钻机闭环测控系统的设计
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摘要
本课题为中国地质调查局项目《地球物理参数随钻测量系统研制》的一部分,主要实现钻机在钻进过程中参数的检测以及对回转速度和钻进压力的闭环控制。
钻机测控系统由PCI7483数据采集卡,传感器,外围电路,电液比例放大器,液压换向阀和液压溢流阀组成,本系统实现对钻机钻进过程中的多项参数进行检测,采集到的数据输入PC机中保存和进行数据处理,然后通过PCI7483数据采集卡输出电压,驱动电液比例放大器控制钻机液压系统,从而实现对钻机的闭环控制。
该测控系统可以检测的参数有:钻进深度、钻进速度、回转速度、回转压力、钻进压力。可以达到的指标:钻进深度检测精度0.1毫米、转速检测范围0～160r/min、压力0～20MPa。本系统检测到的钻机参数类型多、精度高、实时性好,并且针对随钻测量系统要求振动小、钻进平稳可靠、钻孔垂直等复杂的工作特性,设计了改进的增量型PID控制算法和Fuzzy-PID复合控制算法,再通过理论分析和试验研究,优化了控制参数,实现了钻压与转速的闭环反馈控制。
At present, majority of entire hydraulic drill used the simple switch control hydraulic system consist of manual control valve and pump home and abroad, which not only result in the bad drilling control ability , but also the low drilling efficiency and energy efficiency.
In order to overcome the performance deficiencies of the hydraulic system applied in old drilling machine, and satisfy the need of high power drilling and the complex drilling control, in this paper, introduces a new scheme of drilling hydraulic system by combining sensor technology and computer-control technology with hydraulic control system of drilling rig, and a lot of analysis and the research have been done such as the system structure, the control principle and the function characteristic etc. At last, by making use of electro-hydraulic proportional technology, the testing drill system was built up, which has the ability of monitoring, recording and controlling the drilling parameters in real-time.
The results of dynamic testing of control system showed that both response rate of pressure and rotary speed were fast, and the response time of pressure was about 0.2s, and the that of rotary speed was about 0.5s, which can meet the requirement of the real-time control.
There were much disturbing factors, both accuracy and stability of the open-loop control system were not so well. For enhancing the anti-jamming ability of system, the ameliorate PID algorithm which structure and parameters were optimized by theoretical analysis and experimental investigation, was applied to realizing the feedback control of feed force and rotary speed. The testing results show that when proportional coefficient KP is 0.5, integral time coefficient TI is 10, and differential time coefficient TD is zero, the performance of closed-loop control system is outstanding. The pressure error is less than 50N, and rotary speed error is less than 7.5r/min.So the PID algorithm improved the accuracy and stability of control system.
For improving the stability and adaptability to the complex environmental change of control algorithm further, fuzzy algorithm was brought forward. Then by combining the advantages of fuzzy algorithm and PID algorithm, compound fuzzy-PID control algorithm was devised. The actual result showed that rotary speed became more stable, and the penetration rate was limited in a small setting range and the error was only about 10%. So Fuzzy-PID algorithm has outstanding control features such as stronger adaptability and higher precision. Both the stability and reliability of electro-hydraulic control system are enhanced. The design of closed-Loop survey and control system of drill rig is so successful that establish the foundation of the higher drilling efficiency, the automation and the intellectualization of drilling equipment.
钻机测控系统由PCI7483数据采集卡,传感器,外围电路,电液比例放大器,液压换向阀和液压溢流阀组成,本系统实现对钻机钻进过程中的多项参数进行检测,采集到的数据输入PC机中保存和进行数据处理,然后通过PCI7483数据采集卡输出电压,驱动电液比例放大器控制钻机液压系统,从而实现对钻机的闭环控制。
该测控系统可以检测的参数有:钻进深度、钻进速度、回转速度、回转压力、钻进压力。可以达到的指标:钻进深度检测精度0.1毫米、转速检测范围0～160r/min、压力0～20MPa。本系统检测到的钻机参数类型多、精度高、实时性好,并且针对随钻测量系统要求振动小、钻进平稳可靠、钻孔垂直等复杂的工作特性,设计了改进的增量型PID控制算法和Fuzzy-PID复合控制算法,再通过理论分析和试验研究,优化了控制参数,实现了钻压与转速的闭环反馈控制。
At present, majority of entire hydraulic drill used the simple switch control hydraulic system consist of manual control valve and pump home and abroad, which not only result in the bad drilling control ability , but also the low drilling efficiency and energy efficiency.
In order to overcome the performance deficiencies of the hydraulic system applied in old drilling machine, and satisfy the need of high power drilling and the complex drilling control, in this paper, introduces a new scheme of drilling hydraulic system by combining sensor technology and computer-control technology with hydraulic control system of drilling rig, and a lot of analysis and the research have been done such as the system structure, the control principle and the function characteristic etc. At last, by making use of electro-hydraulic proportional technology, the testing drill system was built up, which has the ability of monitoring, recording and controlling the drilling parameters in real-time.
The results of dynamic testing of control system showed that both response rate of pressure and rotary speed were fast, and the response time of pressure was about 0.2s, and the that of rotary speed was about 0.5s, which can meet the requirement of the real-time control.
There were much disturbing factors, both accuracy and stability of the open-loop control system were not so well. For enhancing the anti-jamming ability of system, the ameliorate PID algorithm which structure and parameters were optimized by theoretical analysis and experimental investigation, was applied to realizing the feedback control of feed force and rotary speed. The testing results show that when proportional coefficient KP is 0.5, integral time coefficient TI is 10, and differential time coefficient TD is zero, the performance of closed-loop control system is outstanding. The pressure error is less than 50N, and rotary speed error is less than 7.5r/min.So the PID algorithm improved the accuracy and stability of control system.
For improving the stability and adaptability to the complex environmental change of control algorithm further, fuzzy algorithm was brought forward. Then by combining the advantages of fuzzy algorithm and PID algorithm, compound fuzzy-PID control algorithm was devised. The actual result showed that rotary speed became more stable, and the penetration rate was limited in a small setting range and the error was only about 10%. So Fuzzy-PID algorithm has outstanding control features such as stronger adaptability and higher precision. Both the stability and reliability of electro-hydraulic control system are enhanced. The design of closed-Loop survey and control system of drill rig is so successful that establish the foundation of the higher drilling efficiency, the automation and the intellectualization of drilling equipment.
引文
[1] 焦 阳,凌振宝,王 君,赵大军.基于单片机的钻机参数监测仪的研制. 吉林大学学报(地球科学版).2008,38(1):172～176.
[2] 杨汉立. 国内外石油钻机现状及我国钻机发展探讨. 石油机械,2003(7):59～63
[3] 张红彦,郑午,尚涛,陈贵生. 国内外全液压钻机节能控制发展趋势. 矿业工程. 2006,(3):43～45
[4] 涂书敏. 基于PCI总线的数据采集卡的设计:[硕士学位论文],武汉理工大学,2005. 2～5
[5] PCI9052 Data Book (Version 1.02). PLX Technology. February, 2000
[6] 鄢泰宁,曹鸿国,乌效鸣编著. 检测技术及勘察工程仪表. 武汉:中国地质大学出版社,1996.5:124～180
[7] 王君、凌振宝.传感器原理及检测技术.长春.吉林大学出版社,2003:1～10
[8] 黄继昌等.传感器工作原理及应用实例.北京:人民邮电出版社,1998:77～81
[9] 常健生主编. 检测与转换技术(第 2 版).北京:机械工业出版社,2000,34～37
[10] 新会康宇测控仪器仪表工程有限公司. KYB2003 压力变送器产品使用说明书
[11] 北京华德液压工业集团有限责任公司. VT-2000 电气放大器用于压力和流量比例阀的控制EURO电路板结构, VT-5002电气放大器用于带位置反馈的直动式比例方向控制阀的控制
[12] 北京华德液压工业集团有限责任公司. VT-5002BS20 型电液比例控制器说明书, VT-2000BS40 型电液比例控制器说明书
[13] 焦阳. 钻机参数监测仪的研制[硕士论文]. 吉林大学,2006,5:8～35
[14] 钱海. 柴油发电机组全数字控制系统硬件设计:[硕士学位论文],兰州理工大学,2004,1:1～2
[15] 庞海荣. 全液压钻机电液比例技术的应用研究:[硕士学位论文]. 煤炭科学研究总院西安分院,2003,1:5～6
[16] 高岩. 石油钻机自动送钻智能控制系统:[硕士学位论文].西安建筑科技大学,2004,1:1～2
[17] 杨振杰. 硬土质的便携式钻机的总体设计及加工技术研究:[硕士学位论文],2004,4:29～31
[18] 胡志坚. 钻机负载自适应液压控制系统的研究[博士论文]. 吉林大学,2007,5:86～110 ;6:112～139
[19] 鄢景华著. 自动控制原理. 哈尔滨工业大学出版社,1996.5:52～79
[20] 于海生. 微型计算机控制技术. 清华大学出版社,1999.3:81～95
[21] 何希才,邹炳强. 通用电子电路应用 400 例. 电子工业出版社,2005,77～79
[22] 沈雪. CMOS 集成电路原理及应用. 光明日报出版社,1983.3:104～108
[23] 补家武. 钻井进尺测量电路的防振措施. 地质科技情报,1999.6:91～93
[24] 吴宏鑫,沈少萍. PID 控制的应用与理论依据. 控制工程,2003,10(1):37～42
[25] 姜玉春,吴宏燕. PID 控制器参数的整定. 莱钢科技,2006,122(2):54～55
[26]冯亮. 模糊控制理论及在炉温控制系统中的应用研究:[硕士学位论文],东北大学,2005. 1:17
[27] 何平,王鸿绪著. 模糊控制器的设计及应用.科学出版社,1997.1:140～209
[28] 杜韶云,龙伟. Fuzzy-PID 控制恒压供水系统. 中国仪器仪表,2007(2):76～79
[29] 北京宏拓控制技术有限责任公司. PCI7483 多功能综合接口板使用说明书.
[30] 李国勇著. 智能控制及其 MATLAB 实现. 电子工业出版社,2005.5:194～261
[31] 康华光著. 电子技术基础模拟部分. 高等教育出版社,2002.4:227～336
[32] 康华光著. 电子技术基础数字部分. 高等教育出版社,2002.5:347～377
[33] (美)Evangelos Petroutsos. 邱仲潘等译. Visual Basic6 从入门到精通. 电子工业出版社,1999,1:479～494
[34] 编程高手工作室编. Visual Basic 编程高手. 北京希望电子出版社,2001,2:171～176
[35] Diane Zak, Programming with Microsoft Visual Basic 6.0 ,2006,122～124
[36] Ed Robinson, Michael Bond, Robert Ian Oliver , UPGRADING MICROSOFT VISUAL BASIC 6.0 TO MICROSOFT VISUAL BASIC .NET , 2002,175～181
[37] 杨俊. 基于 Visual Basic 的果树控温生长室温度测控系统软件开发:[硕士学位论文],华南理工大学,2000. 3:18～19
[38] Microsoft Co.Ltd 《Microsoft Visual Basic 6.0 Component Tolls Guide》. 希望图书创作室译。 北京希望电子出版社, 1998,43～47
[39] Microsoft Co.Ltd 《Mastering Visual Basic 6.0 Development Lab Manual》. Microsoft Press, 1998,52～55
[40] Microsoft Co.Ltd 《Mastering Visual Basic 6.0 Development Student Workbook》. Microsoft Press, 1998,70～76
[2] 杨汉立. 国内外石油钻机现状及我国钻机发展探讨. 石油机械,2003(7):59～63
[3] 张红彦,郑午,尚涛,陈贵生. 国内外全液压钻机节能控制发展趋势. 矿业工程. 2006,(3):43～45
[4] 涂书敏. 基于PCI总线的数据采集卡的设计:[硕士学位论文],武汉理工大学,2005. 2～5
[5] PCI9052 Data Book (Version 1.02). PLX Technology. February, 2000
[6] 鄢泰宁,曹鸿国,乌效鸣编著. 检测技术及勘察工程仪表. 武汉:中国地质大学出版社,1996.5:124～180
[7] 王君、凌振宝.传感器原理及检测技术.长春.吉林大学出版社,2003:1～10
[8] 黄继昌等.传感器工作原理及应用实例.北京:人民邮电出版社,1998:77～81
[9] 常健生主编. 检测与转换技术(第 2 版).北京:机械工业出版社,2000,34～37
[10] 新会康宇测控仪器仪表工程有限公司. KYB2003 压力变送器产品使用说明书
[11] 北京华德液压工业集团有限责任公司. VT-2000 电气放大器用于压力和流量比例阀的控制EURO电路板结构, VT-5002电气放大器用于带位置反馈的直动式比例方向控制阀的控制
[12] 北京华德液压工业集团有限责任公司. VT-5002BS20 型电液比例控制器说明书, VT-2000BS40 型电液比例控制器说明书
[13] 焦阳. 钻机参数监测仪的研制[硕士论文]. 吉林大学,2006,5:8～35
[14] 钱海. 柴油发电机组全数字控制系统硬件设计:[硕士学位论文],兰州理工大学,2004,1:1～2
[15] 庞海荣. 全液压钻机电液比例技术的应用研究:[硕士学位论文]. 煤炭科学研究总院西安分院,2003,1:5～6
[16] 高岩. 石油钻机自动送钻智能控制系统:[硕士学位论文].西安建筑科技大学,2004,1:1～2
[17] 杨振杰. 硬土质的便携式钻机的总体设计及加工技术研究:[硕士学位论文],2004,4:29～31
[18] 胡志坚. 钻机负载自适应液压控制系统的研究[博士论文]. 吉林大学,2007,5:86～110 ;6:112～139
[19] 鄢景华著. 自动控制原理. 哈尔滨工业大学出版社,1996.5:52～79
[20] 于海生. 微型计算机控制技术. 清华大学出版社,1999.3:81～95
[21] 何希才,邹炳强. 通用电子电路应用 400 例. 电子工业出版社,2005,77～79
[22] 沈雪. CMOS 集成电路原理及应用. 光明日报出版社,1983.3:104～108
[23] 补家武. 钻井进尺测量电路的防振措施. 地质科技情报,1999.6:91～93
[24] 吴宏鑫,沈少萍. PID 控制的应用与理论依据. 控制工程,2003,10(1):37～42
[25] 姜玉春,吴宏燕. PID 控制器参数的整定. 莱钢科技,2006,122(2):54～55
[26]冯亮. 模糊控制理论及在炉温控制系统中的应用研究:[硕士学位论文],东北大学,2005. 1:17
[27] 何平,王鸿绪著. 模糊控制器的设计及应用.科学出版社,1997.1:140～209
[28] 杜韶云,龙伟. Fuzzy-PID 控制恒压供水系统. 中国仪器仪表,2007(2):76～79
[29] 北京宏拓控制技术有限责任公司. PCI7483 多功能综合接口板使用说明书.
[30] 李国勇著. 智能控制及其 MATLAB 实现. 电子工业出版社,2005.5:194～261
[31] 康华光著. 电子技术基础模拟部分. 高等教育出版社,2002.4:227～336
[32] 康华光著. 电子技术基础数字部分. 高等教育出版社,2002.5:347～377
[33] (美)Evangelos Petroutsos. 邱仲潘等译. Visual Basic6 从入门到精通. 电子工业出版社,1999,1:479～494
[34] 编程高手工作室编. Visual Basic 编程高手. 北京希望电子出版社,2001,2:171～176
[35] Diane Zak, Programming with Microsoft Visual Basic 6.0 ,2006,122～124
[36] Ed Robinson, Michael Bond, Robert Ian Oliver , UPGRADING MICROSOFT VISUAL BASIC 6.0 TO MICROSOFT VISUAL BASIC .NET , 2002,175～181
[37] 杨俊. 基于 Visual Basic 的果树控温生长室温度测控系统软件开发:[硕士学位论文],华南理工大学,2000. 3:18～19
[38] Microsoft Co.Ltd 《Microsoft Visual Basic 6.0 Component Tolls Guide》. 希望图书创作室译。 北京希望电子出版社, 1998,43～47
[39] Microsoft Co.Ltd 《Mastering Visual Basic 6.0 Development Lab Manual》. Microsoft Press, 1998,52～55
[40] Microsoft Co.Ltd 《Mastering Visual Basic 6.0 Development Student Workbook》. Microsoft Press, 1998,70～76