U.S. patent application number 16/690547 was filed with the patent office on 2020-03-19 for systems and methods for determining proper phase rotation in downhole linear motors.
The applicant listed for this patent is Baker Hughes, a GE company, LLC. Invention is credited to Renato L. Pichilingue.
Application Number | 20200088015 16/690547 |
Document ID | / |
Family ID | 57397408 |
Filed Date | 2020-03-19 |
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United States Patent
Application |
20200088015 |
Kind Code |
A1 |
Pichilingue; Renato L. |
March 19, 2020 |
SYSTEMS AND METHODS FOR DETERMINING PROPER PHASE ROTATION IN
DOWNHOLE LINEAR MOTORS
Abstract
Systems and methods for determining proper phase rotation in a
linear motor where the phase rotations associated with power and
return strokes are initially unknown. Power having an initial phase
rotation is provided to a linear motor until the motor's mover
reaches the end of the stroke, and then power to the motor is
discontinued. While power is discontinued, the mover is monitored
to detect its movement. if the mover moves without power, the mover
was at the top of the stroke, so the initial phase rotation is
associated with an upward stroke of the mover, and a second phase
rotation which is opposite the initial phase rotation is associated
with a downward stroke of the mover. Otherwise, the initial phase
rotation is associated with the downward stroke of the mover and
the second, opposite phase rotation is associated with the upward
stroke of the mover.
Inventors: |
Pichilingue; Renato L.;
(Houston, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Baker Hughes, a GE company, LLC |
Houston |
TX |
US |
|
|
Family ID: |
57397408 |
Appl. No.: |
16/690547 |
Filed: |
November 21, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15137115 |
Apr 25, 2016 |
10550676 |
|
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16690547 |
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62169063 |
Jun 1, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B 47/008 20200501;
F04B 49/20 20130101; F04B 47/06 20130101; F04B 17/03 20130101; E21B
43/128 20130101 |
International
Class: |
E21B 43/12 20060101
E21B043/12; F04B 17/03 20060101 F04B017/03; F04B 49/20 20060101
F04B049/20; F04B 47/06 20060101 F04B047/06; E21B 47/00 20060101
E21B047/00 |
Claims
1. A method for determining proper phase rotation in a linear
electric motor, wherein phase rotations associated with power and
return strokes are initially unknown, the method comprising:
providing power having an initial phase rotation to a linear
electric motor; monitoring a position sensor signals from position
sensors in the linear electric motor; determining from the position
sensor signals when a mover of the linear electric motor has
reached the end of a stroke driven by the power having the initial
phase rotation; in response to determining that the mover of the
linear electric motor has reached the end of the stroke,
discontinuing providing power to the linear electric motor;
monitoring the position sensor signals from the position sensors in
the linear electric motor; determining from the position sensor
signals whether the mover moves while the power to the linear
electric motor is discontinued; in response to determining that the
mover moves while the power to the linear electric motor is
discontinued, associating the initial phase rotation with an upward
stroke and associating a second phase rotation which is opposite
the initial phase rotation with a downward stroke; and in response
to determining that the mover does not move while the power to the
linear electric motor is discontinued, associating the initial
phase rotation with a downward stroke and associating a second
phase rotation which is opposite the initial phase rotation with an
upward stroke.
2. The method of claim 1, wherein the linear electric motor
comprises a motor of an electric submersible pump (ESP) system and
wherein the ESP system is installed in a well; wherein the downward
stroke comprises a power stroke of the ESP system and the upward
stroke comprises a return stroke of the ESP system; and further
comprising, after associating the initial and opposite phase
rotations with respective ones of the upward and downward strokes,
operating the ESP system, wherein power is provided to the ESP
system according to a power stroke profile during the power stroke
of the ESP system and according to a return stroke profile during
the return stroke of the ESP system.
3. The method of claim 1, wherein determining when the mover of the
linear electric motor has reached the end of the stroke driven by
the initial phase rotation comprises monitoring position sensor
signals from position sensors in the linear electric motor,
counting signal transitions sensor signals, and determining that a
threshold number of signal transitions have been counted.
4. The method of claim 1, wherein determining when the mover of the
linear electric motor has reached the end of the stroke driven by
the initial phase rotation comprises determining that the mover of
the linear electric motor has reached a hard stop in the motor.
5. The method of claim 1, wherein determining from the position
sensor signals whether the mover moves while the power to the
linear electric motor is discontinued comprises determining whether
any signal transitions are detected in the position sensor
signals.
6. The method of claim 1, wherein prior to providing the power
having the initial phase rotation to the linear electric motor, the
linear electric motor is stopped.
7. The method of claim 6, further comprising, prior to providing
the power having the initial phase rotation to the linear electric
motor, coupling a multiphase power cable between an electric drive
system and the linear electric motor, wherein the electric drive
system provides the power the linear electric motor, and wherein
prior to providing the power having the initial phase rotation to
the linear electric motor, a correspondence of phases at the
electric drive system to phases at the linear electric motor is
unknown.
8. An apparatus comprising: a controller of an electric drive
system for a linear motor, wherein in a startup phase, the
controller is configured to generate output power for the linear
motor, wherein the output power has an initial phase rotation,
monitor position sensor signals received from the linear motor,
determine from the position sensor signals when a mover of the
linear motor has reached the end of a stroke driven by the
generated output power having the initial phase rotation,
discontinue generating the output power, and monitor the position
sensor signals and determine from the position sensor signals
whether the mover moves while the output power is discontinued;
wherein if the mover moves while the power to the linear motor is
discontinued, the controller is configured to associate the initial
phase rotation with an upward stroke and associate a second phase
rotation which is opposite the initial phase rotation with a
downward stroke; and wherein if the mover does not move while the
power to the linear motor is discontinued, the controller is
configured to associate the initial phase rotation with the
downward stroke and associating the second phase rotation which is
opposite the initial phase rotation with the upward stroke.
9. The apparatus of claim 8, wherein the controller is further
configured to, after associating the initial and opposite phase
rotations with respective ones of the upward and downward strokes,
generate output power for the linear motor, wherein the output
power is generated according to a first stroke profile during the
upward stroke of the linear motor and according to a second stroke
profile during the downward stroke of the linear motor.
10. The apparatus of claim 8, wherein the controller is configured
to determine when the mover of the linear motor has reached the end
of the stroke by counting signal transitions in the received sensor
signals and determining that a threshold number of signal
transitions have been counted.
11. The apparatus of claim 8, wherein determining from the position
sensor signals whether the mover moves while the power to the
linear motor is discontinued comprises determining whether any
signal transitions are detected in the position sensor signals.
12. A system comprising: an electric submersible pump (ESP) system
installed in a well; an electric drive system positioned at the
surface of the well; and one or more electrical cables coupled
between the an electric drive system and the ESP system, wherein
the one or more electrical cables carry power from the electric
drive system to the ESP system and carry position sensor signals
from the ESP system to the electric drive system; wherein the
electric drive system includes a controller for a linear motor of
the ESP system; wherein in a startup phase, the controller is
configured to generate output power for the linear motor, wherein
the output power has an initial phase rotation, monitor the
position sensor signals received from the linear motor, determine
from the position sensor signals when a mover of the linear motor
has reached the end of a stroke driven by the generated output
power having the initial phase rotation, discontinue generating the
output power, and monitor the position sensor signals and determine
from the position sensor signals whether the mover moves while the
output power is discontinued; wherein if the mover moves while the
power to the linear motor is discontinued, the controller is
configured to associate the initial phase rotation with an upward
stroke and associate a second phase rotation which is opposite the
initial phase rotation with a downward stroke; and wherein if the
mover does not move while the power to the linear motor is
discontinued, the controller is configured to associate the initial
phase rotation with the downward stroke and associating the second
phase rotation which is opposite the initial phase rotation with
the upward stroke.
13. The system of claim 12, wherein the electric drive system is
configured to, after the initial and opposite phase rotations are
associated with respective ones of the upward and downward strokes,
provide power to the linear motor, wherein the power is generated
by the electric drive system according to a first stroke profile
during the upward stroke of the linear motor and according to a
second stroke profile during the downward stroke of the linear
motor.
14. The system of claim 12, wherein the controller is configured to
determine when the mover of the linear motor has reached the end of
the stroke by counting signal transitions in the received sensor
signals and determining that a threshold number of signal
transitions have been counted.
15. The system of claim 12, wherein determining from the position
sensor signals whether the mover moves while the power to the
linear motor is discontinued comprises determining whether any
signal transitions are detected in the position sensor signals.
16. The system of claim 12, wherein the linear motor includes a
plurality of Hall-effect position sensors and circuitry that
combines a plurality of outputs generated by the Hall-effect
position sensors into a composite signal that is communicated to
the controller, wherein the position sensor signals comprise the
composite signal.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. patent
application Ser. No. 15/137,115, filed Apr. 25, 2016 by Renato L.
Pichilingue, which claims the benefit of U.S. Provisional Patent
Application 62/169,063, filed Jun. 1, 2015 by Renato L.
Pichilingue. Each of these applications is incorporated by
reference as if set forth herein in its entirety.
BACKGROUND
Field of the Invention
[0002] The invention relates generally to downhole tools for use in
wells, and more particularly to means for determining the proper
phase rotation for power that is supplied to a downhole linear
motor.
Related Art
[0003] In the production of oil from wells, it is often necessary
to use an artificial lift system to maintain the flow of oil. The
artificial lift system commonly includes an electric submersible
pump (ESP) that is positioned downhole in a producing region of the
well. The ESP has a motor that receives electrical signals from
equipment at the surface of the well. The received signals run the
motor, which in turn drives a pump to lift the oil out of the
well.
[0004] ESP motors commonly use rotary designs in which a rotor is
coaxially positioned within a stator and rotates within the stator.
The shaft of the rotor is coupled to a pump, and drives a shaft of
the pump to turn impellers within the body of the pump. The
impellers force the oil through the pump and out of the well. While
rotary motors are typically used, it is also possible to use a
linear motor. Instead of a rotor, the linear motor has a mover that
moves in a linear, reciprocating motion. The mover drives a
plunger-type pump to force oil out of the well.
[0005] In order to properly control a linear motor, it is desirable
to know the electrical position of the mover within the stator.
Linear motors may use several sensors (e.g., Hall-effect sensors)
to determine the electrical position and absolute position of the
mover. The signals from these sensors are provided to a control
system, which then produces a drive signal based upon the position
of the mover and provides this drive signal to the motor to run the
motor.
[0006] An ESP using a linear motor typically operates on
three-phase power. Each phase is carried by a separate conductor,
and is typically shifted by 120 degrees from the other phases. An
electrical drive system at the surface of the well generates the
three-phase drive signal that is supplied to the motor, which in
turn drives the pump. When the system is installed, it is commonly
necessary to make various connections (e.g., cable splices) between
the electrical conductors that convey the electrical power to the
motor. It is not unusual for mistakes to be made in these
connections, resulting in electrical connections between the
electrical drive system and pump motor that are incorrect. More
specifically, two or more of the conductors may be switched. Such
misconnection of the conductors may also occur when maintenance is
performed on the electrical drive system or the cabling.
[0007] Because the phasing of a three-phase electrical signal is
reversed (e.g., A-B-C becomes C-B-A) when any two of the three
wires are switched, misconnection of these wires can result in the
pump motor being driven in a direction which is opposite the
intended direction. In other words, when the electrical drive
system produces a drive signal with phasing that is intended to
drive the motor in the forward direction, it actually drives the
motor in the reverse direction. In the case of a linear motor, the
drive's output signal is intended to drive the upstroke/downstroke
of the motor, so if the phase rotation is reversed, the mover will
be driven upward when it is intended to be driven downward, and
downward when it is intended to be driven upward. While this may
still result in some fluid being produced from the well, it
typically is not as efficient as if the proper phasing is used.
Additionally, if the motor is intended to be driven in a particular
manner on upward or downward strokes (e.g., faster on the downward
stroke), this will actually occur on the opposite stroke.
[0008] It would therefore be desirable to provide improved means
for determining the phasing at the output of the drive that is
associated with a linear motor's upstroke and downstroke, and for
utilizing this information to generate signals to drive the linear
motor.
SUMMARY OF THE INVENTION
[0009] This disclosure is directed to systems and methods for
determining the phasing of power generated by an electric drive
system that is associated with the upward and downward strokes of a
linear motor (for example, in an ESP). One particular embodiment is
a method for determining proper phase rotation in a linear motor
where the phase rotations associated with power and return strokes
are initially unknown. In this method, power having an initial
phase rotation is provided to a linear motor. Position sensor
signals from position sensors in the linear motor are monitored,
and it is determined from the position sensor signals when the
mover of the linear motor has reached the end of the stroke that is
driven by the initial phase rotation. After the mover has reached
the end of the stroke, power to the linear motor is discontinued.
When the power to the linear motor is discontinued or suspended,
the position sensor signals from the position sensors in the linear
motor are monitored to determine whether the mover moves. if the
mover moves while the power to the linear motor is discontinued,
the mover had moved to the top of the stroke, so the initial phase
rotation is associated with an upward stroke of the mover, and a
second phase rotation which is opposite the initial phase rotation
is associated with a downward stroke of the mover. If, on the other
hand, the mover does not move while the power to the linear motor
is discontinued, the mover had moved to the top of the stroke, so
the initial phase rotation is associated with the downward stroke
of the mover and the second, opposite phase rotation is associated
with the upward stroke of the mover.
[0010] This method may be implemented in an ESP system that is
installed in a well. In one embodiment, a multiphase (e.g.,
3-phase) power cable is initially coupled between an electric drive
system and the ESP's linear motor so that the electric drive system
provides the power the motor. The correspondence of phases at the
electric drive system to phases at the linear motor at this point
may be unknown. In other words, it is not known which of the phases
(e.g., A, B, C) at the drive is connected to which of the phases
(e.g., A', B', C') at the motor. When the power cable is first
coupled between the drive and the motor, the motor is stopped. The
power having the initial phase rotation is thereafter provided to
the linear motor. In one embodiment, the downward stroke of the ESP
system's motor is the power stroke and the upward stroke is the
return stroke. After determining the correspondence between the
initial and opposite phase rotations with the upward and downward
strokes, and making the appropriate associations between them, the
ESP system can be operated in a manner in which the power and
return strokes are differentiated. For instance, power can be
provided to the motor according to a power stroke profile during
the power stroke and according to a return stroke profile during
the return stroke. It can be determined in various ways when the
initial phase rotation has driven the mover of the linear motor to
the end of the stroke. For example, it may be determined that that
the mover of the linear motor has reached a hard stop in the motor.
Alternatively, signal transitions in the signals from the position
sensors in the linear motor can be counted, and the end of the
stroke may be identified by determining when a threshold number of
signal transitions have been counted. Detecting signal transitions
in the position sensor signals can also be used to determine
whether the mover moves while the power to the linear motor is
discontinued.
[0011] An alternative embodiment comprises an apparatus which is a
controller for an electric drive system of a linear motor. In a
startup phase, the controller is configured to generate output
power for the linear motor, where the output power has an initial
phase rotation that will drive the motor's mover either upward or
downward. The controller monitors position sensor signals received
from the linear motor and determines from these signals when the
mover has reached the end of its stroke. The controller do this,
for example, by detecting that a hard stop in the motor has been
reached, or by counting signal transitions in the received sensor
signals and determining that a threshold number of signal
transitions have been counted. When the mover has reached the end
of its stroke, the controller discontinues generation of the output
power to the motor. With the power discontinued, the position
sensor signals are monitored by the controller to determine whether
the mover moves (falls). This may be done by determining whether
any signal transitions are detected in the position sensor signals
while the power is discontinued. If the mover moves while the power
to the linear motor is discontinued, the mover is falling, so the
controller associates the initial phase rotation with an upward
stroke of the motor and associates the opposite phase rotation with
the downward stroke of the motor. If, on the other hand, the mover
does not move while the power to the linear motor is discontinued,
The mover is already at the bottom of its travel, so the controller
associates the initial phase rotation with the downward stroke of
the motor and associates the opposite phase rotation with the
upward stroke of the motor. After associating the initial and
opposite phase rotations with respective ones of the upward and
downward strokes, the controller may generate output power to run
the linear motor, where the output power is generated according to
a first stroke profile during the upward stroke of the linear motor
and according to a second, different stroke profile during the
downward stroke of the linear motor.
[0012] Another alternative embodiment comprises a system that
includes an ESP system installed in a well. An electric drive
system positioned at the surface of the well is coupled to the
motor of the ESP system by one or more electrical cables that carry
power from the electric drive system to the ESP system and carry
position sensor signals from the sensors (e.g., Hall-effect
sensors) in the ESP system's motor to the electric drive system.
The electric drive system includes a controller that is configured
to control the drive to generate output power for the linear motor.
In a startup phase, the output power has an initial phase rotation.
The controller monitors the position sensor signals received from
the linear motor to determine when the motor's mover has reached
the end of its stroke (travel), as driven by the initial phase
rotation. The system then discontinues the output power and
monitors the position sensor signals to determine whether the mover
moves while the output power is discontinued. If the mover moves
while the power to the linear motor is discontinued, the controller
associates the initial phase rotation with the upward stroke of the
motor and associates the opposite phase rotation with the downward
stroke of the motor. If the mover does not move while the power to
the linear motor is discontinued, the controller associates the
initial phase rotation with the downward stroke of the motor and
associates the opposite phase rotation with the upward stroke of
the motor. After associating the initial and opposite phase
rotations with respective ones of the upward and downward strokes,
the drive may provide output power to run the ESP system's motor.
The power provided to the motor may be generated according to a
first stroke profile during the upward stroke of the linear motor
and according to a second, different stroke profile during the
downward stroke of the linear motor.
[0013] Numerous other embodiments are also possible.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Other objects and advantages of the invention may become
apparent upon reading the following detailed description and upon
reference to the accompanying drawings.
[0015] FIG. 1 is a diagram illustrating an exemplary pump system in
accordance with one embodiment.
[0016] FIG. 2 is a diagram illustrating an exemplary linear motor
in accordance with one embodiment which would be suitable for use
in the pump system of FIG. 1.
[0017] FIGS. 3A and 3B are functional block diagrams illustrating
the structure of control systems for a linear motors in accordance
with two exemplary embodiments.
[0018] FIG. 4 is a flow diagram illustrating a method for
determining whether a phase rotation is associated with an upstroke
or downstroke of a linear motor in accordance with one
embodiment.
[0019] While the invention is subject to various modifications and
alternative forms, specific embodiments thereof are shown by way of
example in the drawings and the accompanying detailed description.
It should be understood, however, that the drawings and detailed
description are not intended to limit the invention to the
particular embodiment which is described. This disclosure is
instead intended to cover all modifications, equivalents and
alternatives falling within the scope of the present invention as
defined by the appended claims. Further, the drawings may not be to
scale, and may exaggerate one or more components in order to
facilitate an understanding of the various features described
herein.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0020] One or more embodiments of the invention are described
below. It should be noted that these and any other embodiments
described below are exemplary and are intended to be illustrative
of the invention rather than limiting.
[0021] As described herein, various embodiments of the invention
comprise systems and methods for determining the phase voltage
rotation (A-B-C or C-B-A) of an electric drive system that is
required to drive a linear motor in a desired direction.
("Direction" as used here refers to the upward or downward motion
of the mover.)
[0022] Generally speaking, in the present systems and methods, a
controller of an electric drive system generates an output having a
known phase rotation, and this output is provided to a linear
motor. It does not matter whether the output phase rotation drives
the upstroke or downstroke of the motor. The output voltage is
provided to the motor until the motor's mover is driven to a hard
stop at the end of its stroke, or until a predetermined number of
hall transitions have occurred. After the mover is driven to the
hard stop, the drive's output is discontinued. Gravity provides a
downward force on the mover which, in the absence of a signal from
the drive, will cause the mover to fall downward if it is at the
top of the stroke. This movement will be detected by the position
sensors in the motor. If movement is detected, then it is known
that the initially applied phase rotation caused the mover to move
upward. If no movement is detected (indicating that the mover is
already at the bottom of the stroke), then it is known that the
initially applied phase rotation caused the mover to move downward.
In either case, the direction associated with the initially applied
phase rotation is now known. The motor can therefore be operated
normally with the proper phase rotation.
[0023] Referring to FIG. 1, a diagram illustrating an exemplary
pump system in accordance with one embodiment of the present
invention is shown. A wellbore 130 is drilled into an oil-bearing
geological structure and is cased. The casing within wellbore 130
is perforated in a producing region of the well to allow oil to
flow from the formation into the well. Pump system 120 is
positioned in the producing region of the well. Pump system 120 is
coupled to production tubing 150, through which the system pumps
oil out of the well. A control system 110 is positioned at the
surface of the well. Control system 110 is coupled to pump 120 by
power cable 112 and a set of electrical data lines 113 that may
carry various types of sensed data and control information between
the downhole pump system and the surface control equipment. Power
cable 112 and electrical lines 113 run down the wellbore along
tubing string 150.
[0024] Pump 120 includes an electric motor section 121 and a pump
section 122. In this embodiment, an expansion chamber 123 and a
gauge package 124 are included in the system. (Pump system 120 may
include various other components which will not be described in
detail here because they are well known in the art and are not
important to a discussion of the invention.) Motor section 121
receives power from control system 110 and drives pump section 122,
which pumps the oil through the production tubing and out of the
well.
[0025] In this embodiment, motor section 121 is a linear electric
motor. Control system 110 receives AC (alternating current) input
power from an external source such as a generator (not shown in the
figure), rectifies the AC input power, converting it to DC (direct
current) voltage of a specific value as determined by the
controller which is then used to produce three-phase AC output
power which is suitable to drive the linear motor. The output power
generated by control system 110 is dependent in part upon the
electrical position of the mover within the stator of the linear
motor. Electrical position sensors in the motor sense the position
of the mover and communicate this information via electrical lines
113 to control system 110 so that that electrical currents are
properly and timely commutated (as will be discussed in more detail
below). The output power generated by control system 110 is
provided to pump system 120 via power cable 112.
[0026] Referring to FIG. 2, a diagram illustrating an exemplary
linear motor which would be suitable for use in the pump system of
FIG. 1 is shown. The linear motor has a cylindrical stator 210
which has a bore in its center. A base 211 is connected to the
lower end of stator 210 to enclose the lower end of the bore, and a
head 212 is connected to the upper end of the stator. Motor head
212 has an aperture therethrough to allow the shaft 222 of the
mover 220 to extend to the pump. In this embodiment, the pump is
configured to draw fluid into the pump on the upstroke and expel
the fluid on the downstroke. In other words, the downstroke is the
power stroke and the upstroke is the return stroke.
[0027] Stator 210 has a set of windings 213 of magnet wire.
Windings 213 include multiple separate coils of wire, forming
multiple poles within the stator. The ends of the windings are
coupled (e.g., via a pothead connector 214) to the conductors of
the power cable 218. Although the power cable has separate
conductors that carry the three phase power to the motor, the
conductors are not depicted separately in the figure for purposes
of simplicity and clarity. Similarly, the coils of magnet wire are
not separately depicted. The coils may have various different
configurations, but are collectively represented as component 213
in the figure.
[0028] The windings are alternately energized by the current
received through the power cable to generate magnetic fields within
the stator. These magnetic fields interact with permanent magnets
221 on the shaft 222 of mover 220, causing mover 220 to move up and
down within the motor. The waveform of the signal provided by the
drive via the power cable (in this case a three-phase signal) is
controlled to drive mover 220 in a reciprocating motion within the
bore of stator 210. Stator 210 incorporates a set of Hall-effect
sensors 215 to monitor the electrical position of mover 220 within
stator 210. The outputs of Hall-effect sensors 215 are transmitted
to the controller and can be used to determine absolute position.
They may be transmitted as distinct signals, or they may be
combined to form one or more composite signals. The mover may also
be coupled to an absolute encoder of some type, and data from this
encoder may be transmitted to the controller. The controller then
tracks the motor position based on the received signals.
[0029] Referring to FIG. 3A, a functional block diagram
illustrating the structure of a control system for a linear motor
in one embodiment is shown. The control system is incorporated into
a drive system (e.g., 110) for the linear motor. The drive system
receives AC input power from an external source and generates
three-phase output power that is provided to the linear motor to
move the pump. The drive system also receives position information
from the linear motor and uses this information when generating the
three-phase power for the motor.
[0030] As depicted in FIG. 3A, drive system 300 has input and
rectifier circuitry 310 that receives AC input power from the
external power source. The input power may be, for example, 480V,
three-phase power. Circuitry 310 converts the received AC power to
DC power at a voltage determined by the line value and provides
this power to a first DC bus. The DC power on the first DC bus is
provided to a variable DC-DC converter 320 that outputs DC power at
a desired voltage to a second DC bus. The voltage of the DC power
output by DC-DC converter 320 can be adjusted within a range from
0V to the voltage on the first DC bus, as determined by a voltage
adjustment signal received from motor controller 340. The DC power
on the second DC bus is input to an inverter 330 which produces
three-phase output power at a desired voltage and frequency as
determined by the controller. The output power produced by inverter
330 is transmitted to the downhole linear motor via a power
cable.
[0031] The power output by inverter 330 is monitored by voltage
monitor 350. Voltage monitor 350 provides a signal indicating the
voltage output by inverter 330 as an input to motor controller 340.
Motor controller 340 also receives position information from the
downhole linear motor. In one embodiment, this position information
consists of the signals generated by the Hall-effect sensors as
described above in connection with FIG. 2. Motor controller 340
uses the received position information to determine the position
and speed of the mover within the linear motor. Based upon this
position and speed information, as well as the information received
from voltage monitor 350, controller 340 controls inverter 330 to
generate the appropriate output signal.
[0032] In one embodiment, motor controller 340 may control the
switching of insulated gate bipolar transistors (IGBT's) in
inverter 330 to generate a three-phase, 6-step, trapezoidal or
sinusoidal waveform. The three phases of the drive's output may be
identified as phases A, B and C. As noted above, although the drive
system outputs are known, it is not uncommon for misconnection of
the conductors between the drive system and the downhole motor to
occur. Consequently, although the outputs of the drive system are
intended to be provided to respective inputs of the downhole motor
(e.g., output A to input A', output B to input B', and output C to
input C'), it is not known whether this is actually the case. The
drive system is therefore configured to identify the phasing at its
output that will provide the proper input phasing at the motor.
[0033] It is assumed for the purposes of this disclosure that the
phase differences between the three phases of the drive unit's
output signals are substantially equal. When any two of the phases
are switched, the effect is to reverse the order of the phases. For
instance, if the phases on lines A, B and C occur in the order
A-B-C, switching the signals on any two of the lines will result in
the phase order C-B-A. It is therefore assumed that any output
signal generated by the drive unit will have one of these two
orders (which may be referred to herein as phasings or phase
rotations).
[0034] In this embodiment, the controller is configured to generate
an output that has a predetermined phase rotation. This will cause
the mover to go to the end of one stroke (either the upward or
downward stroke). The drive then discontinues the output. If the
mover is left at the lower end of the motor, it will simply remain
stationary. If the mover is left at the upper end of the motor, it
will begin to fall, and the movement will be detected by the
controller. Then, based on whether the initial output signal moved
the mover upward or downward, the controller can determine the
proper phasing to drive the motor. This is described in more detail
in connection with FIG. 4.
[0035] Referring to FIG. 3B, a functional block diagram
illustrating an alternative structure of a control system for a
linear motor is shown. The control system is incorporated into a
drive system (e.g., 110) for the linear motor. The drive system
again receives AC input power from an external source and generates
three-phase output power for the linear motor. The drive system
uses feedback on its voltage and current output, as well as
position information from the motor, to control generation of the
three-phase power for the motor.
[0036] As depicted in FIG. 3B, drive system 500 has a variable
AC/DC converter that converts the received AC power to DC. The DC
power is provided to DC bus 520. The DC power on bus 520 is used by
IGBT inverter 530 to produce three-phase output power at a desired
voltage and frequency as determined by controller 540. The output
power produced by IGBT inverter 530 is transmitted to the downhole
linear motor via a power cable.
[0037] The power output by IGBT inverter 530 is monitored by
voltage and current monitor 550. Monitor 550 provides voltage and
current information to motor controller 540. Motor controller 540
also receives position information from the position sensors in the
downhole linear motor. Controller 540 uses the received position
information to determine the position and speed of the mover within
the linear motor. Based upon the information received by controller
540, IGBT inverter 530 is controlled to generate the appropriate
output signal. The methods described above (e.g., in connection
with FIG. 4) are implemented in controller 540 in a manner similar
to controller 340 of FIG. 3.
[0038] Referring to FIG. 4, a flow diagram illustrating a method in
accordance with one embodiment is shown. In this embodiment, an
electric drive which is coupled to a downhole electric linear motor
generates an output voltage in a startup phase that has an assumed
phase rotation (410). More specifically, the phase rotation is
known at the output of the drive, but is assumed at the input to
the motor, since the power conductors may have been misconnected.
The drive may generate an output that has, for example, the
sequence A, B, C. In other words, the voltage at output A is 120
degrees ahead of the voltage at output B, which is 120 degrees
ahead of the voltage at output C.
[0039] The output of the drive is carried to the linear motor via a
power cable and is applied to the inputs of the motor. The position
of the mover within the motor is monitored by means such as signals
from position sensors within the motor (420). As noted above, some
of the conductors of the power cable may have been switched, so it
is unknown which of the drive outputs is applied to which of the
motor inputs. The predetermined phase rotation of the signals
received from the drive cause the motor's mover to move in one
direction (which is not yet known). The signals are applied until
the mover reaches the end of the stroke (430). In one embodiment,
the signals are applied until the mover reaches a hard stop at the
end of the stator. Alternatively, the drive output may be applied
to the motor until a predetermined number of Hall signal
transitions are detected. After the mover reaches the hard stop, or
after the predetermined number of Hall signal transitions are
detected, the drive output is discontinued (440).
[0040] With the drive output discontinued, the only remaining force
on the mover is that of gravity. The position of the mover within
the motor is monitored to determine whether gravity causes it to
move (450). If the position sensors in the motor detect movement of
the mover (460) (e.g., if transitions are detected in the signals
from the Hall-effect sensors), it is assumed that the initial phase
rotation caused the mover to move upward (the return stroke in this
embodiment). After the mover stopped at the top of the stroke, it
began falling due to gravity. The initial phase rotation is
therefore determined to be the proper phase rotation for the upward
(return) stroke and is associated with this upstroke (470). Thus,
if the initial phase rotation produced by the drive was A-B-C, this
rotation will be associated with the upward (return) stroke, and
the C-B-A phase rotation will be associated with the downward
(power) stroke. The association of one of the phase rotations with
the appropriate one of the stroke directions may be accomplished in
various ways, such as by storing appropriate identifiers or setting
appropriate bits in the controller.
[0041] If, on the other hand, the position sensors in the motor do
not detect movement of the mover after the drive output is
discontinued, it is assumed that the initial phase rotation caused
the mover to move downward (the power stroke in this embodiment).
Because the mover would stop at the hard stop at the bottom of the
stroke in this case, gravity would not cause it to move after the
drive output was discontinued. The initial phase rotation is
therefore determined to be the proper phase rotation for the
downward (power) stroke and is associated with the downstroke
(480). If the initial predetermined phase rotation was A-B-C, this
phase rotation will be associated with the downward (power) stroke,
and the C-B-A phase rotation will be associated with the upward
(return) stroke.
[0042] It should be noted that, although this embodiment uses
Hall-effect sensors to detect movement of the mover, alternative
embodiments may use other means. For instance, one alternative
embodiment may monitor the conductors of the power cable to
identify a back-emf (electromotive force) that is generated by
movement of the mover. In this embodiment, the motor effectively
acts as a generator and, as the mover falls, the motor generates a
voltage at its input terminals.
[0043] When it has been determined which direction is associated
with the initial predetermined phase rotation, the drive can begin
generating output signals to operate the linear motor normally
(490) ("normal" operation refers to generating and providing
signals that drive the mover alternately through repeating cycles
of the power and return strokes as desired to produce fluids from
the well). Because the phasing associated with the power and return
strokes are known, the electric drive's controller can implement
desired output profiles in which there are differences between the
power and return strokes. For example, the mover may be driven at
different speeds during the power and return strokes, different
delays may be implemented at the ends of the respective strokes,
and so on.
[0044] The benefits and advantages which may be provided by the
present invention have been described above with regard to specific
embodiments. These benefits and advantages, and any elements or
limitations that may cause them to occur or to become more
pronounced are not to be construed as critical, required, or
essential features of any or all of the described embodiments. As
used herein, the terms "comprises," "comprising," or any other
variations thereof, are intended to be interpreted as
non-exclusively including the elements or limitations which follow
those terms. Accordingly, a system, method, or other embodiment
that comprises a set of elements is not limited to only those
elements, and may include other elements not expressly listed or
inherent to the described embodiment.
[0045] While the present invention has been described with
reference to particular embodiments, it should be understood that
the embodiments are illustrative and that the scope of the
invention is not limited to these embodiments. Many variations,
modifications, additions and improvements to the embodiments
described above are possible. It is contemplated that these
variations, modifications, additions and improvements fall within
the scope of the invention as detailed within the present
disclosure.
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