Horizontal directional drilling rig multi-stage limiting protection system and method

Abstract

This invention relates to a multi-level limit protection system and method. The protection system includes a controller and multiple sensors installed on a horizontal directional drilling rig, a deceleration zone sensing plate (7) installed in the deceleration zone of the drill frame (5) of the horizontal directional drilling rig, and a rack suspension plate (6) set at the end of the drill frame (5). The sensors include a speed sensor (3) installed on the power head assembly (4) of the horizontal directional drilling rig to monitor the rotational speed of the hydraulic motor (2), a load sensor (10) to monitor the load of the hydraulic motor (2), and a limit sensor (9) to monitor the position of the deceleration zone of the drill frame (5). The protection method is based on the above protection system and includes one to four levels of limit protection that operate independently. This invention has a simple structure, high limit reliability, good safety, and low maintenance frequency, and can meet the limit requirements of the power head of a large-tonnage horizontal directional drilling rig, thereby reducing construction costs and improving construction efficiency.

Description

Technical Field

[0001] This invention relates to the field of engineering machinery technology, specifically to a multi-level limit protection system and method for horizontal directional drilling rigs. Background Technology

[0002] Horizontal directional drilling rigs are trenchless construction equipment used to cross highways, railways, buildings, rivers, city streets, cultural relic protection areas, etc., and to lay various underground public facilities (pipelines, cables, etc.). They are currently a widely used type of trenchless construction machinery. As the country's energy demand shifts from traditional coal to clean oil and gas energy, a large number of large-diameter long-distance pipelines need to be laid. In addition, the branch pipes, receiving and storage of oil and gas in various places also require the laying of a large number of underground pipe networks, and the amount of construction projects involving large-tonnage equipment is increasing year by year.

[0003] Currently, the travel limit of the power head on the drill frame of large-tonnage horizontal directional drilling rigs mainly uses two types of methods: mechanical limit and electrical switch limit. The former mainly involves welding a limit structure to the tail of the drill frame, achieving the limit through collision between the drill head and the limit mechanism. However, this method is prone to problems such as excessive speed and deformation of the structure due to collision, which can easily damage the drill rig structure and lead to complex mechanical structures and bulky equipment. The latter mainly uses an electrical switch on the drill frame. When the power head reaches the designated position on the drill frame, it controls the push-pull main valve to de-energize, thus achieving the limit. However, the stability of electrical components is low, and construction risks still exist. Therefore, the existing power head travel limit structures are complex, unreliable, pose high safety risks, require frequent maintenance, increase construction costs, and reduce construction efficiency.

[0004] Therefore, there is an urgent need for a new type of horizontal directional drilling rig limit protection system and method that is simple in structure, highly reliable in limiting, safe, has low maintenance frequency, low construction cost, and high construction efficiency. Summary of the Invention

[0005] The purpose of this invention is to overcome the above-mentioned shortcomings and provide a new type of limit protection system and method that can meet the limit of the power head of a large-tonnage horizontal directional drilling rig, and has a simple structure, high limit reliability, good safety and low maintenance frequency, thereby reducing construction costs and improving construction efficiency.

[0006] The objective of this invention is achieved as follows:

[0007] A multi-level limit protection system for a horizontal directional drilling rig includes a controller and multiple sensors mounted on the horizontal directional drilling rig, a deceleration zone sensing plate mounted in the deceleration zone of the drill frame, and a rack suspension plate disposed at the end of the drill frame. The sensors include a speed sensor mounted on the power head assembly of the horizontal directional drilling rig to monitor the hydraulic motor speed, a load sensor to monitor the hydraulic motor load, and a limit sensor to monitor the position of the drill frame deceleration zone. Each sensor is electrically connected to the controller. The limit sensors and the deceleration zone sensing plate are positioned correspondingly and provide non-contact inductive feedback signals. The controller is electrically connected to a push-pull main valve that controls the rotation of the hydraulic motor.

[0008] Furthermore, the horizontal directional drilling rig includes a drill frame with a rack and a power head assembly that is movable on the drill frame via a translation mechanism.

[0009] Furthermore, the translation mechanism includes multiple hydraulic motors mounted on the power head assembly, each hydraulic motor driving a corresponding push-pull gear to rotate via an independent reducer, the push-pull gear meshing with a rack on the drill frame.

[0010] Furthermore, the deceleration zone sensing plate is a magnetic plate with a length consistent with the length of the deceleration zone; the limit sensor is a magnetic sensor.

[0011] Furthermore, the load sensor is a pressure sensor or flow sensor installed on the hydraulic motor to monitor the pressure or flow rate of the hydraulic oil in the hydraulic motor.

[0012] Furthermore, the rack is not installed on the rack suspension plate and is left empty.

[0013] Furthermore, the controller is connected to a display to show the real-time position of the power head assembly on the drill frame, facilitating human-machine interaction.

[0014] A multi-stage limit protection method for a horizontal directional drilling rig, wherein the protection method is based on any of the above-mentioned multi-stage limit protection systems for horizontal directional drilling rigs, and the specific method is as follows:

[0015] Level 1 limit protection: The speed sensor feeds back the hydraulic motor speed to the controller, and the controller calculates the real-time position of the power head assembly on the drill frame based on the feedback speed and monitors it throughout the entire process;

[0016] Secondary limit protection: When the power head assembly passes through the deceleration zone of the drill frame, the limit sensor obtains a signal of entering the deceleration zone when it approaches the deceleration zone sensing plate. The controller then controls the push-pull main valve to reduce the speed of the hydraulic motor, thereby decelerating the power head assembly. When the limit sensor moves away from the deceleration zone sensing plate, it obtains a signal of leaving the deceleration zone. The controller then closes the push-pull main valve to stop the hydraulic motor from rotating, thereby stopping the power head assembly from moving.

[0017] Three-level limit protection: After the power head assembly leaves the deceleration zone, if the push-pull main valve is not closed, the speed sensor will provide feedback on whether the hydraulic motor is overspeeding. If it is overspeeding, the controller will close the push-pull main valve and the power head assembly will stop moving.

[0018] Level 4 limit protection: Using the rack suspension plate installed at the end of the drill frame, since the rack is not installed, when a set of push-pull gears on the side of the power head assembly moves to this point, it will be suspended and spin freely, causing the hydraulic motor to be under low load. The load sensor will feed back the idling signal to the controller, the controller will close the push-pull main valve, and the power head assembly will stop moving.

[0019] Compared with the prior art, the beneficial effects of the present invention are:

[0020] This invention relates to a multi-stage limit protection system for horizontal directional drilling rigs.

[0021] This invention discloses a multi-level limit protection method for horizontal directional drilling rigs. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the installation structure of a multi-stage limit protection system for a horizontal directional drilling rig according to the present invention.

[0023] Figure 2 This is a schematic diagram of the power head assembly structure of a multi-stage limit protection system for a horizontal directional drilling rig according to the present invention.

[0024] Figure 3 This is a schematic diagram of the operation control of a multi-level limit protection method for a horizontal directional drilling rig according to the present invention.

[0025] in:

[0026] 1. Reducer; 2. Hydraulic motor; 3. Speed ​​sensor; 4. Power head assembly; 5. Drill frame; 6. Rack suspension plate; 7. Reduction interval sensing plate; 8. Rack; 9. Limit sensor; 10. Load sensor. Implementation

[0027] See Figures 1-2 The present invention relates to a multi-level limit protection system for a horizontal directional drilling rig. The horizontal directional drilling rig includes a drill frame 5 with a rack 8 and a power head assembly 4 that is movable on the drill frame 5 via a translation mechanism. The translation mechanism includes a plurality of hydraulic motors 2 mounted on the power head assembly 4. Each hydraulic motor 2 drives a corresponding push-pull gear to rotate via an independent reducer 1. The push-pull gear is meshed with the rack 8 on the drill frame 5.

[0028] The protection system includes a controller and multiple sensors installed on the horizontal directional drilling rig, a deceleration zone sensing plate 7 installed in the deceleration zone of the drill frame 5 of the horizontal directional drilling rig, and a rack suspension plate 6 set at the end of the drill frame 5. The controller is connected to a display to show the real-time position of the power head assembly 4 on the drill frame 5, and to show the working status of the limit protection system, facilitating human-machine interaction. The deceleration zone sensing plate 7 is a magnetic plate with a length consistent with the length of the deceleration zone, used to indicate the position range of the deceleration zone. The rack suspension plate 6 is empty, with no rack 8 installed on it.

[0029] The sensors include a speed sensor 3 installed on the power head assembly 4 of the horizontal directional drilling rig to monitor the rotational speed of the hydraulic motor 2, a load sensor 10 to monitor the load on the hydraulic motor 2, and a limit sensor 9 to monitor the position of the deceleration zone of the drill frame 5. The speed sensor 3 can be installed on the hydraulic motor 2 or the reducer 1 to monitor the rotational speed of the hydraulic motor 2 or the reducer 1. The load sensor 10 is a pressure sensor or a flow sensor installed on the hydraulic motor 2 to monitor the pressure or flow of the hydraulic oil in the hydraulic motor 2. The limit sensor 9 is a magnetic sensor, which is positioned relative to the deceleration zone sensing plate 7 and provides a non-contact induction feedback signal to sense the magnetic range of the deceleration zone sensing plate 7.

[0030] The controller is electrically connected to each sensor, and also electrically connected to the push-pull main valve that controls the rotation of the hydraulic motor 2. The speed sensor 3 feeds back the speed change of the hydraulic motor 2 or the reducer 1. The controller calculates the moving speed and real-time position of the power head assembly 4 on the drill frame 5 based on the speed and displays it on the display. The limit sensor 9 feeds back an entry or exit signal when entering or leaving the magnetic range of the deceleration zone sensing plate 7. The controller accordingly reduces the opening of the push-pull main valve to decelerate the power head assembly 4, or closes the push-pull main valve to stop the power head assembly 4 from moving. When the load sensor 10 senses that the hydraulic motor 2 is running under low load, the controller closes the push-pull main valve to stop the power head assembly 4 from moving. All the above sensors operate independently and complement each other. The structure is simple, the limit reliability is high, the safety is good, there is no collision, and the maintenance is simple. This meets the limit requirements of the power head of a large-tonnage horizontal directional drilling rig, thereby reducing construction costs and improving construction efficiency.

[0031] See Figure 3 This invention relates to a multi-stage limit protection method for horizontal directional drilling rigs. The protection method is based on the multi-stage limit protection system for horizontal directional drilling rigs described in the above embodiments. The specific method is as follows:

[0032] Level 1 limit protection: The speed sensor 3 feeds back the speed of the hydraulic motor 2 to the controller. The controller calculates the moving speed and real-time position of the power head assembly 4 on the drill frame 5 based on the feedback speed and monitors it throughout the process. If the limit position is reached, a warning is issued in time and the push-pull main valve is closed to stop the movement of the power head assembly 4, thereby achieving the power head limit.

[0033] Secondary limit protection: When the power head assembly 4 passes through the deceleration zone of the drill frame 5, the limit sensor 9 obtains a signal of entering the deceleration zone by approaching the deceleration zone sensing plate 7. The controller then controls the push-pull main valve to reduce the speed of the hydraulic motor 2, thereby decelerating the power head assembly 4. When the limit sensor 9 moves away from the deceleration zone sensing plate 7, it obtains a signal of leaving the deceleration zone. The controller then closes the push-pull main valve to stop the hydraulic motor 2 from rotating, thereby stopping the movement of the power head assembly 4.

[0034] Three-level limit protection: After the power head assembly 4 leaves the deceleration zone, if the push-pull main valve is not closed, the speed sensor 3 will provide feedback on whether the hydraulic motor 2 is overspeeding. If it is overspeeding, the controller will close the push-pull main valve and the power head assembly 4 will stop moving.

[0035] Level 4 limit protection: Using the rack suspension plate 6 installed at the end of the drill frame 5, since the rack is not installed, when a set of push-pull gears on the side of the power head assembly 4 moves to this point, it will be suspended and rotate freely, causing the hydraulic motor 2 to be under low load. The load sensor 10 feeds back the low load signal to the controller, the controller closes the push-pull main valve, and the power head assembly 4 stops moving.

[0036] The above-mentioned multi-level limit protection methods operate independently, without interfering with each other and complementing each other, making the limit more reliable and safer. Even if a certain level of limit protection fails due to a malfunction and cannot achieve the power head limit, there is no need to stop the machine. There is no collision-type limit, the equipment has a long service life, reduces the frequency of maintenance, improves the construction efficiency of horizontal directional drilling rigs, and reduces construction costs.

[0037] Additionally, it should be noted that the above-described specific implementation is merely an optimized solution of this patent, and any modifications or improvements made by those skilled in the art based on the above concept are within the scope of protection of this patent.

Claims

1. A multi-level limit protection method for a horizontal directional drilling rig, characterized in that: It is based on a multi-level limit protection system for horizontal directional drilling rigs; The multi-level limit protection system includes a controller and multiple sensors installed on the horizontal directional drilling rig, a deceleration zone sensing plate (7) installed in the deceleration zone of the horizontal directional drilling rig (5), and a rack suspension plate (6) set at the end of the drill frame (5); the sensors include a speed sensor (3) installed on the power head assembly (4) of the horizontal directional drilling rig to monitor the speed of the hydraulic motor (2), a load sensor (10) to monitor the load of the hydraulic motor (2), and a limit sensor (9) to monitor the position of the deceleration zone of the drill frame (5); each sensor is electrically connected to the controller; the position of the limit sensor (9) and the deceleration zone sensing plate (7) are corresponding and are non-contact sensing feedback signals; the controller is electrically connected to the push-pull main valve that controls the rotation of the hydraulic motor (2); The multi-level limit protection method includes: Level 1 limit protection: The speed sensor (3) feeds back the speed of the hydraulic motor (2) to the controller. The controller calculates the real-time position of the power head assembly (4) on the drill frame (5) based on the feedback speed and monitors it throughout the process. Secondary limit protection: When the power head assembly (4) passes through the deceleration zone of the drill frame (5), the limit sensor (9) gets a signal of entering the deceleration zone by approaching the deceleration zone sensing plate (7). The controller then controls the push-pull main valve to reduce the speed of the hydraulic motor (2), thereby decelerating the power head assembly (4). When the limit sensor (9) moves away from the deceleration zone sensing plate (7), it gets a signal of leaving the deceleration zone. The controller then closes the push-pull main valve to stop the hydraulic motor (2) from rotating, thereby stopping the power head assembly (4) from moving. Three-level limit protection: After the power head assembly (4) leaves the deceleration zone, if the push-pull main valve is not closed, the speed sensor (3) will provide feedback on whether the hydraulic motor (2) is overspeeding. If it is overspeeding, the controller will close the push-pull main valve and the power head assembly (4) will stop moving. Level 4 limit protection: Using the rack suspension plate (6) installed at the end of the drill frame (5), since the rack is not installed, when a set of push-pull gears on the side of the power head assembly (4) moves to this point, it will be suspended and idle, causing the hydraulic motor (2) to be under low load. The load sensor (10) will feed back the idle signal to the controller, the controller will close the push-pull main valve, and the power head assembly (4) will stop moving.

2. The multi-level limit protection method for horizontal directional drilling rigs according to claim 1, characterized in that: The horizontal directional drilling rig includes a drill frame (5) with a rack (8) and a power head assembly (4) mounted on the drill frame (5) via a translation mechanism.

3. The multi-level limit protection method for horizontal directional drilling rigs according to claim 2, characterized in that: The translation mechanism includes multiple hydraulic motors (2) mounted on the power head assembly (4). Each hydraulic motor (2) drives a corresponding push-pull gear to rotate through an independent reducer (1). The push-pull gear is meshed with a rack (8) on the drill frame (5).

4. The multi-level limit protection method for horizontal directional drilling rigs according to claim 1, characterized in that: The deceleration zone sensing plate (7) is a magnetic plate with a length consistent with the length of the deceleration zone; the limit sensor (9) is a magnetic sensor.

5. The multi-level limit protection method for horizontal directional drilling rigs according to claim 1, characterized in that: The load sensor (10) is a pressure sensor or flow sensor installed on the hydraulic motor (2) to monitor the pressure or flow of the hydraulic oil in the hydraulic motor (2).

6. The multi-level limit protection method for horizontal directional drilling rigs according to claim 1, characterized in that: The rack (8) is not installed on the rack suspension plate (6), and is in a void state.

7. The multi-level limit protection method for horizontal directional drilling rigs according to claim 1, characterized in that: The controller is connected to a display for displaying the real-time position of the power head assembly (4) on the drill frame (5), which facilitates human-machine interaction.

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