Rotary Steerable Sensor Fault Estimation Without Hardware Redundancy
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Solution Overview
Problem
Current rotary steerable drilling systems face challenges in accurately diagnosing and managing faults in downhole sensors due to harsh environments and bandwidth limitations, leading to inefficiencies and increased costs, as existing methods rely heavily on hardware redundancy and shutdown maintenance.
Innovation Solution
A method and device for fault estimation in rotary steerable drilling systems that utilize state models, fault-free and fault model filters, and pseudo-measurement formulas to accurately determine sensor faults and unknown inputs, enabling real-time fault estimation and reducing the need for redundant components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hardware redundancy is used to ensure system reliability, then reliability is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces hardware redundancy (mechanical/electrical system) with a software-based fault estimation algorithm. The state model and observer-based fault estimation system substitutes for physical redundant sensors, using mathematical modeling and signal processing to detect and estimate faults without requiring additional hardware components.
Solution Approach 2:
The patent changes the approach from static hardware redundancy to dynamic fault estimation by continuously updating state variables and fault estimates based on system measurements. The fault estimation algorithm dynamically adjusts fault detection thresholds and estimates based on real-time system behavior, replacing fixed hardware redundancy with adaptive parameter-based detection.
2Reliability
If hardware redundancy is used to ensure system reliability, then reliability is improved, but cost increases
Solution Approach 1:
The patent replaces hardware redundancy (mechanical/electrical system) with a software-based fault estimation algorithm. The state model and observer-based fault estimation system substitutes for physical redundant sensors, using mathematical modeling and signal processing to detect and estimate faults without requiring additional hardware components.
3Reliability
If the number of components is increased to improve reliability, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent makes the fault estimation system multi-functional by using the same state model and observer framework to detect faults in multiple sensors simultaneously. The unified approach handles current sensors, gyroscope, and tool face angle sensors through a single mathematical framework, eliminating the need for separate detection mechanisms for each component.
Solution Approach 2:
The patent replaces hardware redundancy (mechanical/electrical system) with a software-based fault estimation algorithm. The state model and observer-based fault estimation system substitutes for physical redundant sensors, using mathematical modeling and signal processing to detect and estimate faults without requiring additional hardware components.
4Measurement precision
If quantization error is considered in fault diagnosis, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent incorporates quantization error as an additional parameter in the state model rather than treating it as a separate complexity factor. By modeling quantization error as a bounded disturbance in the state space representation, the patent seamlessly integrates precision considerations into the existing fault estimation framework without requiring additional hardware or complex processing.
Data Source
AI summary
Provided are a method and device for fault estimation of a measurement and control device for a rotary steerable drilling system. The method for fault estimation includes: S1, establishing a state model of the measurement and control device for the rotary steerable drilling system; S2, establishing a fault-free model filter and a fault model filter, and initializing the fault-free model filter and the fault model filter; S3, detecting whether the measurement and control device for the rotary steerable drilling system has a fault; and S4, reinitializing the fault model filter under the condition that a detection result is fault-free; reinitializing the fault-free model filter under the condition that the detection result is faulty; and estimating, by the fault model filter, the fault in real time, and obtaining, by the fault model filter, the estimation value {circumflex over (x)}wf.