RU193003U1 - INTELLIGENT DEPTH PUMP CONTROL SYSTEM CONTROLLER - Google Patents

Abstract

The utility model relates to software control systems, namely to programmable controllers, and is intended for monitoring and control of technological equipment, collection, measurement and processing of analog and digital electrical signals in intelligent control systems of a sucker rod pump (ИУУ ШГН). The technical result achieved by the solution is the implementation of the claimed utility model for the indicated purpose, the management of the IMS ShGN, the ability to collect information and directly control external devices according to a given algorithm. The ISU ShGN controller contains a power source, a logic module, a digital input module, an analog input / output module, a telecontrol module, an indication module, a filter module, interface blocks, a measurement module, an external programmer connection, a real-time clock, and the module input / output of analog signals is implemented on an 8-pin microcontroller due to its internal analog-to-digital converter (ADC) and a pulse-width modulation (PWM) signal conditioner, the logic module is executed n based on the ATmega64 microcontroller.

Description

The utility model relates to software control systems, namely to programmable controllers, and is intended for monitoring and control of technological equipment, collection, measurement and processing of analog and digital electrical signals in intelligent control systems of a sucker rod pump.

Complicated conditions for the functioning of oil production equipment, the multifactorial nature of the processes of interaction between elements of SHGN units with each other and with the external environment, as well as economic constraints, led to the search for new reliable solutions in the design of automatic control systems for operating parameters and assessment of the technical condition of pumping units. The fulfillment of these requirements under given conditions can be achieved using a controller, which will increase the flexibility of the control system, due to the possibility of making various changes to the control system without changing the hardware.

Known controller "Mega", manufactured by the research and production company "IPTEK", a measuring instrument entered in the State Register under No. 19124-991. The controller provides remote monitoring of status, alarms and control of technological equipment, such as rocking machines of oil wells. The controller consists of a high-speed microprocessor, functional circuits of galvanically isolated analog and digital inputs and outputs, and a main power supply circuit of functional circuits. By increasing the number of controllers, it is possible to increase the information capacity of local networks, which is economically disadvantageous.

It should also be noted that the tightly connected controller layout based on galvanically isolated inputs and outputs does not always allow the complex to be integrated into automatic and automated control systems of various architectures.

A device for collecting and transmitting data [Pat. RU 59861. Device for collecting and transmitting data / R.N. Lipsky, E.L. Wesker, D.Yu. Borisov, I.V. Deruzhinsky; applicant Closed Joint-Stock Company Corporate Institute of Electrical Instrument Engineering Energomera; declared 06/05/2006, publ. December 27, 2006], consisting of a microcontroller, a discrete signal input module, RS-485, RS-232, CAN interface signal converters, a real-time clock module. To store the configuration of the device and the collected information, the controller is equipped with volatile memory of large capacity. The interface circuits and internal electrical circuits are galvanically isolated from each other. The device is a detachable design comprising an electronic unit and a cross unit. The latter serves to connect external devices and power.

However, the controller lacks a control module for external actuators, which increases the cost and reduces the functionality of the systems in which it is used.

Known controller [US Pat. RU 2642400. Industrial controller / Yu.V. Dubenko, Yu.N. Timachenko, A.I. Vandina; applicant Federal State Budgetary Educational Institution of Higher Education "Kuban State Technological University" (FSBEI HE "KubGTU"); declared 04/06/2017, publ. 01/24/2018], consisting of a power module connected to a modular board on which a logic module based on the STM32F microcontroller, a RAM expansion module, a volatile memory module, an analog signal input / output module, discrete signal input / output module, display module, control module, communication module and alarm module.

The disadvantage of this device is the integrated complexity and high cost of the controller on an industrial scale.

The closest in technical essence and the achieved result to the claimed is the controller [Pat. RU 149610. Industrial controller / A.S. Kondrashev, N.G. Belkin; applicant Closed Joint-Stock Company Algont; declared 02/18/2014; publ. 01/10/2015], containing a power source, a microcontroller, a real-time clock, random access memory, FLASH memory, LED indicators, terminals for connecting interfaces. Here the Ethernet and (or) CAN interfaces are used to connect to the control computer, the RS-485 interface to connect remote sensors and actuators. In addition, connectors are located on two sides of the controller enclosure, which are designed to connect I / O expansion modules for signals of controlled objects. The contacts of each connector form a separate internal intermodule bus, which contains I2C interface circuits, and the expansion modules are made using a large integrated expansion circuit for the I2C interface.

However, the controller does not allow the measurement of analog signals, thereby reducing the functionality of the device.

The basis of this utility model is the task of minimizing costs and increasing the compactness of the controller.

Achieving this result is ensured by the fact that in the controller for controlling the MPS IGBT, containing a power supply, a logic module, a digital input module, an analog signal input / output module, a telecontrol module, an indication module, a filter module, interface units, a measurement module, a connector for connecting an external programmer, a real-time clock, while the analog signal input / output module is implemented on an 8-pin microcontroller due to its internal ADC and PWM signal conditioner, m The logic module is based on the ATmega6A microcontroller.

Structurally, the controller is made in the form of a metal box with brackets on the rear panel for attaching to the power panel of the frequency converter. On the front panel of the controller are located: a vacuum-luminescent text display, buttons for controlling and displaying information parameters, as well as LED indicators for the status of the IMS SHGN.

The essence of the utility model is illustrated by the structural-functional diagram shown in FIG.

The controller consists of a power supply module (1), which generates output voltages: +5 V for powering the digital circuits of the board, +9 V for powering the relay and generating control signals for opto-thyristors, +24 V for powering discrete signals and the driver board, +9 B- RS for powering the galvanically isolated RS-485 and +9 B-AI interfaces for powering the analog input unit. Additionally, the power supply is equipped with a voltage limiter to protect against voltage surges on the power wires that occur during lightning discharges in the field. Logic module 2 is an 8-bit microcontroller with the ATmega64 RISC architecture, made in the 64-pin TQFP planar package, containing 64 kB of FLASH memory for hosting the programmer and 2 kB of EEPROM memory for storing system settings and settings, as well as electronic archive of events. The module for inputting discrete signals 4, is built on dual optotransistors and provides power with a constant voltage of 24 V and a galvanically isolated input of 8 discrete signals. Telecontrol module 5 through transistor switches generates control signals for the opto-thyristors of the frequency converter: charging VZ and the opto-thyristors of the power rectifier VR, as well as signals for normally open contacts by electromagnetic relays “WORK” and “EMERGENCY” for telemetry. The RS-485 6 interface unit is designed to provide operation of the ShGN ICS in the upper level system at the field. Indication module 7 consists of a 2-line 16-character vacuum-luminescent display that provides information viewing via the SPI interface at the lower limit of the ISU temperature range (minus 60 ° С), LEDs and decoupling diodes for inputting signals from the controller buttons. The filtering module 11 receives a signal from a current sensor, and the ADC of the microcontroller measures the alternating voltages coming from the current sensor. Filters contained in the module clean the signal from high-frequency interference. Real-time clock 8 is designed to provide real-time when registering events in the electronic archive of events. Programming the clock and reading the time is done via the I2C interface. Measurement module 9 is a galvanically isolated meter of analog control signals "REG", "AI1" and "AI2". The “REG” signal has a range from 0 to 5 V and comes from the speed controller, the signals “AI1” and “AI2” are external to the system and are universal control signals. The digital interface is supported by module 10, which includes:

- reset signal of a specialized control controller for a bridge inverter MC3RNAC;

- PWM signal from one of the MC3RNAC outputs for measuring and subsequent emulation of the output voltage of the inverter of the frequency converter;

- signals of the serial channel for transmitting and receiving data from the USART interface of the microcontroller;

- generalized driver reset signal;

- temperature sensor signal transmitted through the driver board.

The controller provides protective load shedding of the ISU ShGN:

- in case of motor overload;

- when the voltage in the network decreases below 0.7⋅U _nom with the subsequent switching on of the load after the time of automatic restart when voltage increases to 0.85⋅U _nom ;

- at own malfunction;

- when the limit sensor is triggered, such as an electro-contact pressure gauge, incl. minimum pressure with adjustable delay;

- under undercurrent of the motor current (breakage of the drive belts of the rocking machine);

- with an imbalance of load currents and out-of-phase operation;

- with unbalance of the rocking machine.

As part of the ISU SHGN controller provides:

- turning on and off the electric motor of the rocking machine;

- formation of telemetric signals;

- the operation of the electric motor of the rocking machine at a frequency;

- automatic inclusion of the electric motor after a set time

- delays after restoration of the disappeared voltage in the network.

The controller works as follows: the power module 1 generates the voltages necessary for the device to work and the controller loads the control program of logic module 2. When this program is launched, it is possible to program the main FLASH memory of the microcontroller with a code received via the USART1 interface (RS-485 top level). External measuring devices are connected to the interface blocks 6.10. The signals from external measurement sensors through these interface blocks are sent to logic module 2, where they are further processed by the microprocessor, which are then sent to the upper-level computer via the RS-485 interface unit 6. The analog signals are read using the ADC. The exact measurement time is formed by the real-time clock 8. To control the power of external devices, the power circuits of external devices are connected to the telecontrol module 5. To interactively display information and control the controller, an external display 7 is connected via the SPI interface. The signals from the display are received by logic module 2, where the control program generates a model of the controller status in graphical form for display on the display. Also, the logic module 2 displays information about the status of the controller on the LED indicators 7.

The technical solution proposed as a utility model - the controller can be actively used in automatic process control systems, in particular, in intelligent control systems for sucker rod pumps. Specially selected controller equipment allows you to use it in the temperature range from minus 60 to plus 50 ° C.

A positive result manifested in the manufacture and use of the proposed controller is to minimize costs and increase the compactness of the controller.

Claims (1)

A controller for controlling an intelligent sucker rod pump control system, comprising a power module, a logic module for executing control programs, a discrete signal input module, an analog signal input / output module, a telecontrol module transmitting control commands from the microcontroller to an external device and performing telemetry functions, a module indications, including LED indicators, a filtering module that measures alternating voltages and clears the signal from the current sensor from high frequency interference, a liquid crystal vacuum-luminescent display, information parameter output buttons, an RS-485 interface unit that provides the intelligent control system in the upper level system, an interface unit with a driver board, while the interface circuits and the device’s internal electrical circuits are galvanically isolated from each other, measurement module, connector for connecting an external programmer, real-time clock, characterized in that the input / output module of analog signals is implemented on an 8-pin the microcontroller due to its internal ADC and PWM signal conditioner, the logic module is based on the ATmega64 microcontroller.

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