Double-loop control architecture of horizontal directional drilling machine remote control system and horizontal directional drilling machine

Abstract

The application discloses a double-ring control architecture of a horizontal directional drilling machine remote control system and a horizontal directional drilling machine, and the double-ring control architecture comprises a functional safety ring and a network security ring which realize data interaction and collaborative response through an edge gateway; the functional safety ring is used for monitoring the mechanical state of the drilling machine in real time and triggering a hierarchical brake according to a preset threshold; the network security ring is used for encrypting and verifying remote control instructions and resisting replay protection; and the edge gateway is used for analyzing the remote control instructions, coordinating the responses of the functional safety ring and the network security ring, and automatically linking the functional safety ring to start the hierarchical brake when a network attack is detected. The application can effectively reduce the risk of drill pipe fracture, ensure reliable communication in a complex underground environment, and improve the operation safety and reliability of the horizontal directional drilling machine under complex working conditions.

Description

Technical Field

[0001] This invention belongs to the field of engineering machinery technology, specifically relating to a dual-loop control architecture for a remote control system of a horizontal directional drilling rig and the horizontal directional drilling rig itself. Background Technology

[0002] With the gradual expansion of remote operating systems for horizontal directional drilling rigs into various application scenarios, especially in hazardous environments or remote areas where they minimize personnel exposure time at high-risk work sites, ensuring safety and efficiency, and leveraging innovative anti-theft technologies such as remote locking, enhancing system security has become paramount. The remote locking function, by locking the drilling rig in real-time, effectively prevents unauthorized personnel from starting the equipment, significantly enhancing its anti-theft capabilities. Operators can lock the equipment at any time via remote commands, ensuring the safe operation of the drilling rig. The system can also automatically send alarms and provide real-time feedback in case of equipment malfunction, ensuring the horizontal directional drilling rig is always under secure monitoring. Furthermore, the remote control system provides operators with greater flexibility, enabling them to simultaneously monitor and manage multiple devices or work sites from a command vehicle or office far from the site, saving time and labor. This improves safety while also optimizing operational efficiency and resource allocation.

[0003] Current technologies still have shortcomings in functional safety, particularly the single-stage emergency stop strategy, which may lead to excessive stress on the drill pipe during drilling operations, resulting in mechanical damage. This problem is even more pronounced in remote operations because operators cannot immediately perceive the physical feedback from the field. Furthermore, the valve bodies of hydraulic systems have insufficient sealing in mud-permeable environments, further increasing the failure rate. Therefore, improving the reliability of hydraulic systems in complex environments has become a pressing technological challenge.

[0004] In terms of network security, existing systems are vulnerable to attack, allowing attackers to easily inject false commands and threaten normal system operation. Meanwhile, existing centralized encryption schemes suffer from high processing latency, failing to meet the real-time requirements of remote drilling rig operation. Especially under high load or complex operating scenarios, excessive latency can cause remote control commands to malfunction, increasing operational risks. The simple incrementing counter mechanism employed faces synchronization difficulties in underground environments with unstable signals prone to packet loss or out-of-order delivery, and is insufficiently protected against targeted replay attacks. Furthermore, the additional data generated by existing command authentication mechanisms, such as the long length of the complete MAC authentication code, encroaches on the transmission space of effective control signals in bandwidth-constrained wireless channels or vehicle buses. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a dual-loop control architecture for a remote control system of a horizontal directional drilling rig and a horizontal directional drilling rig itself. This architecture effectively reduces the risk of drill rod breakage, ensures reliable communication in complex underground environments, and improves the operational safety and reliability of the horizontal directional drilling rig under complex working conditions.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows: Firstly, a dual-loop control architecture for a remote control system of a horizontal directional drilling rig is provided, comprising a functional safety loop and a network security loop that enable data interaction and coordinated response through an edge gateway; the functional safety loop is used to monitor the mechanical status of the drilling rig in real time and trigger graded braking according to a preset threshold; the network security loop is used to encrypt and verify remote control commands and provide anti-replay protection; the edge gateway is used to parse remote control commands, coordinate the responses of the functional safety loop and the network security loop, and automatically activate graded braking in the functional safety loop when a network attack is detected.

[0007] Furthermore, the functional safety loop includes: a hydraulic sensor for acquiring oil pressure; a torque detection module for detecting drill rod torque; and an actuator for performing graded braking when the oil pressure and drill rod torque meet preset thresholds.

[0008] Furthermore, the graded braking includes: when the oil pressure and drill rod torque are detected to meet the preset thresholds, the first-level braking is first executed: the drilling speed of the drill rod is reduced to a safe value; if the fault persists for a set time and is not eliminated, the second-level braking is triggered: the drill rod is controlled to retract a set distance at a set speed to release stress; when the axial force of the drill rod is detected to suddenly exceed the axial force threshold or when hydraulic oil leakage is detected, the third-level braking is immediately activated: the solenoid valve is triggered to cut off the power to the drill rod and start the electromagnetic brake.

[0009] Furthermore, the braking signal during the graded braking process is transmitted to the actuator via the CAN bus.

[0010] Furthermore, the valve body of the solenoid valve, which has a set sealing protection level, is provided with an array of oblique drain holes to prevent electrical faults caused by mud seepage.

[0011] Furthermore, the network security ring includes: a lightweight authentication module, a key management unit, and an intrusion detection system. When the remote control terminal generates a control command, it appends an 8-byte truncated MAC address and a hierarchical counter, and sends it to the edge gateway via LoRa / 5G dual channels. The edge gateway verifies the validity of the MAC address and checks the monotonicity of the counter. If it fails three times in a row, it is determined to be a network attack, triggering the hierarchical braking function of the functional safety ring. After successful verification, the control command is decrypted and forwarded to the vehicle controller for execution.

[0012] Furthermore, the hierarchical counter includes: a global counter that updates according to a set time and a local counter that increments according to instructions.

[0013] Furthermore, the network security ring system adopts lightweight instruction authentication technology, calculates truncated hash values ​​of control instructions as authentication codes, and combines hierarchical counters to defend against replay attacks; key management adopts a distributed storage strategy, with session keys generated by the central platform and stored in fragments at the edge gateway and vehicle controller; it realizes automatic mechanical protection response triggered by network attacks, slows down and reports to the platform when MAC verification fails continuously, and immediately invalidates the current key in the event of hydraulic failure.

[0014] Furthermore, when the network security ring detects a network attack event, it prioritizes triggering the functional safety ring response and performs graded braking; when the functional safety ring detects a mechanical failure, it prioritizes triggering the network security ring response and performs network security upgrade; when both a network attack event and a mechanical failure are detected simultaneously, the graded braking measures of the functional safety ring are executed first, and the key update process of the network security ring is initiated at the same time.

[0015] Secondly, a horizontal directional drilling rig is provided, wherein the horizontal directional drilling rig is equipped with a dual-loop control architecture of the horizontal directional drilling rig remote control system described in the first aspect.

[0016] Compared with the prior art, the beneficial effects achieved by the present invention are as follows: (1) The present invention realizes the functional safety ring and network security ring for data interaction and collaborative response through the edge gateway; the functional safety ring is used to monitor the mechanical status of the drilling rig in real time and trigger graded braking according to the preset threshold; the network security ring is used to encrypt and verify remote control commands and protect against replay; the edge gateway is used to parse remote control commands, coordinate the response of the functional safety ring and the network security ring, and automatically link the functional safety ring to start graded braking when a network attack is detected; it can effectively reduce the risk of drill rod breakage, ensure reliable communication in complex underground environments, and improve the operational safety and reliability of horizontal directional drilling rigs under complex working conditions; (2) This invention adopts a three-level progressive braking mechanism, which effectively reduces the risk of drill pipe breakage through a graded response strategy of deceleration → retraction → locking; in terms of network security, a lightweight authentication protocol is adopted, combined with a hierarchical counter and distributed key management, which significantly improves the security and real-time performance of command transmission. The above dual-ring architecture achieves coordinated linkage through an edge gateway. Network attacks automatically trigger mechanical protection responses, and mechanical failures drive security protocol upgrades, thereby strengthening system reliability from both active protection and passive response dimensions and ensuring safe operation under complex working conditions. Attached Figure Description

[0017] Figure 1This is a schematic diagram of a dual-loop control architecture for a remote control system for a horizontal directional drilling rig provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of the implementation process of graded braking in an embodiment of the present invention; Figure 3 This is a schematic diagram of the timing flow of the lightweight authentication protocol in an embodiment of the present invention. Detailed Implementation

[0018] 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.

[0019] Example 1 like Figures 1-3 As shown, a dual-loop control architecture for a remote control system of a horizontal directional drilling rig includes a functional safety loop and a network security loop that achieve data interaction and coordinated response through an edge gateway. The functional safety loop monitors the mechanical status of the drilling rig in real time and triggers graded braking based on preset thresholds. The network security loop encrypts and verifies remote control commands and provides anti-replay protection. The edge gateway parses remote control commands, coordinates the responses of the functional safety loop and the network security loop, and automatically activates graded braking in the functional safety loop when a network attack is detected. This invention effectively solves the problems of insufficient mechanical failure protection, poor real-time network security, and lack of effective integration of functional safety and network security coordination in existing technologies. Furthermore, existing solutions fail to effectively integrate mechanical protection and network security mechanisms, and cannot cope with complex faults (such as mechanical failure triggered by network attacks).

[0020] The technical solution adopted in this invention includes a dual-loop collaborative architecture of a functional safety loop and a network security loop. Regarding the functional safety loop, a three-stage progressive braking mechanism is employed: when the sensor detects that the drill pipe torque fluctuation exceeds a threshold or the hydraulic pressure is abnormal, the drilling speed is first reduced to a safe value; if the fault is not eliminated, the drill pipe is controlled to retract at a low speed to release stress; finally, when a fracture risk is detected, the solenoid valve is triggered to cut off power and activate the mechanical brake (electromagnetic brake) to lock the drill pipe. In terms of hydraulic system improvements, the valve body is equipped with an array of oblique drainage holes and adopts a high-protection-level sealing design, effectively reducing electrical faults caused by mud infiltration.

[0021] In terms of network security, the system employs lightweight command authentication technology, calculating truncated hash values ​​for control commands as authentication codes. Combined with a hierarchical counter to defend against replay attacks, the latency is only 35ms, meeting real-time control requirements. Key management adopts a distributed storage strategy. Session keys are generated by the central platform and stored in fragments on the edge gateway and vehicle controller, with dual-channel (LoRa / 5G) synchronization enhancing adaptability to weak signal environments. A dual-ring collaborative mechanism automatically triggers mechanical protection responses to network attacks; for example, it slows down and reports to the platform when MAC verification fails consecutively, and immediately invalidates the current key in the event of a hydraulic failure.

[0022] like Figure 1 As shown in the figure, the blue border represents the network security ring (command authentication, key management); the red border represents the functional safety ring (three-level braking, hydraulic monitoring).

[0023] The network security loop and the functional safety loop interact and coordinate responses through an edge gateway. The functional safety loop includes hydraulic sensors for collecting oil pressure, a torque detection module for detecting drill pipe torque, and an actuator for performing graded braking when oil pressure and drill pipe torque meet preset thresholds. It monitors the drilling rig's mechanical status in real time and triggers graded braking based on preset thresholds. The network security loop includes a lightweight authentication module, a key management unit, and an intrusion detection system, which encrypts and verifies remote control commands and provides anti-replay protection. The edge gateway, as the core hub, is responsible for parsing commands, coordinating responses between the two loops, and automatically triggering the functional safety loop to initiate deceleration or braking measures when a network attack is detected, ensuring the system's safe and reliable operation under complex conditions.

[0024] like Figure 2 As shown, the implementation process of the three-level braking strategy of this invention is as follows: After the system starts, it continuously monitors the drill pipe torque and hydraulic pressure. When abnormal fluctuations are detected (i.e., when the oil pressure and drill pipe torque meet preset thresholds; in this invention, the preset thresholds are: torque deviation > deviation threshold (e.g., 15%) or oil pressure > oil pressure limit), the first-level braking (Level 1 speed reduction mode) is executed first: the drilling speed of the drill pipe is reduced to a safe value (50% of the rated value). If the fault persists for a set time (e.g., 2 seconds) without being eliminated, the second-level braking (Level 2 reverse retraction) is triggered: the drill pipe is controlled to retract a set distance (e.g., 5-10 cm) at a set speed (e.g., 0.2 m / s) to release stress. When a sudden change in the axial force of the drill pipe is detected > axial force threshold (e.g., 10 kN) or hydraulic oil leakage is detected, the third-level braking (Level 3 mechanical locking) is immediately activated: the solenoid valve is triggered to cut off the power to the drill pipe and the electromagnetic brake is activated. The braking signals at each level are transmitted to the actuator via the CAN bus to ensure that the total response delay passes the safety assessment.

[0025] The timing flow of the lightweight authentication protocol of this invention is as follows: Figure 3As shown, the implementation method is as follows: After the remote control terminal generates a control command, it appends an 8-byte truncated MAC (based on the HMAC-SM3 algorithm) and a hierarchical counter (the global counter updates hourly, and the local counter increments with each command), and sends it to the edge gateway via LoRa / 5G dual channels; the edge gateway verifies the validity of the MAC and checks the monotonicity of the counter. If it fails three times consecutively, it is determined to be a network attack, triggering Level 1 speed reduction in the functional safety loop; after successful verification, the command is decrypted and forwarded to the vehicle controller for execution, while simultaneously updating the local counter. This protocol, while ensuring security, controls the authentication latency to within 35ms, improving efficiency by 70% compared to the traditional AES-CMAC solution.

[0026] This invention employs a three-level progressive braking mechanism to protect against mechanical failures within a functional safety ring, while a network security ring ensures secure command transmission through lightweight authentication and distributed key management. The system's security response mechanism is configured such that network attack events prioritize functional safety responses, while mechanical failure events prioritize network security upgrades. When both network attacks and mechanical failures are detected simultaneously, the functional safety ring's braking measures are executed first, while the network security ring's key update process is initiated. Functional safety protection relies on effective sensor monitoring to function. During remote control, the network security mechanism can intervene at any time to adjust control permissions, but its execution priority always adheres to the principle of functional safety taking precedence over network security. This invention utilizes standardized interface specifications in its dual-ring data interaction. These mechanisms collectively ensure the system's reliable operation under complex conditions.

[0027] Example 2 Based on the dual-loop control architecture of the remote control system for a horizontal directional drilling rig described in Embodiment 1, this embodiment provides a horizontal directional drilling rig, which is configured with the dual-loop control architecture of the remote control system for a horizontal directional drilling rig described in Embodiment 1.

[0028] 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 dual-loop control architecture for a remote control system of a horizontal directional drilling rig, characterized in that, This includes a functional safety loop and a network security loop that enable data interaction and collaborative response through edge gateways; The functional safety loop is used to monitor the mechanical status of the drilling rig in real time and trigger graded braking according to a preset threshold. The network security ring is used to encrypt and verify remote control commands and provide anti-replay protection. The edge gateway is used to parse remote control commands, coordinate the responses of the functional safety loop and the network security loop, and automatically activate the tiered braking mechanism of the functional safety loop when a network attack is detected. The functional safety ring includes: Hydraulic sensors used to acquire oil pressure; Torque detection module for detecting drill pipe torque; An actuator used to perform graded braking when the oil pressure and drill pipe torque meet preset thresholds; The graded braking includes: When the oil pressure and drill pipe torque are detected to meet the preset thresholds, the first-level braking is executed: the drilling speed of the drill pipe is reduced to a safe value. If the fault persists for the set time without being eliminated, the second-level braking is triggered: the drill pipe is controlled to retract at a set speed and a set distance to release stress; When a sudden change in the axial force of the drill pipe is detected to exceed the axial force threshold or a hydraulic oil leak is detected, the third-stage braking is immediately activated: the solenoid valve is triggered to cut off the power to the drill pipe and the electromagnetic brake is activated. The network security ring includes: a lightweight authentication module, a key management unit, and an intrusion detection system. After the remote control terminal generates a control command, it appends an 8-byte truncated MAC address and a hierarchical counter, and sends it to the edge gateway via LoRa / 5G dual channels. The edge gateway verifies the validity of the MAC address and checks the monotonicity of the counter. If it fails three times in a row, it is determined to be a network attack and triggers the hierarchical braking function of the functional safety loop. After the verification is successful, the control command is decrypted and forwarded to the vehicle controller for execution. When the network security ring detects a network attack event, it prioritizes the functional safety ring response and performs tiered braking. When the functional safety ring detects a mechanical failure, it prioritizes the network security ring response and performs network security upgrade. When both a network attack event and a mechanical failure are detected simultaneously, the tiered braking measures of the functional safety ring are executed first, and the key update process of the network security ring is initiated at the same time.

2. The dual-loop control architecture of the remote control system for horizontal directional drilling rigs according to claim 1, characterized in that, During the graded braking process, the braking signal is transmitted to the actuator via the CAN bus.

3. The dual-loop control architecture of the remote control system for horizontal directional drilling rigs according to claim 1, characterized in that, The solenoid valve, which has a set sealing protection level, has an array of oblique drain holes in its valve body to prevent electrical faults caused by mud seepage.

4. The dual-loop control architecture of the remote control system for horizontal directional drilling rigs according to claim 1, characterized in that, The hierarchical counters include: a global counter that updates according to a set time and a local counter that increments according to instructions.

5. The dual-loop control architecture of the remote control system for horizontal directional drilling rigs according to claim 1, characterized in that, The network security ring adopts lightweight instruction authentication technology, which calculates truncated hash values ​​of control instructions as authentication codes, and combines layered counters to defend against replay attacks. Key management adopts a distributed storage strategy. Session keys are generated by the central platform and stored in fragments on the edge gateway and vehicle controller. This enables automatic mechanical protection response to network attacks. When MAC verification fails consecutively, the speed is reduced and reported to the platform. In case of hydraulic failure, the current key is immediately invalidated.

6. A horizontal directional drilling rig, characterized in that, The horizontal directional drilling rig is equipped with a dual-loop control architecture of the remote control system for the horizontal directional drilling rig as described in any one of claims 1 to 5.

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