Laser Position Finding for Rod Pumped Well Control

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Solution Overview

Problem

Current methods for determining rod position in rod pumped wells are inaccurate, leading to unreliable dynographs and data, as they either model position or require incorrect geometry inputs, resulting in significant errors.

Innovation Solution

A laser positioning system is used, with a laser mounted on the well and a reflector plate positioned to transmit a beam, allowing for precise measurement of the distance between the laser and reflector plate, which is indicative of the rod's position, enhancing accuracy and safety by eliminating the need for manual measurements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If Hall-effect transducers or inclinometers are used to model rod position, then the system can operate with existing sensors, but the measurement accuracy deteriorates due to modeling errors and incorrect geometry inputs

Engineering Contradiction:

Improverod position accuracyVSAvoiddynograph accuracy

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent replaces mechanical modeling methods (Hall-effect transducers, inclinometers, load sensors) with an optical measurement system. A laser transmits a beam to a reflector plate attached to the rod, directly measuring rod position optically without mechanical modeling, thereby eliminating geometry input errors and improving both measurement precision and dynograph reliability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a reflector plate as an intermediary element attached to the rod. The laser beam reflects off this plate to enable precise optical measurement of rod position, serving as a mediator between the laser measurement system and the rod itself without requiring direct contact or mechanical modeling

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If manual measurements are performed to determine rod position, then installation is simple, but worker safety deteriorates due to required climbing and exposure to hazardous environments

Engineering Contradiction:

Improveinstallation simplicityVSAvoidworker safety

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The system enables self-service installation where the laser unit and reflector plate are mounted to automatically perform measurements without requiring workers to climb or manually measure. The automated optical system eliminates hazardous manual operations while maintaining installation feasibility

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual measurement methods with an automated optical measurement system. The laser and reflector plate automatically track rod position without human intervention during operation, eliminating worker exposure to climbing hazards while providing continuous precise measurements

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If traditional position measurement methods are used, then the system can operate with existing components, but maintenance and installation time increase due to calibration requirements and complex setups

Engineering Contradiction:

Improveinstallation and maintenance timeVSAvoidrod position accuracy

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent replaces complex mechanical measurement systems with a simplified optical system. The laser unit and reflector plate require minimal calibration and setup compared to Hall-effect transducers or inclinometer systems, reducing both installation and maintenance time while providing superior measurement precision through direct optical measurement

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The laser positioning system provides increased accuracy to within hundredths of an inch, reduces maintenance and installation time, and allows for safer operations without worker climbing, while offering quicker and more reliable load vs position data for control and diagnostics.

Implementation Method 1

a laser mounted on the well and a reflector plate mounted in a position near the laser such that the laser can transmit a beam onto the reflector plate thereby determining a distance between the laser and the reflector plate

Methodology Applied

Scientific EffectLaser: Laser

Data Source

PatentUS9624765B2Laser position finding device used for control and diagnostics of a rod pumped well

Publication Date: 2017.04.18 CHAMPIONX LLC

AI summary

A system for determining rod position in a rod pumped well is described that includes a laser unit mounted on an underside of the walking beam and a reflector plate mounted on the sampson post of the rod pumped well in a position near the laser unit. The laser transmits a beam onto the reflector plate allowing the laser unit to determine the distance between the laser and the reflector plate. The distance between the laser and reflector plate as determined by the laser is transmitted to a controller which calculates the position of the rod in the rod pumped well based on the distance determined by the laser.