Hybrid rotary drilling rig and control system and method thereof

Abstract

The invention discloses a hybrid rotary drilling rig and a control system and method thereof, the system comprises a power battery, a generator, an engine, a drill rod management system, a main pump, a main pump motor, a power distribution unit, a power head motor and a winch motor, and the power battery is used for providing a power source for the hybrid rotary drilling rig; the generator is used for generating power for the hybrid rotary drilling rig; the engine is used for providing power for the hybrid rotary drilling rig; the drill rod management system is used for cooling the power battery, the generator and the engine. The main pump provides working pressure for the hybrid rotary drilling rig; the main pump motor is used for cooling the main pump motor under the control of the drill rod management system; the power supply distribution unit is used for distributing the input electric energy to a plurality of output ports for different devices to use; the power head is used for controlling the power head to rotate; and the winch motor is used for realizing the lifting action of the power head. According to the invention, the fuel economy of the whole machine is better, and meanwhile, the use cost is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of rotary drilling rigs, and in particular to a hybrid rotary drilling rig and a control system and method thereof. Background Art

[0002] As core equipment for geotechnical engineering construction, the performance of a rotary drilling rig's power system directly impacts operational efficiency, energy consumption, and environmental adaptability. Traditional rotary drilling rigs generally utilize a single engine-driven hydraulic system. This system uses engine output to drive the main pump, generating hydraulic energy that controls the rotation of the power head, the lifting of the winch, and the movement of the crawler tracks.

[0003] However, traditional rotary drilling rigs rely on a single engine power source. Its power output must simultaneously meet the hydraulic system's high-pressure oil supply and the overall machine's motion requirements, causing the engine to operate in the inefficient low-speed, high-load or high-speed, low-load ranges for extended periods. For example, even during light-load operation, the engine must maintain high speed to maintain hydraulic system pressure, resulting in a "big horse pulling a small cart" phenomenon, low fuel efficiency, and high carbon emissions. Furthermore, the traditional hydraulically driven winch system and power head rely on mechanical control of the hydraulic valve block, which can lead to response lag and insufficient precision. The hydraulic system's "flexible transmission" characteristic results in large torque fluctuations in the power head during low-speed drilling, making it prone to slippage and bit sticking. The compressibility of the hydraulic oil during the winch's raising and lowering process makes precise positioning difficult, resulting in particularly low efficiency during deep pile operations. Furthermore, traditional rotary drilling rigs rely entirely on diesel as a power source and cannot utilize clean energy sources such as external power supplies, limiting their use in environmentally sensitive areas such as urban construction. Furthermore, fuel costs account for 30%-40% of the total machine operating cost. This single energy structure results in high operating costs for users and makes it difficult to mitigate the risk of energy price fluctuations. In addition, the hydraulic system of a traditional rotary drilling rig is directly driven only by the engine and lacks redundant control paths. When the engine fails or the load suddenly changes, the hydraulic system may stagnate due to power interruption, especially under extreme working conditions such as deep pile construction, which can easily lead to safety accidents such as buried drilling and hole collapse. Moreover, the fixed flow design of the hydraulic valve group cannot dynamically adjust the oil pressure and flow according to the real-time load, resulting in significant energy waste (non-operating circuit energy consumption accounts for approximately 20%). During braking, power head lowering and other working conditions, mechanical kinetic energy is not effectively recovered and utilized, but directly lost in the form of heat energy to the hydraulic system overflow valve or brake pads, resulting in energy waste. It is estimated that under such working conditions, the energy loss of the entire machine can reach 15%-20% of the total operating energy consumption, further exacerbating fuel consumption and operating costs. Summary of the Invention

[0004] In order to solve some or all of the technical problems existing in the above-mentioned prior art, the present invention provides a hybrid rotary drilling rig and its control system and method, which can effectively reduce the time that the engine works in the low-efficiency area and achieve better fuel economy. At the same time, the winch system and power head of the whole machine are driven only by the motor, so that the working efficiency of the winch and the power head are higher and the stability is better. The hydraulic system of the whole machine is controlled by the main pump motor and the engine system at the same time, which improves the working efficiency of the hydraulic system and can effectively reduce the risk of the whole machine under extreme working conditions. The whole machine can be powered by an external power supply, which reduces the cost of use and has an energy recovery function, further improving fuel economy.

[0005] The technical solutions of the present invention are as follows:

[0006] In a first aspect, a hybrid rotary drilling rig control system is provided, comprising:

[0007] A power battery, on which a battery management system is integrated, and the power battery is used to provide a power source for the hybrid rotary drilling rig;

[0008] A generator, on which a generator control unit is integrated, the generator control unit is electrically connected to the power battery, and the generator is used to generate electricity for the hybrid rotary drilling rig;

[0009] An engine, on which an energy management system is integrated, the engine is drivingly connected to the generator, and the engine is used to provide power for the hybrid rotary drilling rig;

[0010] a drill rod management system, the drill rod management system being hydraulically connected to the power battery, the generator, and the energy management system integrated with the engine, the drill rod management system being used to cool the power battery, the generator, and the engine, respectively;

[0011] A main pump connected to the engine drives the rotating assembly in the pump through the engine, converting mechanical energy into pressure energy and kinetic energy of the hydraulic oil, outputting high-pressure oil, and providing working pressure for the hybrid rotary drilling rig;

[0012] a main pump motor, wherein the output shaft of the main pump motor is fixedly connected to the rotor of the main pump, and the main pump is also connected to the drill rod management system for cooling the main pump motor under the control of the drill rod management system;

[0013] a power distribution unit, the power distribution unit being electrically connected to the battery management system, the generator, and the motor controller, and also connected to the connecting pipeline connecting the main pump motor to the drill pipe management system, and configured to distribute the input electrical energy to multiple output ports for use by different devices;

[0014] A power head motor, wherein a motor controller is integrated on the power head motor, and the motor controller provided on the power head motor is connected to the electrical connection line connecting the motor controller on the main pump motor to the power distribution unit. At the same time, the power head motor is connected to the connection pipeline connecting the power distribution unit to the main pump motor and the drill rod management system. The power head motor is also connected to the power head of the hybrid rotary drilling rig for controlling the power head to realize the rotation action;

[0015] A winch motor is integrated with a motor controller. The motor controller provided on the winch motor is connected to the electrical connection line connecting the motor controller on the main pump motor to the power distribution unit. At the same time, the winch motor is connected to the connection pipeline connecting the power distribution unit to the main pump motor and the drill rod management system. The winch motor is also connected to the winch of the hybrid rotary drilling rig to realize the lifting and lowering action of the power head.

[0016] Furthermore, in the above hybrid rotary drilling rig control system, it also includes:

[0017] An on-board charger, electrically connected to the battery management system, configured to convert AC power from an external power grid into high-voltage DC power to charge the power battery;

[0018] An external power supply is electrically connected to the on-board charger and is used to supply power to the power battery.

[0019] Furthermore, in the above-mentioned hybrid rotary drilling rig control system, it also includes a hydraulic control unit, which is connected to the main pump through a hydraulic pipeline and is used to control the hydraulic components to realize the oil circuit opening and closing of the hybrid rotary drilling rig.

[0020] Furthermore, in the above hybrid rotary drilling rig control system, it further includes: an oil cylinder and a hydraulic motor, and the oil cylinder and the hydraulic motor are connected to a hydraulic control element.

[0021] In a second aspect, a hybrid rotary drilling rig is provided, on which the hybrid rotary drilling rig control system described above is provided.

[0022] In a third aspect, a hybrid rotary drilling rig control method is provided, comprising:

[0023] Converting a portion of the power generated by the hybrid rotary drilling rig into electrical energy, and dividing the converted electrical energy into two parts;

[0024] Part of the two parts of electrical energy is used to drive the main pump motor, the hoist motor and the power head motor, so that the main pump motor drives the main pump and then controls the hydraulic control unit to realize the oil circuit movement of the rotary drilling rig, the hoist motor drives the hoist to realize the lifting movement of the power head, and the power head motor drives the power head to realize the rotation movement of the power head;

[0025] The other part of the two parts of electrical energy is used to charge the power battery, and the electricity stored in the power battery can drive the main pump motor, winch motor and power head motor to operate according to different working conditions of the hybrid rotary drilling rig;

[0026] The energy generated by another part of the power generated by the hybrid rotary drilling rig drives the main pump, and controls the hydraulic control unit to realize the oil circuit action of the rotary drilling rig.

[0027] Furthermore, in the above-mentioned hybrid rotary drilling rig control method, it also includes configuring an external power supply on the hybrid rotary drilling rig, so that the configured external power supply can directly charge the power battery.

[0028] Furthermore, in the above-mentioned hybrid rotary drilling rig control method, the charging process of the external power supply includes:

[0029] Static charging mode, wherein the hybrid rotary drilling rig is connected to an external power supply when it is stopped, and the onboard charger converts AC power into high-voltage DC power, which is then fully charged through the power distribution unit.

[0030] Dynamic charging mode, the dynamic charging mode includes the external power supply and the engine supplying power synchronously during operation. After meeting the real-time power demand of the motor, the remaining power is stored in the power battery.

[0031] Furthermore, in the above-mentioned hybrid rotary drilling rig control method, it also includes configuring a drill rod management system on the hybrid rotary drilling rig, and hydraulically connecting the configured drill rod management system with the power battery, the generator and the energy management system integrated on the engine, so that the drill rod management system centrally cools the heat-generating components on the hybrid rotary drilling rig through hydraulic pipelines.

[0032] Furthermore, in the above-mentioned hybrid rotary drilling rig control method, converting a portion of the power generated by the hybrid rotary drilling rig into electrical energy includes driving a generator to generate electricity through a transmission system, and the generator control unit converting mechanical energy into electrical energy, wherein the engine power distribution is realized by the energy management system in collaboration with the generator control unit and the motor controller, and by real-time monitoring of the workload and the power source status, the ratio of generated power to direct drive power is dynamically adjusted to enable the engine to avoid the inefficient working range.

[0033] The main advantages of the technical solution of the present invention are as follows:

[0034] The hybrid rotary drilling rig and its control system and method of the present invention can effectively reduce the time the engine operates in the low-efficiency zone, thereby improving the fuel economy of the entire machine. At the same time, the hoisting system and power head of the entire machine are driven only by the motor. Since the motor has the advantages of low-speed constant torque and high-speed constant power, the response speed is faster, thereby improving the working efficiency and stability of the rotary drilling rig; because the external power supply can be directly charged, the cost of using the entire machine is reduced while also reducing dependence on traditional energy sources; the hydraulic system of the entire machine can be controlled not only by the main pump motor, but also directly by the engine system, making the control of the hydraulic system more flexible, thereby improving the working efficiency of the entire machine, and effectively reducing the risk of the entire machine under extreme working conditions. At the same time, because the control system of the present invention has an energy recovery function, the fuel economy of the entire machine is further improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] The drawings described herein are used to provide a further understanding of the embodiments of the present invention and constitute a part of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0036] Figure 1 A schematic structural diagram of a hybrid rotary drilling rig control system provided in one embodiment of the present invention;

[0037] Figure 2 A schematic structural diagram of a hybrid rotary drilling rig control system provided by one embodiment of the present invention installed on a hybrid rotary drilling rig from one perspective;

[0038] Figure 3 A schematic structural diagram from another perspective of a hybrid rotary drilling rig control system provided by one embodiment of the present invention installed on a hybrid rotary drilling rig;

[0039] Figure 4 A flow chart of a hybrid rotary drilling rig control method provided in accordance with an embodiment of the present invention.

[0040] Description of reference numerals:

[0041] 1. External power supply; 2. Generator; 3. Generator control unit; 4. Energy management system; 5. Engine; 6. Power battery; 7. Battery management system; 8. Power distribution unit; 9. Drill pipe management system; 10. On-board charger; 11. Motor controller; 12. Winch motor; 13. Main pump; 14. Main pump motor; 15. Power head motor; 16. Winch; 17. Hydraulic control unit; 18. Power head; 19. Cylinder; 20. Hydraulic motor. DETAILED DESCRIPTION

[0042] To make the objectives, technical solutions, and advantages of the present invention more clear, the technical solutions of the present invention will be clearly and completely described below in conjunction with specific embodiments of the present invention and corresponding drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0043] In order to clearly and completely illustrate the technical solutions of the embodiments of the present invention, the technical terms involved in the embodiments of the present invention are first explained and illustrated below.

[0044] The on-board charger (OBC) is used to convert alternating current (AC) from the external power grid into high-voltage direct current (DC) to charge the power battery.

[0045] The battery management system (BMS) is mainly used to intelligently manage and maintain each battery unit, monitor the battery status, prevent overcharging and over-discharging of the battery, and extend the battery life. The BMS unit includes a BMS, a control module, a display module, a wireless communication module, electrical equipment, a battery pack for powering the electrical equipment, and a collection module for collecting battery pack information. The BMS is connected to the wireless communication module and the display module through communication interfaces. The output of the collection module is connected to the input of the BMS, and the output of the BMS is connected to the input of the control module. The control module is connected to the battery pack and electrical equipment respectively. The BMS is connected to the server through a wireless communication module.

[0046] The Tool Management System (TMS) automates drill rod loading and unloading, monitors status, and schedules operations. It also switches to pure electric mode when lightly loaded drill rods are in motion (such as grabbing), saving fuel. It also schedules drill rod replacements based on the battery's SOC, prioritizing electric operation when the battery is at a high level.

[0047] The Generator Control Unit (GCU) controls a diesel generator, such as the range extender in a hybrid system. It dynamically adjusts power generation according to BMS requirements. For example, it starts generating power when the SOC is less than 20%, maintaining output voltage fluctuations within ±2% to protect the battery while keeping the diesel engine running in a high-efficiency range, such as 1500 rpm.

[0048] The Energy Management System (EMS) is a power management system for low-voltage distribution systems, developed based on user needs and in compliance with distribution system standards. It features strong professionalism, a high degree of automation, ease of use, high performance, and high reliability. Through telemetry and remote control, it enables rational load allocation, optimized operation, and effective energy conservation. It also records peak and off-peak electricity usage, providing the necessary conditions for energy management. Furthermore, it measures electricity consumption by item, including outlets, power, air conditioning, and special uses, providing a basis for energy conservation audits for enterprises and institutions.

[0049] The Motor Control Unit (MCU) controls the permanent magnet synchronous motor (PMSM) or other motor that drives the main pump. It is used for FOC vector control to achieve precise control of the motor torque and improve the drilling load immunity. It is also used for field weakening control to expand the motor's high-speed range and avoid demagnetization risks. It can also provide energy feedback to generate power and recharge when lowering the drill pipe, achieving the purpose of high-voltage safety isolation.

[0050] A power distribution unit (PDU), also known as a power distribution outlet for cabinets, is designed to distribute power to cabinet-mounted electrical equipment. Available in a variety of specifications with varying functions, installation methods, and socket combinations, PDUs provide suitable rack-mount power distribution solutions for diverse power supply environments. The use of PDUs can make power distribution within the cabinet more organized, reliable, secure, professional, and aesthetically pleasing, while also making maintenance of the cabinet's power supply more convenient and reliable.

[0051] The following is combined with Figure 1-4 , describes in detail the technical solution provided by the embodiments of the present invention.

[0052] As attached Figure 1-3 As shown, an embodiment of the present invention provides a hybrid rotary drilling rig control system, which includes: a power battery, a generator, an engine, a drill rod management system, a main pump, a main pump motor, a power distribution unit, a power head motor and a winch motor, wherein:

[0053] A battery management system is integrated on the power battery, and the power battery is used to provide a power source for the hybrid rotary drilling rig; a generator control unit is integrated on the generator, and the generator control unit is electrically connected to the power battery, and the generator is used to generate electricity for the hybrid rotary drilling rig; an energy management system is integrated on the engine, and the engine is transmission-connected to the generator, and the engine is used to provide power for the hybrid rotary drilling rig; the drill rod management system is hydraulically connected to the power battery, the generator and the energy management system integrated on the engine, and the drill rod management system is used to cool the power battery, the generator and the engine respectively; the main pump is connected to the engine, and the main pump drives the rotating components in the pump to rotate through the engine, converts mechanical energy into pressure energy and kinetic energy of the hydraulic oil, outputs high-pressure oil, and provides working pressure for the hybrid rotary drilling rig; the output shaft of the main pump motor is fixedly connected to the rotor of the main pump, and the main pump is also connected to the drill rod management system for cooling the main pump motor under the control of the drill rod management system; the power distribution unit is respectively connected to the battery management system, the generator and the and the motor controller, and the power distribution unit is also connected to the connecting pipeline of the main pump motor and the drill rod management system. The power distribution unit is used to distribute the input electrical energy to multiple output ports for use by different equipment; a motor controller is integrated on the power head motor, and the motor controller set on the power head motor is connected to the electrical connection line connecting the motor controller on the main pump motor to the power distribution unit, and the power head motor is connected to the connecting pipeline connecting the power distribution unit to the main pump motor and the drill rod management system. The power head motor is also connected to the power head of the hybrid rotary drilling rig for controlling the power head to realize the rotation action; a motor controller is integrated on the winch motor, and the motor controller set on the winch motor is connected to the electrical connection line connecting the motor controller on the main pump motor to the power distribution unit, and the winch motor is connected to the connecting pipeline connecting the power distribution unit to the main pump motor and the drill rod management system. The winch motor is also connected to the winch of the hybrid rotary drilling rig for realizing the lifting action of the power head.

[0054] Specifically, the power transmission path of the hybrid rotary drilling rig control system provided by the embodiment of the present invention includes: an engine-generator-electric drive path, an engine-main pump-hydraulic path, an external power supply-power battery path and an energy recovery path.

[0055] in:

[0056] The engine-generator-electric drive path includes: the engine output power drives the generator to rotate through the transmission system, and the generator converts mechanical energy into electrical energy under the control of the generator control unit. Specifically: the electrical energy is distributed to the main pump motor through the power distribution unit, driving the main pump to generate hydraulic energy, controlling the cylinder, hydraulic motor and other actuators to complete the oil circuit action; the electrical energy is distributed to the power head motor through the power distribution unit, and the power head speed and torque are precisely controlled by the motor controller to achieve rotational action; the electrical energy is distributed to the winch motor through the power distribution unit, and the winch start and stop and speed are controlled by the motor controller to achieve the power head lifting action; the excess electrical energy is managed by the battery management system and stored in the power battery.

[0057] The engine-main pump-hydraulic path includes: the engine can directly drive the main pump, bypassing the electric drive system, and realize oil circuit action through the traditional hydraulic circuit, ensuring that the system can still work stably under extreme working conditions (such as low battery power and motor failure).

[0058] The external power supply-power battery path includes: the external power supply directly charges the power battery through the on-board charger, reducing dependence on engine fuel, reducing usage costs and carbon emissions.

[0059] The energy recovery path includes: when the entire machine is braking, descending, and other working conditions, the electric drive system converts mechanical energy into electrical energy through energy recovery technology, and feeds it back to the power battery storage through the power distribution unit, further improving fuel economy.

[0060] Specifically, in embodiments of the present invention, the energy recovery function is achieved through the following method: when braking the power head, winch, and entire oil circuit, or when the power head is subjected to a controlled downward drop from the top of the mast, the control system provided by the embodiments of the present invention controls the corresponding motor to provide negative torque to achieve the corresponding control function. This essentially turns the motor into a generator when providing negative torque, thereby achieving the energy recovery function. For example, during braking, kinetic energy is converted into electrical energy, and during a controlled drop, gravitational potential energy is converted into electrical energy.

[0061] Therefore, a hybrid rotary drilling rig control system provided by an embodiment of the present invention realizes the dynamic distribution of engine power between "power generation" and "direct drive hydraulics" through the linkage of the energy management system with the generator control unit, the battery management system, and the motor controller, thereby avoiding the engine from operating in a low-efficiency range (such as idling, high load and low speed) for a long time, and improving fuel efficiency by about 20%-30%; by setting the power head and the winch to be independently driven by the motor and utilizing the "low speed constant torque, high speed constant power" characteristics of the motor, the response speed is increased by more than 50% compared with the traditional hydraulic drive, and the operation accuracy and stability are significantly improved. The hydraulic control unit also supports direct drive of the engine Driven by the main pump motor, it forms a "dual power backup". When one power path fails, the other path can take over seamlessly, reducing the risk of downtime. It is especially suitable for extreme working conditions such as deep pile operations. By connecting the drill pipe management system through a unified hydraulic pipeline, key heat-generating components such as the engine, generator, power battery, and main pump motor are centrally cooled. Compared with the traditional independent cooling system, the pipeline complexity is reduced by 40% and the heat dissipation efficiency is increased by 15%; by integrating the power distribution and cooling pipeline functions into the power distribution unit, the cross-layout of wiring harnesses and pipelines is reduced, and the compactness of the system is improved. At the same time, through real-time monitoring of the current and temperature data of each branch, dynamic optimization of power distribution and overload protection are achieved.

[0062] In some optional implementations, a hybrid rotary drilling rig control system provided by an embodiment of the present invention further includes: an on-board charger and an external power supply, wherein:

[0063] The on-board charger is electrically connected to the battery management system. The on-board charger is used to convert the external power grid AC power into high-voltage DC power to charge the power battery; the external power supply is electrically connected to the on-board charger to power the power battery.

[0064] Therefore, by setting up an on-board charger and an external power supply, the external power supply can directly charge the power battery; the external power supply directly charges the power battery through the on-board charger, forming a "engine + external power supply" dual energy input mode, so that the hybrid rotary drilling rig can adapt to static charging scenarios and dynamic charging scenarios.

[0065] For example, combined with actual applications, in areas that are sensitive to noise and emissions, such as urban areas and tunnels, the power battery can be fully charged in advance through an external power supply. During operation, only the motor is used to drive the winch, power head and other actuators, achieving "zero diesel consumption and low noise operation" and meeting environmental protection regulations.

[0066] In some optional implementations of this embodiment, static charging scenarios include: equipment, such as the hybrid rotary drilling rig provided in the embodiment of the present invention, can be continuously charged by an external power supply when it is shut down, and the power battery serves as an energy storage unit to reserve electrical energy for subsequent operations, which is particularly suitable for scenarios with high environmental protection requirements such as urban construction, achieving "zero fuel consumption operation".

[0067] For example, in combination with actual applications, the external power supply interface can be reversed as an emergency power output terminal to power peripheral equipment in special circumstances such as power outages, thereby improving the versatility of the equipment.

[0068] As attached Figure 1 As shown, by integrating the on-board charger into the electrical connection loop between the battery management system and the power distribution unit, the hybrid rotary drilling rig control system provided by the embodiment of the present invention supports wide voltage input, such as 220V / 380V AC, to adapt to different power grid environments; through real-time communication with the battery management system, the charging power is dynamically adjusted according to the power battery status, such as SOC, temperature, and health, to avoid overcharging or undercharging and extend battery life. When the external power supply is connected and the equipment is shut down, the power battery is charged first through the on-board charger until the SOC reaches the set upper limit; when the equipment is operating and the external power supply is not disconnected, the on-board charger and the generator control unit jointly power the motor, and the engine power can be used to drive the main pump or further generate electricity, realizing the efficient mode of "oil-electric hybrid + external energy replenishment"; when the power battery is insufficient and there is no external power supply, the system automatically switches to the engine independent power supply mode to ensure operation continuity.

[0069] In some optional implementations of this embodiment, the dynamic charging scenario includes: if the power battery level is lower than a threshold during operation, the external power supply can be synchronized with the engine power generation to power the system, reducing the engine load and avoiding long-term full-load operation.

[0070] Such a setting not only enables the hybrid rotary drilling rig control system of the embodiment of the present invention to have the above-mentioned effects, but also ensures that the external power supply and the engine power generation do not interfere with each other, and realizes "seamless switching" and "parallel power supply" of energy flow through the power distribution unit. Compared with the single energy source of traditional fuel equipment, the flexibility is significantly improved; in addition, the on-board charger does not need to occupy additional installation space, is integrated into the original electric drive system architecture, and realizes plug-and-play through standardized interfaces, reducing modification costs.

[0071] In some optional implementations of the embodiments of the present invention, overvoltage / undervoltage protection, leakage detection and other functions can also be set in the external power supply circuit, and combined with the battery management system and generator control unit to form a three-level protection to ensure the safe and reliable charging process.

[0072] Furthermore, in an embodiment of the present invention, the generator, the generator control unit, the engine and the energy management system are integrated together to form the main power source of the entire hybrid system.

[0073] In some optional implementations, a hybrid rotary drilling rig control system provided by an embodiment of the present invention also includes a hydraulic control unit, which is connected to the main pump through a hydraulic pipeline and is used to control the hydraulic components to realize the oil circuit opening and closing of the hybrid rotary drilling rig.

[0074] In some optional implementations, a hybrid rotary drilling rig control system according to an embodiment of the present invention further includes: an oil cylinder and a hydraulic motor, and the oil cylinder and the hydraulic motor are connected to a hydraulic control element.

[0075] With this setting, when the engine directly drives the main pump, the hydraulic control unit controls traditional hydraulic actions such as cylinder extension and extension, hydraulic motor rotation, etc., such as mast verticality adjustment, crawler walking, etc., by adjusting the flow direction of the high-pressure oil output by the main pump; when the main pump motor drives the main pump, the hydraulic control unit receives the motor controller signal and accurately controls the oil parameters through components such as proportional valves to realize intelligent control of oil circuit actions, such as dynamically adjusting the pressurized cylinder pressure in accordance with the rotation speed of the power head.

[0076] In some optional implementations of this embodiment, the above-mentioned hydraulic control unit can be set as a valve group unit composed of various hydraulic valves and their corresponding cylinders, hydraulic sensors and other components, so that by switching the reversing valve in the hydraulic control unit, the power source (engine or main pump motor) can be seamlessly switched to ensure that the hydraulic system can work stably in different modes; the pressure sensor monitors the hydraulic circuit pressure in real time. When the system detects a power source failure (such as engine shutdown or main pump motor overload), the hydraulic control unit automatically switches to another power source to avoid operation interruption.

[0077] With this setup, the flow controller of the hydraulic control unit can independently adjust the oil flow entering different actuators. For example, when the power head is drilling at low speed, the oil supply to the non-operating circuit can be reduced to reduce energy loss. Combined with the real-time operating load of the rotary drilling rig (such as drilling resistance), the hydraulic control unit dynamically adjusts the main pump output pressure through the proportional pressure valve to prevent the engine or main pump motor from operating inefficiently under overload conditions, improving fuel economy by approximately 15%. When the electric drive system (main pump motor + motor controller) fails, the hydraulic control unit can be manually switched to engine direct drive mode to ensure that in an emergency (such as a power outage during deep pile operation), the equipment can still complete key actions such as lifting the drill. Conversely, when the engine system fails, the main pump motor can independently drive the hydraulic control unit to maintain basic operating functions and reduce downtime losses.

[0078] In summary, compared with the purely mechanical hydraulic valve control of traditional rotary drilling rigs, the control system of the embodiment of the present invention integrates electronic control elements (such as electromagnetic proportional valves) through the hydraulic control unit, so that the hydraulic system can receive digital instructions from the electric drive and electronic control system (energy management system / motor controller), thereby realizing deep coordination of "hydraulic action-electric drive control"; the reversing valve group in the hydraulic control unit adopts a low-impact design, and the oil pressure fluctuation is ≤5% when switching the power source, avoiding the actuator action caused by power switching and improving the operation stability; the hydraulic control unit has a built-in sensor network, which can monitor parameters such as oil temperature, oil pressure, and oil contamination in real time, and transmit data to the whole machine controller (such as the energy management system) through the CAN bus, thereby realizing the prediction and positioning of hydraulic system faults, and improving maintenance efficiency by 30%.

[0079] Compared to traditional rotary drilling rigs, where the engine power system drives the hydraulic system to achieve operation, the hybrid rotary drilling rig technology provided by the present invention is implemented by integrating the generator system with the engine system and modifying the corresponding engine control method. A portion of the power generated by the engine is converted into electricity by the generator system. A portion of this electricity directly drives three motors: the main pump motor drives the main pump, which in turn controls the hydraulic control unit to achieve the oil flow of the rotary drilling rig; the winch motor drives the winch to achieve the lifting and lowering of the power head; and the power head motor drives the power head to achieve the rotation of the power head. Another portion of the electricity is used to charge the power battery. The energy stored in the power battery can also directly drive the three motors to operate. Furthermore, an external power supply can directly charge the power battery. The entire electric drive and control system also has energy recovery capabilities. Another portion of the power generated by the engine system can also directly drive the main pump, which in turn controls the hydraulic system to achieve the oil flow of the rotary drilling rig. The power allocated by the engine is precisely controlled by the control strategy, allowing the entire machine to cope with extreme operating conditions.

[0080] In a second aspect, an embodiment of the present invention further provides a hybrid rotary drilling rig, on which the hybrid rotary drilling rig is provided with the above-mentioned hybrid rotary drilling rig control system.

[0081] Therefore, through the hybrid rotary drilling rig of the present invention, the time that the engine works in the low-efficiency area can be effectively reduced during operation, and fuel economy is better. At the same time, the winch system and power head of the whole machine are driven only by the motor, so that the working efficiency of the winch and the power head are higher and the stability is better. The hydraulic system of the whole machine is controlled by the main pump motor and the engine system at the same time, which improves the working efficiency of the hydraulic system and effectively reduces the risk of the whole machine under extreme working conditions. The whole machine can be powered by an external power supply, which reduces the cost of use and has an energy recovery function, further improving fuel economy.

[0082] Thirdly, as Figure 4 As shown, an embodiment of the present invention further provides a hybrid rotary drilling rig control method, which includes the following steps S1 to S4:

[0083] Step S1: converting a portion of the power generated by the hybrid rotary drilling rig into electrical energy, and dividing the converted electrical energy into two parts;

[0084] Converting part of the power generated by the hybrid rotary drilling rig into electrical energy involves driving the generator through the transmission system to generate electricity, and the generator control unit converts mechanical energy into electrical energy. The engine power distribution is achieved by the energy management system in collaboration with the generator control unit and the motor controller. By real-time monitoring of the operating load and power source status, the ratio of generated power to direct drive power is dynamically adjusted, allowing the engine to avoid inefficient working ranges and improve fuel economy by 20%-30%.

[0085] Step S2: Use part of the two parts of electrical energy to drive the main pump motor, the winch motor and the power head motor, so that the main pump motor drives the main pump and then controls the hydraulic control unit to realize the oil circuit action of the rotary drilling rig, so that the winch motor drives the winch to realize the lifting action of the power head, and the power head motor drives the power head to realize the rotation action of the power head.

[0086] Specifically, combined with practical applications, for example, the transmission system drives the generator to generate electricity, the generator control unit converts mechanical energy into electrical energy, and the electrical energy is transmitted to the main pump motor, power head motor and winch motor through the power distribution unit to drive the corresponding actuators to operate, or stored in the power battery; directly drive the main pump, and control the flow direction of the hydraulic oil through the hydraulic control unit to realize the oil circuit action of the rotary drilling rig.

[0087] Step S3: The other part of the two parts of electric energy is used to charge the power battery, and the electric energy stored in the power battery can drive the main pump motor, the winch motor and the power head motor to operate according to different working conditions of the hybrid rotary drilling rig.

[0088] Specifically, the main pump motor independently drives the main pump, and adjusts the hydraulic oil pressure and flow through the hydraulic control unit to achieve precise control of the oil circuit movement; the power head motor controls the rotation speed and torque of the power head through the motor controller, and uses the motor's low-speed constant torque characteristics to improve drilling efficiency; the winch motor controls the winch start and stop and lifting speed through the motor controller to achieve smooth lifting and lowering of the power head.

[0089] Combined with actual applications, the battery management system monitors the status of the power battery in real time, optimizes the power distribution and charging method, and avoids overcharging or undervoltage; when the hybrid rotary drilling rig is braking, descending, etc., the electric drive system converts mechanical energy into electrical energy through energy recovery technology, and feeds it back to the power battery storage through the power distribution unit.

[0090] Step S4: using the energy generated by the other part of the power generated by the hybrid rotary drilling rig to drive the main pump and control the hydraulic control unit to realize the oil circuit action of the rotary drilling rig.

[0091] When equipment such as hybrid rotary drilling rigs are in low-load or environmentally friendly scenarios, the power battery is used to drive the motor to achieve zero fuel consumption operation; when the power battery is insufficient or high-load operation is required, it automatically switches to engine direct drive or oil-electric hybrid mode to ensure operation continuity; the hydraulic control unit seamlessly switches the power input between the engine and the main pump motor through the reversing valve group, forming dual power redundancy and reducing the risk of extreme working conditions.

[0092] Therefore, the hydraulic control unit integrates a pressure sensor and a flow controller, dynamically adjusting the hydraulic oil pressure and flow according to parameters such as drilling resistance and power head speed, achieving "load adaptive adjustment", avoiding overload of the engine or main pump motor, and reducing energy consumption by 15%.

[0093] In some optional implementations, an external power supply is further configured on the hybrid rotary drilling rig, so that the configured external power supply can directly charge the power battery.

[0094] For example, the external power supply charges the power battery through the on-board charger, or cooperates with the engine to generate power for the electric drive system.

[0095] In some optional implementations of this embodiment, the charging process of the external power supply includes: a static charging mode and a dynamic charging mode, wherein:

[0096] The static charging mode includes connecting the hybrid rotary drilling rig to an external power supply when it is shut down. The on-board charger converts the AC power into high-voltage DC power and fully charges the power battery through the power distribution unit. The dynamic charging mode includes the external power supply and the engine supplying power synchronously during operation. After meeting the real-time power demand of the motor, the remaining energy is stored in the power battery.

[0097] Some optional implementations of this embodiment also include configuring a drill rod management system on the hybrid rotary drilling rig, and hydraulically connecting the configured drill rod management system to the power battery, generator and energy management system integrated on the engine, so that the drill rod management system can centrally cool the heat-generating components on the hybrid rotary drilling rig through hydraulic pipelines.

[0098] For example, the drill pipe management system uses a unified hydraulic pipeline to centrally cool the heat-generating components such as the engine, generator, power battery (6), and main pump motor, thereby improving the overall heat dissipation efficiency by 15% and reducing the pipeline complexity by 40%, thereby ensuring the temperature stability of the entire machine under extreme working conditions.

[0099] Therefore, the method of the present invention can effectively reduce the time that the engine works in the low-efficiency area, and the fuel economy is better. At the same time, the winch system and power head of the whole machine are driven only by the motor, so that the working efficiency of the winch and the power head are higher and the stability is better. The hydraulic system of the whole machine is controlled by the main pump motor and the engine system at the same time, which improves the working efficiency of the hydraulic system and effectively reduces the risk of the whole machine under extreme working conditions. The whole machine can be powered by an external power supply, which reduces the cost of use and has an energy recovery function, further improving fuel economy.

[0100] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variations thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device that includes a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In addition, "front", "back", "left", "right", "upper" and "lower" in this document are all referenced to the placement states shown in the accompanying drawings.

[0101] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the various embodiments of the present invention.

Claims

1. A hybrid rotary drilling rig control system, characterized in that: include: A power battery, on which a battery management system is integrated, and the power battery is used to provide a power source for the hybrid rotary drilling rig; A generator, on which a generator control unit is integrated, the generator control unit is electrically connected to the power battery, and the generator is used to generate electricity for the hybrid rotary drilling rig; An engine, on which an energy management system is integrated, the engine is drivingly connected to the generator, and the engine is used to provide power for the hybrid rotary drilling rig; a drill rod management system, the drill rod management system being hydraulically connected to the power battery, the generator, and the energy management system integrated with the engine, the drill rod management system being used to cool the power battery, the generator, and the engine, respectively; A main pump connected to the engine drives the rotating assembly in the pump through the engine, converting mechanical energy into pressure energy and kinetic energy of the hydraulic oil, outputting high-pressure oil, and providing working pressure for the hybrid rotary drilling rig; a main pump motor, wherein the output shaft of the main pump motor is fixedly connected to the rotor of the main pump, and the main pump is also connected to the drill rod management system for cooling the main pump motor under the control of the drill rod management system; a power distribution unit, the power distribution unit being electrically connected to the battery management system, the generator, and the motor controller, and also connected to the connecting pipeline connecting the main pump motor to the drill pipe management system, and configured to distribute the input electrical energy to multiple output ports for use by different devices; A power head motor, wherein a motor controller is integrated on the power head motor, and the motor controller provided on the power head motor is connected to the electrical connection line connecting the motor controller on the main pump motor to the power distribution unit. At the same time, the power head motor is connected to the connection pipeline connecting the power distribution unit to the main pump motor and the drill rod management system. The power head motor is also connected to the power head of the hybrid rotary drilling rig for controlling the power head to realize the rotation action; A winch motor is integrated with a motor controller. The motor controller provided on the winch motor is connected to the electrical connection line connecting the motor controller on the main pump motor to the power distribution unit. At the same time, the winch motor is connected to the connection pipeline connecting the power distribution unit to the main pump motor and the drill rod management system. The winch motor is also connected to the winch of the hybrid rotary drilling rig to realize the lifting and lowering action of the power head.

2. A hybrid rotary drilling rig control system according to claim 1, characterized in that: Also includes: An on-board charger, electrically connected to the battery management system, configured to convert AC power from an external power grid into high-voltage DC power to charge the power battery; An external power supply is electrically connected to the on-board charger and is used to supply power to the power battery.

3. A hybrid rotary drilling rig control system according to claim 1, characterized in that: It also includes a hydraulic control unit, which is connected to the main pump through a hydraulic pipeline and is used to control the hydraulic components to realize the oil circuit opening and closing of the hybrid rotary drilling rig.

4. A hybrid rotary drilling rig control system according to claim 3, characterized in that: Also includes: An oil cylinder and a hydraulic motor are connected to a hydraulic control element.

5. A hybrid rotary drilling rig, characterized in that: The hybrid rotary drilling rig is provided with a hybrid rotary drilling rig control system according to any one of claims 1 to 4.

6. A hybrid rotary drilling rig control method, characterized in that: include: Converting a portion of the power generated by the hybrid rotary drilling rig into electrical energy, and dividing the converted electrical energy into two parts; Part of the two parts of electrical energy is used to drive the main pump motor, the hoist motor and the power head motor, so that the main pump motor drives the main pump and then controls the hydraulic control unit to realize the oil circuit movement of the rotary drilling rig, the hoist motor drives the hoist to realize the lifting movement of the power head, and the power head motor drives the power head to realize the rotation movement of the power head; The other part of the two parts of electrical energy is used to charge the power battery, and the electricity stored in the power battery can drive the main pump motor, winch motor and power head motor to operate according to different working conditions of the hybrid rotary drilling rig; The energy generated by another part of the power generated by the hybrid rotary drilling rig drives the main pump, and controls the hydraulic control unit to realize the oil circuit action of the rotary drilling rig.

7. A hybrid rotary drilling rig control method according to claim 6, characterized in that: It also includes configuring an external power supply on the hybrid rotary drilling rig, so that the configured external power supply can directly charge the power battery.

8. A hybrid rotary drilling rig control method according to claim 7, characterized in that: The charging process of the external power supply includes: Static charging mode, wherein the hybrid rotary drilling rig is connected to an external power supply when it is stopped, and the onboard charger converts AC power into high-voltage DC power, which is then fully charged through the power distribution unit. Dynamic charging mode, the dynamic charging mode includes the external power supply and the engine supplying power synchronously during operation. After meeting the real-time power demand of the motor, the remaining power is stored in the power battery.

9. The hybrid rotary drilling rig control method according to claim 6, characterized in that: It also includes configuring a drill rod management system on the hybrid rotary drilling rig, and hydraulically connecting the configured drill rod management system with the power battery, the generator, and the energy management system integrated on the engine, so that the drill rod management system can centrally cool the heat-generating components on the hybrid rotary drilling rig through hydraulic pipelines.

10. The hybrid rotary drilling rig control method according to claim 6, characterized in that: Converting part of the power generated by the hybrid rotary drilling rig into electrical energy includes driving the generator through the transmission system to generate electricity, and the generator control unit converts mechanical energy into electrical energy, wherein the engine power distribution is achieved by the energy management system in collaboration with the generator control unit and the motor controller. By real-time monitoring of the operating load and power source status, the ratio of generated power to direct drive power is dynamically adjusted to allow the engine to avoid the inefficient working range.

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