Augmenting Controller for Real-Time Drilling Rig Actuator Control
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Solution Overview
Problem
Existing drilling rig control systems, particularly those using programmable logic controllers (PLCs), are limited in their ability to perform advanced operations due to insufficient processing power and communication speed, restricting integration of new technologies and compatibility with advanced drilling domain applications.
Innovation Solution
An augmenting controller is introduced to enhance the control of actuators in drilling rigs, which is a PC-based system that processes algorithms related to drilling domain applications, integrating with existing PLCs to provide augmented control signals and support advanced operations such as stick-slip mitigation and adaptive drilling control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a PLC is used for controlling actuators in drilling rigs, then the control system is simple and reliable, but the processing power and communication speed are insufficient for advanced operations
Solution Approach 1:
The patent combines a PLC and a PC into a hybrid control system. The PLC handles basic real-time control functions while the PC provides enhanced processing power for advanced operations. The two controllers are electronically connected and work together, with the PC able to augment and modify control signals sent to actuators, thereby merging the reliability of PLC with the computational power of PC.
Solution Approach 2:
The patent introduces a PC as an intermediary controller between the PLC and actuators. The PC receives control signals from the PLC, processes them with enhanced computational capabilities, and sends augmented control signals to the actuators. This intermediary approach allows advanced operations to be performed while maintaining the simple PLC architecture for basic control.
2Speed
If a PLC is used for controlling actuators in drilling rigs, then the system is easy to operate, but the communication speed and bandwidth are insufficient for real-time advanced operations
Solution Approach 1:
The hybrid control system merges the ease of PLC operation with the high communication speed of PC-based systems. The PLC maintains simple operation for basic control functions, while the PC provides high-speed communication capabilities for real-time advanced operations through its electronic connection to the PLC and actuators.
3Adaptability or versatility
If existing PLCs are used, then the control system is stable, but it cannot perform advanced operations developed years after deployment
Solution Approach 1:
The PC controller serves multiple functions: it can perform advanced operations, process complex algorithms, provide high-speed communication, and also interface with the existing PLC to maintain stable basic control functions. This multi-functionality allows the system to adapt to new technologies while preserving the reliability of the original PLC-based control.
Solution Approach 2:
The PC acts as an intermediary that bridges between the stable PLC system and new advanced operations. It receives stable control signals from the PLC, adds advanced processing capabilities, and outputs augmented control signals, thereby enabling technology integration without compromising the stability of the original control system.
Data Source
AI summary
An augmenting controller for augmenting control of an actuator by a component controller. The actuator is operable to change an operational parameter of a component of a drilling rig. The component controller is configured for communicating control signals to the actuator to control the actuator and thereby control operation of the component. The augmenting controller is operable to augment the control signals.