Digitized Balance-Shifting Pumpjack with Movable Counterweight
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Solution Overview
Problem
Existing walking beam pumpjacks lack automatic balance adjustment and stroke frequency control, leading to inefficient oil-pumping capacity, increased power consumption, and potential equipment damage due to mismatched oil production and pumping capacity.
Innovation Solution
A digitized automatic control method for oil-pumping using a digitized balance-shifting pumpjack with a movable counterweight box, driven by a central processor that adjusts the counterweight and stroke frequency based on real-time current and power balance calculations, ensuring optimal balance and stroke frequency through sensors and a frequency converter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual balance adjustment is used, then device complexity is reduced, but balance rate decreases and power consumption increases
Solution Approach 1:
The pumpjack system automatically monitors its own balance state through sensors and adjusts the counterweight position without external intervention, achieving self-service balance maintenance that reduces power consumption while avoiding complex external control systems
Solution Approach 2:
The system uses sensors to detect balance status and provides feedback to the control unit, which then adjusts the counterweight position accordingly, creating a closed-loop feedback mechanism that optimizes power consumption while maintaining simple overall system architecture
2Device complexity
If stroke frequency is not adjusted automatically, then device complexity is reduced, but oil-pumping capacity mismatches oil production
Solution Approach 1:
The pumpjack system automatically monitors oil production rates and adjusts its own stroke frequency to match production requirements, achieving self-service operational optimization without complex external control systems
Solution Approach 2:
The system uses sensors to detect oil production rates and provides feedback to the control unit, which then adjusts the motor frequency and stroke rate accordingly, creating a closed-loop feedback mechanism that optimizes productivity while maintaining simple overall system architecture
3Productivity
If stroke frequency is too high, then oil-pumping capacity increases, but equipment damage occurs and energy is wasted
Solution Approach 1:
The system monitors operational parameters and provides feedback to adjust stroke frequency dynamically, preventing excessively high frequencies that would damage equipment while maintaining high productivity within safe operational limits
Solution Approach 2:
The system preemptively adjusts stroke frequency to prevent conditions that would lead to equipment damage, such as liquid impact or empty pumping, by monitoring production rates and limiting maximum frequency based on operational constraints
4Ease of operation
If manual balance adjustment is used, then ease of operation is reduced, but manufacturing cost decreases
Solution Approach 1:
The system automatically performs balance adjustments without requiring operator intervention, achieving self-service operation that greatly improves ease of operation while using simple, cost-effective sensors and control units rather than complex automated systems
Data Source
AI summary
Disclosed are a digitized automatic control method for oil-pumping and a digitized balance-shifting pumpjack, said pumpjack comprising a main motor (15), a decelerator (8), a crank (9), a connecting rod (6), a walking walking beam (3), a balance arm (7), a derrick (5), a horsehead (2), a substructure (12), brake device (13), a beam hanger (1), a load sensor (17), a stroke process measurer, a safety stop device, and a digitized control box (14). A movable counterweight box (28) moves leftward and rightward on the balance arm (7), automatically balancing load at the suspension center in various operating conditions, and pumpjack's frequency of stroke is automatically adjusted according to variations in pump fullness. Features include safety and reliability, convenience of operation, enhanced oil well production, balance rates, energy conservation and consumption reduction.