Drilling machine automation equipment hardware-in-loop simulation debugging system and debugging method

Abstract

The invention discloses a drilling machine automation equipment hardware-in-the-loop simulation debugging system which comprises an operation layer, a sensing layer, a control layer and a display layer which are sequentially connected, the operation layer comprises a driller seat, a simulation server and a network switch, and the driller seat and the simulation server are connected with the network switch. The sensing layer comprises an entity controller input end, a sensor output end, an actuator input end, a PLC, a pressure sensor, a distance sensor and a servo driver, the PLC is connected with the network switch through the entity controller input end, and the pressure sensor and the distance sensor are connected with the network switch through the sensor output end. And the servo driver is connected with the network switch through the input end of the actuator. The invention further discloses a drilling machine automation equipment hardware-in-the-loop simulation debugging method, potential development defects and errors of control programs can be diagnosed, and a safer testing environment is provided for product debugging.

Description

Technical Field

[0001] This invention belongs to the field of drilling equipment automation technology, specifically relating to a hardware-in-the-loop simulation and debugging system for drilling rig automation equipment, and also relating to a hardware-in-the-loop simulation and debugging method for drilling rig automation equipment. Background Technology

[0002] Driven by industrial big data, automation technology is increasingly being applied in the petroleum equipment sector, and oil drilling rigs are rapidly developing towards greater automation. Automated drilling rigs are based on the close integration of theories and technologies such as communication network technology, big data technology, artificial intelligence automation, control engineering, and drilling engineering. Through drilling parameter learning optimization and adaptive adjustment, fault diagnosis and early warning, they achieve automated closed-loop control of the drilling rig. Through the coordinated control of various equipment within the drilling rig, automated drilling rigs possess autonomous learning capabilities and achieve unmanned operation.

[0003] To achieve precise control of all equipment in an automated drilling rig, a significant amount of debugging work is required during the design and development process. Currently, on-site program debugging is typically carried out after the program development is completed and the equipment is mechanically assembled. This program development and debugging method often makes it difficult to predict problems that may arise during production and use. The debugging process consumes a lot of time and costs, prolongs the design cycle, and increases the difficulty of developing complex control algorithms. Summary of the Invention

[0004] The purpose of this invention is to provide a hardware-in-the-loop simulation and debugging system for drilling rig automation equipment, which solves the problems of long on-site debugging time, high difficulty in developing control algorithms, and extended design cycle in the existing technology.

[0005] Another objective of this invention is to provide a hardware-in-the-loop simulation and debugging method for drilling rig automation equipment.

[0006] The technical solution adopted in this invention is a hardware-in-the-loop simulation and debugging system for drilling rig automation equipment, comprising an operation layer, a sensing layer, a control layer, and a display layer connected in sequence. The operation layer includes a driller's seat, a simulation server, and a network switch. The driller's seat and the simulation server are respectively connected to the network switch. The sensing layer includes a physical controller input terminal, a sensor output terminal, an actuator input terminal, a PLC controller, a pressure sensor, a distance sensor, and a servo driver. The PLC controller is connected to the network switch through the physical controller input terminal. The pressure sensor and the distance sensor are both connected to the network switch through the sensor output terminal. The servo driver is connected to the network switch through the actuator input terminal.

[0007] The invention is further characterized by: The control layer includes core system switches, wireless routers, 5G industrial gateways, matrix fusion devices, and virtual simulation PLC controllers; The core system switch is connected to the matrix fusion unit, wireless router, 5G industrial gateway, and virtual simulation PLC controller, respectively, and is also connected to the network switch.

[0008] The display layer includes an operator display terminal and an image display module; The operator display terminal and image display module are respectively connected to the core system switch.

[0009] Another technical solution adopted in this invention is: a hardware-in-the-loop simulation and debugging method for drilling rig automation equipment, which utilizes a hardware-in-the-loop simulation and debugging system for drilling rig automation equipment and is implemented according to the following steps: Step 1: The operator creates a digital prototype of the drilling rig automation equipment through the simulation server, and then operates the digital prototype through the buttons on the driller's seat. Next, the movement state of the digital prototype is controlled through data interaction between the perception layer and the control layer. Step 2: The operator monitors the motion status of the digital prototype in the simulation server using the display terminal, and then displays it through the image display module. The matrix fusion device overlaps the edges of the displayed image. The operator evaluates the consistency between the running results and the expected results based on the display of the digital prototype's motion status, and further modifies and corrects them.

[0010] Another feature of the technical solution of the present invention is that, The hardware-in-the-loop simulation debugging method for drilling rig automation equipment, when performing pure virtual debugging based on a virtual simulation PLC controller, the specific process of step 1 is as follows: Operators access the virtual simulation PLC controller via the local bus. The wireless router and 5G industrial gateway provide real-time data communication and transmission through the core system switch, establishing communication between the simulation server and the virtual simulation PLC controller. The virtual simulation PLC controller obtains the operation commands from the pressure sensor, distance sensor, and servo drive and feeds them back to the simulation server. The simulation server establishes different protocol types through the external signal configuration function and reads the signal parameters fed back by the virtual simulation PLC controller. Based on the signal parameters, operators control the motion status of the digital prototype through the driller's seat.

[0011] The hardware-in-the-loop simulation and debugging method for drilling rig automation equipment, if based on a combination of virtual and physical hardware-in-the-loop simulation and debugging, the specific process of step 1 is as follows: Step 1.1: The operator configures the interfaces of the servo driver, pressure sensor and distance sensor in the digital prototype of the simulation server. The interfaces of the pressure sensor and distance sensor are connected to the sensor output end, and the interface of the servo driver is connected to the actuator input end. The servo driver drives the position and velocity changes of the rigid body of the digital prototype, and the pressure sensor and distance sensor collect the motion status of the digital prototype. Step 1.2: The operator configures the PC station in the simulation server. Then, the operator accesses the PLC controller via Ethernet cable and adds a bidirectional transmission connection between the PLC controller and the PC station. The wireless router and 5G industrial gateway provide real-time data communication and transmission through the core system switch, establishing communication between the simulation server and the PLC controller. The PLC controller obtains the operation commands from the pressure sensor, distance sensor, and servo drive, respectively. The simulation server connects to the PLC controller through the physical controller input terminal. The simulation server accesses the signal parameters of the PLC controller. The operator controls the motion state of the digital prototype through the driller's seat according to the signal parameters.

[0012] The beneficial effects of this invention are as follows: The hardware-in-the-loop simulation and debugging system for drilling rig automation equipment, based on digital twin technology, integrates functional designs such as mechanical design and electrical automation design, and applies advanced control technology to the equipment. The hardware-in-the-loop simulation and debugging method for drilling rig automation equipment tests and verifies the rationality of program development by creating a digital prototype identical to the physical equipment, thus promoting product design. Completing debugging before product production and installation enables the diagnosis of potential development defects and control program errors, providing a safer testing environment for product debugging. Attached Figure Description

[0013] Figure 1 This is the overall architecture diagram of the hardware-in-the-loop simulation and debugging system and debugging method for drilling rig automation equipment of the present invention; Figure 2 This is a flowchart illustrating the process of pure virtual debugging based on a virtual simulation PLC controller in this invention. Figure 3 This is a flowchart of the hardware-in-the-loop simulation and debugging process based on the combination of virtual and real technologies in this invention.

[0014] In the diagram, 1. Driller's seat, 2. Simulation server, 3. Network switch, 4. Physical controller input, 5. Sensor output, 6. Actuator input, 7. PLC controller, 8. Pressure sensor, 9. Distance sensor, 10. Servo driver, 11. Core system switch, 12. Wireless router, 13. 5G industrial gateway, 14. Matrix fusion unit, 15. Virtual simulation PLC controller, 16. Operator display terminal, 17. Image display module. Detailed Implementation

[0015] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0016] like Figure 1 As shown, the hardware-in-the-loop simulation and debugging system for drilling rig automation equipment includes an operation layer, a perception layer, a control layer, and a display layer.

[0017] The operation layer includes the driller's seat 1, the simulation server 2, and the network switch 3. The driller's seat 1 realistically replicates the seat structure inside the driller's cabin of an automated drilling rig. Operators can operate the automated equipment of the drilling rig and observe the equipment's operating status through the buttons on the armrests of the seat, providing operators with a realistic debugging environment. The simulation server 2 is used to provide operators with a virtual simulation debugging environment, in which digital prototypes can be built, simulation parameters can be configured, and virtual programs can be run.

[0018] The driller's seat 1 and the simulation server 2 are connected to the network switch 3. The driller's seat 1 is connected to the network switch 3 to collect the operator's commands to the drilling rig automation equipment (the commands include action commands and emergency stop commands). The simulation server 2, as the core unit of the operation layer, is connected to the network switch 3 and is used to build the digital prototype and configure the interfaces of the servo driver 10, pressure sensor 8, and distance sensor 9. The sensing layer includes a physical controller input terminal 4, a sensor output terminal 5, an actuator input terminal 6, a PLC controller 7, a pressure sensor 8, a distance sensor 9, and a servo driver 10. The PLC controller 7 is connected to the network switch 3 through the physical controller input terminal 4 to complete the deployment and application of the control software, realizing seamless connection between the drilling rig automation equipment and the digital prototype; the pressure sensor 8 and the distance sensor 9 are both connected to the network switch 3 through the sensor output terminal 5 to collect motion status information of the digital prototype; the servo drive 10 is connected to the network switch 3 through the actuator input terminal 6, and controls the motion of the digital prototype through the servo motor during the simulation and debugging process to achieve high-precision motion control.

[0019] The PLC controller 7, pressure sensor 8, distance sensor 9, and servo driver 10 constitute a sensing and interaction module, which tests the reliability and responsiveness of various electronic control devices and achieves seamless connection between the drilling rig automation equipment and the digital prototype.

[0020] Network switch 3 is the hub for operational layer communication, ensuring fast and accurate data transmission between simulation server 2 and the perception layer.

[0021] The control layer includes a core system switch 11, a wireless router 12, a 5G industrial gateway 13, a matrix fusion unit 14, and a virtual simulation PLC controller 15. The core system switch 11 is connected to the matrix fusion unit 14, the wireless router 12, the 5G industrial gateway 13, and the virtual simulation PLC controller 15, respectively.

[0022] The core system switch 11 is connected to the network switch 3, and collects commands from the driller's seat 1 and the simulation server 2 to realize data interaction between the perception layer and the control layer.

[0023] Wireless router 12 and 5G industrial gateway 13 are connected to core system switch 11, supporting real-time data transmission and communication, providing high-speed, low-latency communication capabilities for drilling rig automation equipment debugging. They can also connect to various industrial devices and sensors, enabling interconnection and interoperability between drilling rig automation equipment. Through LAN configuration, several simulation servers can be placed on the same network segment, facilitating simultaneous monitoring, configuration, and control of the digital twin virtual prototype by operators. Matrix fusion unit 14 is connected to core system switch 11 in the control layer. Through dual-screen fusion technology, it overlaps the edges of the dual-screen displays, displaying a seamless, larger, and higher-resolution full-screen image, significantly increasing image size and resolution. This allows operators to monitor the virtual prototype's motion status in real-time during program virtual debugging, effectively improving visual effects. Virtual simulation PLC controller 15 is connected to core system switch 11 and is the core device for executing the program control logic of drilling rig automation equipment. It meets the application requirements of automation equipment such as process control and motion control, ensuring efficient data transmission and real-time system performance, providing a stable, reliable, and flexible testing environment for equipment virtual debugging.

[0024] The wireless router 12, 5G industrial gateway 13, network switch 3, core system switch 11, virtual simulation PLC controller 15, and matrix fusion unit 14 constitute a network management module, which provides unified network management for the wireless router 12, 5G industrial gateway 13, network switch 3, core system switch 11, virtual simulation PLC controller 15, and matrix fusion unit 14.

[0025] The display layer includes an operator display terminal 16 and an image display module 17. The operator display terminal 16 is used by the operator to display the debugging and operation results. The image display module 17 is used to reflect the operating status of the drilling rig's automated equipment during the debugging process. It utilizes dual-screen fusion technology to achieve a realistic visual effect, making it easier for the operator to observe the equipment's operating status.

[0026] The operator display terminal 16 and the image display module 17 are respectively connected to the core system switch 11, which facilitates the operator to monitor the movement status of the virtual prototype and monitor the equipment operating parameters in real time when debugging the program.

[0027] In addition, an external power management module is provided to provide a stable and reliable power supply, ensuring the normal operation of all devices in the system.

[0028] The hardware-in-the-loop simulation and debugging method for drilling rig automation equipment shall be implemented according to the following steps: Step 1: The operator creates a digital prototype of the drilling rig automation equipment through the simulation server 2, and then operates the digital prototype through the buttons on the driller's seat 1. Next, the movement state of the digital prototype is controlled through data interaction between the perception layer and the control layer. Step 2: The operator displays the motion status of the digital prototype in the simulation server 2 on the terminal 16, and then displays it through the image display module 17. The matrix fusion unit 14 overlaps the edges of the displayed image to show a seamless, larger, and higher resolution full image, which significantly increases the size and resolution of the image. This makes it easier for the operator to monitor the motion status of the virtual prototype in real time during virtual debugging of the program. The operator evaluates the consistency between the running results and the expected results based on the display of the motion status of the digital prototype, and further makes modifications and corrections.

[0029] like Figure 2 As shown, in the hardware-in-the-loop simulation debugging method for drilling rig automation equipment, if pure virtual debugging is performed based on the virtual simulation PLC controller 15, the specific process of step 1 is as follows: Operators access the virtual simulation PLC controller 15 via the local bus. The wireless router 12 and the 5G industrial gateway 13 provide real-time data communication and transmission through the core system switch 11, establishing communication between the simulation server 2 and the virtual simulation PLC controller 15. The virtual simulation PLC controller 15 obtains the operation commands from the pressure sensor 8, distance sensor 9, and servo driver 10 and feeds them back to the simulation server 2. The simulation server 2 establishes different protocol types through the external signal configuration function and reads the signal parameters fed back by the virtual simulation PLC controller 15. Based on the signal parameters, operators control the motion state of the digital prototype through the driller's seat, providing a realistic debugging environment.

[0030] like Figure 3 As shown, in the hardware-in-the-loop simulation and debugging method for drilling rig automation equipment, if the hardware-in-the-loop simulation and debugging is based on a combination of virtual and real methods, the specific process of step 1 is as follows: Step 1.1: The operator configures the interfaces of servo driver 10, pressure sensor 8 and distance sensor 9 in the digital prototype of simulation server 2. The interfaces of pressure sensor 8 and distance sensor 9 are connected to sensor output terminal 5, and the interface of servo driver 10 is connected to actuator input terminal 6. Servo driver 10 drives the rigid body position and velocity changes of digital prototype, and pressure sensor 8 and distance sensor 9 collect the motion status of digital prototype. Step 1.2: The operator configures the PC station in the simulation server 2. Then, the operator accesses the PLC controller 7 via Ethernet cable and adds a bidirectional transmission connection between the PLC controller 7 and the PC station. The wireless router 12 and the 5G industrial gateway 13 provide real-time data communication and transmission through the core system switch 11, establishing communication between the simulation server 2 and the PLC controller 7. The PLC controller 7 obtains the operation commands from the pressure sensor 8, the distance sensor 9, and the servo drive 10, respectively. The simulation server 2 connects to the PLC controller 7 through the physical controller input terminal 4. The simulation server 2 accesses the signal parameters of the PLC controller 7. The operator controls the motion state of the digital prototype through the driller's seat 1 according to the signal parameters.

[0031] Example 1 The hardware-in-the-loop simulation and debugging system for drilling rig automation equipment includes an operation layer, a sensing layer, a control layer, and a display layer connected in sequence. The operation layer includes the driller's seat 1, a simulation server 2, and a network switch 3. The driller's seat 1 and simulation server 2 are connected to the network switch 3. The sensing layer includes a physical controller input terminal 4, a sensor output terminal 5, an actuator input terminal 6, a PLC controller 7, a pressure sensor 8, a distance sensor 9, and a servo driver 10. The PLC controller 7 is connected to the network switch 3 through the physical controller input terminal 4. The pressure sensor 8 and the distance sensor 9 are both connected to the network switch 3 through the sensor output terminal 5. The servo drive 10 is connected to the network switch 3 via the actuator input terminal 6; the control layer includes a core system switch 11, a wireless router 12, a 5G industrial gateway 13, a matrix fusion unit 14, and a virtual simulation PLC controller 15; the core system switch 11 is connected to the matrix fusion unit 14, the wireless router 12, the 5G industrial gateway 13, and the virtual simulation PLC controller 15, respectively, and is also connected to the network switch 3; the display layer includes an operator display terminal 16 and an image display module 17; the operator display terminal 16 and the image display module 17 are respectively connected to the core system switch 11.

[0032] Example 2 The hardware-in-the-loop simulation debugging method for drilling rig automation equipment, if based on pure virtual debugging using a virtual simulation PLC controller, is implemented according to the following steps: Step 1: The operator creates a digital prototype of the drilling rig automation equipment through the simulation server 2, and then operates the digital prototype through the buttons on the driller's seat 1. Next, the movement state of the digital prototype is controlled through data interaction between the perception layer and the control layer. The specific process of step 1 is as follows: The operator accesses the virtual simulation PLC controller 15 via the local bus. The wireless router 12 and the 5G industrial gateway 13 provide real-time data communication and transmission through the core system switch 11, establishing communication between the simulation server 2 and the virtual simulation PLC controller 15. The virtual simulation PLC controller 15 obtains the operation commands from the pressure sensor 8, the distance sensor 9, and the servo driver 10 and feeds them back to the simulation server 2. The simulation server 2 establishes different protocol types through the external signal configuration function and reads the signal parameters fed back by the virtual simulation PLC controller 15. The operator controls the motion state of the digital prototype through the driller's seat 1 according to the signal parameters.

[0033] Step 2: The operator displays the motion status of the digital prototype in the simulation server 2 on the terminal 16, and then displays it through the image display module 17. The matrix fusion unit 14 overlaps the edges of the displayed image. The operator evaluates the consistency between the running results and the expected results based on the display of the digital prototype's motion status, and further modifies and corrects them.

[0034] Example 3 The hardware-in-the-loop simulation debugging method for drilling rig automation equipment, if based on a combination of virtual and physical hardware-in-the-loop simulation debugging, shall be implemented according to the following steps: Step 1: The operator creates a digital prototype of the drilling rig automation equipment through the simulation server 2, and then operates the digital prototype through the buttons on the driller's seat 1. Next, the movement state of the digital prototype is controlled through data interaction between the perception layer and the control layer. The specific process of step 1 is as follows: Step 1.1: The operator configures the interfaces of servo driver 10, pressure sensor 8 and distance sensor 9 in the digital prototype of simulation server 2. The interfaces of pressure sensor 8 and distance sensor 9 are connected to sensor output terminal 5, and the interface of servo driver 10 is connected to actuator input terminal 6. Servo driver 10 drives the rigid body position and velocity changes of digital prototype, and pressure sensor 8 and distance sensor 9 collect the motion status of digital prototype. Step 1.2: The operator configures the PC station in the simulation server 2. Then, the operator accesses the PLC controller 7 via Ethernet cable and adds a bidirectional transmission connection between the PLC controller 7 and the PC station. The wireless router 12 and the 5G industrial gateway 13 provide real-time data communication and transmission through the core system switch 11, establishing communication between the simulation server 2 and the PLC controller 7. The PLC controller 7 obtains the operation commands from the pressure sensor 8, the distance sensor 9, and the servo drive 10. The simulation server 2 connects to the PLC controller 7 through the physical controller input terminal 4. The simulation server 2 accesses the signal parameters of the PLC controller 7. The operator controls the motion state of the digital prototype through the driller's seat 1 according to the signal parameters.

[0035] Step 2: The operator displays the motion status of the digital prototype in the simulation server 2 on the terminal 16, and then displays it through the image display module 17. The matrix fusion unit 14 overlaps the edges of the displayed screen. The operator evaluates the consistency between the running results and the expected results based on the display of the digital prototype's motion status, and further modifies and corrects them.

Claims

1. A hardware-in-the-loop simulation and debugging system for automated drilling equipment, characterized in that, The system includes an operation layer, a perception layer, a control layer, and a display layer connected in sequence. The operation layer includes a driller's seat (1), a simulation server (2), and a network switch (3). The driller's seat (1) and the simulation server (2) are respectively connected to the network switch (3). The perception layer includes a physical controller input terminal (4), a sensor output terminal (5), an actuator input terminal (6), a PLC controller (7), a pressure sensor (8), a distance sensor (9), and a servo driver (10). The PLC controller (7) is connected to the network switch (3) through the physical controller input terminal (4). The pressure sensor (8) and the distance sensor (9) are both connected to the network switch (3) through the sensor output terminal (5). The servo driver (10) is connected to the network switch (3) through the actuator input terminal (6).

2. The hardware-in-the-loop simulation and debugging system for drilling rig automation equipment according to claim 1, characterized in that, The control layer includes a core system switch (11), a wireless router (12), a 5G industrial gateway (13), a matrix fusion unit (14), and a virtual simulation PLC controller (15). The core system switch (11) is connected to the matrix fusion unit (14), the wireless router (12), the 5G industrial gateway (13), and the virtual simulation PLC controller (15), respectively. The core system switch (11) is also connected to the network switch (3).

3. The hardware-in-the-loop simulation and debugging system for drilling rig automation equipment according to claim 1, characterized in that, The display layer includes an operator display terminal (16) and an image display module (17). The operator display terminal (16) and the image display module (17) are respectively connected to the core system switch (11).

4. A hardware-in-the-loop simulation and debugging method for drilling rig automation equipment, utilizing the hardware-in-the-loop simulation and debugging system for drilling rig automation equipment as described in any one of claims 1-3, characterized in that, The specific steps are as follows: Step 1: The operator establishes a digital prototype of the drilling rig automation equipment through the simulation server (2), and then operates the digital prototype through the buttons on the driller's seat (1). Secondly, the movement state of the digital prototype is controlled through the data interaction between the perception layer and the control layer. Step 2: The operator displays the digital prototype motion status in the simulation server (2) through the terminal (16) and then displays it through the image display module (17). The matrix fusion device (14) overlaps the edges of the displayed screen. The operator evaluates the consistency between the running results and the expected results based on the display of the digital prototype motion status and then makes further modifications and corrections.

5. The hardware-in-the-loop simulation and debugging method for drilling rig automation equipment according to claim 4, wherein when pure virtual debugging is performed based on a virtual simulation PLC controller, it is characterized in that... The specific process of step 1 is as follows: The operator accesses the virtual simulation PLC controller (15) through the local bus. The wireless router (12) and the 5G industrial gateway (13) provide real-time data communication and transmission through the core system switch (11) to establish communication between the simulation server (2) and the virtual simulation PLC controller (15). The virtual simulation PLC controller (15) obtains the operation commands of the pressure sensor (8), distance sensor (9) and servo driver (10) respectively and feeds them back to the simulation server (2). The simulation server (2) establishes different protocol types through the external signal configuration function and reads the signal parameters fed back by the virtual simulation PLC controller (15). The operator controls the motion state of the digital prototype through the driller's seat (1) according to the signal parameters.

6. The hardware-in-the-loop simulation and debugging method for drilling rig automation equipment according to claim 4, wherein the hardware-in-the-loop simulation and debugging is based on a combination of virtual and real methods, characterized in that... The specific process of step 1 is as follows: Step 1.1: The operator configures the interfaces of servo driver (10), pressure sensor (8) and distance sensor (9) in the digital prototype of the simulation server (2). The interfaces of pressure sensor (8) and distance sensor (9) are connected to the sensor output terminal (5), and the interface of servo driver (10) is connected to the actuator input terminal (6). The servo driver (10) drives the position and speed changes of the rigid body of the digital prototype, and the pressure sensor (8) and distance sensor (9) collect the motion state of the digital prototype. Step 1.2: The operator configures the PC station in the simulation server (2). Then, the operator accesses the PLC controller (7) via Ethernet cable and adds a bidirectional transmission connection between the PLC controller (7) and the PC station. The wireless router (12) and the 5G industrial gateway (13) provide real-time data communication and transmission through the core system switch (11) to establish communication between the simulation server (2) and the PLC controller (7). The PLC controller (7) obtains the operation commands of the pressure sensor (8), distance sensor (9) and servo driver (10) respectively. The simulation server (2) connects to the PLC controller (7) through the physical controller input terminal (4). The simulation server (2) accesses the signal parameters of the PLC controller (7). The operator controls the motion state of the digital prototype through the driller's seat (1) according to the signal parameters.

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