High speed motor drive
A system to provide power to a tool includes an electric motor that can operate at rotary speeds of at least 6,000 rpm, a variable speed drive electrically connected to the electric motor, and a step-up transformer electrically coupled to the electric motor and the variable speed drive, in which the variable speed drive can generate and transmit a drive signal to supply power to the electric motor when the electric motor is spaced apart from the variable speed drive by a distance of at least 100 meters, and the transformer can prevent capacitive leakage in the drive signal transmitted over the distance from the variable speed drive to the electric motor.
1. A system to provide power to a tool, the system comprising:
an electric motor configured to operate at rotary speeds of at least 6,000 rotations per minute (rpm); and
a variable speed drive electrically connected to the electric motor, the variable speed drive configured to generate and transmit a drive signal to supply power to the electric motor when the electric motor is spaced apart from the variable speed drive by a distance of at least 100 meters; and
a step-up transformer electrically coupled to the electric motor and the variable speed drive, the transformer configured to prevent capacitive leakage in the drive signal transmitted over the distance from the variable speed drive to the electric motor.
2. The system of claim 1 , wherein the transformer comprises a gapped core configured to allow a direct current to pass from the variable speed drive to the electric motor for electric motor startup.
3. The system of claim 2 , further comprising:
a direct current source; and
a controller electrically coupled to the direct current source, the transformer, the variable speed drive and the electric motor, the controller, during the electric motor startup, configured to perform operations comprising controlling the direct current source to pass the direct current through the gapped core to the electric motor.
4. The system of claim 3 , wherein the operations further comprise, when the electric motor is pre-spinning prior to start of the variable speed drive, aligning a voltage of an electric stator of the electric motor to synchronize with a rotary speed of an electric rotor of the electric motor.
5. The system of claim 1 , wherein the transformer comprises:
a primary winding;
a secondary winding; and
a shield between the primary winding and the secondary winding, the shield configured to prevent the capacitive leakage.
6. The system of claim 1 , wherein the electric motor is a permanent magnet synchronous motor.
7. The system of claim 1 , wherein a distance between the variable speed drive and the transformer is less than a distance between the transformer and the electric motor.
8. The system of claim 1 , wherein the drive signal comprises a pulse width modulated signal, wherein the variable speed drive is configured to switch frequencies at a rate that is sufficient to generate the drive signal to power the electric motor to operate at the rotary speeds.
9. The system of claim 1 , wherein the variable speed drive is sensorless.
10. The system of claim 1 , wherein the transformer comprises core material configured to transfer the pulse width modulated signal to the electric motor with minimal core loss.
11. A method to provide power to a tool, the method comprising:
generating, by a variable speed drive, a drive signal to supply power to an electric motor that is physically positioned apart from the variable speed drive by a distance of at least 100 meters, the electric motor configured to operate at rotary speeds of at least 6,000 rotations per minute (rpm);
transmitting, by the variable speed drive, the drive signal to a step-up transformer electrically coupled in series to the variable speed drive and the electric motor;
modifying, by the transformer, the drive signal received from the variable speed drive to prevent capacitive leakage in the drive signal;
transmitting the drive signal, modified by the transformer, over the distance of at least 100 meters to the electric motor; and
operating, by the electric motor, at the rotary speeds in response to receiving the drive signal modified by the transformer.
12. The method of claim 11 , further comprising, during electric motor startup, transmitting a direct current to pass through a gapped core of the transformer and to the electric motor.
13. The method of claim 11 , further comprising, when the electric motor is pre-spinning prior to start of the variable speed drive, aligning a voltage of an electric stator of the electric motor to synchronize with a rotary speed of an electric rotor of the electric motor.
14. The method of claim 11 , wherein the drive signal is a pulse width modulated drive signal, wherein generating and transmitting, by the variable speed drive, the pulse width modulated drive signal comprises switching, by the variable speed drive, frequencies at a rate that is sufficient to generate the drive signal to power the electric motor to operate at the rotary speeds.
15. The method of claim 14 , wherein the pulse width modulated signal is transmitted to the electric motor with minimal core loss.
16. The method of claim 11 , wherein the electric motor is positioned at a downhole location within a wellbore, and wherein the variable speed drive and the transformer are positioned at a surface of the wellbore.
17. The method of claim 11 , wherein the electric motor is a permanent magnet synchronous motor.
18. The method of claim 11 , wherein the transformer comprises:
a primary winding;
a secondary winding; and
a shield between the primary winding and the secondary winding, the shield configured to prevent the capacitive leakage.
19. A system to provide power to a downhole-type tool, the system comprising:
a downhole-type electric motor configured to be positioned in a wellbore, the downhole-type electric motor configured to operate at rotary speeds of at least 6,000 rotations per minute (rpm);
a variable speed drive electrically connected to the electric motor, the variable speed drive configured to control and supply power to the electric motor when the electric motor is positioned at a downhole location inside the wellbore, the variable speed drive configured to be at a surface of the wellbore; and
a step-up transformer electrically coupled to the electric motor and the variable speed drive, the transformer configured to prevent capacitive leakage in the drive signal transmitted by the variable speed drive to the electric motor at the downhole location.
20. The system of claim 19 , further comprising:
a direct current source; and
a controller electrically coupled to the direct current source, the transformer, the variable speed drive and the electric motor, the controller, during the electric motor startup, configured to perform operations comprising controlling the direct current source to pass the direct current through the gapped core to the electric motor.
21. The system of claim 20 , wherein the operations further comprise, when the electric motor is pre-spinning prior to start of the variable speed drive, aligning a voltage of an electric stator of the electric motor to synchronize with a rotary speed of an electric rotor of the electric motor.