Top drive control system and method based on bi-directional transmission

Abstract

A top drive control system based on bi-directional transmission, relating to the technical field of petroleum drilling. The system comprises: a power-receiving end, a coupler, and a power-transmitting end. In the coupled power supply process, the power-transmitting end inverts first direct current to alternating current, and transmits the alternating current to the power-receiving end by means of the coupler; and the power-receiving end rectifies the alternating current to obtain second direct current, so as to supply power to sensors, located at the lower portion of a top drive rotating head, of a hydraulic elevator and a drilling elevator link. In the coupled communication process, the power-receiving end modulates acquired sensor data of the sensors into modulated signals, and transmits the modulated signals to the power-transmitting end by means of the coupler. By means of coupled power supply, power is supplied to the sensors mounted at the lower portion of the top drive rotating head, and by means of coupled communication, signals of the sensors at the lower portion of the rotating head are transmitted to a top drive electrical control house, thereby achieving stable power supply to the sensors and reliable transmission of signals.

Description

A top drive control system and method based on bidirectional transmission

[0001] Cross-references to related art

[0002] This application claims priority to Chinese patent application CN202311749924.7 filed on December 19, 2023, entitled “A coupling power supply and communication system for a top drive rotary head” and Chinese patent application CN202311749930.2 filed on December 19, 2023, entitled “A method and system for determining whether a top drive achieves automatic coupling and tightening”, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present invention relates to the technical field of top drive control, and in particular to a top drive control system and method based on bidirectional transmission. Background Art

[0004] With the increasing automation of oil equipment and the continued advancement of industrial intelligence, a solid foundation has been laid for the exploration, transformation, and upgrading of intelligent oil equipment. Currently, the integrated application of drilling string automation equipment has effectively reduced the workload of on-site workers and significantly improved construction safety. Top drives play a crucial role in the entire process of string automation. While automated string handling devices have made significant progress in recent years, gradually moving towards one-touch, unmanned operation, top drives still lack automation and unmanned operation during string connection, drilling, and tripping.

[0005] Due to the difficulty of installing sensors under the top drive rotary head, top drive operation is currently primarily performed manually and confirmed by the driller. Because the top drive rotary head rotates, cables or pipelines cannot be directly connected to the lower part of the rotary head. Currently, hydraulic lines are connected through rotary oil channels, and electrical signals are typically transmitted via a battery-based wireless communication method. However, this is difficult to implement due to limitations in battery capacity and transmission stability. Consequently, power supply and signal transmission for sensors under the top drive rotary head remain a bottleneck in drilling automation.

[0006] In addition, currently, before lowering the tubing string, the top drive saver sub must be connected to the internal threads of the drill string (also known as the pipe string or column). Once connected, high-pressure mud can be circulated through the pipe string. However, conventional top drives require manual connection to the column for drilling, which not only increases the workload but also reduces the efficiency of the column connection operation.

[0007] In response to the problems of the prior art, the present invention needs to provide a coupled power supply and communication system suitable for a top drive rotary head, so as to expand the application of data collected by the sensor components at the bottom of the top drive rotary head. Summary of the Invention

[0008] In response to the problems of the current existing technology, the present invention provides a top drive control system based on bidirectional transmission, comprising: a power sending end, which is used to convert a first direct current into an alternating current; a coupler, which is used to transmit the alternating current by electromagnetic induction; a power receiving end, which is used to receive the alternating current transmitted through the coupler, convert the alternating current into a second direct current, so as to continuously power the sensor assembly in the top drive, and modulate the sensor data from the sensor assembly into a modulation signal, and feed the modulation signal back to the power sending end through the coupler; and a top drive electronic control unit, which is used to receive the sensor data parsed by the power sending end in real time.

[0009] Preferably, the coupler includes: a power sending end magnetic core connected to the top drive body; a power receiving end magnetic core connected to the top drive rotary head; a primary coil wound on the power sending end magnetic core, and the primary coil is sealed inside the power sending end magnetic core; and a secondary coil wound on the power receiving end magnetic core, and the secondary coil is sealed inside the power receiving end magnetic core.

[0010] Preferably, the sending-end magnetic core is constructed into a fan-shaped ring structure by splicing multiple U-shaped magnetic cores, and the primary coil is wound on the U-shaped groove in the sending-end magnetic core; the receiving-end magnetic core is constructed into a circumferential ring structure by splicing multiple U-shaped magnetic cores, and the primary coil is wound on the U-shaped groove in the receiving-end magnetic core, and the vertical projection of the coil area in the fan-shaped ring structure falls on the coil area of ​​the circumferential ring structure.

[0011] Preferably, all the U-shaped grooves in the magnetic core at the power transmitting end form a first annular winding groove inside the annular space of the sector-shaped annular structure, and the primary coil is wound along the circumferential direction of the first annular winding groove; all the U-shaped grooves in the magnetic core at the power receiving end form a second annular winding groove inside the annular space of the angular annular structure, and the secondary coil is wound along the circumferential direction of the second annular winding groove.

[0012] Preferably, a first sealing layer is provided on the coil side of the sector-shaped annular structure; and a second sealing layer is provided on the coil side of the angular annular structure.

[0013] Preferably, the width and length of the bottom surface of each U-shaped magnetic core are greater than the height of the U-shaped magnetic core.

[0014] Preferably, the power receiving end includes: an acquisition module connected to the sensor component, which is used to acquire the sensor data; a rectifier module, which is used to rectify and stabilize the alternating current to obtain the second direct current to power the acquisition module and the sensor component; and a modulation module connected to the acquisition module, which is used to modulate the sensor data into the modulation signal.

[0015] Preferably, the power transmission end includes: an inverter circuit, which uses a full-bridge inverter circuit to invert the first direct current into the alternating current; and a receiving circuit, which is used to transmit the sensor data obtained after demodulating the modulated signal to the top drive electronic control unit.

[0016] Preferably, the top drive control system further comprises: a resonance compensation circuit for compensating for reactive power attenuation caused by the inductance of the primary coil and the secondary coil, wherein the resonance compensation circuit comprises a resonance compensation inductor and a resonance compensation capacitor connected in series.

[0017] Preferably, the top drive control system further includes: an inductive reactance compensation circuit, which is used to balance the leakage inductive reactance of the primary side of the coupler and the mapped inductive reactance of the secondary side, thereby reducing the reactive power of the secondary side, wherein the inductive reactance compensation circuit includes a first capacitor connected in series with the primary coil and a second capacitor connected in series with the secondary coil.

[0018] Preferably, the top drive control system further includes: a wave trap assembly, which is used to reduce the interference of coupled power transmission on coupled communication transmission, wherein the wave trap assembly includes a first wave trap arranged at the power transmitting end and a second wave trap arranged at the power receiving end.

[0019] Preferably, the sensor assembly is located at the lower part of the top drive turret.

[0020] Preferably, the top drive electronic control unit further implements status diagnosis of automatic buckling and tightening of the top drive according to the sensor data.

[0021] Preferably, the top drive electronic control unit further performs status diagnosis through the following steps: after entering the automatic screw-on mode, judging whether the current top drive protection joint and the pipe string joint are successfully screwed together based on the top drive torque data, the position indication signal indicating that the pipe string enters the bell mouth of the top drive back tong, and the displacement data of the top drive balance cylinder; after the screw-on is successful, receiving the tightening instruction, and diagnosing the top drive tightening status by detecting the clamping state of the top drive back tong and the top drive torque data.

[0022] Preferably, the top drive electronic control unit is further configured to determine whether the current top drive protection sub and the tubing string joint are successfully fastened through the following steps: determining whether the tubing string enters the bell mouth of the top drive back-up tong according to the triggering state of the position indication signal; after entering, detecting whether the top drive torque reaches the fastening position state according to the top drive torque data and a preset spin torque threshold, and detecting whether the traveling block reaches the target position according to the displacement data and the preset displacement threshold; when the top drive torque reaches the fastening position state and the traveling block reaches the target position, it is determined that the current top drive protection sub and the tubing string joint are successfully fastened.

[0023] Preferably, when the position indication signal is not triggered, it is determined that the currently lowered tubing string enters the bell mouth of the top drive back tong; otherwise, it is determined that the currently lowered tubing string does not enter the bell mouth of the top drive back tong.

[0024] Preferably, the sensor assembly includes: a proximity switch installed on the anti-torque frame of the top drive back-up tong and a displacement sensor installed in the top drive balance cylinder, wherein the proximity switch is used to detect whether the pipe string enters the bell mouth of the top drive back-up tong; and the displacement sensor is used to detect the displacement data.

[0025] Preferably, when the automatic spin-off mode is turned on, the top drive electronic control unit is further configured to: open the pressure control valve for the top drive balance cylinder so that the upward pulling force on the top drive balance cylinder is less than the gravity of the top drive itself; and send an instruction to the drilling platform control system to continue lowering the traveling block.

[0026] Preferably, the sensor assembly includes: an angle sensor provided at the lifting ring and a load sensor provided at the lifting card, wherein the top drive electronic control unit is further configured to: receive a lower fastening instruction, align the lifting card with the center of the wellhead by detecting the change state of the lifting ring inclination, so that the current pipe string is supported by the drilling floor equipment and positioned at the center of the wellhead, so that the drilling platform control system lowers the traveling block; receive and detect the lifting card load signal, and after the lifting card load signal disappears, generate a first control instruction for controlling the drilling platform control system to lower the traveling block according to a preset first lowering height, and enable the drilling platform control system to lower the traveling block to the first lowering height under the action of the first control instruction, thereby completing the lower fastening task of the pipe string; and feed back a pipe string lowering completion signal to the drilling platform control system.

[0027] Preferably, after completing the task of fastening the lower part of the pipe string, the top drive electronic control unit is further configured to: obtain an upper fastening instruction; generate a second control instruction for controlling the drilling platform control system to continue lowering the traveling block according to a preset second lowering height, and enable the drilling platform control system to lower the traveling block to the top drive bell mouth under the action of the second control instruction to start the automatic spinning mode.

[0028] Preferably, the sensor assembly includes: a pressure sensor arranged at the rodless chamber oil port of the top drive back-up tong, wherein the top drive electronic control unit is further configured to diagnose the top drive tightening status through the following steps: obtaining the top drive back-up tong pressure data in real time through the pressure sensor, and judging whether the tightening action reaches the clamping state based on the data; when the clamping state is reached, detecting whether the top drive and the upper part of the pipe string are tightened according to the top drive torque data and a preset tightening torque threshold, so as to determine the top drive tightening status.

[0029] Preferably, when the top drive torque data reaches or exceeds the preset tightening torque threshold, it is determined that the top drive is currently tightened with the upper portion of the tubing string; otherwise, it is determined that the top drive is not tightened.

[0030] Preferably, whether the current clamping action reaches the clamping state is judged based on the top drive back clamp pressure data and the preset back clamp pressure threshold, wherein when the top drive back clamp pressure data reaches or exceeds the preset back clamp pressure threshold, it is determined that the clamping state is reached; otherwise, the clamping state is not reached.

[0031] On the other hand, an embodiment of the present invention further provides a top drive control method based on bidirectional transmission, and the top drive control method is implemented by the top drive control system as described above.

[0032] The present invention provides a top drive control system and method based on bidirectional transmission, which has the following advantages over the prior art:

[0033] 1) The present invention conducts research on top drive coupled power supply and communication technology. The coupled power supply is used to power the sensor installed at the bottom of the top drive slewing head. The coupled communication is used to transmit the signal of the sensor at the bottom of the slewing head to the top drive electrical control room, thereby achieving stable power supply for the sensor and reliable signal transmission.

[0034] 2) The power transmission end of the present invention converts the DC voltage through a high-frequency inverter circuit to generate a high-frequency AC voltage. The operating frequency of the DC voltage is adjusted by a PWM control circuit that controls the inverter circuit. The generated high-frequency AC voltage is applied to the primary coil of the coupler. According to Faraday's law of electromagnetic induction, the alternating current generates a magnetic field. The secondary coil of the coupler induces the magnetic field and couples out an AC voltage signal. After being rectified and filtered at the power end, it is converted back into a DC signal and output to the load, realizing contactless power transmission.

[0035] 3) The present invention designs and customizes the core size that meets the top drive structure, processes a small-sized U-shaped core, and splices multiple U-shaped small cores to form a large core with a ring structure. The small cores are not easy to break, and even if individual small cores are broken, the overall impact on communication is minimal;

[0036] 4) The present invention uses a resonant compensation circuit to compensate for the reactive power attenuation caused by the inductive nature of the primary and secondary coils of the coupler; uses an inductive reactance compensation circuit to balance the leakage reactance of the primary side of the coupler and the mapped reactance of the secondary side, thereby reducing the reactive power of the secondary side; uses a wave trap to reduce the interference of coupled power transmission on coupled communication transmission; and uses frequency shift keying to achieve modulation and demodulation of sensor data.

[0037] 5) The present invention effectively realizes the automated control of pipe string buckling and screwing operations by adding information collection components to designated locations on the existing ground drilling platform and designing corresponding detection and judgment logic, thereby effectively improving operating efficiency and reducing the workload of ground staff.

[0038] Other features and advantages of the present invention will be described in the following description, and in part will become apparent from the description, or will be understood by practicing the present invention. The purposes and other advantages of the present invention can be realized and obtained by the structures particularly pointed out in the description, claims and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] The accompanying drawings are used to provide a further understanding of the present invention and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation of the present invention. In the accompanying drawings:

[0040] FIG1 shows a functional schematic diagram of a top drive control system based on bidirectional transmission according to an embodiment of the present invention;

[0041] FIG2 shows a schematic structural diagram of a top drive control system based on bidirectional transmission according to an embodiment of the present invention;

[0042] FIG3 shows a schematic structural diagram of a power receiving terminal according to an embodiment of the present invention;

[0043] FIG4 shows a schematic structural diagram of a coupler according to an embodiment of the present invention;

[0044] FIG5 shows a dimension diagram of a magnetic core structure and a sealing schematic diagram according to an embodiment of the present invention;

[0045] FIG6 shows a schematic diagram of the coupling transmission principle according to an embodiment of the present invention;

[0046] FIG7 shows a schematic structural diagram of a coupled power supply process according to an embodiment of the present invention;

[0047] FIG8 shows a topological diagram of a full-bridge inverter circuit according to an embodiment of the present invention;

[0048] FIG9 shows a schematic diagram of PWM pulse width modulation according to an embodiment of the present invention;

[0049] FIG10 shows a schematic diagram of dead zone control according to an embodiment of the present invention;

[0050] FIG11 shows a schematic diagram of a series compensation structure according to an embodiment of the present invention;

[0051] FIG12 shows a schematic diagram of a parallel compensation structure according to an embodiment of the present invention;

[0052] FIG13 shows a comparison of transmission efficiencies of two compensation structures under different light and heavy loads according to an embodiment of the present invention;

[0053] FIG14 shows a schematic diagram of co-transmission of power and signals according to an embodiment of the present invention;

[0054] FIG15 shows a schematic structural diagram of a signal modulation and demodulation circuit according to an embodiment of the present invention;

[0055] FIG16 shows a schematic diagram of the FSK signal modulation principle according to an embodiment of the present invention;

[0056] FIG17 shows a schematic diagram of the FSK signal demodulation principle according to an embodiment of the present invention.

[0057] FIG. 18 is a schematic diagram showing the steps for implementing the state diagnosis of automatic tie-down and tie-down of a top drive according to an embodiment of the present invention.

[0058] FIG. 19 shows a schematic diagram of a specific flow chart for realizing status diagnosis of automatic dovetailing and fastening of a top drive according to an embodiment of the present invention.

[0059] In the accompanying drawings, the same reference numerals are used for the same parts. In addition, the accompanying drawings are not drawn according to the actual scale. DETAILED DESCRIPTION

[0060] To make the objectives, technical solutions and advantages of the present invention more clear, embodiments of the present invention are described in further detail below with reference to the accompanying drawings.

[0061] In response to the defects of the existing technology, the present invention conducts research on top drive coupled power supply and communication technology. Through coupled power supply, the sensor installed at the bottom of the top drive rotary head is powered, and through coupled communication, the signal of the sensor at the bottom of the rotary head is transmitted to the top drive electrical control room, thereby achieving stable power supply to the sensor and reliable transmission of the signal.

[0062] FIG1 shows a functional schematic diagram of a top drive control system based on bidirectional transmission according to an embodiment of the present invention.

[0063] A top drive control system based on bidirectional transmission comprises a power receiving end, a coupler, a power transmitting end and a top drive electric control unit.

[0064] As shown in Figure 1, the power transmitter converts a first DC power source into an AC power source. The coupler transmits the AC power via electromagnetic induction across a coupling surface. The power receiver receives the AC power transmitted by the coupler and converts it into a second DC power source, which is then used to continuously power the sensor assembly within the top drive. This completes power transmission from the power transmitter to the sensor assembly.

[0065] The power receiving end also modulates the sensor data from the sensor assembly into a modulated signal. The coupler then feeds the modulated signal back to the power transmitting end. The power transmitting end then analyzes the modulated signal and feeds it back to the top drive electronic control unit. The top drive electronic control unit then receives the sensor data analyzed by the power transmitting end in real time. This completes communication from the sensor assembly to the power transmitting end.

[0066] Referring to Figure 1, during the coupled power supply process, the power transmitting end inverts the first direct current (e.g., DC24V) into alternating current (e.g., 40kHz high-frequency alternating current), transmits the alternating current to the power receiving end through the coupler on the electromagnetic coupling surface, and the power receiving end rectifies the alternating current to obtain a second direct current (e.g., DC24V) to power the various sensors in the sensor assembly at the bottom of the top drive rotary head.

[0067] As shown in Figure 1, during the coupling communication process, the power receiving end modulates the sensor data collected from the sensor into a modulated signal, and transmits the modulated signal to the power transmitting end through the coupler on the electromagnetic coupling surface. The power transmitting end transmits the signal to the main control PLC in the top drive control room within the top drive electrical control unit via a wired method.

[0068] In one embodiment, the present invention provides a top drive control system based on bidirectional transmission: coupled power supply voltage 24V, power supply power ≥20W, power supply efficiency ≥85%, coupled communication rate ≥9.6kbps, bit error rate ≤1%, sensor data refresh time ≤0.1 second, explosion-proof level ExdⅡBT4.

[0069] It should be noted that the top drive control system described in the embodiment of the present invention can achieve the effect of simultaneously taking into account continuous power supply and real-time feedback of sensor data by reasonably setting the power supply frequency of the first direct current power supply, the coupling communication frequency of the sensor data, and the switching frequency between power supply and communication.

[0070] FIG2 shows a schematic structural diagram of a top drive control system based on bidirectional transmission according to an embodiment of the present invention.

[0071] As shown in Figure 2, the explosion-proof box at the coupled power receiving end supplies power (e.g., DC24V) to the sensor components (e.g., proximity switches 1 through 4, angle sensor, etc.) via a wired connection. The sensor component output signal is wired to the signal acquisition board at the power receiving end. At the coupled receiving end of the coupler, the modulated sensor data is coupled and transmitted to the power transmitting end. The power transmitting end receives the coupled signal via the coupled transmitting end of the coupler and, via a wired connection, transmits the demodulated sensor data as an analog signal to the master PLC in the top drive electrical control unit.

[0072] As shown in Figure 2, the circuit box at the power sending end is an explosion-proof box, which is placed in the elevator control box. It is connected to an external DC24V power supply and data cable, and converts the DC24V into AC power for the coupling transmitting end of the coupler to power the sensor at the receiving end. The coupling receiving end of the coupler receives the sensor data sent by the receiving end, and the power sending end transmits the sensor data through the top drive body electric control box in the top drive electric control unit and the top drive control room to the main control PLC through an analog cable.

[0073] FIG3 shows a schematic structural diagram of a power receiving terminal according to an embodiment of the present invention.

[0074] As shown in Figure 3, the power receiving end includes a rectifier module, a data acquisition module, and a modulation module. The rectifier module rectifies and stabilizes the AC power to generate a DC power source, which powers the data acquisition module and sensor components. The data acquisition module is connected to the sensor components to collect sensor data. The modulation module is connected to the data acquisition module to modulate the sensor data into a modulated signal.

[0075] Specifically, the coupler's secondary coil (secondary end coil, secondary side coil) is connected to the rectifier module through a cable hole in the top drive's slewing head. The rectifier module rectifies the AC power and stabilizes it to 24V DC, which powers the acquisition module and sensor assembly. For example, the sensor assembly contains five sensors: four proximity switches (with digital output) and one angle sensor (with 0-20mA output).

[0076] It should be noted that, in addition to the above five sensors, the sensor assembly can also power other sensors at the bottom of the top drive slewing head, such as the hydraulic elevators and lifting rings, in addition to the sensors at the bottom of the top drive slewing head. The present invention does not limit this.

[0077] For example, in one embodiment, the sensor assembly is a sensor for monitoring the make-up and tightening status of the top drive during the make-up process, thereby achieving continuous detection of the make-up status of the top drive. Specifically, these sensors may include a lifting eye inclination sensor (angle sensor) installed on the top drive, a back-up clamp pressure sensor, a back-up clamp proximity switch, a load signal sensor installed on the elevator, and a displacement sensor installed in the top drive balance cylinder.

[0078] In one embodiment, proximity switch 1 is an IBOP (top drive internal blowout preventer) proximity switch. The proximity switch is fixed to a fixed shaft, and the proximity switch detection plate is fixed to the IBOP bracket. The proximity switch detection plate moves simultaneously with the IBOP switch mechanism to detect switch position information. Proximity switch 2 is a back-up tong proximity switch. The proximity switch is fixed to the back-up tong anti-torque frame, and the proximity switch detection plate is fixed to the back-up tong anti-torque plate. Proximity switch 3 is elevator proximity switch 1, and proximity switch 4 is elevator proximity switch 2. The angle sensor is a hoist ring inclination sensor, fixed to the hoist ring to provide feedback on the hoist ring's inclination angle.

[0079] In one embodiment, the acquisition module acquires sensor signals, modulates them through the modulation module, and transmits them to the secondary coil of the coupler, which then transmits them to the power transmission end via the primary coil. Furthermore, as shown in Figure 2, the rectifier module, acquisition module, and modulation module are located within a flameproof enclosure at the coupled power receiving end.

[0080] Figure 4 shows a schematic diagram of the coupler structure according to an embodiment of the present invention. Figure 5 shows a schematic diagram of the magnetic core structure dimensions and a sealing diagram according to an embodiment of the present invention.

[0081] As shown in Figures 4 and 5, the coupler comprises a transmitting core, a primary coil, a receiving core, and a secondary coil. The receiving core and the transmitting core do not touch each other; the transmitting core is fixedly attached to the top drive body, while the receiving core is connected to the lower portion of the top drive's rotary head. The primary coil is wound around the transmitting core and sealed within it; the secondary coil is wound around the receiving core and sealed within it.

[0082] In one embodiment, the receiving-end magnetic core (rotating end) is mounted on the top drive turret and rotates with it. Specifically, a gap of a predetermined distance (e.g., 1 cm) is formed between the fixed-end transmitting-end magnetic core and the rotating end. The surfaces of the two cores can be sealed with an insulating material such as glass glue. There is no wired electrical connection between the two cores; power and signals are transmitted wirelessly through coupling. For example, a gap of approximately 10 mm is created between the transmitting-end and receiving-end magnetic cores.

[0083] A plurality of U-shaped magnetic cores are spliced ​​together to form a ring-shaped receiving-end magnetic core. The secondary coil is wound on the U-shaped winding groove of the U-shaped magnetic core, and the primary coil is wound on the transmitting-end magnetic core (eg, the U-shaped magnetic core).

[0084] In one embodiment, as shown in Figure 4, the transmitting-end magnetic core is constructed by splicing multiple U-shaped magnetic cores into a sector-shaped ring structure, with the primary coil wound around the U-shaped groove in the transmitting-end magnetic core; the receiving-end magnetic core is constructed by splicing multiple U-shaped magnetic cores into a circumferential ring structure, with the primary coil wound around the U-shaped groove in the receiving-end magnetic core. The vertical projection of the coil area in the sector-shaped ring structure precisely falls within the coil area of ​​the circumferential ring structure.

[0085] Therefore, when the top drive rotary head rotates, the receiving end magnetic core will be driven to rotate. When the vertical projection area of ​​the first annular winding groove of the transmitting end magnetic core just falls into the second annular winding groove area, the coil area of ​​the primary coil just falls into the rotating secondary coil area.

[0086] In one embodiment, as shown in Figures 4-5, all U-shaped grooves in the power-transmitting end magnetic core form a first annular winding groove within the annular space of the sector-shaped annular structure, and the primary coil is wound circumferentially along the first annular winding groove. All U-shaped grooves in the power-receiving end magnetic core form a second annular winding groove within the annular space of the angular annular structure, and the secondary coil is wound circumferentially along the second annular winding groove.

[0087] Furthermore, a first sealing layer is provided on the coil side of the sector ring structure, and a second sealing layer is provided on the coil side of the angular ring structure. This seals the primary coil inside the transmitting-end magnetic core, while the secondary coil is also sealed inside the receiving-end magnetic core.

[0088] In one embodiment, the maximum allowable size of the receiving-end magnetic core is designed based on the top drive structure. Directly molding a toroidal core with exactly matching dimensions would be difficult and result in a high scrap rate. Furthermore, large ferrite cores are extremely fragile or break under pressure, which can affect the coupler's communication performance or even cause complete failure. To address this, the present invention uses small U-shaped cores, splicing multiple U-shaped cores to form a large toroidal core. These small cores are less fragile, and even if individual small cores break, the impact on communication is minimal, as shown in Figure 4.

[0089] In one embodiment, the width ( L1 ) and length ( H1 ) of the bottom surface of each U-shaped magnetic core are greater than the height ( W3 ) of the U-shaped magnetic core.

[0090] In a specific embodiment, when designing the dimensions, the outer diameter (φ1) of the angular annular structure is equal to the inner diameter (φ2) of the angular annular structure + 2×the length of the bottom surface of the U-shaped core (H1), L1=H2=H4, H1=H2+H3+H4, W1=W2, W3=W1+W2, and W4=1 / 2W1. Specifically, considering actual errors, the outer diameter of the receiving end core is φ1=700mm, the inner diameter of the receiving end core is φ2=580mm, the height of the U-shaped core is H1=56mm, H2=15mm, the length of the U-shaped core winding slot is H3=26mm, H4=15mm, the width of the U-shaped core bottom is L1=15mm, the height of the U-shaped core winding slot from the bottom surface is W1=4mm, the height of the U-shaped slot is W2=4mm, the height of the U-shaped core is W3=8mm, and the thickness of the sealing layer is W4=2mm. Furthermore, the sealing material is an insulating material, for example, glass glue is used to pot the coupler.

[0091] In one embodiment, an inverter circuit and a receiver circuit are housed within the circuit box at the power transmission end. The inverter circuit utilizes a full-bridge inverter circuit and employs PWM pulse-width modulation to convert the first DC power into AC power. The receiver circuit demodulates the modulated signal and transmits it to the top drive control room within the top drive electrical control unit. Specifically, the power transmission end receives the modulated signal from the power receiving end and transmits it to the master control PLC via 485, 232, or Ethernet cable, using the Modbus protocol.

[0092] FIG6 shows a schematic diagram of the coupling transmission principle according to an embodiment of the present invention.

[0093] As shown in Figure 6, during coupling transmission, the current i1 generates a magnetic flux Φ passing through the primary coil. 11 , while generating a magnetic flux Φ passing through the secondary coil 21 , Φ 11 Magnetic flux that does not pass through the secondary coil Φ 1n It is called leakage flux, Φ 11 =Φ 21 +Φ 1n .

[0094] In one embodiment, the coupling coefficient:

[0095] In one embodiment, the secondary-side coupled electromotive force is:

[0096] During the coupled power supply process, the transmitting end inverts the first DC power into AC power, transmits the AC power to the secondary coil (secondary coil) of the coupler through the primary coil (primary end coil) of the coupler, and the AC power is transmitted to the receiving end through the secondary coil. The receiving end rectifies the AC power to obtain the second DC power to power the sensor.

[0097] During the coupled communication process, the receiving end modulates the collected sensor data into a modulation signal, transmits the modulation signal to the primary coil of the coupler through the secondary coil of the coupler, and then transmits the modulation signal to the transmitting end.

[0098] FIG7 shows a schematic structural diagram of a coupled power supply process according to an embodiment of the present invention.

[0099] During the coupled power supply process, the inverter circuit at the power sending end inverts the externally provided 24V DC into a 40kHz high-frequency AC signal and modulates it to the coupler; the rectifier circuit at the power receiving end rectifies the AC signal transmitted by the coupler and stabilizes it to 24V to power the acquisition module and sensor components.

[0100] As shown in Figure 7, a DC power supply provides a DC voltage to the inverter circuit at the power transmission end. After passing through the (high-frequency) inverter circuit, the DC voltage generates a high-frequency AC voltage (for example, 40kHz high-frequency AC). Its operating frequency is adjusted by the PWM control circuit (as shown in Figure 9) that controls the inverter circuit. The generated high-frequency AC voltage is applied to the primary coil of the coupler. According to Faraday's law of electromagnetic induction, the alternating current generates a magnetic field. The secondary coil of the coupler induces the magnetic field and couples out an AC voltage signal. After rectification and filtering, it is converted back into a DC signal and output to the load, thereby realizing contactless power transmission.

[0101] FIG8 shows a topological diagram of a full-bridge inverter circuit according to an embodiment of the present invention.

[0102] As shown in Figure 8, a full-bridge inverter circuit is used to realize the inversion from DC to high-frequency AC in the inverter circuit. The DC end of the full-bridge inverter circuit is connected to the external DC power supply V dc , four switching tubes (V1, V2, V3, V4) and four freewheeling diodes (VD1, VD2, VD3, VD4) form two bridge arms (half bridge) to realize full-bridge inverter, and the external DC power supply V dc Inverted into high-frequency AC power U o .

[0103] In one embodiment, as shown in FIG7 , a top drive control system based on bidirectional transmission further includes two resonant compensation circuits (primary-end resonant compensation circuit and secondary-end resonant compensation circuit) for compensating for reactive power attenuation caused by the inductive nature of the primary and secondary coils of the coupler, wherein each resonant compensation circuit includes a resonant compensation inductor and a resonant compensation capacitor connected in series. Specifically, as shown in FIG8 , the output of the inverter circuit is connected to the R p and C p It is the primary end resonant compensation circuit, which is used to compensate for the reactive power attenuation caused by the inductive nature of the primary coil. The primary end resonant compensation circuit is connected to the primary coil (primary end coil) L of the coupler. pFurthermore, the structure of the secondary-end resonant compensation circuit is the same as that of the primary-end resonant compensation circuit, and is connected between the secondary coil (secondary-end coil) of the coupler and the input end of the rectifier module (rectifier circuit).

[0104] FIG9 shows a schematic diagram of PWM pulse width modulation according to an embodiment of the present invention.

[0105] As shown in Figure 9, a high-frequency full-bridge square-wave output inverter circuit is implemented by splicing two half-bridge chips. The square-wave output inverter is driven and controlled by a pulse-width modulation (PWM) integrated circuit, employing the dead-band control method shown in Figure 10. Inductively coupled power transmission systems have large leakage inductance due to the presence of loosely coupled induction coils. The reactive power generated by the inductive coupling limits the active power transmitted, thus affecting the efficiency of the entire system. Therefore, the present invention uses capacitors to compensate for the inductive reactance in the balancing circuit.

[0106] In one embodiment, a top drive control system based on bidirectional transmission further includes an inductive reactance compensation circuit, which is used to balance the leakage inductive reactance of the primary side of the coupler and the mapped inductive reactance of the secondary side, thereby reducing the reactive power of the secondary side. The inductive reactance compensation circuit includes a first capacitor connected in series with the primary coil of the coupler and a second capacitor connected in series with the secondary coil of the coupler.

[0107] Specifically, the compensation capacitor on the primary side (the first capacitor C1) is used to balance the leakage inductance of the primary side and the reflected inductance of the secondary side, thereby reducing the input apparent power and improving the input power factor; the compensation capacitor on the secondary side (the second capacitor C2) is used to reduce the reactive power of the secondary side and increase the output power.

[0108] FIG11 and FIG12 respectively show a schematic diagram of a series compensation structure and a schematic diagram of a parallel compensation structure according to an embodiment of the present invention.

[0109] The comparison curves in Figure 13 show that the transmission efficiency of the two compensation structures varies under different light and heavy loads. In one embodiment, the load is a sensor (e.g., total power requirement <5W), so a series capacitor supplementation method is selected between the primary and secondary terminals, as shown in Figure 11, indicating that the primary and secondary terminals are voltage-type inputs and outputs.

[0110] FIG14 shows a schematic diagram of co-transmission of electric energy and signals according to an embodiment of the present invention.

[0111] During the coupling communication process, the receiving end sends the sensor signal obtained by the acquisition module to the secondary coil of the coupler through the modulation module and then sends it to the sending end; the sending end receives the coupled signal and sends the sensor data to the main control in the form of an analog signal through a wired connection.

[0112] In one embodiment, a top drive control system based on bidirectional transmission further includes a wave trap assembly, which is used to reduce interference caused by coupled power transmission on coupled communication transmission. The wave trap assembly includes a first wave trap disposed at the power transmitting end and a second wave trap disposed at the power receiving end. Specifically, as shown in FIG14 , the first wave trap is disposed between the output of the inverter circuit and the primary coil of the coupler, and the second wave trap is disposed between the secondary coil of the coupler and the input of the rectifier module.

[0113] As shown in FIG14 , a group of coils is used to transmit signals and energy simultaneously, which can save space. However, energy transmission greatly interferes with signal transmission. The present invention adds a wave arrester to reduce the interference of energy transmission on signal transmission, but this puts higher requirements on resonant matching.

[0114] Specifically, the function of the wave trap is to prevent the communication signal from entering the inverter circuit at the primary end and the rectifier circuit at the secondary end, so that the analog signal frequency is equal to the LC resonant frequency, and to prevent the communication signal from attenuating in other circuits. The equivalent impedance of the LC parallel resonance is:

[0115] Where r<<ωL, we get:

[0116] When the analog communication signal is transmitted at this resonant frequency, the equivalent impedance of the resonant circuit is purely resistive and reaches its maximum value, which greatly hinders the flow of the communication signal from the primary end to the inverter circuit and from the secondary end to the rectifier circuit.

[0117] FIG15 shows a schematic structural diagram of a signal modulation and demodulation circuit according to an embodiment of the present invention.

[0118] In one embodiment, as shown in FIG14 , the signal transmission circuit at the power transmitting end is a receiving circuit for demodulating the modulated signal, and the signal transmission circuit at the power receiving end is a modulation module for modulating the sensor data into the modulated signal.

[0119] In one embodiment, frequency-shift keying (FSK) is used to implement modulation and demodulation of sensor data.

[0120] As shown in Figure 15, during the modulation process, the sensor data passes through the 2ASK modulation circuit (binary amplitude shift keying), the modulation amplifier circuit, and the isolation circuit to obtain the modulated signal. Specifically, as shown in Figure 16, the baseband signal passes through the 2ASK modulation circuit, the modulation amplifier circuit, and the isolation circuit to obtain the modulated signal (FSK modulation signal).

[0121] As shown in Figure 15, during the demodulation process, the modulated signal passes through an isolation circuit, a bandpass filter, a demodulation amplifier circuit, and a detection circuit to output sensor data. Specifically, as shown in Figure 17, the modulated signal passes through an isolation circuit, two bandpass filters, a multiplier, and two envelope detectors before entering the sampling decision circuit and outputting the sensor data.

[0122] To utilize sensor data from the sensor assembly at the bottom of the top drive slewing head, an embodiment of the present invention further provides a solution for using the top drive electronic control unit to determine whether the top drive can automatically achieve both lashing and tightening. By adding a lifting eye inclination sensor, a back-clamp pressure sensor, and a back-clamp proximity switch to the top drive at the bottom of the top drive slewing head, a load signal sensor to the elevator, and a displacement sensor to the top drive balance cylinder, the entire column lashing operation, including lower lashing, upper lashing, and upper tightening, can be automatically performed.

[0123] Furthermore, the top drive electronic control unit in this embodiment of the present invention also uses sensor data from the sensor assembly to perform automatic top drive lashing and fastening status diagnosis. In this embodiment of the present invention, the main components implementing the lashing and fastening status diagnosis can be implemented by the main control PLC or other control components in the top drive electronic control unit, which is not specifically limited by the present invention.

[0124] Before step S1801 is implemented, the fastening and tightening status diagnosis process according to the embodiment of the present invention further includes: step S1800 (not shown), automatically completing the fastening operation of the lower part of the pipe string for the pipe string to be run.

[0125] 2 , in step S1800, first, the top drive electronic control unit receives the (pipe string) lower part fastening instruction, and aligns the elevator with the wellhead center by detecting the change state of the lifting eye inclination, so that the current pipe string is supported by the drilling floor equipment and positioned to the wellhead center, thereby lowering the traveling block by the drilling platform control system; then, the top drive electronic control unit receives and detects the elevator load signal, and after the elevator load signal disappears, generates a first control instruction for controlling the drilling platform control system to lower the traveling block according to a preset first lowering height, and causes the drilling platform control system to lower the traveling block to the specified first lowering height under the action of the first control instruction, thereby completing the pipe string lower fastening task; finally, the top drive electronic control unit feeds back a pipe string lower part fastening completion signal to the drilling platform control system.

[0126] In one embodiment, the embodiment of the present invention detects the inclination of the lifting ring in real time by means of an inclination sensor (angle sensor) provided at the lifting position.

[0127] Specifically, the top drive receives a pipe to be lowered from the drill floor equipment in the second-layer platform pipe arrangement. The drilling platform control system sends a pipe lower fastening command to the top drive electronic control unit according to the actual working conditions. After receiving the lower fastening command, the top drive electronic control unit detects the real-time change of the lifting ring inclination angle and controls the lifting ring inclination to ensure that the elevator is aligned with the center of the wellhead (to ensure that the pipe coupling can enter the top drive bell mouth). After that, when the lifting ring runs to the vertical state, the drill floor equipment supports the current pipe to be lowered and accurately positions the pipe to the center of the wellhead. Then, the drilling platform control system lowers the traveling block.

[0128] A load signal sensor (switch quantity) provided at the elevator is used to collect a signal (i.e., a load signal) indicating whether the elevator is bearing the load of the pipe string. The top drive electronic control unit receives and detects the elevator load signal in real time. When the top drive electronic control unit detects that the elevator load signal is set to 0, it indicates that the elevator load signal disappears, and it is determined that the lower thread is successfully fastened. The top drive electronic control unit will control the drilling platform control system to lower the traveling block to the first lowering height, and then control the drilling platform control system to stop lowering the traveling block. At this time, the fastening task of the lower part of the pipe string and the drilling platform is completed, thereby reserving space for the lower drilling rig to fasten. At this time, the iron roughneck goes to the wellhead to perform the fastening operation on the lower part of the pipe string. Afterwards, the top drive electronic control unit will feedback the lower part of the pipe string fastening completion signal to the drilling platform control system.

[0129] In addition, when the traveling block was lowered from the beginning to the first lowering height, the top drive electronic control unit detected that the real-time received elevator load signal had not disappeared. At this time, the connection between the lower part of the pipe string and the drilling platform was unsuccessful, and the current detection process was terminated (i.e., the automatic detection program was stopped and switched to manual operation).

[0130] After the make-up is completed, the top drive electronic control unit will send a signal to the drilling platform control system that the lower part of the pipe string is completed.

[0131] In one embodiment, after receiving the lower part fastening completion signal of the tubing string, the drilling platform control system issues an upper part fastening instruction (of the tubing string) and feeds the upper part fastening instruction back to the top drive electronic control unit.

[0132] After completing the lower and upper threading operations of the tubing string, the top drive electronic control unit will receive the upper threading command, and the drilling platform control system will lower the traveling block carrying the tubing string. When it detects that it has been lowered to the preset position (for example, near the bell mouth), the automatic threading mode will be activated.

[0133] After completing the lower fastening of the pipe string, the top drive electronic control unit will receive an upper fastening instruction sent by the drilling platform control system; then, according to the preset second lowering height, it will generate a second control instruction for controlling the drilling platform control system to continue lowering the traveling block, and the drilling platform control system will lower the traveling block to the top drive bell mouth under the action of the second control instruction to start the automatic fastening mode.

[0134] In one embodiment, the second lowering height represents the distance between the elevator and the bellmouth of the top drive, and is calculated based on information such as the current string length and the lifting eye length provided by the drilling tool management system.

[0135] Specifically, as shown in Figure 19, after the lower drill string is made up, the drilling platform control system issues a command for making the upper portion of the pipe string. The drilling platform control system begins lowering the traveling block. Based on the second control command generated by the top drive electronic control unit and the second lowering height calculated by the top drive electronic control unit, the drilling platform control system, under the action of the second control command, continues to lower the current pipe string to a set height (the second lowering height). When the current pipe string is lowered near the top drive bellmouth, the top drive electronic control unit activates the automatic spin-up mode, thereby entering step S1801. After the automatic spin-up mode is activated, the drilling platform control system slows down the lowering speed.

[0136] Step S1801 (top drive electronic control unit) obtains real-time torque data of the top drive, and based on the real-time torque data of the top drive, combined with the position indication signal indicating that the pipe string enters the bell mouth of the top drive back-up clamp and the displacement data of the top drive balance cylinder, determines whether the current top drive protection joint and the pipe string joint are successfully fastened.

[0137] In addition, when the automatic threading mode is turned on, step S1801 also includes: opening the pressure control valve for the top drive balance cylinder so that the upward pulling force on the top drive balance cylinder is slightly smaller than the gravity of the top drive itself, thereby protecting the thread from compression during the automatic threading process; and then, sending an instruction to the drilling platform control system to continue lowering the traveling block.

[0138] In one embodiment, when the automatic spinning mode is turned on, the top drive begins to spin at a set torque, and the top drive electronic control unit will open a secondary pressure reducing valve for decompressing the top drive balance cylinder to ensure that the lifting force is slightly less than the gravity of the top drive body.

[0139] After the top drive balance cylinder is depressurized, the pressure received by the top drive spindle is kept within a certain range (not too large or too small). At this time, the top drive electronic control unit will send an instruction to the drilling platform control system to continue lowering the traveling block, so that the traveling block will continue to be lowered after the spindle mode is started and the cylinder is depressurized to detect whether the upper part of the pipe string and the top drive protection joint are successfully connected.

[0140] In step S1801, the top drive electronic control unit determines whether the pipe string enters the bell mouth of the top drive back-up tong by detecting the triggering state of the above-mentioned position indication signal in real time. After the pipe string enters the bell mouth of the top drive back-up tong, the top drive electronic control unit detects whether the top drive torque reaches the locked position state based on the top drive real-time torque data and the preset spin-down torque threshold, and detects whether the traveling block reaches the target position based on the displacement data and the preset displacement threshold. When the top drive torque reaches the locked position state and the traveling block reaches the target position (for example, the spin-down end position), it is determined that the current top drive saver sub and the pipe string sub are successfully locked.

[0141] In one embodiment, when the position indication signal is not triggered, it is determined that the currently lowered tubular string has entered the bell mouth of the top drive back tong. Alternatively, after the position indication signal is triggered, it is determined that the currently lowered tubular string has not entered the bell mouth of the top drive back tong.

[0142] In one embodiment, when the real-time torque data of the top drive reaches or exceeds a preset spin-up torque threshold, it is determined that the current top drive torque has reached the locked-in position. Alternatively, when the real-time torque data of the top drive does not reach the preset spin-up torque threshold, it is determined that the current top drive torque has not reached the locked-in position.

[0143] In one embodiment, when the displacement data of the top drive balancing cylinder reaches or exceeds a preset displacement threshold, a top drive cylinder signal is determined to be triggered, indicating that the traveling block has reached the target position. Alternatively, when the displacement data of the top drive balancing cylinder does not reach the preset displacement threshold, a top drive cylinder signal is determined to be untriggered, indicating that the traveling block has not reached the target position.

[0144] Finally, if it is determined that the top drive torque has reached the locked-in position and the traveling block has reached the target position, the top drive protection sub and the upper joint of the string are successfully locked. Alternatively, if it is determined that the top drive torque has not reached the locked-in position and / or the traveling block has not reached the target position, the top drive protection sub and the upper joint of the string are unsuccessfully locked. At this point, the current detection process ends (i.e., the automatic detection process is stopped and manual operation is switched).

[0145] In this embodiment of the present invention, a proximity switch installed on the anti-torque frame of the top drive back-up tong detects whether the tubing string has entered the bell mouth of the top drive back-up tong. Simultaneously, a displacement sensor installed inside the top drive balance cylinder detects the displacement data of the top drive balance cylinder.

[0146] The added proximity switch allows the top drive to be lowered to connect with the tubing during make-up. If the drill string is not introduced into the top drive's back-up tong bell mouth, the tong will move upward. The proximity switch detects this movement. A signal from the proximity switch indicates the drill string is not introduced into the back-up tong. A no signal from the proximity switch indicates the drill string is introduced into the back-up tong. Simultaneously, the top drive is spinning and lowering. The top drive detects the completion of the spin-up when the spin-up torque reaches the specified value and outputs a signal.

[0147] Then, after the fastening is successful, the top drive electronic control unit will also send an instruction to the drilling platform control system to stop lowering the traveling block and notify the drilling platform control system that the current top drive protection joint and the upper joint of the pipe string are successfully fastened. Then, the drilling platform control system will feedback the fastening instruction to the top drive electronic control unit.

[0148] After determining whether the top drive protection joint and the pipe string joint are successfully fastened, the process proceeds to step S1802.

[0149] Step S1802: After the fastening is successful, the top drive electronic control unit receives the fastening instruction and diagnoses the top drive fastening status by detecting the clamping status of the top drive back-up tong and the real-time torque data of the top drive.

[0150] In step S1802, the top drive electronic control unit obtains the top drive back-up tong pressure data in real time, and determines whether the fastening action reaches the clamping state based on the real-time top drive back-up tong pressure data; thereafter, when the clamping state is reached, the top drive electronic control unit will also detect whether the top drive and the upper part of the pipe string are fastened based on the top drive real-time torque data and the preset fastening torque threshold to determine whether the top drive is fastened in place.

[0151] In one embodiment, the top drive electronic control unit determines whether the current upper clasp action has reached a clamping state based on the top drive back-clamp pressure data and a preset back-clamp pressure threshold. Specifically, if the top drive back-clamp pressure data reaches or exceeds the preset back-clamp pressure threshold, the current upper clasp action is determined to have reached a clamping state. If the top drive back-clamp pressure data does not reach the preset back-clamp pressure threshold, the current upper clasp action is determined to have not reached a clamping state.

[0152] In the embodiment of the present invention, a pressure sensor is provided at the oil port of the rodless chamber of the top drive back-up tong so that the top drive electronic control unit can obtain the top drive back-up tong pressure data in real time.

[0153] In one embodiment, when the current upper portion fastening action reaches a clamping state, if the top drive electronic control unit detects that the top drive real-time torque data reaches or exceeds a preset fastening torque threshold, it is determined that the current top drive is fastened to the upper portion of the tubular string (i.e., the top drive is fastened in place). Alternatively, when the current upper portion fastening action reaches a clamping state, if the top drive electronic control unit detects that the top drive real-time torque data does not reach the preset fastening torque threshold, then the current top drive is not fastened to the upper portion of the tubular string (i.e., the top drive is not fastened in place).

[0154] The drilling platform control system issues a tightening command, and the top drive electronic control unit evaluates the clamping status of the backup clamp (the backup clamp is equipped with a pressure sensor). When the backup clamp pressure reaches the set value, the clamping is determined to be successful. The top drive electronic control unit begins to detect according to the set tightening torque value. When the real-time torque value reaches the set tightening torque, it indicates that the top drive is tightened in place, and the entire process is automatically completed.

[0155] On the other hand, based on the above top drive control system, an embodiment of the present invention further provides a top drive control method based on bidirectional transmission. The top drive control method is implemented by the above top drive control system based on bidirectional transmission.

[0156] In summary, the present invention provides a top drive control system based on bidirectional transmission, which has the following advantages over the prior art:

[0157] 1) The present invention conducts research on top drive coupled power supply and communication technology. The coupled power supply is used to power the sensor installed at the bottom of the top drive slewing head. The coupled communication is used to transmit the signal of the sensor at the bottom of the slewing head to the top drive electrical control room, thereby achieving stable power supply for the sensor and reliable signal transmission.

[0158] 2) The power transmission end of the present invention converts the DC voltage through a high-frequency inverter circuit to generate a high-frequency AC voltage. The operating frequency of the DC voltage is adjusted by a PWM control circuit that controls the inverter circuit. The generated high-frequency AC voltage is applied to the primary coil of the coupler. According to Faraday's law of electromagnetic induction, the alternating current generates a magnetic field. The secondary coil of the coupler induces the magnetic field and couples out an AC voltage signal. After being rectified and filtered at the power end, it is converted back into a DC signal and output to the load, realizing contactless power transmission.

[0159] 3) The present invention designs and customizes the core size that meets the top drive structure, processes a small-sized U-shaped core, and splices multiple U-shaped small cores to form a large core with a ring structure. The small cores are not easy to break, and even if individual small cores are broken, the overall impact on communication is minimal;

[0160] 4) The present invention uses a resonant compensation circuit to compensate for the reactive power attenuation caused by the inductive nature of the primary and secondary coils of the coupler; uses an inductive reactance compensation circuit to balance the leakage reactance of the primary side of the coupler and the mapped reactance of the secondary side, thereby reducing the reactive power of the secondary side; uses a wave trap to reduce the interference of coupled power transmission on coupled communication transmission; and uses frequency shift keying to achieve modulation and demodulation of sensor data.

[0161] 5) The present invention effectively realizes the automated control of the pipe string buckling and twisting operations by adding sensors such as a lifting ring inclination sensor, a back-up clamp pressure sensor, and a back-up clamp proximity switch to the top drive, adding a load signal sensor to the elevator, and adding a displacement sensor to the top drive balance cylinder under the action of the designed detection and judgment logic, thereby effectively improving the operating efficiency and reducing the workload of ground staff.

[0162] It should be understood that the embodiments disclosed herein are not limited to the specific structures, processing steps, or materials disclosed herein, but should extend to equivalent substitutions of these features understood by those skilled in the relevant art. It should also be understood that the terminology used herein is for the purpose of describing specific embodiments only and is not intended to be limiting.

[0163] In the description of the present invention, unless otherwise specified, "plurality" means two or more; terms such as "upper," "lower," "left," "right," "inner," "outer," "front end," "rear end," "head," and "tail" indicate positions or relationships based on those shown in the accompanying drawings. These terms are intended solely to facilitate the description of the present invention and simplify the description. They do not indicate or imply that the devices or components referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limiting the present invention. Furthermore, terms such as "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0164] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "connected" and "connection" should be understood in a broad sense. For example, they can refer to fixed connection, detachable connection, or integral connection; mechanical connection, electrical connection; direct connection, or indirect connection through an intermediary. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0165] Certain terms are used throughout this application document to indicate specific system components. As will be appreciated by those skilled in the art, different names may be used to indicate the same component, and thus this application document is not intended to distinguish between components that are only different in name but not in function. In this application document, the terms "comprise," "include," and "have" are used in an open format and should therefore be interpreted as meaning "including, but not limited to...". In addition, the terms "substantially," "substantially," or "approximately" that may be used herein refer to industry-accepted tolerances for the corresponding terms. The term "coupling," as used herein, includes direct coupling and indirect coupling via another component, element, circuit, or module, wherein for indirect coupling, the intervening component, element, circuit, or module does not change the information of the signal but can adjust its current level, voltage level, and / or power level. Inferred coupling (e.g., one element is coupled to another element by inference) includes direct and indirect coupling between two elements in the same manner as "coupling."

[0166] References in this specification to "one embodiment" or "an embodiment" mean that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Therefore, appearances of the phrases "one embodiment" or "an embodiment" in various places throughout this specification do not necessarily refer to the same embodiment.

[0167] The embodiments of the present invention are presented for purposes of illustration and description and are not intended to be exhaustive or to limit the invention to the disclosed forms. Many modifications and variations will be apparent to those skilled in the art. The embodiments are chosen and described in order to better illustrate the principles of the invention and its practical application and to enable those skilled in the art to understand the invention and design various embodiments with various modifications as suited for specific applications.

[0168] Although the embodiments disclosed herein are as described above, the contents described herein are merely embodiments for facilitating understanding of the present invention and are not intended to limit the present invention. Any person skilled in the art of the present invention may make any modifications and changes in the form and details of the implementation without departing from the spirit and scope disclosed herein. However, the scope of patent protection of the present invention shall still be subject to the scope defined by the appended claims.

Claims

1. A top drive control system based on bidirectional transmission, characterized in that: include: A power transmission end, which is used to convert the first direct current into alternating current; A coupler for transmitting the alternating current by electromagnetic induction; A power receiving end, which is used to receive the alternating current transmitted through the coupler, convert the alternating current into a second direct current so as to continuously power the sensor assembly in the top drive, and modulate the sensor data from the sensor assembly into a modulation signal, and feed the modulation signal back to the power sending end through the coupler; The top drive electric control unit is used to receive the sensor data analyzed by the power transmission end in real time.

2. The top drive control system according to claim 1, characterized in that: The coupler comprises: A power supply end magnetic core connected to the top drive body; The power receiving end magnetic core connected to the top drive rotary head; A primary coil wound on the power-transmitting-end magnetic core, wherein the primary coil is sealed inside the power-transmitting-end magnetic core; A secondary coil is wound around the power receiving end magnetic core, and the secondary coil is sealed inside the power receiving end magnetic core.

3. The top drive control system according to claim 2, characterized in that: The power transmission end magnetic core is constructed into a fan-shaped ring structure by splicing a plurality of U-shaped magnetic cores, and the primary coil is wound on the U-shaped groove in the power transmission end magnetic core; The receiving end magnetic core is constructed into a circumferential annular structure by splicing multiple U-shaped magnetic cores, the primary coil is wound on the U-shaped groove in the receiving end magnetic core, and the vertical projection of the coil area in the fan-shaped annular structure falls on the coil area of ​​the circumferential annular structure.

4. The top drive control system according to claim 3, characterized in that: All the U-shaped grooves in the power transmission end magnetic core form a first annular winding groove inside the annular space of the fan-shaped annular structure, and the primary coil is wound along the circumferential direction of the first annular winding groove; All the U-shaped grooves in the power receiving end magnetic core form a second annular winding groove inside the annular space of the angular annular structure, and the secondary coil is wound along the circumferential direction of the second annular winding groove.

5. The top drive control system according to claim 4, characterized in that: A first sealing layer is provided on the coil side of the fan-shaped annular structure; A second sealing layer is arranged on the coil side of the angular annular structure.

6. The top drive control system according to any one of claims 3 to 5, characterized in that: The width and length of the bottom surface of each U-shaped magnetic core are greater than the height of the U-shaped magnetic core.

7. The top drive control system according to any one of claims 2 to 6, characterized in that: The power receiving end comprises: A collection module connected to the sensor assembly, used to collect the sensor data; A rectifier module, used for rectifying and stabilizing the alternating current to obtain the second direct current to power the acquisition module and the sensor assembly; The modulation module connected to the acquisition module is used to modulate the sensor data into the modulation signal.

8. The top drive control system according to claim 7, characterized in that: The power transmission end comprises: An inverter circuit, which uses a full-bridge inverter circuit to invert the first direct current into the alternating current; A receiving circuit is used to transmit the sensor data obtained after demodulating the modulated signal to the top drive electronic control unit.

9. The top drive control system according to claim 8, characterized in that: The top drive control system also includes: A resonant compensation circuit is used to compensate for reactive power attenuation caused by the inductance of a primary coil and a secondary coil, wherein the resonant compensation circuit comprises a resonant compensation inductor and a resonant compensation capacitor connected in series.

10. The top drive control system according to claim 8 or 9, characterized in that: The top drive control system also includes: An inductive reactance compensation circuit is used to balance the leakage inductive reactance of the primary side of the coupler and the mapped inductive reactance of the secondary side, thereby reducing the reactive power of the secondary side, wherein the inductive reactance compensation circuit comprises a first capacitor connected in series with the primary coil and a second capacitor connected in series with the secondary coil.

11. The top drive control system according to any one of claims 8 to 10, characterized in that: The top drive control system also includes: A wave trap assembly is used to reduce the interference of coupled power transmission on coupled communication transmission, wherein the wave trap assembly includes a first wave trap arranged at the power transmitting end and a second wave trap arranged at the power receiving end.

12. The top drive control system according to any one of claims 1 to 11, characterized in that: The sensor assembly is located at the lower part of the top drive rotary head.

13. The top drive control system according to any one of claims 1 to 12, characterized in that: The top drive electric control unit also implements the state diagnosis of automatic buckling and tightening of the top drive according to the sensor data.

14. The top drive control system according to claim 13, characterized in that: The top drive electronic control unit performs status diagnosis through the following steps: After entering the automatic buckle mode, the top drive protection joint and the pipe string joint are judged whether they are buckled successfully according to the top drive torque data, the position indication signal of the pipe string entering the bell mouth of the top drive back clamp and the displacement data of the top drive balance cylinder; After the fastening is successful, a fastening instruction is received, and the fastening status of the top drive is diagnosed by detecting the clamping status of the top drive back-up tong and the top drive torque data.

15. The top drive control system according to claim 14, characterized in that: The top drive electric control unit is also configured to determine whether the top drive protection joint and the pipe string joint are currently fastened successfully through the following steps: Judging whether the pipe string enters the bell mouth of the top drive back clamp by the triggering state of the position indication signal; After entering, detecting whether the top drive torque reaches the buckled position according to the top drive torque data and the preset buckle torque threshold, and detecting whether the traveling block reaches the target position according to the displacement data and the preset displacement threshold; When the top drive torque reaches the buckled position and the traveling block reaches the target position, it is determined that the buckled connection between the top drive protection joint and the pipe string joint is successful.

16. The top drive control system according to claim 15, characterized in that: When the position indication signal is not triggered, it is determined that the currently lowered tubular string enters the bell mouth of the top drive back tong; otherwise, it is determined that the currently lowered tubular string does not enter the bell mouth of the top drive back tong.

17. The top drive control system according to any one of claims 14 to 16, characterized in that: The sensor assembly comprises: a proximity switch installed on the anti-torque frame of the top drive back-up tong and a displacement sensor installed in the top drive balance cylinder, wherein: The proximity switch is used to detect whether the pipe string enters the bell mouth of the top drive back clamp; The displacement data is detected by the displacement sensor.

18. The top drive control system according to any one of claims 14 to 17, characterized in that: When the automatic buckle-spinning mode is turned on, the top drive electronic control unit is also configured to: Open the pressure control valve for the top drive balance cylinder so that the upward pulling force on the top drive balance cylinder is smaller than the gravity of the top drive itself; Send a command to the drilling platform control system to continue lowering the traveling block.

19. The top drive control system according to any one of claims 14 to 18, characterized in that: The sensor assembly includes: an angle sensor arranged at the lifting ring and a load sensor arranged at the lifting card, wherein the top drive electric control unit is further configured to: Receive the lower locking command, and align the elevator with the wellhead center by detecting the change of the lifting ring inclination, so that the current pipe string can be supported by the drilling floor equipment and positioned to the wellhead center, and the traveling block can be lowered by the drilling platform control system; receiving and detecting the elevator load signal, and after the elevator load signal disappears, generating a first control instruction for controlling the drilling platform control system to lower the traveling block according to a preset first lowering height, and causing the drilling platform control system to lower the traveling block to the first lowering height under the action of the first control instruction, thereby completing the task of fastening the lower part of the pipe string; A signal indicating that the lower part of the pipe string is made complete is fed back to the drilling platform control system.

20. The top drive control system according to claim 19, characterized in that: After completing the task of fastening the lower part of the pipe string, the top drive electronic control unit is also configured to: Get the upper clasp command; A second control instruction is generated according to the preset second lowering height to control the drilling platform control system to continue lowering the traveling block, and the drilling platform control system lowers the traveling block to the top drive bell mouth under the action of the second control instruction to start the automatic spinning mode.

21. The top drive control system according to any one of claims 14 to 20, characterized in that: The sensor assembly comprises: a pressure sensor arranged at the oil port of the rodless chamber of the top drive back-up tong, wherein the top drive electric control unit is further configured to diagnose the in-place status of the top drive buckle through the following steps: The pressure sensor is used to obtain the pressure data of the top drive back clamp in real time, and based on this, it is judged whether the clamping action reaches the clamping state; When the clamping state is reached, whether the top drive and the upper part of the pipe string are tightly fastened is detected according to the top drive torque data and a preset tightening torque threshold value, so as to determine the tightening state of the top drive.

22. The top drive control system according to claim 21, characterized in that: When the top drive torque data reaches or exceeds the preset tightening torque threshold, it is determined that the top drive is currently tightened with the upper portion of the pipe string; otherwise, it is not tightened.

23. The top drive control system according to claim 21 or 22, characterized in that: According to the top drive back-clamp pressure data and the preset back-clamp pressure threshold, it is judged whether the current buckling action reaches the clamping state, wherein when the top drive back-clamp pressure data reaches or exceeds the preset back-clamp pressure threshold, it is determined that the clamping state is reached, otherwise, the clamping state is not reached.

24. A top drive control method based on bidirectional transmission, characterized in that: The top drive control method is implemented by a top drive control system according to any one of claims 1-23.

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