Efficient hole-forming construction method for zero-emission electric rotary drilling rig

Abstract

The invention discloses an efficient hole-forming construction method of a zero-emission electric rotary drilling rig, and relates to the technical field of efficient hole-forming construction of electric rotary drilling rigs, which comprises the following steps: site pretreatment and equipment configuration: hardening a construction site, adopting an electric rotary drilling rig, carrying a power system on the electric rotary drilling rig, the power system comprises a pure electric mode, a range extending mode and a plug-in mode, descending potential energy of the hoisting mechanism is converted into electric energy to be stored through the energy recovery device, and all-sleeve slurry-free hole forming is achieved, specifically, a drilling machine driving sleeve is dynamically connected with a first steel sleeve in a locked mode, the length of the first steel sleeve is 7-4 m, and the first steel sleeve is pressurized and screwed into the stratum in a graded mode; the bottom opening of the casing pipe always advances the excavation face by 0.7-0.5 m, a barrel drill dry method is adopted for soil sampling synchronously, slurry wall protection is not needed in the whole process, and embedded rock stratum crushing is conducted, specifically, when rock stratums with medium weathering or above are met, a rock-socketed barrel drill or a bullet spiral drill bit is switched, and rock masses are rubbed, ground, sheared and crushed through multi-dimensional stress.

Description

Technical Field

[0001] This invention relates to the field of high-efficiency hole-forming construction technology using electric rotary drilling rigs, specifically a zero-emission high-efficiency hole-forming construction method using electric rotary drilling rigs. Background Technology

[0002] Traditional fuel-fired rotary drilling rigs rely on diesel engines, resulting in problems such as excessive exhaust emissions, noise pollution, and high fuel costs. In loose strata or soil layers with high water content, traditional equipment requires mud wall protection technology, but the mud preparation, discharge, and treatment processes can easily cause environmental pollution, and its application is limited in arid areas or water-scarce scenarios. Pure electric drive systems completely eliminate exhaust emissions, and their operating noise is reduced by more than 15dB compared to fuel-fired models, which can extend nighttime construction time and reduce the impact on surrounding residents. However, existing electric rotary drilling rigs have high energy consumption and increase energy waste in efficient hole-forming construction.

[0003] The shortcomings of existing high-efficiency hole-forming construction methods using electric rotary drilling rigs are:

[0004] 1. Patent document CN119308612A discloses a detachable drill rod box for high-level drilling construction of an electric drilling rig and its usage method. It describes a system with "a first box unit, at least one second box unit, and a third box unit; the first, second, and third box units are vertically slidably connected and driven by a lifting assembly on the side; a base plate assembly is slidably installed at the bottom of each of the first, second, and third box units, and a base plate cylinder is installed under the base plate assembly. This invention's detachable drill rod box for high-level drilling construction of an electric drilling rig features flexible movement, large rod carrying capacity, high efficiency in loading and unloading drill rods, and strong adaptability to roadways; it has an internal drill rod lifting mechanism for high rod loading efficiency; the robotic arm's gripping position for the drill rod is fixed, resulting in good stress distribution and a high mechanical structure safety factor; during construction, there is no need for personnel to climb to fill the drill rod box, significantly reducing worker labor intensity and the incidence of safety accidents, further improving the automation of drilling equipment." However, existing electric rotary drilling rigs have high energy consumption and increase energy waste in high-efficiency hole-forming construction.

[0005] 2. Patent document CN113982494A discloses an oil well drilling rig with a support frame and its usage method, "including a support frame, an electric hoist, and a drilling rig body. The electric hoist is fixedly installed on the support frame, and the drilling rig body is installed on the bottom of the hook of the electric hoist. A stabilizing mechanism is installed at the bottom of the support frame, and positioning mechanisms are provided on both sides of the bottom of the support frame. A cleaning mechanism is fixedly installed on the top of one of the positioning mechanisms. Through the setting of the stabilizing mechanism, the limiting wheels on multiple adjusting shells can limit and guide the lifting process of the drilling rig body, ensuring that the lifting process of the drilling rig body is more stable and preventing excessive shaking during the lifting process of drilling rig bodies of different diameters. Through the setting of the upper limit cylinder and the limiting plate on multiple adjusting shells, the drilling rig body of different diameters can be effectively positioned during the working process to prevent shaking of the drilling rig body during the working process." However, the existing high-efficiency hole-forming construction method of electric rotary drilling rigs cannot be combined with multi-dimensional stress rolling and graded hole expansion technology, resulting in low drilling efficiency in hard rock.

[0006] 3. Patent document CN111927346B discloses a drilling rig and a construction method for directional drilling at the bottom of a river channel using the drilling rig. "Two placement frames are fixedly installed on the drilling rig frame, and connecting blocks are fixedly installed at the ends of the placement frames. Limiting blocks are fixedly installed on opposite sides of the two connecting blocks, and the two limiting blocks are respectively limited within limiting grooves opened on both sides of a first placement plate. A slot is opened on the side of the first placement plate near the trenchless pipe-laying drilling rig, and an electric slide is fixedly installed at the bottom of the slot. A lifting mechanism is fixedly installed on the slide of the electric slide. This invention allows for the pre-placement of drill rods through the first placement plate. When the drilling rig needs to install drill rods, the electric slide transports the drill rods to the trenchless pipe-laying drilling rig, automating the function of transporting drill rods and solving the defect in the prior art where personnel need to manually pick up and install them on the trenchless pipe-laying drilling rig; the second placement plate can also pre-place drill rods, improving work efficiency to a certain extent." However, the construction quality of existing electric rotary drilling rigs for efficient hole formation cannot be traced throughout the entire process, and human intervention results in large errors. Summary of the Invention

[0007] The purpose of this invention is to provide a zero-emission electric rotary drilling rig efficient hole-forming construction method to solve the technical problems of high energy consumption and increased energy waste in existing electric rotary drilling rigs mentioned in the background art.

[0008] To achieve the above objectives, the present invention provides the following technical solution: a high-efficiency hole-forming construction method using a zero-emission electric rotary drilling rig, comprising:

[0009] S1. Site pretreatment and equipment configuration: The construction site is hardened and an electric rotary drilling rig is used. The electric rotary drilling rig is equipped with a power system, which includes pure electric mode, range-extending mode and plug-in mode. The energy recovery device converts the descending potential energy of the winch mechanism into electrical energy for storage.

[0010] S2. Full casing without mud drilling: The drilling rig drives the sleeve to dynamically lock the first section of the steel casing. The length of the first section of the steel casing is 7-4m. The first section of the steel casing is screwed into the formation in stages under pressure. The bottom of the casing is always 0.7-0.5m ahead of the excavation face. The dry method of tubular drilling is used to remove soil at the same time. No mud wall protection is required throughout the process.

[0011] S3. Embedded rock strata breaking: When encountering moderately weathered or more weathered rock strata, switch to an embedded rock drill or bullet-shaped auger bit to break the rock mass through multi-dimensional stress crushing and shearing.

[0012] S4. Digital control system: Real-time monitoring of verticality, hole diameter, and hole depth via an onboard CAN bus system, with vertical deviation of 0.4-1%, hole diameter error of 30-50mm, and hole depth error of 60-100mm, and automatic adjustment of drilling pressure and rotation speed.

[0013] S5. Low-carbon concrete grouting: After drilling, the steel cage is hoisted and dry-hole concrete is grouted using a high-frequency vibrator, or underwater grouting is carried out using an air-lift reverse circulation system in conjunction with low-slump concrete.

[0014] Preferably, the electric rotary drilling rig includes a permanent magnet synchronous motor direct drive system, the power head of the permanent magnet synchronous motor direct drive system has an output torque of 260-240 kN·m, a drilling diameter of 0.8-2.5 m, and a maximum drilling depth of 30-70 m.

[0015] Preferably, the energy recovery device includes a potential energy to electrical energy conversion circuit and a range extender.

[0016] Preferably, the steel sleeve connection adopts a drive sleeve hydraulic locking mechanism, and the standard sleeve sections are fastened by flange bolts. The first sleeve section with alloy cutter head is spun down at a speed of 2–4 m / h.

[0017] Preferably, when the rock strata are broken, the drill bit speed is controlled at 8–15 rpm, the pressure is 80–150 kN, and the drilling depth of each stage of staged reaming is 0.4–1 m.

[0018] Preferably, the digital control system integrates a bottom rock layer scanning module, which uses ultrasonic waves to detect the thickness of sediment at the bottom of the borehole (30-50 mm) and uploads the data to the cloud management platform in real time.

[0019] Preferably, the slump of the dry-hole concrete grout is controlled at 160–180 mm, the vibration frequency is 8500–8000 times / min, and the underwater grouting adopts dynamic monitoring of the burial depth of the guide pipe.

[0020] Preferably, the system includes:

[0021] Step S6: The range-extended electric chassis includes a tracked walking mechanism and is equipped with a three-electric system;

[0022] Step S7: The modular drill bit library includes rock-embedded tube drills, staged reaming drill bits, and bullet-shaped auger bits, which are suitable for different rock and soil layers.

[0023] Step S8: The full casing drive device includes a hydraulically driven wedge locking mechanism between the sleeve and the casing, with a verticality self-correction accuracy of ±0.5°;

[0024] Step S9: The cloud-based collaborative terminal supports remote adjustment of construction parameters and fault early warning.

[0025] Preferably, the drill bit has a wedge-shaped linear cutting edge structure with a hardness of HRC60 to HRC80, which is suitable for continuous cutting operations in abrasive rock formations.

[0026] Compared with the prior art, the beneficial effects of the present invention are:

[0027] 1. This invention, through the installation of site pretreatment and equipment configuration: hardening of the construction site, use of electric rotary drilling rig, the electric rotary drilling rig is equipped with a power system, the power system includes pure electric mode, range-extended mode and plug-in mode, and the energy recovery device converts the descending potential energy of the winch mechanism into electrical energy storage, thereby realizing the integration of range-extended electric power, energy recovery and dry drilling, breaking through the high energy consumption bottleneck of traditional drilling rigs;

[0028] 2. This invention utilizes an embedded rock stratum crushing system: when encountering moderately weathered or more weathered rock strata, the system switches between an embedded rock casing drill or a bullet-shaped auger bit to crush the rock mass through multi-dimensional stress grinding and shearing. Standard casing sections are secured with flange bolts. The first casing section with alloy cutter head is spun down at a speed of 2–4 m / h. During rock stratum crushing, the drill bit speed is controlled at 8–15 rpm, the pressure is 80–150 kN, and the staged reaming depth is 0.4–1 m per stage. This system combines multi-dimensional stress grinding and staged reaming processes to solve the problem of low drilling efficiency in hard rock.

[0029] 3. This invention features a digital control system: an onboard CAN bus system monitors verticality, borehole diameter, and borehole depth in real time, with vertical deviation of 0.4-1%, borehole diameter error of 30-50mm, and borehole depth error of 60-100mm. The system automatically adjusts drilling pressure and rotation speed. The digital control system integrates a bottom-hole rock strata scanning module, using ultrasonic waves to detect the thickness of sediment at the bottom of the borehole (30-50mm) and uploading the data to a cloud management platform in real time. The slump of the dry-hole concrete grout is controlled at 160-180mm, and the vibration frequency is 8500-8000 times / min. Underwater grouting utilizes dynamic monitoring of the guide pipe burial depth. This system enables full traceability of construction quality through the CAN bus and cloud system, reducing errors caused by human intervention. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the test data for the present invention. Detailed Implementation

[0031] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] In the description of this invention, it should be noted that the terms "upper," "lower," "inner," "outer," "front end," "rear end," "both ends," "one end," and "the other end," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0033] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed," "equipped with," "connected," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand this according to the specific circumstances.

[0034] Example 1: Please refer to Figure 1 One embodiment of the present invention provides: a high-efficiency hole-forming construction method using a zero-emission electric rotary drilling rig, comprising:

[0035] S1. Site pretreatment and equipment configuration: The construction site is hardened and an electric rotary drilling rig is used. The electric rotary drilling rig is equipped with a power system, which includes pure electric mode, range-extending mode and plug-in mode. The energy recovery device converts the descending potential energy of the winch mechanism into electrical energy for storage.

[0036] S2. Full casing without mud: The drilling rig drives the sleeve to dynamically lock the first section of the steel casing. The first section of the steel casing is 7m long. The first section of the steel casing is screwed into the formation in stages under pressure. The bottom of the casing is always 0.7m ahead of the excavation face. The dry method of tubular drilling is used to remove soil at the same time. No mud is needed for wall protection throughout the process.

[0037] S3. Embedded rock strata breaking: When encountering moderately weathered or more weathered rock strata, switch to an embedded rock drill or bullet-shaped auger bit to break the rock mass through multi-dimensional stress crushing and shearing.

[0038] S4. Digital control system: Real-time monitoring of verticality, hole diameter, and hole depth via airborne CAN bus system, with a vertical deviation of 0.4, a hole diameter error of 30mm, and a hole depth error of 60mm, and automatic adjustment of drilling pressure and rotation speed.

[0039] S5. Low-carbon concrete grouting: After drilling, the steel cage is hoisted and dry-hole concrete is grouted using a high-frequency vibrator, or underwater grouting is carried out using an air-lift reverse circulation system in conjunction with low-slump concrete.

[0040] The electric rotary drilling rig includes a permanent magnet synchronous motor direct drive system. The power head output torque of the permanent magnet synchronous motor direct drive system is 260–240 kN·m, the drilling diameter is 0.8–2.5 m, and the maximum drilling depth is 30–70 m. The energy recovery device includes a potential energy to electrical energy conversion circuit and a range extender. The steel casing connection adopts a drive sleeve hydraulic locking mechanism. The standard casing sections are fastened by flange bolts. The first casing section with alloy cutter head has a rotary sinking speed of 2–4 m / h. The rock strata are broken. During this process, the drill bit speed is controlled at 8–15 rpm, the pressure is 80–150 kN, and the drilling depth is 0.4–1 m per stage. The digital control system integrates a bottom rock layer scanning module, which detects the thickness of sediment at the bottom of the hole by 30–50 mm using ultrasonic waves and uploads the data to the cloud management platform in real time. The slump of the dry hole concrete grout is controlled at 160–180 mm, the vibration frequency is 8500–8000 times / min, and the underwater grouting adopts dynamic monitoring of the burial depth of the guide pipe.

[0041] The system includes: a range-extended electric chassis with a tracked walking mechanism and a three-electric system; a modular drill bit magazine including a rock-socket drill, a staged reaming drill bit, and a bullet-shaped auger bit, adaptable to different rock and soil layers; a full casing drive device including a hydraulically driven wedge-shaped locking mechanism between the casing and the casing, with a verticality self-correction accuracy of ±0.5°; and a cloud-based collaborative terminal supporting remote adjustment of construction parameters and fault warning. The drill bit teeth have a wedge-shaped linear cutting edge structure with a hardness of HRC60~HRC80, suitable for continuous cutting operations in abrasive rock layers.

[0042] Example 2: Please refer to Figure 1 One embodiment of the present invention provides: a high-efficiency hole-forming construction method using a zero-emission electric rotary drilling rig, comprising:

[0043] S1. Site pretreatment and equipment configuration: The construction site is hardened and an electric rotary drilling rig is used. The electric rotary drilling rig is equipped with a power system, which includes pure electric mode, range-extending mode and plug-in mode. The energy recovery device converts the descending potential energy of the winch mechanism into electrical energy for storage.

[0044] S2. Full casing without mud: The drilling rig drives the sleeve to dynamically lock the first section of the steel casing. The first section of the steel casing is 4m long. The first section of the steel casing is screwed into the formation in stages with pressure. The bottom of the casing is always 0.5m ahead of the excavation face. The dry method of tubular drilling is used to remove soil at the same time. No mud is needed for wall protection throughout the process.

[0045] S3. Embedded rock strata breaking: When encountering moderately weathered or more weathered rock strata, switch to an embedded rock drill or bullet-shaped auger bit to break the rock mass through multi-dimensional stress crushing and shearing.

[0046] S4. Digital control system: Real-time monitoring of verticality, hole diameter, and hole depth via an onboard CAN bus system, with a vertical deviation of 1%, a hole diameter error of 50mm, and a hole depth error of 100mm, and automatic adjustment of drilling pressure and rotation speed.

[0047] S5. Low-carbon concrete grouting: After drilling, the steel cage is hoisted and dry-hole concrete is grouted using a high-frequency vibrator, or underwater grouting is carried out using an air-lift reverse circulation system in conjunction with low-slump concrete.

[0048] The electric rotary drilling rig includes a permanent magnet synchronous motor direct drive system. The power head output torque of the permanent magnet synchronous motor direct drive system is 260–240 kN·m, the drilling diameter is 0.8–2.5 m, and the maximum drilling depth is 30–70 m. The energy recovery device includes a potential energy to electrical energy conversion circuit and a range extender. The steel casing connection adopts a drive sleeve hydraulic locking mechanism. The standard casing sections are fastened by flange bolts. The first casing section with alloy cutter head has a rotary sinking speed of 2–4 m / h. The rock strata are broken. During this process, the drill bit speed is controlled at 8–15 rpm, the pressure is 80–150 kN, and the drilling depth is 0.4–1 m per stage. The digital control system integrates a bottom rock layer scanning module, which detects the thickness of sediment at the bottom of the hole by 30–50 mm using ultrasonic waves and uploads the data to the cloud management platform in real time. The slump of the dry hole concrete grout is controlled at 160–180 mm, the vibration frequency is 8500–8000 times / min, and the underwater grouting adopts dynamic monitoring of the burial depth of the guide pipe.

[0049] The system includes: a range-extended electric chassis with a tracked walking mechanism and a three-electric system; a modular drill bit magazine including a rock-socket drill, a staged reaming drill bit, and a bullet-shaped auger bit, adaptable to different rock and soil layers; a full casing drive device including a hydraulically driven wedge-shaped locking mechanism between the casing and the casing, with a verticality self-correction accuracy of ±0.5°; and a cloud-based collaborative terminal supporting remote adjustment of construction parameters and fault warning. The drill bit teeth have a wedge-shaped linear cutting edge structure with a hardness of HRC60~HRC80, suitable for continuous cutting operations in abrasive rock layers.

[0050] Example 3: Please refer to Figure 1 One embodiment of the present invention provides: a high-efficiency hole-forming construction method using a zero-emission electric rotary drilling rig, comprising:

[0051] S1. Site pretreatment and equipment configuration: The construction site is hardened and an electric rotary drilling rig is used. The electric rotary drilling rig is equipped with a power system, which includes pure electric mode, range-extending mode and plug-in mode. The energy recovery device converts the descending potential energy of the winch mechanism into electrical energy for storage.

[0052] S2. Full casing without mud drilling: The drilling rig drives the sleeve to dynamically lock the first section of the steel casing. The first section of the steel casing is 5m long. The first section of the steel casing is screwed into the formation under pressure in stages. The bottom of the casing is always 0.6m ahead of the excavation face. The dry method of tubular drilling is used to remove soil at the same time. No mud wall protection is required throughout the process.

[0053] S3. Embedded rock strata breaking: When encountering moderately weathered or more weathered rock strata, switch to an embedded rock drill or bullet-shaped auger bit to break the rock mass through multi-dimensional stress crushing and shearing.

[0054] S4. Digital control system: Real-time monitoring of verticality, hole diameter, and hole depth via an onboard CAN bus system, with a vertical deviation of 0.5%, a hole diameter error of 35mm, and a hole depth error of 70mm, and automatic adjustment of drilling pressure and rotation speed;

[0055] S5. Low-carbon concrete grouting: After drilling, the steel cage is hoisted and dry-hole concrete is grouted using a high-frequency vibrator, or underwater grouting is carried out using an air-lift reverse circulation system in conjunction with low-slump concrete.

[0056] The electric rotary drilling rig includes a permanent magnet synchronous motor direct drive system. The power head output torque of the permanent magnet synchronous motor direct drive system is 260–240 kN·m, the drilling diameter is 0.8–2.5 m, and the maximum drilling depth is 30–70 m. The energy recovery device includes a potential energy to electrical energy conversion circuit and a range extender. The steel casing connection adopts a drive sleeve hydraulic locking mechanism. The standard casing sections are fastened by flange bolts. The first casing section with alloy cutter head has a rotary sinking speed of 2–4 m / h. The rock strata are broken. During this process, the drill bit speed is controlled at 8–15 rpm, the pressure is 80–150 kN, and the drilling depth is 0.4–1 m per stage. The digital control system integrates a bottom rock layer scanning module, which detects the thickness of sediment at the bottom of the hole by 30–50 mm using ultrasonic waves and uploads the data to the cloud management platform in real time. The slump of the dry hole concrete grout is controlled at 160–180 mm, the vibration frequency is 8500–8000 times / min, and the underwater grouting adopts dynamic monitoring of the burial depth of the guide pipe.

[0057] The system includes: a range-extended electric chassis with a tracked walking mechanism and a three-electric system; a modular drill bit magazine including a rock-socket drill, a staged reaming drill bit, and a bullet-shaped auger bit, adaptable to different rock and soil layers; a full casing drive device including a hydraulically driven wedge-shaped locking mechanism between the casing and the casing, with a verticality self-correction accuracy of ±0.5°; and a cloud-based collaborative terminal supporting remote adjustment of construction parameters and fault warning. The drill bit teeth have a wedge-shaped linear cutting edge structure with a hardness of HRC60~HRC80, suitable for continuous cutting operations in abrasive rock layers.

[0058] Example 4: Please refer to Figure 1 One embodiment of the present invention provides: a high-efficiency hole-forming construction method using a zero-emission electric rotary drilling rig, comprising:

[0059] S1. Site pretreatment and equipment configuration: The construction site is hardened and an electric rotary drilling rig is used. The electric rotary drilling rig is equipped with a power system, which includes pure electric mode, range-extending mode and plug-in mode. The energy recovery device converts the descending potential energy of the winch mechanism into electrical energy for storage.

[0060] S2. Full casing without mud: The drilling rig drives the sleeve to dynamically lock the first section of the steel casing. The first section of the steel casing is 6m long. The first section of the steel casing is screwed into the formation under pressure in stages. The bottom of the casing is always 0.6m ahead of the excavation face. The dry method of tubular drilling is used to remove soil at the same time. No mud is needed for wall protection throughout the process.

[0061] S3. Embedded rock strata breaking: When encountering moderately weathered or more weathered rock strata, switch to an embedded rock drill or bullet-shaped auger bit to break the rock mass through multi-dimensional stress crushing and shearing.

[0062] S4. Digital control system: Real-time monitoring of verticality, hole diameter, and hole depth via airborne CAN bus system, with a vertical deviation of 0.7%, a hole diameter error of 40mm, and a hole depth error of 80mm, and automatic adjustment of drilling pressure and rotation speed.

[0063] S5. Low-carbon concrete grouting: After drilling, the steel cage is hoisted and dry-hole concrete is grouted using a high-frequency vibrator, or underwater grouting is carried out using an air-lift reverse circulation system in conjunction with low-slump concrete.

[0064] The electric rotary drilling rig includes a permanent magnet synchronous motor direct drive system. The power head output torque of the permanent magnet synchronous motor direct drive system is 260–240 kN·m, the drilling diameter is 0.8–2.5 m, and the maximum drilling depth is 30–70 m. The energy recovery device includes a potential energy to electrical energy conversion circuit and a range extender. The steel casing connection adopts a drive sleeve hydraulic locking mechanism. The standard casing sections are fastened by flange bolts. The first casing section with alloy cutter head has a rotary sinking speed of 2–4 m / h. The rock strata are broken. During this process, the drill bit speed is controlled at 8–15 rpm, the pressure is 80–150 kN, and the drilling depth is 0.4–1 m per stage. The digital control system integrates a bottom rock layer scanning module, which detects the thickness of sediment at the bottom of the hole by 30–50 mm using ultrasonic waves and uploads the data to the cloud management platform in real time. The slump of the dry hole concrete grout is controlled at 160–180 mm, the vibration frequency is 8500–8000 times / min, and the underwater grouting adopts dynamic monitoring of the burial depth of the guide pipe.

[0065] The system includes: a range-extended electric chassis with a tracked walking mechanism and a three-electric system; a modular drill bit magazine including a rock-socket drill, a staged reaming drill bit, and a bullet-shaped auger bit, adaptable to different rock and soil layers; a full casing drive device including a hydraulically driven wedge-shaped locking mechanism between the casing and the casing, with a verticality self-correction accuracy of ±0.5°; and a cloud-based collaborative terminal supporting remote adjustment of construction parameters and fault warning. The drill bit teeth have a wedge-shaped linear cutting edge structure with a hardness of HRC60~HRC80, suitable for continuous cutting operations in abrasive rock layers.

[0066] Example 5: Please refer to Figure 1 One embodiment of the present invention provides: a high-efficiency hole-forming construction method using a zero-emission electric rotary drilling rig, comprising:

[0067] S1. Site pretreatment and equipment configuration: The construction site is hardened and an electric rotary drilling rig is used. The electric rotary drilling rig is equipped with a power system, which includes pure electric mode, range-extending mode and plug-in mode. The energy recovery device converts the descending potential energy of the winch mechanism into electrical energy for storage.

[0068] S2. Full casing without mud drilling: The drilling rig drives the sleeve to dynamically lock the first section of the steel casing. The first section of the steel casing is 6.5m long. The first section of the steel casing is screwed into the formation under pressure in stages. The bottom of the casing is always 0.6m ahead of the excavation face. The dry method of tubular drilling is used to remove soil at the same time. No mud wall protection is required throughout the process.

[0069] S3. Embedded rock strata breaking: When encountering moderately weathered or more weathered rock strata, switch to an embedded rock drill or bullet-shaped auger bit to break the rock mass through multi-dimensional stress crushing and shearing.

[0070] S4. Digital control system: Real-time monitoring of verticality, hole diameter, and hole depth via an onboard CAN bus system, with a vertical deviation of 0.8%, a hole diameter error of 45mm, and a hole depth error of 90mm, and automatic adjustment of drilling pressure and rotation speed.

[0071] S5. Low-carbon concrete grouting: After drilling, the steel cage is hoisted and dry-hole concrete is grouted using a high-frequency vibrator, or underwater grouting is carried out using an air-lift reverse circulation system in conjunction with low-slump concrete.

[0072] The electric rotary drilling rig includes a permanent magnet synchronous motor direct drive system. The power head output torque of the permanent magnet synchronous motor direct drive system is 260–240 kN·m, the drilling diameter is 0.8–2.5 m, and the maximum drilling depth is 30–70 m. The energy recovery device includes a potential energy to electrical energy conversion circuit and a range extender. The steel casing connection adopts a drive sleeve hydraulic locking mechanism. The standard casing sections are fastened by flange bolts. The first casing section with alloy cutter head has a rotary sinking speed of 2–4 m / h. The rock strata are broken. During this process, the drill bit speed is controlled at 8–15 rpm, the pressure is 80–150 kN, and the drilling depth is 0.4–1 m per stage. The digital control system integrates a bottom rock layer scanning module, which detects the thickness of sediment at the bottom of the hole by 30–50 mm using ultrasonic waves and uploads the data to the cloud management platform in real time. The slump of the dry hole concrete grout is controlled at 160–180 mm, the vibration frequency is 8500–8000 times / min, and the underwater grouting adopts dynamic monitoring of the burial depth of the guide pipe.

[0073] The system includes: a range-extended electric chassis with a tracked walking mechanism and a three-electric system; a modular drill bit magazine including a rock-socket drill, a staged reaming drill bit, and a bullet-shaped auger bit, adaptable to different rock and soil layers; a full casing drive device including a hydraulically driven wedge-shaped locking mechanism between the casing and the casing, with a verticality self-correction accuracy of ±0.5°; and a cloud-based collaborative terminal supporting remote adjustment of construction parameters and fault warning. The drill bit teeth have a wedge-shaped linear cutting edge structure with a hardness of HRC60~HRC80, suitable for continuous cutting operations in abrasive rock layers.

[0074] Comparative experiment:

[0075] The difference between Comparative Example 1 and Example 1 is that;

[0076] Site Pretreatment and Equipment Configuration: The construction site was hardened, and an electric rotary drilling rig was used. This rig is equipped with a power system including pure electric mode, range-extended mode, and plug-in mode. An energy recovery device converts the descending potential energy of the winch mechanism into electrical energy for storage. The entire casing drilling process was mud-free: the drilling rig dynamically locked the first section of the steel casing, which was 7m long. The first section was screwed into the ground under pressure in stages, with the bottom of the casing always 0.7m ahead of the excavation face. Simultaneous dry drilling with a tubular drill was used for soil removal, eliminating the need for mud wall protection throughout the entire process. Embedded rock strata fracturing: When encountering moderately weathered or more weathered rock strata, switch to embedded rock drill or bullet-shaped auger bit to fracture the rock mass through multi-dimensional stress crushing and shearing. Digital control system: Real-time monitoring of verticality, hole diameter, and hole depth via airborne CAN bus system, with a vertical deviation of 0.4, a hole diameter error of 30mm, and a hole depth error of 60mm, and automatic adjustment of drilling pressure and rotation speed. Low-carbon concrete grouting: After hole formation, hoist the steel cage and use a high-frequency vibrator for dry hole concrete grouting, or use an air-lift reverse circulation system in conjunction with low-slump concrete for underwater grouting.

[0077] The difference between Comparative Example 1 and Example 2 is that;

[0078] Site Pretreatment and Equipment Configuration: The construction site was hardened, and an electric rotary drilling rig was used. This rig is equipped with a power system including pure electric mode, range-extended mode, and plug-in mode. An energy recovery device converts the descending potential energy of the winch mechanism into electrical energy for storage. The entire casing drilling process was mud-free: the drilling rig dynamically locked the first section of the steel casing, which was 4m long. The first section was screwed into the ground under pressure in stages, with the bottom of the casing always 0.5m ahead of the excavation face. Simultaneous dry excavation using a tubular drill was employed, eliminating the need for mud wall protection throughout the entire process. Embedded rock strata breaking: When encountering moderately weathered or more weathered rock strata, switch to embedded rock drill or bullet-shaped auger bit to break the rock mass through multi-dimensional stress crushing and shearing. Digital control system: Real-time monitoring of verticality, hole diameter, and hole depth through an airborne CAN bus system, with a vertical deviation of 1%, a hole diameter error of 50mm, and a hole depth error of 100mm, and automatic adjustment of drilling pressure and rotation speed. Low-carbon concrete grouting: After hole formation, hoist the steel cage and use a high-frequency vibrator for dry hole concrete grouting, or use an air-lift reverse circulation system in conjunction with low-slump concrete for underwater grouting.

[0079] The difference between Comparative Example 1 and Example 3 is that;

[0080] Site pretreatment and equipment configuration: The construction site was hardened, and an electric rotary drilling rig was used. This rig is equipped with a power system including pure electric mode, range-extended mode, and plug-in mode. An energy recovery device converts the descending potential energy of the winch mechanism into stored electrical energy. The entire casing drilling process is mud-free: the drilling rig dynamically locks the first 5m section of the steel casing. The first section is screwed into the ground under pressure in stages, with the bottom of the casing always 0.6m ahead of the excavation face. Simultaneously, dry excavation using a tubular drill is employed, eliminating the need for mud wall protection throughout the entire process. Embedded rock strata fracturing: When encountering moderately weathered or more weathered rock strata, switch to an embedded rock drill or a bullet-shaped auger bit to fracture the rock mass through multi-dimensional stress crushing and shearing. Digital control system: Real-time monitoring of verticality, hole diameter, and hole depth via an onboard CAN bus system, with a vertical deviation of 0.5%, a hole diameter error of 35mm, and a hole depth error of 70mm, and automatic adjustment of drilling pressure and rotation speed. Low-carbon concrete grouting: After drilling, hoist the reinforcing cage and use a high-frequency vibrator for dry-hole concrete grouting, or use an air-lift reverse circulation system in conjunction with low-slump concrete for underwater grouting.

[0081] The difference between Comparative Example 1 and Example 4 is that;

[0082] Site pretreatment and equipment configuration: The construction site was hardened, and an electric rotary drilling rig was used. This rig is equipped with a power system including pure electric mode, range-extended mode, and plug-in mode. An energy recovery device converts the descending potential energy of the winch mechanism into electrical energy for storage. Full casing drilling without mud: The drilling rig dynamically locks the first steel casing section, which is 6m long. The first steel casing section is screwed into the ground under pressure in stages, with the bottom of the casing always 0.6m ahead of the excavation face. Simultaneously, dry drilling with a tubular drill is used for soil removal, eliminating the need for mud wall protection throughout the entire process. Embedded rock strata fracturing: When encountering moderately weathered or more weathered rock strata, switch to an embedded rock drill or bullet-shaped auger bit to fracture the rock mass through multi-dimensional stress crushing and shearing. Digital control system: The onboard CAN bus system monitors verticality, hole diameter, and hole depth in real time, with a vertical deviation of 0.7%, a hole diameter error of 40mm, and a hole depth error of 80mm, and automatically adjusts the drilling pressure and rotation speed. Low-carbon concrete grouting: After drilling, the reinforcing cage is hoisted, and a high-frequency vibrator is used for dry hole concrete grouting, or an air-lift reverse circulation system is used in conjunction with low-slump concrete for underwater grouting.

[0083] The difference between Comparative Example 1 and Example 5 is that;

[0084] Site pretreatment and equipment configuration: The construction site was hardened, and an electric rotary drilling rig was used. The electric rotary drilling rig is equipped with a power system, which includes pure electric mode, range-extended mode, and plug-in mode. An energy recovery device converts the descending potential energy of the winch mechanism into electrical energy for storage. Full casing drilling without mud: The drilling rig drive sleeve dynamically locks the first section of the steel casing, which is 6.5m long. The first section of the steel casing is screwed into the formation under pressure in stages, with the bottom of the casing always 0.6m ahead of the excavation face. Simultaneously, dry excavation using a tubular drill is employed, eliminating the need for mud wall protection throughout the entire process. Embedded rock strata fracturing: When encountering moderately weathered or more weathered rock strata, switch to embedded rock drill or bullet-shaped auger bit to fracture the rock mass through multi-dimensional stress crushing and shearing. Digital control system: Real-time monitoring of verticality, hole diameter, and hole depth via airborne CAN bus system, with a vertical deviation of 0.8%, a hole diameter error of 45mm, and a hole depth error of 90mm, and automatic adjustment of drilling pressure and rotation speed. Low-carbon concrete grouting: After hole formation, hoist the reinforcing cage and use a high-frequency vibrator for dry hole concrete grouting, or use an air-lift reverse circulation system in conjunction with low-slump concrete for underwater grouting.

[0085] The high-efficiency hole-forming construction methods of electric rotary drilling rigs in Examples 1, 2, 3, 4, and 5 of this invention were compared with the traditional high-efficiency hole-forming construction method of electric rotary drilling rigs (Comparative Example 1). Energy consumption experiments and rock breaking time experiments were conducted respectively, and their values ​​were calculated and statistically analyzed. The results are shown in Table 1.

[0086] Reduced energy consumption Rock breaking time (min) Example 1 40％ 30 Example 2 42％ 35 Example 3 43％ 33 Example 4 41％ 36 Example 5 44％ 37 Comparative Example 1 23％ 63

[0087] As can be seen from the data in Table 1, the energy consumption experimental coefficients of the high-efficiency hole-forming construction method using the electric rotary drilling rig in Examples 1, 2, 3, 4, and 5 of this invention are 40, 42, 43, 41, and 44, respectively, which are significantly higher than the energy consumption experimental coefficient of the high-efficiency hole-forming construction method using the electric rotary drilling rig in Comparative Example 1. Therefore, it is shown that the energy consumption experimental coefficient of the high-efficiency hole-forming construction method using the electric rotary drilling rig of this invention is significantly improved, and it achieves a breakthrough in the high energy consumption bottleneck of traditional drilling rigs by integrating range-extended electric power, energy recovery, and dry hole forming.

[0088] As can be seen from the data in Table 1, the energy consumption experimental coefficients of the high-efficiency hole-forming construction method using the electric rotary drilling rig in Examples 1, 2, 3, 4 and 5 of this invention are 30, 35, 33, 36 and 37 respectively, which are significantly lower than the rock breaking time of the high-efficiency hole-forming construction method using the electric rotary drilling rig in Comparative Example 1. Therefore, it is shown that the rock breaking time of the high-efficiency hole-forming construction method using the electric rotary drilling rig of this invention is significantly reduced, and the combination of multi-dimensional stress rolling and graded hole expansion process solves the problem of low drilling efficiency in hard rock.

[0089] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A high-efficiency hole-forming construction method using a zero-emission electric rotary drilling rig, characterized in that, include: S1. Site pretreatment and equipment configuration: The construction site is hardened and an electric rotary drilling rig is used. The electric rotary drilling rig is equipped with a power system, which includes pure electric mode, range-extending mode and plug-in mode. The energy recovery device converts the descending potential energy of the winch mechanism into electrical energy for storage. S2. Full casing without mud drilling: The drilling rig drives the sleeve to dynamically lock the first section of the steel casing. The length of the first section of the steel casing is 7-4m. The first section of the steel casing is screwed into the formation in stages under pressure. The bottom of the casing is always 0.7-0.5m ahead of the excavation face. The dry method of tubular drilling is used to remove soil at the same time. No mud wall protection is required throughout the process. S3. Embedded rock strata breaking: When encountering moderately weathered or more weathered rock strata, switch to an embedded rock drill or bullet-shaped auger bit to break the rock mass through multi-dimensional stress crushing and shearing. S4. Digital control system: Real-time monitoring of verticality, hole diameter, and hole depth via an onboard CAN bus system, with vertical deviation of 0.4-1%, hole diameter error of 30-50mm, and hole depth error of 60-100mm, and automatic adjustment of drilling pressure and rotation speed. S5. Low-carbon concrete grouting: After drilling, the steel cage is hoisted and dry-hole concrete is grouted using a high-frequency vibrator, or underwater grouting is carried out using an air-lift reverse circulation system in conjunction with low-slump concrete.

2. The high-efficiency hole-forming construction method of a zero-emission electric rotary drilling rig according to claim 1, characterized in that: The electric rotary drilling rig includes a permanent magnet synchronous motor direct drive system. The power head of the permanent magnet synchronous motor direct drive system has an output torque of 260-240 kN·m, a drilling diameter of 0.8-2.5 m, and a maximum drilling depth of 30-70 m.

3. The high-efficiency hole-forming construction method of a zero-emission electric rotary drilling rig according to claim 1, characterized in that: The energy recovery device includes a potential energy to electrical energy conversion circuit and a range extender.

4. The high-efficiency hole-forming construction method of a zero-emission electric rotary drilling rig according to claim 1, characterized in that: The steel casing connection adopts a hydraulic locking mechanism, and the standard casing sections are fastened by flange bolts. The first casing section with alloy cutter head is spun down at a speed of 2–4 m / h.

5. The high-efficiency hole-forming construction method of a zero-emission electric rotary drilling rig according to claim 1, characterized in that: When the rock strata are broken, the drill bit speed is controlled at 8–15 rpm, the pressure is 80–150 kN, and the drilling depth of each stage of reaming is 0.4–1 m.

6. The high-efficiency hole-forming construction method of a zero-emission electric rotary drilling rig according to claim 1, characterized in that: The digital control system integrates a bottom rock layer scanning module, which uses ultrasonic waves to detect the thickness of sediment at the bottom of the borehole (30-50 mm) and uploads the data to the cloud management platform in real time.

7. The high-efficiency hole-forming construction method of a zero-emission electric rotary drilling rig according to claim 1, characterized in that: The slump of the dry-hole concrete grout is controlled at 160–180 mm, the vibration frequency is 8500–8000 times / min, and the underwater grouting adopts dynamic monitoring of the burial depth of the guide pipe.

8. A zero-emission electric rotary drilling rig system, applicable to the efficient hole-forming construction method of a zero-emission electric rotary drilling rig as described in any one of claims 1-7, characterized in that, The system includes: Step S6: The range-extended electric chassis includes a tracked walking mechanism and is equipped with a three-electric system; Step S7: The modular drill bit library includes rock-embedded tube drills, staged reaming drill bits, and bullet-shaped auger bits, which are suitable for different rock and soil layers. Step S8: The full casing drive device includes a hydraulically driven wedge locking mechanism between the sleeve and the casing, with a verticality self-correction accuracy of ±0.5°; Step S9: The cloud-based collaborative terminal supports remote adjustment of construction parameters and fault early warning.

9. A zero-emission electric rotary drilling rig system according to claim 8, characterized in that, The drill bit has a wedge-shaped linear cutting edge structure with a hardness of HRC60 to HRC80, making it suitable for continuous cutting operations in abrasive rock formations.

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