Injection head control system and method and coiled tubing operation equipment

Abstract

The invention relates to the technical field of injection heads, and discloses an injection head control system and method and coiled tubing operation equipment, and the system comprises a hydraulic execution unit, an electric control hydraulic valve group, a data acquisition unit and a control unit; the hydraulic execution unit comprises a driving motor for driving the injection head to act, a tensioning oil cylinder for adjusting the tensioning force of the injection head and a plurality of clamping oil cylinders for adjusting the clamping force of the injection head; the electric control hydraulic valve group comprises at least one electric proportional pressure control valve, an electric proportional flow control valve and a plurality of electromagnetic directional valves which are connected with the hydraulic execution unit; the data acquisition unit acquires real-time operation parameters and sends the real-time operation parameters to the control unit, so that the control unit generates control signals according to preset control logic based on the real-time operation parameters and sends the control signals to the electric control hydraulic valve group, and the electric control hydraulic valve group acts based on the control signals; the driving pressure or the driving speed of the driving motor, the tensioning force of the tensioning oil cylinder and the clamping force of the multiple clamping oil cylinders are cooperatively controlled, and the operation safety and efficiency of the system can be remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of injection head technology, and more specifically to injection head control systems, methods, and coiled tubing operation equipment. Background Technology

[0002] Coiled tubing equipment is a new type of equipment in the petroleum machinery field. It is widely used in oil and gas field workover, drilling, completion, logging and other operations, and is known as the "all-purpose workover machine".

[0003] In coiled tubing operations, both the insertion and removal of the coiled tubing from the well are accomplished by the injection head. Currently, the drive and control of the injection head in coiled tubing are entirely hydraulically controlled. Operators manually operate multiple independent hydraulic valves on the control panel to control parameters such as the drive speed, drive force, clamping force, and tension of the injection head chain. Because these control modules are independent of each other, and their settings need to be adjusted in real time and empirically based on dynamic conditions such as tubing weight and wellhead pressure, the entire operation process is cumbersome, highly dependent on the operator's skills and experience, labor-intensive, and lacks response speed and coordination in dealing with unexpected situations.

[0004] While existing technologies have focused on improving the reliability of the injection head drive system itself, such as solving the synchronization problem of multiple motors, their control methods remain at the level of traditional hydraulics or partial manual adjustment. They fail to fundamentally achieve intelligent sensing based on operating conditions and automatic coordination and adaptive control of various execution modules. Therefore, how to enable the injection head drive system to possess intelligent and integrated automatic control capabilities to reduce operational complexity and improve operational safety and efficiency has become an urgent technical problem to be solved in this field. Summary of the Invention

[0005] This invention provides an injection head control system, method, and coiled tubing operation equipment to solve the problems of cumbersome operation, high labor intensity, and high requirements for the professional skills of operators in existing fully hydraulic manual control of injection head movements, which seriously affect the injection head control efficiency, equipment operation stability, and safety.

[0006] In a first aspect, the present invention provides an injection head control system, the system comprising: Hydraulic actuator, electro-hydraulic valve assembly, data acquisition unit, and control unit; The hydraulic actuator includes: a drive motor for driving the injection head, a tensioning cylinder for adjusting the tension of the injection head, and multiple clamping cylinders for adjusting the clamping force of the injection head. The electro-hydraulic valve assembly includes: at least one electro-proportional pressure control valve, at least one electro-proportional flow control valve, and multiple solenoid directional valves connected to the hydraulic actuator. The data acquisition unit is used to acquire real-time operating parameters and send them to the control unit. The real-time operating parameters include at least tubing load and wellhead pressure. The control unit is connected to the data acquisition unit and the electro-hydraulic valve group respectively. It is used to generate control signals according to the preset control logic based on the received real-time operation parameters and send them to the electro-hydraulic valve group so that the electro-hydraulic valve group can act based on the control signals to coordinately control the driving pressure or driving speed of the drive motor, the tensioning force of the tensioning cylinder, and the clamping force of multiple clamping cylinders. The preset control logic is an operation rule formulated based on the input wellhead process operation information.

[0007] This invention replaces traditional manual hydraulic valves with electro-proportional pressure control valves and electro-proportional flow control valves, enabling continuous, precise, and stepless adjustment of pressure and flow. Combined with a data acquisition unit for real-time acquisition of key parameters such as tubing load and wellhead pressure, the control unit can dynamically fine-tune control signals according to changes in operating conditions, ensuring that the adjustment of each execution parameter better matches actual operational needs. Simultaneously, the preset control logic is customized based on wellhead process operation information, avoiding subjective errors caused by human experience judgment. This not only reduces the professional skill requirements of operators and lowers manpower training and usage costs but also further improves the accuracy of parameter control, effectively ensuring the construction quality of coiled tubing insertion and extraction operations. Furthermore, by synchronously controlling the drive motor's drive pressure / speed, the tensioning cylinder's tension force, and the clamping force of multiple clamping cylinders, each parameter dynamically matches with real-time operating conditions, avoiding problems such as chain slippage, coiled tubing wear, and equipment vibration caused by improper adjustment of a single parameter. This greatly ensures the synchronous adaptation of the actions of each execution component of the injection head, improving the overall operational stability and efficiency.

[0008] In one alternative implementation, The electro-proportional pressure control valve in the electro-hydraulic valve assembly includes: an electro-proportional relief valve for controlling the main driving force of the injection head; The electro-proportional flow control valve includes: an electro-proportional motor variable control valve for adjusting the displacement of the drive motor, and an electro-proportional pump displacement control valve for adjusting the injection head speed.

[0009] In this invention, the electro-proportional relief valve, electro-proportional motor variable control valve, and electro-proportional pump displacement control valve are precisely matched with the regulation requirements of the main driving force, drive motor displacement, and injection head speed, respectively. This achieves precise, independent, and coordinated electro-proportional regulation of the core parameters of the injection head main drive system. Compared with the traditional fully hydraulic manual control method for main drive adjustment, this invention solves the problems of rough adjustment of driving force and speed, poor linkage, and lag in response, laying a key hardware foundation for the intelligent operation of the entire injection head control system.

[0010] In one optional embodiment, the electro-proportional pressure control valve in the electro-hydraulic valve assembly further includes: a tension electro-proportional pressure regulating valve for controlling the tension force of the injection head, and a clamping electro-proportional pressure regulating valve for controlling the clamping force of the injection head.

[0011] This invention employs dedicated electro-proportional pressure regulating valves for tension and clamping forces as electro-proportional pressure control valves. This represents a precise electro-hydraulic design for the injection head auxiliary control module. Addressing the core shortcomings of traditional manual hydraulic control of tension and clamping forces—namely, coarse adjustment, poor linkage, and excessive manual intervention—this invention achieves independent, precise, and automated electro-proportional control of the injection head chain tension and clamping forces. Simultaneously, it synergizes with the electro-proportional control of the main drive system, further enhancing the intelligence, stability, and safety of the overall injection head control. It also effectively protects the continuous tubing and equipment components.

[0012] In one alternative embodiment, the plurality of solenoid directional valves include: a clamping state selection valve for switching the operating conditions of the clamping system, a tensioning state selection valve for switching the operating conditions of the tensioning system, and a brake solenoid valve for controlling the braking action of the injection head.

[0013] This invention utilizes dedicated clamping state selection valves, tensioning state selection valves, and brake solenoid valves as electromagnetic directional valves for the clamping system, tensioning system, and braking action, respectively. This enables the electronic, specialized, and coordinated operation of key working condition switching and braking actions in the injection head auxiliary control. It replaces the manual switching of hydraulic valves and manual braking in traditional fully hydraulic manual control, solving the problems of delayed working condition switching, slow braking response, and poor coordination of various actions in the traditional mode. At the same time, it complements the electro-proportional pressure / flow regulating valve, constructing a complete electro-hydraulic control system of "precise proportional adjustment, reliable working condition switching, and rapid braking triggering," further improving the automation, safety, and operational reliability of the injection head control system.

[0014] In one optional embodiment, the hydraulic actuator further includes: an injection head brake component that cooperates with the brake solenoid valve; the control unit is also used to determine whether the preset emergency conditions are met based on the real-time operating parameters, and when the real-time operating parameters meet the preset emergency conditions, generate an emergency control signal and send it to the electro-hydraulic valve group, so that the electro-hydraulic valve group can reduce the driving speed of the drive motor based on the emergency control signal, and control the injection head brake component to start braking.

[0015] This invention constructs an intelligent automatic emergency protection system for sudden working conditions of the injection head by adding an injection head braking component adapted to the brake solenoid valve to the hydraulic actuator unit and giving the control unit automatic judgment of emergency working conditions and step-by-step execution of deceleration and braking. This completely solves the core drawbacks of traditional fully hydraulic manual control, which relies on manual judgment for emergency handling, has delayed operation, and uses a crude braking method. This results in a qualitative improvement in the safety protection capability and intelligence level of the injection head control system, while effectively protecting the equipment and continuous oil pipes from impact damage under emergency working conditions.

[0016] In one alternative implementation, the data acquisition unit is further configured to acquire at least one actual parameter among the drive motor's drive pressure and the coiled tubing lifting or lowering speed and send it to the control unit, so that the control unit can generate a control signal based on the actual parameters, tubing load, and wellhead pressure.

[0017] This invention expands the parameter acquisition dimensions of the data acquisition unit by adding core operational parameters such as drive motor pressure and coiled tubing lifting / lowering speed. This allows the control unit to generate control signals based on the fusion calculation of multi-dimensional operational parameters, rather than relying solely on tubing load and wellhead pressure. Essentially, it constructs a comprehensive operational condition perception and closed-loop feedback control system for the injection head's operating status. This solves the problems of limited control basis, low control signal accuracy, and easy misjudgment of operational conditions in traditional systems with limited parameter acquisition. It further improves the control system's regulation accuracy, operational stability, and operational condition identification accuracy, while also providing data support for predicting equipment anomalies.

[0018] In a second aspect, the present invention provides an injection head control method, applied to an injection head control system of the first aspect or any corresponding embodiment thereof, the method comprising: Obtain real-time operating parameters for the injection head operation, including at least tubing load and wellhead pressure; Based on real-time operating parameters, control signals are generated according to preset control logic and sent to the electro-hydraulic valve group, so that the electro-hydraulic valve group can act based on the control signals to coordinately control the driving pressure or driving speed of the drive motor, the tensioning force of the tensioning cylinder, and the clamping force of multiple clamping cylinders; wherein, the preset control logic is an operation rule formulated based on the input wellhead process operation information.

[0019] The injection head control method of this invention acquires core operating parameters of the injection head operation in real time, such as tubing load and wellhead pressure. This allows the control unit to calculate and adjust the control signal in real time according to the dynamic changes in downhole conditions, achieving dynamic adaptive control of each execution parameter. Furthermore, only wellhead process operation information needs to be input before operation, and corresponding preset control logic needs to be formulated. No manual intervention is required during operation. The fully automated operation, which automatically acquires real-time operating parameters, automatically calculates and generates control signals, and automatically drives the valve assembly, replaces the traditional fully hydraulic manual control method where the operator independently adjusts the driving force through manual valves. The cumbersome operation of adjusting speed, tension, and clamping force fundamentally solves the problems of numerous steps and high real-time adjustment requirements in traditional control operations, significantly reducing the physical labor intensity and mental concentration requirements of operators. Furthermore, the preset control logic is formulated based on the input wellhead process operation information, and can be customized to design the control benchmarks and linkage rules for driving force, speed, tension, and clamping force according to the individual needs of different wellhead geological conditions, operation types, tubing specifications, safety limit parameters, etc. This helps the control strategy of the injection head to be highly compatible with the specific wellhead operation process, ensuring the pertinence and rationality of the control from the source.

[0020] In one optional implementation, a control signal is generated based on real-time operating parameters and according to preset control logic, including: Obtain at least one actual parameter from the drive motor's drive pressure and the continuous tube's lifting or lowering speed; Based on the driving pressure of the drive motor, the tubing load and the wellhead pressure, calculate the target value of the driving pressure of the drive motor, and generate the corresponding control signal for the electro-proportional relief valve based on the target value of the driving pressure. Based on the coiled tubing lifting or lowering speed, tubing load, and wellhead pressure, calculate the target tension force of the tensioning cylinder, and generate the corresponding control signal for the tensioning electro-proportional pressure regulating valve based on the target tension force. Based on the coiled tubing lifting or lowering speed, tubing load, and wellhead pressure, calculate the corresponding clamping force target value for each clamping cylinder, and generate the control signal for the corresponding clamping electro-proportional pressure regulating valve based on each clamping force target value.

[0021] This invention addresses the control requirements of three core parameters—driving force, tension force, and clamping force—by matching them with dedicated multi-dimensional calculation bases. This makes the generation of control signals more targeted, precise, and logical, fully leveraging the adjustment advantages of the electro-hydraulic valve group. It achieves precise independent control and coordinated matching of each core execution parameter of the injection head. Compared with the method of generating control signals by calculating a single parameter, this invention further solves the problems of large control deviations and poor compatibility between the main and auxiliary systems, making the implementation of intelligent control more closely aligned with the actual operating characteristics of the injection head.

[0022] In an optional implementation, after obtaining the real-time operation parameters of the injection head operation, the injection head control method further includes: Determine whether the preset emergency conditions are met based on real-time operation parameters; When the real-time operating parameters meet the preset emergency conditions, an emergency control signal is generated and sent to the electro-hydraulic valve group, so that the electro-hydraulic valve group can reduce the driving speed of the drive motor based on the emergency control signal, and control the injection head brake component to start braking.

[0023] This invention adds a dedicated step-by-step emergency judgment and emergency response process to the conventional intelligent control process of the injection head, deeply integrating emergency protection into the control logic of the entire injection head operation process. Relying on the hardware foundation of the control system, it realizes the automation, intelligence and precision of emergency handling, completely solving the core pain points of traditional manual control, such as reliance on manual emergency handling, delayed response and crude braking method. It significantly improves the safety protection level of injection head operation, and effectively protects the equipment and continuous tubing from impact damage in emergency conditions.

[0024] Thirdly, the present invention provides a coiled tubing operation apparatus, the apparatus including an injection head control system as described in the first aspect above or any corresponding embodiment thereof. Attached Figure Description

[0025] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0026] Figure 1 This is a structural block diagram of the injection head control system according to an embodiment of the present invention; Figure 2 This is a schematic diagram of the electro-hydraulic control system of the injection head; Figure 3 This is a schematic diagram of the structure of another injection head electro-hydraulic control system; Figure 4 This is a schematic diagram of the structure of another injection head electro-hydraulic control system; Figure 5 This is a schematic diagram of the hardware structure of the controller according to an embodiment of the present invention; Figure 6 This is a flowchart illustrating the injection head control method according to an embodiment of the present invention; Figure 7 This is a flowchart illustrating another injection head control method according to an embodiment of the present invention. Detailed Implementation

[0027] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0028] This embodiment provides an injection head control system. Figure 1 This is a schematic diagram of the injection head control system according to an embodiment of the present invention. Figure 1 As shown, the system includes: a hydraulic actuator 101, an electro-hydraulic valve group 102, a data acquisition unit 103, and a control unit 104. The hydraulic actuator 101 includes: a drive motor for driving the injection head, a tension cylinder for adjusting the tension of the injection head, and multiple clamping cylinders for adjusting the clamping force of the injection head; an electro-hydraulic valve group 102 connected to the hydraulic actuator 101 includes at least one electro-proportional pressure control valve, at least one electro-proportional flow control valve, and multiple solenoid directional valves; a data acquisition unit 103 for acquiring real-time operating parameters and sending them to the control unit 104, the real-time operating parameters including at least tubing load and wellhead pressure; and a control unit 104 connected to both the data acquisition unit 103 and the electro-hydraulic valve group 102, for generating control signals based on the received real-time operating parameters according to preset control logic and sending them to the electro-hydraulic valve group 102, so that the electro-hydraulic valve group 102 operates based on the control signals to coordinately control the driving pressure or driving speed of the drive motor, the tension of the tension cylinder, and the clamping force of the multiple clamping cylinders; wherein the preset control logic is a set of calculation rules based on the input wellhead process operation information.

[0029] It should be noted that in this embodiment, the drive motor, tensioning cylinder, and clamping cylinder are the three core actuators of the hydraulic actuator 101. These three components have clearly defined roles and work together to complete core operational actions such as the injection head driving the coiled tubing into and out of the well, and maintaining a fixed depth. They are the key carriers for the injection head to convert hydraulic energy into mechanical energy and realize coiled tubing operations. Specifically, the drive motor receives high-pressure hydraulic oil from the main drive hydraulic circuit, converts hydraulic energy into rotational mechanical energy, and drives the main drive chain of the injection head to rotate through gears, chains, and other transmission mechanisms. This, in turn, drives the clamped coiled tubing to achieve upward lifting (out of the well) and downward lowering (into the well) linear motion, serving as the "power source" for the injection head. The control unit 104, by adjusting the electro-hydraulic valve group, can change the hydraulic oil pressure and flow rate input to the drive motor, thereby achieving precise control of the power and speed of coiled tubing operations.

[0030] In this embodiment, the tensioning cylinder provides adjustable tension to the main drive chain and clamping chain of the injection head. The cylinder's extension and retraction tightens / loosens the chain tensioning wheel, eliminating chain slack and ensuring the chain maintains appropriate tension. This prevents the chain from skipping teeth, slipping, or veering due to excessive looseness, or from aggravating bearing wear and increasing the drive motor load due to excessive tightness. The specific type can be adjusted according to actual needs. For example, this embodiment uses a hydraulic cylinder, which can be used in conjunction with a tensioning electro-proportional pressure regulating valve and a tension state selection valve. Its output tension is precisely adjusted by the electro-proportional pressure regulating valve, and the tension setting is linked to the coiled tubing operating speed, tubing load, and wellhead pressure. If the operating speed increases or the tubing load increases, the control unit 104 automatically increases the tension to match the chain's tension requirements. After operation, the pressure can be released through the state selection valve, allowing the chain to relax for easier equipment maintenance.

[0031] In this embodiment, the clamping cylinder, through its extension and retraction, drives the clamping blocks (also known as slips) of the injection head to clamp the tubing body from both sides, forming a rigid linkage between the tubing and the transmission chain of the injection head. This ensures that the rotational motion of the transmission chain is precisely transmitted to the tubing, causing it to move linearly. Simultaneously, the clamping force can be adjusted according to the working conditions to ensure reliable clamping without damaging the tubing. The specific type and quantity can be adaptively adjusted based on actual needs. For example, in this embodiment, a multi-group clamping position arrangement (such as upper, middle, and lower clamping cylinders) is used, all of which are matched with clamping electro-proportional pressure regulating valves and clamping state selection valves. The clamping force of each group of cylinders can be independently and precisely adjusted through the electro-proportional pressure regulating valves. The set value of the clamping force is linked to the continuous tubing operation speed, tubing load, and wellhead pressure. If the tubing load increases or the lowering speed accelerates, the clamping force is automatically increased to prevent the tubing from slipping on the clamping block. For tubing of different specifications, the clamping force can be precisely matched to avoid slippage due to insufficient clamping force or tubing extrusion deformation / surface wear due to excessive clamping force.

[0032] To further explain, the electro-proportional pressure control valve, electro-proportional flow control valve, and solenoid directional valve in this embodiment are the three core components of the electro-hydraulic valve assembly 102. These three components complement each other and work together to play key roles in precise pressure regulation, precise speed regulation, and switching of operating conditions / circuit on / off states. They are the key carriers for realizing intelligent "electro-hydraulic" control. Specifically, the electrical signals output by the control unit 104 can precisely drive the actions of these three types of valves, thereby regulating the pressure, speed, and action state of the drive motor, tension cylinder, and clamping cylinder in the hydraulic actuator 101. This can replace the manual valve operation of traditional fully hydraulic manual control, achieving automated and precise control of various parameters of the injection head. Specifically, the electro-proportional pressure control valve continuously and steplessly adjusts the working pressure of the hydraulic circuit through proportional changes in the electrical signal. The pressure output has a linear proportional relationship with the input electrical signal (e.g., the larger the electrical signal, the higher the output pressure), ultimately precisely controlling the output force of the hydraulic actuator 101 (e.g., the clamping / tensioning force of the cylinder and the driving torque of the motor).

[0033] In this embodiment, the electro-proportional flow control valve continuously and steplessly adjusts the flow rate of hydraulic oil in the hydraulic circuit by changing the proportionality of the electrical signal. The flow output is linearly proportional to the input electrical signal, ultimately precisely controlling the operating speed / rotation speed of the hydraulic actuator (such as the rotational speed of a motor or the extension / retraction speed of a cylinder). Simultaneously, flow regulation can also indirectly coordinate with pressure regulation to achieve a match between power and speed. The solenoid directional valve uses the switching of an electromagnetic coil to achieve the directional action of the valve core, thereby switching the oil flow direction, on / off state, or operating mode of the hydraulic circuit. It is the basic valve component for realizing the "action triggering, operating mode switching, and circuit on / off" of the hydraulic actuator 101. Its action is driven by the switching electrical signal of the control unit 104, offering advantages such as fast response speed and reliable operation.

[0034] In one specific embodiment, the coordinated control of the electro-proportional pressure control valve, the electro-proportional flow control valve, and the solenoid directional valve includes: a working condition switching stage (i.e., the control unit 104 first sends an electrical signal to drive the clamping / tensioning state selection valve to switch the clamping / tensioning circuit to the working pressure holding condition, providing a stable hydraulic circuit foundation for subsequent pressure regulation; at the same time, it drives the brake solenoid valve to energize, opening the injection head brake and releasing the operating restriction), a precise pressure regulation stage (i.e., the control unit 104 sends a proportional electrical signal to the clamping / tensioning electro-proportional pressure regulating valve and the electro-proportional relief valve based on real-time working parameters, precisely adjusting the clamping force, tension force, and drive motor driving pressure respectively, so that the output force of each actuator matches the current working condition), and a precise speed regulation stage (i.e., the control unit 104 synchronously sends a proportional electrical signal to the electro-proportional pressure regulating valve and the electro-proportional relief valve). The pump displacement control valve and the electro-proportional motor variable control valve work together to regulate the flow rate of the main drive circuit and precisely control the speed of the drive motor. This enables the smooth lowering of the continuous tubing and facilitates emergency handling (if an obstruction or other emergency situation is detected, the control unit 104 first sends a proportional electrical signal to the electro-proportional flow control valve to reduce the flow rate of the main drive circuit and slow down the drive motor; then it sends an electrical signal to the brake solenoid valve to de-energize and trigger the injection head braking; at the same time, it maintains the pressure output of the electro-proportional pressure control valve to maintain the clamping force and prevent tubing from slipping). The operation completion stage (i.e., the control unit 104 first drives the electro-proportional pressure control valve to reset and reduce the pressure; then it drives the brake solenoid valve to de-energize and brake; finally, it drives the clamping / tensioning state selection valve to switch the clamping / tensioning circuit to the pressure relief state, completing the operation) is only an example.

[0035] To further explain, in this embodiment, the tubing load and wellhead pressure correspond to the mechanical stress state of the coiled tubing and the hydraulic environment state at the wellhead / downhole, respectively. Both are collected in real time by dedicated sensors and transmitted to the control unit 104. The tubing load can be collected by a weight sensor (usually installed below the gooseneck of the injection head, above the clamping mechanism at a critical stress position of the coiled tubing, or at the force-measuring support point of the injection head base). When the injection head is operating, the weight sensor detects the axial tension of the tubing in real time. When the load value corresponding to the detected electrical signal suddenly increases from 10kN to 30kN, the control unit 104 determines that the tubing is obstructed and triggers subsequent emergency actions such as deceleration and braking. Wellhead pressure can be measured by pressure sensors (often installed at the pressure measurement ports of oil and gas wellhead flanges, blowout preventer assemblies, and wellhead production trees). If, during operation, the wellhead pressure sensor detects that the pressure rises rapidly from 5 MPa to 15 MPa in real time, the control unit 104 determines that the downhole pressure is abnormal and immediately generates a control signal to reduce the descent speed of the drive motor and at the same time appropriately increase the clamping force to prevent the tubing from moving due to the downhole jacking force.

[0036] To further explain, the wellhead process operation information in this embodiment includes specific wellhead operation safety limits and process specification requirements, such as wellhead specifications, well depth, tubing parameters, operation type, and safety thresholds. These details are manually entered and determined by the operator before operation. The preset control logic in this embodiment is based on the calculation rules formulated from the wellhead process operation information. For different wellheads and different operation types (such as well workover, drilling, completion, and logging), only the input wellhead process operation information needs to be changed or adjusted before operation to customize and generate suitable control logic. This eliminates the need for significant modifications to the system's hydraulic execution unit 101, electro-hydraulic valve group 102, and other hardware. This design allows the system to adapt to wellhead operations in oil and gas fields with different geological conditions and operational requirements, expanding the system's applicability and reducing the cost of adapting equipment to different locations and operating conditions.

[0037] The injection head control system of this invention replaces traditional manual hydraulic valves with electro-proportional pressure control valves and electro-proportional flow control valves, enabling continuous, precise, and stepless adjustment of pressure and flow. Combined with real-time acquisition of key parameters such as tubing load and wellhead pressure by a data acquisition unit, the control unit can dynamically fine-tune control signals according to changes in operating conditions, making the adjustment of each execution parameter more aligned with actual operational needs. Simultaneously, the preset control logic is customized based on wellhead process operation information, avoiding subjective errors caused by human experience judgment. This not only reduces the professional skill requirements of operators and lowers manpower training and usage costs but also further improves the accuracy of parameter control, effectively ensuring the construction quality of coiled tubing insertion and extraction operations. Furthermore, by synchronously controlling the drive motor's drive pressure / speed, the tensioning cylinder's tension force, and the clamping force of multiple clamping cylinders, each parameter dynamically matches with real-time operating conditions, avoiding problems such as chain slippage, coiled tubing wear, and equipment vibration caused by improper adjustment of a single parameter. This greatly ensures the synchronous adaptation of the actions of each execution component of the injection head, improving the overall operational stability and efficiency.

[0038] In this embodiment, the electro-proportional pressure control valve in the electro-hydraulic valve group includes: an electro-proportional relief valve for controlling the main driving force of the injection head; the electro-proportional flow control valve includes: an electro-proportional motor variable control valve for adjusting the displacement of the drive motor, and an electro-proportional pump displacement control valve for adjusting the speed of the injection head.

[0039] It should be noted that the electro-proportional relief valve continuously and proportionally controls the relief pressure of the hydraulic system by inputting electrical signals, such as current / voltage, to achieve stepless adjustment and stable relief of the system pressure. In this embodiment, the electro-proportional relief valve is used to control the main driving force of the injection head. It can achieve continuous, stepless, and precise adjustment of the pressure of the main driving circuit through the electrical signal of the control unit 104, directly corresponding to the magnitude of the main driving force of the injection head. Compared with the coarse adjustment of the traditional manual relief valve, it can dynamically adapt the driving force according to the real-time changes of tubing load and wellhead pressure. For example, under the condition of continuous tubing entering the well under heavy load, the driving force can be precisely adjusted to balance the weight of the tubing and prevent excessive driving force from causing hydraulic shock. When exiting the well, the driving force can be increased as needed to meet the power requirements for tubing lifting. This effectively avoids work stoppage caused by insufficient driving force or tubing stretching and equipment overload damage caused by excessive driving force, ensuring that the main driving force control is highly consistent with the actual working conditions.

[0040] In this embodiment, the electro-proportional motor variable control valve and the electro-proportional pump displacement control valve are also regulated by the corresponding electrical signals emitted by the drive motor displacement control unit 104. By adopting a dual flow control architecture of electro-proportional pump displacement control valve and electro-proportional motor variable control valve, the output displacement of the main hydraulic pump and the displacement of the drive motor are independently electro-proportionally regulated. Compared with the traditional method of adjusting the displacement of a single pump or motor, a wide range of adjustment and fine control of the injection head speed is achieved. The electro-proportional pump displacement control valve regulates the flow from the hydraulic power source end, and the electro-proportional motor variable control valve regulates the flow from the power execution end. The two work together to achieve stepless speed regulation of the injection head, which can meet the low-speed and precise operation requirements near the wellhead and when encountering obstacles, as well as the high-efficiency and high-speed operation requirements of deep well sections, greatly improving the flexibility and accuracy of speed regulation.

[0041] In this embodiment of the invention, by precisely matching the electro-proportional relief valve, electro-proportional motor variable control valve, and electro-proportional pump displacement control valve with the regulation requirements of the main driving force, drive motor displacement, and injection head speed, the precise, independent, and coordinated electro-proportional control of the core parameters of the injection head main drive system is achieved. Compared with the traditional fully hydraulic manual control method of main drive adjustment, it solves the problems of rough adjustment of driving force and speed, poor linkage, and lag in response, laying a key hardware foundation for the intelligent operation of the entire injection head control system.

[0042] In this embodiment, the electro-proportional pressure control valve in the electro-hydraulic valve group further includes: a tension electro-proportional pressure regulating valve for controlling the tension of the injection head, and a clamping electro-proportional pressure regulating valve for controlling the clamping force of the injection head.

[0043] It should be noted that in this embodiment, the tension and clamping forces are independently controlled by dedicated electro-proportional pressure regulating valves, replacing the traditional manual pressure regulating valves / throttle valves. Continuous, stepless, and high-precision pressure adjustment is achieved through the electrical signals of the control unit 104. Based on real-time operating parameters such as tubing load, wellhead pressure, and injection head running speed, the tension and clamping forces can be dynamically adjusted at the microsecond level, completely solving the problems of low precision and large adjustment steps in traditional manual gear-type adjustments. For example, the tension can be precisely increased according to the "negative load condition" of the tubing descent to prevent chain swaying, and the clamping force can be precisely matched according to the tubing specifications. This avoids chain slippage and tubing deviation caused by insufficient clamping force, and also avoids continuous tubing compression deformation and surface wear caused by excessive clamping force. Simultaneously, precise tension adjustment ensures the chain is always in optimal tension, preventing excessively loose chains from skipping teeth or excessively tight chains from exacerbating mechanical wear.

[0044] Note that "negative load condition" means that the load direction is the same as the movement direction of the actuator. For example, when lowering the tubing / drill pipe, the tubing's own weight moves downwards, and the injection head also moves downwards. Because gravity assists the movement, this is a negative load condition. In this embodiment, the specific content of the negative load condition can be determined according to the actual scenario. For example, the motor / cylinder may be carried by the load.

[0045] To further explain, in this embodiment, the tensioning electro-proportional pressure regulating valve and the clamping electro-proportional pressure regulating valve, along with the electro-proportional relief valve and electro-proportional flow control valve of the main drive system, are all subject to unified control by the same control unit 104. That is, dynamic coordination and matching of tension force, clamping force, main drive force, and injection head running speed are achieved through preset control logic. For example, when the injection head speeds up, the control unit 104 can synchronously drive the tensioning electro-proportional pressure regulating valve to slightly increase the tension force, adapting to the tension changes of the chain running; when the oil pipe load increases, the clamping force is synchronously increased to prevent relative slippage between the oil pipe and the chain. This breaks the drawback of independent adjustment and parameter disconnection of tensioning, clamping, and the main drive module in traditional technology, making the actions of each actuator of the injection head highly compatible, greatly improving the overall stability of operation, and reducing vibration and impact during equipment operation.

[0046] In this embodiment of the invention, dedicated electro-proportional pressure regulating valves for tension and clamping forces are configured as electro-proportional pressure control valves. This represents a precise electro-hydraulic design for the injection head auxiliary control module. Addressing the core shortcomings of traditional manual hydraulic control of tension and clamping forces, such as coarse adjustment, poor linkage, and excessive manual intervention, this invention achieves independent, precise, and automated electro-proportional control of the injection head chain tension and clamping forces. Simultaneously, it works in synergy with the electro-proportional control of the main drive system, further enhancing the intelligence, stability, and safety of the overall control of the injection head, and effectively protecting the continuous tubing and equipment components.

[0047] In this embodiment, the plurality of electromagnetic reversing valves include: a clamping state selection valve for switching the operating conditions of the clamping system, a tensioning state selection valve for switching the operating conditions of the tensioning system, and a brake solenoid valve for controlling the braking action of the injection head.

[0048] It should be noted that in this embodiment, the clamping state selection valve and the tensioning state selection valve respectively realize the electronic control switching of the clamping system's "operation / pressure relief" and the tensioning system's "operation / pressure relief," replacing the traditional manual switching of hydraulic valves. Before operation, the control unit 104 can synchronously switch the clamping and tensioning systems to the operating condition through preset commands; when temporary pressure relief adjustment is required during operation, it can be completed simply by sending an electrical signal through the operating terminal; after the operation is completed, it can automatically switch to the pressure relief condition, eliminating the need for operators to manually adjust each valve individually, significantly reducing manual operation steps, improving the overall process efficiency of wellhead operations, and further reducing the on-site labor intensity of operators.

[0049] To further explain, in this embodiment, the brake solenoid valve serves as the core of the electronically controlled trigger for the injection head braking action. It achieves rapid on / off switching of the braking circuit through electrical signals. Compared to traditional manual hydraulic braking, the response speed of electrical signal transmission is much faster than the mechanical transmission speed of hydraulic oil, enabling braking triggering in milliseconds. When the control unit 104 detects emergency conditions such as excessive oil pipe load or obstruction, it can immediately send an electrical signal to drive the brake solenoid valve, initiating the injection head braking. This significantly shortens the braking response time, effectively preventing accidents such as continuous oil pipe stretching, chain slippage, and equipment overload caused by braking lag. Simultaneously, it provides a rapid electronically controlled triggering basis for the coordinated action of "decelerating first, then braking" in emergency situations, further strengthening the operational safety line.

[0050] In this embodiment of the invention, dedicated clamping state selection valves, tensioning state selection valves, and brake solenoid valves are configured as electromagnetic directional valves for the clamping system, tensioning system, and braking action, respectively. This achieves electronic, dedicated, and coordinated operation of the injection head auxiliary control for key working condition switching and braking actions, replacing the manual switching of hydraulic valves and manual braking in traditional fully hydraulic manual control. It solves the problems of delayed working condition switching, slow braking response, and poor coordination of various actions in the traditional mode. At the same time, it complements the electro-proportional pressure / flow regulating valve, constructing a complete electro-hydraulic control system of "precise proportional adjustment, reliable working condition switching, and rapid braking triggering", which further improves the automation, safety, and operational reliability of the injection head control system.

[0051] In this embodiment, the hydraulic actuator 101 further includes an injection head brake component that cooperates with the brake solenoid valve; the control unit is also used to determine whether the preset emergency conditions are met based on the real-time operating parameters, and when the real-time operating parameters meet the preset emergency conditions, generate an emergency control signal and send it to the electro-hydraulic valve group, so that the electro-hydraulic valve group can reduce the driving speed of the drive motor based on the emergency control signal, and control the injection head brake component to start braking.

[0052] It should be noted that the preset emergency conditions are trigger conditions for the system to determine the current danger and decelerate and brake. That is, when the control unit 104 detects an abnormality, over-limit, or loss of control risk through real-time operating parameters, it automatically reduces the speed of the drive motor and activates the braking component of the injection head. Note that the specific content of the preset emergency conditions in this embodiment can be adaptively adjusted according to actual needs. For example, the preset emergency conditions include, but are not limited to, at least one of the following: overspeed of the injection head, overspeed of the drive motor, abnormal hydraulic system pressure, detection of a risk of loss of control under heavy load, triggering of an emergency stop command, over-limit operating load, and sensor malfunction.

[0053] In this embodiment of the invention, by adding an injection head braking component adapted to the brake solenoid valve to the hydraulic actuator, and by giving the control unit the control function of automatic judgment of emergency conditions and step-by-step execution of deceleration and braking, an intelligent automatic emergency protection system for sudden conditions of the injection head is constructed. This completely solves the core drawbacks of traditional fully hydraulic manual control, which relies on manual judgment for emergency handling, has delayed operation, and uses a crude braking method. This results in a qualitative improvement in the safety protection capability and intelligence level of the injection head control system, while effectively protecting the equipment and continuous oil pipes from impact damage under emergency conditions.

[0054] In this embodiment, the data acquisition unit 103 is also used to acquire at least one actual parameter among the drive pressure of the drive motor and the lifting or lowering speed of the coiled tubing and send it to the control unit, so that the control unit can generate a control signal based on the actual parameters, tubing load and wellhead pressure.

[0055] It should be noted that in this embodiment, the driving pressure of the drive motor directly reflects the power output state of the main drive system, while the lifting / lowering speed of the continuous tube reflects the actual operation rhythm of the injection head. The specific acquisition methods can be determined by referring to conventional data acquisition methods in this field, such as setting a pressure sensor in the oil inlet circuit of the drive motor and using the pressure sensor to collect the oil inlet pressure of the drive motor in real time, i.e., the driving pressure.

[0056] In this embodiment of the invention, by expanding the parameter acquisition dimensions of the data acquisition unit, core operational parameters such as drive motor driving pressure and coiled tubing lifting / lowering speed are added. This allows the control unit to generate control signals based on the fusion calculation of multi-dimensional actual operating parameters, rather than relying solely on tubing load and wellhead pressure. Essentially, this constructs a full-dimensional working condition perception and closed-loop feedback control system for the injection head's operating status. This solves the problems of limited control basis, low control signal accuracy, and easy misjudgment of working conditions under traditional limited parameter acquisition. It further improves the control system's regulation accuracy, operational stability, and working condition identification accuracy, while providing data support for equipment anomaly prediction.

[0057] In one specific embodiment, Figure 2 This is a schematic diagram of the electro-hydraulic control system for the injection head. It should be noted that the main drive of the injection head in the diagram provides feedback on the operating status related to power and speed; the auxiliary control of the injection head provides feedback on the status of auxiliary actions such as tensioning, clamping, and braking. Various sensors, such as cameras for visual monitoring and auxiliary condition judgment, weight sensors for collecting tubing load data, speed sensors for collecting coiled tubing lift / lower speed data, pressure sensors for collecting hydraulic parameters such as drive motor pressure, and wellhead sensors for collecting downhole operating parameters such as wellhead pressure, are included. The data acquisition system in the diagram receives and integrates various sensor data from the sensing layer, and also receives wellhead process operation information (input commands) input before operation. The controller (i.e., the control unit) is used to calculate the acquired real-time data and input commands based on preset control logic to generate control signals. The hydraulic system, namely the electro-hydraulic valve group 102 and the hydraulic actuator 101 mentioned above, is used to receive control signals from the controller and drive actuators such as the drive motor, tension cylinder, clamping cylinder, and brake components to complete the coordinated control of the power, speed, tension force, and clamping force of the injection head.

[0058] It should be noted that the electro-hydraulic control system of the injection head in this embodiment includes a main drive system (which is the core power source for the injection head to lift and lower the continuous tubing, and adopts an integrated electro-hydraulic design) and an auxiliary control system (which is the core for ensuring stable transmission of the injection head chain and reliable clamping of the continuous tubing, and also adopts precise electro-hydraulic control to achieve automated and coordinated adjustment of tension and clamping forces).

[0059] In one specific embodiment, the specific structure of the main drive system can be found in [reference needed]. Figure 3 .Depend on Figure 3It can be seen that the structure includes: a hydraulic piston pump 1 (providing the main force to the injection head drive motor, which is a hydraulically controlled variable piston pump), a pilot control handle 2 (used to control the output direction of the hydraulic piston pump 1, and thus control the working direction of the injection head), a pump displacement control valve 3 (an electro-proportional valve used to control the output displacement of the hydraulic piston pump 1, and thus control the speed of the injection head), a replenishment filter 4 (filtering the replenishment oil of the hydraulic piston pump 1), and a replenishment pressure source 5 (used to replenish the hydraulic piston pump 1, so that the piston pump can perform pilot control and reduce the system pressure). Temperature), high-pressure filter 6 (used to filter the main drive system; multiple filters can be used, as shown in 6-1 and 6-2), brake control valve assembly 7 (used to perform logic control on the brake of the injection head; the brake will only open when the brake solenoid valve 11 is open and the main system pressure reaches 500 psi), balance valve 8 (used to control the motor speed when the motor is under "under load" to prevent overspeed; multiple valves can also be used, as shown in 8-1 and 8-2), hydraulic motor 9 (used to convert hydraulic energy into mechanical energy to drive the motor). The system includes: a movable injection head (e.g., rotation); multiple injection heads can be used, as shown in figures 9-1 and 9-2); an injection head brake 10 (a mechanical brake for the injection head, normally closed, releasing hydraulic energy; multiple brake heads can be used, as shown in figures 10-1 and 10-2); a brake solenoid valve 11 (used to control the on / off state of the brake signal, working in conjunction with the brake control valve group 7 to achieve logic control); and a pilot control oil source 12 (provides a pressure source for motor variables, injection head brakes, hydraulic piston pump variables, etc.; multiple pilot control oil sources can be used, as shown in figures 12-1 and 12-2). ), motor variable control valve 13 (an electro-proportional pressure reducing valve that controls the displacement of the hydraulic motor, controls the rotational speed of the motor, and thus controls the speed of the injection head), flushing valve 14 (used to replace the hydraulic oil in the main hydraulic system for cooling the system), pressure control valve block 15 (electro-proportional control, used in conjunction with the hydraulic piston pump 1 to control the maximum output pressure of the piston pump), electro-proportional relief valve 16 (used in conjunction with the pressure control valve block 15 to control the main driving force of the injection head), and hydraulic oil tank 17 (used to store cooling hydraulic oil).

[0060] In one specific embodiment, the specific structure of the auxiliary control system can be found in [reference needed]. Figure 4 .Depend on Figure 4As can be seen, the structure includes: a high-pressure oil source 18 (providing power for the auxiliary control of the injection head, i.e., the tension and clamping force of the injection head chain), a clamping electro-proportional pressure regulating valve 19 (an electro-proportional pressure reducing valve used to adjust the clamping force of the injection head; its set value is related to the load of the injection head), a clamping state selection valve 20 (a solenoid valve used to set the working state of the clamping system, switching between "pressure relief" and "operation" states), a clamping solenoid ball valve 21 (divided into upper, middle, and lower clamping solenoid valves, i.e., 21-1, 21-2, and 21-3 in the figure; note that after the clamping system pressure is adjusted, the solenoid ball valve needs to be closed), an accumulator 22 (used to compensate for leakage in the clamping system and maintain the clamping force during operation, i.e., when the clamping solenoid ball valve 21 is closed), and an upper clamping cylinder 23 (a clamping cylinder group at the top of the injection head used to adjust the clamping force of the chain at the top of the injection head; there can be multiple such cylinders, as shown in 23-1 and 23-2 in the figure). The system includes: a middle clamping cylinder 24 (a clamping cylinder group in the middle of the injection head, used to adjust the clamping force of the chain in the middle of the injection head; there can be multiple clamping cylinders, such as 24-1 and 24-2 in the figure); a lower clamping cylinder 25 (a clamping cylinder group at the bottom of the injection head, used to adjust the clamping force of the chain at the bottom of the injection head; there can be multiple clamping cylinders, such as 25-1 and 25-2 in the figure); a tensioning electro-proportional pressure regulating valve 26 (an electro-proportional pressure reducing valve, used to adjust the magnitude of the tensioning force of the injection head, the setting value of which is related to the working direction and load of the injection head); a tensioning state selection valve 27 (a solenoid valve, used to set the working state of the tensioning system, switching between "pressure relief" and "operation" states); a tensioning hydraulic lock 28 (used to maintain the pressure of the tensioning system); a tensioning cylinder 29 (used to adjust the tension of the chain in the injection head); and a tensioning pressure relief control valve 30 (a solenoid valve, used to open the tensioning hydraulic lock 28 to relieve pressure in the tensioning system).

[0061] It should be noted that in this embodiment, the control unit is the controller. Figure 5 This is a schematic diagram of the hardware structure of the controller according to an embodiment of the present invention. See below for details. Figure 5 This diagram illustrates a suitable structural design for implementing a controller in an embodiment of the present invention. The controller includes a processor (e.g., a central processing unit, a graphics processing unit, etc.) 501, which can perform various appropriate actions and processes based on a program stored in a read-only memory (ROM) 502 or a program loaded from memory 508 into a random access memory (RAM) 503. The RAM 503 also stores various programs and data required for controller operation. The processor 501, ROM 502, and RAM 503 are interconnected via a bus 504. An input / output (I / O) interface 505 is also connected to the bus 504.

[0062] Typically, the following devices can be connected to I / O interface 505: input devices 506 including, for example, touchscreens, touchpads, keyboards, mice, cameras, microphones, accelerometers, gyroscopes, etc.; output devices 507 including, for example, liquid crystal displays (LCDs), speakers, vibrators, etc.; memory devices 508 including, for example, magnetic tapes, hard disks, etc.; and communication devices 509. Communication device 509 allows the controller to communicate wirelessly or wiredly with other devices to exchange data. Although Figure 5 A controller with various devices is shown, but it should be understood that it is not required to implement or have all of the devices shown, and may alternatively implement or have more or fewer devices.

[0063] In particular, according to embodiments of the present invention, the processes described above with reference to the flowcharts can be implemented as computer software programs. For example, embodiments of the present invention include a computer program product comprising a computer program carried on a non-transitory computer-readable medium, the computer program containing program code for performing the methods shown in the flowcharts. In such embodiments, the computer program can be downloaded and installed from a network via a communication device 509, or installed from a memory 508, or installed from a ROM 502. When the computer program is executed by the processor 501, it performs the functions defined in the in-vehicle voice testing method of the embodiments of the present invention. Note that... Figure 5 The controller shown is merely an example and should not be construed as limiting the functionality and scope of use of the embodiments of the present invention.

[0064] In this embodiment of the invention, based on the above-described electro-hydraulic control structure for the injection head, a corresponding embodiment of an electro-hydraulic control method for the injection head is also provided. It should be noted that the steps shown in the flowcharts of the accompanying drawings can be executed in a computer system such as a set of computer-executable instructions, and although a logical order is shown in the flowcharts, in some cases, the steps shown or described may be executed in a different order than that shown here.

[0065] This embodiment provides a method for controlling the electro-hydraulic fluid in an injection head, which is applied to an electro-hydraulic fluid control system for an injection head. Figure 6 This is a flowchart illustrating the injection head control method according to an embodiment of the present invention, as shown below. Figure 6 As shown, the process includes the following steps: Step S601: Obtain real-time operating parameters for the injection head operation. The real-time operating parameters include at least the tubing load and wellhead pressure.

[0066] It should be noted that the relevant content and specific acquisition methods of tubing load and wellhead pressure in this embodiment can be referred to the previous text, and will not be repeated here. Note that the specific content of the real-time operation parameters can be added or deleted according to actual needs, such as adding the coiled tubing operation speed (installing a Hall speed sensor at the injection head drive chain to collect the chain speed, which is then converted into the tubing lifting / lowering speed through the gear ratio).

[0067] Step S602: Based on real-time operating parameters, a control signal is generated according to a preset control logic and sent to the electro-hydraulic valve group so that the electro-hydraulic valve group can act based on the control signal to coordinately control the driving pressure or driving speed of the drive motor, the tensioning force of the tensioning cylinder, and the clamping force of multiple clamping cylinders; wherein, the preset control logic is an operation rule formulated based on the input wellhead process operation information.

[0068] It should be noted that the relevant content of the preset control logic in this embodiment can also be found in the previous text, and will not be repeated here.

[0069] The injection head control method of this invention acquires core operating parameters of the injection head operation, such as tubing load and wellhead pressure, in real time. This allows the control unit to calculate and adjust the control signal in real time according to the dynamic changes in downhole conditions, achieving dynamic adaptive control of each execution parameter. Furthermore, only wellhead process operation information needs to be input before operation, and corresponding preset control logic needs to be formulated. No manual intervention is required during operation. The fully automated operation, which automatically acquires real-time operating parameters, automatically calculates and generates control signals, and automatically drives the valve group, replaces the traditional fully hydraulic manual control method where the operator independently adjusts the valves manually. The cumbersome operation of power, speed, tension, and clamping force fundamentally solves the problems of numerous steps and high real-time adjustment requirements in traditional control operations, significantly reducing the physical labor intensity and mental concentration requirements of operators. Furthermore, the preset control logic is formulated based on the input wellhead process operation information, and can be customized to meet the individual needs of different wellhead geological conditions, operation types, tubing specifications, safety limit parameters, etc., to design the control benchmarks and linkage rules for driving force, speed, tension, and clamping force. This helps the control strategy of the injection head to be highly compatible with the specific wellhead operation process, ensuring the pertinence and rationality of the control from the source.

[0070] This embodiment provides a method for controlling the electro-hydraulic fluid in an injection head, which is applied to an electro-hydraulic fluid control system for an injection head. Figure 7 This is a schematic flowchart of another injection head electro-hydraulic control method according to an embodiment of the present invention, as shown below. Figure 7 As shown, the process includes the following steps: Step S701: Obtain real-time operating parameters for the injection head operation. These parameters must include at least the tubing load and wellhead pressure. For details, please refer to [link to relevant documentation]. Figure 6Step S601 of the illustrated embodiment will not be described again here.

[0071] Step S702: Based on real-time operating parameters, a control signal is generated according to a preset control logic and sent to the electro-hydraulic valve group so that the electro-hydraulic valve group can act based on the control signal to coordinately control the driving pressure or driving speed of the drive motor, the tensioning force of the tensioning cylinder, and the clamping force of multiple clamping cylinders; wherein, the preset control logic is an operation rule formulated based on the input wellhead process operation information.

[0072] Specifically, in step S702 above, generating control signals based on real-time operating parameters and according to preset control logic includes: Step S7021: Obtain at least one actual parameter from the drive motor's drive pressure and the continuous tube lifting or lowering speed.

[0073] It should be noted that the relevant information and acquisition methods of the driving pressure, continuous tube lifting or lowering speed in this embodiment can be found in the previous text, and will not be repeated here.

[0074] Step S7022: Calculate the target value of the drive pressure of the drive motor based on the drive pressure of the drive motor, the tubing load and the wellhead pressure, and generate the corresponding control signal for the electro-proportional relief valve based on the target value of the drive pressure.

[0075] In this embodiment, this step belongs to the closed-loop precise control logic of the drive motor driving pressure. That is, the current actual driving pressure of the drive motor, the tubing load (reflecting the stress on the tubing), and the wellhead pressure (reflecting the downhole hydraulic environment) are the three core input parameters. Through preset control logic (calculation rules based on wellhead process operation information), the target value of the driving pressure adapted to the current working conditions is calculated. Then, the target value is converted into an electrical signal to drive the electro-proportional relief valve to act, so that the actual driving pressure of the drive motor is stabilized at the target value, realizing the dynamic matching of driving force and real-time working conditions, and ensuring smooth operation.

[0076] Step S7023: Calculate the target value of the tensioning force of the tensioning cylinder based on the lifting or lowering speed of the coiled tubing, the tubing load, and the wellhead pressure, and generate the control signal of the corresponding tensioning electro-proportional pressure regulating valve based on the target value of the tensioning force.

[0077] In this embodiment, this step belongs to the tension force closed-loop control logic. The controller acquires the coiled tubing lifting or lowering speed, tubing load, and wellhead pressure. Based on preset control logic, it calculates the target tension force value for the tensioning cylinder and generates a corresponding electrical signal based on this target value. This signal is then output to the tensioning electro-proportional pressure regulating valve to adjust the tensioning circuit pressure, ensuring that the tension force output by the tensioning cylinder dynamically matches the real-time operating conditions and guarantees stable and reliable chain operation. For example, when the coiled tubing lowering speed is 0.3 m / s, the tubing load is 20 kN, and the wellhead pressure is 8 MPa, the controller calculates a target tension force value of 3.5 MPa and outputs a corresponding electrical signal to control the tensioning electro-proportional pressure regulating valve, stabilizing the tensioning cylinder at the target pressure.

[0078] Step S7024: Calculate the corresponding clamping force target value for each clamping cylinder based on the coiled tubing lifting or lowering speed, tubing load, and wellhead pressure; and generate the corresponding control signal for the clamping electro-proportional pressure regulating valve based on each clamping force target value.

[0079] In this embodiment, this step pertains to the graded, independent, and precise clamping control of multiple clamping cylinders. The controller acquires the coiled tubing lifting or lowering speed, tubing load, and wellhead pressure. Based on preset control logic, it calculates the target clamping force value for each clamping cylinder and generates control signals for corresponding clamping electro-proportional pressure regulating valves. This allows for independent adjustment of the output clamping force of each group of clamping cylinders, achieving graded, adaptive, and precise clamping of the coiled tubing, ensuring reliable clamping without damaging the coiled tubing. For example, when the coiled tubing lowering speed is 0.3 m / s, the tubing load is 25 kN, and the wellhead pressure is 8 MPa, the controller calculates the target clamping force values ​​for the upper, middle, and lower groups of clamping cylinders to be 3.0 MPa, 3.5 MPa, and 4.0 MPa, respectively, and outputs corresponding electrical signals to control the clamping electro-proportional pressure regulating valves of each group, achieving stable clamping of the coiled tubing.

[0080] In this embodiment of the invention, by matching dedicated multi-dimensional calculation criteria to the control requirements of three core parameters—driving force, tension force, and clamping force—the generation of control signals becomes more targeted, precise, and logical. This fully leverages the adjustment advantages of the electro-hydraulic valve group, achieving precise independent control and coordinated matching of each core execution parameter of the injection head. Compared to the method of generating control signals through single-parameter calculation, this further solves the problems of large control deviations and poor compatibility between the main and auxiliary systems, making the implementation of intelligent control more closely aligned with the actual operating characteristics of the injection head.

[0081] In practical applications, for abnormal, dangerous operating conditions requiring immediate protection, such as a sudden and significant increase in load causing tubing obstruction or jamming, or a sudden rise / fall in wellhead pressure, these indicate abnormal downhole pressure and necessitate triggering emergency control to protect operational safety. Therefore, after acquiring the real-time operating parameters of the injection head operation, the injection head control method in this embodiment further includes: Step A1: Determine whether the preset emergency conditions are met based on real-time operation parameters.

[0082] In this embodiment, the preset emergency condition refers to the abnormal / dangerous judgment condition that needs to be immediately protected, which is preset in the controller before the operation based on the wellhead process operation information, equipment safety parameters, and coiled tubing operation specifications. The specific content is not limited here, such as the preset emergency condition being the tubing load exceeding the limit or sudden change.

[0083] Step A2: When the real-time operating parameters meet the preset emergency conditions, an emergency control signal is generated and sent to the electro-hydraulic valve group, so that the electro-hydraulic valve group can reduce the driving speed of the drive motor based on the emergency control signal, and control the injection head brake component to start braking.

[0084] It should be noted that this step employs a phased emergency response of "decelerating first, then braking." Specifically, the emergency control signal drives the electro-hydraulic valve assembly to first reduce the drive motor speed, and then activates the injection head braking component to apply the brakes. This creates a gradual, step-by-step soft braking process, rather than the instantaneous hard braking of traditional manual control. This design effectively buffers hydraulic shocks and mechanical inertia under emergency conditions, preventing problems such as continuous tubing stretching and deformation, chain slippage and breakage, sudden pressure increases in the hydraulic circuit, and mechanical structural damage caused by sudden drive motor shutdown and instantaneous brake lock-up. It effectively protects core components such as the drive motor, clamping / tensioning cylinders, and continuous tubing, extending the overall service life of the equipment and reducing operational costs caused by tubing damage.

[0085] In this embodiment of the invention, by adding a dedicated link for real-time emergency judgment and step-by-step emergency handling to the conventional intelligent control process of the injection head, emergency protection is deeply integrated into the control logic of the entire operation process of the injection head. Relying on the hardware foundation of the control system, the automation, intelligence and precision of emergency handling are realized, which completely solves the core pain points of traditional manual control, such as reliance on manual emergency handling, delayed response and crude braking method. It significantly improves the safety protection level of injection head operation, and effectively protects the equipment and continuous tubing from the impact damage of emergency conditions.

[0086] In one specific embodiment, based on Figure 3 and Figure 4 The electro-hydraulic control system for the injection head is proposed, and a control scheme for an intelligent drive hydraulic system for the injection head is described below: 1) Before operation, input the wellhead process operation information into the operating system. ; 2) After the injection head starts, the data acquisition system will use the pre-entered process information. Real-time data acquisition from the injection head, such as the main drive pressure of the injection head motor. The continuous tube lifting or lowering speed V, and the tension of the injection head. With clamping force Pipeline load and wellhead pressure The controller performs logical calculations on parameters such as these, and then sends control commands to each solenoid valve and electro-proportional valve in the hydraulic system to achieve intelligent control. 3) Intelligent operation of the injection head: Based on information acquisition, closed-loop control, real-time feedback and real-time control, the entire system operates intelligently, specifically including: <1> Adaptive cruise control.

[0087] It should be noted that the pressure of the injection head main drive motor... : with tubing load Wellhead pressure Related, among which The driving coefficient is related to the mechanical transmission ratio design of the injection head, and its expression is:

[0088] To further explain, the automatic control system collects information and adjusts the electro-proportional overflow valve 16 in real time to change the pressure of the main drive motor of the injection head. ,in The control coefficient for the electro-proportional relief valve 16. The control current of this control valve is expressed as:

[0089] To further explain, the lifting or lowering speed V of the continuous tube is related to the predefined operation process, i.e., the expression is:

[0090] To further explain, the automatic control system collects information and adjusts the pump displacement control valve 3 in real time to change the pump's displacement, and the motor variable displacement control valve 13 to change the motor's displacement. This "dual-variable" combination controls the lifting or lowering speed V of the continuous tube. The control coefficient for pump displacement control valve 3. This is the control current of the control valve, where For motor variable control valve 13, The control current of this control valve is expressed as:

[0091] The system automatically adjusts the speed to achieve efficient and stable control; <2> Automatic tensioning and clamping control.

[0092] Throughout the operation, the set values ​​of tension and clamping forces are related to the tubing load. Wellhead pressure Related.

[0093] To further explain, tension force : When the oil pipe is in a state of raising or lowering, that is The positive or negative correlation with the tubing load Wellhead pressure Related, The tension coefficient is related to the design parameters of the injection head tensioning cylinder, and its expression is:

[0094] To further explain, the automatic control system adjusts the tension force by collecting information and adjusting the tension proportional pressure regulating valve 26, the tension state selection valve 27, and the tension relief control valve 30 in real time. The tension coefficient is related to the design of the tensioning cylinder of the injection head. , , These are the control signals for the tension proportional pressure regulating valve 26, the tension state selection valve 27, and the tension relief control valve 30, respectively, expressed as:

[0095] To further explain, clamping force It is divided into upper, middle, and lower clamping sections, all of which are related to the oil pipe load. Wellhead pressure Related, The clamping coefficient is related to the design parameters of the injection head clamping cylinder, and its expression is:

[0096]

[0097]

[0098] To further explain, the automatic control system adjusts the clamping force in real time by collecting information and regulating the clamping proportional pressure regulating valve 19, the clamping state selection valve 20, the upper clamping solenoid ball valve 21-1, the middle clamping solenoid ball valve 21-2, and the lower clamping solenoid ball valve 21-3. The clamping coefficient is related to the design of the clamping cylinder of the injection head. , , , , The control signals for the clamping proportional pressure regulating valve 19, clamping state selection valve 20, upper clamping solenoid ball valve 21-1, middle clamping solenoid ball valve 21-2, and lower clamping solenoid ball valve 21-3 are respectively expressed as:

[0099]

[0100]

[0101] To further explain, through system data acquisition and processing, automatic control of tensioning and clamping is achieved, improving efficiency and reducing the workload and requirements for operators.

[0102] <3> Automatic response.

[0103] During operation, the system responds quickly and handles unexpected situations automatically. Specifically, in the event of an obstruction, the control system issues an alarm and adjusts the pump's displacement via pump displacement control valve 3 and motor variable displacement control valve 13, thereby reducing the speed of the injection head. Simultaneously, the control system brakes the drive system via brake solenoid valve 11. This achieves automatic reduction of the drive speed until the machine stops and automatic braking.

[0104] In summary, the electro-hydraulic control system for the injection head in this embodiment is an electro-proportional hydraulic system. By combining the electro-proportional hydraulic system, the data acquisition system, and the controller, a logical relationship is established between the main drive of the injection head and the controller. Through data transmission and closed-loop feedback control, intelligent operations such as adaptive cruise, automatic control, and automatic emergency response of the injection head are realized, reducing the labor intensity of the operator, improving the accuracy of operation, and improving the response efficiency to sudden operational situations.

[0105] This embodiment also provides a coiled tubing installation device, which includes the injection head control system described above. The system is used to implement the above embodiments and preferred embodiments, and details already described will not be repeated. It should be noted that the coiled tubing installation device also includes components such as a vehicle body and a coiled tubing roller assembly (other components can be understood by referring to relevant content in the art). The coiled tubing roller assembly is mounted on the vehicle body, and coiled tubing is wound around the coiled tubing roller. The actuators of the injection head control system can clamp the coiled tubing and overcome the upward force and friction of downhole pressure on the coiled tubing, lowering the coiled tubing into the well, clamping it, or retrieving it from the well, controlling the injection and retrieval speeds of the coiled tubing.

[0106] The coiled tubing operation equipment of this invention, through the injection head control system, effectively avoids the problems of cumbersome operation, high labor intensity, and high requirements for the professional skills of operators in the existing fully hydraulic manual control of the injection head, which seriously affect the control efficiency of the injection head, the stability and safety of equipment operation. It enables the injection head drive system to have intelligent and integrated automatic control capabilities, thereby significantly improving the operating efficiency of the equipment.

[0107] Although embodiments of the invention have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the invention, and such modifications and variations all fall within the scope defined by the appended claims.

Claims

1. An injection head control system, characterized in that, The system includes: Hydraulic actuator, electro-hydraulic valve assembly, data acquisition unit, and control unit; The hydraulic actuator includes: a drive motor for driving the injection head, a tensioning cylinder for adjusting the tension of the injection head, and multiple clamping cylinders for adjusting the clamping force of the injection head. The electro-hydraulic valve group includes: at least one electro-proportional pressure control valve, at least one electro-proportional flow control valve, and multiple solenoid directional valves connected to the hydraulic actuator. The data acquisition unit is used to acquire real-time operating parameters and send them to the control unit. The real-time operating parameters include at least tubing load and wellhead pressure. The control unit is connected to the data acquisition unit and the electro-hydraulic valve group respectively, and is used to generate control signals according to preset control logic based on the received real-time operation parameters and send them to the electro-hydraulic valve group, so that the electro-hydraulic valve group can act based on the control signals to coordinately control the driving pressure or driving speed of the drive motor, the tensioning force of the tensioning cylinder, and the clamping force of the multiple clamping cylinders; wherein, the preset control logic is an operation rule formulated based on the input wellhead process operation information.

2. The injection head control system according to claim 1, characterized in that, The electro-proportional pressure control valve in the electro-hydraulic valve group includes: an electro-proportional relief valve for controlling the main driving force of the injection head; The electro-proportional flow control valve includes: an electro-proportional motor variable control valve for adjusting the displacement of the drive motor, and an electro-proportional pump displacement control valve for adjusting the injection head speed.

3. The injection head control system according to claim 2, characterized in that, The electro-proportional pressure control valve in the electro-hydraulic valve group further includes: a tension electro-proportional pressure regulating valve for controlling the tension of the injection head, and a clamping electro-proportional pressure regulating valve for controlling the clamping force of the injection head.

4. The injection head control system according to claim 1, characterized in that, The plurality of electromagnetic directional valves include: a clamping state selection valve for switching the operating conditions of the clamping system, a tensioning state selection valve for switching the operating conditions of the tensioning system, and a brake solenoid valve for controlling the braking action of the injection head.

5. The injection head control system according to claim 4, characterized in that, The hydraulic actuator further includes an injection head brake component that cooperates with the brake solenoid valve; the control unit is also used to determine whether the preset emergency conditions are met based on the real-time operating parameters, and when the real-time operating parameters meet the preset emergency conditions, generate an emergency control signal and send it to the electro-hydraulic valve group, so that the electro-hydraulic valve group drives the electro-hydraulic valve group to reduce the driving speed of the drive motor based on the emergency control signal, and controls the injection head brake component to start braking.

6. The injection head control system according to any one of claims 1 to 5, characterized in that, The data acquisition unit is also used to acquire at least one actual parameter among the driving pressure of the drive motor and the lifting or lowering speed of the coiled tubing and send it to the control unit, so that the control unit can generate a control signal based on the actual parameter, the tubing load, and the wellhead pressure.

7. An injection head control method, applied to the injection head control system according to any one of claims 1 to 6, characterized in that, The method includes: Obtain real-time operating parameters for the injection head operation, wherein the real-time operating parameters include at least tubing load and wellhead pressure; Based on the real-time operating parameters, a control signal is generated according to the preset control logic and sent to the electro-hydraulic valve group, so that the electro-hydraulic valve group can act based on the control signal to coordinately control the driving pressure or driving speed of the drive motor, the tensioning force of the tensioning cylinder, and the clamping force of multiple clamping cylinders; wherein, the preset control logic is an operation rule formulated based on the input wellhead process operation information.

8. The injection head control method according to claim 7, characterized in that, The step of generating control signals based on the real-time operation parameters and according to preset control logic includes: Obtain at least one actual parameter from the drive motor's drive pressure and the continuous tube's lifting or lowering speed; Based on the driving pressure of the drive motor, the tubing load, and the wellhead pressure, calculate the target value of the driving pressure of the drive motor, and generate the corresponding control signal for the electro-proportional relief valve based on the target value of the driving pressure. Based on the coiled tubing lifting or lowering speed, tubing load, and wellhead pressure, calculate the target tension force of the tensioning cylinder, and generate the corresponding control signal for the tensioning electro-proportional pressure regulating valve based on the target tension force. Based on the coiled tubing lifting or lowering speed, tubing load, and wellhead pressure, calculate the corresponding clamping force target value for each clamping cylinder, and generate the control signal for the corresponding clamping electro-proportional pressure regulating valve based on the clamping force target value.

9. The injection head control method according to claim 7 or 8, characterized in that, After obtaining the real-time job parameters of the injection head job, the method further includes: Determine whether the preset emergency conditions are met based on the real-time operation parameters; When the real-time operating parameters meet the preset emergency conditions, an emergency control signal is generated and sent to the electro-hydraulic valve group, so that the electro-hydraulic valve group, based on the emergency control signal, drives the electro-hydraulic valve group to reduce the driving speed of the drive motor and controls the injection head brake component to start braking.

10. A coiled tubing installation apparatus, characterized in that, The device includes an injection head control system as described in any one of claims 1 to 6.

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