Air compressor control system and method for a down-the-hole drill

Abstract

The application discloses a kind of pneumatic machine control system and method of down-the-hole drill, including the engine drives the screw head rotation of the screw machine and is sent to compressed gas-liquid mixture and oil-gas separator;The air inlet of the screw head is provided with air inlet valve;The oil-gas separator is equipped with control port above, and the control port is connected by pipeline input end of loading solenoid valve and input end of pressure regulating valve;The output end of the loading solenoid valve, the output end of pressure regulating valve and the control end of air inlet valve are communicated;The engine and loading solenoid valve are electrically connected to the output end of controller, and the input end of controller is electrically connected with pressure sensor;The pressure sensor is used to detect the pressure of the output end of loading solenoid valve and the output end of pressure regulating valve, and the controller controls the rotating speed of engine according to the detection data of pressure sensor;Avoid engine always in high-speed running state, effectively reduce fuel consumption.

Description

Technical Field

[0001] This invention belongs to the field of down-the-hole drilling rig technology, specifically relating to the air compressor control system and method for down-the-hole drilling rigs. Background Technology

[0002] Down-the-hole (DH) drills are commonly used for drilling blast holes in open-pit mines and can also be used in municipal engineering projects, making them an important piece of equipment in open-pit rock excavation. These drills typically include auxiliary equipment such as an air compressor (hereinafter referred to as the air compressor) to provide compressed air, which drives the impactor for rock drilling. During operation, the air compressor consumes approximately two-thirds of the total power of the machine, making it a major energy consumer.

[0003] Air compressor power is directly related to air consumption and exhaust pressure. During drilling, rock drilling and hole washing require compressed air, and the air consumption differs between the two conditions. Air consumption during rock drilling also varies continuously with geological conditions. Traditional air compressor control systems adjust the air compressor intake valve opening in real time based on air volume changes to reduce power consumption. However, engine speed does not change with air consumption; that is, even when air consumption is low, the engine may still operate at high speed, resulting in energy waste. Summary of the Invention

[0004] The purpose of this invention is to provide an air compressor control system and method for down-the-hole drilling rigs, which avoids the engine running at high speed all the time and effectively reduces fuel consumption.

[0005] To achieve the above objectives, the technical solution adopted by the present invention in the first aspect is: an air compressor control system for a down-the-hole drill rig, comprising an engine, a screw compressor head, and an oil-gas separator; the screw compressor head and the oil-gas separator are connected by pipelines; the engine drives the screw compressor head to rotate to generate a compressed gas-liquid mixture, the oil-gas separator separates the compressed gas-liquid mixture to obtain compressed gas, and the oil-gas separator delivers the compressed gas to an impactor;

[0006] The screw compressor head is equipped with an intake valve at its air inlet; the oil-gas separator is equipped with a control port above it, which is connected to the input end of the loading solenoid valve and the input end of the pressure regulating valve via a pipeline; the output end of the loading solenoid valve, the output end of the pressure regulating valve, and the control end of the intake valve are connected.

[0007] The engine and the loading solenoid valve are electrically connected to the output of the controller, and a pressure sensor is electrically connected to the input of the controller. The pressure sensor is used to detect the pressure at the output of the loading solenoid valve and the output of the pressure regulating valve, and the controller controls the engine speed based on the detection data of the pressure sensor.

[0008] Preferably, the control end of the intake valve is provided with a first check valve; the direction of the first check valve is set from the output end of the loading solenoid valve and the output end of the pressure regulating valve to the control end of the intake valve.

[0009] Preferably, the oil-gas separator is externally connected to a safety valve.

[0010] Preferably, a second check valve is provided between the oil-gas separator and the impactor; the direction of the second check valve is set from the oil-gas separator to the impactor.

[0011] Preferably, an air intake filter is provided at the input end of the intake valve.

[0012] Preferably, the controller is equipped with a human-machine interface, which is used to input control commands and retrieve detection data.

[0013] In a second aspect, the present invention provides an air compressor control method for a down-the-hole drill rig, comprising:

[0014] Determine the working mode of the air compressor, wherein the working mode of the air compressor includes adaptive mode and constant speed mode;

[0015] When the air compressor is in constant speed mode, the engine rotation is controlled according to the input speed A.

[0016] When the air compressor is in adaptive mode and no loading signal is received, the loading solenoid valve is in the normally open state, and the compressed gas in the oil-gas separator closes the intake valve through the loading solenoid valve and the first check valve, and controls the engine rotation according to the preset speed B1.

[0017] When the air compressor is in adaptive mode and receives a loading signal, it controls the loading solenoid valve to close and determines whether the down-the-hole drill is in rod changing or drilling mode. If the down-the-hole drill is in rod changing mode, it controls the engine to rotate according to the preset speed B2. If the down-the-hole drill is in drilling mode, it controls the engine speed according to the detection data of the pressure sensor.

[0018] Preferably, the method for controlling the engine speed based on the detection data of the pressure sensor includes:

[0019] Set the speed control pressure value P1; set the speed stability coefficient k;

[0020] When the regulating pressure P detected by the pressure sensor is between k*P1 and P1, the intake valve is fully open, controlling the engine speed to maintain the current speed.

[0021] When the regulating pressure P is lower than k*P1, the compressed gas-liquid mixture in the oil-gas separator is increased by increasing the engine speed until the set maximum engine speed is reached.

[0022] When the regulating pressure P detected by the pressure sensor is greater than the set value P1, the compressed gas-liquid mixture in the oil-gas separator is reduced by decreasing the engine speed until the set minimum engine speed is reached; if the minimum engine speed is reached and the regulating pressure P detected by the pressure sensor is greater than the set value P1, the compressed gas in the oil-gas separator adjusts the opening of the intake valve through the regulating valve and the first one-way valve.

[0023] Preferably, the minimum engine speed is set to 1300 rpm and the maximum engine speed is set to 1800 rpm.

[0024] Preferably, the pressure value P1 is less than the opening pressure of the first check valve.

[0025] Preferably, the rotational speed stability coefficient k is set to 0.9.

[0026] Compared with the prior art, the beneficial effects achieved by the present invention are as follows:

[0027] In this invention, the engine and the loading solenoid valve are electrically connected to the output terminal of the controller, and the input terminal of the controller is electrically connected to a pressure sensor. The pressure sensor is used to detect the pressure at the output terminal of the loading solenoid valve and the output terminal of the pressure regulating valve. The controller controls the engine speed according to the detection data of the pressure sensor to avoid the engine running at high speed all the time, thereby effectively reducing fuel consumption. Attached Figure Description

[0028] Figure 1 This is a structural diagram of the air compressor control system of a down-the-hole drill provided in Embodiment 1;

[0029] Figure 2 This is a flowchart of an air compressor control method for a down-the-hole drill provided in Example 2;

[0030] In the diagram, 102 is the loading solenoid valve, 2 is the pressure regulating valve, 3 is the intake valve, 4 is the intake air filter, 5 is the second check valve, 6 is the safety valve, 7 is the first check valve, and 8 is the pressure sensor. Detailed Implementation

[0031] The present invention will be further described below with reference to the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and should not be used to limit the scope of protection of the present invention.

[0032] It should be noted that in the description of this invention, the terms "front," "rear," "left," "right," "upper," "lower," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are used only for the convenience of describing the invention and do not require the invention to be constructed and operated in a specific orientation; therefore, they should not be construed as limitations on the invention. The terms "front," "rear," "left," "right," "upper," and "lower" used in the description of this invention refer to the directions shown in the accompanying drawings, while the terms "inner" and "outer" refer to directions toward or away from the geometric center of a specific component, respectively.

[0033] Example 1

[0034] like Figure 1 As shown, an air compressor control system for a down-the-hole drill includes an engine, a screw compressor head, and an oil-gas separator; the screw compressor head and the oil-gas separator are connected by pipelines; the engine drives the screw compressor head to rotate and generate a compressed gas-liquid mixture, the oil-gas separator separates the compressed gas-liquid mixture to obtain compressed gas, and the oil-gas separator delivers the compressed gas to an impactor; a safety valve 6 is externally connected to the oil-gas separator; a second check valve 5 is provided between the oil-gas separator and the impactor; the direction of the second check valve is set from the oil-gas separator to the impactor.

[0035] The screw compressor head is equipped with an intake valve 3 at its air inlet; the oil-gas separator is equipped with a control port above it, which is connected to the input end of the loading solenoid valve 102 and the input end of the pressure regulating valve 2 via a pipeline; the output end of the loading solenoid valve 102, the output end of the pressure regulating valve 2, and the control end of the intake valve 3 are connected.

[0036] The control end of the intake valve 3 is provided with a first one-way valve 7; the direction of the first one-way valve 7 is set from the output end of the loading solenoid valve 102 and the output end of the pressure regulating valve 2 to the control end of the intake valve 3; the input end of the intake valve 3 is provided with an intake air filter 4.

[0037] The engine and the loading solenoid valve 102 are electrically connected to the output of the controller, and the input of the controller is electrically connected to a pressure sensor 8. The pressure sensor 8 is used to detect the pressure at the output of the loading solenoid valve 102 and the output of the pressure regulating valve 2. The controller controls the opening and closing of the loading solenoid valve 102 according to the input loading signal. The controller is equipped with a human-machine interface, which is used to input control commands and retrieve detection data. The controller controls the engine speed according to the detection data of the pressure sensor 8 to avoid the engine running at high speed all the time, thus effectively reducing fuel consumption.

[0038] Example 2

[0039] likeFigure 2 As shown, an air compressor control method for a down-the-hole drill rig is described. The control method provided in this embodiment can be applied to the control system described in Embodiment 1. The control method includes:

[0040] Determine the working mode of the air compressor, wherein the working mode of the air compressor includes adaptive mode and constant speed mode;

[0041] When the air compressor is in constant speed mode, the engine rotation is controlled according to the input speed A. Constant speed mode is usually used when the strata are relatively complex or a small exhaust volume is required. The engine speed is kept at the manually set speed value, which can give full play to the initiative of the personnel.

[0042] When the air compressor is in adaptive mode and does not receive a loading signal, the loading solenoid valve 102 is normally open. The compressed gas in the oil-gas separator closes the intake valve 3 through the loading solenoid valve 102 and the first one-way valve 7, resulting in low energy consumption. The engine rotation is controlled according to the preset speed B1. In this embodiment, the preset speed B1 is set to 1300 rpm.

[0043] When the air compressor is in adaptive mode and receives a loading signal, it controls the loading solenoid valve 102 to close, determining whether the down-the-hole drill is in rod-changing or drilling mode. If the down-the-hole drill is in rod-changing mode, the air consumption is zero, the oil-gas separator pressure continuously increases, and the regulating pressure detected by the pressure sensor 8 does not participate in the control. The compressed gas in the oil-gas separator closes the intake valve 3 completely through the regulating valve 2 and the first one-way valve 7. The engine rotation is controlled according to the preset speed B2. In this embodiment, the preset speed B2 is set to 1500 rpm. The preset speed B2 can ensure that sufficient compressed gas is produced quickly when switching from rod-changing mode to drilling mode, satisfying drilling stability and avoiding overload shutdown when the load changes suddenly. In addition, this speed value is set with a certain difference from the maximum speed (1800 rpm), effectively reducing energy consumption.

[0044] If the down-the-hole drill is in drilling operation, the method for controlling the engine speed based on the detection data of the pressure sensor 8 includes:

[0045] The speed control pressure value P1 is set, which is less than the opening pressure of the first one-way valve 7. The first one-way valve 7 isolates the control air path of the oil-gas separator, so that the intake valve 3 is kept at a large opening. The speed stability coefficient k is set. In this embodiment, the speed stability coefficient k is 0.9. This ensures that the engine speed is adjusted first, and avoids the engine speed being adjusted no longer after the intake valve is closed.

[0046] When the regulating pressure P detected by the pressure sensor 8 is between k*P1 and P1, the intake valve 3 is in a fully open state, controlling the engine speed to maintain the current speed;

[0047] When the regulating pressure P is lower than k*P1, the compressed gas-liquid mixture in the oil-gas separator is increased by increasing the engine speed until the set maximum engine speed is reached.

[0048] When the regulating pressure P detected by the pressure sensor 8 is greater than the set value P1, the compressed gas-liquid mixture in the oil-gas separator is reduced by decreasing the engine speed until the set minimum engine speed is reached; if the minimum engine speed is reached and the regulating pressure P detected by the pressure sensor is greater than the set value P1, the compressed gas in the oil-gas separator adjusts the opening of the intake valve 3 through the regulating valve 2 and the first one-way valve 7; in this embodiment, the minimum engine speed is set to 1300 rpm and the maximum engine speed is set to 1800 rpm.

[0049] In this embodiment, engine speed is adjusted first to achieve adaptive matching between gas consumption and engine speed. When the engine speed is reduced to the minimum but gas production is still abundant, the opening of intake valve 3 is further reduced to maintain stable exhaust pressure, ensuring drilling efficiency and slag removal effect, while further reducing energy consumption.

[0050] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A method for controlling the air compressor of a down-the-hole drill rig, characterized in that, An air compressor control method is applied to an air compressor control system; the air compressor control system includes an engine, a screw compressor head, and an oil-gas separator; the screw compressor head and the oil-gas separator are connected by pipelines; the engine drives the screw compressor head to rotate to generate a compressed gas-liquid mixture, the oil-gas separator separates the compressed gas-liquid mixture to obtain compressed gas, and the oil-gas separator delivers the compressed gas to an impactor; The screw compressor head is equipped with an intake valve at its air inlet; the oil-gas separator is equipped with a control port above it, which is connected to the input end of the loading solenoid valve and the input end of the pressure regulating valve via a pipeline; the output end of the loading solenoid valve, the output end of the pressure regulating valve, and the control end of the intake valve are connected. The engine and the loading solenoid valve are electrically connected to the output of the controller, and a pressure sensor is electrically connected to the input of the controller. The pressure sensor is used to detect the pressure at the output of the loading solenoid valve and the output of the pressure regulating valve, and the controller controls the engine speed based on the detection data of the pressure sensor. Determine the working mode of the air compressor, wherein the working mode of the air compressor includes adaptive mode and constant speed mode; When the air compressor is in constant speed mode, the engine rotation is controlled according to the input speed A. When the air compressor is in adaptive mode and no loading signal is received, the loading solenoid valve is in the normally open state, and the compressed gas in the oil-gas separator closes the intake valve through the loading solenoid valve, and controls the engine rotation according to the preset speed B1. When the air compressor is in adaptive mode and receives a loading signal, it controls the loading solenoid valve to close and determines whether the down-the-hole drill is in rod changing or drilling mode. If the down-the-hole drill is in rod changing mode, it controls the engine to rotate according to the preset speed B2. If the down-the-hole drill is in drilling mode, it controls the engine speed according to the detection data of the pressure sensor.

2. The air compressor control method according to claim 1, characterized in that, The control end of the intake valve is provided with a first check valve; the direction of the first check valve is set from the output end of the loading solenoid valve and the output end of the pressure regulating valve to the control end of the intake valve.

3. The air compressor control method according to claim 1, characterized in that, The oil-gas separator is externally connected to a safety valve.

4. The air compressor control method according to claim 1, characterized in that, A second check valve is provided between the oil-gas separator and the impactor; the direction of the second check valve is set from the oil-gas separator to the impactor.

5. The air compressor control method according to claim 1, characterized in that, An air intake filter is provided at the input end of the intake valve.

6. The air compressor control method according to claim 1, characterized in that, The controller is equipped with a human-machine interface, which is used to input control commands and retrieve detection data.

7. The air compressor control method according to claim 1, characterized in that, The method for controlling engine speed based on the detection data of the pressure sensor includes: Set the speed control pressure value P1, and set the speed stability coefficient k; When the regulating pressure P detected by the pressure sensor is between k*P1 and P1, the intake valve is fully open, controlling the engine speed to maintain the current speed. When the regulating pressure P is lower than k*P1, the compressed gas-liquid mixture in the oil-gas separator is increased by increasing the engine speed until the set maximum engine speed is reached. When the regulating pressure P detected by the pressure sensor is greater than the set value P1, the compressed gas-liquid mixture in the oil-gas separator is reduced by decreasing the engine speed until the set minimum engine speed is reached; if the minimum engine speed is reached and the regulating pressure P detected by the pressure sensor is greater than the set value P1, the compressed gas in the oil-gas separator adjusts the opening of the intake valve through the regulating valve and the first one-way valve.

8. The air compressor control method according to claim 7, characterized in that, The pressure value P1 is less than the opening pressure of the first check valve.

9. The air compressor control method according to claim 7, characterized in that, The rotational speed stability coefficient k is set to 0.9.

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