High-temperature shock wave motor controller and high-temperature control bin

Abstract

The utility model discloses a high-temperature shock wave motor controller and a high-temperature control cabin, the high-temperature shock wave motor controller comprises a control module, a driver and a motor; the driver comprises an H-bridge circuit and a high-temperature driving chip; the pulse signal output end of the control module is connected with the input end of the high-temperature driving chip; the output end of the high-temperature driving chip is connected with the input end of the H-bridge circuit, and the output end of the H-bridge circuit is connected with the control signal input end of the motor. The high-temperature control bin comprises a high-temperature shock wave motor controller and further comprises a power source and a shell. The output end of the power supply is electrically connected with the power supply end of the high-temperature shock wave motor controller; and the high-temperature shock wave motor controller is arranged on the shell. The stepping motor control system solves the problem that a stepping motor control system in the prior art cannot meet the requirements of large driving current and operation in a high-temperature environment.

Description

Technical Field

[0001] This application relates to the field of motor control technology, and in particular to a high-temperature shock wave motor controller and a high-temperature control chamber. Background Technology

[0002] Controlled shock wave technology is a purely physical reservoir stimulation method where the intensity, duration, operating area, and number of repetitions are controllable. To achieve the repeated generation of controllable shock waves, the pulsed power drive source can be repeatedly charged under the direct control of a ground controller. After each energetic rod explodes, another energetic rod needs to be added to the energy converter. The power motor can be triggered by picking up shock wave signals or electromagnetic signals to start, driving the energetic rod pusher to replenish the energy converter. The novel application of this technology in shale oil reservoirs requires overcoming the challenges of operating in high-temperature environments.

[0003] A stepper motor is a special type of motor that converts electrical pulse signals into mechanical angular or linear displacement. Its structure and operating principle are similar to those of a synchronous motor. Due to the limited working environment in wells, it is impossible to communicate with a host computer. Therefore, it is necessary to design a motor control board that can work offline and has signal recording and timing functions. Existing stepper motor control systems cannot meet the conditions of high drive current and high temperature environment operation. Utility Model Content

[0004] This application provides a high-temperature shock wave motor controller and a high-temperature control chamber, which solves the problem that the existing stepper motor control system cannot meet the requirements of large drive current and operation in high-temperature environments, and achieves the technical effect of controlling the stepper motor in a high-temperature environment.

[0005] In a first aspect, this utility model provides a high-temperature shock wave motor controller, including a control module, a driver, and a motor; the driver includes an H-bridge circuit and a high-temperature driving chip; the pulse signal output terminal of the control module is connected to the input terminal of the high-temperature driving chip; the output terminal of the high-temperature driving chip is connected to the input terminal of the H-bridge circuit, and the output terminal of the H-bridge circuit is connected to the control signal input terminal of the motor.

[0006] In conjunction with the first aspect, in one possible implementation, a storage module, a sensor, and a trigger are also included; the control module includes a threshold comparison module; the signal output terminals of the sensors are all connected to the first input terminal of the storage module and the first input terminal of the trigger, and the sensors are configured to detect the signal of an energetic rod explosion; the second input terminal of the trigger is connected to the threshold comparison module; and the output terminal of the trigger is connected to the second input terminal of the storage module.

[0007] In conjunction with the first aspect, in one possible implementation, the storage module includes a storage processing module and a memory; the trigger includes a comparator; the threshold comparison module includes an ADC acquisition module; the first input terminal of the comparator is connected to the signal output terminal of the sensor, and the second input terminal of the comparator is connected to the ADC acquisition module; the signal output terminal of the sensor is connected to the input terminal of the ADC acquisition module; the output terminal of the ADC acquisition module is connected to the first input terminal of the storage processing module, the second input terminal of the storage processing module is connected to the output terminal of the comparator, and the output terminal of the storage processing module is connected to the memory.

[0008] In conjunction with the first aspect, in one possible implementation, the driver further includes a current sampling resistor R1 and a current sampling resistor R2; there are two H-bridge circuits, the first input terminals of both H-bridge circuits are connected to the high-temperature driver chip, and the output terminals of both H-bridge circuits are connected to the control signal input terminal of the motor; the second input terminal of the current sampling resistor R1 is connected to one end of one of the H-bridge circuits, and the other end of the current sampling resistor R1 is grounded; the second input terminal of the current sampling resistor R2 is connected to the other end of the other H-bridge circuit, and the other end of the current sampling resistor R2 is grounded.

[0009] In conjunction with the first aspect, one possible implementation also includes a timing module; the timing module includes an external GPS module and an internal RTC timing module of the microcontroller.

[0010] Secondly, this utility model embodiment provides a high-temperature control chamber, which includes the high-temperature shock wave motor controller described in the first aspect or any possible implementation of the first aspect, and also includes a power supply and a housing; the output terminal of the power supply is connected to the power supply terminal of the high-temperature shock wave motor controller; the high-temperature shock wave motor controller is disposed on the housing.

[0011] In conjunction with the second aspect, one possible implementation also includes a thermal insulation component; the thermal insulation component has a sandwich layer filled with aerogel; the thermal insulation component is disposed on the outside of the high-temperature shock wave motor controller, the power supply, and the housing.

[0012] In conjunction with the second aspect, one possible implementation also includes liquid metal; a cavity is provided inside the shell; the cavity is filled with liquid metal.

[0013] One or more technical solutions provided in this application have at least the following technical effects or advantages:

[0014] This embodiment of the invention employs a high-temperature shockwave motor controller, including a control module, a driver, and a motor. The driver includes an H-bridge circuit and a high-temperature drive chip. The pulse signal output terminal of the control module is connected to the input terminal of the high-temperature drive chip. The output terminal of the high-temperature drive chip is connected to the input terminal of the H-bridge circuit, and the output terminal of the H-bridge circuit is connected to the control signal input terminal of the motor. The high-temperature drive chip can withstand operating conditions up to 150°C, and its microstepping function is adjustable, enabling each coil of the motor to draw a current of up to 5A. The operator can send pulse signals to the driver via the control module, and the driver, connected to the motor, can control the motor's rotation.

[0015] This utility model embodiment employs a high-temperature control chamber, including a high-temperature shockwave motor controller, a power supply, and a housing. The output terminal of the power supply is connected to the power supply terminal of the high-temperature shockwave motor controller; the high-temperature shockwave motor controller is mounted on the housing. The high-temperature shockwave motor controller features high integration and strong driving capability. Its hardware circuit design utilizes components with good high-temperature performance, employs a low-power, high-temperature resistant microcontroller for control, and adopts a comprehensive thermal management approach. It can meet the requirements of high drive current and operation in high-temperature environments up to 150°C. This application solves the problem in existing stepper motor control systems that cannot meet the requirements of high drive current and operation in high-temperature environments, achieving the technical effect of reasonable control of stepper motors in high-temperature environments. Attached Figure Description

[0016] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the description of the embodiments of this utility model will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 An isometric view of a high-temperature control chamber provided in an embodiment of this application;

[0018] Figure 2 A schematic diagram of a high-temperature shock wave motor controller provided in an embodiment of this application;

[0019] Figure 3 A schematic diagram of the storage module provided in an embodiment of this application;

[0020] Figure 4 The driver circuit diagram provided for the embodiments of this application.

[0021] Icons: 1-Power supply; 2-Housing casing; 3-Insulation component. Detailed Implementation

[0022] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some, not all, of the embodiments of the present utility model. Based on the embodiments of the present utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present utility model.

[0023] In the description of the embodiments of this utility model, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings and are only for the convenience of describing the embodiments of this utility model and simplifying the description. They 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 utility model. The terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. In addition, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; 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 connection of two components. For those skilled in the art, the specific meaning of the above terms in the embodiments of this utility model can be understood according to the specific circumstances.

[0024] This utility model provides a high-temperature shock wave motor controller, such as... Figure 1-4 As shown, it includes a control module, a driver, and a motor; the driver includes an H-bridge circuit and a high-temperature driver chip; the pulse signal output terminal of the control module is connected to the input terminal of the high-temperature driver chip; the output terminal of the high-temperature driver chip is connected to the input terminal of the H-bridge circuit, and the output terminal of the H-bridge circuit is connected to the control signal input terminal of the motor.

[0025] For example, the high-temperature driver chip in this application uses the TMC2160 chip.

[0026] For example, it also includes buttons, through which the operator can send a trigger signal to the control module, and the control module controls the motor through the trigger signal.

[0027] For example, the motor controller operates in two modes: autonomous and manual. Before lowering the controllable shockwave equipment into the well, during the assembly of the energy rods, the pusher is adjusted in manual mode to operate in three states: forward rotation, reverse rotation, and stop. After assembly, a cycle pusher test is performed using the manual mode's cycle button. Once confirmed to be working correctly, the equipment can be lowered into the well for testing. During operation underground, the controller operates in autonomous mode. By collecting and processing the electric field, magnetic field, and shockwave signals generated by the energy rod explosion, the controller triggers the motor to enter a cycle of operation, replenishing the energy converter window with an energy rod, thereby enabling continuous operation of the controllable shockwave equipment underground.

[0028] For example, this application provides a high-temperature power controller for a two-phase four-wire hybrid stepper motor. Facing the confined space and high-temperature, high-pressure, and high-impact environment of underground mines, the motor controller is designed using highly integrated components with strong driving capabilities and good high-temperature performance. The control module employs an STM32 microcontroller, which controls the motor by identifying trigger signals.

[0029] For example, the motor controller is designed with a comprehensive thermal management approach, enabling the operation of a high-temperature power controller containing an energy rod pusher. It should be noted that the motor controller of this application can meet high-temperature operating conditions of 150°C, and its subdivision function is adjustable, with each motor coil capable of handling a current of up to 5A.

[0030] For example, due to the limitations of the downhole working environment, the TMC2160 chip operates in stand-alone mode. In this mode, the driver is a pure step and direction driver. The STM32 microcontroller's timer outputs pulses with adjustable frequency and number. The pins of the STM32 microcontroller are electrically connected to the pulse pins of the TMC2160 chip. Specifically, the two GPIO ports of the STM32 microcontroller output high or low levels and are connected to the enable and direction pins of the TMC2160 chip, respectively.

[0031] For example, the DIP switches of the TMC2160 chip can be used to set the microstepping configuration, operating current configuration, chopper mode selection, and holding current configuration of the stepper motor input. Stepper motors controlled by microstepping have smaller step angles than those controlled by full-step or half-step drives, resulting in higher accuracy. The motor is also less susceptible to oscillations related to its inherent frequency. Furthermore, the stepper motor control in this application employs a trapezoidal acceleration and deceleration method, which effectively avoids motor jitter during acceleration and deceleration.

[0032] In the embodiments of this application, such as Figure 1-4As shown, it also includes a storage module, a sensor, and a trigger; the control module includes a threshold comparison module; the signal output terminals of the sensor are all connected to the first input terminal of the storage module and the first input terminal of the trigger, and the sensor is configured to detect the explosion signal of the energetic rod; the second input terminal of the trigger is connected to the threshold comparison module; the output terminal of the trigger is connected to the second input terminal of the storage module.

[0033] For example, the storage module can record the electric field, magnetic field, and shock wave signals generated by the controllable shock wave device during underground operation. After the operation is completed, the storage module performs data analysis and signal identification verification. The STM32L496ZGT3 microcontroller has an SDMMC module, which supports reading and writing to MMC cards and SDIO interface devices. It uses SD4bitsWidebus for data transmission, storing the recorded signals to a TF card.

[0034] In the embodiments of this application, such as Figure 1-4 As shown, the storage module includes a storage processing module and a memory; the trigger includes a comparator; the threshold comparison module includes an ADC acquisition module; the first input terminal of the comparator is connected to the signal output terminal of the sensor, and the second input terminal of the comparator is connected to the ADC acquisition module; the signal output terminal of the sensor is connected to the input terminal of the ADC acquisition module; the output terminal of the ADC acquisition module is connected to the first input terminal of the storage processing module, the second input terminal of the storage processing module is connected to the output terminal of the comparator, and the output terminal of the storage processing module is connected to the memory.

[0035] For example, the three signals acquired by the trigger are processed using three independent A / D converters contained in the STM32L496ZGT3. The electric and magnetic field signals have smaller amplitudes, so a single trigger threshold is used; the shock wave signal has a larger amplitude, so a separate trigger threshold is used, requiring two ADC acquisition modules and three comparators. The signals detected by the sensors can be recorded by the trigger. When the signal voltage reaches or exceeds the set trigger level, the signal before and after the trigger is recorded for a period of time. The trigger's function is implemented through comparators and ADC acquisition modules in the STM32 microcontroller. The positive terminal of the comparator is connected to the corresponding sensor, and the negative terminal is connected to the output of the ADC acquisition module. When the sensor signal strength exceeds the set output of the ADC acquisition module, the comparator's action achieves the threshold trigger function. There is no signal distortion before and after the threshold trigger. The electric field, magnetic field, and shock wave signals generated by the controllable shock wave device during underground operation are stored in memory. After operation, data analysis can be performed to determine the signal-triggered motor drive method.

[0036] For example, the signal acquisition and processing method of this application enables each signal to store the waveform before and after the threshold trigger with only one independent A / D converter, and the acquired signal will not be distorted.

[0037] In the embodiments of this application, such as Figure 1-4 As shown, the driver also includes current sampling resistors R1 and R2; there are two H-bridge circuits, the first input terminals of both H-bridge circuits are connected to the high-temperature driver chip, and the output terminals of both H-bridge circuits are connected to the control signal input terminal of the motor; one end of the current sampling resistor R1 is connected to the second input terminal of one of the H-bridge circuits, and the other end of the current sampling resistor R1 is grounded; one end of the current sampling resistor R2 is connected to the second input terminal of the other H-bridge circuit, and the other end of the current sampling resistor R2 is grounded.

[0038] For example, the driver circuit consists of two H-bridge circuits. One H-bridge circuit connects to the A+ and A- phases of the stepper motor, and the other H-bridge circuit connects to the B+ and B- phases of the stepper motor. The output of the TMC2160 chip controls the on / off signals of eight MOSFETs, and high-precision current sampling resistors R1 and R2 are used to feed back the motor's operating status to the TMC2160 chip. The power transistors are selected based on the system voltage and maximum current. By selecting power transistors with sufficient margin, the heat generated by the same current flowing through the motor coil can be reduced. The MOSFETs are arranged on the top and bottom sides of the TMC2160, and the current sampling resistors use a Kelvin connection for differential sampling.

[0039] In the embodiments of this application, such as Figure 1-4 As shown, the H-bridge circuit includes MOSFETs Q1, Q2, Q3, and Q4. The gate of MOSFET Q1 is electrically connected to the TMC2160 chip, and the drain of MOSFET Q1 is electrically connected to the power supply terminal. The gate of MOSFET Q2 is electrically connected to the TMC2160 chip, and the drain of MOSFET Q2 is electrically connected to the source of MOSFET Q1. The gate of MOSFET Q3 is electrically connected to the TMC2160 chip, and the drain of MOSFET Q3 is electrically connected to the power supply terminal. The gate of MOSFET Q4 is electrically connected to the TMC2160 chip, and the drain of MOSFET Q4 is electrically connected to the source of MOSFET Q3. The sources of MOSFETs Q2 and Q4 are both electrically connected to resistor R1.

[0040] In the embodiments of this application, such as Figure 1-4As shown, the H-bridge circuit also includes MOSFETs Q5, Q6, Q7, and Q8; the gate of MOSFET Q5 is electrically connected to the TMC2160 chip, and the drain of MOSFET Q1 is electrically connected to the power supply terminal; the gate of MOSFET Q6 is electrically connected to the TMC2160 chip, and the drain of MOSFET Q6 is electrically connected to the source of MOSFET Q5; the gate of MOSFET Q7 is electrically connected to the TMC2160 chip, and the drain of MOSFET Q7 is electrically connected to the power supply terminal; the gate of MOSFET Q8 is electrically connected to the TMC2160 chip, and the drain of MOSFET Q8 is electrically connected to the source of MOSFET Q7; the sources of MOSFETs Q6 and Q8 are both electrically connected to resistor R2.

[0041] In the embodiments of this application, such as Figure 1-4 As shown, it also includes a timing module; the timing module includes an external GPS module and an internal RTC timing module of the microcontroller.

[0042] For example, the timing module includes an external GPS module and an internal RTC timing unit within the microcontroller. Since the GPS module is only resistant to temperatures below 85°C (i.e., not to high temperatures), it cannot receive satellite signals in the downhole environment and cannot be used independently. The STM32 microcontroller, however, can use its built-in RTC for timing, and a button battery can be used as a backup power source. By using a GPS module and RTC for timing, the current time is calibrated via the GPS module before installation in the motor control compartment, providing an accurate timing start point. The GPS module is then removed, and the microcontroller's crystal oscillator and RTC clock are used downhole to accurately record the signal trigger time. Using both the external GPS module and the microcontroller's internal RTC timing unit, the time when the signal generated by the explosion of the energetic rod downhole triggers the motor's operation can be accurately recorded.

[0043] This utility model provides a high-temperature control chamber, such as... Figure 1-4 As shown, the high-temperature control chamber includes a high-temperature shock wave motor controller, a power supply 1, and a housing 2; the output terminal of the power supply 1 is connected to the power supply terminal of the high-temperature shock wave motor controller; the high-temperature shock wave motor controller is mounted on the housing 2.

[0044] For example, power supply 1 is a 36V high-temperature battery that can power the high-temperature shock wave motor controller. Three high-temperature resistant step-down converters with a temperature of 150℃ are set on the control circuit board to achieve four voltage levels of power supply: 36V-12V-5V-3.3V. The microcontroller uses a 3.3V power supply, and different pins of the TMC2160 chip use 36V, 12V, and 5V power supplies respectively. The motor and H-bridge circuit both use a 36V power supply. The 12V and 5V interfaces of the TMC2160 chip can be used to disable the gate voltage regulator and the internal 5V regulator of the TMC2160 chip, thereby reducing the power consumption of the TMC2160 chip and reducing the heat generated by the internal step-down conversion of the TMC2160 chip.

[0045] In the embodiments of this application, such as Figure 1-4 As shown, it also includes a thermal insulation component 3; the thermal insulation component 3 is provided with a sandwich layer, and the sandwich layer is filled with aerogel; the thermal insulation component 3 is located on the outside of the high temperature shock wave motor controller, power supply 1 and housing 2.

[0046] In the embodiments of this application, such as Figure 1-4 As shown, it also includes liquid metal; a cavity is provided inside the shell 2; the cavity is filled with liquid metal.

[0047] For example, housing 2 is an aluminum-based driver housing. The PCB board adopts a four-layer design, with the inner two layers being the power layer and the ground layer, separating the control ground from the power ground. Chips, resistors, capacitors, and other components are mounted on the top layer of the PCB, while eight MOSFETs (IRFB4310) are mounted on the bottom layer, with an operating temperature up to 175℃. At high temperatures, the MOSFETs generate significant heat due to high-frequency switching losses, requiring physical heat dissipation design. TO220 through-hole packaged MOSFETs are routed to the aluminum-based driver housing, which is filled with liquid metal. The high latent heat of liquid metal's phase transition slows down the temperature rise within the control compartment. A thermally conductive silicon sheet is placed between the back of the MOSFET and housing 2 to achieve heat dissipation and insulation. High-temperature resistant insulating particles are placed on the front of the MOSFET and fixed to housing 2 with screws to reduce the impact of shock wave vibrations on the board. All components selected for the hardware circuit meet the 125℃ temperature requirement with sufficient margin.

[0048] For example, the power supply 1, the housing 2, and the high-temperature shock wave motor controller are provided with a heat insulation component 3. The heat insulation component 3 has an inner layer filled with silica aerogel. Silica aerogel has the characteristic of low thermal conductivity, which can effectively isolate the high-temperature environment of the oil well. That is, the heat insulation component 3 plays a heat insulation role for the high-temperature shock wave motor controller and the power supply 1, while the liquid metal in the housing 2 has a heat absorption function, thereby enabling the motor controller to be used in downhole temperatures of 150°C.

[0049] The various embodiments in this specification are described in a progressive manner. Similar or identical parts between embodiments can be referred to interchangeably. Each embodiment focuses on its differences from other embodiments. The above embodiments are only used to illustrate the technical solutions of this application and are not intended to limit this application. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of this application.

Claims

1. A high temperature shockwave motor controller characterized by, The control module, the driver and the motor are included. The driver includes an H-bridge circuit and a high-temperature driving chip. The pulse signal output end of the control module is connected with the input end of the high-temperature driving chip. The output end of the high-temperature driving chip is connected with the input end of the H-bridge circuit, and the output end of the H-bridge circuit is connected with the control signal input end of the motor.

2. The high temperature shock wave motor controller of claim 1, wherein, The storage module, the sensor and the flip-flop are further included. The control module includes a threshold comparison module. The signal output end of the sensor is connected with the first input end of the storage module and the first input end of the flip-flop, and the sensor is configured to detect an explosion signal of an energetic rod. The second input end of the flip-flop is connected with the threshold comparison module. The output end of the flip-flop is connected with the second input end of the storage module.

3. The high temperature shock wave engine controller of claim 2, wherein, The storage module includes a storage processing module and a storage. The flip-flop includes a comparator. The threshold comparison module includes an ADC acquisition module. The first input end of the comparator is connected with the signal output end of the sensor, and the second input end of the comparator is connected with the ADC acquisition module. The signal output end of the sensor is connected with the input end of the ADC acquisition module. The output end of the ADC acquisition module is connected with the first input end of the storage processing module, the second input end of the storage processing module is connected with the output end of the comparator, and the output end of the storage processing module is connected with the storage.

4. The high temperature shock wave motor controller of claim 1, wherein, The driver further includes a current sampling resistor R1 and a current sampling resistor R2. The H-bridge circuit is two, the first input end of the two H-bridge circuits is connected with the high-temperature driving chip, and the output end of the two H-bridge circuits is connected with the control signal input end of the motor. One end of the current sampling resistor R1 is connected with the second input end of one of the H-bridge circuits, and the other end of the current sampling resistor R1 is grounded. One end of the current sampling resistor R2 is connected with the second input end of the other H-bridge circuit, and the other end of the current sampling resistor R2 is grounded.

5. The high temperature shock wave motor controller of claim 1, wherein, The timing module is further included. The timing module includes an external GPS module and an internal RTC timing of a single-chip microcomputer.

6. A high temperature control pod characterized by, The high-temperature control bin includes the high-temperature shock wave motor controller in any one of the preceding claims 1-5, further includes a power supply (1) and a shell (2); The output end of the power supply (1) is connected with the power supply end of the high-temperature shock wave motor controller; The high-temperature shock wave motor controller is arranged on the shell (2).

7. The high temperature control cartridge of claim 6, wherein, The thermal insulation piece (3) is further included. The thermal insulation piece (3) is provided with a sandwich layer, and the sandwich layer is filled with aerogel; The thermal insulation piece (3) is arranged outside the high-temperature shock wave motor controller, the power supply (1) and the shell (2).

8. The high temperature control cartridge of claim 6, wherein, The liquid metal is further included. The shell (2) is provided with a cavity; The cavity is filled with liquid metal.

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