Pump Jack Controller Harnessing Waste Energy for Grid Power
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Solution Overview
Problem
Current technologies do not utilize the potential energy generated by pump jacks to feed electricity back into the grid, despite the potential for energy conversion during their operation.
Innovation Solution
A pump jack controller system that includes a motor drive unit and a generator drive unit, capable of converting DC power to AC power and vice versa, allowing the pump jack to operate as a micro electric generator by harnessing waste energy and feeding it back into the electrical grid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the pump jack operates as a conventional motor-driven device, then it consumes electrical power from the grid, but it wastes the potential energy generated during the downward stroke of the beam
Solution Approach 1:
The controller system enables the induction motor to perform dual functions: operating as a motor during the upward stroke to lift the donkey head, and as a generator during the downward stroke to capture potential energy. This multi-functionality resolves the contradiction by allowing the same device to both consume and generate energy, converting waste energy into usable electrical power without requiring a completely separate generation system.
Solution Approach 2:
The system converts the previously harmful waste energy (potential energy lost during the downward stroke) into a beneficial resource (electrical energy fed back to the grid). The controller detects when the beam is in the downward position and switches the induction motor to generator mode, transforming the energy that would have been wasted into usable power, thereby resolving the energy loss issue while managing the complexity through intelligent control.
2Productivity
If the pump jack is modified to capture and convert waste energy into electricity, then energy utilization is optimized, but the device complexity increases due to additional control systems
Solution Approach 1:
The controller incorporates feedback mechanisms that continuously monitor the position of the beam and the operational state of the pump jack. Based on this feedback, the controller automatically switches between motor and generator modes, optimizing energy utilization by capturing potential energy during the downward stroke. The feedback system manages the complexity by providing automated, position-based control rather than requiring complex manual intervention or overly sophisticated control algorithms.
Solution Approach 2:
The system enables the pump jack to serve itself by generating its own electrical power during the downward stroke, which is then fed back to the grid or used to offset power consumption during the upward stroke. This self-service capability improves energy utilization by making the system partially self-sufficient, while the complexity is managed by using the existing induction motor infrastructure rather than adding completely separate motor and generator systems.
3Power
If the induction motor operates at speeds higher than synchronous speed to generate electricity, then waste energy is converted to electrical power, but the control precision required to manage slip increases
Solution Approach 1:
The system dynamically adjusts the operational mode of the induction motor based on the real-time position of the beam. During the downward stroke, when potential energy is available, the motor operates in generator mode with negative slip (speed higher than synchronous speed). The controller dynamically manages the transition between motor and generator modes, allowing the system to adapt its power generation characteristics to the varying mechanical conditions without requiring excessively precise speed control throughout the entire operational cycle.
Solution Approach 2:
The system changes the operational parameters of the induction motor, specifically allowing the slip parameter to become negative during generator operation. By controlling the motor to operate at speeds higher than synchronous speed (negative slip region), the system converts mechanical energy from the downward stroke into electrical power. The controller manages the parameter changes by switching based on beam position rather than requiring continuous precise speed regulation, thereby achieving power generation with manageable control precision requirements.
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
Enables the conversion of waste energy from pump jack operations into usable AC electric power, allowing the pump jack to function as a micro electric generator, aligning with grid interconnection standards and optimizing energy utilization.
Implementation Method 1
An induction or asynchronous motor is an alternating current ('AC') motor in which all electromagnetic energy is transferred by inductive coupling from a primary winding to a secondary winding
Implementation Method 2
the MDU configured to invert DC power supplied to the DC input into AC power that is outputted from the AC output to power the motor, the MDU further configured to rectify AC electric power generated by the motor into generated DC power
Implementation Method 3
the GDU configured to rectify a source of supplied AC electric power from the power grid coupled to the AC input into DC power that is outputted onto the DC bus, the GDU further configured to invert DC power supplied to the DC output into generated AC power that is outputted from the AC input back to the power grid
Data Source
AI summary
A pump jack controller is provided that can harness the waste energy generated during the operation of a pump jack when its electrical motor is in an over-speed condition, and convert that waste energy into electrical energy that can be supplied back onto an electrical power grid thus converting the pump jack into a micro electric power generator.