Pumpjack Motor Speed Profile Optimization
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Solution Overview
Problem
Conventional pumpjacks operate with fixed or constant speed profiles, which can lead to inefficient fluid production and increased risk of detrimental operating conditions such as pump-off, high stress on the rod system, and high torque at the gearbox, due to their sinusoidal pumping motion.
Innovation Solution
Implementing a method where an electric motor operates a pumpjack with a dynamic motor speed profile adjusted based on real-time sensory feedback from sensors, such as load cells and rotation sensors, to optimize motor speeds throughout the stroke cycle, thereby increasing fluid production and reducing operational stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a fixed speed profile is used to operate the pumpjack, then the device complexity is reduced and ease of operation is improved, but fluid production efficiency decreases and detrimental operating conditions increase
Solution Approach 1:
The system implements real-time feedback by monitoring sensory data from sensors during pump stroke cycles and using this information to dynamically adjust motor speed profiles. The controller receives feedback about actual pumpjack operation and modifies control parameters for subsequent cycles, creating a closed-loop control system that optimizes fluid production while preventing detrimental conditions.
Solution Approach 2:
The patent transitions from static fixed speed profiles to dynamic speed profiles that adapt in real-time based on operating conditions. The motor speed is continuously adjusted during pump stroke cycles according to sensory feedback, allowing the system to respond to changing conditions and optimize performance without requiring complex manual intervention.
2Reliability
If real-time sensory feedback and dynamic speed adjustment are implemented, then fluid production efficiency increases and detrimental operating conditions are prevented, but device complexity and computational requirements increase
Solution Approach 1:
The pumpjack control system operates autonomously by self-adjusting motor speed profiles based on sensory feedback without requiring external user intervention. The controller automatically processes sensor data, determines appropriate speed adjustments, and implements control modifications for subsequent pump stroke cycles, enabling the system to self-optimize and self-protect against detrimental conditions.
Solution Approach 2:
The system uses sensory feedback from one pump stroke cycle to make preliminary adjustments to the motor speed profile before the next cycle begins. This allows the controller to proactively prevent detrimental operating conditions by adjusting speeds in advance based on predicted or anticipated issues, rather than reacting after problems occur.
3Productivity
If motor speed is increased to enhance fluid production, then productivity improves, but stress on the rod system and torque at the gearbox increase
Solution Approach 1:
The system dynamically changes motor speed parameters based on real-time sensory feedback about rod system stress and gearbox torque conditions. By adjusting speed profiles within acceptable limits and preventing excessive speeds, the system optimizes fluid production while maintaining structural integrity and avoiding detrimental operating conditions.
Data Source
AI summary
A pumpjack is operated continuously over a sequence of two adjacent pump stroke cycles, by energizing an electric motor to operate the pumpjack over a first pump stroke cycle according to a motor speed profile over a plurality of discrete control periods within the cycle, while receiving sensory feedback from one or more sensors. In response to the feedback, and while continuing to operate the pumpjack, one or more speed adjustments are made to specific control periods, so as to alter the motor speed profile while continuing to operate the electric motor to drive the pump jack. The intra-cycle control optimizes flow while reacting to detrimental and changing conditions.