A wire-line coring winch for ultra-deep hole drilling

Abstract

The application discloses a wireline coring winch for super-deep hole drilling and relates to the technical field of wireline coring, which comprises the following steps: a preset deviation amount is superimposed on the basis of the feedback rotating speed of a main traction motor, so that the slave traction motor continuously generates driving torque, and the cable tension between the main and slave friction wheels is kept; meanwhile, the first target torque of the main traction motor is taken as the upper limit of the torque of the slave traction motor, and the output torque of the slave traction motor automatically follows the change of the main traction motor; in addition, the cable tension is detected in real time through a slack compensator, a local PLC performs PID operation according to the deviation between the current cable tension and a preset constant tension target value, generates a linear speed correction amount, superimposes the linear speed correction amount on the current linear speed of the slave friction wheel, generates a target linear speed of the cable storage reel, and makes the cable storage motor follow the target linear speed, so that the tension closed-loop control is formed. The application can improve the traction capacity and load adaptability of the winch and realize automatic closed-loop adjustment of the tension.

Description

Technical Field

[0001] This application relates to the field of wireline coring technology, and in particular to a wireline coring winch for ultra-deep hole drilling. Background Technology

[0002] Wireline coring is a highly efficient method for core extraction, and its core equipment is the wireline coring winch. Currently, wireline coring winches mainly adopt a single-drum traction structure, meaning that a single motor (hydraulic motor or variable frequency motor) drives one drum to achieve the winding and unwinding of the cable. In terms of drive methods, there are two mainstream solutions: hydraulic drive and variable frequency electric drive. Regarding the control system, existing winches have gradually incorporated PLC-based control systems, enabling functions such as retrieval device position control and tension monitoring.

[0003] However, existing rope coring winches still have shortcomings in the following aspects: 1) Traction force: Existing winches use single-drum drive, and the traction force relies entirely on a single motor. As the coring depth increases (especially in ultra-deep holes above 5000 meters), the cable length increases and the load increases, making the output capacity of the single motor a limiting factor. 2) Load adaptability: During deep hole hoisting, as the number of layers of cable wound on the drum increases, the drum's working radius gradually increases. With the cable tension remaining constant, the required driving torque increases proportionally to the drum radius. Under the rated power limitation, the single-motor drive scheme needs to reduce the motor speed accordingly to output greater torque, resulting in a decrease in hoisting speed. In ultra-deep hole (such as above 5000 meters) coring operations, this contradiction of "increasing torque demand and decreasing hoisting speed" is particularly prominent. 3) Tension control: Although existing winches are equipped with tension detection devices, they are mostly used for display and alarm, lacking closed-loop control.

[0004] Currently, there is an urgent need for a winch suitable for wireline coring operations in ultra-deep holes of 5,000 meters or even more than 10,000 meters. Summary of the Invention

[0005] The purpose of this application is to provide a wireline coring winch for ultra-deep hole drilling that improves traction capacity and load adaptability, and enables automatic closed-loop tension adjustment.

[0006] To achieve the above objectives, this application provides the following solution: In a first aspect, this application provides a wireline coring winch for ultra-deep hole drilling, comprising: a control end, an electrical control system, a traction mechanism, a cable laying mechanism, a slack compensator, and a cable storage mechanism; the electrical control system includes a local PLC, a master station frequency converter, a slave station frequency converter, and a cable storage frequency converter; the traction mechanism includes a main friction wheel, a main traction motor, a slave friction wheel, and a slave traction motor; the cable storage mechanism includes a cable storage motor and a cable storage drum.

[0007] The local PLC is used to: generate the first target rotational speed of the main friction wheel according to the target cable speed command sent by the control terminal and send it to the main station frequency converter.

[0008] The master station frequency converter is used to: calculate the first target torque of the main traction motor based on the first target speed of the main friction wheel and the current speed fed back by the main traction motor, with the speed of the main traction motor following the first target speed as the control target, drive the main traction motor according to the first target torque, and send the first target torque to the slave station frequency converter.

[0009] The slave frequency converter is used to: generate a second target torque for the slave traction motor based on a first target torque and the current speed fed back from the slave traction motor, with the first target torque as the upper limit of the torque of the slave traction motor and the speed of the slave traction motor following the second target speed as the control target; and drive the slave traction motor according to the second target torque; the second target speed is the current speed fed back from the master traction motor plus a preset deviation; the preset deviation is used to tension the cable between the master and slave friction wheels.

[0010] The slack compensator is used to: sense the current tension of the cable and convert it into a corresponding pressure signal to be output to the local PLC.

[0011] The local PLC is also used to: calculate the current tension of the cable based on the pressure signal sent by the slack compensator; perform PID calculations based on the difference between the current tension of the cable and the preset constant tension target value to obtain the linear speed correction amount of the cable storage drum; determine the current linear speed of the friction wheel based on the current rotational speed fed back from the traction motor; superimpose the linear speed correction amount of the cable storage drum with the current linear speed of the friction wheel to obtain the target linear speed of the cable storage drum; determine the current linear speed of the cable storage drum; and send the target linear speed and current linear speed of the cable storage drum to the cable storage frequency converter.

[0012] The cable storage inverter is used to: generate a third target torque for the cable storage motor based on the current linear speed of the cable storage drum, with the linear speed of the cable storage drum following the target linear speed as the control target, and drive the cable storage motor according to the third target torque.

[0013] The cable winding mechanism is used to guide the cable to move back and forth left and right according to the control instructions issued by the local PLC, so that the cable is neatly wound on the cable storage drum.

[0014] According to the specific embodiments provided in this application, this application has the following technical effects: This application provides a wireline coring winch for ultra-deep hole drilling. By designing a master-slave traction mechanism, a preset deviation is superimposed on the feedback speed of the master traction motor to serve as the second target speed for the slave traction motor. This ensures the slave traction motor continuously generates driving torque, maintaining cable tension between the master and slave friction wheels. Simultaneously, the first target torque of the master traction motor serves as the upper limit of the slave traction motor's torque. When the load changes, the output torque of the slave traction motor automatically follows the change in the master traction motor, achieving a balanced distribution of torque between the master and slave motors. Compared to existing single-motor solutions, this application better balances torque output and lifting speed requirements under variable load conditions caused by changes in drum radius, effectively improving overall traction capacity. Furthermore, a slack compensator monitors cable tension in real time. The local PLC performs PID calculations based on the deviation between the current cable tension and the preset constant tension target value, generating a linear speed correction. This correction is then superimposed on the current linear speed of the slave friction wheel to generate the target linear speed of the cable storage drum. The cable storage motor is then driven by a cable storage frequency converter to follow this target linear speed, thus forming a closed-loop tension control. Compared to existing open-loop monitoring solutions, this technology enables automatic tension adjustment. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 A schematic diagram of a wireline coring winch for ultra-deep hole drilling provided in an embodiment of this application; Figure 2 This is a schematic diagram of the structure of a winch electrical control system provided in one embodiment of this application; Figure 3 This is a schematic diagram of a winch double friction wheel traction mechanism provided in an embodiment of this application; Figure 4 This is a schematic diagram of another winch double friction wheel traction mechanism provided in one embodiment of this application; Figure 5 This is a schematic diagram illustrating the cable tension acquisition principle according to an embodiment of this application; Figure 6 A schematic diagram of a constant tension closed-loop control system for a cable storage winch provided in an embodiment of this application; Figure 7 This is a schematic diagram of the Profinet communication network topology provided in an embodiment of this application; Figure 8 This is a schematic diagram of the remote centralized control main interface of the drilling rig operator's room provided in an embodiment of this application; Figure 9 This is a schematic diagram of the remote centralized control parameter setting interface for the drilling rig operator's room provided in an embodiment of this application; Figure 10 This is a schematic diagram of the appearance of a wireless remote controller provided in an embodiment of this application; Figure 11 This is a schematic diagram of a wireless remote control panel design provided in an embodiment of this application; Figure 12 This is a schematic diagram of the screen interface of a wireless remote control provided in an embodiment of this application. Detailed Implementation

[0017] Currently, the maximum coring depth of land-based wireline coring winches, both domestically and internationally, is approximately 6,500 meters. However, winches designed for marine scientific research at depths of 10,000 meters are difficult to directly apply to ultra-deep-hole coring operations on land due to differences in structure, power, and control modes. Existing deep-hole wireline coring winches, especially those using hydraulic drives and simple mechanical structures, generally suffer from insufficient traction response and tension control, as well as difficulties in automatic rope deployment. These issues make it difficult to meet the stringent requirements for system stability, reliability, and control precision in wireline coring operations exceeding 5,000 meters, and especially those exceeding 10,000 meters.

[0018] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0019] To make the above-mentioned objectives, features and advantages of this application more apparent and understandable, the application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0020] In one exemplary embodiment, such as Figure 1 As shown, a wireline coring winch for ultra-deep hole drilling is provided, comprising: a control end, an electrical control system, a traction mechanism, a cable laying mechanism, a slack compensator, and a cable storage mechanism; the electrical control system includes a local PLC, a master station frequency converter, a slave station frequency converter, and a cable storage frequency converter; the traction mechanism includes a main friction wheel, a main traction motor, a slave friction wheel, and a slave traction motor; the cable storage mechanism includes a cable storage motor and a cable storage drum.

[0021] The local PLC is used to: generate the first target rotational speed of the main friction wheel according to the target cable speed command sent by the control terminal and send it to the main station frequency converter.

[0022] The master station frequency converter is used to: calculate the first target torque of the main traction motor based on the first target speed of the main friction wheel and the current speed fed back by the main traction motor, with the speed of the main traction motor following the first target speed as the control target, drive the main traction motor according to the first target torque, and send the first target torque to the slave station frequency converter.

[0023] The slave frequency converter is used to: generate a second target torque for the slave traction motor based on a first target torque and the current speed fed back from the slave traction motor, with the first target torque as the upper limit of the torque of the slave traction motor and the speed of the slave traction motor following the second target speed as the control target; and drive the slave traction motor according to the second target torque; the second target speed is the current speed fed back from the master traction motor plus a preset deviation; the preset deviation is used to tension the cable between the master and slave friction wheels.

[0024] The slack compensator is used to: sense the current tension of the cable and convert it into a corresponding pressure signal to be output to the local PLC.

[0025] The local PLC is also used to: calculate the current tension of the cable based on the pressure signal sent by the slack compensator; perform PID calculations based on the difference between the current tension of the cable and the preset constant tension target value to obtain the linear speed correction amount of the cable storage drum; determine the current linear speed of the friction wheel based on the current rotational speed fed back from the traction motor; superimpose the linear speed correction amount of the cable storage drum with the current linear speed of the friction wheel to obtain the target linear speed of the cable storage drum; determine the current linear speed of the cable storage drum; and send the target linear speed and current linear speed of the cable storage drum to the cable storage frequency converter.

[0026] The cable storage inverter is used to: generate a third target torque for the cable storage motor based on the current linear speed of the cable storage drum, with the linear speed of the cable storage drum following the target linear speed as the control target, and drive the cable storage motor according to the third target torque.

[0027] The cable winding mechanism is used to guide the cable to move back and forth left and right according to the control instructions issued by the local PLC, so that the cable is neatly wound on the cable storage drum.

[0028] As an optional implementation, the main traction motor is used to drive the main friction wheel to rotate; the driven traction motor is used to drive the driven friction wheel to rotate; the main friction wheel is a friction wheel that is directly connected to the load through a cable.

[0029] As an optional implementation, the first target rotational speed is generated by the local PLC based on the target cable speed command issued by the control terminal, combined with the radius of the main friction wheel.

[0030] As an optional implementation, the current linear speed of the cable storage drum is determined by the local PLC based on the current working radius of the cable storage drum and the current rotational speed fed back by the cable storage motor.

[0031] As an optional implementation, the current working radius of the cable storage drum is determined using the thickness integral method or the linear velocity method.

[0032] As an optional implementation, the preset deviation is positive in cable take-up mode and negative in cable release mode.

[0033] As an optional implementation, the cable laying mechanism includes a cable laying driver, a cable laying motor, a lead screw, and a guide wheel; the cable laying driver is a frequency converter or a servo driver.

[0034] The cable laying driver is used to receive control commands issued by the local PLC, generate a fourth target torque for the cable laying motor, and drive the cable laying motor according to the fourth target torque; the control commands include speed commands and direction commands.

[0035] The cable-laying motor is used to drive the lead screw to rotate, thereby causing the guide wheel to move left and right.

[0036] The guide wheel is used to drive the cable to move left and right under the action of the lead screw.

[0037] As an optional implementation, the cable laying mechanism further includes left and right travel limit switches; the left and right travel limit switches are respectively disposed at both ends of the guide wheel's travel; when triggered by the guide wheel, the left and right travel limit switches respectively send corresponding travel limit signals to the local PLC.

[0038] The local PLC is also used to: generate corresponding turning commands based on the left travel limit signal or the right travel limit signal and send them to the cable laying driver; the corresponding turning commands are used to change the rotation direction of the cable laying motor.

[0039] As an optional implementation, the control terminal includes at least one of a local control box, a host computer in the driller's room of the drilling rig, and a wireless remote controller.

[0040] As an optional implementation, the relaxation compensator includes a hydraulic cylinder, a pressure sensor, and a movable pulley; the movable pulley is located at the other end of the piston rod of the hydraulic cylinder.

[0041] The movable pulley contacts the cable and transmits the sensed cable tension to the hydraulic cylinder.

[0042] The pressure sensor is used to sense the pressure inside the hydraulic cylinder and generate a pressure signal to be output to the local PLC.

[0043] To aid understanding by those skilled in the art, the following embodiments further illustrate the points.

[0044] (1) General introduction.

[0045] To address the needs of deep hole wireline coring operations, this embodiment provides a wireline coring winch (hereinafter referred to as the wireline coring winch or winch) for deep hole drilling, which mainly consists of three parts: a dual-motor master-slave driven traction mechanism, a constant tension automatic cable laying mechanism (cable laying device), and a central control and data communication system.

[0046] The dual-motor master-slave driven traction mechanism uses two friction wheels with a non-rigid connection, and introduces closed-loop synchronous control to solve the problem of uneven load distribution.

[0047] The constant tension automatic cable laying mechanism ensures that the linear speed of the cable storage drum is consistent with the linear speed of the traction mechanism, which can neatly and tightly arrange the cable on the cable storage drum, and can promptly change direction when the cable moves to one end of the cable storage drum.

[0048] The central control system is based on a combination of VFD frequency conversion drive and PLC control (electrical control system), and integrates three control methods: local control, wireless remote control, and remote control from the driller's cabin. It is equipped with a multi-source information acquisition system, utilizing various sensors to acquire winch operating parameters in real time, and achieving data interaction and closed-loop control between various parts through Profinet and Modbus buses. This embodiment significantly improves the automation level, control accuracy, and operational safety of deep-lined coring operations, and can be used for wireline coring at depths of up to 13,000 meters.

[0049] (2) Electrical control system.

[0050] like Figure 2 As shown, the core of the rope coring winch provided in this embodiment is the electrical control system (hereinafter referred to as the electrical control system).

[0051] The electrical control system is powered by an external 380VAC power supply; the core of the electrical control system is the winch control container (VFD room), which integrates PLC control cabinet, VFD control cabinet, etc.

[0052] The winch is controlled by three methods: a local control box, a host computer in the driller's room, and a wireless remote control. The local control box is... Figure 2 The winch local control box; the drilling rig operator's room host computer, i.e. Figure 2 The drilling rig's operator's room has a centralized control system; a wireless remote control is also available. Figure 2 The winch wireless remote control box in the middle.

[0053] The various sensor signals of the winch are connected to the electrical control system through the local control box, and after passing through the VFD room (including frequency converters, contactors, relays, etc.), the corresponding signals are output to the motors of each mechanism (traction, rope laying, cable storage, hydraulic, lubrication and heat dissipation auxiliary mechanisms, etc.) and solenoid valves.

[0054] (3) Specific technical solutions.

[0055] The embodiments of this application achieve high-precision synchronous drive, constant tension automatic cable laying and integrated control of the winch through a series of coherent steps.

[0056] 1) Dual-motor master-slave drive and synchronous control process.

[0057] This embodiment relates to the traction mechanism of a winch, the structure of which is as follows: Figure 3 and Figure 4 As shown, it consists of two non-rigidly connected friction wheels, each driven by an independent motor. Friction wheel 1 is the master friction wheel, and friction wheel 2 is the slave friction wheel.

[0058] The cable laying device uses an encoder-equipped variable frequency motor (i.e., cable laying motor) to drive a lead screw to achieve reciprocating cable laying. Limit switches are installed at both ends of the lead screw of the cable laying device. When the cable laying device runs to the end point and triggers the limit switch, the main control system (i.e., the local PLC) receives this trigger signal and causes the cable laying motor to run in reverse to change direction.

[0059] Figure 3 and Figure 4 In the diagram, friction wheel 1 (cable outlet side, near the winch load side) is on the left, and friction wheel 2 (cable inlet side, near the cable storage winch side) is on the right. The cables on both friction wheels are wound on the same side. The number of turns of the cable on each wheel is primarily determined by the ratio of the maximum cable tension on the cable outlet side (high tension side) to the maximum cable tension on the cable inlet side (low tension side), combined with the friction coefficient of the wheel grooves, using Euler's formula. Increasing the number of turns exponentially increases the upper limit of this tension ratio, thereby increasing the maximum static friction between the friction wheel and the cable. This allows the system to drive heavier loads without slippage, making it particularly suitable for deep-hole coring operations requiring high traction and long-distance transport.

[0060] Step 1: Master station speed closed-loop control and command generation.

[0061] The main control system sends the target speed command to the master station frequency converter. The master station frequency converter drives the main traction motor and receives the real-time speed signal from the encoder (master station encoder) installed on the main traction motor. The main traction motor drives the main friction wheel to rotate. Internally, the master station frequency converter compares the target speed command with the actual speed feedback from the master station encoder, calculates and adjusts it through the built-in speed loop PID controller, and outputs a stable motor control signal to make the linear speed of the main friction wheel reach and maintain the set value (i.e., the target speed). The input of this step is the target speed command, and the output is the stable actual linear speed of the main friction wheel and the real-time torque command of the main traction motor.

[0062] The main control system refers to the core control unit of the winch, which is responsible for receiving external commands and internal status data, processing them through preset algorithms, and issuing control commands to realize the automated operation, safety protection, and optimized management of the winch.

[0063] Step 2: Balance the load torque between the master and slave motors.

[0064] To achieve reasonable load distribution between the two friction wheels and prevent single motor overload, a torque balancing strategy is introduced into the system. The slave inverter is configured in torque-limited following mode. The slave inverter receives the real-time torque command of the main traction motor generated in step 1 and uses it as the reference upper limit or following target for its own torque output, thereby ensuring that the torque output of the two traction motors matches under the premise that the speeds of the main and slave traction motors are the same, achieving high-precision synchronization and load balancing. The input of this step is the real-time torque command of the main inverter, and the output is the final control signal of the slave traction motor after torque limiting or adjustment.

[0065] This step employs a "speed deviation + torque limiting" control strategy suitable for flexible connections. The master inverter operates in speed control mode, while the slave traction motor follows the real-time torque command from the master inverter in a closed-loop torque loop. A small deviation (typically ±5%~10%) is added to the speed setpoint of the slave traction motor. The torque limiting value of the slave traction motor is the actual output torque of the master traction motor. After activating this control strategy, the speed deviation causes the wire rope to quickly tension, saturating the speed loop of the slave traction motor. The output torque is then constrained by the torque limiting, thus achieving torque following the master traction motor.

[0066] 2) Control process of constant tension automatic cable laying mechanism.

[0067] This embodiment relates to the constant tension control of the cable between the traction mechanism and the cable storage drum, and its tension acquisition principle is as follows: Figure 5 As shown, cable tension is indirectly obtained by measuring the pressure of the hydraulic cylinder of the slack compensator. The slack compensator can also be used to: maintain stable cable tension and prevent the cable from becoming too loose or too tight momentarily when the traction winch and the cable storage winch are not synchronized.

[0068] exist Figure 5 In this structure, the relaxation compensator includes a hydraulic cylinder and a movable pulley connected to its right side. A pressure sensor is mounted on the hydraulic cylinder.

[0069] Step 3: Real-time tension acquisition and calculation of the cable.

[0070] A pressure sensor installed on the hydraulic cylinder of the slack compensator in the cable storage mechanism collects the pressure signal P inside the hydraulic cylinder in real time and uploads it to the main control system. The main control system calculates the force f on the piston rod end based on the effective working area S of the hydraulic cylinder piston using the formula f = P × S. This force is directly related to the cable tension F (which can usually be obtained by considering the mechanical efficiency of the movable pulley, etc.). The input to this step is the analog signal of the hydraulic cylinder pressure, and the output is the calculated real-time cable tension value F.

[0071] Step 4: Calculate tension deviation and generate speed correction command.

[0072] The main control system compares the real-time cable tension value F calculated in step 3 with the set constant tension target value F_set to obtain the tension deviation ΔF (ΔF = F_set - F). This deviation signal is sent to the tension closed-loop controller (such as a PID controller). The controller calculates according to a predetermined control algorithm based on the sign and magnitude of ΔF and outputs a command Δv (i.e., linear speed correction amount or speed correction command) to correct the speed of the cable storage drum motor (i.e., the cable storage motor). The cable storage frequency converter receives Δv and executes speed control to correct the speed of the cable storage motor in real time. The inputs to this step are the real-time tension value F and the target tension value F_set, and the output is the linear speed correction command Δv of the cable storage drum.

[0073] Setting a constant tension target value ensures that the tension on the rope is within a reasonable range during rope laying (i.e., cable laying), neither too low, which would cause the rope to become loose and tangled, nor too high, which would cause the rope to become too tight, deformed, or damaged.

[0074] Step 5: Matching the linear speed of the cable storage drum and maintaining constant tension.

[0075] The control system (i.e., the local PLC) knows the real-time linear velocity of friction wheel 2 (i.e., the current linear velocity of the friction wheel) v0 (as guaranteed by steps 1 and 2). Simultaneously, it measures the real-time angular velocity ω of the cable storage drum motor via an encoder, and combines this with the real-time working radius r of the cable storage drum (which can be calculated from the number of cable layers or directly measured), to calculate the current linear velocity v1 of the cable storage drum (v1 = ω × r). v1, v0, and the speed correction command Δv obtained in step 4 are then combined for calculation (e.g., the target linear velocity v1). = v0 + Δv), generating the final speed command for the cable storage drum motor (sent to the cable storage frequency converter). The cable storage drum drive motor (i.e., the cable storage motor) is adjusted by the cable storage frequency converter so that its linear speed v1 dynamically tracks v0. When v1 and v0 are consistent and the tension stabilizes at F_set, dF / dt = 0, achieving constant tension control. For the principle of the cable storage winch constant tension closed-loop control system, please refer to [link to relevant documentation]. Figure 6 The inputs for this step are the linear velocity of the traction motor (i.e., the current linear velocity of the friction wheel) v0, the current linear velocity of the cable storage drum v1, and the speed correction command Δv. The output is the final control command for the cable storage drum motor to maintain constant tension.

[0076] That is, under the action of the constant tension PID controller, the control system changes the cable winding and unwinding by adjusting the speed difference between v1 and v0, so that the actual tension F approaches F_set. When the PID regulation enters steady state, the actual tension F = F_set, at which point Δv = 0, v1 and v0 are consistent, dF / dt = 0, and constant tension control is achieved.

[0077] The real-time working radius of the cable storage drum can be calculated using either the thickness integration method or the linear velocity method. For example, for the linear velocity method, it is calculated using the formula D = (i × V) / (π × n); where D represents the real-time working diameter of the cable storage drum; V represents the real-time linear velocity of the cable at the cable storage drum (under constant tension control in a steady state, its value is equal to the real-time linear velocity from the friction wheel), which can be measured in real time; n represents the real-time rotational speed of the cable storage motor; and i represents the reduction ratio between the cable storage motor and the cable storage drum, i.e., the mechanical transmission ratio. In this embodiment, a direct drive method is used, so i = 1. For the thickness integration method, it is calculated using the formula D = D0 ± 2 × h × N; where "±" indicates that + is taken when reeling in the cable and - is taken when releasing the cable; D0 represents the diameter of the cable storage drum when it is empty; h is the thickness of a single layer of cable (i.e., the cable diameter); and N is the total number of turns made by the cable storage drum.

[0078] Figure 6 This is a standard PID control process, where c(t) is the linear velocity v1 of the cable reel, and u(t) is the linear velocity correction Δv of the cable reel.

[0079] 3) Integrated control and data communication.

[0080] This embodiment enables local, remote, and wireless multi-control of the winch. The Profinet communication network topology is as follows: Figure 7 As shown.

[0081] Step 6: Acquisition and summarization of multi-source control commands.

[0082] The core PLC of the winch's electrical control system (such as Siemens S7-1500) acquires commands and data through the following parallel channels: a) Reading button / knob signals from the operation panel (i.e., human-machine interface) of the local control box, such as winch cable winding / unwinding signals, single-action / linkage (i.e., cable storage drum controlled independently, or synchronously linked with the traction mechanism) signals, etc. Single-action (cable storage drum controlled independently) means that there is no synchronous linkage between the various mechanisms, and it is only used for emergency manual control in case of maintenance, debugging, or failure; linkage refers to the synchronous control mode of cable storage drum and traction mechanism mentioned above; b) Reading commands and data from the upper computer in the driller's room of the drilling rig (whose human-machine interface is as follows) via the Profinet industrial Ethernet bus. Figure 8 , Figure 9 (a) Receives remote control commands and parameter settings, such as winch cable winding / unwinding commands, and sets parameters as mentioned above for constant tension; c) Receives commands from a wireless remote control (whose appearance and panel are shown in the image) via a 434MHz wireless communication module. Figure 10 , Figure 11 As shown, the screen (monitor) interface is as follows: Figure 12 The PLC sends operation commands (as shown). Simultaneously, it aggregates the status data from each inverter, the speed / position feedback from all encoders, and the (cable) tension data from the pressure sensor.

[0083] The three control methods described above have essentially the same control functions, constituting multi-location control. Since local control has the highest control authority, switching between these three control methods can be achieved on the local control HMI, avoiding conflicts.

[0084] Figure 7 In the middle, the lower-level PLC0 is a lower-level PLC used for winch control. Its inputs consist of sensors from various components or modules of the winch, as well as control panel handles, switch knobs, and potentiometers, etc., and its outputs are sent to electrical actuators such as relays, contactors, and solenoid valves.

[0085] Traction motor 1 frequency converter is the master frequency converter, and traction motor 2 frequency converter is the slave frequency converter. The wireless remote control receiver is used to receive commands sent by the wireless remote control. HMI (Human-Machine Interface). The winch local control HMI is the HMI of the winch local control box. The drilling rig main control system HMI is the HMI of the drilling rig operator's room.

[0086] Figure 8 In the diagram, the inner and outer limit switches of the compensator indicate whether the inner and outer travel limit switches of the slack compensator are triggered, respectively, and are used to indicate the minimum and maximum travel positions of the slack compensator. For example... Figure 5 When the piston rod inside the hydraulic cylinder of the relaxation compensator is in the leftmost position, the internal limit switch of the compensator is triggered; when the piston rod inside the hydraulic cylinder of the relaxation compensator is in the rightmost position, the external limit switch of the compensator is triggered.

[0087] Separate mode refers to the independent control of the cable storage drum (i.e., single-action), not linked to the traction mechanism for synchronization. It is used for debugging or emergency control in case of synchronization failure, similar to manual or independent control. Local control refers to controlling the winch from the local control box of the winch, forming one of the three control modes of the winch, along with the remote centralized control from the drilling rig operator's room and the wireless remote control.

[0088] in addition, Figure 8 The dashed lines representing the tension and velocity in the lower left corner are the coordinate axis grid lines.

[0089] Figure 8 All parameters displayed (such as cable length, tension, internal tension, speed, and slack compensator stroke) are real-time measured values. Among them, cable length refers to the current length of the cable released by the winch (measured by the sensor on the cable release pulley on the guide wheel); tension refers to the current load tension at the free end of the cable (measured by the sensor on the cable release pulley pin shaft), which is the torque of the main traction motor of the traction friction wheel 1; internal tension refers to the constant tension target value F_set; speed refers to the cable winding and releasing speed; and slack compensator stroke refers to the stroke of the piston rod in the hydraulic cylinder.

[0090] Figure 9 In this table, all parameters are set values. Maximum tension refers to the set maximum torque of the main traction motor of traction friction wheel 1, used to limit the maximum load and protect the cable, ensuring it does not exceed the maximum allowable working tension. Acceleration refers to the set maximum acceleration of the cable, set to ensure that the acceleration of the cable during start-up, stopping, and deceleration does not exceed this value. Its effect is to ensure smooth cable operation, especially under heavy loads, as excessive acceleration may lead to unstable control. During winch operation, the acceleration is calculated by measuring the rotational speed on the encoder of the main traction motor of traction friction wheel 1, combined with the mechanical transmission ratio, the diameter of friction wheel 1, and the time interval. Internal tension is the set rope tension, specifically the constant tension target value F_set mentioned earlier. This constant tension means it remains constant within a certain range, that is, between the minimum and maximum internal tension values. Here, the minimum and maximum internal tension values ​​constitute the range setting for this constant tension.

[0091] Figure 11 In the center, the tension control knob is used to set the rope tension. The emergency stop button is used to control whether the winch stops suddenly. When the fast mode knob is turned to the left (FAST position), the winch is in fast mode; when it is turned to the right (NORMAL position), the winch is in normal mode (safety mode). Normal mode means that the winch can only operate at a limited cable speed (generally, the limited cable speed is 1m / s), used for commissioning or safe operation under specific load conditions. The cable release / reel-in knob is used to set the cable release and reel-in.

[0092] Figure 12In the wireless remote control screen, the displayed cable length, tension, and speed are all real-time measured values.

[0093] Step 7: Control logic execution and data mapping communication.

[0094] The local PLC prioritizes and performs comprehensive logic checks on all instructions summarized in step 6, executing synchronous control of the master-slave traction dual motors, constant tension cable laying control, and other safety interlocking logic. The local PLC then sends the processed control instructions to the corresponding frequency converters and actuators. Simultaneously, the local PLC organizes all operating status, sensor data, and alarm information collected in step 6 according to a predefined data block (DB) structure and sends it in real-time via the Profinet network to the drilling rig operator's cabin's host computer and the wireless remote controller. This allows for centralized display on the human-machine interface of the drilling rig operator's cabin and the wireless remote controller, completing the closed-loop control and status monitoring of the entire system.

[0095] For example, when the operator inputs a rapid cable reeling command, the local PLC receives the analog signal collected during cable reeling and, based on the current status of each sensor and under the combined calculation of various parameter settings (such as acceleration, maximum tension, internal tension settings, etc.), processes it into the operating signal of the main traction motor of friction wheel 1 (i.e., the speed setpoint of the main traction motor of friction wheel 1, where the speed setpoint is manually set by the electro-proportional operating handle, and a ramp control is introduced to ensure smooth cable operation), and simultaneously outputs the operating signals of the cable storage motor and the cable laying motor, etc.

[0096] This application employs a non-rigidly connected master-slave dual traction motor "speed-torque" closed-loop synchronous control method. Combining speed closed-loop and active load distribution synchronization control strategies, it solves the problems of uneven load distribution, single-motor overload, or slippage that can easily occur with traditional dual winch technology in non-rigid connections where only speed synchronization is performed. The master traction motor uses speed closed-loop control to ensure a baseline speed; the slave traction motor not only uses the actual speed of the master motor (not a given speed) as the target for closed-loop synchronization, but also incorporates the torque command from the master traction motor in real time as a torque limit or following reference for the slave traction motor. This method forms a two-stage closed loop (speed loop and torque loop) through encoder feedback, achieving dynamic load balancing between the two wheels while ensuring strict speed synchronization. This significantly improves the load sharing capability and operational stability of the dual-drive traction mechanism, avoiding wear, vibration, or rope slippage caused by uneven load distribution, and is particularly suitable for deep-hole traction operations with large loads and varying working conditions.

[0097] Furthermore, this application employs a constant tension control mechanism for cable storage based on dynamic matching of linear velocity. A mathematical model of the difference between cable tension and linear velocity is established, and an indirect tension control method is proposed. Cable tension is indirectly detected through a pressure sensor, forming a tension closed loop. The core algorithm does not directly control the motor torque, but rather dynamically calculates the required compensation linear velocity of the cable storage drum based on the tension deviation, and dynamically matches its linear velocity with the constant linear velocity of the traction wheel in real time. The system calculates the variable diameter linear velocity of the cable storage drum in real time and achieves this matching by adjusting the speed of the cable storage motor. This achieves high-precision constant tension control of the cable during continuous changes in the drum radius, effectively preventing cable tangling, cable jumping, and tension impact, ensuring the structural safety and lifespan of the orderly deployment and retrieval of ultra-long cables.

[0098] This application integrates a multi-mode collaborative control system architecture encompassing local, remote, and wireless control. A modular system architecture with a PLC as the central processing unit and integrating three control channels is designed. The system integrates three control modes: local control box control, drilling rig operator's room host computer, and wireless remote control. Through a unified Profinet bus protocol, real-time, bidirectional, and reliable interaction and synchronous display of all control commands, sensor data, and status information are achieved between the local control box, local PLC, drilling rig operator's room host computer (HMI), and wireless remote control. It provides flexible and redundant operation methods adaptable to complex well site environments, enabling geographically separated remote precise control and transparent global status monitoring, significantly improving operational safety and ease of operation.

[0099] The system employs a coupled and coordinated control logic of "speed synchronization - tension control - automatic cable laying". It uses the dual-wheel synchronous control of the traction mechanism as the speed benchmark, the constant tension control of the cable storage mechanism as the connecting link, and the precise position tracking and reversing of the cable laying mechanism as the execution guarantee. The local PLC acts as the brain, uniformly scheduling these three processes to ensure stable traction, constant cable tension, and orderly cable laying throughout the entire cable deployment and retrieval cycle. This achieves coordinated control of the three subsystems: winch traction, cable storage, and cable laying.

[0100] Compared to traditional winches, the winch of this application has the following advantages: (1) Traction winch type: The winch of this application is a traction winch, which is different from the straight pull winch (which only uses the cable storage drum). The traction winch separates traction and cable laying and cable storage, optimizes the force and structural design of the mechanism. The cable storage winch, together with the rope laying mechanism, can realize reliable rope laying under controllable tension, which can better protect the wire rope.

[0101] (2) Modular structure: The winch of this application adopts a split structure of "frame integrated body structure + VFD room", which not only optimizes the overall structure of the winch, making it easy to transport and transfer, but also improves the heat dissipation and maintainability of the winch.

[0102] (3) Full electric drive and automation level: The winch of this application adopts full electric drive and is equipped with a variety of sensors such as pressure, tension and encoder to monitor the real-time working status parameters and operating data of the winch in all aspects, thereby improving the level of automation control.

[0103] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0104] This document uses specific examples to illustrate the principles and implementation methods of this application. The descriptions of the above embodiments are only for the purpose of helping to understand the methods and core ideas of this application. Furthermore, those skilled in the art will recognize that, based on the ideas of this application, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this application.

Claims

1. A wireline coring winch for ultra-deep hole drilling, characterized in that, include: The system includes a control terminal, an electrical control system, a traction mechanism, a cable laying mechanism, a slack compensator, and a cable storage mechanism. The electrical control system includes a local PLC, a master frequency converter, a slave frequency converter, and a cable storage frequency converter. The traction mechanism includes a main friction wheel, a main traction motor, a slave friction wheel, and a slave traction motor. The cable storage mechanism includes a cable storage motor and a cable storage drum. The local PLC is used to: generate the first target rotational speed of the main friction wheel according to the target cable speed command sent by the control terminal and send it to the main station frequency converter; The master station frequency converter is used to: calculate the first target torque of the main traction motor based on the first target speed of the main friction wheel and the current speed fed back by the main traction motor, with the speed of the main traction motor following the first target speed as the control target, drive the main traction motor according to the first target torque, and send the first target torque to the slave station frequency converter. The slave frequency converter is used to: generate a second target torque for the slave traction motor based on a first target torque and the current speed fed back from the slave traction motor, with the first target torque as the upper limit of the torque of the slave traction motor and the speed of the slave traction motor following the second target speed as the control target; and drive the slave traction motor according to the second target torque; the second target speed is the current speed fed back from the main traction motor plus a preset deviation amount. The preset deviation is used to tension the cable between the master and slave friction wheels; The slack compensator is used to: sense the current tension of the cable and convert it into a corresponding pressure signal to be output to the local PLC; The local PLC is also used to: calculate the current tension of the cable based on the pressure signal sent by the slack compensator; perform PID calculations based on the difference between the current tension of the cable and the preset constant tension target value to obtain the linear speed correction amount of the cable storage drum; determine the current linear speed of the friction wheel based on the current rotational speed fed back from the traction motor; superimpose the linear speed correction amount of the cable storage drum with the current linear speed of the friction wheel to obtain the target linear speed of the cable storage drum; determine the current linear speed of the cable storage drum; and send the target linear speed and current linear speed of the cable storage drum to the cable storage frequency converter. The cable storage frequency converter is used to: generate a third target torque for the cable storage motor based on the current linear speed of the cable storage drum, with the linear speed of the cable storage drum following the target linear speed as the control target, and drive the cable storage motor based on the third target torque. The cable winding mechanism is used to guide the cable to move back and forth left and right according to the control instructions issued by the local PLC, so that the cable is neatly wound on the cable storage drum.

2. The wireline coring winch for ultra-deep hole drilling according to claim 1, characterized in that, The main traction motor is used to drive the main friction wheel to rotate; the driven traction motor is used to drive the driven friction wheel to rotate; the main friction wheel is a friction wheel that is directly connected to the load through a cable.

3. The wireline coring winch for ultra-deep hole drilling according to claim 1, characterized in that, The first target rotational speed is generated by the local PLC based on the target cable speed command issued by the control terminal, combined with the radius of the main friction wheel.

4. The wireline coring winch for ultra-deep hole drilling according to claim 1, characterized in that, The current linear speed of the cable storage drum is determined by the local PLC based on the current working radius of the cable storage drum and the current rotational speed fed back by the cable storage motor.

5. The wireline coring winch for ultra-deep hole drilling according to claim 4, characterized in that, The current working radius of the cable storage drum is determined using either the thickness integral method or the linear velocity method.

6. The wireline coring winch for ultra-deep hole drilling according to claim 1, characterized in that, The preset deviation is positive in cable take-up mode and negative in cable release mode.

7. The wireline coring winch for ultra-deep hole drilling according to claim 1, characterized in that, The cable laying mechanism includes a cable laying driver, a cable laying motor, a lead screw, and guide wheels; the cable laying driver is a frequency converter or a servo driver. The cable laying driver is used to receive control commands issued by the local PLC, generate a fourth target torque for the cable laying motor, and drive the cable laying motor according to the fourth target torque; the control commands include speed commands and direction commands. The cable-laying motor is used to drive the lead screw to rotate, thereby causing the guide wheel to move left and right; The guide wheel is used to drive the cable to move left and right under the action of the lead screw.

8. The wireline coring winch for ultra-deep hole drilling according to claim 7, characterized in that, The cable laying mechanism also includes left and right travel limit switches; the left and right travel limit switches are respectively set at both ends of the guide wheel's travel; when triggered by the guide wheel, the left and right travel limit switches respectively send corresponding travel limit signals to the local PLC; The local PLC is also used to: generate corresponding turning commands based on the left travel limit signal or the right travel limit signal and send them to the cable laying driver; the corresponding turning commands are used to change the rotation direction of the cable laying motor.

9. The wireline coring winch for ultra-deep hole drilling according to claim 1, characterized in that, The control terminal includes at least one of a local control box, a host computer in the driller's room of the drilling rig, and a wireless remote controller.

10. The wireline coring winch for ultra-deep hole drilling according to claim 1, characterized in that, The relaxation compensator includes a hydraulic cylinder, a pressure sensor, and a movable pulley; the movable pulley is located at the other end of the piston rod of the hydraulic cylinder. The movable pulley contacts the cable and transmits the sensed cable tension to the hydraulic cylinder; The pressure sensor is used to sense the pressure inside the hydraulic cylinder and generate a pressure signal to be output to the local PLC.

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