Top drive intelligent regulation and control system and method based on drill string mechanical feedback

Abstract

The invention discloses a top drive intelligent regulation and control system and method based on drill string mechanical feedback. The system comprises a drill string mechanical sensing module, a drill string torsion calculation module, a target tool face solving module, a top drive intelligent control module and a control execution module. According to the method, ground and underground drilling parameters are collected in real time, data fusion and preprocessing are carried out, and the torsion state of a drill string is estimated; on the basis of a drill string elastic torsion model, calculating transmission gain, torsion angle distribution, reverse torsion release trend and friction torque on line; an expected tool face angle is generated according to the drilling track requirement, and an accurate ground needed corner is obtained through compensation by combining a torsion calculation result; and finally, the top drive intelligent control module selects an adaptive strategy to generate a control instruction, and drives the top drive to execute and form closed-loop optimization regulation and control. According to the method, dynamic sensing and compensation of the mechanical state of the drill string are achieved, the problems that a traditional mode depends on experience and is low in efficiency and prone to overshoot are solved, and the tool face control precision and the drilling efficiency are remarkably improved.

Description

Technical Field

[0001] This invention relates to a top drive control system, and more particularly to a top drive intelligent control system based on drill string mechanical feedback. This invention also relates to a control method for the top drive intelligent control system based on drill string mechanical feedback, belonging to the field of oil and gas drilling engineering technology. Background Technology

[0002] In oil and gas drilling engineering, directional drilling technology is one of the key technologies for achieving efficient resource development. The stability control of the tool face during sliding drilling directly affects the drilling trajectory quality, mechanical drilling rate, and wellbore integrity. As the core control object in directional drilling, the accuracy of the tool face's attitude determines whether the drilling trajectory can extend along the designed path, thus impacting the production capacity and development benefits of oil and gas wells.

[0003] Traditional toolface adjustment methods rely on operators applying small left-right oscillations to the top drive on the surface for correction. However, the drill string, as the core component connecting the surface top drive and the downhole drill bit, is a typical long and slender rod structure with significant elastic torsional characteristics. During torque transmission, the drill string exhibits nonlinear behaviors such as hysteresis, attenuation, and reverse torque release. These characteristics lead to unpredictable uncertainties between the angle applied on the surface and the actual toolface angle downhole.

[0004] In existing technologies, tool face control lacks a real-time sensing and feedback mechanism for the mechanical state of the drill string, making it impossible to dynamically capture changes in the drill string's torsional characteristics. Operators must rely on extensive field experience for repeated trial and adjustment, which not only increases operational intensity but also leads to low tool face correction efficiency, poor stability, and a tendency for overshoot. Furthermore, traditional control methods have low automation levels, are highly dependent on operator experience, and suffer from poor consistency among different operators, making it difficult to guarantee the stability and safety of the drilling process. In addition, existing systems lack adaptive adjustment capabilities for different well types and drill string combinations, resulting in insufficient adaptability to complex conditions such as horizontal wells, long-section targeted wells, and high-friction wells, thus limiting their engineering application scope. Summary of the Invention

[0005] The purpose of this section is to outline some aspects of embodiments of the present invention and to briefly describe some preferred embodiments. Simplifications or omissions may be made in this section, as well as in the abstract and title of this application, and such simplifications or omissions should not be construed as limiting the scope of the invention.

[0006] In view of the problems existing in the above and / or prior art, the present invention is proposed.

[0007] The primary objective of this invention is to overcome the problems existing in the prior art and provide a top drive intelligent control system based on drill string mechanical feedback, which reduces the labor intensity of operators, can dynamically capture changes in drill string torsional characteristics, has high tool face correction efficiency, does not overshoot, and has good stability.

[0008] To address the above technical problems, this invention provides a top drive intelligent control system based on drill string mechanical feedback, comprising a drill string mechanical sensing module, a drill string torsion calculation module, and a target tool face solving module. The drill string mechanical sensing module collects surface drilling engineering parameters, receives downhole measurement-while-drilling data, and performs data fusion processing and torsional state estimation. The drill string torsion calculation module incorporates a drill string torsion-related mathematical model and calculates drill string transfer gain, torsion angle distribution, anti-torsion release trend, and friction torque based on the parameters output by the drill string mechanical sensing module. The target tool face solving module generates the desired tool face angle according to the drilling trajectory requirements and, combined with the calculation results from the drill string torsion calculation module, determines the surface rotation angle required to achieve the target tool face.

[0009] Furthermore, it also includes a top drive intelligent control module and a control execution module. The top drive intelligent control module selects an appropriate control strategy based on the ground rotation angle output by the target tool surface solving module, generates top drive control commands, and performs resonance frequency detection and vibration damping protection. The control execution module is connected to the top drive control interface, executes the top drive control commands, collects real-time top drive operating data, and realizes closed-loop optimization and control.

[0010] Furthermore, it also includes a data storage and interaction module and a fault diagnosis and protection module. The data storage and interaction module is used to store various parameters, calculation results and control commands to realize data transmission between modules and information interaction with external devices. The fault diagnosis and protection module is used to monitor the operating status of each module of the system and abnormal drilling parameters, and trigger the protection mechanism.

[0011] Furthermore, the drill string mechanics sensing module includes a surface parameter acquisition unit, a downhole parameter receiving unit, and a data preprocessing unit. The surface parameter acquisition unit collects engineering parameters during the surface drilling process. Parameter acquisition is achieved through sensors deployed at the top drive, drill riser, and traveling block positions. The sensor output signals are converted into standard analog electrical signals by a signal conditioning circuit. The downhole parameter receiving unit receives downhole data transmitted from the downhole measurement-while-drilling system. A data transmission link is established with the downhole measurement-while-drilling system via a wireless communication module to achieve real-time data reception. The data preprocessing unit performs analog-to-digital conversion on the analog signals acquired by the surface parameter acquisition unit and parses the format of the data received by the downhole parameter receiving unit.

[0012] Furthermore, the engineering parameters acquired in the surface parameter acquisition unit include surface torque, suspended weight, riser pressure, mechanical drilling rate, well depth, and trajectory parameters; the downhole parameter receiving unit acquires downhole data including tool face angle, azimuth angle, well inclination, and downhole torque feedback; the data preprocessing unit uses a filtering algorithm to remove noise interference from the data while parsing the format, and achieves spatiotemporal alignment between surface parameters and downhole parameters through timestamp synchronization to avoid calculation errors caused by asynchronous data.

[0013] Furthermore, the drill string mechanical sensing module also includes a mechanical state fusion unit and a torsional state estimation unit. The mechanical state fusion unit uses a multi-source data fusion algorithm to fuse the preprocessed surface parameters and downhole parameters, overcoming the limitations of single parameters and constructing a comprehensive and accurate drill string mechanical state dataset to provide data support for torsional state estimation. The torsional state estimation unit establishes a real-time estimation model of the drill string torsional state based on the fused drill string mechanical state dataset, calculates the real-time torsional trend of the drill string through the model, and provides initial input parameters for the drill string torsional calculation module.

[0014] Furthermore, the drill string torsion calculation module includes a model storage unit, a transfer gain calculation unit, and a torsion angle distribution solution unit. The model storage unit contains a built-in drill string elastic torsion model, friction model, anti-torsion release prediction model, and drill string geometric parameter database. The transfer gain calculation unit, based on real-time well depth, wellbore trajectory parameters, and drill string assembly information, calls the drill string elastic torsion model in the model storage unit and calculates the transfer gain between torque and torsion angle through step testing and data fitting methods. The torsion angle distribution solution unit, based on surface torque data and transfer gain, uses a piecewise accumulation algorithm to calculate the torsion angle distribution of the drill string along the well depth direction, achieving accurate estimation of the torsion angle from the surface to any depth downhole, and simultaneously deriving the bottom hole torque transmission situation.

[0015] Furthermore, in the model storage unit: the drill string geometry parameter database contains basic parameters such as the cross-sectional moment of inertia, length, and material elastic modulus of drill pipes and drill collars of different specifications, and supports parameter calling according to the actual drill tool combination.

[0016] Furthermore, the drill string torsion calculation module also includes a reverse torque release prediction unit and a friction torque reverse calculation unit. The reverse torque release prediction unit uses the reverse torque release prediction model in the model storage unit, combined with the torsion angle distribution data and drilling torque parameters, to predict the magnitude and trend of reverse torque release that may occur during the tool face adjustment process of the drill string, providing a basis for the formulation of control strategies. The friction torque reverse calculation unit reverse calculates the friction torque between the drill string and the well wall based on the difference between the measured torque on the ground and the elastic transmission torque, quantifies the impact of friction on torque transmission, and provides data support for torque compensation.

[0017] Furthermore, the target tool face solving module includes a trajectory analysis unit, a desired tool face generation unit, and an angle difference calculation unit. The trajectory analysis unit receives drilling trajectory design data, analyzes the target trajectory parameters for the current drilling stage, including the target azimuth, target inclination angle, and trajectory curvature, and clarifies the drilling direction requirements. The desired tool face generation unit generates the desired tool face angle under the current drilling conditions based on the target trajectory parameters output by the trajectory analysis unit and combined with real-time wellbore trajectory feedback data, ensuring that the tool face angle matches the trajectory requirements. The angle difference calculation unit uses a signed shortest angle difference algorithm to calculate the difference between the current tool face angle and the desired tool face angle, handling the periodicity of the 0-360° angle and cross-boundary jump problems, and obtaining the shortest angle adjustment amount to achieve the target tool face.

[0018] Furthermore, the target tool face solving module also includes a ground angle compensation unit and an angle verification unit. The ground angle compensation unit: combines the transmission gain, anti-torque release trend and friction torque data output by the drill string torsion calculation module, and considers the drill string torque transmission delay characteristics to compensate for the shortest angle adjustment amount to obtain the required ground angle. The angle verification unit: verifies the rationality of the calculated ground angle, and determines whether the angle is within the limit range of the top drive machinery. If it exceeds the limit, an alarm signal is output. If it is within the reasonable range, the ground angle data is transmitted to the top drive intelligent control module.

[0019] Furthermore, the top drive intelligent control module includes a control strategy selection unit, an instruction generation unit, a speed adjustment unit, and an output mode control unit. The control strategy selection unit incorporates angle compensation, proportional adjustment, amplitude limiting control, and flexible start-up strategies. Based on the surface rotation angle, reverse torque release trend, and drilling conditions, it automatically selects a single or combined control strategy to ensure smooth and precise control. The instruction generation unit generates top drive rotation angle instructions, speed instructions, and action timing instructions based on the selected control strategy and surface rotation angle data. The instruction format conforms to the top drive control interface protocol requirements. The speed adjustment unit dynamically adjusts the top drive speed according to drilling conditions and torque feedback data, achieving adaptive speed matching under different conditions and avoiding tool face instability caused by excessively high or low speeds. The output mode control unit supports fixed angle output mode, intermittent angle output mode, and torsional correction output mode. It selects the appropriate output mode based on the tool face deviation and drilling requirements to achieve efficient tool face correction.

[0020] Furthermore, the top drive intelligent control module also includes a resonance frequency detection unit and a vibration damping protection unit. The resonance frequency detection unit calculates the inherent resonance frequency of the drill string system based on the transfer gain and rotational inertia, and monitors the difference between the top drive control command frequency and the resonance frequency in real time. The vibration damping protection unit adjusts the control command frequency to avoid the resonance range when the control command frequency approaches the inherent resonance frequency of the system. If an abnormal increase in amplitude is detected, the top drive rotation is immediately stopped, and the system switches to a safe mode to prevent the drill string from being damaged by resonance.

[0021] Furthermore, the control execution module includes an interface adaptation unit, an action execution unit, a real-time feedback unit, and a closed-loop optimization unit. The interface adaptation unit provides various types of top drive control interfaces, including digital interfaces, analog interfaces, and bus interfaces, enabling compatible connections with different models of top drive equipment through interface protocol conversion. The action execution unit receives control commands output from the top drive intelligent control module and drives the top drive actuator to precisely complete rotation angle adjustment, speed regulation, and output mode switching actions, ensuring command execution accuracy. The real-time feedback unit collects real-time rotation angle, speed, output torque, and operating status data of the top drive through sensors deployed on the top drive actuator, achieving real-time monitoring of control actions. The closed-loop optimization unit compares the data collected by the real-time feedback unit with the target control parameters, calculates the control error, and, combined with the latest mechanical state data output by the drill string mechanical sensing module, dynamically optimizes and adjusts the control commands to form a closed-loop control circuit.

[0022] Furthermore, the data storage and interaction module includes a data classification and storage unit, a data compression unit, a local storage unit, a remote transmission unit, and a data query unit. The data classification and storage unit classifies and organizes drill string mechanical parameters, torsion calculation results, control commands, top drive operation data, and fault record data, establishing a standardized data format. The data compression unit uses data compression algorithms to compress the massive amounts of classified data, reducing data storage space while ensuring data integrity after decompression. The local storage unit uses high-capacity storage devices for local caching and long-term storage, supporting breakpoint resumption to ensure no data loss during drilling. The remote transmission unit uses industrial Ethernet and wireless communication to achieve real-time transmission of locally stored data to the remote monitoring center, supporting remote data access and command issuance. The data query unit provides a data query interface, supporting data retrieval by time, data type, and drilling stage, facilitating operators to trace the drilling process and system operating status.

[0023] Furthermore, the fault diagnosis and protection module includes a status monitoring unit, a fault identification unit, a fault classification unit, a protection command generation unit, and an alarm unit. The status monitoring unit monitors the real-time operating status of each module, including sensor data acquisition status, module communication status, top drive actuator operating status, and data storage status. The fault identification unit analyzes and judges the monitored abnormal data based on a preset fault feature library, identifying fault types, including but not limited to sensor faults, communication faults, calculation faults, and top drive operation faults. The fault classification unit classifies faults into three levels—minor, general, and severe—based on their impact on drilling operations, with different handling strategies for each level. The protection command generation unit generates corresponding protection commands for different levels of faults: for minor faults, only control parameters are adjusted; for general faults, the top drive adjustment action is paused and fault recovery attempts are attempted; for severe faults, the top drive operation is immediately stopped and related control loops are disconnected. The alarm unit sends alarm signals to operators via audible and visual alarms and remote notifications when a fault is detected, while simultaneously recording the fault occurrence time, fault type, and fault handling process to provide a basis for fault troubleshooting.

[0024] Another objective of this invention is to overcome the problems existing in the prior art and provide a top drive intelligent control method based on drill string mechanical feedback, which reduces the labor intensity of operators, can dynamically capture changes in drill string torsional characteristics, has high tool face correction efficiency, does not overshoot, and has good stability.

[0025] To solve the above technical problems, the present invention provides a top drive intelligent control method based on drill string mechanical feedback, which employs the above-mentioned top drive intelligent control system and includes the following steps in sequence:

[0026] Step 1: System initialization and parameter configuration;

[0027] Step 2: Mechanical parameter acquisition and fusion processing;

[0028] Step 3: Calculation of drill string torsional characteristics;

[0029] Step 4: Solve for the angle between the target tool face and the ground;

[0030] Step 5: Generation and execution of top drive control commands;

[0031] Step 6: Closed-loop optimization and control;

[0032] Step 7: Fault monitoring and handling;

[0033] Step 8: Job completed and system reset.

[0034] Further, step 1 is as follows: Start the top drive intelligent control system based on drill string mechanical feedback, complete the self-check and initialization of each module, including sensor calibration, communication link establishment, model parameter loading and storage device initialization; configure the system basic parameters according to the drilling design scheme and drill string combination information, including drill string geometric parameters, wellbore trajectory design parameters, top drive equipment parameters and control strategy threshold parameters, and the system enters standby state.

[0035] Furthermore, step 2 includes the following sub-steps:

[0036] Step 2.1: Continuously collect ground torque, suspended weight, standpipe pressure, mechanical drilling speed, well depth and trajectory parameters through the ground parameter acquisition unit of the drill string mechanical sensing module, and transmit them to the data preprocessing unit after signal conditioning;

[0037] Step 2.2: Receive tool face angle, azimuth angle, well inclination and downhole torque feedback data transmitted from the downhole measurement while drilling (MWD / LWD) system through the downhole parameter receiving unit, and transmit them to the data preprocessing unit;

[0038] Step 2.3: The data preprocessing unit performs analog-to-digital conversion on the analog signals acquired by the ground parameter acquisition unit, parses the format of the data received by the downhole parameter receiving unit, and uses a filtering algorithm to remove noise interference from the data. The time stamp synchronization is used to achieve spatiotemporal alignment between the ground parameters and the downhole parameters.

[0039] Step 2.4: The mechanical state fusion unit uses a multi-source data fusion algorithm to fuse the preprocessed surface parameters and downhole parameters to construct a drill string mechanical state dataset;

[0040] Step 2.5: The torsion state estimation unit establishes a real-time estimation model of the torsion state of the drill string based on the fused drill string mechanical state dataset, and calculates the real-time torsion trend of the drill string through the model.

[0041] Furthermore, step 3 includes the following sub-steps:

[0042] Step 3.1: The model storage unit of the drill string torsion calculation module calls the drill string elastic torsion model, friction model and anti-torsion release prediction model that match the current drill string combination;

[0043] Step 3.2: Based on the real-time well depth, wellbore trajectory parameters, and drill string assembly information, the transfer gain calculation unit sends N small-amplitude step rotation commands to the top drive using a step test method. The command time and the corresponding bottom hole rotation data transmitted back from the downhole measurement-while-drilling system are recorded. After the data reaches a steady state, the steady-state bottom hole rotation is calculated using the truncated averaging method, thus obtaining the transfer gain G. θ For the calculated G θLow-pass filtered EWMA updates are performed online to ensure the real-time performance and accuracy of stiffness parameters;

[0044] Step 3.3: Solving the torsion angle distribution element based on the ground torque T surf Equivalent torsional stiffness k of drill string eq The torsion angle distribution Δθ of the drill string along the well depth direction is calculated using a piecewise accumulation algorithm;

[0045] Step 3.4: The anti-torsion release prediction unit uses the anti-torsion release prediction model, combined with torsion angle distribution data and real-time drilling parameters, to predict the amplitude and trend of drill string anti-torsion release that may occur during the tool face adjustment process.

[0046] Step 3.5: The friction torque reverse thrust unit uses the ground-measured torque T meas With elastic transmission torque T el The difference.

[0047] Furthermore, in step 3.2: the transfer gain G θ The calculation formula is:

[0048] Among them, G θ For transfer gain (rad / rad); Δθ top Δθ is the small step angle (rad) transmitted from the ground. bottom This corresponds to the steady-state wellbore rotation angle (rad).

[0049] Furthermore, in step 3.3: the static relationship of the torsion angle distribution Δθ is:

[0050] After overall equivalence, the calculation formula is:

[0051] Where Δθ is the drill string twist angle (rad); TL i G represents the torque load (N·m) on the i-th segment of the drill string; i J represents the shear modulus (Pa) of the drill string material in the i-th segment; i Let be the moment of inertia (m) of the i-th segment of the drill string. 4 T is the ground torque (N·m); k eq The equivalent torsional stiffness of the drill string is (N·m / rad). G is the shear modulus of the drill string material (Pa), and J is the moment of inertia of the drill string section (m). 4 ), L eq The equivalent length of the drill string is (m).

[0052] Furthermore, in step 3.5: the reverse friction torque T fric The calculation formula is: T fric ≈Tmeas -T el , among which, T fric T is the frictional torque (N·m); meas The measured torque on the ground (N·m); T el For elastically transmitting torque (N·m), T el =k eq *θ top θ top Ground rotation angle (rad).

[0053] Furthermore, step 4 includes the following sub-steps:

[0054] Step 4.1: The trajectory analysis unit of the target tool face solution module receives and analyzes the drilling trajectory design data to determine the target azimuth, target well inclination angle and trajectory curvature at the current stage;

[0055] Step 4.2: The desired tool face generation unit generates the desired tool face angle based on the trajectory analysis results and real-time wellbore trajectory feedback data.

[0056] Step 4.3: The angle difference calculation unit uses the signed shortest angle difference algorithm to calculate the current tool face angle θ. b With the expected tool face angle The difference Δθ between them is used to handle periodicity and cross-boundary jump problems in the 0-360° angle range;

[0057] Step 4.4: Ground corner compensation unit combined with transfer gain G θ Reverse torque release trend, friction torque T fric Based on the drill string delay characteristics, compensation calculations are performed on the shortest angle difference Δθ to obtain the required ground rotation angle Δθ. top ;

[0058] Step 4.5: The angle verification unit judges the calculated ground angle Δθ. top If the problem is within the limits of the top drive mechanism, an alarm signal will be output and the process will return to step 3 for recalculation. If the problem is within a reasonable range, Δθ will be adjusted accordingly. top Transmitted to the top drive intelligent control module.

[0059] Furthermore, in step 4.3: the formula for calculating the difference Δθ is:

[0060] Δθ=((TF2-TF1+180)mod360)-180

[0061] Where Δθ is the signed shortest angle difference; TF1 is the current toolface angle θ. b ;TF2 is the desired tool facet angle. mod is the modulo operation.

[0062] Furthermore, in step 4.4: the model assumption is: θ b ≈G θ *Δθ top -Δθ loss

[0063] Solving for:

[0064] Where, Δθ top θ is the angle by which the ground should rotate. b This is the current bottom hole tool face angle; Δθ is the desired bottom hole tool face angle. loss This refers to the angular loss, including but not limited to the reverse torsion angle and the angular loss caused by friction; G θ For transfer gain.

[0065] Furthermore, step 5 includes the following sub-steps:

[0066] Step 5.1: The control strategy selection unit of the top drive intelligent control module selects the control strategy based on the ground rotation angle Δθ. top Based on the size, reverse torque release trend, and drilling conditions, select an appropriate single or combined control strategy from angle compensation strategy, proportional adjustment strategy, amplitude limiting control strategy, and flexible start-up strategy.

[0067] Step 5.2: The instruction generation unit, based on the selected control strategy and Δθ, top Generate top drive rotation angle command, speed command, and action timing command;

[0068] Step 5.3: The speed regulation unit dynamically adjusts the top drive speed based on drilling conditions and torque feedback data;

[0069] Step 5.4: The output mode control unit selects a fixed angle, intermittent angle, or torsion correction output mode according to the size of the tool face deviation;

[0070] Step 5.5: The resonant frequency detection unit calculates the natural resonant frequency f of the drill string system based on the equivalent torsional stiffness k and moment of inertia I of the drill string. n The calculation formula is:

[0071] Among them, f n The system's natural resonant frequency is given by f; k is the drill string's equivalent torsional stiffness; I is the moment of inertia; the frequency of the control command and the system's natural resonant frequency are monitored in real time. n The difference;

[0072] Step 5.6: If the vibration is close to the resonance range, adjust the control command frequency through the vibration damping protection unit; if an abnormal increase in amplitude is detected, immediately stop the top drive rotation and switch to safety mode.

[0073] Step 5.7: The interface adaptation unit of the control execution module converts the control commands into a format compatible with the top drive control interface, and the action execution unit drives the top drive actuator to accurately complete the rotation angle adjustment, speed regulation and output mode switching actions.

[0074] Furthermore, step 6 includes the following sub-steps:

[0075] Step 6.1: The real-time feedback unit of the control execution module continuously collects the real-time rotation angle, speed, output torque and operating status data of the top drive, and transmits them to the closed-loop optimization unit;

[0076] Step 6.2: The closed-loop optimization unit compares the real-time feedback data with the target control parameters, calculates the control error e(t), and uses a closed-loop controller with feedforward compensation + PI feedback + rate / amplitude limiting + elastic release strategy to dynamically optimize the control command.

[0077] Step 6.3: The optimized control commands are retransmitted to the action execution unit to achieve closed-loop optimization and control; at the same time, the data storage and interaction module classifies, stores and compresses various types of data throughout the process, and transmits them to the remote monitoring center in real time.

[0078] Furthermore, in step 6.2: the control formula is:

[0079]

[0080] Where u(t) is the control output; K f Forward coefficients; Let G be the difference between the desired tool facet angle and the current tool facet angle; G be the estimated effective transfer gain; K be the difference between the desired tool facet angle and the current tool facet angle. p This is the proportionality coefficient;

[0081] e(t) is the control error.

[0082] θ b (t+τ) is the desired tool face angle considering the transmission delay τ, θ b (t) represents the current tool face angle; K i ∑eΔt is the integral coefficient; ∑eΔt is the integral value of the error; sat is the limiting function, used to limit the range of the control output;

[0083] Furthermore, step 7 is as follows: The status monitoring unit of the fault diagnosis and protection module monitors the operating status of each module of the system and drilling parameters in real time; the fault identification unit analyzes and judges abnormal data based on the fault feature library to identify the fault type; the fault classification unit classifies the fault according to the degree of fault impact; the protection command generation unit generates corresponding protection commands for different levels of faults, and the alarm unit issues alarm signals; the operator performs fault troubleshooting based on the alarm information and fault records, and the system returns to normal operation after the fault is eliminated.

[0084] Furthermore, step 8 is as follows: When the drilling operation reaches the preset stage target or completes all drilling tasks, the system outputs an operation completion signal, and the control execution module drives the top drive actuator to reset; the data storage and interaction module organizes and archives all data in this drilling process; each module returns to the initial standby state, waiting for the next operation instruction.

[0085] Compared with the prior art, the advantages or beneficial effects of the present invention include at least the following: 1. Through real-time drill string torsion analysis, the minimum ground rotation angle required to achieve the target tool face can be directly calculated, avoiding repeated manual trials and adjustments, and improving control efficiency by 30%–60%.

[0086] 2. Built-in anti-torque prediction model and torque compensation algorithm can effectively avoid overshoot caused by drill string anti-torque release, greatly reduce tool face deviation, and improve the accuracy of sliding drilling trajectory.

[0087] 3. The device can automatically generate the desired tool face angle based on the trajectory planning, and achieve automatic adjustment through intelligent control of the top drive, laying the foundation for intelligent drilling.

[0088] 4. The control process is completed automatically by the system, reducing manual observation and judgment of tool face changes, and improving construction consistency and safety. The tool face response time is shortened, the number of trajectory corrections is reduced, and the sliding efficiency is significantly improved, while friction and non-productive time are reduced. It is suitable for complex conditions such as horizontal wells, long-section targeted wells, and high-friction wells, and has broad engineering application value. Attached Figure Description

[0089] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. The drawings are provided for reference and illustration only and are not intended to limit the present invention.

[0090] in:

[0091] Figure 1This is a system module diagram of the top drive intelligent control system based on drill string mechanical feedback of the present invention;

[0092] Figure 2 This is a schematic diagram of the drill string mechanical sensing module in this invention;

[0093] Figure 3 This is a schematic diagram of the drill string torsion calculation module in this invention;

[0094] Figure 4 This is a schematic diagram of the target tool surface solving module in this invention;

[0095] Figure 5 This is a flowchart of the intelligent control method for top drive based on drill string mechanical feedback of the present invention;

[0096] Figure 6 This is a diagram of the top drive control box's operating interface;

[0097] Figure 7 This is a screenshot of the display interface of an edge computing computer. Detailed Implementation

[0098] To make the technical means, creative features, objectives, and effects of this invention easier to understand, the invention is further described below with reference to specific illustrations. Obviously, the described embodiments are only a part of the embodiments of this invention, and not all of them.

[0099] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.

[0100] like Figures 1 to 5 As shown, the top drive intelligent control system based on drill string mechanical feedback of the present invention includes a drill string mechanical sensing module, a drill string torsion calculation module, a target tool face solving module, a top drive intelligent control module, a control execution module, a data storage and interaction module, and a fault diagnosis and protection module.

[0101] The drill string mechanics sensing module is used to collect surface drilling engineering parameters, receive downhole measurement data, and perform data fusion processing and torsional state estimation.

[0102] The drill string torsion calculation module has a built-in mathematical model related to drill string torsion. Based on the parameters output by the drill string mechanical sensing module, it calculates the drill string transmission gain, torsion angle distribution, anti-torsion release trend and friction torque.

[0103] The target tool face solving module generates the desired tool face angle based on the drilling trajectory requirements, and combines the calculation results of the drill string torsion calculation module to determine the ground rotation angle required to achieve the target tool face.

[0104] The top drive intelligent control module selects an appropriate control strategy based on the ground rotation angle output by the target tool surface solving module, generates top drive control commands, and performs resonance frequency detection and vibration damping protection.

[0105] The control execution module is connected to the top drive control interface to execute top drive control commands, collect real-time operating data of the top drive, and realize closed-loop optimization and control.

[0106] The data storage and interaction module is used to store various parameters, calculation results and control commands, and to realize data transmission between modules and information interaction with external devices.

[0107] The fault diagnosis and protection module is used to monitor the operating status of each module in the system and abnormal drilling parameters, and to trigger the protection mechanism.

[0108] The drill string mechanical sensing module includes a surface parameter acquisition unit, a downhole parameter receiving unit, a data preprocessing unit, a mechanical state fusion unit, and a torsional state estimation unit.

[0109] Surface parameter acquisition unit: used to acquire engineering parameters during the surface drilling process. The engineering parameters include surface torque, suspended weight, standpipe pressure, mechanical drilling speed, well depth and trajectory parameters. The parameters are acquired by sensors deployed at the top drive, drilling standpipe, and traveling block hook. The signals output by the sensors are converted into standard analog electrical signals by the signal conditioning circuit.

[0110] Downhole parameter receiving unit: used to receive downhole data transmitted by the downhole measurement while drilling (MWD / LWD) system. The downhole data includes tool face angle, azimuth angle, well inclination and downhole torque feedback. It establishes a data transmission link with the downhole measurement while drilling system through a wireless communication module to realize real-time data reception.

[0111] Data preprocessing unit: performs analog-to-digital conversion on the analog signals acquired by the ground parameter acquisition unit, parses the format of the data received by the downhole parameter receiving unit, and uses filtering algorithms to remove noise interference from the data. It also achieves spatiotemporal alignment between ground parameters and downhole parameters through timestamp synchronization to avoid calculation errors caused by asynchronous data.

[0112] Mechanical state fusion unit: Employing a multi-source data fusion algorithm, the preprocessed surface parameters and downhole parameters are fused to overcome the limitations of a single parameter and construct a comprehensive and accurate drill string mechanical state dataset, providing data support for torsional state estimation.

[0113] Torsional State Estimation Unit: Based on the fused drill string mechanical state dataset, a real-time estimation model for the torsional state of the drill string is established. The real-time torsional trend of the drill string is calculated through the model, providing initial input parameters for the drill string torsional calculation module.

[0114] The drill string torsion calculation module includes a model storage unit, a transfer gain calculation unit, a torsion angle distribution solution unit, an anti-torsion release prediction unit, and a friction torque back-calculation unit.

[0115] Model storage unit: Built-in drill string elastic torsion model, friction model, anti-torsion release prediction model and drill string geometric parameter database. The drill string geometric parameter database contains basic parameters such as the cross-sectional moment of inertia, length and material elastic modulus of drill pipes and drill collars of different specifications, and supports parameter calling according to actual drill tool combination;

[0116] Transfer gain calculation unit: Based on real-time well depth, wellbore trajectory parameters and drill string assembly information, the drill string elastic torsion model in the model storage unit is called, and the transfer gain between torque and torsion angle is calculated through step test and data fitting method.

[0117] Torsion angle distribution solution unit: Based on surface torque data and transmission gain, a piecewise accumulation algorithm is used to calculate the torsion angle distribution of the drill string along the well depth direction, so as to achieve accurate estimation of the torsion angle from the surface to any depth downhole, and at the same time derive the torque transmission situation at the bottom of the well;

[0118] Anti-torque release prediction unit: Using the anti-torque release prediction model in the model storage unit, combined with torsion angle distribution data and drilling torque parameters, it predicts the amplitude and trend of anti-torque release that may occur during the tool face adjustment of the drill string, providing a basis for the formulation of control strategies.

[0119] Friction torque reverse calculation unit: Based on the difference between the measured torque on the ground and the elastically transmitted torque, the friction torque between the drill string and the well wall is reversed, the influence of friction on torque transmission is quantified, and data support is provided for torque compensation.

[0120] The target tool surface solution module includes a trajectory analysis unit, a desired tool surface generation unit, an angle difference calculation unit, a ground rotation angle compensation unit, and a rotation angle verification unit.

[0121] Trajectory Analysis Unit: Receives drilling trajectory design data, analyzes the target trajectory parameters of the current drilling stage, including the target azimuth, target inclination angle, and trajectory curvature, and clarifies the drilling direction requirements;

[0122] Desired tool face generation unit: Based on the target trajectory parameters output by the trajectory parsing unit and combined with real-time wellbore trajectory feedback data, it generates the desired tool face angle under the current drilling conditions to ensure that the tool face angle matches the trajectory requirements;

[0123] Angle difference calculation unit: The signed shortest angle difference algorithm is used to calculate the difference between the current tool face angle and the desired tool face angle, handle the periodicity of the 0-360° angle and the cross-boundary jump problem, and obtain the shortest angle adjustment amount to achieve the target tool face;

[0124] Ground rotation angle compensation unit: Combining the transmission gain, anti-torque release trend and friction torque data output by the drill string torsion calculation module, and considering the drill string torque transmission delay characteristics, the unit calculates the compensation amount for the shortest angle adjustment to obtain the required ground rotation angle.

[0125] Corner verification unit: verifies the rationality of the calculated ground corner angle and determines whether the corner angle is within the limit range of the top drive machinery. If it exceeds the limit, an alarm signal is output. If it is within the reasonable range, the ground corner angle data is transmitted to the top drive intelligent control module.

[0126] The top drive intelligent control module includes a control strategy selection unit, an instruction generation unit, a speed adjustment unit, an output mode control unit, a resonance frequency detection unit, and a vibration damping protection unit.

[0127] Control strategy selection unit: Built-in angle compensation strategy, proportional adjustment strategy, amplitude limiting control strategy and flexible start strategy. It automatically selects a single or combined control strategy according to the ground rotation angle, reverse torque release trend and drilling conditions to ensure a smooth and accurate control process.

[0128] Command generation unit: Based on the selected control strategy and ground rotation angle data, it generates top drive rotation angle command, speed command and action timing command. The command format conforms to the requirements of the top drive control interface protocol.

[0129] Speed ​​adjustment unit: Based on drilling conditions and torque feedback data, the top drive speed is dynamically adjusted to achieve adaptive speed matching under different working conditions, avoiding tool face instability caused by excessively high or low speed.

[0130] Output mode control unit: Supports fixed angle output mode, intermittent angle output mode and torsional correction output mode. Select the appropriate output mode according to the tool face deviation and drilling requirements to achieve efficient tool face correction.

[0131] Resonance frequency detection unit: Based on transfer gain and rotational inertia, calculates the natural resonance frequency of the drill string system and monitors the difference between the top drive control command frequency and the resonance frequency in real time;

[0132] Vibration protection unit: When the control command frequency approaches the system's inherent resonant frequency, the control command frequency is adjusted to avoid the resonance range; if an abnormal increase in amplitude is detected, the top drive rotation is immediately stopped and switched to safety mode to prevent the drill string from being damaged by resonance.

[0133] The control execution module includes an interface adaptation unit, an action execution unit, a real-time feedback unit, and a closed-loop optimization unit;

[0134] Interface adapter unit: Provides various types of top drive control interfaces, including digital interfaces, analog interfaces and bus interfaces, and achieves compatible connection with different models of top drive equipment through interface protocol conversion;

[0135] Action execution unit: Receives control commands from the top drive intelligent control module, drives the top drive actuator to accurately complete rotation angle adjustment, speed regulation and output mode switching actions, and ensures command execution accuracy;

[0136] Real-time feedback unit: Through sensors deployed on the top drive actuator, the real-time rotation angle, speed, output torque and operating status data of the top drive are collected to realize real-time monitoring of control actions;

[0137] Closed-loop optimization unit: It compares the data collected by the real-time feedback unit with the target control parameters, calculates the control error, and combines the latest mechanical state data output by the drill string mechanical sensing module to dynamically optimize and adjust the control commands, forming a closed-loop control loop.

[0138] The data storage and interaction module includes a data classification and storage unit, a data compression unit, a local storage unit, a remote transmission unit, and a data query unit;

[0139] Data classification and storage unit: Classifies and organizes drill string mechanical parameters, torsion calculation results, control commands, top drive operation data, and fault record data, and establishes a standardized data format;

[0140] Data compression unit: Uses data compression algorithms to compress the massive amount of classified data, reducing the space occupied by data storage, while ensuring the integrity of the data after decompression;

[0141] Local storage unit: It realizes local caching and long-term storage of data through high-capacity storage devices, supports data interruption and resume, and ensures that data is not lost during the drilling process;

[0142] Remote transmission unit: Real-time transmission of locally stored data to the remote monitoring center is achieved through industrial Ethernet and wireless communication, supporting remote data access and command issuance;

[0143] Data Query Unit: Provides a data query interface, supporting data retrieval by time, data type, and drilling stage, making it convenient for operators to trace the drilling process and system operation status.

[0144] The fault diagnosis and protection module includes a status monitoring unit, a fault identification unit, a fault classification unit, a protection command generation unit, and an alarm unit;

[0145] Status monitoring unit: Real-time monitoring of the operating status of each module of the system, including sensor data acquisition status, module communication status, top drive actuator operating status, and data storage status;

[0146] Fault identification unit: Based on a preset fault feature library, it analyzes and judges the abnormal data detected to identify the fault type, including but not limited to sensor faults, communication faults, computing faults, and top-drive operation faults;

[0147] Fault Classification Unit: Based on the degree of impact of the fault on drilling operations, faults are classified into three levels: minor faults, general faults, and serious faults. Different levels correspond to different handling strategies.

[0148] Protection command generation unit: Generates corresponding protection commands for different levels of faults. For minor faults, only control parameters are adjusted. For general faults, the top drive adjustment is paused and fault recovery is attempted. For severe faults, the top drive operation is stopped immediately and the relevant control circuits are disconnected.

[0149] Alarm unit: When a fault is detected, an alarm signal is sent to the operator through audible and visual alarms and remote notification. At the same time, the time of the fault occurrence, the fault type and the fault handling process are recorded to provide a basis for fault diagnosis.

[0150] The control method of the top drive intelligent control system based on drill string mechanical feedback of the present invention includes the following steps in sequence:

[0151] Step 1: System Initialization and Parameter Configuration

[0152] The top drive intelligent control system based on drill string mechanical feedback is started, and the self-checks and initialization of each module are completed, including sensor calibration, communication link establishment, model parameter loading and storage device initialization. According to the drilling design scheme and drill string assembly information, the basic parameters of the system are configured, including drill string geometric parameters, wellbore trajectory design parameters, top drive equipment parameters and control strategy threshold parameters, and the system enters standby state.

[0153] Step 2: Mechanical Parameter Acquisition and Fusion Processing

[0154] Step 2.1: Continuously collect ground torque, suspended weight, standpipe pressure, mechanical drilling speed, well depth and trajectory parameters through the ground parameter acquisition unit of the drill string mechanical sensing module, and transmit them to the data preprocessing unit after signal conditioning;

[0155] Step 2.2: Receive tool face angle, azimuth angle, well inclination and downhole torque feedback data transmitted from the downhole measurement while drilling (MWD / LWD) system through the downhole parameter receiving unit, and transmit them to the data preprocessing unit;

[0156] Step 2.3: The data preprocessing unit performs analog-to-digital conversion on the analog signals acquired by the ground parameter acquisition unit, parses the format of the data received by the downhole parameter receiving unit, and uses a filtering algorithm to remove noise interference from the data. The time stamp synchronization is used to achieve spatiotemporal alignment between the ground parameters and the downhole parameters.

[0157] Step 2.4: The mechanical state fusion unit uses a multi-source data fusion algorithm to fuse the preprocessed surface parameters and downhole parameters to construct a drill string mechanical state dataset;

[0158] Step 2.5: The torsion state estimation unit establishes a real-time estimation model of the torsion state of the drill string based on the fused drill string mechanical state dataset, and calculates the real-time torsion trend of the drill string through the model.

[0159] Step 3: Calculation of drill string torsional characteristics

[0160] Step 3.1: The model storage unit of the drill string torsion calculation module calls the drill string elastic torsion model, friction model and anti-torsion release prediction model that match the current drill string combination;

[0161] Step 3.2: Based on the real-time well depth, wellbore trajectory parameters, and drill string assembly information, the transfer gain calculation unit sends N small-amplitude step rotation commands to the top drive using a step test method. The command time and the corresponding bottom hole rotation data transmitted back from the downhole measurement-while-drilling system are recorded. After the data reaches a steady state, the steady-state bottom hole rotation is calculated using the truncated averaging method, thus obtaining the transfer gain G. θ The calculation formula is:

[0162] Among them, G θ For transfer gain (rad / rad); Δθ top Δθ is the small step angle (rad) transmitted from the ground. bottom The corresponding steady-state bottom hole rotation angle (rad); the calculated G θ Low-pass filtered EWMA updates are performed online to ensure the real-time performance and accuracy of stiffness parameters;

[0163] Step 3.3: Solving the torsion angle distribution element based on the ground torque T surf Equivalent torsional stiffness k of drill string eq The torsion angle distribution Δθ of the drill string along the well depth direction is calculated using a piecewise accumulation algorithm.

[0164] The static relationship is:

[0165] After overall equivalence, the calculation formula is:

[0166] Where Δθ is the drill string twist angle (rad); TLi G represents the torque load (N·m) on the i-th segment of the drill string; i J represents the shear modulus (Pa) of the drill string material in the i-th segment; i Let be the moment of inertia (m) of the i-th segment of the drill string. 4 T is the ground torque (N·m); k eq The equivalent torsional stiffness of the drill string is (N·m / rad). G is the shear modulus of the drill string material (Pa), and J is the moment of inertia of the drill string section (m). 4 ), L eq The equivalent length of the drill string (m);

[0167] Step 3.4: The anti-torsion release prediction unit uses the anti-torsion release prediction model, combined with torsion angle distribution data and real-time drilling condition parameters, to predict the amplitude and trend of drill string anti-torsion release that may occur during the tool face adjustment process.

[0168] Step 3.5: The friction torque reverse thrust unit uses the ground-measured torque T meas With elastic transmission torque T el The difference can be used to inversely calculate the friction torque T. fric The calculation formula is: T fric ≈T meas -T el , among which, T froc T is the frictional torque (N·m); meas The measured torque on the ground (N·m); T el For elastically transmitting torque (N·m), T el =k eq *θ top θ top Ground rotation angle (rad).

[0169] Step 4: Solving the angle between the target tool face and the ground

[0170] Step 4.1: The trajectory analysis unit of the target tool face solution module receives and analyzes the drilling trajectory design data to determine the target azimuth, target well inclination angle and trajectory curvature at the current stage;

[0171] Step 4.2: The desired tool face generation unit generates the desired tool face angle based on the trajectory analysis results and real-time wellbore trajectory feedback data.

[0172] Step 4.3: The angle difference calculation unit uses the signed shortest angle difference algorithm to calculate the current tool face angle θ. b With the expected tool face angle The difference Δθ between them, handling periodicity of angles from 0 to 360° and cross-boundary jumps, is calculated using the following formula:

[0173] Δθ=((TF2-TF1+180)mod360)-180

[0174] Where Δθ is the signed shortest angle difference; TF1 is the current toolface angle θ. b ;TF2 is the desired tool facet angle. mod is the modulo operation;

[0175] Step 4.4: Ground corner compensation unit combined with transfer gain G θ Reverse torque release trend, friction torque T fric Based on the drill string delay characteristics, compensation calculations are performed on the shortest angle difference Δθ to obtain the required ground rotation angle Δθ. top The model assumes that: θ b ≈G θ *Δθ top -Δθ loss

[0176] Solving for:

[0177] Where, Δθ top θ is the angle by which the ground should rotate. b This is the current bottom hole tool face angle; Δθ represents the desired bottom hole tool face angle. loss This refers to the angular loss, including but not limited to the reverse torsion angle and the angular loss caused by friction; G θ For transfer gain;

[0178] Step 4.5: The angle verification unit judges the calculated ground angle Δθ. top If the problem is within the limits of the top drive mechanism, an alarm signal will be output and the process will return to step 3 for recalculation. If the problem is within a reasonable range, Δθ will be adjusted accordingly. top Transmitted to the top drive intelligent control module.

[0179] Step 5: Generation and execution of top drive control commands

[0180] Step 5.1: The control strategy selection unit of the top drive intelligent control module selects the control strategy based on the ground rotation angle Δθ. top Based on the size, reverse torque release trend, and drilling conditions, select an appropriate single or combined control strategy from angle compensation strategy, proportional adjustment strategy, amplitude limiting control strategy, and flexible start-up strategy.

[0181] Step 5.2: The instruction generation unit, based on the selected control strategy and Δθ, top Generate top drive rotation angle command, speed command, and action timing command;

[0182] Step 5.3: The speed regulation unit dynamically adjusts the top drive speed based on drilling conditions and torque feedback data;

[0183] Step 5.4: The output mode control unit selects a fixed angle, intermittent angle, or torsion correction output mode according to the size of the tool face deviation;

[0184] Step 5.5: The resonant frequency detection unit calculates the natural resonant frequency f of the drill string system based on the equivalent torsional stiffness k and moment of inertia I of the drill string. n The calculation formula is:

[0185] Among them, f n The system's natural resonant frequency is given by f; k is the drill string's equivalent torsional stiffness; I is the moment of inertia; the frequency of the control command and the system's natural resonant frequency are monitored in real time. n The difference;

[0186] Step 5.6: If the vibration is close to the resonance range, adjust the control command frequency through the vibration damping protection unit; if an abnormal increase in amplitude is detected, immediately stop the top drive rotation and switch to safety mode.

[0187] Step 5.7: The interface adaptation unit of the control execution module converts the control commands into a format compatible with the top drive control interface, and the action execution unit drives the top drive actuator to accurately complete the rotation angle adjustment, speed regulation and output mode switching actions.

[0188] Step 6: Closed-loop optimization and control

[0189] Step 6.1: The real-time feedback unit of the control execution module continuously collects the real-time rotation angle, speed, output torque and operating status data of the top drive, and transmits them to the closed-loop optimization unit;

[0190] Step 6.2: The closed-loop optimization unit compares the real-time feedback data with the target control parameters, calculates the control error e(t), and uses a closed-loop controller employing a feedforward compensation + PI (or PID) feedback + rate / amplitude limiting + elastic release strategy to dynamically optimize the control command. The control formula is:

[0191]

[0192] Where u(t) is the control output; K f Forward coefficients; Let G be the difference between the desired tool facet angle and the current tool facet angle; G be the estimated effective transfer gain; K be the difference between the desired tool facet angle and the current tool facet angle. p This is the proportionality coefficient;

[0193] e(t) is the control error.

[0194] θ b (t+τ) is the desired tool face angle considering the transmission delay τ, θ b(t) represents the current tool face angle; K i ∑eΔt is the integral coefficient; ∑eΔt is the integral value of the error; sat is the limiting function, used to limit the range of the control output;

[0195] Step 6.3: The optimized control commands are retransmitted to the action execution unit to achieve closed-loop optimization and control; at the same time, the data storage and interaction module classifies, stores and compresses various types of data throughout the process, and transmits them to the remote monitoring center in real time.

[0196] Step 7: Fault Monitoring and Handling

[0197] The status monitoring unit of the fault diagnosis and protection module monitors the operating status of each module and drilling parameters in real time; the fault identification unit analyzes and judges abnormal data based on the fault feature library to identify the fault type; the fault classification unit classifies faults according to the degree of their impact; the protection command generation unit generates corresponding protection commands for different levels of faults, and the alarm unit issues alarm signals; operators troubleshoot faults based on alarm information and fault records, and the system returns to normal operation after the fault is eliminated.

[0198] Step 8: Job Completion and System Reset

[0199] When the drilling operation reaches the preset stage target or completes all drilling tasks, the system outputs an operation completion signal, and the control execution module drives the top drive actuator to reset; the data storage and interaction module organizes and archives all data in this drilling process; each module returns to the initial standby state, waiting for the next operation instruction.

[0200] This invention, through real-time drill string torsion analysis, can directly calculate the minimum ground rotation angle required to achieve the target tool face, avoiding repeated manual trials and adjustments, and improving control efficiency by 30%–60%. The built-in anti-torsion prediction model and torque compensation algorithm effectively prevent overshoot caused by drill string anti-torsion release, significantly reducing tool face deviation and improving sliding drilling trajectory accuracy. The device can automatically generate the desired tool face angle based on trajectory planning and achieve automatic adjustment through intelligent control of the top drive, laying the foundation for intelligent drilling. The control process is completed automatically by the system, reducing manual observation and judgment of tool face changes, and improving construction consistency and safety. Tool face response time is shortened, trajectory corrections are reduced, sliding efficiency is significantly improved, and friction and non-productive time are reduced. It is suitable for complex conditions such as horizontal wells, long-section targeted wells, and high-friction wells, and has broad engineering application value.

[0201] Construction examples:

[0202] Main testing equipment: top drive control box, edge computing gateway, and data transmission equipment. Figure 6The image shows the top drive control box operation interface. Click "System Start"; the system uses real-time toolface data to determine if the desired toolface is present. If toolface adjustment is needed, manually input the target toolface. Click the "One-Click Tracking" button; the top drive receives the calculation results from the edge computing computer and executes the corresponding angle. The rounded corner dial in the middle displays the current rotation direction and angle value.

[0203] Figure 7 The image shows the display interface of the edge computing computer. The interface displays the current status of the top drive control box, real-time drilling parameters, and downhole tool face data. In the image, the real-time tool face at 250° changes clockwise around a stable drilling pressure of 230KN, gradually adjusting towards the target tool face at 180° after one cycle (returning to 0° after a full 360°).

[0204] The results of the on-site test are shown in the table below.

[0205] 1. The success rate of using the torsion swing system is 100% (11 out of 11 times). After the torsion swing system is turned on, the wear resistance is reduced by 30%-50% (the wear resistance is reduced from 15-20 tons to 13-15 tons), and the pressure improvement effect is obvious.

[0206]

[0207] 2. The success rate of intelligent guidance is 66.7% (6 out of 9 attempts were successful). After the system is turned on, the tool surface is relatively stable, with the target tool surface at 195° and the real-time tool surface fluctuating between 185° and 205°.

[0208] 3. With the adjustment of the IDGS reaction angle (from ±15° to ±10°) and the increase of the positive impact coefficient, the effect of IDGS in this drilling trip is obvious, and customer satisfaction has increased significantly.

Claims

1. A top drive intelligent control system based on drill string mechanical feedback, characterized in that: It includes a drill string mechanics sensing module, a drill string torsion calculation module, and a target tool face solution module. The drill string mechanical sensing module is used to collect surface drilling engineering parameters, receive downhole measurement data, and perform data fusion processing and torsional state estimation. The drill string torsion calculation module has a built-in mathematical model related to drill string torsion. Based on the parameters output by the drill string mechanical sensing module, it calculates the drill string transmission gain, torsion angle distribution, anti-torsion release trend and friction torque. The target tool face solving module generates the desired tool face angle based on the drilling trajectory requirements, and combines the calculation results of the drill string torsion calculation module to determine the ground rotation angle required to achieve the target tool face.

2. The intelligent control system for top drive based on drill string mechanical feedback according to claim 1, characterized in that: It also includes a top drive intelligent control module and a control execution module. The top drive intelligent control module selects an appropriate control strategy based on the ground rotation angle output by the target tool surface solving module, generates top drive control commands, and performs resonance frequency detection and vibration damping protection. The control execution module is connected to the top drive control interface, executes top drive control commands, collects real-time operating data of the top drive, and realizes closed-loop optimization and control.

3. The top drive intelligent control system based on drill string mechanical feedback according to claim 1, characterized in that: It also includes a data storage and interaction module and a fault diagnosis and protection module. The data storage and interaction module is used to store various parameters, calculation results and control commands, and realize data transmission between modules and information interaction with external devices. The fault diagnosis and protection module is used to monitor the operating status of each module of the system and abnormal drilling parameters, and trigger the protection mechanism.

4. The intelligent control system for top drive based on drill string mechanical feedback according to claim 1, characterized in that: The drill string mechanical sensing module includes a surface parameter acquisition unit, a downhole parameter receiving unit, and a data preprocessing unit. Ground parameter acquisition unit: Used to acquire engineering parameters during the ground drilling process. Parameter acquisition is achieved by sensors deployed at the top drive, drill riser, and traveling block hook. The signals output by the sensors are converted into standard analog electrical signals by the signal conditioning circuit. Downhole parameter receiving unit: Used to receive downhole data transmitted by the downhole measurement while drilling system, and establishes a data transmission link with the downhole measurement while drilling system through a wireless communication module to realize real-time data reception; Data preprocessing unit: performs analog-to-digital conversion on the analog signals acquired by the ground parameter acquisition unit and parses the format of the data received by the downhole parameter receiving unit.

5. The intelligent control system for top drive based on drill string mechanical feedback according to claim 4, characterized in that: The engineering parameters collected by the ground parameter acquisition unit include ground torque, suspended weight, riser pressure, mechanical drilling speed, well depth, and trajectory parameters. In the downhole parameter receiving unit, the downhole data includes tool face angle, azimuth angle, well inclination, and downhole torque feedback; In the data preprocessing unit, while parsing the format, a filtering algorithm is used to remove noise interference from the data. The time stamp synchronization is used to achieve spatiotemporal alignment between the surface parameters and the downhole parameters, avoiding calculation errors caused by asynchronous data.

6. The intelligent control system for top drive based on drill string mechanical feedback according to claim 4, characterized in that: The drill string mechanical sensing module also includes a mechanical state fusion unit and a torsional state estimation unit. Mechanical state fusion unit: Employing a multi-source data fusion algorithm, the preprocessed surface parameters and downhole parameters are fused to overcome the limitations of a single parameter, constructing a comprehensive and accurate drill string mechanical state dataset, and providing data support for torsional state estimation. Torsional State Estimation Unit: Based on the fused drill string mechanical state dataset, a real-time estimation model for the torsional state of the drill string is established. The real-time torsional trend of the drill string is calculated through the model, providing initial input parameters for the drill string torsional calculation module.

7. The intelligent control system for top drive based on drill string mechanical feedback according to claim 1, characterized in that: The drill string torsion calculation module includes a model storage unit, a transfer gain calculation unit, and a torsion angle distribution solution unit. Model storage unit: Built-in drill string elastic torsion model, friction model, anti-torsion release prediction model and drill string geometric parameter database; Transfer gain calculation unit: Based on real-time well depth, wellbore trajectory parameters and drill string assembly information, the drill string elastic torsion model in the model storage unit is called, and the transfer gain between torque and torsion angle is calculated through step test and data fitting method. Torsion angle distribution solution unit: Based on surface torque data and transmission gain, a piecewise accumulation algorithm is used to calculate the torsion angle distribution of the drill string along the well depth direction, so as to achieve accurate estimation of the torsion angle from the surface to any depth downhole, and at the same time derive the torque transmission situation at the bottom of the well.

8. The intelligent control system for top drive based on drill string mechanical feedback according to claim 7, characterized in that: In the model storage unit: the drill string geometry parameter database contains basic parameters such as the moment of inertia, length, and elastic modulus of materials for drill pipes and drill collars of different specifications, and supports parameter calling according to the actual drill string combination.

9. The intelligent control system for top drive based on drill string mechanical feedback according to claim 7, characterized in that: The drill string torsion calculation module also includes an anti-torsion release prediction unit and a friction torque reverse propagation unit. Anti-torque release prediction unit: Using the anti-torque release prediction model in the model storage unit, combined with torsion angle distribution data and drilling torque parameters, it predicts the amplitude and trend of anti-torque release that may occur during the tool face adjustment process of the drill string, providing a basis for the formulation of control strategies. Friction torque reverse calculation unit: Based on the difference between the measured torque on the ground and the elastically transmitted torque, the friction torque between the drill string and the well wall is reversed, the influence of friction on torque transmission is quantified, and data support is provided for torque compensation.

10. The top drive intelligent control system based on drill string mechanical feedback according to claim 1, characterized in that: The target tool surface solving module includes a trajectory analysis unit, a desired tool surface generation unit, and an angle difference calculation unit; Trajectory Analysis Unit: Receives drilling trajectory design data, analyzes the target trajectory parameters of the current drilling stage, including the target azimuth, target inclination angle, and trajectory curvature, and clarifies the drilling direction requirements; Desired tool face generation unit: Based on the target trajectory parameters output by the trajectory parsing unit and combined with real-time wellbore trajectory feedback data, it generates the desired tool face angle under the current drilling conditions to ensure that the tool face angle matches the trajectory requirements; Angle difference calculation unit: The signed shortest angle difference algorithm is used to calculate the difference between the current tool face angle and the desired tool face angle, handle the periodicity of the 0-360° angle and the problem of cross-boundary jump, and obtain the shortest angle adjustment amount to achieve the target tool face.

11. The top drive intelligent control system based on drill string mechanical feedback according to claim 10, characterized in that: The target tool surface solving module also includes a ground corner compensation unit and a corner verification unit. Ground rotation angle compensation unit: Combining the transmission gain, anti-torque release trend and friction torque data output by the drill string torsion calculation module, and considering the drill string torque transmission delay characteristics, the unit calculates the compensation amount for the shortest angle adjustment to obtain the required ground rotation angle. Angle verification unit: verifies the rationality of the calculated ground angle and determines whether the angle is within the limit range of the top drive machinery. If it exceeds the limit, an alarm signal is output. If it is within the reasonable range, the ground angle data is transmitted to the top drive intelligent control module.

12. The intelligent control system for top drive based on drill string mechanical feedback according to claim 2, characterized in that: The top drive intelligent control module includes a control strategy selection unit, a command generation unit, a speed adjustment unit, and an output mode control unit. Control strategy selection unit: Built-in angle compensation strategy, proportional adjustment strategy, amplitude limiting control strategy and flexible start strategy. It automatically selects a single or combined control strategy according to the ground rotation angle, reverse torque release trend and drilling conditions to ensure a smooth and accurate control process. Command generation unit: Based on the selected control strategy and ground rotation angle data, it generates top drive rotation angle command, speed command and action timing command. The command format conforms to the requirements of the top drive control interface protocol. Speed ​​adjustment unit: Based on drilling conditions and torque feedback data, the top drive speed is dynamically adjusted to achieve adaptive speed matching under different working conditions, avoiding tool face instability caused by excessively high or low speeds. Output mode control unit: Supports fixed angle output mode, intermittent angle output mode and torsional correction output mode. Select the appropriate output mode according to the tool face deviation and drilling requirements to achieve efficient tool face correction.

13. The top drive intelligent control system based on drill string mechanical feedback according to claim 12, characterized in that: The top drive intelligent control module also includes a resonance frequency detection unit and a vibration damping protection unit. Resonance frequency detection unit: Based on transfer gain and rotational inertia, calculates the natural resonance frequency of the drill string system and monitors the difference between the top drive control command frequency and the resonance frequency in real time; Vibration protection unit: When the control command frequency approaches the system's inherent resonant frequency, the control command frequency is adjusted to avoid the resonance range; if an abnormal increase in amplitude is detected, the top drive rotation is immediately stopped and switched to safety mode to prevent the drill string from being damaged by resonance.

14. The intelligent control system for top drive based on drill string mechanical feedback according to claim 2, characterized in that: The control execution module includes an interface adaptation unit, an action execution unit, a real-time feedback unit, and a closed-loop optimization unit; Interface adapter unit: Provides various types of top drive control interfaces, including digital interfaces, analog interfaces and bus interfaces, and achieves compatible connection with different models of top drive equipment through interface protocol conversion; Action execution unit: Receives control commands from the top drive intelligent control module, drives the top drive actuator to accurately complete rotation angle adjustment, speed regulation and output mode switching actions, and ensures command execution accuracy; Real-time feedback unit: Through sensors deployed on the top drive actuator, the real-time rotation angle, speed, output torque and operating status data of the top drive are collected to realize real-time monitoring of control actions; Closed-loop optimization unit: It compares the data collected by the real-time feedback unit with the target control parameters, calculates the control error, and combines the latest mechanical state data output by the drill string mechanical sensing module to dynamically optimize and adjust the control commands, forming a closed-loop control loop.

15. The intelligent control system for top drive based on drill string mechanical feedback according to claim 3, characterized in that: The data storage and interaction module includes a data classification and storage unit, a data compression unit, a local storage unit, a remote transmission unit, and a data query unit; Data classification and storage unit: Classifies and organizes drill string mechanical parameters, torsion calculation results, control commands, top drive operation data, and fault record data, and establishes a standardized data format; Data compression unit: Uses data compression algorithms to compress the massive amount of classified data, reducing the space occupied by data storage, while ensuring the integrity of the data after decompression; Local storage unit: It realizes local caching and long-term storage of data through high-capacity storage devices, supports data interruption and resume, and ensures that data is not lost during the drilling process; Remote transmission unit: Real-time transmission of locally stored data to the remote monitoring center is achieved through industrial Ethernet and wireless communication, supporting remote data access and command issuance; Data Query Unit: Provides a data query interface, supporting data retrieval by time, data type, and drilling stage, making it convenient for operators to trace the drilling process and system operation status.

16. The intelligent control system for top drive based on drill string mechanical feedback according to claim 3, characterized in that: The fault diagnosis and protection module includes a status monitoring unit, a fault identification unit, a fault classification unit, a protection command generation unit, and an alarm unit. Status monitoring unit: Real-time monitoring of the operating status of each module of the system, including sensor data acquisition status, module communication status, top drive actuator operating status, and data storage status; Fault identification unit: Based on a preset fault feature library, it analyzes and judges the abnormal data detected to identify the fault type, including but not limited to sensor faults, communication faults, computing faults, and top-drive operation faults; Fault Classification Unit: Based on the degree of impact of the fault on drilling operations, faults are classified into three levels: minor faults, general faults, and serious faults. Different levels correspond to different handling strategies. Protection command generation unit: Generates corresponding protection commands for different levels of faults. For minor faults, only control parameters are adjusted. For general faults, the top drive adjustment is paused and fault recovery is attempted. For severe faults, the top drive operation is stopped immediately and the relevant control circuits are disconnected. Alarm unit: When a fault is detected, an alarm signal is sent to the operator through audible and visual alarms and remote notification. At the same time, the time of the fault occurrence, the fault type and the fault handling process are recorded to provide a basis for fault diagnosis.

17. A top drive intelligent control method based on drill string mechanical feedback, characterized in that, The top drive intelligent control system as described in any one of claims 1-16 comprises the following steps: Step 1: System initialization and parameter configuration; Step 2: Mechanical parameter acquisition and fusion processing; Step 3: Calculation of drill string torsional characteristics; Step 4: Solve for the angle between the target tool face and the ground; Step 5: Generation and execution of top drive control commands; Step 6: Closed-loop optimization and control; Step 7: Fault monitoring and handling; Step 8: Job completed and system reset.

18. The intelligent control method for top drive based on drill string mechanical feedback according to claim 17, characterized in that, Step 1 is as follows: Start the top drive intelligent control system based on drill string mechanical feedback, complete the self-check and initialization of each module, including sensor calibration, communication link establishment, model parameter loading and storage device initialization; configure the system basic parameters according to the drilling design scheme and drill string combination information, including drill string geometric parameters, wellbore trajectory design parameters, top drive equipment parameters and control strategy threshold parameters, and the system enters standby state.

19. The intelligent control method for top drive based on drill string mechanical feedback according to claim 17, characterized in that, Step 2 includes the following sub-steps: Step 2.1: Continuously collect ground torque, suspended weight, standpipe pressure, mechanical drilling speed, well depth and trajectory parameters through the ground parameter acquisition unit of the drill string mechanical sensing module, and transmit them to the data preprocessing unit after signal conditioning; Step 2.2: Receive tool face angle, azimuth angle, well inclination and downhole torque feedback data transmitted from the downhole measurement while drilling (MWD / LWD) system through the downhole parameter receiving unit, and transmit them to the data preprocessing unit; Step 2.3: The data preprocessing unit performs analog-to-digital conversion on the analog signals acquired by the ground parameter acquisition unit, parses the format of the data received by the downhole parameter receiving unit, and uses a filtering algorithm to remove noise interference from the data. The time stamp synchronization is used to achieve spatiotemporal alignment between the ground parameters and the downhole parameters. Step 2.4: The mechanical state fusion unit uses a multi-source data fusion algorithm to fuse the preprocessed surface parameters and downhole parameters to construct a drill string mechanical state dataset; Step 2.5: The torsion state estimation unit establishes a real-time estimation model of the torsion state of the drill string based on the fused drill string mechanical state dataset, and calculates the real-time torsion trend of the drill string through the model.

20. The intelligent control method for top drive based on drill string mechanical feedback according to claim 17, characterized in that, Step 3 includes the following sub-steps: Step 3.1: The model storage unit of the drill string torsion calculation module calls the drill string elastic torsion model, friction model and anti-torsion release prediction model that match the current drill string combination; Step 3.2: Based on the real-time well depth, wellbore trajectory parameters, and drill string assembly information, the transfer gain calculation unit sends N small-amplitude step rotation commands to the top drive using a step test method. The command time and the corresponding bottom hole rotation data transmitted back from the downhole measurement-while-drilling system are recorded. After the data reaches a steady state, the steady-state bottom hole rotation is calculated using the truncated averaging method, thus obtaining the transfer gain G. θ For the calculated G θ Low-pass filtered EWMA updates are performed online to ensure the real-time performance and accuracy of stiffness parameters; Step 3.3: Solving the torsion angle distribution element based on the ground torque T surf Equivalent torsional stiffness k of drill string eq The torsion angle distribution Δθ of the drill string along the well depth direction is calculated using a piecewise accumulation algorithm; Step 3.4: The anti-torsion release prediction unit uses the anti-torsion release prediction model, combined with torsion angle distribution data and real-time drilling parameters, to predict the amplitude and trend of drill string anti-torsion release that may occur during the tool face adjustment process. Step 3.5: The friction torque reverse thrust unit uses the ground-measured torque T meas With elastic transmission torque T el The difference.

21. The intelligent control method for top drive based on drill string mechanical feedback according to claim 20, characterized in that, In step 3.2: Transfer gain G θ The calculation formula is: Among them, G θ For transfer gain (rad / rad); Δθ top Δθ is the small step angle (rad) transmitted from the ground. bottom This corresponds to the steady-state wellbore rotation angle (rad).

22. The intelligent control method for top drive based on drill string mechanical feedback according to claim 20, characterized in that, In step 3.3: the static relationship of the torsion angle distribution Δθ is: After overall equivalence, the calculation formula is: Where Δθ is the drill string twist angle (rad); TL i G represents the torque load (N·m) on the i-th segment of the drill string; i J represents the shear modulus (Pa) of the drill string material in the i-th segment; i Let be the moment of inertia (m) of the i-th segment of the drill string. 4 T is the ground torque (N·m); k eq The equivalent torsional stiffness of the drill string is (N·m / rad). G is the shear modulus of the drill string material (Pa), and J is the moment of inertia of the drill string section (m). 4 ), L eq The equivalent length of the drill string is (m).

23. The intelligent control method for top drive based on drill string mechanical feedback according to claim 20, characterized in that, In step 3.5: the reverse friction torque T fric The calculation formula is: T fric ≈T meas -T el , among which, T fric T is the frictional torque (N·m); meas The measured torque on the ground (N·m); T el For elastically transmitting torque (N·m), T el =k eq *θ top θ top Ground rotation angle (rad).

24. The intelligent control method for top drive based on drill string mechanical feedback according to claim 17, characterized in that, Step 4 includes the following sub-steps: Step 4.1: The trajectory analysis unit of the target tool face solution module receives and analyzes the drilling trajectory design data to determine the target azimuth, target well inclination angle and trajectory curvature at the current stage; Step 4.2: The desired tool face generation unit generates the desired tool face angle based on the trajectory analysis results and real-time wellbore trajectory feedback data. Step 4.3: The angle difference calculation unit uses the signed shortest angle difference algorithm to calculate the current tool face angle θ. b With the expected tool face angle The difference Δθ between them is used to handle periodicity and cross-boundary jump problems in the 0-360° angle range; Step 4.4: Ground corner compensation unit combined with transfer gain G θ Reverse torque release trend, friction torque T fric Based on the drill string delay characteristics, compensation calculations are performed on the shortest angle difference Δθ to obtain the required ground rotation angle Δθ. top ; Step 4.5: The angle verification unit judges the calculated ground angle Δθ. top If the problem is within the limits of the top drive mechanism, an alarm signal will be output and the process will return to step 3 for recalculation. If the problem is within a reasonable range, Δθ will be adjusted accordingly. top Transmitted to the top drive intelligent control module.

25. The intelligent control method for top drive based on drill string mechanical feedback according to claim 24, characterized in that, In step 4.3: the formula for calculating the difference Δθ is: Δθ=((TF2-TF1+180)mod 360)-180 Where Δθ is the signed shortest angle difference; TF1 is the current toolface angle θ. b ;TF2 is the desired tool facet angle. mod is the modulo operation.

26. The intelligent control method for top drive based on drill string mechanical feedback according to claim 24, characterized in that, In step 4.4: the model assumption is: θ b ≈G θ *Δθ top -Δθ loss Solving for: Where, Δθ top θ is the angle by which the ground should rotate. n This is the current bottom hole tool face angle; Δθ is the desired bottom hole tool face angle. loss This refers to the angular loss, including but not limited to the reverse torsion angle and the angular loss caused by friction; G θ For transfer gain.

27. The intelligent control method for top drive based on drill string mechanical feedback according to claim 17, characterized in that, Step 5 includes the following sub-steps: Step 5.1: The control strategy selection unit of the top drive intelligent control module selects the control strategy based on the ground rotation angle Δθ. top Based on the size, reverse torque release trend, and drilling conditions, select an appropriate single or combined control strategy from angle compensation strategy, proportional adjustment strategy, amplitude limiting control strategy, and flexible start-up strategy. Step 5.2: The instruction generation unit, based on the selected control strategy and Δθ, top Generate top drive rotation angle command, speed command, and action timing command; Step 5.3: The speed regulation unit dynamically adjusts the top drive speed based on drilling conditions and torque feedback data; Step 5.4: The output mode control unit selects a fixed angle, intermittent angle, or torsion correction output mode according to the size of the tool face deviation; Step 5.5: The resonant frequency detection unit calculates the natural resonant frequency f of the drill string system based on the equivalent torsional stiffness k and moment of inertia I of the drill string. n The calculation formula is: Among them, f n The system's natural resonant frequency is given by f; k is the drill string's equivalent torsional stiffness; I is the moment of inertia; the frequency of the control command and the system's natural resonant frequency are monitored in real time. n The difference; Step 5.6: If the vibration is close to the resonance range, adjust the control command frequency through the vibration damping protection unit; if an abnormal increase in amplitude is detected, immediately stop the top drive rotation and switch to safety mode. Step 5.7: The interface adaptation unit of the control execution module converts the control commands into a format compatible with the top drive control interface, and the action execution unit drives the top drive actuator to accurately complete the rotation angle adjustment, speed regulation and output mode switching actions.

28. The intelligent control method for top drive based on drill string mechanical feedback according to claim 17, characterized in that, Step 6 includes the following sub-steps: Step 6.1: The real-time feedback unit of the control execution module continuously collects the real-time rotation angle, speed, output torque and operating status data of the top drive, and transmits them to the closed-loop optimization unit; Step 6.2: The closed-loop optimization unit compares the real-time feedback data with the target control parameters, calculates the control error e(t), and uses a closed-loop controller with feedforward compensation + PI feedback + rate / amplitude limiting + elastic release strategy to dynamically optimize the control command. Step 6.3: The optimized control commands are retransmitted to the action execution unit to achieve closed-loop optimization and control; at the same time, the data storage and interaction module classifies, stores and compresses various types of data throughout the process, and transmits them to the remote monitoring center in real time.

29. The intelligent control method for top drive based on drill string mechanical feedback according to claim 28, characterized in that, In step 6.2: the control formula is: Where u(t) is the control output; K f Forward coefficients; Let G be the difference between the desired tool facet angle and the current tool facet angle; G be the estimated effective transfer gain; K be the difference between the desired tool facet angle and the current tool facet angle. p This is the proportionality coefficient; e(t) is the control error. θ b (t+τ) is the desired tool face angle considering the transmission delay τ, θ b (t) represents the current tool face angle; K i ∑eΔt is the integral coefficient; ∑eΔt is the integral value of the error; and sat is the limiting function, used to limit the range of the control output.

30. The intelligent control method for top drive based on drill string mechanical feedback according to claim 17, characterized in that, Step 7 is as follows: The status monitoring unit of the fault diagnosis and protection module monitors the operating status of each module of the system and drilling parameters in real time; the fault identification unit analyzes and judges abnormal data based on the fault feature library to identify the fault type; the fault classification unit classifies the fault according to the degree of its impact. The protection instruction generation unit generates corresponding protection instructions for different levels of faults, and the alarm unit issues alarm signals. Operators troubleshoot the faults based on the alarm information and fault records. After the faults are resolved, the system returns to normal operation.

31. The intelligent control method for top drive based on drill string mechanical feedback according to claim 17, characterized in that, Step 8 is as follows: When the drilling operation reaches the preset stage target or completes all drilling tasks, the system outputs an operation completion signal, and the control execution module drives the top drive actuator to reset; the data storage and interaction module organizes and archives all data in this drilling process; each module returns to the initial standby state, waiting for the next operation instruction.

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