Intelligent regulation and control device for oil pumping unit

Abstract

The invention belongs to the technical field of oil field well site equipment control, and particularly relates to an intelligent regulation and control device of a pumping unit. The invention provides the intelligent regulation and control device for the oil pumping unit, the intelligent regulation and control device for the oil pumping unit can realize real-time monitoring of the voltage of the motor, and can also realize accurate measurement of load displacement in a mechanical extraction system, so that the requirement on intelligent control of the oil pumping unit in oil and gas production is met, and the adaptive scene of the regulation and control device for the oil pumping unit is widened. The invention provides an intelligent regulation and control device for an oil pumping unit. The intelligent regulation and control device for the oil pumping unit comprises structural units such as a PLC (Programmable Logic Controller), a data acquisition micro-processing unit, a voltage signal acquisition sensor, a direct current converter, a voltage frequency conversion unit, a displacement sensor and a driving module.

Description

Technical Field

[0001] The present invention belongs to the technical field of oilfield well site equipment control, and in particular relates to an intelligent control device for an oil pumping unit. Background Art

[0002] As my country's oilfield development continues to deepen, the oil and gas production of existing oilfield enterprises continues to grow year by year. However, the inventors have discovered that during oil and gas field development, mechanical production systems such as pumping units still experience a high rate of no-load or light-load conditions. This low load rate results in low pumping unit efficiency and significant energy waste. The main issues with existing technologies are as follows: 1. There are still many old equipment. Some existing mechanical extraction systems still have outdated equipment. Some mechanical equipment and motors have been used for more than 10 years. Their manufacturing processes and various technical performance parameters are far behind those of new equipment. As a result, the overall operation burden of the pumping system is heavy and the efficiency of the whole machine is low. 2. Improper matching of mechanical equipment and motors, and unscientific operating settings. Improper matching of mechanical equipment and motors can lead to a high degree of inefficiency. If the motor's rated power is too large for the matching power, it can cause no-load losses, a phenomenon known as "a large horse pulling a small cart." If the opposite is true, the pumping unit motor will be chronically overloaded, seriously impacting the reliability of the pumping system.

[0003] To address the above-mentioned issues, technicians have made numerous technical attempts. For example, the patent document titled "An Intelligent Energy-Saving Controller for Oilfield Pumping Units" and application number CN201120332177.3 describes the following technical solution: "This utility model relates to an oilfield pumping unit motor control system, and more particularly, to an intelligent energy-saving controller for oilfield pumping units." The technical solution is as follows: An intelligent microprocessor is connected to an acoustic wave probe, a display, an alarm, and a pumping unit motor controller. Using a TI control mechanism, the pumping unit's pumping time is controlled in real time based on specific information about the actual pumping system, eliminating redundant idle pumping time in lean wells to achieve energy savings. The system enters automatic operation from the moment it is started, requiring no human intervention. It has the advantages of a simple structure and significant energy-saving effects.

[0004] However, after further research, the inventors found that the existing oil pumping unit control equipment, including those relying on the above-mentioned patent documents, is still not very intelligent, and the actual working process still requires manual intervention by technicians (on the pumping system), which leads to limitations in its application scenarios and cannot meet the needs of oilfield enterprises for intelligent automatic control. Summary of the Invention

[0005] The present invention provides an intelligent control device for an oil pumping unit. This intelligent control device for an oil pumping unit can realize real-time monitoring of the motor voltage and accurate measurement of the load displacement in the machine extraction system, thereby meeting the demand for intelligent control of oil pumping units in oil and gas production and broadening the applicable scenarios of the oil pumping unit control device.

[0006] In order to solve the above technical problems, the present invention adopts the following technical solutions: An intelligent control device for an oil pumping unit, comprising: PLC controller, data acquisition microprocessor unit; wherein, the PLC controller and the data acquisition microprocessor unit realize data interconnection through the ZigBee wireless transceiver module; Voltage signal acquisition sensor, DC converter and voltage-frequency conversion unit; wherein, the voltage signal acquisition sensor is used to collect the voltage signal of the oil pump motor, and the voltage signal acquisition sensor, DC converter and voltage-frequency conversion unit are connected in sequence and communicate with the data acquisition microprocessor unit.

[0007] More preferably, it further includes: a displacement sensor; wherein the displacement sensor communicates with the data acquisition microprocessor unit for collecting displacement information of the oil pumping unit.

[0008] Preferably, it further includes: a driving module; The drive module is composed of a relay and a solenoid valve; the relay and the data acquisition microprocessor unit communicate with each other.

[0009] More preferably, the system further comprises: a host computer; wherein the host computer realizes data interconnection with the PLC controller via GPRS wireless communication mode.

[0010] Preferably, the model of the PLC controller is SIMATIC S7-300.

[0011] More preferably, it further comprises: a voltage reducer provided in conjunction with the voltage signal acquisition sensor; The voltage reducer is used to reduce the voltage of the 220V / 380V AC signal at the motor end of the oil pump to a 3V AC signal.

[0012] Preferably, the data acquisition microprocessor unit uses a chip of model STC12C5A60S2; the DC converter uses a chip of model AD536A.

[0013] Preferably, the displacement sensor is a self-resetting linear displacement sensor of model KTR.

[0014] The present invention provides an intelligent control device for a pumping unit. The device includes a PLC controller, a data acquisition microprocessor, a voltage signal acquisition sensor, a DC converter, a voltage-frequency conversion unit, a displacement sensor, a drive module, and other structural units. This intelligent control device, featuring these structural features, achieves intelligent control of the pumping unit through real-time monitoring of the pumping system and motor, utilizing an intelligent control algorithm. This contributes to energy conservation and increased production, and is suitable for intelligent pumping control in various applications, including intelligent pumping control of various rod pumping wells and intelligent intermittent pumping control. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The accompanying drawings are used to provide a further understanding of the present invention and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation of the present invention. In the following drawings: Figure 1 This is a structural block diagram of the intelligent control device for oil pumping units provided by the present invention; Figure 2 This is an electrical schematic diagram of the data acquisition microprocessor unit STC12C5A60S2 chip provided by the present invention; Figure 3 This is an electrical schematic diagram of the voltage-to-frequency conversion unit LM331 chip provided by the present invention; Figure 4 Provides an electrical schematic diagram of a displacement sensor KTR chip for the present invention; Figure 5 This is an electrical schematic diagram of the relay ULN2803 chip provided by the present invention. DETAILED DESCRIPTION

[0016] The present invention provides an intelligent control device for an oil pumping unit. This intelligent control device for an oil pumping unit can realize real-time monitoring of the motor voltage and accurate measurement of the load displacement in the machine extraction system, thereby meeting the demand for intelligent control of oil pumping units in oil and gas production and broadening the applicable scenarios of the oil pumping unit control device.

[0017] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0018] In the description of the present invention, it should be understood that the terms "length," "width," "up," "down," "front," "back," "left," "right," "vertical," "horizontal," "top," "bottom," "inside," "outside," and the like, indicating positions or location relationships, are based on the positions or location relationships shown in the accompanying drawings and are intended only to facilitate the description of the present invention and simplify the description. They do not indicate or imply that the devices or elements referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limiting the present invention. Furthermore, in the description of the present invention, "plurality" means two or more, unless otherwise expressly and specifically defined. Example 1

[0019] The present invention provides an intelligent control device for an oil pumping unit. Figure 1 As shown, the intelligent control device of the oil pumping unit includes a PLC controller, a data acquisition microprocessor unit, a voltage signal acquisition sensor, a DC converter, a voltage-frequency conversion unit, a displacement sensor, a drive module and other structural units.

[0020] Specifically, as a preferred embodiment of the present invention, the PLC controller can be a SIMATIC S7-300, and the data acquisition microprocessor unit can be an STC12C5A60S2 chip. The data interconnection between the PLC controller and the data acquisition microprocessor unit is achieved through a ZigBee wireless transceiver module.

[0021] It should be noted that the SIMATIC S7-300 model PLC controller is a medium-sized programmable controller with high reliability, good anti-interference ability and general performance. Therefore, it can fully meet the requirements of the intelligent control device for the oil pump provided by the present invention in data calculation and intelligent control.

[0022] The data acquisition microprocessor uses the STC12C5A60S2 chip. As a new-generation 8051 microcontroller, the STC12C5A60S2's instruction code is fully compatible with the traditional 8051, but it operates at a much faster speed (approximately 8-12 times faster than the traditional 8051). It also integrates a dedicated reset circuit, two PWM channels, and eight high-speed 10-bit A / D converter interfaces.

[0023] Furthermore, the connection relationship of each pin of the data acquisition microprocessor unit with the chip model STC12C5A60S2 is explained as follows. Figure 2As shown, a 12 MHz crystal oscillator is set between the XTAL1 pin and the XTAL2 pin of the data acquisition microprocessor unit with the chip model STC12C5A60S2, the VCC pin of the data acquisition microprocessor unit with the chip model STC12C5A60S2 is connected to a +5 V DC voltage, and the GND pin of the data acquisition microprocessor unit with the chip model STC12C5A60S2 is grounded.

[0024] like Figure 1 As shown, the voltage signal acquisition sensor, the DC converter and the voltage-frequency conversion unit are arranged in sequence, and then communicate with the data acquisition microprocessor unit. Among them, the voltage signal acquisition sensor is used to collect the voltage signal of the oil pump motor. It is worth noting that as a more preferred embodiment, a voltage reducer can be further provided at the position of the voltage signal acquisition sensor. The purpose of such arrangement is to protect the safe operation of the voltage signal acquisition sensor. Since the working voltage of the oil pump motor is usually 220V / 380V AC, the above-mentioned voltage reducer can be used to reduce the voltage of the 220V / 380V AC signal at the oil pump motor end to a 3V AC signal.

[0025] More preferably, the DC converter uses a chip model AD536A, which is specifically used to further convert the AC signal into a DC signal. Specifically, the voltage-frequency conversion unit can use a chip model LM331, such as Figure 3 shown.

[0026] It's worth noting that the voltage-to-frequency conversion unit, using the LM331 chip, boasts a wide dynamic monitoring range, minimal nonlinear distortion, and high conversion processing accuracy. This unit further converts the DC signal into frequency pulses for subsequent data collection by the data acquisition microprocessor. The pin connections are as follows: the signal input of the AD536A voltage-to-frequency conversion unit is connected to the signal output of the voltage signal acquisition sensor; the signal output of the AD536A voltage-to-frequency conversion unit is connected to the Comparator Input pin of the LM331 voltage-to-frequency conversion unit; and the Frequency Output pin of the LM331 voltage-to-frequency conversion unit is connected to any unused pin between P2.0 and P2.7 of the STC12C5A60S2 data acquisition microprocessor.

[0027] In addition, the Ref Current pin of the LM331 voltage-frequency conversion unit is used to input a reference current value; the R / C pin of the LM331 voltage-frequency conversion unit is selectively connected to the timing circuit. Furthermore, the VCC pin of the LM331 voltage-frequency conversion unit is connected to a +12V DC voltage, and the GND pin of the LM331 voltage-frequency conversion unit is connected to ground.

[0028] In addition, as a more preferred embodiment of the present invention, Figure 1 As shown, the intelligent control device for an oil pumping unit provided by the present invention further includes a displacement sensor. The displacement sensor is specifically in data communication with the data acquisition microprocessor unit and is used to collect displacement information of the oil pumping unit.

[0029] As an optional embodiment of the present invention, the displacement sensor can preferably be a KTR self-resetting linear displacement sensor. Specifically, the KTR displacement sensor has a variety of standard / optional sensor heads / sensor components, which can be combined with the pumping system to form a variety of displacement monitoring forms. For example, Figure 4 As shown, the positive signal output of the KTR displacement sensor is connected to the ADC0 pin of the data acquisition microprocessor unit (STC12C5A60S2); the negative signal output of the KTR displacement sensor is connected to the ADC1 pin of the data acquisition microprocessor unit (STC12C5A60S2). It should be noted that the voltage signal output by the displacement sensor linearly corresponds to the displacement value to be monitored (0-maximum rated range). The corresponding voltage signal is output to the data acquisition microprocessor unit, which processes it (converting it into digital data) for further calculations and use (for example, uploading it for display).

[0030] Among them, the specific pin connection relationship of KTR's self-resetting linear displacement sensor can be referred to as follows: the VCC pin of the KTR displacement sensor is connected to the +5V DC voltage, and the GND pin of the KTR displacement sensor is grounded.

[0031] Finally, as a more preferred embodiment of the present invention, Figure 1 As shown, the intelligent control device for an oil pumping unit provided by the present invention further includes a driving module, wherein the driving module is specifically composed of a relay and a solenoid valve.

[0032] Specifically, the relay communicates data with the data acquisition microprocessor. Through this relay and solenoid valve, the intelligent control device for the oil pumping unit provided by the present invention can (in conjunction with a preset control program) respond to warnings and control commands from the oil pumping system, motors, and other equipment, for example, by activating a buzzer to sound an alarm. Example 2

[0033] The second embodiment includes all the technical features of the first embodiment. In addition, the second embodiment further defines a host computer structure unit.

[0034] Specifically, the present invention provides an intelligent control device for an oil pumping unit, such as Figure 1 As shown, the system also includes a host computer. The host computer connects to the PLC controller via GPRS wireless communication. Notably, the host computer can remotely establish data communication with (or multiple) PLC controllers, enabling remote human-computer interaction, data statistics processing, and remote control. Example 3

[0035] The third embodiment includes all the technical features of the first embodiment. In addition, the third embodiment further defines the relay as follows.

[0036] Specifically, as a more preferred embodiment of the present invention, Figure 5 As shown, the relay uses the ULN2803 chip. This ULN2803 relay consists of eight NPN Darlington-connected transistors and a common clamping diode. It is used to switch multiple load units under the control of the control signal output by the data acquisition microprocessor unit (in combination with the solenoid valve).

[0037] Among them, the connection relationship of each pin of the relay with chip model ULN2803 can be referred to as follows: the IN1-IN8 pins of the relay with chip model ULN2803 are connected to the P0.0-P0.7 pins of the data acquisition microprocessor unit of STC12C5A60S2 one by one; the OUT pin of the relay with chip model ULN2803 is connected to the control end of the solenoid valve.

[0038] The present invention provides an intelligent control device for a pumping unit. The device includes a PLC controller, a data acquisition microprocessor, a voltage signal acquisition sensor, a DC converter, a voltage-frequency conversion unit, a displacement sensor, a drive module, and other structural units. This intelligent control device, featuring these structural features, achieves intelligent control of the pumping unit through real-time monitoring of the pumping system and motor, utilizing an intelligent control algorithm. This contributes to energy conservation and increased production, and is suitable for intelligent pumping control in various applications, including intelligent pumping control of various rod pumping wells and intelligent intermittent pumping control.

[0039] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any modifications or substitutions that can be easily conceived by a person skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be based on the scope of protection of the claims.

Claims

1. An intelligent control device for an oil pumping unit, characterized in that: Includes: PLC controller, data acquisition microprocessor unit; wherein, the PLC controller and the data acquisition microprocessor unit realize data interconnection through the ZigBee wireless transceiver module; Voltage signal acquisition sensor, DC converter and voltage-frequency conversion unit; wherein, the voltage signal acquisition sensor is used to collect the voltage signal of the oil pump motor, and the voltage signal acquisition sensor, DC converter and voltage-frequency conversion unit are connected in sequence and communicate with the data acquisition microprocessor unit.

2. The intelligent control device for an oil pumping unit according to claim 1, characterized in that: It also includes: a displacement sensor; wherein the displacement sensor communicates with the data acquisition microprocessor unit for collecting displacement information of the oil pumping unit.

3. The intelligent control device for an oil pumping unit according to claim 1, characterized in that: Also included are: a drive module; The drive module is composed of a relay and a solenoid valve; the relay and the data acquisition microprocessor unit communicate with each other.

4. The intelligent control device for an oil pumping unit according to claim 1, characterized in that: The system also includes: a host computer; wherein the host computer realizes data interconnection with the PLC controller through a GPRS wireless communication mode.

5. The intelligent control device for an oil pumping unit according to claim 1, characterized in that: The model of the PLC controller is SIMATIC S7-300.

6. The intelligent control device for an oil pumping unit according to claim 1, characterized in that: It also includes: a voltage reducer matched with the voltage signal acquisition sensor; The voltage reducer is used to reduce the voltage of the 220V / 380V AC signal at the motor end of the oil pump to a 3V AC signal.

7. The intelligent control device for an oil pumping unit according to claim 1, characterized in that: The data acquisition microprocessor unit uses the chip model STC12C5A60S2; the DC converter uses the chip model AD536A.

8. The intelligent control device for an oil pumping unit according to claim 1, characterized in that: The displacement sensor is a self-resetting linear displacement sensor of model KTR.

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