A fault analysis method, device, equipment and medium of a rotary drilling rig

Abstract

The application discloses a rotary drilling machine fault analysis method, device, equipment and medium, and belongs to the technical field of engineering machinery. The rotary drilling machine fault analysis method comprises the following steps: obtaining equipment parameters of the rotary drilling machine, and establishing corresponding mathematical models for multiple function systems of the rotary drilling machine according to the equipment parameters; wherein the function systems comprise a mechanical system, a hydraulic system, a control system and a power system; a model library is established by using the mathematical models; a simulation model corresponding to each function system is connected based on the model library, and a digital prototype of the rotary drilling machine is obtained; the digital prototype is controlled to operate under multiple fault conditions, and component energy loss of the digital prototype under each fault condition is obtained; a mapping relationship between the component energy loss and a fault type of the fault condition is established, and fault analysis is performed on the rotary drilling machine according to the mapping relationship. The application can improve the fault analysis precision and efficiency of the rotary drilling machine.

Description

Technical Field

[0001] This application relates to the field of engineering machinery technology, and in particular to a fault analysis method, device, equipment and medium for rotary drilling rigs. Background Technology

[0002] Rotary drilling rigs are high-efficiency drilling equipment used in construction. They drill through the ground by rotating a drill bit and are suitable for various geological conditions. During operation, rotary drilling rigs may experience mechanical, hydraulic, or control system failures. Related technologies typically analyze these failures based on key parameters during the actual operation of the rotary drilling rig. However, this method relies on a large amount of actual operating data and suffers from low accuracy and long response times in the fault analysis.

[0003] Therefore, improving the accuracy and efficiency of fault analysis for rotary drilling rigs is a technical problem that needs to be solved by those skilled in the art. Summary of the Invention

[0004] The purpose of this application is to provide a fault analysis method, apparatus, equipment, and medium for rotary drilling rigs, which can improve the accuracy and efficiency of fault analysis for rotary drilling rigs.

[0005] To address the aforementioned technical problems, this application provides a fault analysis method for rotary drilling rigs, the method comprising:

[0006] The equipment parameters of the rotary drilling rig are obtained, and corresponding mathematical models are established for the multiple functional systems of the rotary drilling rig based on the equipment parameters; wherein, the functional systems include mechanical system, hydraulic system, control system and power system;

[0007] A model library is established using the mathematical model; wherein the model library includes simulation models of multiple components in the functional system;

[0008] Based on the model library, the simulation models corresponding to each functional system are connected to obtain the digital prototype of the rotary drilling rig.

[0009] The digital prototype is controlled to operate under various fault conditions, and the component energy loss of the digital prototype under each fault condition is obtained.

[0010] Establish a mapping relationship between the energy loss of the component and the fault type of the fault condition, and perform fault analysis on the rotary drilling rig based on the mapping relationship.

[0011] Optionally, fault analysis is performed on the rotary drilling rig based on the mapping relationship, including:

[0012] The digital prototype is controlled to operate according to the current working condition of the rotary drilling rig, and the current component energy loss of the digital prototype under the current working condition is obtained;

[0013] Based on the mapping relationship, query the current fault type corresponding to the current component energy loss.

[0014] Optionally, after querying the current fault type corresponding to the current component energy loss based on the mapping relationship, the method further includes:

[0015] Query the fault handling method corresponding to the current fault type;

[0016] The fault handling method is verified using the digital prototype to obtain the corresponding processing result; wherein, the processing result includes component energy loss change information and processing time;

[0017] The effectiveness of the fault handling method is determined based on the processing results.

[0018] If the effectiveness of the fault handling method is lower than a preset value, then an invalid mark is added to the fault handling method.

[0019] Optionally, the simulation model corresponding to each of the functional systems is connected based on the model library, including:

[0020] The simulation model of the kinematic pair is used to connect the simulation model of the mechanical system in the model library.

[0021] The simulation model corresponding to the hydraulic system in the model library is connected through the pressure-flow interface simulation model;

[0022] The simulation models corresponding to the control system in the model library are connected by control signals.

[0023] Optional, also includes:

[0024] The engine simulation model is connected to the main pump motor simulation model through the torque-speed interface simulation model;

[0025] The speed reducer simulation model is connected to the rotary hydraulic motor simulation model and the power head motor simulation model respectively;

[0026] Connect the simulation model of the hydraulic cylinder with the simulation model of the pressurizing device.

[0027] Optionally, after obtaining the digital prototype of the rotary drilling rig, the method further includes:

[0028] A bench test was conducted on the rotary drilling rig to obtain test operation data under multiple working conditions; wherein, the test operation data included load, hydraulic system pressure, hydraulic system flow rate, and component stress;

[0029] The digital prototype is calibrated using the test run data to ensure that the deviation between the simulation run data and the test run data of the digital prototype is within a preset range.

[0030] Optionally, mathematical models are established for each of the multiple functional systems of the rotary drilling rig based on the equipment parameters, including:

[0031] Based on the equipment parameters, determine the three-dimensional mechanical model, mechanical working principle, engine structural parameters, engine performance parameters, engine operating parameters, hydraulic component performance parameters, electrical control logic, and electrical control program;

[0032] A mathematical model corresponding to the mechanical system is established based on the three-dimensional mechanical model and the working principle of the machine.

[0033] A mathematical model of the power system is established based on the engine structural parameters, engine performance parameters, and engine operating parameters.

[0034] A mathematical model of the hydraulic system is established based on the performance parameters of the hydraulic components and the hydraulic principle.

[0035] A mathematical model corresponding to the control system is established based on the electrical control logic and the electrical control program.

[0036] This application also provides a fault analysis device for rotary drilling rigs, the device comprising:

[0037] The modeling module is used to acquire the equipment parameters of the rotary drilling rig and establish corresponding mathematical models for the multiple functional systems of the rotary drilling rig based on the equipment parameters; wherein, the functional systems include mechanical system, hydraulic system, control system and power system;

[0038] A model library creation module is used to create a model library using the mathematical model; wherein, the model library includes simulation models of multiple components in the functional system;

[0039] The prototype creation module is used to connect the simulation models corresponding to each of the functional systems based on the model library to obtain the digital prototype of the rotary drilling rig.

[0040] The loss determination module is used to control the digital prototype to operate under various fault conditions and obtain the component energy loss of the digital prototype under each fault condition.

[0041] The fault analysis module is used to establish a mapping relationship between the energy loss of the component and the fault type of the fault condition, and to perform fault analysis on the rotary drilling rig based on the mapping relationship.

[0042] This application also provides a storage medium storing a computer program thereon, which, when executed, implements the steps of the above-described fault analysis method for rotary drilling rigs.

[0043] This application also provides an electronic device, including a memory and a processor, wherein the memory stores a computer program, and the processor, when calling the computer program in the memory, implements the steps of the above-described fault analysis method for rotary drilling rigs.

[0044] This application provides a fault analysis method for rotary drilling rigs. The method establishes corresponding mathematical models for multiple functional systems based on the equipment parameters of the rotary drilling rig, and uses these mathematical models to build a model library containing simulation models of multiple components. Based on the simulation models in the model library, a digital prototype of the rotary drilling rig is constructed, and then the digital prototype is used to perform fault analysis on the rotary drilling rig. The digital prototype generated in this application contains simulation models of each component of the rotary drilling rig, thus enabling the simulation of various fault conditions in a virtual environment, thereby improving the accuracy and efficiency of fault analysis for the rotary drilling rig. Furthermore, this application uses the digital prototype to determine the component energy loss under fault conditions and performs fault analysis based on the mapping relationship between component energy loss and fault type. Since component energy loss changes when the equipment's operating state is abnormal, this application implements fault analysis of the rotary drilling rig based on component energy loss. Compared with conventional fault analysis schemes based on equipment operating parameters, this application can more accurately locate faults, reduce misjudgments and omissions, and improve the accuracy and efficiency of fault analysis. This application also provides a fault analysis device for rotary drilling rigs, a storage medium, and an electronic device, which have the aforementioned beneficial effects, and will not be elaborated further here. Attached Figure Description

[0045] To more clearly illustrate the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0046] Figure 1 A flowchart illustrating a fault analysis method for a rotary drilling rig provided in an embodiment of this application;

[0047] Figure 2 This is a schematic diagram illustrating the implementation principle of a digital prototype of a rotary drilling rig provided in an embodiment of this application.

[0048] Figure 3 This is a schematic diagram of a fault analysis principle provided in an embodiment of this application. Detailed Implementation

[0049] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0050] Please see below. Figure 1 , Figure 1 This is a flowchart illustrating a fault analysis method for a rotary drilling rig provided in an embodiment of this application.

[0051] Specific steps may include:

[0052] S101: Obtain the equipment parameters of the rotary drilling rig, and establish corresponding mathematical models for the multiple functional systems of the rotary drilling rig based on the equipment parameters.

[0053] This embodiment can be applied to electronic devices with digital twin functionality. This step obtains the equipment parameters of the rotary drilling rig to be analyzed. Equipment parameters refer to data describing the characteristics of each functional system of the rotary drilling rig, such as a three-dimensional mechanical model, mechanical working principle, engine structural parameters, engine performance parameters, engine operating parameters, hydraulic component performance parameters, electrical control logic, and electrical control program.

[0054] Rotary drilling rigs consist of multiple functional systems, such as mechanical systems, hydraulic systems, control systems, and power systems; each functional system has its specific functions and operating characteristics, which can be described by mathematical models.

[0055] This embodiment can establish a corresponding mathematical model for each functional system. For mechanical systems, this embodiment can establish a model describing the motion and dynamic behavior of mechanical components, such as kinematic and dynamic equations. For hydraulic systems, this embodiment can establish a model describing the relationship between hydraulic oil flow, pressure, and flow rate, such as fluid dynamics equations. For control systems, this embodiment can establish a model describing the system control logic and response, such as control algorithms and feedback mechanisms. For power systems, this embodiment can establish a model describing power transmission and conversion efficiency, such as energy balance equations.

[0056] S102: Establish a model library using the mathematical model.

[0057] Each functional system may include multiple components. Based on the mathematical model of each functional system, this embodiment can use the mathematical model to build a model library, which includes simulation models of multiple components in the functional system.

[0058] The model library integrates simulation models of multiple components, such as hydraulic pumps, motors, and controllers, each built based on its physical characteristics and working principles. These simulation models can simulate the behavior of actual components under different working conditions, providing components for digital prototypes of rotary drilling rigs. Through the model library, simulations of the entire system can be quickly built and tested, enabling performance and fault analysis in a virtual environment.

[0059] S103: Connect the simulation models corresponding to each of the functional systems based on the model library to obtain the digital prototype of the rotary drilling rig.

[0060] This step involves connecting the simulation models of the components corresponding to each functional system based on a model library to construct a digital prototype of the rotary drilling rig. During this process, interfaces and parameters between the simulation models can be set to ensure that all components work collaboratively and simulate the actual operating state of the rotary drilling rig.

[0061] S104: Control the digital prototype to operate under various fault conditions, and obtain the component energy loss of the digital prototype under each fault condition.

[0062] Component energy loss can include the energy loss of multiple components (such as the engine, hydraulic main pump, hydraulic actuator, etc.); component energy loss refers to the energy lost in other forms (such as heat energy, sound energy, etc.) during equipment operation when components cannot completely and effectively convert all input energy into useful work. Before this step, this embodiment can also control the digital prototype to operate under normal working conditions to obtain the normal energy loss range of each component; after obtaining the component energy loss under fault conditions, the component energy loss within the normal energy loss range can be eliminated. In the subsequent fault detection process, fault analysis is performed only based on the mapping relationship between component energy loss exceeding the normal energy loss range and fault type.

[0063] S105: Establish a mapping relationship between the energy loss of the component and the fault type of the fault condition, and perform fault analysis on the rotary drilling rig based on the mapping relationship.

[0064] This step determines the fault type for each fault condition and establishes a mapping relationship between component energy loss and fault type. Based on this, this embodiment can reproduce the current operating condition of the rotary drilling rig on a digital prototype, identify faults according to the mapping relationship between component energy loss and fault type, and evaluate the effectiveness of different fault handling strategies. Specifically, this embodiment can synchronize data with the digital prototype based on the actual operating status of the rotary drilling rig, so that the digital prototype can accurately reflect the real state of the rotary drilling rig. Based on this, this embodiment can control the digital prototype to operate according to the current operating condition of the rotary drilling rig, obtain the current component energy loss, and determine the fault type corresponding to the current component energy loss based on the mapping relationship. Furthermore, this embodiment can also directly detect the actual component energy loss of the rotary drilling rig and determine the fault type of the rotary drilling rig based on the mapping relationship and the actual component energy loss.

[0065] This embodiment provides a fault analysis method for rotary drilling rigs. The method establishes corresponding mathematical models for multiple functional systems based on the equipment parameters of the rotary drilling rig, and uses these mathematical models to build a model library containing simulation models of multiple components. Based on the simulation models in the model library, a digital prototype of the rotary drilling rig is constructed, and then the digital prototype is used to perform fault analysis on the rotary drilling rig. The digital prototype generated in this embodiment contains simulation models of each component of the rotary drilling rig, thus enabling the simulation of various fault conditions in a virtual environment, thereby improving the accuracy and efficiency of fault analysis for the rotary drilling rig. Furthermore, this embodiment uses the digital prototype to determine the component energy loss under fault conditions and performs fault analysis based on the mapping relationship between component energy loss and fault type. Since component energy loss changes when the equipment's operating state is abnormal, this application implements fault analysis of the rotary drilling rig based on component energy loss. Compared with conventional fault analysis schemes based on equipment operating parameters, this application can more accurately locate faults, reduce misjudgments and omissions, and improve the accuracy and efficiency of fault analysis.

[0066] As for Figure 1 A further description of the corresponding embodiment: the process of performing fault analysis on the rotary drilling rig using the digital prototype is as follows: Multiple fault conditions of the rotary drilling rig are acquired, and the digital prototype is controlled to operate according to these multiple fault conditions; the component energy loss of the digital prototype under each fault condition is determined; a mapping relationship is established between the component energy loss and the fault type of the fault condition; if a fault analysis request is received, the digital prototype is controlled to operate according to the current condition of the rotary drilling rig to obtain the current component energy loss of the digital prototype under the current condition; based on the mapping relationship, the current fault type corresponding to the current component energy loss is queried.

[0067] Abnormal energy loss in components usually indicates that the equipment's operating state deviates from normal. When equipment components experience problems such as wear, loosening, blockage, or aging, energy cannot be effectively transferred or converted, resulting in additional energy loss. This embodiment, by monitoring and analyzing changes in these energy losses, can detect potential faults in advance, accurately locate the faulty part, and take timely repair or replacement measures to prevent further damage to the equipment and improve its reliability and operating efficiency.

[0068] Specifically, this embodiment can determine the current operating conditions of the rotary drilling rig, such as the values ​​of parameters like load, speed, pressure, flow rate, and voltage, based on the fault analysis request.

[0069] Furthermore, after querying the current fault type corresponding to the current component's energy loss based on the mapping relationship, the fault handling method corresponding to the current fault type can also be queried; the fault handling method is verified using the digital prototype to obtain the processing result corresponding to the fault handling method; wherein, the processing result includes component energy loss change information and processing time; the effectiveness of the fault handling method is determined based on the processing result; if the effectiveness of the fault handling method is lower than a preset value, an invalid mark is added to the fault handling method. The above method evaluates and optimizes fault handling strategies without actually interfering with physical equipment, thereby improving the accuracy and efficiency of maintenance decisions. By marking invalid fault handling methods, the above method can continuously update and improve the fault handling knowledge base, providing more reliable data support for fault diagnosis.

[0070] As for Figure 1 A further description of the corresponding embodiment: the process of connecting the simulation models corresponding to each functional system based on the model library includes: connecting the simulation models in the model library corresponding to the mechanical system through the simulation models of kinematic pairs. Kinematic pairs are components in a mechanical system used to transmit motion and force, such as bearings and gears. Through the simulation models of kinematic pairs, various simulation models (such as connecting rods and joints) related to the mechanical system in the model library can be connected to simulate the relative motion and dynamic behavior between components. Connecting the simulation models in the model library corresponding to the hydraulic system through the pressure-flow interface simulation models. Through the pressure-flow interface simulation models, simulation models (such as hydraulic pumps, hydraulic motors, and hydraulic cylinders) corresponding to the hydraulic system in the model library can be connected to simulate the flow and pressure changes of hydraulic oil in the system. Connecting the simulation models in the model library corresponding to the control system through control signals to simulate the regulating effect of the control system on the behavior of the entire rotary drilling rig.

[0071] Accordingly, in this embodiment, the engine simulation model can be connected to the main pump motor simulation model through the torque-speed interface simulation model; the reducer simulation model can be connected to the rotary hydraulic motor simulation model and the power head motor simulation model respectively; and the hydraulic cylinder simulation model can be connected to the pressurizing device simulation model.

[0072] As for Figure 1 As further described in the corresponding embodiment, after obtaining the digital prototype of the rotary drilling rig, bench tests can be conducted on the rotary drilling rig to obtain test operation data under multiple working conditions. The test operation data includes load, hydraulic system pressure, hydraulic system flow rate, and component stress. The digital prototype is calibrated using the test operation data to ensure that the deviation between the simulated operation data and the test operation data of the digital prototype is within a preset range. The parameters of the digital prototype can be corrected through the above method.

[0073] As for Figure 1 A further description of the corresponding embodiment: the process of establishing corresponding mathematical models for the multiple functional systems of the rotary drilling rig based on the equipment parameters includes: determining a three-dimensional mechanical model, mechanical working principle, engine structural parameters, engine performance parameters, engine operating parameters, hydraulic component performance parameters, electrical control logic, and electrical control program based on the equipment parameters; establishing a mathematical model corresponding to the mechanical system based on the three-dimensional mechanical model and the mechanical working principle; establishing a mathematical model corresponding to the power system based on the engine structural parameters, engine performance parameters, and engine operating parameters; establishing a mathematical model corresponding to the hydraulic system based on the hydraulic component performance parameters and hydraulic principles; and establishing a mathematical model corresponding to the control system based on the electrical control logic and the electrical control program.

[0074] During rotary drilling rig operation, traditional methods typically detect faults based solely on equipment operating parameters. However, operator habits and skill levels can interfere with fault detection results, leading to low accuracy. To address this issue, this embodiment offers an improvement: a recognition model is trained using normal fluctuations in equipment operating parameters (i.e., positive samples) and abnormal fluctuations caused by user operating habits (i.e., negative samples). Before fault analysis, the recognition model is used to detect any abnormal parameter fluctuations caused by user operating habits. If such fluctuations exist, a prompt is generated to guide operators in standardizing their actions. If not, fault analysis of the rotary drilling rig is performed using the digital prototype.

[0075] The process described in the above embodiments is illustrated below through a digital prototype implementation scheme of a rotary drilling rig based on multi-system coupling in a practical application.

[0076] This solution enables joint simulation modeling of four systems: mechanical, hydraulic, control, and power. It utilizes a device to manage the joint simulation system model library, parametric modeling, experimental test data management, simulation result data management, and data and 3D model visualization. This embodiment establishes model libraries for each system of the rotary drilling rig and connects models from different disciplines; it also develops a parametric platform for creating digital prototypes, managing data, and visualizing it. The solution specifically includes the following steps:

[0077] Step 1: Establish mathematical models of the mechanical system, hydraulic system, control system, and power system of the rotary drilling rig.

[0078] The mechanical system of a rotary drilling rig includes: a rotating platform, base frame, drill string, power head, drill rod, gooseneck boom, drill mast, luffing mechanism, main winch, tripod, connecting rod, and boom. Based on the 3D CAD (Computer-Aided Design) model of the rotary drilling rig and the motion mechanism of each structural component during operation, a mathematical model of the mechanical structure and its connections is established, mainly including the physical parameters of each component and the kinematic pairs between them.

[0079] The hydraulic system of a rotary drilling rig includes: pump control circuit, power head rotation circuit, pressurization circuit, pilot control circuit, main winch circuit, luffing circuit, and rotation circuit. Based on the principles of hydraulic systems, mathematical models are performed on the hydraulic oil, main pump, relief valve, cylinder, solenoid directional valve, accumulator, motor, oil pipes, and other components and circuits of the hydraulic system.

[0080] The control system of a rotary drilling rig includes: main pump, main valve, auxiliary valve, power head, and main winch motor control. Mathematical models are created for each control module based on the control logic. The main pump control includes constant power, ramp, and main pump pressure fluctuation control units; the main valve, power head, and main winch motor control includes single-action, compound-action, and ramp control units; the auxiliary valve control includes rotation, luffing, and pressurization control units; the power head motor variable control unit; and the main winch motor variable control unit.

[0081] The power system of a rotary drilling rig includes an engine unit that takes into account external characteristic curves.

[0082] Step 2: Build a model library based on Modelica (an open, object-oriented, equation-based computer language).

[0083] A model library for each system module of a rotary drilling rig was built using the Modelica language. The mechanical system model library includes component libraries, primarily for the rotary platform, underframe, drill tools, power head, drill rod, gooseneck boom, drill mast, luffing mechanism, main winch, tripod, connecting rod, and boom. The hydraulic system model library includes hydraulic system components, primarily for hydraulic oil, main pump, relief valve, cylinder, solenoid directional valve, accumulator, motor, and oil pipes. The control system model library includes the main pump, main valve, auxiliary valve, power head, and main winch motor control unit libraries. The power system model library includes the engine library or lithium battery and motor.

[0084] Step 3: Use the models in each model library to connect and build a whole system simulation model (i.e., digital prototype).

[0085] (1) Mechanical system connection: The simulation models of each component in the mechanical system model library are connected through kinematic pairs. The main components are the rotating platform and its connection with the base frame, boom, and connecting rod; the base frame is fixedly connected to the ground; the power head is connected to the gear pair of the drill rod; the power head is connected to the translational pair of the drill mast and the pressurizing cylinder; the main winch is connected to the rotating platform by rope; the gooseneck arm provides support for the main winch rope when lifting the power head and is fixedly connected to the drill mast; the tripod is used to change the direction of movement and is connected to the connecting rod, boom, and the two cylinder mounting points of the luffing mechanism by a rotary pair.

[0086] (2) Hydraulic system connection: The simulation models of each component in the hydraulic system model library are connected through the pressure and flow interface. The main pump outputs pressure and flow to the main valve and auxiliary valve. The main valve and auxiliary valve output their flow and pressure according to the electronic control signal. The luffing cylinder, main winch motor, power head motor and upper slewing motor receive pressure and flow from the main valve and auxiliary valve to realize luffing action, main winch action, power head slewing action and upper slewing action.

[0087] (3) Control system connection: The simulation models of each component in the model library of the control system are connected through signals. Each control signal is connected to the main pump variable, main valve, auxiliary valve action, power head and main hoist motor variable control. The main pump variable control mainly considers the engine speed, pressurization pressure, power head pressure, main pump outlet pressure, auxiliary pump pressure, pressurization cylinder action and main hoist action signal.

[0088] (4) Connection between engine and hydraulic system: The simulation models of each component in the engine system model library are connected to the main pump motor through the torque speed interface. The target speed of the engine is preset, and the speed is stabilized by collecting the output speed and using PID (Proportion Integral Differential) feedback control. When the system load increases, the engine output torque is increased. The maximum output torque of the engine is limited according to the universal characteristic curve of the engine to simulate the engine speed drop condition.

[0089] (5) Connection between hydraulic system and mechanical system: The rotary hydraulic motor outputs pressure and flow to the reducer to drive the upper vehicle to rotate; the power head motor outputs pressure and flow to the reducer to drive the power head to rotate; and the hydraulic cylinder outputs pressure and flow to drive the pressurization device.

[0090] Step 4: Compare and correct the experimental data with the simulation data.

[0091] Through bench testing of the prototype, load and hydraulic system pressure and flow data and component stress data (i.e. component stress) under different working conditions were obtained. The electromechanical-hydraulic and power system joint simulation model was calibrated to ensure that the accuracy of the system model is above 85%.

[0092] Step 5: Digital prototype realization device for rotary drilling rig based on multi-system coupling.

[0093] The digital prototype realization device is a software system. This system imports the test data collected by the data acquisition system into the software for storage, display, and comparison with simulation results. The system calls the Modelica model and connection module of the four major systems of the rotary drilling rig to build the digital prototype and can realize parametric modeling. The system saves and displays the simulation results and compares and analyzes them with the test results. The system outputs the acquired data and simulation results to the 3D visualization unit to drive the 3D model and display the whole machine animation.

[0094] Please see Figure 2 , Figure 2 This is a schematic diagram illustrating the implementation principle of a digital prototype of a rotary drilling rig provided in this application embodiment. The modeling input data includes: data acquisition (including data from various sensors), a 3D mechanical model and its working principle, engine structure, performance, operating parameters, hydraulic principles, performance parameters of hydraulic components, and electrical control logic and programs. Data parsing can be performed on the parameterization platform, and an electromechanical-hydraulic power co-simulation model can be run. The electromechanical-hydraulic power co-simulation model can generate Modelica mechanical system unit libraries, Modelica engine unit libraries, Modelica hydraulic system unit libraries, and Modelica control system unit libraries. After parameterization of each model, operations such as saving test data, simulation data, mechanical system kinematic data, hydraulic system pressure and flow data, engine speed, torque, and power data, control system signal data, and overall machine energy flow data can be performed. In the visualization section, test data display, simulation data display, mechanical system kinematic data display, hydraulic system pressure and flow data display, engine speed display, torque data display, power data display, control system signal data display, overall machine energy flow data display, and 3D animation display are available.

[0095] Step Six: Fault Analysis of Digital Prototype of Rotary Drilling Rig Based on Multi-System Coupling.

[0096] Digital prototypes can use simulation models to conduct virtual tests of fault countermeasures that cannot be verified in normal testing environments. Based on the digital prototype and combined with various actual operating data, energy flow analysis of the entire machine is performed to obtain the normal energy loss range of each component. Various fault conditions are input into the digital prototype, and then the energy loss of each component is analyzed to find the mapping relationship between faults and energy losses. When an actual fault occurs, its energy loss is detected to determine the source of the fault and ultimately resolve it.

[0097] Please see Figure 3 , Figure 3 This is a schematic diagram of a fault analysis principle provided in an embodiment of this application. The diagram shows a rotary drilling rig including: fuel, engine, hydraulic main pump, multi-way valve, and hydraulic actuator. The hydraulic actuator can output effective power. Based on this, engine-related losses, pump efficiency losses, overflow and throttling losses, and potential energy and friction losses can be determined.

[0098] This embodiment combines multiple disciplines in the simulation calculation of rotary drilling rig operation, solving the problem that most system simulation design fields involve only one discipline or do not consider the coupling of physical quantities from multiple disciplines. The simulation results are more accurate and can verify the performance of multiple aspects of the system, and provide intuitive visualization, which facilitates the cooperation of designers from different disciplines during the research and development process and improves the efficiency of research and development. The digital functional prototype simulation model conducts virtual tests on fault countermeasures that cannot be verified in the actual test environment.

[0099] The fault analysis device for a rotary drilling rig provided in this application includes:

[0100] The modeling module is used to acquire the equipment parameters of the rotary drilling rig and establish corresponding mathematical models for the multiple functional systems of the rotary drilling rig based on the equipment parameters; wherein, the functional systems include mechanical system, hydraulic system, control system and power system;

[0101] A model library creation module is used to create a model library using the mathematical model; wherein, the model library includes simulation models of multiple components in the functional system;

[0102] The prototype creation module is used to connect the simulation models corresponding to each of the functional systems based on the model library to obtain the digital prototype of the rotary drilling rig.

[0103] The loss determination module is used to control the digital prototype to operate under various fault conditions and obtain the component energy loss of the digital prototype under each fault condition.

[0104] The fault analysis module is used to establish a mapping relationship between the energy loss of the component and the fault type of the fault condition, and to perform fault analysis on the rotary drilling rig based on the mapping relationship.

[0105] This embodiment provides a fault analysis method for a rotary drilling rig. The method establishes corresponding mathematical models for multiple functional systems based on the equipment parameters of the rotary drilling rig, and uses these mathematical models to build a model library containing simulation models of multiple components. Based on the simulation models in the model library, a digital prototype of the rotary drilling rig is constructed, and then the digital prototype is used to perform fault analysis on the rotary drilling rig. The digital prototype generated in this embodiment contains simulation models of each component of the rotary drilling rig, thus enabling the simulation of various fault conditions in a virtual environment, thereby improving the accuracy and efficiency of fault analysis for the rotary drilling rig. Furthermore, this application uses the digital prototype to determine the component energy loss under fault conditions and performs fault analysis based on the mapping relationship between component energy loss and fault type. Since component energy loss changes when the equipment's operating state is abnormal, this application implements fault analysis of the rotary drilling rig based on component energy loss. Compared with conventional fault analysis schemes based on equipment operating parameters, this application can more accurately locate faults, reduce misjudgments and omissions, and improve the accuracy and efficiency of fault analysis.

[0106] Furthermore, the fault analysis module performs fault analysis on the rotary drilling rig based on the mapping relationship, including: controlling the digital prototype to operate according to the current working condition of the rotary drilling rig, obtaining the current component energy loss of the digital prototype under the current working condition; and querying the current fault type corresponding to the current component energy loss based on the mapping relationship.

[0107] Furthermore, it also includes:

[0108] The fault handling module is configured to query the fault handling method corresponding to the current fault type after querying the current fault type corresponding to the current component energy loss based on the mapping relationship; it is also configured to verify the fault handling method using the digital prototype to obtain the processing result corresponding to the fault handling method; wherein the processing result includes component energy loss change information and processing time; it is also configured to determine the effectiveness of the fault handling method based on the processing result; and it is also configured to add an invalid mark to the fault handling method if the effectiveness of the fault handling method is lower than a preset value.

[0109] Furthermore, the process by which the prototype building module connects the simulation models corresponding to each functional system based on the model library includes: connecting the simulation model corresponding to the mechanical system in the model library through the simulation model of the kinematic pair; connecting the simulation model corresponding to the hydraulic system in the model library through the pressure and flow interface simulation model; and connecting the simulation model corresponding to the control system in the model library through the control signal.

[0110] Furthermore, the prototype building module is also used to connect the engine simulation model and the main pump motor simulation model through the torque-speed interface simulation model; it is also used to connect the reducer simulation model to the rotary hydraulic motor simulation model and the power head motor simulation model respectively; and it is also used to connect the hydraulic cylinder simulation model to the pressurizing device simulation model.

[0111] Furthermore, it also includes:

[0112] The calibration module is used to conduct bench tests on the rotary drilling rig after obtaining the digital prototype of the rotary drilling rig, and obtain test operation data under multiple working conditions. The test operation data includes load, hydraulic system pressure, hydraulic system flow rate and component stress. The module is also used to calibrate the digital prototype using the test operation data so that the deviation between the simulation operation data of the digital prototype and the test operation data is within a preset range.

[0113] Furthermore, the process by which the modeling module establishes corresponding mathematical models for the multiple functional systems of the rotary drilling rig based on the equipment parameters includes: determining the three-dimensional mechanical model, mechanical working principle, engine structural parameters, engine performance parameters, engine operating parameters, hydraulic component performance parameters, electrical control logic, and electrical control program based on the equipment parameters; establishing the mathematical model corresponding to the mechanical system based on the three-dimensional mechanical model and the mechanical working principle; establishing the mathematical model corresponding to the power system based on the engine structural parameters, the engine performance parameters, and the engine operating parameters; establishing the mathematical model corresponding to the hydraulic system based on the hydraulic component performance parameters and hydraulic principles; and establishing the mathematical model corresponding to the control system based on the electrical control logic and the electrical control program.

[0114] Since the embodiments of the apparatus and the embodiments of the method correspond to each other, please refer to the description of the embodiments of the method for the embodiments of the apparatus, which will not be repeated here.

[0115] This application also provides a storage medium on which a computer program is stored, which, when executed, can perform the steps provided in the above embodiments. The storage medium may include various media capable of storing program code, such as a USB flash drive, a portable hard drive, a read-only memory (ROM), a random access memory (RAM), a magnetic disk, or an optical disk.

[0116] This application also provides an electronic device that may include a memory and a processor. The memory stores a computer program, and when the processor calls the computer program in the memory, it can implement the steps provided in the above embodiments. Of course, the electronic device may also include various network interfaces, power supplies, and other components.

[0117] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the apparatus disclosed in the embodiments, since it corresponds to the method disclosed in the embodiments, the description is relatively simple; relevant parts can be referred to in the method section. It should be noted that those skilled in the art can make various improvements and modifications to this application without departing from the principles of this application, and these improvements and modifications also fall within the protection scope of this application.

[0118] It should also be noted that, in this specification, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

Claims

1. A fault analysis method for a rotary drilling rig, characterized in that, include: The equipment parameters of the rotary drilling rig are obtained, and corresponding mathematical models are established for the multiple functional systems of the rotary drilling rig based on the equipment parameters; wherein, the functional systems include mechanical system, hydraulic system, control system and power system; A model library is established using the mathematical model; wherein the model library includes simulation models of multiple components in the functional system; Based on the model library, the simulation models corresponding to each functional system are connected to obtain the digital prototype of the rotary drilling rig. The digital prototype is controlled to operate under various fault conditions, and the component energy loss of the digital prototype under each fault condition is obtained. Establish a mapping relationship between the energy loss of the component and the fault type of the fault condition, and perform fault analysis on the rotary drilling rig based on the mapping relationship; The fault analysis of the rotary drilling rig based on the mapping relationship includes: The digital prototype is controlled to operate according to the current working condition of the rotary drilling rig, and the current component energy loss of the digital prototype under the current working condition is obtained; Based on the mapping relationship, query the current fault type corresponding to the current component energy loss; The process, after querying the current fault type corresponding to the current component energy loss based on the mapping relationship, further includes: Query the fault handling method corresponding to the current fault type; The fault handling method is verified using the digital prototype to obtain the corresponding processing result; wherein, the processing result includes component energy loss change information and processing time; The effectiveness of the fault handling method is determined based on the processing results. If the effectiveness of the fault handling method is lower than a preset value, then an invalid mark is added to the fault handling method.

2. The fault analysis method for rotary drilling rigs according to claim 1, characterized in that, Connecting the simulation models corresponding to each functional system based on the model library includes: The simulation model of the kinematic pair is used to connect the simulation model of the mechanical system in the model library. The simulation model corresponding to the hydraulic system in the model library is connected through the pressure-flow interface simulation model; The simulation models corresponding to the control system in the model library are connected by control signals.

3. The fault analysis method for rotary drilling rigs according to claim 2, characterized in that, Also includes: The engine simulation model is connected to the main pump motor simulation model through the torque-speed interface simulation model; The speed reducer simulation model is connected to the rotary hydraulic motor simulation model and the power head motor simulation model respectively; Connect the simulation model of the hydraulic cylinder with the simulation model of the pressurizing device.

4. The fault analysis method for rotary drilling rigs according to claim 1, characterized in that, After obtaining the digital prototype of the rotary drilling rig, the following are also included: A bench test was conducted on the rotary drilling rig to obtain test operation data under multiple working conditions; wherein, the test operation data included load, hydraulic system pressure, hydraulic system flow rate, and component stress; The digital prototype is calibrated using the test run data to ensure that the deviation between the simulation run data and the test run data of the digital prototype is within a preset range.

5. The fault analysis method for rotary drilling rigs according to claim 1, characterized in that, Based on the equipment parameters, corresponding mathematical models are established for each of the multiple functional systems of the rotary drilling rig, including: Based on the equipment parameters, determine the three-dimensional mechanical model, mechanical working principle, engine structural parameters, engine performance parameters, engine operating parameters, hydraulic component performance parameters, electrical control logic, and electrical control program; A mathematical model corresponding to the mechanical system is established based on the three-dimensional mechanical model and the working principle of the machine. A mathematical model of the power system is established based on the engine structural parameters, engine performance parameters, and engine operating parameters. A mathematical model of the hydraulic system is established based on the performance parameters of the hydraulic components and the hydraulic principle. A mathematical model corresponding to the control system is established based on the electrical control logic and the electrical control program.

6. A fault analysis device for a rotary drilling rig, characterized in that, include: The modeling module is used to acquire the equipment parameters of the rotary drilling rig and establish corresponding mathematical models for the multiple functional systems of the rotary drilling rig based on the equipment parameters; wherein, the functional systems include mechanical system, hydraulic system, control system and power system; A model library creation module is used to create a model library using the mathematical model; wherein, the model library includes simulation models of multiple components in the functional system; The prototype creation module is used to connect the simulation models corresponding to each of the functional systems based on the model library to obtain the digital prototype of the rotary drilling rig. The loss determination module is used to control the digital prototype to operate under various fault conditions and obtain the component energy loss of the digital prototype under each fault condition. The fault analysis module is used to establish a mapping relationship between the energy loss of the component and the fault type of the fault condition, and to perform fault analysis on the rotary drilling rig based on the mapping relationship. The fault analysis module performs fault analysis on the rotary drilling rig according to the mapping relationship, including: controlling the digital prototype to operate according to the current working condition of the rotary drilling rig, obtaining the current component energy loss of the digital prototype under the current working condition; and querying the current fault type corresponding to the current component energy loss based on the mapping relationship. The fault analysis device for the rotary drilling rig also includes: The fault handling module is configured to query the fault handling method corresponding to the current fault type after querying the current fault type corresponding to the current component energy loss based on the mapping relationship; it is also configured to verify the fault handling method using the digital prototype to obtain the processing result corresponding to the fault handling method; wherein the processing result includes component energy loss change information and processing time; it is also configured to determine the effectiveness of the fault handling method based on the processing result; and it is also configured to add an invalid mark to the fault handling method if the effectiveness of the fault handling method is lower than a preset value.

7. An electronic device, characterized in that, It includes a memory and a processor, wherein the memory stores a computer program, and the processor, when calling the computer program in the memory, implements the steps of the fault analysis method for the rotary drilling rig as described in any one of claims 1 to 5.

8. A storage medium, characterized in that, The storage medium stores computer-executable instructions, which, when loaded and executed by a processor, implement the steps of the fault analysis method for rotary drilling rigs as described in any one of claims 1 to 5.

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