Electric drive fracturing motor diagnostic control system
By installing multiple sensors on the electric fracturing motor for real-time monitoring and diagnosis, the problem of untimely motor monitoring has been solved, enabling timely early warning and handling of motor faults, and improving the operational reliability and safety of the equipment.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- YANTAI JEREH PETROLEUM EQUIP & TECH CO LTD
- Filing Date
- 2025-05-08
- Publication Date
- 2026-07-03
AI Technical Summary
In the existing technology, the monitoring and diagnosis of electric fracturing motors are not timely and have low reliability. The motor condition cannot be predicted in advance, which leads to the equipment being discovered only when the problem is serious, affecting on-site operations.
The system employs current transformers, main motor winding temperature sensors, bearing temperature sensors, cooling fan winding sensors, and cooling fan current sensors to monitor motor current and temperature data in real time. Multi-dimensional diagnostics are performed through a PLC controller to provide timely warnings and take appropriate action.
It enables timely early warning and handling of motor failures, improves the reliability and stability of equipment operation, avoids problems such as motor overload and overheating, and ensures the safe and efficient conduct of fracturing operations.
Smart Images
Figure CN224459563U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of oil and gas field fracturing technology, and in particular to a diagnostic and control system for an electric fracturing motor. Background Technology
[0002] Fracturing is a widely adopted and effective method for increasing oil production in oilfields. Meanwhile, electrically driven fracturing equipment is a relatively new type of fracturing equipment. During operation, this type of equipment typically uses a high-power frequency converter (2MW or higher) to drive a high-power motor. The high-power motor drives the fracturing plunger pump, and the frequency converter drives the motor and monitors and diagnoses parameters such as current and voltage.
[0003] Because motors used in fracturing are characterized by high power and complex structure, and because they are rotating components connected to a vibrating plunger pump, they themselves experience significant vibration. Furthermore, they operate outdoors for extended periods in harsh environments. Currently, monitoring and diagnosing the motor solely through a frequency converter is insufficient to predict its condition in advance. Consequently, by the time problems are detected, the motor has already undergone substantial weight reduction, impacting on-site operations. Utility Model Content
[0004] The purpose of this application is to provide a diagnostic control system for an electric fracturing motor, so as to solve the technical problems of untimely monitoring and diagnosis and low reliability of traditional electric fracturing motors in related technologies.
[0005] This application provides a diagnostic and control system for an electric fracturing motor, including: a current transformer, a main motor winding temperature sensor, a bearing temperature sensor, a cooling fan winding sensor, and a cooling fan current sensor. The current transformer is used to acquire the input current of the motor, the main motor winding temperature sensor is used to acquire the motor winding temperature, the bearing temperature sensor is used to acquire the bearing temperature of the motor bearing, the cooling fan winding temperature sensor is used to acquire the cooling fan winding temperature, and the cooling fan current sensor is used to acquire the actual operating current of the cooling fan.
[0006] This application provides a diagnostic control system for an electric fracturing motor, including: a current transformer, a main motor winding temperature sensor, a bearing temperature sensor, a cooling fan winding sensor, and a cooling fan current sensor. The current transformer acquires the motor's input current, the main motor winding temperature sensor acquires the motor winding temperature, the bearing temperature sensor acquires the bearing temperature, the cooling fan winding temperature sensor acquires the cooling fan winding temperature, and the cooling fan current sensor acquires the actual operating current of the cooling fan. By installing corresponding sensors at various parts of the electric fracturing motor, multi-dimensional diagnostic monitoring of the motor is achieved. Real-time monitoring of motor current and temperature data allows for timely warnings of motor faults, enabling early problem resolution and improving equipment reliability. Attached Figure Description
[0007] Figure 1 This is a schematic diagram of an application device for the diagnostic control system for an electric fracturing motor provided in an embodiment of this application;
[0008] Figure 2 This is a schematic block diagram of a diagnostic control system for an electric fracturing motor provided in an embodiment of this application;
[0009] Among them, there are frequency converter 1, electric drive fracturing motor 2, plunger pump 3, current transformer 10, main motor winding temperature sensor 20, bearing temperature sensor 30, cooling fan winding temperature sensor 40, cooling fan current sensor 50, voltage transformer 60, vibration sensor 70, PLC controller 41, and touch screen 42. Detailed Implementation
[0010] 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 of ordinary skill in the art without creative effort are within the scope of protection of this application.
[0011] It should be understood that the steps described in the method embodiments of this disclosure may be performed in different orders and / or in parallel. Furthermore, the method embodiments may include additional steps and / or omit the steps shown. The scope of this disclosure is not limited in this respect.
[0012] The term "comprising" and its variations as used herein are open-ended inclusions, meaning "including but not limited to". The term "based on" means "at least partially based on". The term "one embodiment" means "at least one embodiment"; the term "another embodiment" means "at least one additional embodiment"; the term "some embodiments" means "at least some embodiments". Definitions of other terms will be given in the description below.
[0013] To address the technical problems existing in related technologies, this application provides a diagnostic control system for an electric fracturing motor. Please refer to [link to relevant documentation]. Figure 1 , Figure 1 This is a schematic diagram of an application device for the diagnostic control system for an electric fracturing motor provided in this application embodiment. The application device has a frequency converter 1 at the front end to drive the electric fracturing motor (hereinafter referred to as the motor) 2. The motor 2 then drives the plunger pump 3 to perform fracturing operations. A PLC controller 41 and a touch screen 42 are housed inside the electrical control box 4. When the application device diagnoses and monitors the electric fracturing motor 2 based on the diagnostic control system, the PLC controller 41 performs diagnostic judgments based on data collected by various sensors installed on the electric fracturing motor 2, and displays the diagnostic results on the touch screen 42.
[0014] Furthermore, referring to Figure 2 , Figure 2 This is a schematic block diagram of a diagnostic control system for an electric fracturing motor provided in an embodiment of this application. The diagnostic control system for the electric fracturing motor includes: a current transformer 10, a main motor winding temperature sensor 20, a bearing temperature sensor 30, a cooling fan winding sensor 40, and a cooling fan current sensor 50. The current transformer 10 is used to acquire the input current of the motor, the main motor winding temperature sensor 20 is used to acquire the motor winding temperature, the bearing temperature sensor 30 is used to acquire the bearing temperature of the motor bearing, the cooling fan winding temperature sensor 40 is used to acquire the cooling fan winding temperature, and the cooling fan current sensor 50 is used to acquire the actual operating current of the cooling fan.
[0015] In one embodiment, the electric fracturing motor diagnostic control system is equipped with multiple sensors, each used to collect data from different structures and locations. The system then performs real-time diagnostic processing based on the collected sensor data. By comprehensively analyzing the data from each sensor, the system can accurately identify the motor's operating status, provide timely warnings of potential faults, and ensure efficient and safe fracturing operations.
[0016] For example, the current transformer 10 installed in the electric fracturing diagnostic control system acquires the motor's input current in real time by being placed at the input terminal of the motor 2. During diagnostic processing, the acquired input current is compared with the set motor alarm current value. If the input current exceeds the preset range, the system can immediately trigger the alarm mechanism, prompting the operator to take appropriate measures to prevent motor overload damage. Simultaneously, the system records abnormal data for subsequent analysis and maintenance.
[0017] The main motor winding temperature sensor 20, installed in the electric fracturing diagnostic control system, is used to monitor the winding temperature of motor 2 in real time. Similarly, during diagnostic processing, the acquired winding temperature is compared with the winding temperature warning value. If the winding temperature exceeds the warning value, the system immediately initiates cooling measures, alerting operators to intervene promptly to prevent overheating and subsequent malfunctions, ensuring stable equipment operation. Simultaneously, the system can record abnormal data, providing a basis for subsequent optimization and maintenance.
[0018] The bearing temperature sensor 30 installed in the electric fracturing diagnostic control system is used to monitor the temperature of the bearing of motor 2 in real time during operation. Similarly, during diagnostic processing, the acquired bearing temperature is compared with the bearing temperature warning value. If the bearing temperature is higher than the set bearing temperature warning value, the system can immediately trigger the alarm mechanism to prompt the operator to take corresponding measures to ensure the stable operation of the equipment.
[0019] The cooling fan winding temperature sensor 40 installed in the electric fracturing diagnostic control system is used to monitor the winding temperature of the cooling fan in motor 2 in real time during operation. Similarly, during diagnostic processing, the acquired cooling fan winding temperature is compared with the cooling fan winding temperature warning value. If the cooling fan winding temperature is higher than the temperature warning value, the system can immediately trigger the alarm mechanism to prompt the operator to take corresponding measures to ensure the stable operation of the equipment.
[0020] The cooling fan current sensor 50 installed in the electric fracturing diagnostic control system is used to monitor the operating current of the cooling fan in motor 2 in real time. Similarly, during diagnostic processing, the actual operating current of the cooling fan is compared with the cooling fan's electric trigger alarm mechanism to prompt the operator to make timely adjustments to avoid excessive current causing equipment damage and ensure the efficiency of the cooling system.
[0021] In practical applications, the diagnostic control system for electric fracturing motors can provide protection for current, temperature, and the main motor cooling system. When performing different protection actions, the system performs diagnostic processing based on the real-time sensor data collected by each sensor, and then adjusts the motor 2 in real time according to the diagnostic results to ensure the stable operation of the motor.
[0022] Furthermore, the diagnostic control system for electric fracturing motor also includes a PLC controller 41. The PLC controller 41 is used to make early warning judgments based on the input current, winding temperature, bearing temperature, cooling fan winding temperature and actual operating current to obtain judgment results, and to adjust the motor speed based on the judgment results.
[0023] For example, when performing protection processing on the electric fracturing diagnostic control system, the PLC controller 41 performs diagnostic analysis processing based on the relevant data collected in real time by each sensor, and then performs protection processing on the motor based on the obtained diagnostic analysis results, including current protection, temperature protection and main motor cooling system protection.
[0024] Furthermore, the current transformer 10 includes a first current transformer, a second current transformer, and a third current transformer. The first current transformer is used to obtain the A-phase input current of the motor, the second current transformer is used to obtain the B-phase input current of the motor, and the third current transformer is used to obtain the C-phase input current of the motor.
[0025] For example, when acquiring the input current of motor 2 in real time, data is collected using the configured current transformer 10. Specifically, the current transformer 10 includes a first current transformer, a second current transformer, and a third current transformer, which are used to acquire the three-phase input current of motor 2 during operation, including phase A input current, phase B input current, and phase C input current. Then, the PLC controller 41 performs diagnostic analysis based on the acquired motor input current to determine whether the input current of motor 2 is too high. If it is determined that the input current is too high, the motor speed can be adjusted, such as reducing the speed of motor 2.
[0026] In actual operation, three current transformers acquire the three-phase input current of the motor. When performing diagnostic processing based on the real-time acquired three-phase input current, the input currents of phase A, phase B, and phase C are compared to select the largest current value as the current value for subsequent diagnostic analysis. Then, the determined current value is compared with the set motor alarm current value, the specific value of which is related to the motor power. For example, when the motor power is 4200KW, the alarm current value can be set to 920A. If the current value exceeds the alarm current value, an alarm signal will be triggered, and the PLC controller will send a speed reduction signal to inverter 1. After receiving the speed reduction signal, inverter 1 immediately adjusts the speed of motor 2 to ensure that the current is reduced to a safe range to prevent motor 2 from being overloaded and damaged.
[0027] Furthermore, the main motor winding temperature sensor 20 includes a first main motor winding temperature sensor, a second main motor winding temperature sensor, and a third main motor winding temperature sensor. The first main motor winding temperature sensor is used to acquire the temperature of the A-phase winding of the motor, the second main motor winding temperature sensor is used to acquire the temperature of the B-phase winding of the motor, and the third main motor winding temperature sensor is used to acquire the temperature of the C-phase winding of the motor.
[0028] For example, when monitoring the motor winding temperature in real time, data is collected using corresponding temperature sensors. Specifically, the temperature sensors include a first main motor winding temperature sensor, a second main motor winding temperature sensor, and a third main motor winding temperature sensor, which are used to acquire the three-phase winding temperatures of the motor during operation, including the A-phase winding temperature, the B-phase winding temperature, and the C-phase winding temperature. Then, the PLC controller 41 performs diagnostic analysis based on the collected motor winding temperatures.
[0029] Furthermore, the bearing temperature sensor 30 includes a shaft extension end temperature sensor and a non-shaft extension end temperature sensor. The shaft extension end temperature sensor is used to obtain the shaft extension end temperature of the bearing, and the non-shaft extension end temperature sensor is used to obtain the non-shaft extension end temperature of the bearing.
[0030] For example, when monitoring the bearing temperature in real time, data is acquired using the set shaft extension end temperature sensor and non-shaft extension end temperature sensor to obtain the bearing's shaft extension end temperature and non-shaft extension end temperature, respectively. Then, the PLC controller 41 can perform diagnostic analysis based on the acquired bearing temperatures.
[0031] In actual operation, when performing temperature protection for the diagnostic control system of the electric fracturing motor, diagnostic analysis is conducted based on the temperature data collected in real time by the main motor winding temperature sensor 20 and the bearing temperature sensor 30. Specifically, during the diagnostic analysis, the acquired three-phase winding temperature, shaft extension end temperature, and non-shaft extension end temperature are used for diagnosis. By comparing the three temperature data with the corresponding alarm thresholds, if any temperature exceeds the corresponding threshold, it is determined that appropriate adjustments are needed to reduce the temperature.
[0032] Taking the three-phase winding temperature as an example, the temperatures of phase A, phase B, and phase C windings are first compared, and the highest temperature value is selected as the current temperature value. This value is then compared with the preset alarm temperature value. The alarm temperature threshold is set according to the actual operating conditions, such as 110℃. If the temperature exceeds the limit, an alarm is triggered. Subsequently, the PLC controller 41 sends a speed reduction signal to the frequency converter 1. After receiving the speed reduction signal, the frequency converter 1 immediately adjusts the three-dimensional speed of the motor 2 to reduce the temperature of the motor 2 to a safe range.
[0033] It should be noted that when using the shaft extension end temperature or the non-shaft extension end temperature for diagnosis, a similar logic is used. The shaft extension end temperature or the non-shaft extension end temperature is compared with the corresponding temperature alarm value. The shaft extension end temperature alarm value and the non-shaft extension end temperature alarm value are generally set to 80℃. If the limit is exceeded, an alarm is triggered, and the PLC controller 41 then sends an adjustment command to the frequency converter 1, which in turn causes the frequency converter 1 to send a speed reduction signal to the motor 2 for speed reduction processing.
[0034] Furthermore, the cooling fan winding sensor 40 includes a first cooling fan winding sensor and a second cooling fan winding sensor. The cooling fan includes a first cooling fan and a second cooling fan. The first cooling fan winding sensor is used to obtain the first winding temperature of the first cooling fan, and the second cooling fan winding sensor is used to obtain the second winding temperature of the second cooling fan.
[0035] For example, when monitoring the temperature of the cooling fan in real time, data is collected using a first cooling fan winding sensor and a second cooling fan winding sensor to obtain the winding temperatures of the first and second cooling fans, including the first winding temperature and the second winding temperature. When protecting the main motor cooling system, the first winding temperature and the second winding temperature can be used as one of the indicators for diagnostic analysis.
[0036] Furthermore, the cooling fan current sensor 50 includes a first cooling fan current sensor and a second cooling fan current sensor. The first cooling fan current sensor is used to acquire the first operating current of the first cooling fan, and the second cooling fan current sensor is used to acquire the second operating current of the second cooling fan.
[0037] For example, when monitoring the operating status of the cooling fan in real time, the first cooling fan current sensor and the second cooling fan current sensor are also used to collect data, and the operating current of the first cooling fan and the second cooling fan are obtained respectively, including the first operating current and the second operating current. When protecting the main motor cooling system, these current data are used as auxiliary indicators for diagnostic analysis to ensure the stability and safety of the system operation.
[0038] In practical applications, when protecting the main motor cooling system, it is necessary to comprehensively consider the winding temperature and operating current, accurately identify potential risks through multi-dimensional data analysis, and take timely control measures to effectively extend the service life of the equipment and ensure the continuity and reliability of the production process.
[0039] Specifically, motor 2 includes a first cooling fan and a second cooling fan. Therefore, when protecting the main motor cooling system, the operating status of the first cooling fan and the second cooling fan is monitored simultaneously. When performing diagnostic processing based on the temperature of the first winding of the first cooling fan, the temperature of the first winding is compared with the corresponding temperature alarm value. For example, if the temperature alarm value is 90℃, when the temperature of the first winding is greater than the corresponding temperature alarm value, the system immediately triggers the early warning mechanism. PLC control 41 sends a speed reduction signal to inverter 1 so that inverter 1 controls motor 2 to reduce speed.
[0040] It should be noted that when performing diagnostic analysis based on the first operating current of the first cooling fan, the process is similar to that based on the first winding temperature. By comparing the first operating current with the corresponding current alarm value, the system will trigger an early warning mechanism when the first operating current exceeds the corresponding current alarm value. The current alarm value of the first cooling fan is related to the fan power. For example, when the fan power is 15KW, the current alarm value of the first cooling fan can be set to 24A.
[0041] Then, when protecting the cooling system based on the second cooling fan, the same diagnostic logic and early warning mechanism as the first cooling fan are adopted. The corresponding alarm values (including temperature alarm values and current alarm values) can be set according to the actual situation of the cooling fan. In this way, the winding temperature and operating current of the second cooling fan are kept within the safe range through real-time monitoring and adjustment, thereby realizing dual-machine collaborative protection and comprehensively improving the stability and safety of system operation.
[0042] In addition, when protecting the main motor cooling system, the current balance of the cooling fans can also be diagnosed. Specifically, the first operating current of the first cooling fan can be compared with the current alarm value of the second cooling fan. The motor balance is diagnosed by determining the current difference between the two. For example, if the set difference threshold is 2A, the current difference is then compared with the difference threshold. If the current difference is greater than the difference threshold, the system immediately starts the balance adjustment program to ensure the motor's balanced operation. It should be noted that the second operating current of the second cooling fan can also be compared with the current alarm threshold of the first cooling fan to diagnose the motor balance.
[0043] Furthermore, the diagnostic control system for electric fracturing motors also includes a touch screen 42, which is used to display the judgment results.
[0044] In other words, after performing diagnostic analysis based on the data collected in real time by each sensor, the diagnostic analysis results (judgment results) can be displayed so that operators can accurately know the specific cause of the fault.
[0045] Furthermore, the diagnostic control system for the electric fracturing motor also includes a voltage transformer 60, which is used to obtain the operating voltage of the motor.
[0046] For example, the voltage transformer 60 monitors the operating voltage of the motor 2 in real time, and can then manage and adjust the motor 2 accordingly based on the operating voltage, such as by reducing its speed.
[0047] Furthermore, the diagnostic control system for the electric fracturing motor also includes a vibration sensor 70, which is used to acquire vibration information of the motor 2, including vibration frequency and vibration direction.
[0048] For example, the vibration information of motor 2 can be used to diagnose the operating status of the motor. In addition to monitoring the relevant current and temperature of motor 2 as described above, the vibration frequency and direction data of motor 2 can also be obtained. By comprehensively analyzing this vibration information, it can be determined whether motor 2 is displaced or vibrating too fast. Then, when a problem is found, timely adjustments can be made to ensure the stable operation of motor 2.
[0049] In summary, this application discloses a diagnostic and control system for an electric fracturing motor, comprising: a current transformer, a main motor winding temperature sensor, a bearing temperature sensor, a cooling fan winding sensor, and a cooling fan current sensor. The current transformer is used to acquire the motor's input current; the main motor winding temperature sensor is used to acquire the motor winding temperature; the bearing temperature sensor is used to acquire the bearing temperature; the cooling fan winding temperature sensor is used to acquire the cooling fan winding temperature; and the cooling fan current sensor is used to acquire the actual operating current of the cooling fan. By installing corresponding sensors at various parts of the electric fracturing motor, multi-dimensional diagnostic monitoring of the motor is achieved. Real-time monitoring of motor current and temperature data allows for timely early warning of motor faults, enabling problem handling in its early stages and improving equipment reliability.
[0050] The above provides a detailed description of an electrically driven fracturing motor diagnostic control system provided in the embodiments of this application. Specific examples have been used to illustrate the principles and implementation methods of this application. The descriptions of the embodiments above are only for the purpose of helping to understand the method 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. Moreover, those skilled in the art can make several improvements and modifications without departing from the principles of this application, and these improvements and modifications are also considered to be within the protection scope of this application.
Claims
1. An electrically driven fracturing motor diagnostic control system, characterized in that, include: The system includes a current transformer, a main motor winding temperature sensor, a bearing temperature sensor, a cooling fan winding sensor, and a cooling fan current sensor. The current transformer is used to acquire the input current of the motor. The main motor winding temperature sensor is used to acquire the motor winding temperature. The bearing temperature sensor is used to acquire the bearing temperature of the motor bearing. The cooling fan winding temperature sensor is used to acquire the cooling fan winding temperature. The cooling fan current sensor is used to acquire the actual operating current of the cooling fan.
2. The electrically driven fracturing motor diagnostic control system of claim 1, wherein, The diagnostic control system for the electric fracturing motor also includes a PLC controller. The PLC controller is used to make a judgment based on the input current, the winding temperature, the bearing temperature, the cooling fan winding temperature and the actual operating current to obtain a judgment result, and to adjust the speed of the motor based on the judgment result.
3. The electrically driven fracturing motor diagnostic control system of claim 1, wherein, The current transformer includes a first current transformer, a second current transformer, and a third current transformer. The first current transformer is used to obtain the A-phase input current of the motor, the second current transformer is used to obtain the B-phase input current of the motor, and the third current transformer is used to obtain the C-phase input current of the motor.
4. The electrically driven fracturing motor diagnostic control system of claim 1, wherein, The main motor winding temperature sensor includes a first main motor winding temperature sensor, a second main motor winding temperature sensor, and a third main motor winding temperature sensor. The first main motor winding temperature sensor is used to obtain the temperature of the A-phase winding of the motor, the second main motor winding temperature sensor is used to obtain the temperature of the B-phase winding of the motor, and the third main motor winding temperature sensor is used to obtain the temperature of the C-phase winding of the motor.
5. The electrically driven fracturing motor diagnostic control system of claim 1, wherein, The bearing temperature sensor includes a shaft extension end temperature sensor and a non-shaft extension end temperature sensor. The shaft extension end temperature sensor is used to obtain the temperature of the shaft extension end of the bearing, and the non-shaft extension end temperature sensor is used to obtain the temperature of the non-shaft extension end of the bearing.
6. The diagnostic control system for an electric fracturing motor as described in claim 1, characterized in that, The cooling fan winding sensor includes a first cooling fan winding sensor and a second cooling fan winding sensor. The cooling fan includes a first cooling fan and a second cooling fan. The first cooling fan winding sensor is used to obtain the first winding temperature of the first cooling fan, and the second cooling fan winding sensor is used to obtain the second winding temperature of the second cooling fan.
7. The electrically driven fracturing motor diagnostic control system of claim 6, wherein, The cooling fan current sensor includes a first cooling fan current sensor and a second cooling fan current sensor. The first cooling fan current sensor is used to obtain the first operating current of the first cooling fan, and the second cooling fan current sensor is used to obtain the second operating current of the second cooling fan.
8. The electrically driven fracturing motor diagnostic control system of claim 2, wherein, The electric fracturing motor diagnostic control system also includes a touch screen, which is used to display the judgment result.
9. The electrically driven fracturing motor diagnostic control system of claim 1, wherein, The diagnostic control system for the electric fracturing motor also includes a voltage transformer, which is used to obtain the operating voltage of the motor.
10. The electrically driven fracturing motor diagnostic control system of claim 1, wherein, The diagnostic control system for the electric fracturing motor also includes a vibration sensor, which is used to acquire vibration information of the motor, wherein the vibration information includes vibration frequency and vibration direction.