Electric control system and method for small and medium-sized horizontal directional drilling machine

Abstract

The invention discloses an electric control system and method for a small and medium-sized horizontal directional drilling machine, and relates to the technical field of horizontal directional drilling, comprising a signal source unit, an information processing unit, an execution unit and a power supply module, the system is mainly divided into three parts, the first part is a signal source, the second part is an information processing part, and the third part is an execution unit. The signal source comprises a button panel, a handle and a sensor; the information processor comprises a controller and a display; the execution unit comprises an engine, a pump and the like; the power supply module supplies power to the controller, the controller receives electric signals of the handle, the button and the sensor, the electric signals are analyzed and calculated by the controller, then control signals are output, the system changes logic processing components of a conventional system, hardware is changed into software, current signals are changed into program logic, and therefore the logic processing capacity is greatly improved.

Description

Technical Field

[0001] The invention relates to the technical field of horizontal directional drilling, and in particular to an electric control system and method for a small and medium-sized horizontal directional drilling machine. Background Art

[0002] Conventional small and medium-sized drilling rigs have simple control logic, with buttons directly controlling valves. Simple logic must be executed through intermediate relays. There are many types of electronic components, many logic loops in physical circuits, and the electrical systems of equipment are mostly discrete. The human-computer interaction of the electrical systems of conventional small and medium-sized equipment is not friendly enough, and multiple parameters require the installation of a corresponding number of physical dials.

[0003] To this end, the present invention proposes an electronic control system and method for small and medium-sized horizontal directional drilling rigs, which simplifies the circuit system, reduces the number of electronic components, and improves the flexibility and logic processing capability of the system. Summary of the invention

[0004] In view of the deficiencies in the prior art, the present invention provides an electric control system and method for a small and medium-sized horizontal directional drilling rig, which solves the problems raised in the background technology.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solutions: an electric control system and method for a small and medium-sized horizontal directional drilling rig, including a signal source unit, an information processing unit, an execution unit and a power module;

[0006] The signal source unit integrates a button panel, a handle and various sensors, including position, speed and pressure sensors as signal inputs. The signal source unit is responsible for collecting the operator's instructions and the real-time status information of the machine; the information processing unit uses an advanced microprocessor as a controller and cooperates with the display to display information. The controller is responsible for receiving the electrical signal from the signal source, parsing and calculating it through the built-in software, and then outputting the control signal; the execution unit includes the engine and pump components, and performs specific actions according to the instructions of the controller; the power module is used to provide a stable power supply for the controller to ensure the normal operation of the system.

[0007] Preferably, the method steps are:

[0008] S1. Signal acquisition: The operator inputs instructions through the button panel and handle. The instruction signal is sent to the receiver through the wireless communication module and then transmitted to the controller. The sensor monitors the machine status in real time and converts the signal into an electrical signal and sends it to the controller; S2. Information processing: After receiving the signal, the controller processes it according to the preset program logic, including signal amplification, filtering, and analog-to-digital conversion; S3. Logical judgment and decision-making: The internal software of the controller performs logical judgment based on the processed signal and calculates the optimal control strategy; S4. Execution control: The calculation result is converted into a control signal and sent to the execution unit to drive the mechanical components to act according to the established strategy; S5. Human-computer interaction: The display shows the machine status and operation feedback in real time, and the operator can make further control adjustments based on the displayed information; S6. System optimization and self-learning: The system continuously optimizes the control strategy and improves the response speed and accuracy by collecting operation data and feedback; S7. Safety protection: Design safety modules such as leakage lockout and leakage current detection to ensure that the power supply can be quickly cut off under abnormal conditions to protect the safety of equipment and operators.

[0009] Preferably, the signal in S1 passes through:

[0010] a. Receiving instructions: The operator selects the machine's operating mode or function, including start, stop, and speed adjustment, through the button panel; the operator controls the direction or depth of the drill rig through the handle, and the position change of the handle is converted into an electrical signal; b. Status monitoring: Sensors installed at key parts of the drill rig (such as encoders, pressure sensors, and temperature sensors) monitor the operating status of the machine in real time; the monitoring encoder measures the rotation speed and position of the drill rig, the pressure sensor monitors the pressure of the hydraulic system, and the temperature sensor monitors the temperature of the machine; c. Signal conversion: The sensor converts the monitored position, speed, pressure, and temperature data into electrical signals. Among them, the displacement sensor uses a potentiometer to convert the position change into a voltage signal, and the speed sensor uses a Hall effect sensor to measure the rotation speed and convert it into a pulse signal; d. Signal transmission: The converted electrical signal is transmitted to the controller via a cable.

[0011] Preferably, the signal amplification in S2 increases the amplitude of the signal through a common-phase amplifier so that the signal can be more accurately processed by a subsequent system (such as an analog-to-digital converter ADC). The gain (Gain) of the common-phase amplifier is given by the following formula:

[0012]

[0013] Among them, R i is the input resistance, R f is the feedback resistor; the output signal V out With input signal V in The relationship is: V out =

[0014] Gain non-invertin ·V in .

[0015] If an inverting amplifier is used, its gain (Gain) is given by the following formula:

[0016]

[0017] The negative sign indicates that the output signal is opposite in phase to the input signal; the output signal V out With input signal V in The relationship is:

[0018] V out =-Gain inverting ·V in

[0019] Preferably, the filtering process in S2 removes noise and unnecessary frequency components through a low-pass filter, thereby improving the quality of the signal. The low-pass filter allows low-frequency signals to pass through while blocking high-frequency signals; its transfer function is expressed as:

[0020]

[0021] Among them, ω c is the cutoff angular frequency, and s is the complex variable in the Laplace transform.

[0022] Preferably, the analog-to-digital conversion in S2 converts the digital signal into an analog signal through an analog-to-digital converter ADC, and the output voltage V out According to the input digital value D and the reference voltage V ref Calculation, the formula is:

[0023]

[0024] Where D is the digital input value (in binary form), N is the resolution of the DAC in bits, and V ref is the reference voltage used by the DAC.

[0025] Among them, when the range of the analog signal is determined, the resolution of the D / A converter determines the minimum change of the analog quantity; for the same analog signal range, the higher the resolution (that is, the larger the number of bits n), the smaller the change of the analog signal corresponding to each increase of 1 in the binary number, thereby improving the accuracy of the analog signal;

[0026] Preferably, in S3, key information is extracted from the feature recognition signal, the system state is determined according to the feature and preset conditions, the control quantity is calculated using a control algorithm (such as PID), the calculation result is converted into a control signal, and the control signal is sent to the actuator to implement control, and the control strategy is adjusted according to system feedback.

[0027] Preferably, the optimization strategy in S6 collects operation and performance data in real time, evaluates the difference between system output and expected value, adjusts control parameters (such as PID gain) according to feedback, simulates and verifies new parameters before implementation, applies the adjusted parameters to the control system, observes the performance of the adjusted system, confirms the improvement effect, reviews the control strategy regularly, and continuously optimizes.

[0028] Preferably, by assigning a unique Node-ID to the display, handle, and button panel in the system, and using an object dictionary, device parameters are accessed and set through the object dictionary, data is transmitted using PDO to transmit real-time control and status data, SDO is used for device configuration, network management is performed through NMT and other protocol services for network monitoring and device management, error detection and processing are implemented, and communication security is guaranteed.

[0029] The present invention provides an electric control system and method for a small and medium-sized horizontal directional drilling rig, which has the following beneficial effects:

[0030] The invention discloses an electric control system and method for small and medium-sized horizontal directional drilling rigs. The system is mainly divided into three parts, the first part is a signal source, the second part is an information processing part, and the third part is an execution unit. The signal source includes a button panel, a handle, and a sensor. The information processing part includes a controller and a display. The execution unit includes an engine, a pump, etc. The power module provides power to the controller, and the controller receives the electrical signals of the handle, the button, and the sensor, which are then analyzed and calculated by the controller, and then the control signal is output. The system changes the logic processing components of the conventional system from hardware to software, and the current signal to program logic, which greatly improves the logic processing capability. At the same time, the execution results are exchanged with people through a display interface to achieve better control of the horizontal directional drilling rig. In this system, the display, the handle, the button panel, etc. use the CANopen communication function, which fundamentally optimizes the line system and makes the system simpler and more reliable. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 It is a schematic diagram of the module of the present invention;

[0032] Figure 2 It is a schematic diagram of the process of the present invention. DETAILED DESCRIPTION

[0033] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0034] See also Figure 1-2 ,The embodiment of the present invention provides a technical solution: an electric control system and method for a small and medium-sized horizontal directional drilling rig, including a signal source unit, an information processing unit, an execution unit and a power module;

[0035] The signal source unit integrates a button panel, a handle and various sensors, including position, speed and pressure sensors as signal inputs. The signal source unit is responsible for collecting the operator's instructions and the real-time status information of the machine;

[0036] The information processing unit uses an advanced microprocessor as a controller, which works with the display to display information. The controller is responsible for receiving the electrical signal from the signal source, analyzing and calculating it through the built-in software, and then outputting the control signal;

[0037] The execution unit includes the engine and pump components, and performs specific actions according to the instructions of the controller;

[0038] The power module is used to provide stable power to the controller to ensure normal operation of the system.

[0039] The method steps are:

[0040] S1. Signal acquisition: The operator inputs commands through the button panel and handle. The command signal is sent to the receiver through the wireless communication module and then transmitted to the controller. The sensor monitors the machine status in real time and converts the signal into an electrical signal and sends it to the controller.

[0041] S2. Information processing: After receiving the signal, the controller processes it according to the preset program logic, including signal amplification, filtering, and analog-to-digital conversion;

[0042] S3. Logical judgment and decision-making: The internal software of the controller performs logical judgment based on the processed signals and calculates the optimal control strategy;

[0043] S4. Execution control: convert the calculation results into control signals, send them to the execution unit, and drive the mechanical parts to act according to the established strategy;

[0044] S5. Human-machine interaction: The display shows the machine status and operation feedback in real time, and the operator can make further control adjustments based on the displayed information;

[0045] S6. System optimization and self-learning: The system continuously optimizes the control strategy and improves the response speed and accuracy by collecting operation data and feedback;

[0046] S7. Safety protection: Design safety modules such as leakage lockout and leakage current detection to ensure that the power supply can be quickly cut off under abnormal circumstances to protect the safety of equipment and operators.

[0047] The signal in S1 passes through:

[0048] a. Receiving instructions: The operator selects the machine's operating mode or function through the button panel, including start, stop, and speed adjustment; the operator controls the direction or depth of the drill through the handle, and the position change of the handle is converted into an electrical signal;

[0049] b. Status monitoring: Sensors (such as encoders, pressure sensors, and temperature sensors) installed at key locations on the drilling rig monitor the machine's operating status in real time; the monitoring encoder measures the drilling rig's rotation speed and position, the pressure sensor monitors the pressure of the hydraulic system, and the temperature sensor monitors the machine's temperature;

[0050] c. Signal conversion: The sensor converts the monitored position, speed, pressure, and temperature data into electrical signals. The displacement sensor uses a potentiometer to convert the position change into a voltage signal, and the speed sensor uses a Hall effect sensor to measure the rotation speed and convert it into a pulse signal.

[0051] d.Signal transmission: The converted electrical signal is transmitted to the controller via cable.

[0052] The signal amplification in S2 increases the amplitude of the signal through the in-phase amplifier so that the signal can be processed more accurately by the subsequent system (such as the analog-to-digital converter ADC). The gain of the in-phase amplifier is given by the following formula:

[0053]

[0054] Among them, R i is the input resistance, R f is the feedback resistor; the output signal V out With input signal V in The relationship is: V out =

[0055] Gain non-inverting ·V in .

[0056] The filtering process in S2 removes noise and unnecessary frequency components through a low-pass filter, thereby improving the quality of the signal. The low-pass filter allows low-frequency signals to pass through while blocking high-frequency signals; its transfer function is expressed as:

[0057]

[0058] Among them, ω c is the cutoff angular frequency, and s is the complex variable in the Laplace transform.

[0059] The analog-to-digital conversion in S2 converts the digital signal into an analog signal through the analog-to-digital converter ADC. The output voltage V out According to the input digital value D and the reference voltage V ref Calculation, the formula is:

[0060]

[0061] Where D is the digital input value (in binary form), N is the resolution of the DAC in bits, and V fef is the reference voltage used by the DAC.

[0062] In S3, key information is extracted from the feature recognition signal, the system state is determined according to the features and preset conditions, the control quantity is calculated using a control algorithm (such as PID), the calculation result is converted into a control signal, and the control signal is sent to the actuator to implement control, and the control strategy is adjusted according to system feedback.

[0063] PID stands for Proportional, Integral, and Differential. The formulas for each part are as follows:

[0064] Proportional (P) part:

[0065] The proportional term adjusts the control amount proportionally according to the magnitude of the current error; the formula is:

[0066] u P =K P ×e(t)

[0067] Among them, u P is the proportional control output, K P is the proportional gain, e(t) is the error at the current time point, that is, the difference between the set value and the actual output;

[0068] Integration (I) part:

[0069] The integral term is to eliminate steady-state errors and take into account the effects of past error accumulation; the formula is:

[0070] u I =K1×∫0 t e(τ)dτ

[0071] Among them, u I is the integral control output, K Iis the integral gain, is the integral of the error from 0 to the current time t; the differential (D) part:

[0072] The differential term is to predict the trend of the error and provide advance control to speed up the response speed and stability; the formula is:

[0073]

[0074] Among them, u D is the differential control output, K D is the differential gain, is the rate of change of error

[0075] Combining the three, the output of the PID controller can be expressed as:

[0076]

[0077] Determine the three gains K by PID controller P ,K I , and K i value to ensure the system achieves the best control effect;

[0078] The optimization strategy in S6 collects operation and performance data in real time, evaluates the difference between system output and expected value, adjusts control parameters (such as PID gain) according to feedback, simulates and verifies new parameters before implementation, applies adjusted parameters to the control system, observes the performance of the adjusted system, confirms the improvement effect, and regularly reviews control strategies for continuous optimization. By assigning unique Node-IDs to the displays, handles, and button panels in the system, and using object dictionaries to access and set device parameters, data transmission uses PDO to transmit real-time control and status data, uses SDO for device configuration, and network management uses NMT and other protocol services for network monitoring and device management, implements error detection and processing, and ensures communication security.

[0079] In summary, the system is mainly divided into three parts. The first part is the signal source, the second part is the information processing, and the third part is the execution unit. The signal source includes the button panel, handle, and sensor; the information processing includes the controller and the display; the execution unit includes the engine, pump, etc. The power module provides power to the controller, and the controller receives the electrical signals from the handle, button, and sensor, which are then analyzed and calculated by the controller, and then the control signal is output. This system changes the logic processing components of the conventional system from hardware to software, and the current signal becomes program logic, which greatly improves the logic processing capability.

[0080] The above shows and describes the basic principles and main features of the present invention and the advantages of the present invention. It is obvious to those skilled in the art that the present invention is not limited to the details of the above exemplary embodiments, and the present invention can be implemented in other specific forms without departing from the spirit or basic features of the present invention. Therefore, no matter from which point of view, the embodiments should be regarded as exemplary and non-restrictive. The scope of the present invention is defined by the attached claims rather than the above description, and it is intended that all changes falling within the meaning and scope of the equivalent elements of the claims are included in the present invention. Any figure mark in the claims should not be regarded as limiting the claims involved.

[0081] In addition, it should be understood that although the present specification is described according to implementation modes, not every implementation mode contains only one independent technical solution. This description of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment may also be appropriately combined to form other implementation modes that can be understood by those skilled in the art.

Claims

1. An electronic control system for small and medium-sized horizontal directional drilling rigs, characterized in that: It includes a signal source unit, an information processing unit, an execution unit and a power supply module; The signal source unit integrates a button panel, a handle and various sensors, including position, speed and pressure sensors as signal inputs, and is responsible for collecting the operator's instructions and the real-time status information of the machine; The information processing unit uses an advanced microprocessor as a controller, and cooperates with a display to display information. The controller is responsible for receiving the electrical signal from the signal source, analyzing and calculating it through the built-in software, and then outputting the control signal; The execution unit includes an engine and a pump component, and performs specific actions according to the instructions of the controller; The power module is used to provide a stable power supply to the controller to ensure the normal operation of the system.

2. The electronic control method for a small and medium-sized horizontal directional drilling rig according to claim 1, characterized in that: The method steps are: S1. Signal acquisition: The operator inputs commands through the button panel and handle. The command signal is sent to the receiver through the wireless communication module and then transmitted to the controller. The sensor monitors the machine status in real time and converts the signal into an electrical signal and sends it to the controller. S2. Information processing: After receiving the signal, the controller processes it according to the preset program logic, including signal amplification, filtering, and analog-to-digital conversion; S3. Logical judgment and decision-making: The internal software of the controller performs logical judgment based on the processed signals and calculates the optimal control strategy; S4. Execution control: convert the calculation results into control signals, send them to the execution unit, and drive the mechanical parts to act according to the established strategy; S5. Human-machine interaction: The display shows the machine status and operation feedback in real time, and the operator can make further control adjustments based on the displayed information; S6. System optimization and self-learning: The system continuously optimizes the control strategy and improves the response speed and accuracy by collecting operation data and feedback; S7. Safety protection: Design safety modules such as leakage lockout and leakage current detection to ensure that the power supply can be quickly cut off under abnormal circumstances to protect the safety of equipment and operators.

3. The electronic control method for a small and medium-sized horizontal directional drilling rig according to claim 2, characterized in that: The signal in S1 passes through: a. Receiving instructions: The operator selects the machine's operating mode or function through the button panel, including start, stop, and speed adjustment; the operator controls the direction or depth of the drill through the handle, and the position change of the handle is converted into an electrical signal; b. Status monitoring: Sensors (such as encoders, pressure sensors, and temperature sensors) installed at key locations on the drilling rig monitor the machine's operating status in real time; the monitoring encoder measures the drilling rig's rotation speed and position, the pressure sensor monitors the pressure of the hydraulic system, and the temperature sensor monitors the machine's temperature; c. Signal conversion: The sensor converts the monitored position, speed, pressure, and temperature data into electrical signals. The displacement sensor uses a potentiometer to convert the position change into a voltage signal, and the speed sensor uses a Hall effect sensor to measure the rotation speed and convert it into a pulse signal. d.Signal transmission: The converted electrical signal is transmitted to the controller via cable.

4. The electronic control method for a small and medium-sized horizontal directional drilling rig according to claim 2, characterized in that: The signal amplification in S2 increases the amplitude of the signal through the in-phase amplifier so that the signal can be more accurately processed by the subsequent system (such as the analog-to-digital converter ADC). The gain (Gain) of the in-phase amplifier is given by the following formula: Among them, R i is the input resistance, R f is the feedback resistor; the output signal V out With input signal V in The relationship is: V out =Gain non-inverting ·V in .

5. The electronic control method for a small and medium-sized horizontal directional drilling rig according to claim 2, characterized in that: The filtering process in S2 removes noise and unnecessary frequency components through a low-pass filter, thereby improving the quality of the signal. The low-pass filter allows low-frequency signals to pass through, while blocking high-frequency signals; Its transfer function is expressed as: Among them, ω c is the cutoff angular frequency, and s is the complex variable in the Laplace transform.

6. The electronic control method for a small and medium-sized horizontal directional drilling rig according to claim 2, characterized in that: The analog-to-digital conversion in S2 converts the digital signal into an analog signal through an analog-to-digital converter ADC, and the output voltage V out According to the input digital value D and the reference voltage V ref Calculation, the formula is: Where D is the digital input value (in binary form), N is the resolution of the DAC in bits, and V ref is the reference voltage used by the DAC.

7. The electronic control method for a small and medium-sized horizontal directional drilling rig according to claim 2, characterized in that: In S3, key information in the feature recognition signal is extracted, the system state is determined according to the features and preset conditions, the control quantity is calculated using a control algorithm (such as PID), the calculation result is converted into a control signal, and the control signal is sent to the actuator to implement control, and the control strategy is adjusted according to system feedback.

8. The electronic control method for a small and medium-sized horizontal directional drilling rig according to claim 2, characterized in that: The optimization strategy in S6 collects operation and performance data in real time, evaluates the difference between system output and expected value, adjusts control parameters (such as PID gain) according to feedback, simulates and verifies new parameters before implementation, applies the adjusted parameters to the control system, observes the performance of the adjusted system, confirms the improvement effect, reviews the control strategy regularly, and continuously optimizes.

9. The electronic control method for a small and medium-sized horizontal directional drilling rig according to claim 2, characterized in that: By assigning unique Node-IDs to the displays, handles, and button panels in the system and using object dictionaries, device parameters are accessed and set through the object dictionary, data is transmitted using PDO to transmit real-time control and status data, SDO is used for device configuration, and network management is performed through NMT and other protocol services for network monitoring and device management, error detection and processing are implemented, and communication security is guaranteed.

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