New energy fracturing truck pump flow control system, control method and fracturing truck

Abstract

The invention discloses a new energy fracturing truck pump flow control system and method and a fracturing truck, and belongs to the technical field of new energy petroleum equipment.The new energy fracturing truck pump flow control method comprises the steps that pump target flow parameters and an engine mode are received; calculating the target rotating speed of the pump motor, and sending the target rotating speed of the pump motor to a pump main motor controller; the feedback real-time torque value and real-time rotating speed are received and sent to the pump slave motor controller; calculating the total input target power of the pump motor; calculating a generator output target total power based on the pump motor input target total power; determining a generator target speed based on the engine mode and the generator output target total power; based on the generator output target total power, calculating generator input target total power; and calculating a generator target torque based on the generator input target total power and the generator target speed, and sending the generator target torque to a generator controller. According to the invention, pump flow multi-mode control or / and stepless real-time intelligent flow regulation is realized.

Description

Technical Field

[0001] This invention relates to a new energy fracturing truck pump flow control system, control method, and fracturing truck, belonging to the field of new energy petroleum equipment technology. Background Technology

[0002] Fracturing trucks are the core equipment in oil and gas field fracturing operations, used to inject high-pressure fracturing fluid downhole to fracture rock formations and increase oil and gas production. With the development of unconventional resources such as shale oil and gas and tight oil and gas, fracturing truck technology continues to be upgraded.

[0003] The current mechanical drive system for fracturing trucks, consisting of a diesel engine, gearbox, and fracturing pump, has several drawbacks: slow and fluctuating pump flow rate during gear shifts can cause sudden pressure changes in the pipeline exceeding 60%; high fuel consumption due to the engine operating at full power; inability to continuously adjust flow rate according to actual demand; and the presence of wear-prone components in the mechanical transmission. Another option is an electrically driven fracturing truck, which connects to a 6kV / 10kV high-voltage industrial power grid via cable, using a transformer and frequency converter to drive the motor. This requires a stable power grid and has limited applicability in remote well sites such as deserts and polar regions. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and provide a new energy fracturing truck pump flow control system, control method and fracturing truck, to realize multi-mode control of pump flow or stepless real-time intelligent flow adjustment.

[0005] To achieve the above objectives, the present invention is implemented using the following technical solution: In a first aspect, the present invention provides a method for controlling the flow rate of a new energy fracturing truck pump, comprising: Receive control parameters from a local host computer or a remote host computer, the control parameters including pump target flow parameters and engine mode; The target speed of the pump motor is calculated based on the target flow parameters of the pump, and the target speed of the pump motor is sent to the main motor controller of the pump. Receive the real-time torque value and real-time speed fed back by the pump main motor controller, and send the real-time torque value to the pump slave motor controller; Based on the real-time torque value, the real-time speed, and the preset pump motor efficiency, calculate the target total power input to the pump motor; Based on the target total power input to the pump motor, the pre-acquired charging / discharging power of the power battery, and the power of other loads, the target total power output of the generator is calculated by summing the values. The generator target speed is determined based on the engine mode and / or the generator output target total power; Calculate the target total power output of the generator and the preset generator efficiency; Based on the target total power input to the generator and the target speed of the generator, the target torque of the generator is calculated and sent to the generator controller.

[0006] Furthermore, the control parameters also include overpressure protection parameters, and the method further includes: The real-time discharge pressure is obtained by detecting the pump discharge pressure in real time using a pressure sensor; The real-time discharge pressure value is compared with the overpressure protection parameter, and a speed adjustment command is generated based on the comparison result. The speed adjustment command is sent to the pump main motor controller to adjust the target speed of the pump motor.

[0007] Furthermore, sending the target speed of the pump motor to the main pump motor controller includes: sending an instruction to the main pump motor controller containing the host status, speed mode, the target speed of the pump motor, and the maximum torque limit value; Sending the real-time torque value to the pump slave motor controller includes: sending an instruction to the pump slave motor controller containing the slave status, torque mode, the real-time torque value as the target torque value, and the maximum speed limit value.

[0008] Furthermore, the target speed of the pump motor is calculated based on the target flow rate parameter of the pump, specifically by calculating according to a preset proportional relationship between the target flow rate parameter of the pump and the speed of the pump motor.

[0009] Furthermore, the method for determining the target speed of the generator includes: If the engine mode is standard mode, then the rated speed is determined as the corresponding generator target speed; If the engine mode is the economy mode, then the speed at the rated torque is determined as the corresponding generator target speed; If the engine mode is automatic, then based on the target total output power of the generator, the pre-stored engine universal characteristic curve is queried, and the most economical speed is matched with the generator target speed.

[0010] Furthermore, sending the generator target torque to the generator controller specifically involves sending an instruction containing torque mode control and the generator target torque to all generator controllers connected to the same engine.

[0011] Furthermore, the target total output power of the generator is the algebraic sum of the target total input power of the pump motor, the charging / discharging power of the power battery, and the power of the other loads; The target total power input to the generator is calculated by dividing the target total power output of the generator by the generator efficiency. The generator target torque is calculated using the generator input target total power and the generator target speed.

[0012] Furthermore, the power battery is a power-type battery, used to balance load fluctuations through charging / discharging when the system stops suddenly, the pump starts or stops, or the target flow changes.

[0013] Furthermore, the step of comparing the real-time discharge pressure value with the overpressure protection parameter and generating a speed adjustment command based on the comparison result includes: When the real-time discharge pressure value reaches or exceeds the overpressure protection parameter, the target speed of the pump motor is 0 and the target torque is 0. Call the pre-stored pump motor power limit parameters; When the power of the target flow rate and real-time discharge pressure exceeds the power limit, the speed adjustment command is generated according to the pump motor power limit parameter to reduce the target speed of the pump motor and maintain a constant pump discharge pressure.

[0014] Secondly, the present invention provides a new energy fracturing truck pump flow control system for implementing the new energy fracturing truck pump flow control method described in any one of the foregoing claims, comprising: The receiving unit is used to receive control parameters from a local host computer or a remote host computer, the control parameters including pump target flow parameters and engine mode; A processing unit, connected to the receiving unit, is used to calculate the target speed of the pump motor based on the target flow parameters of the pump. The pump control unit, connected to the processing unit, is used to send the target speed of the pump motor to the main pump motor controller, receive the real-time torque value and real-time speed fed back by the main pump motor controller, and send the real-time torque value to the slave pump motor controller. The processing unit is further configured to: Based on the real-time torque value, the real-time speed, and the preset pump motor efficiency, calculate the target total power input to the pump motor; Based on the target total power input to the pump motor, the pre-acquired charging / discharging power of the power battery, and the power of other loads, the target total power output of the generator is calculated by summing the values. The generator target speed is determined based on the engine mode and / or the generator output target total power; Calculate the target total power output of the generator and the preset generator efficiency; Calculate the generator target torque based on the generator input target total power and the generator target speed; A power control unit, connected to the processing unit, is used to send the target torque of the generator to the generator controller.

[0015] Thirdly, the present invention provides a fracturing truck, comprising the new energy fracturing truck pump flow control system as described above, and / or configured to perform the new energy fracturing truck pump flow control method as described in any of the preceding claims.

[0016] Compared with the prior art, the beneficial effects achieved by the present invention are as follows: 1. This invention provides a new energy fracturing truck pump flow control system, control method, and fracturing truck. By calculating the target total power input to the pump motor in real time, and considering the charging / discharging power of the power battery and other load power, the target total power output of the generator is dynamically determined, and finally, the engine speed and generator torque are intelligently allocated. This global power matching mechanism ensures that the energy of the entire power chain is allocated on demand and efficiently, realizing precise coordinated work of multiple power units such as the motor, engine, generator, and battery within the pump unit. 2. The power system of this invention can operate flexibly in standard mode, economic mode, and automatic mode based on universal characteristic curve, according to the total power demand. Especially in automatic mode, the engine can always operate in the most economical speed range, avoiding the high fuel consumption of traditional equipment running at full power, effectively reducing operating costs and carbon emissions, and conforming to the green transformation trend of the oil and gas industry; 3. This invention adds an independent overpressure protection feedback closed loop to the core control circuit. When the real-time discharge pressure exceeds the set protection value, the system can immediately intervene to prevent pump damage due to overload; when the real-time discharge pressure and target flow rate exceed the power limit value, the pump motor speed is automatically adjusted to maintain constant pressure. This dual control architecture of "feedforward + feedback" provides reliable safety redundancy for the precise control of the core process, greatly improving the intrinsic safety level of the entire fracturing system. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall architecture of a new energy fracturing truck pump flow control system according to the present invention.

[0018] Figure 2 This is a schematic diagram of the generator target speed requirement of a new energy fracturing truck flow control system according to the present invention.

[0019] Figure 3 This is a schematic diagram of the generator input target total power requirement of a new energy fracturing truck flow control system according to the present invention.

[0020] Figure 4This is a schematic diagram of the generator target torque requirement of a new energy fracturing truck flow control system according to the present invention. Detailed Implementation

[0021] The present invention will be further described below with reference to the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and should not be used to limit the scope of protection of the present invention.

[0022] Example 1: This example introduces a method for controlling the flow rate of a new energy fracturing truck pump, including: Receive control parameters from a local host computer or a remote host computer, the control parameters including pump target flow parameters and engine mode; The target speed of the pump motor is calculated based on the target flow parameters of the pump, and the target speed of the pump motor is sent to the main motor controller of the pump. Receive the real-time torque value and real-time speed fed back by the pump main motor controller, and send the real-time torque value to the pump slave motor controller; Based on the real-time torque value, the real-time speed, and the preset pump motor efficiency, calculate the target total power input to the pump motor; Based on the target total power input to the pump motor, the pre-acquired charging / discharging power of the power battery, and the power of other loads, the target total power output of the generator is calculated by summing the values. The generator target speed is determined based on the engine mode and / or the generator output target total power; Calculate the target total power output of the generator and the preset generator efficiency; Based on the target total power input to the generator and the target speed of the generator, the target torque of the generator is calculated and sent to the generator controller.

[0023] like Figures 1-4 As shown in this embodiment, the application process of the new energy fracturing truck pump flow control method involves the following steps: Step 1: The system receives control parameters from a local or remote host computer. These control parameters include the pump target flow rate parameter, engine mode, and overpressure protection parameters. The pump target flow rate parameter is a stepless target flow rate parameter, allowing for arbitrary value setting from zero to maximum flow rate, meeting the needs of precise fracturing operations.

[0024] Step 2: Based on the received target pump flow rate parameters, the system calculates the target pump motor speed according to a preset proportional relationship. This calculation process establishes a direct correspondence between the target pump flow rate and the pump motor speed, providing a foundation for precise control of the target flow rate.

[0025] Step 3: The system sends the calculated target speed of the pump motor to the main pump motor controller. When sending the command, the system sends a complete control command to the main pump motor controller, including the main motor status, speed mode, target speed value, and maximum torque limit value. The main pump motor controller operates in speed mode and feeds back real-time torque and speed measurements to the system.

[0026] Step 4: The system sends the received real-time torque value as the target torque value to the pump slave motor controller. Specifically, it sends a control command to the pump slave motor controller containing the slave status, torque mode, target torque value, and maximum speed limit. This control method enables precise coordinated control when multiple motors drive the same fracturing pump in parallel, ensuring load balance among the motors.

[0027] Step 5: Based on the received real-time torque value, real-time speed, and preset pump motor efficiency data, the system calculates the target total input power to the pump motor. This calculation process comprehensively considers the actual operating state and energy conversion efficiency, providing an accurate basis for subsequent power allocation.

[0028] Step 6: After obtaining the target total input power of the pump motor, the system further calculates the target total output power of the generator. This power value is the algebraic sum of the target total input power of the pump motor, the pre-acquired charging and discharging power of the power battery, and the power of other auxiliary loads. These other auxiliary loads include the power required by the cooling system, lubrication system, and low-voltage power supply system.

[0029] Step 7: Based on the engine mode and the calculated total target output power of the generator, the system determines the target speed of the generator. The specific determination method includes: when the engine mode is standard mode, the rated speed is determined as the target speed; when the engine mode is economy mode, the speed at rated torque is determined as the target speed; when the engine mode is automatic mode, the most economical speed is obtained by querying the pre-stored engine universal characteristic curve based on the total target output power of the generator and matching it as the target speed.

[0030] Step 8: Based on the generator's target total output power and preset generator efficiency data, the system calculates the generator's target total input power. Then, based on the generator's target total input power and the determined generator target speed, it calculates the generator's target torque.

[0031] Step 9: The system sends the calculated target torque of the generator to the generator controller. For multiple generators installed on the same engine drive shaft, instructions containing torque mode control and the target torque value are sent to each generator controller to ensure coordinated operation of all generators.

[0032] Step 10: The system executes the overpressure protection control process. The pump discharge pressure is monitored in real time by a pressure sensor to obtain the real-time discharge pressure value. This real-time discharge pressure value is compared with the received overpressure protection parameters. When the real-time discharge pressure value reaches or exceeds the overpressure protection parameters, the target speed and target torque of the pump motor are set to 0. Pre-stored pump motor power limit parameters are invoked. When the power of the pump target flow rate and the real-time discharge pressure value exceeds the limit power, a speed adjustment command is generated based on the pump motor power limit parameters and sent to the pump main motor controller to reduce the target speed of the pump motor and maintain a constant pump discharge pressure.

[0033] Throughout the control process, the system uses a power battery, which can effectively balance load fluctuations and maintain stable system operation by rapidly charging and discharging when the system stops suddenly, the pump starts and stops, or the target flow rate changes drastically.

[0034] This embodiment has the following beneficial effects: 1. This embodiment calculates the target total power input to the pump motor in real time, and dynamically determines the target total power output of the generator by comprehensively considering the charging / discharging power of the power battery and the power of other loads. Finally, it intelligently allocates the engine speed and generator torque. This global power matching mechanism ensures that the energy of the entire power chain is allocated on demand and efficiently, realizing the precise coordinated work of multiple power units such as motors, engines, generators, and batteries within the pump unit. 2. The power system in this embodiment can operate flexibly in standard mode, economy mode, and automatic mode based on the universal characteristic curve, according to the total power demand. Especially in automatic mode, the engine can always operate in the most economical speed range, avoiding the high fuel consumption of traditional equipment running at full power, effectively reducing operating costs and carbon emissions, which is in line with the green transformation trend of the oil and gas industry; 3. This embodiment adds an independent overpressure protection feedback closed loop to the core control circuit. When the real-time discharge pressure exceeds the set protection value, the system can immediately intervene to prevent pump damage due to overload; when the real-time discharge pressure and target flow exceed the power limit value, the pump motor speed is automatically adjusted to maintain constant pressure. This dual control architecture of "feedforward + feedback" provides reliable safety redundancy for the precise control of the core process, greatly improving the intrinsic safety level of the entire fracturing system.

[0035] Example 2: This example provides a new energy fracturing truck pump flow control system to implement the new energy fracturing truck pump flow control method described in any one of Examples 1. The system includes: The receiving unit is used to receive control parameters from a local host computer or a remote host computer, the control parameters including pump target flow parameters and engine mode; A processing unit, connected to the receiving unit, is used to calculate the target speed of the pump motor based on the target flow parameters of the pump. The pump control unit, connected to the processing unit, is used to send the target speed of the pump motor to the main pump motor controller, receive the real-time torque value and real-time speed fed back by the main pump motor controller, and send the real-time torque value to the slave pump motor controller. The processing unit is further configured to: Based on the real-time torque value, the real-time speed, and the preset pump motor efficiency, calculate the target total power input to the pump motor; Based on the target total power input to the pump motor, the pre-acquired charging / discharging power of the power battery, and the power of other loads, the target total power output of the generator is calculated by summing the values. The generator target speed is determined based on the engine mode and / or the generator output target total power; Calculate the target total power output of the generator and the preset generator efficiency; Calculate the generator target torque based on the generator input target total power and the generator target speed; A power control unit, connected to the processing unit, is used to send the target torque of the generator to the generator controller.

[0036] The specific functions of each of the above units are described in the relevant content of the method in Embodiment 1, and will not be repeated here.

[0037] Example 3: This example provides a fracturing truck, which includes the new energy fracturing truck pump flow control system as described above, and / or is configured to execute the new energy fracturing truck pump flow control method as described in any of the preceding examples.

[0038] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A method for controlling the flow rate of a pump in a new energy fracturing truck, characterized in that, include: Receive control parameters from a local host computer or a remote host computer, the control parameters including pump target flow parameters and engine mode; The target speed of the pump motor is calculated based on the target flow parameters of the pump, and the target speed of the pump motor is sent to the main motor controller of the pump. Receive the real-time torque value and real-time speed fed back by the pump main motor controller, and send the real-time torque value to the pump slave motor controller; Based on the real-time torque value, the real-time speed, and the preset pump motor efficiency, calculate the target total power input to the pump motor; Based on the target total power input to the pump motor, the pre-acquired charging / discharging power of the power battery, and the power of other loads, the target total power output of the generator is calculated by summing the values. The generator target speed is determined based on the engine mode and / or the generator output target total power; Calculate the target total power output of the generator and the preset generator efficiency; Based on the target total power input to the generator and the target speed of the generator, the target torque of the generator is calculated and sent to the generator controller.

2. The new energy fracturing truck pump flow control method according to claim 1, characterized in that, The control parameters also include overpressure protection parameters, and the method further includes: The real-time discharge pressure is obtained by detecting the pump discharge pressure in real time using a pressure sensor; The real-time discharge pressure value is compared with the overpressure protection parameter, and a speed adjustment command is generated based on the comparison result. The speed adjustment command is sent to the pump main motor controller to adjust the target speed of the pump motor.

3. The new energy fracturing truck pump flow control method according to claim 1, characterized in that, Sending the target speed of the pump motor to the main pump motor controller includes: sending an instruction to the main pump motor controller containing the host status, speed mode, the target speed of the pump motor, and the maximum torque limit value; Sending the real-time torque value to the pump slave motor controller includes: sending an instruction to the pump slave motor controller containing the slave status, torque mode, the real-time torque value as the target torque value, and the maximum speed limit value.

4. The new energy fracturing truck pump flow control method according to claim 1, characterized in that, The target speed of the pump motor is calculated based on the target flow rate parameter of the pump, specifically by calculating according to the preset proportional relationship between the target flow rate parameter of the pump and the speed of the pump motor.

5. The new energy fracturing truck pump flow control method according to claim 1, characterized in that, The method for determining the target speed of the generator includes: If the engine mode is standard mode, then the rated speed is determined as the corresponding generator target speed; If the engine mode is the economy mode, then the speed at the rated torque is determined as the corresponding generator target speed; If the engine mode is automatic, then based on the target total output power of the generator, the pre-stored universal characteristic curve of the engine is queried, and the most economical speed is matched with the target speed of the generator.

6. The new energy fracturing truck pump flow control method according to claim 1, characterized in that, Sending the generator target torque to the generator controller specifically involves sending an instruction containing torque mode control and the generator target torque to all generator controllers connected to the same engine.

7. The new energy fracturing truck pump flow control method according to claim 1, characterized in that, The target total output power of the generator is the algebraic sum of the target total input power of the pump motor, the charging / discharging power of the power battery, and the power of the other loads; The target total power input to the generator is calculated by dividing the target total power output of the generator by the generator efficiency. The generator target torque is calculated by the generator input target total power and the generator target speed.

8. The new energy fracturing truck pump flow control method according to claim 1, characterized in that, The power battery is a power-type battery used to balance load fluctuations through charging / discharging when the system stops suddenly, the pump starts or stops, or the target flow changes.

9. The new energy fracturing truck pump flow control method according to claim 2, characterized in that, The step of comparing the real-time discharge pressure value with the overpressure protection parameter and generating a speed adjustment command based on the comparison result includes: When the real-time discharge pressure value reaches or exceeds the overpressure protection parameter, the target speed of the pump motor is 0 and the target torque is 0. Recall the pre-stored pump motor power limit parameters; When the power of the target flow rate and real-time discharge pressure exceeds the power limit, the speed adjustment command is generated according to the pump motor power limit parameter to reduce the target speed of the pump motor and maintain a constant pump discharge pressure.

10. A flow control system for a new energy fracturing truck pump, used to implement the flow control method for a new energy fracturing truck pump as described in any one of claims 1-9, characterized in that, include: The receiving unit is used to receive control parameters from a local host computer or a remote host computer, the control parameters including pump target flow parameters and engine mode; A processing unit, connected to the receiving unit, is used to calculate the target speed of the pump motor based on the target flow parameters of the pump. The pump control unit, connected to the processing unit, is used to send the target speed of the pump motor to the main pump motor controller, receive the real-time torque value and real-time speed fed back by the main pump motor controller, and send the real-time torque value to the slave pump motor controller. The processing unit is further configured to: Based on the real-time torque value, the real-time speed, and the preset pump motor efficiency, calculate the target total power input to the pump motor; Based on the target total power input to the pump motor, the pre-acquired charging / discharging power of the power battery, and the power of other loads, the target total power output of the generator is calculated by summing the values. The generator target speed is determined based on the engine mode and / or the generator output target total power; Calculate the target total power output of the generator and the preset generator efficiency; Calculate the generator target torque based on the generator input target total power and the generator target speed; A power control unit, connected to the processing unit, is used to send the target torque of the generator to the generator controller.

11. A fracturing truck, characterized in that, It includes the new energy fracturing truck pump flow control system as described in claim 10, and / or is configured to perform the new energy fracturing truck pump flow control method as described in any one of claims 1-9.

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