A wellbore measuring device and a method for compensating for roller wear.

Abstract

This application relates to a wellbore measuring device and a method for compensating for roller wear, comprising: a roller, an encoder, a laser displacement sensor, and a controller mounted on the main body of the measuring device; the roller is in contact with a positioning wire rope, the encoder is connected to the roller, and detects the number of rotations of the roller; the laser displacement sensor is installed on the measuring device to measure the real-time distance between the device and the wellbore pit; the controller is connected to both the encoder and the laser displacement sensor, receiving real-time height data provided by the laser displacement sensor and the number of rotations detected by the encoder, and calculating the height deviation between the two measurement methods; based on the deviation, the effective diameter of the roller is dynamically corrected, a wear compensation model is established, and the corrected effective diameter of the roller is used to calculate the measured height. The solution provided in this application can correct the effective diameter of the roller in real time during the early stages of measurement, giving the measuring device good self-adaptive capabilities and improving the reliability of the equipment and the stability of the measurement results under complex working conditions.

Description

Technical Field

[0001] This application relates to the field of wellbore measurement technology, and in particular to wellbore measurement devices and roller wear compensation methods. Background Technology

[0002] In the field of elevator shaft measurement technology, to achieve high-precision measurement of parameters such as elevator shaft dimensions and guide rail deviations, measuring equipment based on traction devices is typically used, which moves vertically within the shaft to collect data. The height of the measuring device relative to the shaft pit is one of the key measurement parameters.

[0003] Currently, common height measurement schemes rely on rotary encoders mounted on the rollers of the measuring device. Based on the theoretical diameter of the rollers and the number of rotations recorded by the encoder, the length of the traction steel wire rope is calculated, and thus the real-time height of the measuring device is deduced. Even with a low-cost encoder, this method can theoretically achieve millimeter-level measurement accuracy when the roller diameter is accurate and there is no wear, offering good economic efficiency and practicality. However, in practical applications, the rollers of rotary encoder-based measurement technology are typically made of wear-resistant materials such as nylon. During long-term friction with the positioning steel wire rope, wear is inevitable, leading to a gradual reduction in the actual effective diameter and causing systematic measurement errors. These errors accumulate with increasing running distance, severely affecting the reliability and repeatability of the measurement results.

[0004] Before each test, the actual diameter of the roller must be measured manually and manually entered into the system for calibration. It is difficult to guarantee the timeliness and accuracy of the calibration. Especially in frequent and continuous measurement tasks, it does not have the ability to automatically detect and compensate for roller wear during the measurement process. The height measurement relies on fixed parameters throughout the process and cannot adapt to the dynamic changes in roller diameter, making it difficult to maintain high-precision measurement in frequent operation.

[0005] Therefore, there is an urgent need for a device and method that can automatically and in real time compensate for roller wear during the measurement process, eliminate manual intervention, overcome error accumulation caused by wear, and improve the automation level and measurement accuracy consistency of the wellbore measurement system. Summary of the Invention

[0006] To address or partially address the problems existing in related technologies, this application provides a wellbore measuring device and a roller wear compensation method, aiming to solve the problem of rapid and automatic compensation for roller wear in the measuring device.

[0007] The first aspect of this application provides a wellbore measuring device, comprising: Traction unit, measuring device, and pit; The traction section, located at the top of the shaft, is used to drive the measuring device. The pit section is fixed to the bottom of the shaft and is connected to the traction section and the measuring device by a positioning steel wire rope. The positioning steel wire rope constrains the rotation of the main body of the measuring device. The measuring device is connected to the traction section via a traction steel wire rope; The main body of the measuring device is equipped with rollers, an encoder, a laser displacement sensor, and a controller; The roller contacts the positioning wire rope and rotates as the main body of the measuring device moves; The encoder is connected to a roller and is used to detect the number of rotations of the roller; A laser displacement sensor is installed at the bottom of the main body of the measuring device to measure the real-time distance between the main body of the measuring device and the bottom of the well pit; The controller connects to both the encoder and the laser displacement sensor, receiving real-time height data from the laser displacement sensor within its measurement range. Simultaneously, it calculates the encoder-detected height using the number of rotations detected by the encoder and the theoretical diameter of the roller. Within the laser displacement sensor's range, it calculates the deviation between the encoder-detected height and the laser displacement sensor-detected height. Based on this deviation, it dynamically corrects the effective roller diameter used for encoder height calculation and establishes a wear compensation model. When the measured height exceeds the laser displacement sensor's range, the controller switches the detection mode to encoder detection, using the corrected effective roller diameter and the number of rotations detected by the encoder to calculate the measured height.

[0008] Optionally, the bottom of the positioning wire rope is installed on the pit section, and the upper end passes through both sides of the measuring device body and connects to the traction section.

[0009] Optionally, the measuring device is positioned at a height of 200-500mm from the bottom of the wellbore when it is started, and the starting height is determined by the laser displacement sensor.

[0010] Optionally, the laser displacement sensor has a range of 5 meters.

[0011] The second aspect of this application provides a method for compensating for roller wear in a wellbore measuring device, comprising: The measuring device is started at a height of 200-500mm from the bottom of the pit. The starting height of the measuring device is measured and provided in real time by the laser displacement sensor. When the height of the measuring device is within the range of the laser displacement sensor, the height data is directly collected by the laser displacement sensor; when the height of the measuring device exceeds the range of the laser displacement sensor, it automatically switches to encoder calculation mode. The encoder records the number of rotations of the roller in real time and calculates the cumulative running height of the measuring device based on the theoretical diameter of the roller. Within the effective range of the measurement data of the laser displacement sensor, the height measured by the laser displacement sensor and the height calculated by the encoder are recorded simultaneously. The height deviation between the two is calculated, and then the actual effective diameter of the roller is calculated based on the height deviation to establish a wear compensation model. During the encoder's stand-alone operation phase, the actual effective diameter of the roller in the wear compensation model is used to replace the theoretical diameter, and the height is calculated to complete the automatic compensation of wear.

[0012] Optionally, a wear compensation model can be established, including: Calculate the actual effective diameter of the roller based on the relationship between the deviation and the known running distance: (3) In the formula, This indicates the deviation between the encoder-detected height and the laser displacement sensor-detected height. This indicates the theoretical diameter of the roller. Indicates the actual effective diameter of the roller. This indicates the number of rotations of the roller.

[0013] The technical solution provided in this application may include the following beneficial effects: By using a laser displacement sensor to provide a high-precision height reference within the effective range, and comparing it with the encoder's calculated value in real time, the actual effective diameter of the roller is dynamically deduced, and a wear compensation model is established. The effective diameter of the roller is corrected in real time in the early stage of measurement, eliminating the need for frequent measurement of the real-time diameter of the roller. This gives the measuring device good self-adaptability, making it suitable for long-term, high-frequency wellbore measurement operations. It improves the reliability of the equipment and the stability of the measurement results under complex working conditions; it overcomes the accumulation of measurement errors caused by roller wear, ensuring that the measurement process can maintain millimeter-level measurement accuracy.

[0014] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Attached Figure Description

[0015] The above and other objects, features and advantages of this application will become more apparent from the more detailed description of exemplary embodiments thereof in conjunction with the accompanying drawings, wherein the same reference numerals generally represent the same components in the exemplary embodiments thereof.

[0016] Figure 1 This is a schematic diagram of the structure of the wellbore measuring device shown in the embodiments of this application; Figure 2 This is a schematic flowchart illustrating the roller wear compensation method for a wellbore measuring device according to an embodiment of this application.

[0017] Reference numerals: 1-Traction section, 2-Measuring device, 3-Pit section, 4-Rolled traction steel wire rope, 5-Laser displacement sensor, 6-Roller, 7-Encoder, 8-Positioning steel wire rope. Detailed Implementation

[0018] Embodiments of this application will now be described in more detail with reference to the accompanying drawings. While embodiments of this application are shown in the drawings, it should be understood that this application may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided to make this application more thorough and complete, and to fully convey the scope of this application to those skilled in the art.

[0019] In the description of this application, it should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0020] Unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0021] The technical solutions of the embodiments of this application are described in detail below with reference to the accompanying drawings.

[0022] Figure 1 This is a schematic diagram of the structure of the wellbore measuring device shown in the embodiments of this application.

[0023] In some implementations, see Figure 1 A shaft measuring device, used for automatic operation within an elevator shaft to measure data such as shaft dimensions and guide rail deviations, includes: Traction section 1, measuring device 2, and pit section 3; The traction section 1 is installed at the shaft opening of the top-level station of the shaft. Its core components include a PLC programmable logic controller, a stepper motor drive system, and a wire rope guide wheel. The traction section 1 controls the lifting and lowering of the main body of the measuring device 2 by releasing or retracting the traction wire rope 4. Two fixed positioning wire ropes 8 are used to position the measuring device 2 on both sides to prevent the measuring device 2 from rotating.

[0024] The pit section 3 is fixedly installed on the ground of the wellbore pit using expansion bolts. The main body of the pit section 3 is a sturdy frame, from which two positioning steel wire ropes 8 extend. These two positioning steel wire ropes 8 are slidably connected to both sides of the measuring device 2 via flexible connectors. The upper end of the positioning steel wire ropes 8 is connected to the traction section 1. The positioning steel wire ropes 8 are used to limit the rotation of the measuring device 2 on the traction steel wire rope 4, ensuring the stability of the measuring device 2's operating posture.

[0025] The measuring device 2 is connected to the traction wire rope 4 and the positioning wire rope 8. The measuring device 2 integrates various sensors for measuring wellbore parameters. The main body of the measuring device 2 is equipped with a roller 6, an encoder 7, a laser displacement sensor 5, and a controller. The roller 6 is made of wear-resistant materials such as nylon, and its theoretical design diameter is 55mm. Its outer circumference is pressed into contact with any of the positioning wire ropes 8. When the measuring device 2 moves up and down with the traction wire rope 4, it slides on the positioning wire rope 8, driving the roller 6 to rotate through friction.

[0026] The encoder 7 is preferably a high-precision rotary encoder. The encoder 7 shaft is coaxially connected to the roller 6 and is used to accurately detect and record the number of rotations N of the roller 6.

[0027] The laser displacement sensor 5 is mounted vertically downwards at the bottom of the measuring device 2 to measure the distance from the measuring device 2 to the ground of the wellbore pit or a specific reference surface on the pit section 3 in real time. The laser displacement sensor 5 has a measuring range of approximately 5 meters and exhibits extremely high absolute measurement accuracy within its range.

[0028] The controller function is integrated into the PLC system of the traction unit 1. The PLC receives pulse signals from the encoder 7 and distance data from the laser displacement sensor 5 wirelessly, and performs subsequent calculations, judgments, and compensation logic. Alternatively, the controller can be an independent calculation module installed on the main body of the measuring device 2.

[0029] In some embodiments, corresponding to the aforementioned application function implementation device embodiments, this application also provides a method for compensating for roller wear in a wellbore measuring device and corresponding embodiments.

[0030] See Figure 2 A method for compensating for roller wear in a wellbore measuring device, comprising: Before measurement begins, the PLC controls the traction unit to slowly lower the measuring device, while simultaneously reading data from the laser displacement sensor in real time. When the laser displacement sensor detects that the distance between the measuring device and the pit floor falls within a preset starting height range, such as 200mm to 500mm, the PLC immediately controls the traction motor to stop and identifies this position as the starting zero point of the measurement. This process is entirely ensured by a high-precision laser displacement sensor, avoiding zero-point errors caused by initial roller diameter errors or previous wear.

[0031] The measuring device starts its ascent from the initial zero point. During the first 5 meters of ascent, within the range of the laser displacement sensor, the measurement process is in laser-dominated mode, and the real-time height output by the measuring device is recorded. The distance traveled is directly measured using a laser displacement sensor. This serves as the baseline truth value for this stage.

[0032] Regardless of the operating mode, the encoder is always working, continuously recording the cumulative number of rotations N of the roller. During the laser-dominated phase, the controller synchronously records at a very high sampling frequency. And N data. Based on the theoretical diameter of the roller, i.e., the initial value of 55mm, the controller simultaneously calculates the corresponding theoretical encoder height value at this moment: (1) In the formula, D represents the theoretical diameter of the roller, and N represents the number of rotations of the roller; During the laser-dominated phase, due to It is considered to be a high-precision true height, therefore it can be measured at the same time. and Compare and calculate the instantaneous height deviation: (2) Theoretically, if the roller is unworn and its initial diameter is precisely D, the height deviation... It should be close to zero. However, due to wear, the actual effective diameter of the roller... It will be less than D, causing the distance calculated by the encoder to be less than D. Less than the actual running distance That is, height deviation .

[0033] Based on the relationship of circular motion, the actual distance traveled... The theoretical height value Through logical operations, we obtain: (3) The actual effective diameter of the roller is determined by ΔH. : (4) The controller utilizes multiple sets of data acquired within the laser range. Based on the N data, the actual effective diameter of the roller is dynamically and accurately determined through real-time calculation, moving average, or fitting. ,this This is the corrected diameter that already includes the current wear condition.

[0034] When the main body of the measuring device continues to rise and the running distance reaches its upper limit, the laser data will become invalid. The controller will automatically trigger a mode switch and enter the encoder compensation mode. In this mode, the laser data is no longer used, and the real-time height is obtained entirely from the data of encoder 7 after compensation.

[0035] The controller replaces the original theoretical diameter D with the obtained actual effective diameter of the roller. This is used for subsequent height calculations. The real-time height calculation formula becomes: (5) Automatic compensation for wear and tear.

[0036] The aforementioned roller wear compensation method for wellbore measuring devices, from startup zeroing, simultaneous dual data acquisition, deviation analysis, diameter calibration to mode switching and compensation calculation, is all pre-set in the controller's automatic roller wear compensation and correction program, and is automatically and continuously executed throughout a complete wellbore measurement process. The measuring personnel only need to issue a start command; there is no need to manually measure and input the roller diameter before measurement. This completely eliminates systematic measurement errors caused by roller wear. Even if new wear occurs on the roller between the current and previous measurements, the wear amount can be automatically calibrated and compensated within the effective laser range at the initial stage of the current measurement, thus ensuring that the entire measurement process maintains millimeter-level high precision.

[0037] The various embodiments of this application have been described above. These descriptions are exemplary and not exhaustive, nor are they limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments. The terminology used herein is chosen to best explain the principles, practical application, or improvement of the technology in the market, or to enable others skilled in the art to understand the embodiments disclosed herein.

Claims

1. A wellbore measuring device, characterized in that, include: Traction unit, measuring device, and pit; The traction section, located at the top of the shaft, is used to drive the measuring device. The pit section is fixed to the bottom of the shaft and is connected to the traction section and the measuring device by a positioning steel wire rope. The positioning steel wire rope constrains the rotation of the measuring device. The measuring device is connected to the traction section via a traction steel wire rope; The main body of the measuring device is equipped with rollers, an encoder, a laser displacement sensor, and a controller; The roller contacts the positioning wire rope and rotates as the main body of the measuring device moves; An encoder is connected to the roller and is used to detect the number of rotations of the roller; A laser displacement sensor is installed at the bottom of the main body of the measuring device to measure the real-time distance between the main body of the measuring device and the bottom of the well pit; The controller is connected to both the encoder and the laser displacement sensor, receiving real-time height data provided by the laser displacement sensor within its measurement range. Simultaneously, it calculates the encoder-detected height using the number of rotations detected by the encoder and the theoretical diameter of the roller. Within the laser displacement sensor's measurement range, it calculates the deviation between the encoder-detected height and the laser displacement sensor-detected height. Based on this deviation, it dynamically corrects the effective roller diameter used for encoder height calculation and establishes a wear compensation model. When the measured height exceeds the laser displacement sensor's measurement range, the controller switches the detection mode to encoder detection, using the corrected effective roller diameter and the number of rotations detected by the encoder to calculate the measured height.

2. The wellbore measuring device according to claim 1, characterized in that: The bottom of the positioning wire rope is installed on the pit section, and the upper end passes through both sides of the measuring device body and connects to the traction section.

3. The wellbore measuring device according to claim 1, characterized in that: The measuring device is positioned at a height of 200-500 mm from the bottom of the well when it is started, and the starting height is determined by the laser displacement sensor.

4. The wellbore measuring device according to claim 1, characterized in that: The range of the laser displacement sensor is 5 meters.

5. A wellbore measuring device and roller wear compensation method, applicable to the wellbore measuring device according to any one of claims 1-4, characterized in that, include: The measuring device is activated at a height of 200-500mm from the bottom of the pit. The activation height of the measuring device is measured and provided in real time by the laser displacement sensor. When the height of the measuring device is within the range of the laser displacement sensor, the height data is directly acquired by the laser displacement sensor; when the height of the measuring device exceeds the range of the laser displacement sensor, it automatically switches to encoder calculation mode. The encoder records the number of rotations of the roller in real time and calculates the cumulative operating height of the measuring device based on the theoretical diameter of the roller. Within the effective range of the measurement data of the laser displacement sensor, the height measured by the laser displacement sensor and the height calculated by the encoder are recorded simultaneously. The height deviation between the two is calculated, and the actual effective diameter of the roller is inferred from the height deviation to establish a wear compensation model. During the encoder's stand-alone operation phase, the actual effective diameter of the roller in the wear compensation model is used to replace the theoretical diameter, and the height is calculated to complete the automatic compensation of wear.

6. The wellbore measuring device and roller wear compensation method according to claim 5, characterized in that, The establishment of the wear compensation model includes: Calculate the actual effective diameter of the roller based on the relationship between the deviation and the known running distance: （3） In the formula, This indicates the deviation between the encoder-detected height and the laser displacement sensor-detected height. This indicates the theoretical diameter of the roller. Indicates the actual effective diameter of the roller. This indicates the number of rotations of the roller.

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