Wireless internet-of-things information acquisition system for tower type pumping unit

Abstract

The invention relates to the technical field of monitoring of pump systems. The invention discloses a wireless internet-of-things information acquisition system for a tower type pumping unit. The wireless internet-of-things information acquisition system comprises a motor test module, a transmission shaft test module, a speed reduction roller test module, a guide bracket test module and a wireless signal acquisition device. According to the invention, a complete sensing network covering a power source-transmission chain-bearing structure is established by integrating four testing modules including a motor, a transmission shaft, a speed reduction roller and a guide bracket; according to the structural characteristics of the tower type pumping unit, strain gauges are deployed in a high-stress area at the root of a guide support to monitor micro-strain changes, and an eddy current sensor and a dynamic torque sensor are adopted at key nodes of a transmission shaft to cooperatively monitor low-frequency bending and high-frequency torsional vibration coupling characteristics; a performance degradation model is conveniently established through long-term data accumulation, and transformation from post maintenance to predictive maintenance is realized in combination with a threshold early warning and trend prediction algorithm.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of monitoring of pump systems. BACKGROUND

[0002] The transmission system of the tower type pumping unit is composed of a driving motor, a transmission shaft, a speed reduction drum, a guide support, a balance weight block and a belt, and through the power transmission system, the sucker rod in the oil well is driven to move up and down reciprocally, thereby completing the extraction of crude oil in the oil layer. The pumping unit is connected with the speed reduction drum through the coupling of the driving motor, and the speed reduction drum drives the balance weight block and the sucker rod column to move reciprocally in a straight line through the winding and unwinding of the belt, thereby driving the downhole oil extraction pump to extract crude oil.

[0003] In the prior art, most information collection systems are designed based on the structural characteristics of the conventional beam type pumping unit, and a special system has not been developed for the new type tower type pumping unit. The arrangement of the sensors does not consider the unique structure of the new type tower type pumping unit, such as the stress distribution of the tower and the motion characteristics of the transmission components, and cannot effectively cover the key monitoring nodes of the new type tower type pumping unit, especially in the aspects of multi-parameter and systematic wireless monitoring. There are still technical gaps in three dimensions: firstly, in the monitoring system architecture, the existing scheme lacks the multi-level collaborative monitoring perspective of the tower type pumping unit "power source-transmission chain-bearing structure", and cannot establish a monitoring network covering the motor vibration noise, transmission shaft torque and trajectory, drum multi-parameter and support strain displacement; secondly, in the sensor configuration and measurement point strategy, special arrangement is not made according to the stress distribution characteristics (such as the high stress area at the root of the guide support) and fault mode characteristics (such as the coupling of low frequency bending and high frequency torsional vibration of the transmission shaft), resulting in missed detection of key fault characteristic signals; thirdly, in the data fusion mechanism, the existing technology cannot realize high-precision synchronous collection and correlation analysis of multi-source heterogeneous data, cannot analyze the coupling relationship of vibration, strain, torque and other parameters in time domain and frequency domain, and makes it difficult to trace the fault. SUMMARY

[0004] The purpose of the present application is to provide a tower type pumping unit wireless Internet of Things information collection system, which integrates a motor test module, a transmission shaft test module, a speed reduction drum test module and a guide support test module, cooperatively works with special sensors such as an eddy current sensor, a dynamic torque sensor and a strain gauge, combines high-precision synchronous collection and wireless transmission technology, realizes real-time synchronous monitoring of multi-physical parameters and accurate fault tracing, and provides complete and reliable data support for predictive maintenance and intelligent management of the tower type pumping unit.

[0005] To solve the above technical problems, the present application provides a tower type pumping unit wireless Internet of Things information collection system, which comprises:

[0006] The motor test module is connected with a control vibration sensor and a noise sensor, and is used for monitoring vibration characteristics and noise characteristics of the driving motor.

[0007] The transmission shaft test module is connected with a control eddy current displacement sensor and a dynamic torque sensor, and is used for monitoring transmission shaft rotation abnormalities through shaft center trajectory and load data.

[0008] The reduction drum test module is connected with a control eddy current sensor, a vibration sensor, a photoelectric sensor and a noise sensor, and is used for evaluating shaft center trajectory, vibration response, rotation speed fluctuation and acoustic characteristics of the core transmission mechanism, and establishing a performance model of the reduction drum.

[0009] The guide support test module is connected with an electric resistance strain gauge and an eddy current displacement sensor, and is used for synchronously monitoring local strain and overall displacement of a key load-bearing structural member.

[0010] The wireless signal collector is connected with the motor test module, the transmission shaft test module, the reduction drum test module and the guide support test module, and is used for collecting data from the motor test module, the transmission shaft test module, the reduction drum test module and the guide support test module and sending the data to a terminal display through a wireless network.

[0011] The motor test module, the transmission shaft test module, the reduction drum test module and the guide support test module acquire data based on the same timestamp reference, and the data time stamps acquired by the motor test module, the transmission shaft test module, the reduction drum test module and the guide support test module are consistent in the same time sequence.

[0012] The transmission shaft rotation abnormalities include shaft misalignment, bending deformation and torque overrun.

[0013] The motor test module is connected with at least two vibration sensors and one noise sensor, one vibration sensor is vertically installed on the surface of the motor casing, another vibration sensor is installed on the motor base, the noise sensor is installed and fixed opposite to the driving motor at a distance of 0.3 meters to 0.7 meters away from the driving motor, and the installation height of the noise sensor is not less than one meter.

[0014] The vibration sensor vibration frequency response range covers 1 to 5000 Hz, and the sensitivity is not less than 8.0 mV / m·s -2 The dynamic range of the noise sensor covers 30 to 130 dB, and the frequency range covers 10 to 20000 Hz.

[0015] The transmission shaft test module is connected with at least two eddy current displacement sensors and one dynamic torque sensor, the two eddy current displacement sensors are installed opposite to the transmission shaft between the driving motor and the coupling at a 90° angle and equidistantly in a non-contact manner, and the dynamic torque sensor is installed and fixed on the transmission shaft between the brake device and the coupling.

[0016] The eddy current displacement sensor has a frequency response of not less than 1.5KHz, a static resolution of not less than 0.5% FSO, a dynamic torque sensor measurement error of not less than ±0.02% FS, and a sampling frequency of not less than 400Hz.

[0017] The speed reduction roller test module is connected with at least two eddy current sensors, two vibration sensors, one photoelectric sensor and one noise sensor. The two eddy current sensors are at a 90° angle and are equidistantly arranged to non-contact the driving motor far-end bearing seat and the speed reduction roller. The two vibration sensors are installed on the bearing supports at the two ends of the speed reduction roller. The photoelectric sensor is fixedly installed on the motor near-end side of the speed reduction roller and faces the speed reduction roller. A plurality of reflective strips are evenly arranged along the circumferential direction of the speed reduction roller. The noise sensor is fixedly installed at a distance of 0.3m to 0.7m from the speed reduction roller and faces the speed reduction roller. The installation height of the noise sensor is not less than one meter.

[0018] The eddy current sensor has a frequency response of not less than 1.5KHz and a static resolution of not less than 0.5% FSO. The vibration sensor has a frequency response range of 1 to 5000Hz and a sensitivity of not less than 8.0mV / m·s -2 The noise sensor has a dynamic range of 30 to 130dB and a frequency range of 10 to 20000Hz. The photoelectric sensor has a response time parameter of not more than 10ms and a protection level of not less than IP66.

[0019] The guiding support test module is connected with at least one resistance strain gauge and one eddy current displacement sensor. The resistance strain gauge is fixedly attached to the root area where the guiding support is connected with the main body of the pumping unit tower. The eddy current displacement sensor is fixedly installed on the stable reference surface of the guiding support frame and faces the lower side of the cantilever far end of the guiding support.

[0020] The resistance strain gauge has a sensitive grid length of not less than 3mm and a sensitivity coefficient dispersion parameter of not more than ±0.1%. The eddy current displacement sensor has a frequency response of not less than 1.5KHz and a static resolution of not less than 0.5% FSO.

[0021] Compared with the prior art, the four test modules of the motor, the transmission shaft, the speed reduction roller and the guiding support are integrated to establish a complete sensing network covering the "power source-transmission chain-bearing structure". According to the structural characteristics of the tower type pumping unit, the strain gauges are arranged in the high stress area at the root of the guiding support to monitor the micro-strain change. The eddy current sensor and the dynamic torque sensor are used to cooperatively monitor the low-frequency bending and high-frequency torsional vibration coupling characteristics at the key nodes of the transmission shaft. Long-term data accumulation is used to establish a performance degradation model. The threshold early warning and trend prediction algorithm are combined to realize the transformation from "after-maintenance" to "predictive maintenance".

[0022] In addition, based on the wireless Internet of Things architecture, special sensors are used for optimized arrangement at key stress and vibration nodes, filling the limitations of traditional single-point monitoring, realizing multi-dimensional perception of the tower type pumping unit system operation state, and constructing a multi-level collaborative systematic monitoring system; based on the special arrangement scheme of stress distribution characteristics and transmission system dynamics characteristics, an effective technical solution is provided for special monitoring of oil exploitation equipment, realizing a special measurement point configuration strategy based on structural characteristics; potential faults such as bearing wear and shaft misalignment can be identified in advance, reducing unplanned downtime, having significant economic benefits, and improving the level of fault early warning and intelligent operation and maintenance.

[0023] The above description is only a summary of the technical solutions of the present application, in order to more clearly understand the technical means of the present application, the content of the specification can be implemented, and in order to make the above and other purposes, characteristics and advantages of the present application more obvious and easy to understand, the specific embodiments of the present application are described below. BRIEF DESCRIPTION OF DRAWINGS

[0024] One or more embodiments are illustrated by the pictures in the corresponding drawings, which do not constitute a limitation on the embodiments, and elements with the same reference numerals in the drawings represent similar elements, unless otherwise specified, the drawings do not constitute a proportional limit.

[0025] Figure 1 is a system architecture schematic diagram of at least one embodiment of the present application;

[0026] Figure 2 is Figure 1 a module connection schematic diagram of the wireless signal collector in

[0027] Figure 3 is Figure 1 a schematic diagram of the installation position of the motor test module connecting the sensor in

[0028] Figure 4 is Figure 3 a top view of

[0029] Figure 5 is Figure 1 a schematic diagram of the installation position of the transmission shaft test module connecting the sensor in

[0030] Figure 6 is Figure 5 a side view of

[0031] Figure 7 is Figure 1 a schematic diagram of the installation position of the speed reduction drum test module connecting the sensor in

[0032] Figure 8 isFigure 7 Another perspective structural schematic view;

[0033] Figure 9 is Figure 1 The installation position schematic view of the guide support test module connecting the sensor.

[0034] In the figure: 11-motor noise sensor, 12-motor first vibration sensor, 13-motor second vibration sensor, 21-transmission shaft eddy current sensor, 22-transmission shaft torque sensor, 31-roller noise sensor, 32-roller eddy current sensor, 33-roller vibration sensor, 34-optoelectronic sensor, 35-reflective strip, 41-support eddy current sensor, 42-strain gauge. DETAILED DESCRIPTION

[0035] To make the objectives, technical solutions, and advantages of the present application clearer, the embodiments of the present application will be described in detail below with reference to the drawings. However, those skilled in the art can understand that, in the embodiments of the present application, many technical details are presented in order to make the readers better understand the present application. However, the technical solutions claimed by the present application can be realized even without these technical details and based on various changes and modifications of the following embodiments. The division of the following embodiments is for the convenience of description, and should not constitute any limitation on the specific implementation of the present application, and the embodiments can be combined with each other and cited to each other without contradiction.

[0036] The first embodiment of the present application relates to a tower type pumping unit wireless Internet of Things information acquisition system as shown in Figure 1 、 Figure 2 The tower type pumping unit wireless Internet of Things information acquisition system comprises:

[0037] The motor test module is connected to the control vibration sensor and the noise sensor, and is used for monitoring the vibration characteristics and noise characteristics of the driving motor;

[0038] The transmission shaft test module is connected to the control eddy current displacement sensor and the dynamic torque sensor, and is used for monitoring the transmission shaft rotation anomaly through the shaft center track and load data of the transmission shaft;

[0039] The reduction roller test module is connected to the control eddy current sensor, the vibration sensor, the optoelectronic sensor, and the noise sensor, and is used for evaluating the shaft center track, the vibration response, the rotation speed fluctuation, and the acoustic characteristics of the core transmission mechanism, and establishing a performance model of the reduction roller;

[0040] The guide support test module is connected to the resistance strain gauge and the eddy current displacement sensor, and is used for synchronously monitoring the local strain and the overall displacement of the key load-bearing structural member;

[0041] The wireless signal collector is connected with the motor test module, the transmission shaft test module, the speed reduction roller test module and the guide support test module, and is used for collecting data from the motor test module, the transmission shaft test module, the speed reduction roller test module and the guide support test module and sending the data to a terminal display through a wireless network.

[0042] The motor test module, the transmission shaft test module, the speed reduction roller test module and the guide support test module acquire data based on the same timestamp reference, and the data timestamps acquired by the motor test module, the transmission shaft test module, the speed reduction roller test module and the guide support test module in the same time sequence are consistent.

[0043] It is worth mentioning that each module involved in the embodiment is a logical module, and in actual application, one logical unit can be one physical unit, or a part of one physical unit, or realized in combination of multiple physical units. In addition, in order to highlight the innovative part of the application, units not closely related to solving the technical problems proposed in the application are not introduced in the embodiment, but this does not mean that there are no other units in the embodiment.

[0044] Further, the transmission shaft rotation anomaly includes shaft misalignment, bending deformation and torque overrun.

[0045] The second embodiment of the application is substantially the same as the first embodiment, and mainly differs in that the motor test module is connected to control at least two vibration sensors and one noise sensor, one vibration sensor is vertically installed on the surface of the motor casing, another vibration sensor is installed on the motor base, the noise sensor is installed and fixed opposite to the driving motor at a distance of 0.3-0.7 meters away from the driving motor, and the installation height of the noise sensor is not less than one meter.

[0046] Preferably, the vibration frequency response range of the vibration sensor covers 1-5000 Hz, and the sensitivity is not less than 8.0 mV / m·s -2 , the dynamic range of the noise sensor covers 30-130 dB, and the frequency range covers 10-20000 Hz.

[0047] The third embodiment of the application is substantially the same as the first embodiment, and mainly differs in that the transmission shaft test module is connected to control at least two eddy current displacement sensors and one dynamic torque sensor, the two eddy current displacement sensors are installed opposite to the transmission shaft between the driving motor and the coupling at a 90° angle and equidistantly in a non-contact manner, and the dynamic torque sensor is installed and fixed on the transmission shaft between the brake device and the coupling.

[0048] Preferably, the frequency response of the eddy current displacement sensor is not less than 1.5KHz, the static resolution is not less than 0.5% FSO, the measurement error of the dynamic torque sensor is not less than ±0.02% FS, and the sampling frequency is not less than 400Hz.

[0049] Since the second embodiment corresponds to the present embodiment, the present embodiment can be implemented in cooperation with the second embodiment. The technical details mentioned in the second embodiment are still valid in the present embodiment, and the technical effects achieved in the second embodiment can also be achieved in the present embodiment. In order to reduce repetition, they will not be described here. Correspondingly, the technical details mentioned in the present embodiment can also be applied in the second embodiment.

[0050] The fourth embodiment of the present application is basically the same as the first embodiment, mainly in that the speed reduction drum test module is connected to control at least two eddy current sensors, two vibration sensors, an optical sensor and a noise sensor. The two eddy current sensors are at a 90° angle and are equidistantly non-contacting and directly opposite the drive motor distal bearing seat and the speed reduction drum. The two vibration sensors are installed on the bearing supports at both ends of the speed reduction drum. The optical sensor is fixedly installed on the motor proximal side of the speed reduction drum, and the optical sensor is directly opposite the side of the speed reduction drum. A plurality of reflective strips are installed on the speed reduction drum along the drum circumference. The noise sensor is installed fixedly at a distance of 0.3 meters to 0.7 meters from the speed reduction drum and directly opposite the speed reduction drum, and the installation height of the noise sensor is not less than one meter.

[0051] Preferably, the frequency response of the eddy current sensor is not less than 1.5KHz, the static resolution is not less than 0.5% FSO, the frequency response range of the vibration sensor covers 1~5000Hz, and the sensitivity is not less than 8.0mV / m·s -2 , the dynamic range of the noise sensor covers 30~130dB, the frequency range covers 10~20000Hz, the response time parameter of the optical sensor is not greater than 10ms, and the protection level is not less than IP66.

[0052] Since the aforementioned embodiments correspond to the present embodiment, the present embodiment can be implemented in cooperation with the aforementioned embodiments. The technical details mentioned in the aforementioned embodiments are still valid in the present embodiment, and the technical effects achieved in the aforementioned embodiments can also be achieved in the present embodiment. In order to reduce repetition, they will not be described here. Correspondingly, the technical details mentioned in the present embodiment can also be applied in the aforementioned embodiments.

[0053] The fifth embodiment of the present application is basically the same as the first embodiment, mainly in that the guide bracket test module is connected to at least one of a resistance strain gauge and an eddy current displacement sensor. The resistance strain gauge is fixedly attached to the root area of the guide bracket and the main body of the pumping unit tower. The eddy current sensor is fixedly installed on the stable reference surface of the guide bracket body, and the eddy current sensor is directly opposite the lower side of the cantilever distal end of the guide bracket.

[0054] Preferably, the sensitive gate length of the resistance strain gauge is not less than 3mm, the sensitive coefficient dispersion parameter is not more than ±0.1%, the frequency response of the eddy current displacement sensor is not less than 1.5KHz, and the static resolution is not less than 0.5% FSO.

[0055] Since the foregoing embodiments correspond to each other, the present embodiment can be implemented in cooperation with the foregoing embodiments. The technical details mentioned in the foregoing embodiments are still valid in the present embodiment, and the technical effects achieved in the foregoing embodiments can also be achieved in the present embodiment. In order to reduce repetition, they will not be described again. Correspondingly, the technical details mentioned in the present embodiment can also be applied in the foregoing embodiments.

[0056] The sixth embodiment of the present application is combined with the above-mentioned embodiments, which is composed of four core sub-modules: motor test module, transmission shaft test module, speed reduction drum test module and guide support test module. The motor test module is responsible for monitoring the vibration and noise characteristics of the driving source, capturing the running state of the motor under complex working conditions through vibration sensors and noise sensors; the transmission shaft test module focuses on the power transmission system, synchronously collects shaft trajectory and load data using eddy current displacement sensors and dynamic torque sensors, and diagnoses abnormalities such as shaft misalignment and bending deformation; the speed reduction drum test module comprehensively evaluates the shaft trajectory, vibration response, speed fluctuation and acoustic characteristics of the core transmission mechanism through multi-sensor fusion technology (including eddy current sensors, vibration sensors, photoelectric sensors and noise sensors), and establishes a performance model of the speed reduction drum under frequent start-stop and load alternating working conditions; the guide support test module adopts a combination scheme of resistance strain gauges and eddy current displacement sensors to realize synchronous monitoring of local strain and overall displacement of key load-bearing structural components. Specifically as follows:

[0057] I. Motor test module

[0058] The driving motor of the tower type pumping unit is long-term operated under the working conditions of impact torque change, frequent start-stop and long-term variable speed, which causes the motor vibration and noise signals to present strong non-stationary characteristics, and simultaneously excites shell high-frequency vibration and wideband noise. During the start-stop acceleration and deceleration process, vibration is mainly caused by mechanical impact, and during smooth operation, noise is mainly caused by electromagnetic characteristics. Therefore, this module adopts vibration sensors and noise sensors to be deployed cooperatively, and through the complementarity of vibration and noise, the blind area of single-point monitoring is avoided.

[0059] Test target: This module takes the driving motor as the test object, deploys vibration and noise sensors at key test points of the motor, and real-time collects and transmits vibration and noise signals, aiming to monitor the running state of the motor under complex variable speed and load working conditions, and to provide key data support for early fault warning, optimization of operation efficiency and long-period safe operation of the equipment.

[0060] Test scheme: This module uses vibration sensors and noise sensors to monitor the running state of the motor. The vibration sensor converts the vibration acceleration into an electrical signal by sensing the mechanical vibration of the motor shell and base; the noise sensor captures the sound pressure changes generated by the motor during operation to obtain acoustic characteristic signals. During the monitoring process, the system collects vibration acceleration parameters and noise data in real time to establish a basic database of the motor operating state. Through long-term data accumulation, the system can identify the operating characteristics of the motor under different operating conditions and provide data support for state evaluation.

[0061] The measurement point positions are shown in Figure 3 , Figure 4 : (1) The second vibration sensor 13 of the motor is vertically installed on the surface of the motor shell, and the first vibration sensor 12 of the motor is located on the motor base; (2) The motor noise sensor 11 is fixed by a bracket and is located 0.5 meters away from the motor, with a height of not less than 1 meter from the ground, and the main shaft of the noise sensor is aligned with the geometric center of the motor.

[0062] Sensor selection: The tower-type pumping unit drive motor is subjected to complex variable load conditions during operation, including periodic torque load, frequent start-stop impact, and the effects of long-term continuous operation. These operating characteristics make the vibration and noise signals of the motor exhibit obvious non-stationary characteristics, containing rich equipment state information. In view of this test background, the vibration sensor can be a CA-YD-186 piezoelectric acceleration sensor. It has a wide frequency range (0.5-5000 Hz) and high sensitivity (9.96 mV / m·s⁻²), which can capture the wideband vibration signals of the motor under variable conditions, and is suitable for extracting the medium and high frequency vibration characteristics of the motor. The specific parameters are shown in Table 1; the noise sensor model can be AWA14423. The motor noise includes electromagnetic noise, mechanical noise, and aerodynamic noise, etc. The capacitive sensor has the advantages of dynamic range (30-130 dB) and flat frequency response, and the sensor is equipped with a preamplifier to ensure stable operation in a strong electromagnetic environment. The specific parameters are shown in Table 2.

[0063] Table 1 Vibration sensor model

[0064] Sensor model CA-YD-186 Product standard number Q / 321001L0C1-2010 Installation method Magnetic base, bolt Quality 35g Output method L5 Vibration frequency response range 0.5-5000Hz Operating current 2-10mA IC operating voltage 12-24V Sensitivity 9.96 mV / m·s -2 ]]

[0065] Table 2 Noise sensor model

[0066] Model AWA14423 Outer diameter 12.7mm (1 / 2") Sensitivity 50mV / Pa Dynamic range 17-145dB Frequency range 10-20000Hz

[0067] Therefore, a special collaborative strategy is designed based on the non-stationary signal characteristics of the motor. Through collaborative deployment, vibration signals are used to capture mechanical impact responses during the start-stop phase, and noise signals are used to identify electromagnetic abnormalities during stable operation, forming a complementary analysis mechanism. This collaborative strategy not only avoids single-point blind areas, but also provides a more comprehensive description of the motor operation process.

[0068] II. Test module for transmission shaft

[0069] The alternating torque generated by the periodic up-and-down movement of the sucker rod of the tower-type pumping unit, and the instantaneous torque impact during start-stop process, are prone to cause shaft misalignment, bending deformation or torque overrun and other faults. Mechanically, the low-frequency bending and high-frequency torsional vibration coupling characteristics exhibited by the transmission shaft under complex working conditions are due to the increase in radial displacement caused by shaft misalignment, which in turn causes periodic fluctuations in torque. Therefore, this module adopts a collaborative monitoring scheme of eddy current displacement sensors and dynamic torque sensors. By synchronously collecting displacement and torque data, the shaft center running trajectory can be reconstructed, and the combined fault diagnosis of bending and torsional vibration interaction can be realized.

[0070] Test target: This module takes the transmission shaft system as the test object, and diagnoses the abnormal states such as shaft misalignment, bending deformation, and torque overrun by synchronously collecting shaft center trajectory and torque data, aiming to realize the monitoring of the load adaptability and operation reliability of the transmission system under complex working conditions, and to provide key basis for the optimization design and preventive maintenance of the transmission chain.

[0071] Test scheme: This module adopts a combined monitoring scheme of eddy current displacement sensors and dynamic torque sensors. The eddy current sensor measures the dynamic displacement change of the shaft center in a non-contact manner; the torque sensor directly monitors the torsional deformation of the shaft body during power transmission. During the monitoring process, the system synchronously collects shaft center displacement data and torque load information, reconstructs the shaft center running trajectory through data analysis, and evaluates the operation stability of the transmission system. All monitoring data are sent to the analysis terminal through wireless transmission, providing basis for equipment state evaluation.

[0072] The test point positions are shown in Figure 5 , Figure 6 The transmission shaft eddy current sensor 21 is located on the transmission shaft between the motor and the coupling, and is installed at a 90-degree angle on the bracket; the transmission shaft torque sensor 22 is fixed on the transmission shaft between the coupling and the brake device.

[0073] Sensor selection: The transmission shaft is subjected to complex alternating loads and torque shocks during operation, which can easily cause shaft misalignment, bending deformation, and torque overload. These working conditions require the monitoring system to have high precision and high response measurement capabilities, and to be able to adapt to high-speed rotating measurement environments. In the aspect of shaft orbit monitoring, ZH3010J eddy current displacement sensor can be selected to measure the shaft orbit. This sensor works based on electromagnetic induction principle, has the characteristics of non-contact measurement, fast response speed (frequency response 2 kHz), high resolution (0.5% FSO), and can capture the radial displacement changes of the transmission shaft under high-speed rotation. The specific parameters are shown in Table 3. In the aspect of torque monitoring, UT2301 dynamic torque sensor can be used. For the torsional deformation characteristics of the transmission shaft during power transmission, this sensor is based on strain measurement principle, has the technical advantages of high measurement accuracy (±0.01% FS) and fast response frequency (500 Hz sampling frequency), and the specific parameters are shown in Table 4.

[0074] Table 3 Eddy current sensor model

[0075] Sensor model ZH3010J Power supply ±15V DC / 350mA Static resolution 0.5% FSO Linearity ≤±0.25% FSO Frequency response 2KHz (-3dB) Pre-amp operating temperature range -25~50°C Probe and cable operating temperature range -50~260°C

[0076] Table 4 Dynamic torsion sensor model

[0077] Sensor model UT2301 Sampling frequency 500Hz Strain measurement range ±0.4~±16000με Measurement error ±0.01% FS±0.5με Bridge balance range ±8000με Rotational speed measurement range 10000rpm Bridge voltage 2V

[0078] Therefore, under alternating loads and torque shocks, the fault mode of the transmission shaft is often coupled with bending and torsional vibration, and a single sensor lacks correlation and cannot capture this interaction. The design of this scheme can analyze the correlation between the offset characteristics of the shaft orbit and the torque fluctuations when the transmission shaft is misaligned, determine the fault type and severity. In the long-term operation, through the trend analysis of displacement and torque data, the performance degradation of the transmission shaft can be predicted, which provides a basis for preventive maintenance.

[0079] Three, speed reduction drum test module

[0080] The speed reduction drum has a compact internal structure and is prone to wear, meshing abnormalities or structural looseness under frequent start-stop and alternating load conditions. Its fault characteristics under complex working conditions have obvious multi-parameter correlation. When the bearing wears, it will cause the bearing gap to increase, not only causing the offset of the shaft orbit, but also causing the mechanical vibration to intensify; when the gear appears meshing abnormalities, not only will it produce vibration signals of characteristic frequency, but also will cause abnormal noise.

[0081] Test target: This module takes the reduction drum assembly as the test object, aiming to evaluate the comprehensive operation state of the reduction drum and internal components. By synchronously monitoring multiple parameters such as shaft trajectory, vibration response, speed fluctuation, and noise characteristics, the module realizes the diagnosis and prediction of faults such as bearing wear, gear meshing abnormalities, and structural looseness, establishes a performance degradation model of the reduction drum under frequent start-stop and load alternation conditions, and provides data support for condition-based maintenance and life prediction of the reduction drum and internal components.

[0082] Test scheme: This module uses eddy current sensors, vibration sensors, photoelectric sensors, and noise sensors. The eddy current displacement sensor monitors the dynamic trajectory of the reduction drum shaft; the vibration sensor collects bearing vibration signals; the photoelectric sensor obtains speed information by identifying reflective markers; and the noise sensor captures acoustic parameters during operation. During the monitoring process, the system synchronously collects multiple physical parameters to establish a multi-dimensional database of the reduction drum operating state. Through correlation analysis of various parameters, the operating state and reliability of the reduction drum as a power transmission core component are evaluated.

[0083] The test point positions are shown in Figure 7 , Figure 8 : (1) The drum eddy current sensor 32 is located between the motor distal bearing seat and the reduction drum, with a 90-degree angle (i.e., horizontal and vertical directions) facing each other and installed on the bracket; (2) The drum vibration sensor 33 is arranged on the bearing support at both ends of the reduction drum; (3) The photoelectric sensor 24 is fixedly installed on the motor near side of the drum, ensuring that its light path can accurately sweep the reflective strip 35 attached to the side of the drum, with 8 reflective strips 35 evenly spaced along the drum circumference; (4) The drum noise sensor 31 is fixed through a special bracket and arranged 0.5 meters away from the reduction drum, with a height of not less than 1 meter from the ground, and the sensor main shaft is aligned with the middle part of the drum shell.

[0084] Sensor selection: The deceleration roller and its surrounding components are installed compactly and complexly, and its working environment has the characteristics of large temperature difference and high humidity. According to the structural characteristics and working characteristics of the roller, the sensors used in this module need to have high sensitivity, strong flexibility, and good robustness. Based on the above working condition requirements, in the detection of the deceleration roller shaft center trajectory, ZH3010J eddy current sensor can be selected, which has high linearity and fast response speed. The specific parameters are shown in Table 3. In the vibration detection, CA-YD-186 vibration sensor can be selected, which has a wide frequency range and good adaptability. The specific parameters are shown in Table 1. In the noise detection, AWA14423 type noise sensor is selected, which has a small outer diameter, a wide dynamic range, and high sensitivity. The specific parameters are shown in Table 2. In the deceleration roller speed monitoring, PM-TB010N type photoelectric sensor can be selected. The sensor is a reflective type, easy to install, and has good flexibility. The sensor response time is less than 5ms, and the sensitivity is high. The sensor has an IP66 protection level, good anti-interference performance, small measurement error, and strong robustness. The specific parameters are shown in Table 5.

[0085] Table 5 Photoelectric sensor type

[0086] Sensor model PM-TB010N Light source type Invisible infrared light (880nm) Operating voltage 10~30VDC Response time ≤5ms Maximum light ≤10.000Lux Housing size M12*1*58mm Protection level IP66

[0087] Therefore, compared with the traditional single sensor monitoring scheme which is difficult to distinguish the fault type (such as bearing wear or gear engagement), this module integrates eddy current sensor, vibration sensor, photoelectric sensor and noise sensor, provides timing reference for other sensors by real-time monitoring of roller speed change, realizes multi-parameter synchronous monitoring and data fusion, and effectively avoids the problem of fault misjudgment caused by insufficient monitoring dimensions in general scheme.

[0088] Four, guide support test module

[0089] The guide support is located at the extension end of the pumping unit platform and is prone to stress concentration, fatigue fracture or plastic deformation under alternating load. The root area of the support connected to the tower has the maximum bending moment and is the stress concentration point, and the micro-strain change can directly reflect the structural fatigue; while the displacement of the distal end of the support indicates the overall deformation, and the fatigue damage accumulation is the direct cause of the structural deformation. Therefore, this module combines resistance strain gauges and eddy current displacement sensors to establish the correlation between local strain and overall deformation, and through synchronous data analysis, the structural response characteristics under alternating load can be quantitatively analyzed.

[0090] Test target: The guide support of this module is the test object, and by synchronously monitoring the local strain and overall displacement parameters, the mechanical response characteristics of the guide support under alternating load are quantitatively analyzed. The purpose is to identify potential risks such as stress concentration at the root of the support, structural fatigue and plastic deformation, to evaluate the safety margin and service performance of the load-bearing structure, and to provide scientific basis for the optimization design and safe operation of the guide support.

[0091] Test scheme: This module adopts a combination scheme of resistance strain gauges and eddy current displacement sensors. The strain gauges directly measure the micro-strain changes at the stress concentration parts of the guide bracket; the eddy current sensors non-contact measure the dynamic displacement changes of the guide bracket. During the monitoring process, the system synchronously collects strain and displacement data, and evaluates the structural integrity of the guide bracket under alternating loads through the correlation analysis of local strain and overall deformation.

[0092] The measurement point positions are shown in Figure 9 (1) The resistance strain gauges 42 are pasted at the root area of the guide bracket connected to the tower body, which is the area with the maximum bending moment and the most concentrated stress of the bracket. (2) The bracket eddy current sensor 41 is fixedly installed on the reference surface of the bracket body, and its probe is directed to the lower side of the cantilever distal end of the guide bracket.

[0093] Sensor selection: The guide bracket is located at the extended end of the pumping unit platform, and it is difficult to arrange sensors. Its working environment has the characteristics of large temperature difference and high humidity. According to the structural characteristics and working characteristics of the guide bracket, the strain gauges should have the characteristics of small and light shape, easy to arrange, high sensitivity, and strong robustness. Based on the above requirements, the strain gauge model can be selected as BE-350-4BB-A11-P400. The grid length of the strain gauge is 4mm, which is suitable for measuring the area with large stress gradient near the weld. The base material of the strain gauge is phenolic, which is suitable for firmly bonding the surface of the measured bracket metal material. The sensitivity is less than or equal to 0.1% and the use temperature range is below -20℃, which can maintain high sensitivity measurement under the harsh working conditions of the pumping unit. The specific parameters are shown in Table 6. In terms of deformation detection at the extended end of the guide bracket, ZH3010J eddy current sensor can be selected. This sensor has high linearity and fast response speed. The parameters of this sensor are the same as the above-mentioned eddy current sensor. The specific parameters are shown in Table 3.

[0094] Table 6 Strain gauge model

[0095] Sensor model BE-350-4BB-A11-P400 Strain gauge nominal resistance 350Ω Operating temperature range -30℃~80℃ Sensitivity coefficient dispersion ≤±0.1% Sensitive grid length 4mm Base material Phenolic-acetal Lead length 400mm

[0096] Therefore, compared with the traditional monitoring scheme with single sensor, it is difficult to capture the fatigue damage process of the bracket structure. Based on the stress characteristics of the guide bracket, this scheme realizes the specialized monitoring from micro-strain to macro-deformation. Through the correlation analysis of local strain and overall deformation, the system can early identify potential risks such as stress concentration and fatigue damage.

[0097] Five, wireless signal collector

[0098] Each test module is connected with a wireless signal collector through a low-noise cable to form a data acquisition link. The wireless signal collector, as the core processing unit of the system, is responsible for synchronous acquisition of multiple sensor signals, signal conditioning and data packaging, and then transmits the data to a remote terminal display device in real time through an embedded wireless communication module, realizing full-process coverage from on-site monitoring to remote analysis.

[0099] Table 7: Wireless signal collector model

[0100] Wireless signal collector model TX9 Outer size 42×42×77mm Data transmission method 100M Ethernet Communication protocol Ethernet, UDP / TCP Sampling resolution 24bit Interface type EDG wiring Sampling frequency 1KHz, 2KHz, 4KHz, 16KHz, 32KHz

[0101] During system operation, the sensors of each test module synchronously acquire data at a preset sampling frequency. A high-precision clock is used inside the acquisition module to synchronize the data of each channel, ensuring consistent timestamps and providing a reliable basis for subsequent data analysis. The specific parameters are shown in Table 7. The wireless signal collector uses a TX9 data acquisition module, which has 16 interfaces. The connection method is shown in Figure 2 After data preprocessing by the acquisition module, it is transmitted to the cloud platform or local server through the built-in wireless gateway. Users can view the data trend of each measurement point in real time on a computer or mobile terminal through a dedicated software interface. The system supports functions such as waveform display, spectrum analysis, threshold alarm, and can generate a device health status report based on historical data, providing decision support for predictive maintenance. This implementation not only solves the difficulties of traditional wired deployment, but also realizes multi-parameter collaborative monitoring, filling the technical gap in wireless monitoring of tower-type pumping unit systems.

[0102] It is easy to understand that the aforementioned motor test module, transmission shaft test module, speed reduction drum test module, and guide bracket test module are preferably implemented using a conventional FPGA (such as the AG10K series), which mainly serves as a relay for data from the sensor to the wireless signal collector. The wireless signal collector connects to each sensor signal using an interface, enabling parallel data transmission to ensure synchronization of data acquisition. In addition to conventional FPGA, signal interface switching circuits can be used to save costs, and high-performance MCUs (such as GD32F4 series chips) can be used to improve intelligence, all of which can achieve the corresponding technical effects.

[0103] Therefore, the faults of the tower type oil pumping unit are mostly in the form of multi-parameter coupling (such as synchronous change of vibration and torque), the data acquisition module is used as a wireless signal collector, the data of each channel is synchronized through a high-precision clock, the feasibility of multi-parameter correlation analysis is ensured, the system collects multiple sensor signals in real time and establishes a multi-dimensional database, the internal relationship between parameters is analyzed, the wireless transmission to the cloud platform is realized, the visual analysis such as waveform display, spectrum analysis and threshold alarm is supported, the running state of the deceleration roller as a power transmission core component is evaluated through correlation analysis of various parameters, and this cannot be realized by a single module.

[0104] Those skilled in the art can understand that the above-mentioned embodiments can be variously changed in form and details in practical application without departing from the spirit and scope of the present application.

Claims

1. A wireless Internet of Things (IoT) information acquisition system for tower-type oil pumping units, characterized in that, include: The motor testing module connects to control vibration sensors and noise sensors to monitor the vibration and noise characteristics of the drive motor. The drive shaft testing module connects to control the eddy current displacement sensor and the dynamic torque sensor, and is used to monitor abnormal drive shaft rotation by using the shaft center trajectory and load data. The reduction roller test module connects to control eddy current sensors, vibration sensors, photoelectric sensors, and noise sensors to evaluate the shaft trajectory, vibration response, speed fluctuation, and acoustic characteristics of the core transmission mechanism, and to establish a performance model of the reduction roller. The guide support test module connects a resistance strain gauge and an eddy current displacement sensor to simultaneously monitor the local strain and overall displacement of key load-bearing structural components. The wireless signal acquisition device connects to the motor test module, drive shaft test module, reduction roller test module, and guide bracket test module. It is used to collect data from the motor test module, drive shaft test module, reduction roller test module, and guide bracket test module and send it to the terminal for display via wireless network. The motor test module, drive shaft test module, reduction roller test module, and guide bracket test module acquire data based on the same timestamp reference, and the timestamps of the data acquired by the motor test module, drive shaft test module, reduction roller test module, and guide bracket test module in the same time sequence are consistent.

2. The wireless IoT information acquisition system for tower-type pumping units as described in claim 1, characterized in that, Abnormal rotation of the drive shaft includes shaft misalignment, bending deformation, and excessive torque.

3. The wireless IoT information acquisition system for tower-type pumping units as described in claim 1, characterized in that, The motor testing module connects and controls at least two vibration sensors and one noise sensor. One vibration sensor is vertically mounted on the surface of the motor housing, and the other vibration sensor is mounted on the motor base. The noise sensor is mounted and fixed directly opposite the drive motor at a distance of 0.3 to 0.7 meters, and the installation height of the noise sensor is not less than one meter.

4. The wireless IoT information acquisition system for tower-type pumping units as described in claim 3, characterized in that, The vibration sensor has a vibration frequency response range of 1~5000Hz and a sensitivity of not less than 8.0mV / m·s. -2 The noise sensor has a dynamic range of 30~130dB and a frequency range of 10~20000Hz.

5. The wireless IoT information acquisition system for tower-type pumping units as described in claim 1, characterized in that, The drive shaft testing module connects and controls at least two eddy current displacement sensors and one dynamic torque sensor. The two eddy current displacement sensors are installed facing the drive shaft between the drive motor and the coupling at a 90° angle and in a non-contact manner. The dynamic torque sensor is installed and fixed on the drive shaft between the brake device and the coupling.

6. The wireless IoT information acquisition system for tower-type pumping units as described in claim 5, characterized in that, The eddy current displacement sensor has a frequency response of not less than 1.5 kHz, a static resolution of not less than 0.5% FSO, and a dynamic torque sensor has a measurement error of not less than ±0.02% FS and a sampling frequency of not less than 400 Hz.

7. The wireless IoT information acquisition system for tower-type pumping units as described in claim 1, characterized in that, The reduction roller test module connects and controls at least two eddy current sensors, two vibration sensors, one photoelectric sensor, and one noise sensor. The two eddy current sensors are positioned at a 90° angle, equidistantly and non-contactly facing the far-end bearing seat of the drive motor and the reduction roller. The two vibration sensors are installed on the bearing supports at both ends of the reduction roller. The photoelectric sensor is fixedly installed on the side of the reduction roller near the motor end, facing the side of the reduction roller. Multiple reflective strips are evenly distributed along the circumference of the reduction roller. The noise sensor is fixedly installed 0.3 to 0.7 meters away from the reduction roller, facing the reduction roller, and the installation height of the noise sensor is not less than one meter.

8. The wireless IoT information acquisition system for tower-type pumping units as described in claim 7, characterized in that, The eddy current sensor has a frequency response of not less than 1.5 kHz and a static resolution of not less than 0.5% FSO. The vibration sensor has a frequency response range of 1~5000 Hz and a sensitivity of not less than 8.0 mV / m·s. -2 The noise sensor has a dynamic range of 30~130dB and a frequency range of 10~20000Hz. The photoelectric sensor has a response time parameter of no more than 10ms and a protection level of no less than IP66.

9. The wireless IoT information acquisition system for tower-type pumping units as described in claim 1, characterized in that, The guide support test module is connected to at least one resistance strain gauge and one eddy current displacement sensor. The resistance strain gauge is pasted and fixed to the root area where the guide support is connected to the main body of the pumping unit tower. The eddy current sensor is fixedly installed on the stable reference surface of the guide support frame, and the eddy current sensor is directly below the far end of the guide support cantilever.

10. The wireless IoT information acquisition system for tower-type pumping units as described in claim 9, characterized in that, The resistance strain gauge has a sensitive grid length of not less than 3 mm, a sensitivity coefficient dispersion parameter of not more than ±0.1%, an eddy current displacement sensor frequency response of not less than 1.5 kHz, and a static resolution of not less than 0.5% FSO.

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