Energy saving system and method for devices with rotating or reciprocating masses.

(54) Title: SYSTEM AND METHOD FOR SAVING ENERGY FOR DEVICES WITH ROTATING OR ALTERNATIVE MASSES.

(54) Title: ENERGY SAVING SYSTEM AND METHOD FOR DEVICES WITH ROTATING OR RECIPROCATING MASSES.

(57) Summary

A method and system are provided to reduce the power consumed by a pump stand electric motor by reducing the supply voltage to the motor when the motor may be generating power in an open cycle mode. By substantially eliminating the power generation mode, the braking action of the electrical service network to limit engine and system acceleration that might otherwise occur is substantially removed. The motor and system will be accelerated, allowing the natural kinetic energy of the cyclic motion to do part of the pumping action. A closed loop controller in electrical connection to the motor calculates the necessary observed phase angle information between the voltage and current supplied to the motor. By reducing the motor supply voltage, the observed phase angle can be reduced to a target phase angle value.

(57) Abstract

A system and method are provided for reducing the energy consumed by a pump jack electl # c motor by reducing the supply voltage to the motor when the motor would be generating energy in open loop mode By substantially eliminating the energy generation mode, the braking action of the utility grid in limiting the acceleration of the motor and system that would otherwise occur is substantially removed The motor and system will speed up, allowing the natural kinetic energy of the cyclic motion to perform part of the pumping action A closed loop controller in electrical connection with the motor computes the necessary Information from the observed phase angle between the voltage and current supplied to the motor By reducing the supply voltage to the motor, the observed phase angle may be reduced to a target phase angle value.

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PATENT TITLE NO. 342012

THE POWERWISE GROUP, INC.

4855 Technology Way, Suite 550, Boca Raton, Florida, 33431, USA

SYSTEM AND METHOD TO SAVE ENERGY FOR DEVICES WITH ROTATING OR ALTERNATIVE MASSES. lnt.CI.8: F04B35 / 04; H02P27 / 02

JOHN L. LUMSDEN; PAUL H. KELLEY; VASAN VENKATARAMAN

Number:

MX / a 2316/008643

APPLICATION • Submission Peeha 'wlMSIt September 2010 Divisional Patent Number: 330339

Country:

US

PRIORITY

Date:

September 2009

Number:

61/240,399

Request: Twenty | Years ^ Expiration Date: September 1, 2030 s

The reference patent is granted with foundation Λ * k * i 1st, 2nd fraction V, 6th fraction ill, and 59 of the Industrial Property Law and this patent is valid for twenty years imjfcrrogabies, ai and will be subject to the payment of the fee to maintain (in force the d | conformity with article 23 of If'ley sung from the Date of presentation of the i Tipiedatf ation of the sMciM rir w based on the provisions í &gt; or atícelos 6th fractions Dt and 7th bis 2 of S Federation Law (DOF) 27 / (36/1991 amended on 02/0 / 19S4, 10/25/1996, 12/26/1997, 47 / 05/1999,

105 / 2009.06 / 01/2010. 18Λβ / Μΐβ (¿* / 00/2010. 27.1) 1/201 ^ 0 &lt;* ¿/ 2012); 1st articles, t? fraction V so a), 4th and 12th fractions I and III * 1 Regulation of the Mexican institute ¢ 1¾ 1¾ Industrial property (DOF 12/14/1999, formed on 07/2002, 07/15/2004, 2M7 / 2004 and j / 09/2007); articles 1, 3, 4, 5, section Vmclso a), 16 sections I and III and 30 of the Organic Statute 4M / * uioMeiti «en» do4 »Property tedu8! TiaI- (QOF 27/4 ^ te ^ 4etarM (taMMaMMMMMMMM ^ M * MM (BiQ7); 1st, 3rd and 5th subsection a) of the Agreement that delegates powers to the Deputy Directors General, Coordinator, Divisional Directors, Regional Office Holders, Divisional Deputy Directors. Departmental Coordinators and other subordinates of the Mexican Institute of Industrial Property. (DOF 12/15/1999, amended on 02/04/2000, 07/29/2004, 08/04/2004 and 09/13/2007).

Who subscribes to this title Industrial Property (Official Gazette of 01/49/2004, 06/16/2005, 25431/2006 Siso a), 4 'and 12' sections I and III

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Issue Date: September 9, 2016

DIVISIONAL DIRECTOR OF PATENTS

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NAHANNY CANAL REYES

Arenal No. 550, Floor 1.

Cok Pueblo Santa María Tepepan. Xochirrtüco, CP 15020,

Mexico City

Tei. (55) 53 34 07 00 www.impi qob.mx

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MX / 2016/73170 ^ΙΜΡΪ®3

MEXICAN INSTITUTE OF THE mOP | £ I&gt; AI&gt; INDUSTRIAL

SYSTEM AND METHOD TO SAVE ENERGY FOR _

DEVICES WITH ROTATING OR ALTERNATIVE MASSES

CROSS REFERENCE TO RELATED REQUESTS

This application claims the benefit of US Provisional Application No. 61 / 240,399 filed on September 8, 2009, which is incorporated herein for reference for all purposes in its entirety. This application is also a continuation in part of co-pending US Application No. 12 / 207,913 filed on September 10, 2008, which claims the benefit of the US Provisional Application. 61 / 135,402 filed on July 21, 2008, and US Provisional Application 60 / 993,706 filed on September 14, 2007, all of these applications are incorporated herein by reference for all purposes in their entirety.

STATEMENT WITH RESPECT TO INVESTIGATION OR

FEDERALLY SPONSORED DEVELOPMENT

N / A

REFERENCE TO ANNEX OF MICROPHONE

N / A

MEXICAN INSTITUTE OF PROPERTY

INDUSTRIAL

<img file="MX342012B_D0007.tif" />

BACKGROUND OF THE INVENTION

one. Field of the Invention

This invention relates to electric motors used to operate pump stands and other devices with rotating or alternative masses.

2. Description of Related Technique

A pump ridge is an above-ground drilling device for an impeller-aspirating piston pump installed at the bottom of the bore in an oil well. The pump ridge mechanically raises liquid out of the well when there is not enough bottom hole pressure for the liquid to flow itself to the surface. The pump stand is usually powered by an electric motor that receives electrical power from an electrical service network. A pump stand converts the motor's rotary mechanism to reciprocating motion to drive the pump from the bottom of the bore. There are many different designs of pump stands, including, but not limited to, Lufkin Mark II Conventional, Balanced Beam, Air Balanced, Deviated Well, and Conventional Portable. Pump stands are available from many different suppliers, including Lufkin Industries, Inc. of Lufkin, Texas and Cook Pump Company of Coffeyville, Kansas.

The electric pump stand motor usually does

<img file="MX342012B_D0008.tif" />

turning a group of pulleys for a gear or transmission system, which in turn drives a pair of cranks or crank arms. For a typical conventional pump trestle design, the manivs are raised and lowered by one end of a lever or arm, known as a "moving stringer," which is provided on an A-shaped master post or frame. A curved metal box known as a "horse's head" is on the other end of the movable stringer from where the crank arms are connected to the arm. A counterweight or alternative mass is typically attached to one end of the cranks. A steering link rod usually extends between the counterweight and the end of the movable cross member opposite the horse's head. A cable connects the horse's head to a vertical polished bar, which is connected to the vertical chain of tubular or sucker rods that run to the pump at the bottom of the bore in an oil well.

The counterweight helps the engine lift the sucker rod chain or tubular chain. When the motor raises the counterweight up, the horse's head moves downward, pushing the sucker rods or tubular chain down. After the counterweight reaches the top of its rotation, it swings around and helps the motor rotate the movable beam in the opposite direction using the momentum of the counterweight and mass (kinetic energy). When the counterweight is freely falling down from its uppermost position, the horse's head moves upward,

I swinging the rod rod from the bomb upwards. The patent

IMPÍ Mexican iNjttmrro OF INDUSTRIAL PROPERTY

<img file="MX342012B_D0009.tif" />

No. 4,051,736 proposes an improved pump stand ^ ϋΒ · —Μ &lt;Ι1Ι · &lt;»· 4ΜΙ · ΙΙΙΜ&gt; ΙΙ»&gt; ....... II that reciprocates an oil well pump.

Although there are different designs of a downhole pump in an oil well, downhole pumps in an oil well have traditionally comprised a piston or piston that reciprocates within a pumping barrel located at or near from the end of the production line. Two independent valves typically achieve the pumping action. A right hand check valve can be secured in the pump barrel below the piston, and the piston can include a travel check valve. The upward stroke of the piston opens the right valve, and draws fluid into the pump barrel as the travel valve remains closed. The downward stroke of the piston opened the flow valve and forces the fluid to go up from the pump barrel as the right barrel remains closed. US Patent Nos. 3,578,886; 4,173,451; and 6,904,973 propose downhole drilling pumps in an oil well.

It is well known that electric motors can enter an operating power generation mode. For an electric motor used with a pump stand, the power generation mode can occur at any time during counterweight rotation, depending on the condition of the balance between the counterweight and the tubular or rod chain. Balance condition may fluctuate from stroke to stroke during pumping,

BEUPROrifiüAÜ MEXICAN INSTITUTE

INDUSTRIAL «gg depending on the quantity and composition of fluid that is raised by the rod chain in each stroke. The polished rod and the attached sucker rod or tubular stroke can be moved up or down in the power generation mode.

A well owner must pay his electric bill based on the amount of energy that the pump ridge motor consumes. The amount of energy consumed is measured through an energy meter. In the past, the amount of energy consumed was measured through an analog electricity meter. Many digital electricity meters are now used. The energy meter, whether of analog or digital design, can be configured, at the discretion of the service company, it allows or avoids crediting the customer for generated energy that is supplied back to the energy network. A pump ridge system is an inefficient generator that the amount of energy consumed required to produce any generation significantly exceeds the energy generated. Therefore, regardless of energy service company credits, it is always beneficial for the customer to avoid power generation.

During generation periods, a motor will attempt to obtain a voltage that exceeds the utility line voltage, thereby causing current to flow in the opposite direction. The load provided by the electrical service network serves as a brake, limiting engine acceleration that might otherwise have occurred.

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MEXICAN INSTITUTE OF INDUSTRIAL PROPERTY

This motor braking action prevents dropping of loads from the pump stand from the development of additional kinetic energy that may have assisted in the pumping action. This converted kinetic energy may have served as an alternative to electrical energy from the utility grid.

In the past, engineers have unsuccessfully attempted to save significant amounts of energy by shutting down the electric motor of the pump stand during a portion of the pump stand cycle that may have included a generation period. This has been attempted with various mechanical switches and relays. However, the parameters of downhole pumps in an oil well and wells vary over time, so mechanical solutions have not been worked on.

Fluid flow in the well can vary as the well fills, and then "evacuates." In some cases, the volume of fluid pumped can change from one stroke to the next. The changing volumes, densities, weights, and other properties of materials and / or fluids pumped, such as gas, oil, water, and slurry, can greatly alter the combined weight of the rod stroke and the fluid column, thereby affecting the balance of the system and the demand on the engine. In some wells, tubular runs can be thousands of meters long. The influx of different fluids in the well over time will significantly impact engine operation.

With the introduction of the microprocessor, it has become possible

ΙΜΡΪ. INSTITUTO Μ SXICA NO DE LA EROHEPAL »turn off the electric motor when observing the current^Neitherand^T* # l 'voltKFS ^ However, the problem was known when O'TI ΙΎΤΌΪόΓ é'léfctrictric Tfe turned on again. In the past, several open cycle time delays have been attempted without success. Microprocessor solutions also failed, as the parameters of the downhole pumps in an oil well and wells vary over time.

US Patent No. 6,489,742 proposes a motor controller that includes power transmission to an induction motor with a digital signal processor that calculates and optimizes the current supply for the existing motor load from a main voltage and power supply through a control element.

US Publication No. 2009/0046490 proposes an IGBT / FET-based energy saving device, system, and method, where a predetermined amount of voltage is saved below a nominal line voltage and / or below a nominal resource voltage. US Publication No. 2009/0051344 proposes a TRIAC / SCR-based energy-saving device, system, and method, whereby a predetermined amount of voltage is saved below a nominal line voltage and / or below a nominal resource voltage. US Publication No. 2009/0200981 proposes a system and method to provide a constant load in AC power applications, where at least one point of nd of at least

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C 'UTO MEXICANO °' .A PROPERTY • NDUSTRIAL half cycle of a modulating sine wave, at least one off point of at least half a cycle of modulating sine wave is determined, and at least one piece located is removed between at least one on point and at least one off point. US Publication No. 2010/0033155 proposes a power supply for IGBT / FET controllers that provides separate, isolated power for each IGBT / FET controller.

Integral proportional derivative control (PID) is a widely used technique applied to control logarithms and feedback mechanisms. A PID controller, as it is generally called, calculates a value based on an "error". Typically, "error" is calculated as the difference between a measured procedure variable and a desired set point or target value. The PID controller tries to minimize the error by adjusting the procedure control variables. In essence, the PID controller is a digital filter that has proportional, integral, and derivative parameters. The proportional value determines the reaction to a current error, the integral value determines the reaction based on the sum of recent errors, and the derivative value determines the reaction based on the rate at which the error has been changed.

US Patent Nos. 3,578,886; 4,051,736; 4,173,451; 6,489,742; and 6,904,973; and US Publications Nos. 2009/0046490; 2009/0051344; 2009/0200981; and 2009/0033155, ant s discussed, are incorporated here for rf renda for all

<img file="MX342012B_D0012.tif" />

purposes in its entirety.

There is a need to efficiently manage the energy use of a pumping stand electric motor, particularly during the power generation mode.

BRIEF DESCRIPTION OF THE INVENTION

A closed cycle motor controller system reduces the supply voltage to a pump stand electric motor, or when the motor may be generating power in open cycle mode, when the phase angle between voltage and current may be greater. than 90 degrees. By reducing the supply voltage to the motor, the observed phase angle between the voltage and current can be reduced to a value below 90 degrees. Under these conditions, the motor no longer consumes energy. Through pulse width modulation techniques, the actual energy component can be reduced to virtually zero, leaving a reactive component greater than zero. By allowing some current flow, primarily of a reactive nature, an observable feedback parameter in the closed loop control system can be used as an indication of the motor load condition, to which the motor controller may react. , allowing power to be supplied when needed. Similarly, the closed cycle motor controller system can achieve more energy savings by reducing the supply voltage.

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to the motor when the motor is lightly loaded and consumes energy. By minimizing or eliminating energy that might otherwise be consumed by the system, energy savings can be obtained from both reducing the motor supply voltage and minimizing or eliminating braking action from of the electrical service network on the engine. The motor and system will be accelerated allowing the natural kinetic energy of the cyclic motion to perform part of the pumping action.

A target phase angle can be supplied either as a constant for all motor loads, or as a variable function of the motor load at any time. The target phase angle may be equal to or less than 90 degrees, although a target phase angle greater than 90 degrees is also contemplated. When the motor is generating or consuming power, and the observed phase angle in open cycle mode may be greater than the target phase angle, the system can reduce the supply voltage until the observed phase angle is substantially the angle phase objective. Any other reduction in the phase angle observed below the target phase angle can be interpreted as an increase in motor load, such as during power consumption mode, to which the system can respond by increasing the supply voltage. until once again the target phase angle is reached. The necessary information can be calculated from the observed phase angle between I voltage and current consumed by the motor.

BRIEF DESCRIPTION OF THE DRAWINGS

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MEXICAN INSTITUTE OF INDUSTRIAL AMMONITY

<img file="MX342012B_D0014.tif" />

Another better understanding of the present invention can be obtained with the following detailed description of the various embodiments described in the drawings where similar parts are provided with similar reference numbers, and where:

Figure 1 is a block diagram of a digital signal processor (DSP) with hardware inputs and outputs.

Figure 2 is a block diagram of a DSP-based motor controller.

Figure 3 is a diagram showing a phase rotation detection method.

Figure 4 is a flow chart showing a phase rotation detection method.

Figure 5 is a graph showing power control device outputs for positive phase rotation.

Figure 6 is a graph showing power control device outputs for negative phase rotation.

Figure 7 is a block diagram of a window comparator.

Figure 8 is a schematic view of the window comparator.

Figure 9 is a graph of a current waveform and zero axis crossover signals.

Figure 10 is a schematic view of a n utro circuit

INSTITUTO MEXICANO virtual.

Figure 11 is a graph showing power control device outputs for single phase applications.

Figure 12 is a three-dimensional graph showing a three-dimensional control line.

Figure 13 is a three-dimensional graph showing a control line projected onto a plane.

Figure 14 is a graph showing a two-dimensional plotted control line.

Figure 15 is a graph showing a sweep firing angle / usage cycle in a semi-automatic calibration.

Figure 16 is a graph showing a directed sweep of a firing angle / cycle of use.

Figure 17 is a graph showing graphed semi-automatic calibration data.

Figure 18 is a graph showing plotted semi-automatic calibration data.

Figure 19 is a graph showing plotted semi-automatic calibration data.

Figure 20 is a flow chart of a semi-automatic high-level calibration.

Figure 21 is a flow chart of a semi-automatic high-level calibration.

Figure 22 is a flow chart of a manual calibration.

Figure 23 is a flow chart of a fixed voltage fixer.

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Figure 24 is a graph showing an RMS motor voltage clamp.

Figure 25 is a graph showing an RMS motor voltage clamp.

Figure 26 is a flow chart of a loss mitigation technique.

Figure 27 is a graph showing a loss mitigation technique.

FIG. 28 is an elevation view of one embodiment of a pump ridge placed with a tubular chain in a well.

Figure 29 is an observed phase angle versus time graph for a pump trestle motor in an open cycle mode.

Figure 30 is a system block diagram connected to the motor.

Figure 31 is a graph of observed phase angle versus time for a pump trestle motor in a closed cycle control mode with a reduction in motor voltage to achieve a target phase angle within a complete pump cycle.

Figure 32 is a single phase waveform graph of the incoming line voltage.

Figure 32A is a strongly cut single phase waveform graph of the voltage supplied to the motor after the application of pulse width modulation (PWM) technique.

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MEXICAN INSTITUTE -T¡ «

Ot THE INDUSTRIAL PROPERTY&gt; g ^ ny

Figure 32B is a strongly cut single phase waveform graph of the voltage applied to the motor after the application of PWM techniques.

Figure 32C is a graph of variably cut individual phase waveform of the voltage supplied to the motor after application of PWM techniques.

Figure 32D is the graph of Figure 31 illustrating the periods when heavy cutting, light cutting, and no cutting can occur.

DETAILED DESCRIPTION OF THE INVENTION

Referring to Figure 1, a block diagram of a digital signal processor (DSP) 1 and hardware inputs and outputs are shown. DSP 1 can observe the operational characteristics of a motor and make corrections to the least squares voltage (RMS) for the motor that is running and under closed cycle control. Hardware inputs 2 capture phase 36 zero axis crossover inputs, fas line voltage 37, phase motor voltage 38, and current 9 and pass through DSP 1 for processing and then into power control devices through the power control device outputs 14.

Referring now to Figure 2, a block diagram of a DSP-based motor controller system and method 4 is shown. First, the motor controller 4 reads the

IMPI τπτυτο MEXICAN

I ”. THE COIN"

INDUSTRbU voltages 37 of each phase A, B, and C and current 9 to capture the zero-axis crossover inputs 36. At this point, voltage 13 and current 9 can be converted from analog to digital using converters 62. Then, compute the motor phase angle calculations 63 for each phase to produce an observed phase angle 5. Then, a target phase angle 10, which has been derived from a pre-programmed control line 6, is compared to the observed phase angle 5. The difference between the target phase angle 10 and the observed phase angle 5 produces a resulting phase error signal (11, 28), which is processed by a PID controller 12, which has proportional, integral, and differential components. The output of the PID controller 12 is the new control voltage (13, 29) towards the motor 3, which can be obtained through the use of energy control devices 33, such as TRIACs, SRCs, IGBTs or MOSFETS, to produce Power control device outputs 14 of the motor voltage RMS 13 supplied with line voltages 50 for each phase for maximum energy savings.

In this closed cycle system, the voltage 13 of each phase of motor 3 and the current are continuously verified. The motor controller 4 will direct the observed phase angle 5 to the point on the calibrated control line 6 that corresponds to the load on the motor. At this point, maximum energy savings will be realized since control line 6 is based on known calibration data from motor 3. Motor controller 4 can control motor 3

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INDUSTRIAL just as if a technician set voltage 13 by hand. The difference is that DSP 1 can dynamically respond to load changes in real time and make these adjustments on a cycle-by-cycle basis.

Referring now to Figure 3, in a three phase system, motor controller 4 is used to automatically determine phase rotation. Zero axis crossover detectors at line voltages provide an accurate measurement of the angle between phase A line voltage zero axis crossings 15 and phase line voltage zero axis crossovers B 16. For a positive phase rotation 18, the angle is nominally 20 ° and for negative phase rotation 19, the angle is nominally 60 °.

Referring to Figure 4, a flow chart for phase rotation detection is shown. After resetting n ignition (POR) 20, it is easy for the motor controller 4 to determine the positive phase rotation 18 and the negative phase rotation 19. First, the time is measured from the zero axis crossovers of voltage of phase line A to the zero axis junctions of phase line voltage B 39. It is then determined whether the time is greater than or less than 90 degrees 40. IF it is greater than 90 degrees, then it is an ACB 42 rotation. If the time is less than 90 degrees, then it is an ABC 41 rotation. Motor controller 4 can control three-phase or single-phase motors with the same architecture. basic software and hardware. In the case of three phases, depending on the phase rotation, the motor controller 4 can direct outputs 14 d I ngia control device.

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Referring now to Figure 5, which shows power control device outputs for positive direction rotation, the motor controller drives outputs 14 of the phase A power control device and outputs 14 of the power control device. Phase B energy together during the ignition timing of phase A line voltage zero axis crossings 15, as indicated by oval 22a. Similarly, the motor controller directs power control devices, which direct outputs 14 of the phase B 16 and phase C energy control device together during the phase B ignition timing, as indicated by the oval 22b. Finally, the motor controller 4 drives the outputs 14 of the phase C 17 and phase A power control device together during the on time of the outputs 14 of the phase C power control device, as indicated by oval 22c. Note that the example shown in Figures 5 and 6 shows a firing angle / cycle of use of 90 °.

Referring now to Figure 6, which shows the TRIAC direction outputs for negative phase rotation, I motor controller 4 directs outputs 14 of the A phase energy control device and outputs 14 of the phase energy control device C together during the ignition timing of phase A line voltage zero axis crossings 15, as indicated by oval 22c. Similarly, motor controller 4 directs outputs 14 d I phase B 16 and phase A n power control device

<img file="MX342012B_D0017.tif" />

set during the ignition timing of junctions 16 of phase zero line voltage zero ej, as indicated by oval 22a. Finally, the motor controller drives outputs 14 d I phase C power control device and outputs 14 d I phase B power control device together during the ignition timing of zero axis crossings 17 of phase line C, as indicated by oval 22b.

Referring now to Figure 7, a block diagram of a window comparator is shown. The DSP-based motor controller uses window comparator 88 to detect zero axis crossovers of both positive and negative halves of a current waveform. When the RMS motor voltage is reduced by the motor controller, it is difficult to detect zero axis crossings of the current waveform since the current is zero for a significant portion of both my cycles. First, 89, a motor current is provided, 90, a positive voltage is provided as a reference for a positive average cycle, and 91, a negative voltage is provided, as a reference. The current, positive voltage, and negative voltage are then presented to two comparators 92 and then passed through an operating gate (OR) 93 to create a digital composite zero-axis crossover signal 94.

As further illustrated in Figure 8, a schematic view of the window comparator 88 is shown. The motor current, 89, is provided, providing 90, a positive voltage, such as a

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<img file="MX342012B_D0018.tif" />

reference for a positive mean cycle and 91, a negative voltage is provided as a reference. The current, represented as a positive voltage and a negative voltage, is then processed by comparators 92 and then passed to an OR gate 93 to create a composite zero-axis crossover digital signal.

94.

In addition, Figure 9 shows graphs of a current d waveform 95, a positive voltage mean cycle 96, a negative voltage mean cycle 97 and an OR function 98.

Referring now to Figure 10, a schematic view of a virtual neutral circuit is shown. A virtual neutral circuit can be used as a reference to situations where three phase power is available only in delta mode and no neutral present to be used as a reference. The virtual n utro circuit comprises three amplifiers from differential to individual end 77. Since the phase-to-phase voltages are high, input resistors 78 are used to form a suitable attenuator 79 along with feedback resistors 80 and ground reference resistors 81. There is already damage from a phase loss, diodes of Protection 82 to protect amplifiers from differential end to individual 77. The differential to individual end amplifiers 77 are coupled to a summing amplifier 83 via DC blocking capacitors 84 and summing resistors s 85 together with feedback resistor 80. The output of summing amplifier 83 is promoted by amplifier 27, thus providing

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MEXICAN INSTITUTE f&gt; * weK &lt;¡»Λ, OF THE PROPERTY tSwrA-Mn ^ a low impedance output, which is at '^ T ^ cisPPneraTro. Additional resistors divide a supply rail so that the summing amplifier 83 handles alternating positive and negative signals. An alternate connection is available in the event that a neutral 86 is available along with a flywheel block for the alternate neutral connection 87.

Referring now to Figure 11 showing an energy control device output 14 for a single phase application, output 14 for phase A is turned on in each half cycle based on a derived energy control device output 14 voltage zero axis crossover input 15. The power control device output 14 for line B voltage zero axis crossovers and line to C voltage zero axis crossovers is disabled on DSP 1 and hardware may not be present. The outputs of the power control device 14 are not in pairs as they were in the case of three phases.

Referring now to Figure 12, which illustrates a three-dimensional control line for the motor operating space of a motor linked by an observed phase angle 5 on the y axis. A controlled firing / duty cycle angle 23 showing the reduction in voltage is shown on the x axis and the percent load 24 on a motor is shown on the z axis.

Each motor operates along a parametric control line 25 within its operating space. For example, when a given motor is loaded at 50% and I firing angle /

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INDUSTRIAL utilization cycle 23 is set to 100 °, a phase angle 5 of approximately 55 ° is observed.

The parametric control line 25 shown in Figure 12 is defined by five parametric operating points 26 which vary from a loaded case 44 in the upper left corner to an unloaded case 45 in the lower right corner. Furthermore, the parametric control line 25 has a special meaning since it is the line where a motor is using the least possible energy. If the firing / duty cycle angle 23 is increased and the motor voltage 13 is reduced then a motor could slow down and possibly leak. Similar results could be seen if the load on motor 3 increases.

As illustrated in Figure 13, the parametric control line 25 can be parameterized and projected onto a plane described by the phase angle 5 in the vertical direction and the firing / cycle angle 23 in the horizontal direction.

Furthermore, as shown in Figure 14, the parametric control line 25 can be presented in a two-dimensional graph. On the x-axis, the increase in firing angle / utilization cycle 23 can be equated to a decreasing motor voltage. This is because a small firing angle / utilization cycles results in a high voltage and a large firing angle / utilization cycles results in a low voltage. The motor controller will direct the observed phase angle 5 toward the point of control line 25 that corresponds to the load currently on a motor. For i ivi jr 1

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SAY THE PROPERTY OR * -. In order to accomplish this, a DSP calculates the phase angle 5 between the voltage and the current.

Referring back to the block diagram in Figure 2, DSP 1 then calculates the next target phase angle 5 based on the current value of RMS voltage 13, or equivalently the current value of the trigger angle / cycle of use. The difference between the observed phase angle and the target phase angle 10 results in a phase angle error, which is processed through a PID controller 12 or similar device to generate a new control target. This control target changes the voltage in such a way that the phase angle error is minimized. The target phase angle 10 is dynamic and changes as a function of the firing / cycle angle of use.

As stated above, motor controller 4 will direct the observed phase angle 5 to the point on control line 25 that corresponds to the load currently on motor 3. This operating point 26 provides the maximum possible energy savings since control line 25 is calibrated directly from motor 3 being controlled.

This method of calibration is called semi-automatic calibration. Semi-automatic calibration is based on I sweep, with DSP 1, of the motor control space. As shown in Figure 15, the control space sweep means that the DSP increases I firing angle / utilization cycle 23 and

<img file="MX342012B_D0019.tif" />

records current 9 and firing angle / utilization cycle 23 of each phase at discrete points along the way. In this way, it is possible to see the start of the loss point 21 of the motor. A well-defined linear portion of observed calibration data curve obtained from sweep of control space 7, which is used to determine control line points 6, has a constant negative slope at a lower firing angle / cycle of use 2. 3. Then, as the firing angle / utilization cycles 23 continues to increase, the current 9 begins to drop and actually begins to increase as the motor 3 slides and begins to enter the loss, called "knee" 31 .

As shown in Figure 16, subsequent sweeps can be directed to smaller scales of motor voltages for "approach" to the knee. The motor controller 4 requires multiple sweeps in order to obtain data that is statistically accurate. There is a trade between the number of sweeps and the time required to calibrate control line 25. A measure of the quality of the calibration can be maintained by DSP 1 using known statistical procedures and, if necessary, additional scans can be made. This is true since DSP 1 has learned the proximal location of knee 31 since the first sweep.

There is a slight risk of loss during semi-automatic sweeping due to the controlled environment of the configuration. A

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<img file="MX342012B_D0020.tif" />

Technician or operator helps ensure that sudden loads will be applied to motor 3 under test while a semi-automatic calibration is in progress.

The control space sweep procedure can be performed at any fixed load. For example, it can be done once with the engine 3 fully loaded and once with the engine 3 unloaded. These two points become two points that define control line 25. Calibration does not need to be performed at exactly these two points. DSP 1 will extend control line 25 beyond these two points, if required.

There are many numerical methods that can be applied to find loss point 21 on the graph of actual motor voltage 23. As shown in Figure 17, one method is to use the least squares method to calculate a straight line. better fitting tabulated cumulative data from the first five motor voltages 23.

The continuation of this method is shown in Figure 18. Using the previous data points, the value of current 9 can be predicted. Graphically, DSP 1 is verifying one or more points that deviate in the positive direction from the predicted straight line.

As shown in Figure 19, DSP 1 is looking for the start of the knee in the curve. The first point that deviates from the predicted control line may or may not be the start of knee 31. The first point with a positive error simply cannot be a

<img file="MX342012B_D0021.tif" />

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<img file="MX342012B_D0022.tif" />

noise data point. The only way to verify that observed calibration data sweeping control space 7 is rotating is to observe the data obtained from additional scans.

Semi-automatic calibration can be performed in the field. Referring now to Figure 20, a flow chart is shown showing how semi-automatic calibration is performed. First, motor 3 is placed in a heavily loaded configuration 44. Ideally, this setting is greater than 50% of the fully rated load. Then a calibration button 32 on the motor controller 4 is pressed to tell the DSP 1 to perform a fully loaded measurement. DSP 1 runs a calibration 46 that requires several seconds to scan the operating space of motor 3 to determine the fully loaded point. Motor controller 4 indicates that this step of lighting an LED has been completed.

The motor 3 is then placed in an unloaded configuration 45. Ideally, this configuration is less than 25% of the rated load. Then, a calibration button 32 on motor controller 4 is pressed, 47, to tell DSP 1 to perform a discharge measurement. DSP 1 runs calibration 46 to determine the discharge point. The motor controller 4 indicates that the calibration of both ends 47 of the control line 25 has finished by turning on a light emitting diode (LED). DSP 1 after terminating control line 48 using two measurements and

<img file="MX342012B_D0023.tif" />

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INDUSTRIAL applies this control line when it is driving motor 3. The values ​​of control line 25 are stored in non-volatile memory 49.

Figure 21 shows a more detailed flow chart of the semi-automatic calibration. First, a first calibration sweep is run 46 with the motor voltage set to a certain degree 51, depending on whether a first sweep or previous sweeps have been run 106, where the motor controller measures motor 52 until the motor detects a knee 53. If s detects a knee 53, the firing angle / cycle of use is reduced by two degrees 54 and the phase angle and motor voltage are recorded to memory 55. This procedure is repeated to obtain at least four sweeps 56 to obtain a calculated average value 57 of the phase angle and the firing angle / cycle of use. If during any step along the calibration sweep the knee is not detected, then the firing / utilization cycle angle is increased by at least one degree 58 and the next step is measured 59.

An alternative method for calibration is called manual calibration. Figure 22 shows a manual calibration flow chart. First a motor is placed on a dynamometer

70. The motor is then connected to a computer for manual control 71, which allows the motor to be run in an open cycle mode and the firing angle / cycle of utilization of the AC induction motor to be manually set at any point of

<img file="MX342012B_D0024.tif" />

operation. The motor is then placed in a fully discharged configuration 45. Next, the firing / duty cycle angle is increased and the RMS motor voltage is reduced, 72, until the motor is just about to loss. The firing / usage cycle angle and phase angle are recorded and this becomes the calibrated point, which is recorded 73. The engine is then fully started, 74, with steering elements. The motor is then placed in a fully loaded configuration 44. The firing / duty cycle angle is then increased or decreased until the RMS motor voltage is cut off by the motor controller 75 until the motor is just about ready loss. The firing angle / utilization cycle are recorded and this becomes another calibration point, which is recorded 73. Finally, the two calibrated points are used to form a control line 76.

When the RMS line voltage is greater than a programmed fixed voltage, the DSP controller sets the RMS motor voltage at that fixed voltage so that energy savings are possible even at full load. For example, if the grid voltage is above the 115V motor service voltage in the case of a single phase motor then the motor voltage is set to 115V. This motor voltage setting operation allows the motor controller to save energy even when the motor is fully charged in single phase or three phase applications.

Figure 23 shows a flow chart of the voltage clamp

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<img file="MX342012B_D0025.tif" />

permanent. First, 64, a phase error is calculated. Then it is calculated,

65, a voltage error. Then, the RMS motor voltage of the AC induction motor is determined and compared to a fixed voltage threshold

66. If the RMS motor voltage is greater than the fixed voltage threshold then it is determined whether or not the control target is positive 67. If the control target is positive then 68, one cycle of voltage control is run. IF the AC induction motor RMS motor voltage is less than a fixed voltage threshold, then a closed control line cycle is run, 69, and the entire procedure is repeated. If it is determined that the control target is not positive, then a control line cycle is run, 69, and the entire procedure is repeated.

In some cases, it may not be possible to fully charge motor 3 during the calibration procedure. Perhaps 50% of the largest load that can be achieved while the engine is field installed. Conversely, it may not be possible to completely discharge the engine; it may be that only 40% is the lightest charge that can be obtained.

Figure 24 shows an example of both load points that are near the middle of the operating scale. At the discharged end 45 to the right of control line 25, DSP 1 will set the fixed voltage clamp 60 from the voltage to a minimum voltage of 35. When the load on the motor is increased, DSP 1 will follow the control line. moving to the left and up of control segment 61. This implementation is a

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<img file="MX342012B_D0026.tif" />

conservative appearance and protects the motor 3 from running in an uncalibrated space.

As shown further in Figure 25, at the fully loaded end 44 on the left, DSP 1 will synthesize a control segment 61 with a large negative slope. This implementation is a conservative aspect and directs the voltage to full fill.

Referring now to Figure 26, the DSP-based motor controller uses a special technique to protect a motor from loss. First, the DSP actively checks for a significant increase in current 99 indicating that the load on the motor has increased. Then, if 100 is observed, a significant increase, then the DSP turns the motor voltage completely on, 101. The DSP will then attempt to reduce the motor voltage to return to control 102 and the DSP returns to actively verify a significant increase in current 99. This technique is a conservative and safe alternative for the DSP to attempt to track the power requirements that are unknown at the time.

As further illustrated in Figure 27, a graph of the loss mitigation technique, the load on the motor is plotted on an x-axis and the time is plotted on a y-axis. The button line represents the load on the motor 103 and the top line represents the power applied to the motor by the DSP 104. Prior to point 105, I DSP is dynamically controlling the motor at a fixed load. Between point a 105 and I point b 30, the load on the motor suddenly

ΠΤι p P ^{, T}'l^{one n} M EX! CA NO (.a 'ROHEDAD voltáféW increases and the DSP completely turns on at point c 34, the DSP reduces the motor voltage erTelpunid d 43 .—— In Figure 28, a pump stand 30' is placed on the adjacent ground well W. A driving machine or motor 6 'drives a gear or transmission system 8' with a conveyor belt 18 '. Motor 6' can be connected to an electrical service network for power supply. One end of the counterweight arm or crank arm 10 'is arranged with the gear system 8', and the other end of the counterweight arm 10 'is arranged with the counterweight or rotary mass 12'. Preferably, there are two counterweight arms 10 ', with a counterweight 12' disposed between them. A lever or movable stringer 2 'is pivoted on a master post or A-frame 14'. One end of the crank arm or brace 16 'is rotatably connected to one end of the beam 2', and the other end of brace 16 'is rotatably connected to the rotating mass 12' and one end of the counterweight arm 10 '. A protrusion or beam head 4 'is disposed at the end of beam 2' adjacent to well W. As will now be understood, the pump ridge 30 'has a conventional design.

One end of cable 20 'is attached to beam head 4', and the other end of cable 20 'is attached to a polished bar or bar 22'. The bar 22 'is arranged with the substantially vertical tubular chain or sucker rods 26' extending into the well W through the production line to the bottom pump 28 'of the τ ·. " 31

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<img file="MX342012B_D0027.tif" />

drilling in an oil well. The tubular chain may comprise sucker rods, tubing, tubulars, or other components used with a sucker jack or other similar device to aid in the pumping or lifting of fluids from a well. The motor 6 'can drive the pump stand 30' by rotating one end of the counterweight arm 10 'about a horizontal axis. As the counterweight 12 'moves upward, the beam 2' is pivoted about a horizontal axis on the A-frame 14 'and moves the beam head 4' downward. As the counterweight 12 'moves beyond its uppermost position, it falls free downward due to gravity and its momentum, and the beam 2' pivots around the A-frame 14 'and moves the head of beam 4 'up. The thrust and pull of the tubular chain 26 'by the beam head 4' operate the piston in the borehole bottom pump in an oil well 28 '. Tubular chain 26 'moves reciprocally and substantially vertically in well W.

The 6 'motor is normally in power consumption mode. However, the 6 'motor may be in the power generation mode when the dropping masses (either the counterweight 12' or the bar or tubular chain 12 ') fall freely, thus accelerating the motor 6' beyond its synchronous speed, where the speed is limited by the current generated. Although a conventional illustrative pumping stand 30 'is shown in Figure 28, it is stated that all of the

INSTITUTO MÍXICANÜ £ Ζ *** ζ &amp; ^ JA Dt THE PROPERTY pumping, including, but not limited to, different conventional aTséfíos, the design of Lufkin Mark II, the design of beam¹Balanced, and conventional portable design, can be used with the embodiments of the invention. Although the modalities are shown with pumping stands, it is also contemplated that all modalities can be used with any device having a rotating or alternative mass.

Returning to Figure 29, a graph 36 'with an observed phase angle on the vertical axis 32' and time on the horizontal axis 34 'is shown, for an electric motor attached to a pump stand, such as motor 6 'and pump stand 30' in Figure 28, in an open cycle mode. The embodiments of the invention described below in Figures 30-32D have not been attached to the electric motor; therefore, the motor is in open cycle mode. A second horizontal line 40 'is drawn at an observed phase angle of 90 degrees on the vertical axis 32'. When the graph 36 'exceeds an observed phase angle of 90 degrees, as it is on the graph in the first segment 42' above the second horizontal line 40 ', then the motor is in the power generation mode. At those times when the motor is generating, rather than consuming power, the current d kicks back the voltage by a phase angle in excess of 90 degrees. The greater the phase angle during generation, the greater the energy being generated. The engine is in heavy mode d consumption dn rgía n the graph, η I second segment 44 'by

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INDUSTRIAL below the first horizontal line 38 '. The first horizontal line 38 'is drawn at a target phase angle less than 90 degrees on the vertical axis 32'. The objective phase angle is discussed in detail below with Figures 30 and 31.

In Figure 30, the closed cycle motor controller 50 'is schematically shown connected to an electronic motor 62', such as motor 6 'in Figure 28, which may be connected to a pump stand, such as the pump stand 30 'in Figure 28. Other pump stand designs for use in Figure 30 are also contemplated. Motor controller 50' may be a PID controller. However, other closed cycle motor controllers are also contemplated. A digital signal processor (DSP) based motor controller is contemplated, such as the DSP based motor controller of Figures 1 and 2, although other types of DSP based motor controllers are also contemplated. The closed cycle motor controller 50 'can be connected to the motor (6', 62 ') in the same way as shown in Figures 1 and 2. A microprocessor based controller is also contemplated. In one embodiment, the closed loop controller system may have a PID controller as a component. In the closed cycle control system or servo system 48 ', controller 50' can calculate 42 'the observed phase angles from the voltage and current supplied to the motor 62'.

Advantageously, no sensors need to be placed with the motor

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FROM THE PROPERTY 'Ctetcmgq &amp; ÍLjrgj / (6', 62 '), the pump stand 30' or the pump £ⁿHJ ^^Lforftter-ÍJ drilling in an oil well 28 '. A d ei 11 ¿re r'et 'sístviii a'Ütí UtCtO closed 48' can be adapted to each 28 'downhole pump in an individual oil well and to change parameters and requirements of the 28' pump and well W with I time, including, but not limited to, changing volumes, densities, viscosities, weights, and other properties of pumped material and / or fluid, such as gas, oil, water, and slurry. The voltage and current verified by system 48 'serve as an indicator of well condition, allowing the system to be adaptable to changing well parameters. Verifying voltage and current on a substantially continuous basis allows a substantially continuous reading of well conditions. The closed cycle system 48 'is also adapted when the existing components of the pump ridge system are replaced with other components having different characteristics, such as, for example, replacing the tubular chain with a different tubular chain having different weight, or Replace the counterweight with a different size counterweight nt, provided the mechanical system rebalances after the components have been replaced. After rebalancing the mechanical system, the embodiments of the invention allow the energy savings to be resumed.

A target phase angle input 58 'on controller 50' can be compared to the calculated observed phase angle

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<img file="MX342012B_D0028.tif" />

52 ', and the error 60' or difference between the two values ​​determined by the controller 50 '. It is contemplated that the objective phase angle 58 'may be substantially 90 degrees, or the objective phase angle 58' may be greater than 90 degrees. At the time of installation, a target phase angle 58 'can be selected that produces optimum results for the motor during use. The target phase angle 58 'may be constant for all motor loads, such as 65 degrees, although other constant target phase angles 58' are also contemplated. The objective phase angle 58 'can also be a variable function of the motor load at any time. The target phase angle setting 58 'may be the lowest possible phase angle possible that maintains a sufficiently observable current flow at all times while still supplying enough power to meet the motor requirement at all loads.

The motor controller 50 'can control the supply voltage 54' applied to the motor 62 'based on the error signal 60'. When the error 60 'is important because the observed phase angle is too large, such as during the open cycle power generation mode period, the controller 50' may reduce the supply voltage to the motor 62 'to a lower value. , to reduce the observed phase angle 52 'to the objective phase angle 58'. When the error 60 'is important because the observed phase angle 52' is too small, such as during the high power consumption mode, the controller 50 'may

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<img file="MX342012B_D0029.tif" />

increasing the supply voltage 54 'to the motor 62' to a higher value to move the observed phase angle 52 'to the target phase angle 58'. In this closed cycle system 48 ', the voltage and current can be continuously verified and controlled by the motor controller 50'. It is also contemplated that the supply voltage 54 'can be controlled through the use of power control devices, such as TRIACs, SCRs, IGBTs, or MOSFETs, as shown in Figure 2. Also, controller 50' uses timers and pulse width modulation (PWM) techniques for controlling supply voltage, which are discussed in detail later in Figures 32-32D. Other techniques are also contemplated.

Returning to Figure 30, controller 50 'reads the voltages of each phase and current in motor 62' to capture zero axis crossover points. Figures 5 and 6 of US Publication No. 2009/0046490 propose an oscillogram and circuit system diagram, respectively, of means for determining a contemplated zero-axis crossing point of volts. Other means of determining a zero-axis crossover point of volts are also contemplated. Voltage and current can be converted to analog to digital using one or more analog to digital converters for verification and / or control purposes, as shown in Figure 2. Controller 50 'can perform 52' angle calculations motor phase to produce an observed phase angle. The 50 'controller can compare the phase angle

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<img file="MX342012B_D0030.tif" />

observed 52 'with the target phase angle 58' and in response control the motor supply voltage 54 '. The angle of fas ”can be verified in one or more phases. Controller 50 'can be used to automatically determine the rotation of fas. A circuit diagram of a phase support means and phase rotation determining means, which is contemplated, is proposed in Figure 7 of US Publication No. 2009/0046490, where multiple phase operations are used.

Furthermore, it is contemplated that the voltages can be verified phase-to-phase or phase-to-neutral. A schematic view of a contemplated virtual neutral circuit is shown in Figure 10. Other virtual neutral circuits are also contemplated. A virtual neutral circuit can be used as a reference in situations where three phase power is available only in delta mode and there is no neutral aspect present for use as a reference. It is also contemplated that a window comparator can be used to detect zero axis crossovers of both positive and negative halves of a current waveform. Figures 7 and 8 show a window comparator. Other window comparators are also contemplated. Figures 8, 9 and 10 of US Publication No. 2009/0046490 propose a circuit diagram and oscillogram, respectively, of a contemplated medium cycle identification means.

Returning to Figure 31, a graph 64 'is shown with an observed phase angle at I jv rtical 32' and time at I j

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INDUSTRIAL PRORITY PROPERTY 34 'for an electric motor attached to a pump stand, such as the 6' motor and the 3 'pump stand' in Figure 28, in a closed cycle mode. As seen in Figure 29, there is a target phase angle of less than 90 degrees on a first horizontal line 38 '. Unlike Figure 29, the electric motor output depicted in Figure 31 is from a closed cycle system 48d arranged with the motor as shown in Figure 30. The trace of the first segment 70 ', in Figure 31, is where the observed phase angle could exceed the target phase angle in an open cycle mode. However, in closed loop mode on the first segment graph 70 ', the error signal 60' creates a control effort by the controller 50 'to reduce the supply voltage 54' to the motor to maintain the angle d fas goal 38 '. When the observed phase angle exceeds 90 degrees in open cycle mode, the high observed phase angle values ​​create high values ​​of the error signal 60 'in Figure

30.

During the tracing of the first segment 70 ', the engine is effectively started using PWM techniques, but actually without shutting off the power to the engine. During this time, current flow continues in the motor, allowing the controller 50 'to know when to increase the necessary motor supply voltage during power consumption mode. The actual component of the current can be reduced to virtually zero, leaving a reactive component greater than zero. By allowing some flow of

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<img file="MX342012B_D0031.tif" />

Current when the voltage is being reduced, mostly of a reactive nature, an observable feedback parameter is provided which is used in the closed cycle control system 48 'as an indication of the load condition, at which I controller 50 'can react, supplying power when needed in the power consumption phase.

Since the current is reactive in nature, the only remaining current is of an apparent nature. The current flow p enables the controller to continuously observe the phase angle between the current and the voltage. The maximum motor voltage reduction occurs approximately on the graph of the first location 66 'in Figure 31 when the observed phase angle in open cycle mode as shown in Figure 29 could otherwise be at its maximum value greater than 90 degrees.

When the observed phase angle exceeds the target phase angle in a closed loop mode, the supply voltage can be reduced with PWM techniques until the observed phase angle reaches the target phase angle. At the beginning of the graph of the first segment 70 'in Figure 31, the motor controller 50' reduces the observed phase angle from open cycle mode to the target phase angle. Controller 50 'then maintains the observed phase angle substantially at the target phase angle. Any additional reduction in angle d fas observed below the target phase angle can be interpreted as an increase in load, at which the controller

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<img file="MX342012B_D0032.tif" />

50 'can respond by increasing the supply voltage 54' until the target phase angle is once again reached. The maximum increase in motor supply voltage occurs on a second location graph 68 'when the observed phase angle falls below the target phase angle. When the counterweight or alternative mass is driven by the motor, the observed phase angle values ​​will typically be less than the target angle, which will create an error signal that creates a control effort by the controller 50 'to increase the supply voltage to the motor. The engine is in heavy power consumption mode on the second segment graph 44 'below the horizontal line 38'.

Returning to Figure 32, the waveform graph 200 of the input line voltage is illustrated in single phase, although a three phase voltage is also contemplated, in Figure 32A, PWM techniques have been used to cut or remove the voltage waveform graph segments 204, while leaving the voltage waveform graph segments 202. Figure 32A shows a sharp cut-off of the supply voltage where large segments 204 of the voltage waveform are cut off. Figure 32B shows a slight cut of the voltage waveform with PWM techniques, where the voltage waveform graph segments 206 that are cut are smaller than the cut segment 204 shown in Figure 32A. In Figure 32B, the waveform graph segments 208 that were left

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INDUSTRIAL y are larger than the waveform graph segments 202 left in Figure 32A. '

The sharp cut in Figure 32A occurs during the period in which an open cycle power generation mode could occur, such as in Figure 31 in the first location graph 66 '. In Figure 32D, the strong cutoff period 210A is illustrated in a graph segment 210. The voltage reduction shown in Figure 32A reduces the actual component of the current to virtually zero, while leaving a reactive component greater than zero. This is the period when the motor is effectively off, while still leaving enough current to observe the phase angle.

When the motor is in a heavy power consumption mode, as in Figure 31 in the second graph segment 44 ', then substantially no voltage waveform segment is removed, and the motor supply voltage s substantially as shown in Figure 32. In Figure 32D, the period of substantially no cutoff 212A occurs in the graph segment 212.

In Figure 32D, the DSP controller is in the control mode at graph locations 226 and 228. During those periods, the motor is not in a heavy power consumption mode and not in the period when the drive mode could occur. open cycle power generation. In control mode, a slight cut 226A may occur as shown in Figure 32B or a variable cut may occur as shown in Figure 32C

MEXICAN INSTITUTE 0Ϊ THE PROPERTY,. INDUSTRIAL to control motor voltage. This can happen when the motor is lightly loaded, saving energy while the rño'tó'r continues to consume energy. The variable cut in Figure 32A uses PWM to cut waveform graph segments (214, 216, 218, 220, 222, 224) of varying sizes to control motor voltage. The size of the voltage waveform graph segments (214, 216, 218, 220, 222, 224) cut in Figure 32C may all be different, leaving voltage waveform graph segments that are also all of different sizes.

It should be understood that the motor controller can use any combination or permutation of light cut, strong cut, variable cut, or no cut to control the observed phase angle of the motor supply voltage at the target phase angle. The digital signal processor (DSP) or motor controller attempts to maintain a substantially constant observed phase angle and will cut the amount required to do that. The DSP controls the motor voltage based on the observation of the phase angle. The cut-off amount of the supply voltage may vary.

When the electronic motor running in an open cycle is in an emergency generation mode, the load presented by the electrical service network effectively acts as a η I motor brake, thus limiting its speed. This occurs due to the generated voltage that tries to exceed the voltage presented by the electrical service, thus causing the current to flow in the

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opposite direction. When the controller system only ceffaxro and method are applied as shown in Figures 30-32D, this braking action can be effectively minimized or removed, and the motor and system will typically accelerate during this time. . This additional kinetic energy stored in the system will be used to perform a portion of the pumping action without consuming energy in the motor. Minimizing or substantially avoiding power generation eliminates the need to consume energy in other parts of the pump cycle, thereby saving energy.

As can now be understood, the electrical power supplied to the motor is effectively "turned off" during the power generation mode that could occur in the open cycle, while maintaining the voltage and current feedback signals to determine when to turn the power back on. electric motor when the observed phase angle is decreased. This system and method will constantly adapt to changing parameters in the well, which could not be done in the past. For example, the motor and system are adaptable to pumping two or more fluids at different times having different densities or weights. The voltage and current verified by the system serve as an indicator of well condition, allowing the system to be adaptable to changing well parameters. By not entering the power generation mode, the braking action that is created by the open cycle power generation mode can be minimized or eliminated, so that the benefit of the

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<img file="MX342012B_D0034.tif" />

acceleration in the system. By minimizing or eliminating energy that could otherwise be consumed by the system, energy savings can occur from both reducing the motor supply voltage and minimizing or eliminating motor braking action. when it is in the generation mode.

All types and designs of electric motors are contemplated for use with the different embodiments of the invention described above, including, but not limited to, AC induction motors and AC synchronous motors. All types and designs of pump stands are contemplated for use with the different modalities of the invention described above, including, but not limited to, all conventional designs, the Lufkin Mark II design, the balanced beam design, and conventional portable design. Although the modalities have been shown as pumping stands, it is also contemplated that all of the modalities described above can be used with any device having a rotating or alternative mass. Although some of the embodiments have been shown with single phase voltage and current, all the embodiments of the invention are contemplated with single phase and multi phase voltage and current.

The foregoing description and description of the invention are illustrative and illustrative thereof, and various changes in the details of the illustrated apparatus and system, and the construction and method of operation can be made without departing from the spirit of the invention.