Method to save energy for devices with rotating or reciprocating masses

• US 8,698,446 B2
• Filed: 12/14/2010
• Issued: 04/15/2014
• Est. Priority Date: 09/08/2009
• Status: Active Grant

• Current Assignee: Powerwise Group, Inc.
• Original Assignee: Powerwise Group, Inc.
• Inventors: Venkataraman, Vasan
• Primary Examiner(s): GLASS, ERICK DAVID
• Application Number:
  US12/967,128
• Publication Number:
  US 20110080130A1
• Time in Patent Office: 1,218 Days
• Field of Search: 318/799, 318/812, 318/621, 318/400.14, 417/12, 417/18, 417/45
• US Class Current: 318/799
• CPC Class Codes: H02P 1/04 Means for controlling progress of starting sequence in dependence upon time or upon current, speed, or other motor parameter
• CPC Class Codes: H02P 23/0004 Control strategies in general, e.g. linear type, e.g. P, PI, PID, using robust control
• CPC Class Codes: H02P 23/24 Controlling the direction, e.g. clockwise or counterclockwise
• CPC Class Codes: H02P 6/182 using back-emf in windings
• CPC Class Codes: H02P 6/28 Arrangements for controlling current H02P6/10 takes precedence

Abstract

A system and method are disclosed for turning off the voltage to a pump jack electric motor during predetermined periods of time to save energy. In the method, the motor'"'"'s response to closed-loop control may be evaluated over several pump strokes. The periods of the pump stroke when it is feasible to turn off the motor may be identified. The consistency of the measurements over several strokes may be evaluated. The motor may be turned off during predetermined periods on subsequent pump strokes when each pump stroke shows sufficiently similar behavior to that predicted during the closed-loop control process. The system may return to the closed-loop control process after a predetermined period of time to adjust to any changes in the system.

Claims

1. A method of saving energy for a pump jack with a counterweight disposed with a well, comprising the steps of:

connecting a closed loop motor controller to an electric motor connected with the pump jack, wherein said motor controller having switching devices;

supplying a line voltage and current to said motor;

rotating the pump jack counterweight with said motor for a plurality of pumping cycles;

observing the phase angle between the voltage and current supplied to said motor with said motor controller;

comparing the observed phase angle with a threshold phase angle;

adjusting the supply voltage upon reaching said threshold phase angle using a firing angle of said switching devices to maintain the observed phase angle at a value no greater than a target phase angle;

reinstating the full supply voltage to said motor when the firing angle falls below a threshold firing angle;

identifying the time periods during the pumping cycles that the supply voltage is adjusted;

comparing said time periods to establish predetermined turn-off time periods for switching off the supply voltage;

after the step of comparing, switching off the supply voltage to the motor during said predetermined turn-off time periods; and

switching on the supply voltage during the other times periods, wherein the other time periods being predetermined turn-on time periods.

2. The method of claim 1, further comprising the step of:

observing a turn-on phase angle immediately after beginning the predetermined turn-on time periods.

3. The method of claim 2, further comprising the step of:

comparing the turn-on phase angle with an ideal phase angle.

4. The method of claim 3, further comprising the step of:

increasing said predetermined turn-off time periods if the turn-on phase angle is greater than the ideal phase angle, and decreasing said predetermined turn-off time periods if the turn-on phase angle is less than the ideal phase angle.

5. The method of claim 4, wherein said threshold phase angle is 70 degrees, said target phase angle is 60 degrees, said threshold firing angle is 90 degrees, and said ideal phase angle is 75 degrees.

6. The method of claim 4, further comprising the step of:

after the steps of switching off and switching on, repeating the steps of supplying, adjusting, reinstating, and comparing.

7. The method of claim 6, wherein the step of repeating performed at predetermined times.

8. The method of claim 1, wherein the step of reinstating occurring when there is an increase in a load on said motor.

9. The method of claim 1, wherein the step of adjusting still allowing sufficient current to observe the phase angle.

10. The method of claim 1, further comprising the step of:

determining whether the identified time periods during the pumping cycles are repetitive to establish said predetermined turn-off time periods.

11. The method of claim 10, wherein said time periods are repetitive when there is no variation of more than 200 milliseconds in the periods of the pumping cycles.

12. The method of claim 10, wherein said time periods are repetitive when there is no variation of more than 150 milliseconds in said time periods.

13. The method of claim 1, further comprising the step of:

moving a tubular string connected with the pump jack in a substantially vertical direction in the well during the pumping cycles;

wherein the step of switching off causing the tubular string to move faster than the tubular string would move if there were no step of switching off; and

wherein the step of switching off causing the pump jack counterweight to rotate faster than the counterweight would rotate if there were no step of switching off.

14. A method of saving energy for a pump jack with a counterweight disposed with a well, comprising the steps of:

supplying a line voltage and current to an electric motor connected with the pump jack, wherein the current having a real component and a reactive component;

rotating the pump jack counterweight with said electric motor for a plurality of pumping cycles;

observing the phase angle between the voltage and current supplied to said motor with a motor controller electrically connected with said motor;

comparing the observed phase angle with a threshold phase angle;

controlling the supply voltage to said motor upon reaching said threshold phase angle to maintain the observed phase angle at a target phase angle and causing the current real component to be substantially zero and the current reactive component to be greater than zero;

reinstating the full supply voltage to said motor when there is an increase in a load on said motor;

identifying the time periods during the pumping cycles that the supply voltage is controlled;

setting predetermined turn-off time periods for turning off the supply voltage from said identified time periods; and

switching off the supply voltage to said motor during said predetermined turn-off time periods and switching on the supply voltage during the other times.

15. The method of claim 14, further comprising the steps of:

comparing a turn-on phase angle observed immediately after beginning the step of switching on with an ideal phase angle; and

increasing said predetermined turn-off time periods if the turn-on phase angle is greater than the ideal phase angle, and decreasing said predetermined turn-off time periods if the turn-on phase angle is less than the ideal phase angle.

16. The method of claim 14, wherein there is an increase in a load on said motor when a firing angle of said motor falls below a threshold firing angle.

17. The method of claim 14, further comprising the step of:

determining whether said identified time periods during the pumping cycles are repetitive to establish said predetermined turn-off time periods.

18. A method of saving energy for a pump jack with a counterweight disposed with a well, comprising the steps of:

supplying a line voltage and current to an electric motor connected with the pump jack, wherein the current having a real component and a reactive component;

rotating the pump jack counterweight with said electric motor for a plurality of pumping cycles;

observing the phase angle between the voltage and current supplied to said motor with a closed-loop PID motor controller in electrical connection with said motor;

comparing the observed phase angle with a threshold phase angle with said motor controller;

adjusting the supply voltage upon reaching said threshold phase angle to maintain the observed phase angle at a value no greater than a target phase angle;

reinstating the supply voltage to said motor when a firing angle of said motor falls below a threshold firing angle;

identifying the time periods during the pumping cycles occurring between the threshold phase angle and the threshold firing angle;

comparing said time periods to establish predetermined turn-off time periods for switching off the supply voltage;

switching off the supply voltage to said motor during said predetermined turn-off time periods and switching on the supply voltage during the other time periods, wherein said other time periods being predetermined turn-on time periods;

observing a turn-on phase angle immediately after beginning the predetermined turn-on time periods;

comparing said turn-on phase angle with an ideal phase angle;

increasing said predetermined turn-off time periods if the turn-on phase angle is greater than the ideal phase angle, and decreasing said predetermined turn-off time periods if the turn-on phase angle is less than the ideal phase angle; and

after the steps of switching off and switching on, repeating the steps of supplying, adjusting, reinstating, and comparing.

19. The method of claim 18, further comprising the step of:

determining whether said identified time periods during the pumping cycles are repetitive to establish said predetermined turn-off time periods.

20. The method of claim 18, wherein said threshold phase angle is 70 degrees, said target phase angle is 60 degrees, said threshold firing angle is 90 degrees, and said ideal phase angle is 75 degrees.