body comprises a base, a hydraulic cylinder, a sucker rod, a transmission assembly, a counterweight box, a hydraulic station and an electric control cabinet; the counterweight box and the hydraulic cylinder are installed on the base, the hydraulic rod of the hydraulic cylinder is connected with the first end of the transmission assembly, the second end of the transmission assembly is connected with one end of the sucker rod, the pump control unit is arranged in the electric control cabinet, the variable pump is arranged in the hydraulic station, and the transmission assembly drives the sucker rod to move up and down under the drive of the hydraulic cylinder.

[0016] Preferably, the transmission assembly comprises a belt pulley, a movable pulley block, a balance belt, a first swing arm, a second swing arm, a rope hanger, a fixed arm pull rod and a drive belt, the first end of the rope hanger is connected with the sucker rod, the second end of the rope hanger is connected with the first end of the drive belt, the second end of the drive belt is connected with the hydraulic cylinder after passing through the pulley of the first swing arm and the movable pulley block in sequence, the first end of the balance belt is connected with the movable pulley block, the second end of the balance belt is connected with the counterweight box after passing through the pulley of the second swing arm in sequence, and the fixed arm pull rod is connected with the first swing arm and the second swing arm.

[0017] Preferably, the first pressure sensor and the second pressure sensor monitor the pressures of the lower cavity and the upper cavity of the hydraulic cylinder respectively, the controller inputs the efficiency characteristic distribution law of the servo motor and the variable pump as priori experience knowledge based on the monitored pressure values and the rotating speed monitored by the encoder, combines the oil cylinder speed and the output required by the oil production process to construct an optimization objective function, and adjusts the rotating speed and the displacement in real time to optimize the objective function, and the optimization objective function is:

[0018] Wherein, α and β are weighting coefficients, Q (t) is the system real-time flow, Q max is the system maximum flow, η m (n) is the servo motor efficiency, η p (D) is the variable pump efficiency.

[0019] Preferably, the fault monitoring alarm unit combines a neural network algorithm to construct an optimization objective function to automatically optimize pumping parameters, and the optimization objective function is:

[0020]

[0021] Wherein, Q opt is the theoretical maximum flow, λ is a fault suppression weight, φ 空 (t) is an empty pumping flag, φ 过 (t) is an overload flag.

[0022] Preferably, the empty pumping and overload fault constraint conditions are:

[0023]

[0024] wherein, is an indicator function, Q min ,p 干 , L max ,p max is a system safety threshold.

[0025] Compared with the prior art, the beneficial effects of the present application are as follows:

[0026] (1) The electro-hydraulic servo closed pump-controlled pumping unit with fault monitoring and real-time regulation of the present application realizes intelligent monitoring of the state of the pumping unit through the setting of load sensors, pressure sensors, flow meters, temperature sensors, liquid level sensors, vibration sensors, electric parameter measurement sensors and central processing units, thereby realizing fault monitoring and being able to quickly alarm and adjust when a fault may occur.

[0027] (2) The electro-hydraulic servo closed pump-controlled pumping unit with fault monitoring and real-time regulation of the present application adopts a pump-controlled hydraulic pumping scheme, realizes real-time adjustment of system pressure and flow through a variable displacement and variable speed power driving unit, meets the demand of different speeds and outputs of the hydraulic cylinder, and matches the real-time obtained oil production process. At the same time, in order to further improve the operation efficiency, an adaptive oil production process method based on a neural network is proposed, the efficiency characteristic distribution law of the servo motor and the variable pump is input as prior experience knowledge, the speed and output of the oil cylinder are combined with the demand of the oil production process, the speed and displacement are adjusted in real time, and finally the double improvement of the oil production efficiency and the transmission efficiency is realized.

[0028] (3) The hydraulic pump of the present application adopts a closed hydraulic circuit design, the hydraulic oil is circulated in the system, the throttling loss and heat loss of the traditional open system are reduced, the energy utilization rate is improved by 20% to 40%, the gravitational potential energy when the pumping rod is lowered is converted into hydraulic energy through potential energy recovery technology, the motor load is reduced, and the comprehensive energy saving can reach more than 30%. At the same time, the high power density and precise control ability of the closed pump control system make it more advantageous in deep well (>3000 meters) and super heavy oil exploitation.

[0029] (4) The pumping unit body of this invention no longer incorporates the complex mechanical transmission components of traditional pumping units, such as walking beams, gearboxes, and belts. It adopts a direct-drive hydraulic cylinder method, resulting in a compact structure, a weight reduction of over 50%, and easier installation and maintenance. The integrated design of core hydraulic components allows for flexible configuration of power modules according to well requirements, reducing manufacturing costs. The absence of gearboxes, belts, and other easily damaged parts extends maintenance cycles by over 50%, reducing downtime. Precise control of pumping parameters prevents excessively rapid formation pressure drop, slows the rise in well water cut, and significantly improves recovery rate. Attached Figure Description

[0030] Figure 1 This is a schematic block diagram of the electro-hydraulic servo closed-loop pump-controlled oil pumping unit with fault monitoring and real-time control according to the present invention.

[0031] Figure 2 This is a schematic diagram of the pump control unit of the electro-hydraulic servo closed-loop pump-controlled oil pump with fault monitoring and real-time control according to the present invention.

[0032] Figure 3 This is a schematic diagram of the pumping unit body structure of the electro-hydraulic servo closed-loop pump-controlled pumping unit with fault monitoring and real-time control according to the present invention.

[0033] Figure 4 This is a structural block diagram of the fault monitoring and alarm unit of the electro-hydraulic servo closed-loop pump-controlled oil pumping unit with fault monitoring and real-time control according to the present invention.

[0034] Figure 5 This is a structural block diagram of the remote control unit of the electro-hydraulic servo closed-loop pump-controlled oil pumping unit with fault monitoring and real-time regulation according to the present invention. Detailed Implementation

[0035] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.

[0036] like Figures 1 to 5 As shown, this invention provides an electro-hydraulic servo closed-loop pump-controlled oil pumping unit with fault monitoring and real-time control, comprising an oil pumping unit body 100, a pump control unit 101, a remote control unit 102, and a fault monitoring and alarm unit 103. The fault monitoring and alarm unit 103 monitors the oil pumping unit body 100 and the pump control unit 101 and feeds back fault status signals to the remote control unit 102, which then remotely controls the pump control unit 101 based on the fault status signals.

[0037] The fault monitoring and alarm unit 103 monitors load, pressure, flow rate, temperature, oil level, vibration and electrical parameters, and constructs a nonlinear health assessment model based on dynamic coupling weights to monitor faults and predict whether a fault will occur. When a fault occurs, it sends an alarm signal to the pump control unit 101.

[0038] The nonlinear health assessment model based on dynamic coupling weight is specifically:

[0039]

[0040] Wherein, x={P 载荷 ,P 压力 ,Q 流量 ,T,L,V 振动 ,E 电} is a multi-dimensional monitoring vector, u i ,σ i respectively represent the running basic value and the standard value of each parameter, P 载荷 ,P 压力 ,Q 流量 ,T,L,V 振动 ,E 电 are the monitored load, pressure, flow, temperature, oil level, vibration and electrical parameters, characterize the parameter change rate, γ i is the adaptive nonlinear order associated with the maximum parameter deviation, η i ,τ i are the coupling coefficient and time constant respectively; and α is the weight.

[0041] When Ψ≥Ψ th , it is judged that a fault occurs and a fault state signal is generated, and the fault state signal is characterized by:

[0042]

[0043] The remote control unit 102 is in communication connection with the pump control unit 101 and performs remote control, and if a fault occurs, the fault monitoring and alarm unit 103 sends the fault state signal to the remote control unit 102, the remote control unit 102 analyzes the fault state signal and generates a hierarchical instruction, and adjusts the operating parameters of the pump control unit 101 or triggers the shutdown protection according to the hierarchical instruction. At the same time, the remote control unit 102 is also in communication connection with a cloud server, and can store relevant information in the cloud server. The fault monitoring and alarm unit 103 monitors parameters such as load, pressure, displacement in real time through sensors, automatically optimizes pumping parameters in combination with a neural network algorithm, avoids empty pumping or overloading, and improves oil production efficiency.

[0044] The fault monitoring and alarm unit combines a neural network algorithm to construct an optimization objective function to automatically optimize pumping parameters, and the optimization objective function is:

[0045]

[0046] Wherein, Q opt is the theoretical maximum flow, λ is the fault suppression weight, φ 空 (t) is an empty pumping flag, φ 过(t) is an overload flag.

[0047] The fault constraints of empty pumping and overload are:

[0048]

[0049] where, is an indicator function, Q min ,p 干 , L max ,p max is the system safety threshold.

[0050] At the same time, the neural network optimizer is constructed as:

[0051]

[0052] where, θ is the network parameter, which is updated by real-time fault feedback. L(t) is the load, p(t) is the pressure, s(t) is the displacement, Q(t) is the flow, f(t) is the pumping stroke frequency, l(t) is the stroke length, and n(t) is the pump speed.

[0053] Finally, an adaptive learning mechanism is constructed.

[0054]

[0055] The network parameter θ is updated by the gradient descent method, where γ is the learning rate.

[0056] The pump control unit 101 includes a controller, a servo driver, a servo motor 1, a variable pump 2, a first pressure sensor 61, a second pressure sensor 62, and a displacement sensor 7. The controller and the servo driver are in bidirectional communication. The output of the servo driver is connected to the input of the servo motor 1. The driving end of the servo motor 1 is connected to the variable pump 2, which is controlled in real time according to the command of the servo driver. The first end and the second end of the variable pump 2 are respectively connected to the upper chamber and the lower chamber of the hydraulic cylinder 8 of the pumping unit body 100. The first pressure sensor 61, the second pressure sensor 62, and the displacement sensor 7 are all connected to the input end of the controller. An encoder is arranged between the servo motor 1 and the variable pump 2. The output of the encoder is connected to the servo driver. The variable pump 2 is connected to an energy accumulator 3. Unidirectional valves 41 and 42, safety valves 51 and 52 are respectively arranged on the pipelines connecting the first end and the second end of the variable pump 2 to the upper chamber and the lower chamber of the hydraulic cylinder 8.

[0057] The servo motor 1 and the variable pump 2 are directly driven to drive the closed pump control system of the hydraulic cylinder 8, the encoder is installed between the servo motor 1 and the variable pump 2, the real-time monitoring feedback signal of the servo motor speed is transmitted to the servo driver, the servo driver is further fed back to the controller, the controller judges the flow and sends the command to the servo controller. The first pressure sensor 61 and the second pressure sensor 62 are used to monitor the pressure of the lower cavity and the upper cavity of the hydraulic cylinder 8 respectively, and the feedback signal is transmitted to the controller. The variable pump directly drives the hydraulic cylinder, the response speed is faster, which can reach milliseconds, and the stepless speed regulation and stroke parameter real-time dynamic adjustment of the pumping unit can be realized, and the complex well working conditions can be adapted. The controller adjusts the pressure and flow by intelligence, optimizes the oil production process, thereby improving the oil production, and at the same time, the pump control unit can cope with the complex working conditions such as downhole liquid level fluctuation, heavy oil or high sand content, and reduce the risk of pump jamming.

[0058] Specifically, the controller inputs the efficiency characteristic distribution law of the servo motor and the variable pump as priori experience knowledge based on the monitored pressure value and the speed monitored by the encoder, combines the oil cylinder speed and the output required by the oil production process, constructs an optimization objective function, and adjusts the speed and displacement in real time, and the optimization objective function is:

[0059] Wherein, α, β are weighting coefficients, Q (t) is the real-time flow of the system, Q max is the maximum flow of the system, η m (n) is the efficiency of the servo motor, η p (D) is the efficiency of the variable pump.

[0060] The hydraulic power constraint is:

[0061]

[0062] In the formula, A is the effective action area of the oil cylinder, v req (t) is the speed of the oil cylinder, F req (t) is the output.

[0063] The neural network controller is:

[0064]

[0065] Wherein, θ is the network parameter, which is dynamically updated through online learning. n(t) is the speed of the servo motor, and D(t) is the displacement of the variable pump.

[0066] Finally, the adaptive adjustment mechanism is constructed as:

[0067]

[0068] The control quantity u=[n, D] is adjusted in real time through the neural network back propagationT K is a regulation coefficient. Δn, ΔD are the differences between real-time speed and displacement and target speed and displacement.

[0069] The periodic operation of the pumping unit causes the load to fluctuate dramatically. The accumulator 3 can absorb excess energy such as gravitational potential energy or inertial kinetic energy during the downstroke, and release the stored energy during the high load of the upstroke, significantly reducing the energy consumption of the system and improving the overall efficiency. The pressure of the closed system is easily affected by sudden changes in load. The accumulator 3 can smooth pressure spikes and fluctuations by quickly absorbing or releasing oil, protecting pumps, hydraulic cylinders and other components from impact, extending the life of the equipment, and ensuring smooth operation. In the event of a sudden shutdown such as a power outage or pump failure, the accumulator 3 can serve as a temporary power source to maintain the system for a short time, avoiding damage to the equipment or safety accidents caused by the failure of critical components. In the long run, the closed system may have a small amount of leakage or volume changes caused by changes in oil temperature. The accumulator 3 maintains stable system pressure by automatically adjusting the volume of the oil, reducing the frequent start of the oil makeup pump, and improving reliability. In working conditions that require rapid action, such as load changes or start-up phase, the accumulator 3 can instantaneously release high-pressure oil to improve system response speed and optimize the efficiency of the pumping unit.

[0070] In the closed pump-controlled pumping unit system, the use of the accumulator 3 in combination with the check valve can achieve more precise energy management, pressure control and system protection. The check valve acts as a one-way passage, allowing hydraulic oil to flow to the accumulator for energy storage during the downstroke of the pumping unit, while preventing the oil in the accumulator from flowing back to the low-pressure side. During the upstroke, the high-pressure oil stored in the accumulator releases energy through other channels, while the check valve prevents high-pressure oil from flowing directly to the low-pressure line, ensuring that energy only acts in the direction of load demand. This achieves improved energy recovery efficiency, reduced energy loss, and avoids system pressure fluctuations caused by disordered energy flow. When the pump switches direction or is temporarily shut down, the accumulator 3 supplements pressure oil to the system through the check valve, preventing pressure from dropping due to oil backflow or leakage. The check valve isolates the accumulator 3 from the low-pressure side, ensuring that the accumulator 3 is always in a high-pressure state, avoiding energy waste. When the load changes suddenly, the accumulator 3 quickly absorbs high-pressure oil, while the check valve prevents high-pressure oil from impacting the pump or low-pressure line in the opposite direction. When the pressure drops, the accumulator 3 releases oil in a targeted manner through the check valve, avoiding the spread of pressure fluctuations to the entire system. This reduces system noise and vibration, and improves the smoothness of operation. When the pumping unit starts or the load changes, the accumulator 3 quickly supplements high-pressure oil to the system through the check valve, making up for the temporary flow deficiency of the main pump and reducing the peak power demand of the motor. This improves the dynamic response speed of the system. Long-term operation of the closed system may cause pressure changes due to oil leakage or thermal expansion. The accumulator 3 supplements or absorbs oil to the system through the check valve, avoiding reverse flow of oil to pollute the low-pressure side. This maintains the cleanliness and stability of the closed system.

[0071] The pumping unit body 100 comprises a base 19, a hydraulic cylinder 8, a sucker rod 17, a transmission assembly, a counterweight box 20, a hydraulic station 21 and an electric control cabinet 22. The counterweight box 20 and the hydraulic cylinder 8 are installed on the base 19, the hydraulic rod of the hydraulic cylinder 8 is connected with the first end of the transmission assembly, the second end of the transmission assembly is connected with one end of the sucker rod 17, the pump control unit 101 is arranged in the electric control cabinet 22, the variable pump 2 is arranged in the hydraulic station 21, and the transmission assembly drives the sucker rod 17 to move up and down under the drive of the hydraulic cylinder 8, so that the sucker rod 17 extends into or separates from the wellhead 18.

[0072] The transmission assembly comprises a belt pulley 9, a movable pulley block 10, a balance belt 11, a first swing arm 12, a second swing arm, a rope hanger 14, a fixed arm pull rod 15 and a drive belt 16, the first end of the rope hanger 14 is connected with the sucker rod, the second end of the rope hanger 14 is connected with the first end of the drive belt 16, the second end of the drive belt 16 is sequentially connected with the hydraulic cylinder 8 through the pulley of the first swing arm 12 and the movable pulley block 10, the first end of the balance belt 11 is connected with the movable pulley block 10, the second end of the balance belt 11 is sequentially connected with the counterweight box 20 through the pulley of the second swing arm, and the fixed arm pull rod 15 is connected with the first swing arm 12 and the second swing arm. The first swing arm 12 and the second swing arm are symmetrically arranged on both sides, and the first swing arm 12 and the second swing arm are respectively connected with a swing arm oil cylinder 13.

[0073] The fault monitoring and alarming unit 103 comprises a load sensor 1031, a third pressure sensor 1032, a flow meter 1033, a temperature sensor 1034, a liquid level sensor 1035, a vibration sensor 1036, an electric parameter measuring sensor 1037 and a central processing unit 1038, the central processing unit 1038 receives the monitored load, pressure, flow, temperature, oil level, vibration and electric parameter and outputs a fault state signal.

[0074] A load sensor 1031 is arranged on the sucker rod, and is used to acquire the load of the sucker rod and send it to the central processor 1038. A third pressure sensor 1032 is arranged at the outlet of the variable pump 2, and is used to acquire the pressure at the outlet of the variable pump 2 and send it to the central processor 1038. A flow meter 1033 is arranged at the outlet of the variable pump 2, and is used to acquire the flow at the outlet of the variable pump 2 and send it to the central processor 1038. A temperature sensor 1034 is arranged on the pipeline between the hydraulic pump 8, and is used to acquire the temperature of the pipeline between the variable pump 2 and the hydraulic cylinder 8 and send it to the central processor 1038. A liquid level sensor 1035 monitors the oil level of the hydraulic oil and sends it to the central processor 1038. A vibration sensor 1036 is arranged on the shaft of the variable pump 2, and is used to acquire the vibration of the shaft of the variable pump 2 and send it to the central processor 1038. An electric parameter measuring sensor 1037 is arranged on the power line of the servo motor 1, and is used to acquire the electric parameters of the servo motor 1 and send them to the central processor 1038; the electric parameters include voltage, current and power.

[0075] The central processor 1038 performs fault prediction according to the load, pressure, flow, temperature, oil level, vibration and electric parameters, and obtains whether there is a fault; when a fault occurs, the central processor 1038 sends an alarm signal to the remote control unit 102.

[0076] Further, the remote control unit 102 includes a monitoring center 1021, a communication network 1022 and an intelligent controller 1023.

[0077] The monitoring center 1021 and the intelligent controller 1023 are both connected with the pump control unit 101 through the communication network 1022.

[0078] The intelligent controller 1023 is used to send control signals to the controller, and the monitoring center 1021 is used to display the load, pressure, flow, temperature, oil level, vibration and electric parameters.

[0079] The main functions of the monitoring center 1021 include real-time monitoring, data recording and analysis, fault diagnosis, remote control, video monitoring, security assurance, production optimization, report generation, communication system, and user interface functions. The real-time monitoring function is realized through the fault monitoring alarm unit 103, which can obtain the running state of the pumping unit in real time. The data recording and analysis function is manifested as the monitoring center 1021 records the historical running data of the pumping unit and processes the data through data analysis tools to facilitate performance evaluation and trend prediction. The remote control function allows the operator to remotely control the start and stop of the pumping unit and adjust the operating parameters in the monitoring center 1021. Video monitoring is used to observe the visual state of the pumping unit and the surrounding environment in real time. The security assurance function is manifested as the monitoring center 1021 can monitor potential safety risks such as leakage and fire, and take immediate measures when detecting abnormalities. The production optimization function is realized by analyzing the working efficiency of the pumping unit, and the monitoring center 1021 can help optimize the production plan and improve the overall output of the oilfield. The monitoring center 1021 can automatically generate operation reports to provide decision support for management. The communication system function is manifested as the monitoring center 1021 is usually equipped with devices that maintain communication with the pumping unit site to ensure real-time transmission of information. The user interface provides an intuitive user interface, allowing the operator to easily monitor and manage the pumping unit.

[0080] In order to realize the supply of electric energy, a cloud server and a power module are further included; the power module is used to supply power for the servo controller 13. The cloud server is used to store the faults.

[0081] The above-described embodiments are only used to describe the preferred embodiments of the present application, and do not limit the scope of the present application. Without departing from the design spirit of the present application, various modifications and improvements to the technical solutions of the present application made by those skilled in the art shall fall within the protection scope determined by the claims of the present application.

Claims

1. An electro-hydraulic servo closed pump-controlled pumping unit with fault monitoring and real-time regulation, characterized in that, It comprises a pumping unit body, a pump control unit, a remote control unit and a fault monitoring and alarm unit; the fault monitoring and alarm unit monitors the pumping unit body and the pump control unit and feeds back a fault state signal to the remote control unit, and the remote control unit remotely controls the pump control unit based on the fault state signal; The fault monitoring and alarm unit monitors load, pressure, flow, temperature, oil level, vibration and electrical parameters and constructs a nonlinear health assessment model based on dynamic coupling weight to monitor faults and predict whether a fault occurs, and sends an alarm signal to the pump control unit when a fault occurs; The nonlinear health assessment model based on dynamic coupling weight is specifically: where x = {P 载荷 ,P 压力 ,Q 流量 ,T,L,V 振动 ,E 电} is a multi-dimensional monitoring vector, u i ,σ i represent the basic value and standard value of each parameter respectively, P 载荷 ,P 压力 ,Q 流量 ,T,L,V 振动 ,E 电 are the monitored load, pressure, flow, temperature, oil level, vibration and electrical parameters respectively, characterizes the parameter change rate, γ i is the adaptive nonlinear order associated with the maximum parameter deviation, η i ,τ i are the coupling coefficient and time constant respectively; α is the weight; When Ψ ≥ Ψ th a fault occurs and a fault state signal is generated, the fault state signal being characterized by:

2. The electro-hydraulic servo closed pump-controlled pumping unit with fault monitoring and real-time regulation according to claim 1, characterized in that, The pump control unit comprises a controller, a servo driver, a servo motor, a variable pump, a first pressure sensor, a second pressure sensor and a displacement sensor; the controller is in bidirectional communication with the servo driver, the output of the servo driver is connected with the input of the servo motor, the driving end of the servo motor is connected with the variable pump, the first end and the second end of the variable pump are respectively connected with the upper chamber and the lower chamber of the hydraulic cylinder of the pumping unit body, and the first pressure sensor, the second pressure sensor and the displacement sensor are all connected with the input end of the controller.

3. The electro-hydraulic servo closed pump-controlled pumping unit with fault monitoring and real-time regulation according to claim 2, characterized in that, An encoder is arranged between the servo motor and the variable pump, the output of the encoder is connected with the servo driver, the variable pump is connected with an energy accumulator, and a one-way valve and a safety valve are respectively arranged on the pipeline connecting the first end and the second end of the variable pump with the upper chamber and the lower chamber of the hydraulic cylinder.

4. The electro-hydraulic servo closed pump-controlled pumping unit with fault monitoring and real-time regulation of claim 1, wherein, The remote control unit is in communication connection with the controller and remotely controls the controller, if a fault occurs, the fault monitoring and alarm unit sends a fault state signal to the remote control unit, the remote control unit analyzes the fault state signal and generates a hierarchical instruction, and adjusts the running parameters of the servo controller or triggers the stop protection according to the hierarchical instruction.

5. The electro-hydraulic servo closed pump-controlled pumping unit with fault monitoring and real-time regulation according to claim 4, characterized in that, The fault monitoring and alarm unit comprises a load sensor, a third pressure sensor, a flowmeter, a temperature sensor, an oil level sensor, a vibration sensor, an electrical parameter measuring sensor and a central processing unit, the central processing unit receives the monitored load, pressure, flow, temperature, oil level, vibration and electrical parameters and outputs a fault state signal.

6. The electro-hydraulic servo closed pump-controlled pumping unit with fault monitoring and real-time regulation of claim 1, wherein, The pumping unit body comprises a base, a hydraulic cylinder, a sucker rod, a transmission assembly, a counterweight box, a hydraulic station and an electric control cabinet; the counterweight box and the hydraulic cylinder are installed on the base, the hydraulic rod of the hydraulic cylinder is connected with the first end of the transmission assembly, the second end of the transmission assembly is connected with one end of the sucker rod, the pump control unit is arranged in the electric control cabinet, the variable pump is arranged in the hydraulic station, and the transmission assembly drives the sucker rod to move up and down under the drive of the hydraulic cylinder.

7. The electro-hydraulic servo closed pump-controlled pumping unit with fault monitoring and real-time regulation according to claim 1, characterized in that, The transmission assembly comprises a belt pulley, a movable pulley block, a balance belt, a first swing arm, a second swing arm, a rope hanger, a fixed arm pull rod and a driving belt, the first end of the rope hanger is connected with the sucker rod, the second end of the rope hanger is connected with the first end of the driving belt, the second end of the driving belt is connected with the hydraulic cylinder after passing through the pulley of the first swing arm and the movable pulley block in sequence, the first end of the balance belt is connected with the movable pulley block, the second end of the balance belt is connected with the counterweight box after passing through the pulley of the second swing arm in sequence, and the fixed arm pull rod connects the first swing arm and the second swing arm.

8. The electro-hydraulic servo closed pump-controlled pumping unit with fault monitoring and real-time regulation according to claim 2, characterized in that, The first pressure sensor and the second pressure sensor monitor the pressure of the lower cavity and the upper cavity of the hydraulic cylinder respectively, the controller inputs the efficiency characteristic distribution law of the servo motor and the variable pump as priori experience knowledge based on the monitored pressure value and the rotating speed monitored by the encoder, combines the oil cylinder speed and the output required by the oil extraction process to construct an optimization objective function, and adjusts the rotating speed and the displacement in real time to optimize the objective function, and the optimization objective function is: where, α, β are weighting coefficients, Q (t) Q is the system real-time flow rate, Q max Q is the system maximum flow rate, η m η (n) is the servo motor efficiency, η p η (D) is the variable pump efficiency.

9. The electro-hydraulic servo closed pump-controlled pumping unit with fault monitoring and real-time regulation according to claim 2, characterized in that, The fault monitoring and alarm unit combines the neural network algorithm to construct an optimization objective function to automatically optimize the swabbing parameters, and the optimization objective function is: where Q opt is the theoretical maximum flow, λ is the fault containment weight, φ 空 (t) is an empty flag, φ 过 (t) is an overload flag.

10. The electro-hydraulic servo closed pump-controlled pumping unit with fault monitoring and real-time regulation according to claim 9, characterized in that, The fault constraint conditions of air extraction and overload are: wherein, Q is an indicator function, Q min p 干 L max p max is a system safety threshold.

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