Dual-mode control switching method for unattended reconstruction of rotary drill

Abstract

The invention discloses a dual-mode control switching method for unattended reconstruction of a rotary drilling rig, and particularly relates to the technical field of mechanical equipment mode switching, and the method specifically comprises the steps of S1, switching request triggering and instruction freezing, S2, full-state snapshot generation and synchronization, S3, three-level progressive arbitration decision, and S4, dual-factor verification and switching execution. And S5, network fluctuation fault tolerance. According to the invention, through overall planning of the vehicle-mounted controller, after a switching request is received, an instruction is frozen, full-state snapshots including sensor data, operation links, equipment health and environment data are synchronized, and switching is completed through three-level arbitration including safety state judgment, authority network verification and target end confirmation and then double-factor recheck. Safe seamless switching between a remote mode and a local mode can be achieved, the situations of instruction conflicts and information faults are avoided, the operation efficiency is improved, fault-tolerant processing is carried out on scenes such as network fluctuation and emergency takeover, and the reliability and safety of unattended operation are further improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of mechanical equipment mode switching, and more particularly to a dual-mode control switching method for unmanned reconstruction of a rotary drill. BACKGROUND

[0002] In open-pit mining operations, the rotary drill, as a key device, undertakes the important task of drilling large blasting holes. Under the operation mode of the traditional rotary drill, the operator needs to control the device on site, and the working environment is usually extremely harsh, facing problems such as dust diffusion, serious noise pollution, and complex and variable geological conditions, which not only poses a great threat to the health of the operator, but also makes the labor cost high. With the rise of the concept of intelligent mine, safety, cost reduction, efficiency improvement, fewer people, and unmanned have become important trends for development. Under this background, the demand for unmanned reconstruction of the rotary drill is increasingly urgent. After realizing unmanned operation, the labor cost can be significantly reduced, the exposure risk of the operator in the dangerous environment can be reduced, and the safety of the mining operation can be improved.

[0003] At present, although some rotary drills have introduced remote control and automatic positioning technologies, there are still many deficiencies in the switching between the remote control mode and the local control mode. In the switching process, the prior art cannot comprehensively and timely obtain the real-time state information of the drill, which may cause command conflicts before and after switching, affect the normal operation of the device, and reduce the operation efficiency. The switching decision lacks a perfect safety evaluation mechanism, and the safety of the drill cannot be accurately judged. In addition, in the case of unstable network environment, the device may be switched to the remote control mode recklessly, which may cause control delay and command loss, and seriously affect the control stability and operation accuracy of the device.

[0004] In view of the above, the present application provides a dual-mode control switching method for unmanned reconstruction of a rotary drill. SUMMARY

[0005] In order to overcome the above-mentioned defects of the prior art, the present application provides a dual-mode control switching method for unmanned reconstruction of a rotary drill to solve the problems in the background art.

[0006] To achieve the above-mentioned purpose, the present application provides the following technical solution: a dual-mode control switching method for unmanned reconstruction of a rotary drill, specifically comprising the following steps: S1, switching request triggering and command freezing: when the remote control end or the local control end needs to switch the control mode and initiates a switching request, the vehicle-mounted controller responsible for overall control will immediately suspend all control command outputs being executed, so as to avoid command conflicts during the switching process. S2, full state snapshot generation and synchronization, the vehicle-mounted controller collects the current complete state information of the rig and generates a full state snapshot, which is sent to the target control end that needs to be switched to, wherein the full state snapshot contains sensor data reflecting the real-time situation of the rig, the current operation link being performed, the position of the drill bit, the depth of the drilled hole, the health status of the equipment itself, and surrounding environment data obtained through the environment perception equipment; S3, three-level progressive arbitration decision, a three-level progressive arbitration decision process is executed to ensure safe and reliable switching: First-level arbitration of safety state judgment: based on real-time sensor data and surrounding environment perception data of the rig, it is judged whether the safety conditions for switching are met, if any of the following conditions is detected, such as the rig being in the key action stage of automatic walking, leveling and drilling rod loading and unloading, or the inclination of the rig exceeding the safe range, or the environment perception finding that personnel or obstacles are close, or the equipment having fault alarm, etc., it is determined as a dangerous state and the switching request is refused; Second-level arbitration of permission and network verification: verify whether the control end initiating the switching request has the corresponding operation permission, if switching to the remote control mode is required, the quality of the wireless network link relied on by the remote control must also be checked forcibly, when the network delay exceeds 200ms or the data packet loss rate exceeds 5%, in order to ensure control stability, the switching request will be refused or delayed; Third-level arbitration of target end confirmation: the target control end receives and confirms that the full state snapshot has been completely obtained, and the operator or system confirms that the takeover conditions are met, then sends a command to the vehicle-mounted controller to confirm the takeover; S4, double-factor verification and switching execution, the vehicle-mounted controller performs double-factor safety verification, after receiving the confirmation command from the target end, the vehicle-mounted controller again quickly checks the current safety state and network state, if both meet the requirements, the source of the control command is switched to the target control end, at the same time the instruction channel of the target end is activated and the instruction channel of the original control end is closed, finally the switching completion signal is sent to the original control end and the target control end, to ensure that both sides know the change of control right.

[0007] Preferably, in the S2 step, the synchronization of the full state snapshot adopts incremental compression and verification technology, and the environment perception data is derived from the AI recognition results of multi-line laser radar and video monitoring.

[0008] Preferably, in the S2 step, the target control end is a remote control end or a local control end to which switching is requested. The current operation link being performed includes any one of hole drilling, drilling and lifting drilling rod.

[0009] Preferably, in the first-level arbitration of the S3 step of safety state judgment, the sensor data comprises wind pressure, hydraulic pressure, rotation pressure, pressurization pressure, drill pipe vibration signal, drilling depth, drilling machine inclination, engine speed, temperature data and drill bit wear information.

[0010] Preferably, the network fluctuation fault tolerance step is further included. The vehicle-mounted controller continuously monitors the network connection state with the remote end, When the network interruption duration exceeds 3s, the forced switching from the remote mode to the local mode is automatically triggered; The S2-S4 steps are executed to synchronize the full state snapshot to the local end and send the network interruption alarm and forced takeover prompt to the local end.

[0011] Preferably, after the network is restored, the switching request needs to be reinitiated by the remote end, and the third-level arbitration decision and double-factor security check of the target end confirmation are completed, so as to switch to the remote mode.

[0012] Preferably, in the remote control mode: In response to the emergency takeover operation of the local operation panel, the vehicle-mounted controller immediately freezes the remote control instruction; The key safety state review is executed, when the inclination is not out of limit and there is no collision risk, the local mode is switched to instantaneously, if the inclination is out of limit or there is a collision risk, the emergency shutdown is executed.

[0013] Preferably, in the third-level arbitration of the target end confirmation, if the first-level arbitration or the second-level arbitration fails, the rejection reason information containing the fault type identification and real-time sensor data is sent to the initiator of the mode switching request.

[0014] Preferably, in the S2 step, the device health state comprises self-checking results and fault alarm information, and the fault alarm information covers at least one of chain breakage, oil leakage, horizontal limit and clamp rod.

[0015] Technical effects and advantages of the present application: The present application can accurately identify the dangerous state of the drilling machine in automatic walking, inclination out of limit, personnel approaching and the like through the third-level arbitration mechanism and double-factor security check, in combination with the environmental perception devices such as multi-line laser radar and high-definition camera deployed in the project and the fault diagnosis system, so as to prevent blind switching in unsafe working conditions or unstable network, and the local emergency takeover function can preferentially guarantee the controllability of the equipment in emergency, thereby comprehensively reducing the safety risk in the switching process. The application relies on the incremental compression synchronization technology of full-state snapshots, rapidly synchronizes the drilling rig real-time sensor data, operation links, device health states and other information to the target control end, eliminates the information difference between the remote and local control ends, realizes seamless handover of control rights, avoids operation interruption or efficiency reduction caused by state information discontinuity in the traditional switching mode, ensures that the operation efficiency after switching is not less than 90% of the artificial local efficiency, and meets the core performance requirements of the project. The application makes full use of the results of the drive-by-wire transformation in the project, redundant wireless networks, open interfaces such as PLC / OPC, and software functions such as three-dimensional geological modeling and hole network parameter design, so that the dual-mode switching method is deeply integrated with the drilling rig remote control software, the vehicle-mounted automatic control software and the perforation management system. The dual-mode switching method not only meets the mode switching needs of a single device, but also provides support for intelligent mine overall data sharing and collaborative operation, and improves the overall intelligent level of the project. BRIEF DESCRIPTION OF DRAWINGS

[0016] Figure 1 The overall step flowchart of the application.

[0017] Figure 2 The control flowchart of the application.

[0018] Figure 3 The three-level arbitration control flowchart of the application. DETAILED DESCRIPTION

[0019] The technical solutions in the embodiments of the application will be clearly and completely described below with reference to the drawings in the embodiments of the application. Obviously, the described embodiments are only part of the embodiments of the application, rather than all the embodiments of the application. Based on the embodiments in the application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the application.

[0020] The application provides a dual-mode control switching method for unmanned transformation of a rotary drilling rig, and also relates to a dual-mode control system including three core parts: The remote control end is deployed with a remote control console, a server, an industrial computer, a display and wireless network communication equipment, can receive drilling rig state data and send control instructions; The vehicle-mounted controller is used as a core arbitration unit, adopts a PLC controller compatible with Modbus / OPC interfaces, integrates an RTK high-precision positioning module, an AI sensing processing unit and a sensor data acquisition module, and is responsible for receiving, arbitrating and executing control instructions; The local control end retains the original manual operation panel of the drilling rig, additionally adds an emergency takeover button and a state display screen, and supports local operation and emergency takeover functions.

[0021] The mode control system collects environmental and equipment status data through multi-line lidar, high-definition cameras, and various sensors to provide decision-making basis for mode switching. Among them, high-definition cameras are deployed on the drill bit, the top of the drill frame, the cab, and around the drilling rig, while various sensors are used to detect wind pressure, hydraulic pressure, vibration, and tilt angle.

[0022] The specific switching steps for this application are as follows: S1, Switch between request triggering and command freezing When a remote operator initiates a "local → remote" switch request via the remote control console, or a local operator initiates a "remote → local" switch request via the local panel: The vehicle-mounted controller receives request signals in real time via wireless network and immediately triggers the "command freeze mechanism" to suspend all currently executing control commands (such as drilling pressure adjustment, drill pipe lifting, etc.) to avoid command conflicts during the switching process that could cause equipment malfunctions. S2, Full-State Snapshot Generation and Synchronization Within 100ms of the command being frozen, the vehicle controller completes the following operations: Full-state snapshot acquisition includes sensor data such as wind pressure, hydraulic pressure, rotational pressure, pressurization pressure, drill rod vibration signal, drilling depth, drilling rig tilt angle, engine speed, radiator temperature, and drill bit wear; operation phase is marked as "in hole," "drilling," or "lifting drill rod"; equipment health status includes self-check results (such as whether the lubrication system is normal) and fault alarm information (such as chain breakage, oil leakage, etc.); environmental data includes obstacle information within a 30m radius scanned by multi-line lidar and AI recognition results from high-definition cameras (such as whether personnel are approaching). The snapshot is synchronized to the target control terminal using incremental compression and verification technology (only transmitting the data that differs from the previous state). The snapshot is sent to the target control terminal via wireless network (or to the remote control terminal if switched to remote mode). After receiving the snapshot, the target control terminal displays it on a monitor to ensure that the operator can keep track of the drilling rig status in real time (such as drilling depth, inclination angle and other key parameters). S3, Three-tiered progressive arbitration decision-making In the first-level arbitration for determining safety under safe conditions, the vehicle controller makes a safety determination based on the following data: If the drilling rig is in the automatic walking, leveling, or drilling rod loading / unloading state (critical action stage), or the inclination angle is > ±3° (safety threshold), or the environmental perception detects personnel / obstacles within 10m, or there is a fault alarm (such as oil leak detection sensor trigger), it is determined to be a "dangerous state", the switch is refused and an alarm is sent to the requesting party. If none of the above conditions are met, it is determined to be a "safe state" and enters the second-level arbitration. Under the secondary arbitration of permission and network verification, the vehicle controller checks the operation permission of the request initiator, such as whether the remote operator has "remote takeover qualification". At the same time, it detects the real-time latency and packet loss rate of the wireless network. If the network latency is 250ms or the packet loss rate is 8%, the switch is rejected and "network quality is not up to standard" is displayed. After the network recovers to a latency of 150ms and a packet loss rate of 2%, the verification is retried. In the third-level arbitration confirmed by the target end, the target control end operator confirms through the display that the full-state snapshot has been received completely (such as no missing data such as drilling depth and inclination angle), and that he / she has the conditions to take over (such as the remote operator is ready to operate), then clicks the "Confirm Takeover" button to send instructions to the vehicle controller; S4, Two-Factor Verification and Switching Execution After receiving the confirmation instruction from the target end, the vehicle controller performs a two-factor verification and executes the switching operation after passing the verification. In two-factor review: Safety status verification: Recheck the tilt angle (if the current tilt is 1.5°, it is within the safe range) and the environment (no one is near). Network status verification (remote mode only): Confirmed latency of 180ms and packet loss rate of 1%, meeting the requirements; When performing a switchover operation: Switch the control command receiving source to the target control end (such as a remote control end), activate the target end command channel, close the original control end channel (such as cutting off the command sending permission of the local panel), and send a "switch complete" signal (with key data such as the current drilling depth) to both the original control end and the target control end. The control rights indicator is updated synchronously on both displays.

[0023] When this invention performs switching processing in the following special scenarios: Scenario 1: Network fluctuation fault tolerance When the network interruption lasts for 3 seconds in remote control mode, the vehicle controller automatically triggers a forced switch from remote to local, executing steps S2-S4 to synchronize the full-state snapshot to the local end. The local panel display will show a "Network interruption, forced takeover" prompt. The local operator can take over control without initiating a request, ensuring that the device does not lose control. After the network is restored, the remote end needs to re-initiate the switch request. Only after a complete three-level arbitration and verification can the remote mode be switched back.

[0024] Scenario 2: Local Emergency Takeover In remote control mode, if the local operator detects abnormal vibration of the drill bit (via the local display screen), press the "Emergency Takeover" button. The vehicle controller will immediately freeze the remote command (which has higher priority than remote control) and quickly check the safety status. If the tilt angle is 2° (not exceeding the limit) and there is no risk of collision, it will switch to local mode within 0.5 seconds. If the tilt angle is 6° (exceeding the limit) at this time, it will immediately execute an emergency stop (cut off the power source) to avoid a rollover accident.

[0025] Scenario 3: Feedback on unsuccessful arbitration: If the first-level arbitration determines that the situation is dangerous (e.g., the drilling rig tilt angle is 4°, exceeding the safety threshold of 3°), the vehicle controller sends a rejection message to the requester, including the fault type identifier "tilt angle exceeds limit" and the real-time data "current tilt angle 4°". The requester's display will show the reason simultaneously, and the operator needs to eliminate the risk before re-initiating the request.

[0026] In summary: This invention provides a dual-mode control switching method for unattended retrofitting of roller cone drilling rigs. In practical use, the vehicle-mounted controller serves as the core arbitration unit. Upon receiving a switching request from a remote or local control terminal, the current control command is first frozen to avoid conflicts. Subsequently, a full-state snapshot containing sensor data, operational procedures, equipment health status, and environmental data is generated and synchronized to the target control terminal. Next, a three-level progressive arbitration decision is used to ensure a safe handover: the first level of arbitration determines whether the drilling rig is in a safe state; the second level of arbitration verifies the operating authority and network quality; the third level of arbitration requires the target control end to confirm the takeover; and finally, after a two-factor safety verification, the handover of control is completed, the target end command channel is activated and the original channel is closed, and a handover completion signal is sent to both parties. In addition, corresponding fault tolerance mechanisms and priority processing logic are set up for special scenarios such as network fluctuations and local emergency takeover, to ensure reliable mode switching under various working conditions, guarantee the continuity and safety of drilling rig operations, and fully rely on the hardware and software foundations such as sensor networks, AI perception, and remote control platforms in the project to achieve the above functions.

[0027] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A dual-mode control switching method for unattended retrofitting of a rotary drill rig, characterized in that: Specifically, the following steps are included: S1. Switching request trigger and command freeze: When the remote control terminal or the local control terminal needs to switch the control mode and initiates a switching request, the vehicle controller responsible for overall control will immediately pause the output of all currently executing control commands to avoid command conflicts during the switching process. S2. Full-state snapshot generation and synchronization: The vehicle controller then collects the current complete state information of the drilling rig and generates a full-state snapshot, which is synchronously sent to the target control terminal that needs to be switched to. The full-state snapshot includes sensor data that reflects the real-time status of the drilling rig, the current operation, the location of the drill bit, the depth of the drilled hole, the health status of the equipment itself, and the surrounding environment data obtained through the environmental sensing device. S3, a three-tiered progressive arbitration decision-making process, ensures a safe and reliable switchover: The first-level arbitration for safety status judgment: Based on the real-time sensor data of the drilling rig and the surrounding environment perception data, it is determined whether the safety conditions for switching are met. If the drilling rig is detected to be in the critical action stage of automatic walking, leveling and loading and unloading of drill rods, or the drilling rig inclination angle exceeds the safe range, or the environmental perception detects that personnel or obstacles are approaching, or the equipment has a fault alarm, it is determined to be a dangerous state and the switching request is rejected. Secondary arbitration for permissions and network verification: Verify whether the control terminal that initiated the switching request has the corresponding operation permissions. If switching to remote control mode is required, the quality of the wireless network link on which remote control depends must also be checked. When the network latency exceeds 200ms or the data packet loss rate exceeds 5%, the switching request will be rejected or postponed to ensure control stability. The target control terminal confirms the three-level arbitration: after receiving and confirming that the full state snapshot has been fully acquired, and after the operator or system confirms that the takeover conditions are met, it sends a takeover confirmation instruction to the vehicle controller. S4. Two-factor verification and handover execution: The vehicle controller performs two-factor security verification. After receiving the confirmation command from the target end, the vehicle controller quickly checks the current security status and network status again. If both meet the requirements, the source of the control command is switched to the target control end. At the same time, the command channel of the target end is activated and the command channel of the original control end is closed. Finally, a handover completion signal is sent to both the original control end and the target control end to ensure that both parties are aware of the change of control.

2. The dual-mode control switching method for unattended retrofitting of a rotary drilling rig according to claim 1, characterized in that: In step S2, the synchronization of the full-state snapshot adopts incremental compression and verification technology, and the environmental perception data comes from the AI ​​recognition results of multi-line LiDAR and video surveillance.

3. The dual-mode control switching method for unattended retrofitting of a rotary drilling rig according to claim 1, characterized in that: In step S2, the target control terminal is the remote control terminal or the local control terminal to which the switch is requested; The current operational phase includes any one of the following: hole preparation, drilling, and drill pipe hoisting.

4. The dual-mode control switching method for unattended retrofitting of a rotary drilling rig according to claim 1, characterized in that: In the first-level arbitration of the safety status judgment in step S3, the sensor data includes wind pressure, hydraulic pressure, rotational pressure, pressurization pressure, drill rod vibration signal, drilling depth, drilling rig inclination angle, engine speed, temperature data, and drill bit wear information.

5. The dual-mode control switching method for unattended retrofitting of a rotary drilling rig according to claim 1, characterized in that: It also includes network fluctuation fault tolerance steps: The vehicle controller continuously monitors the network connection status with the remote terminal. If the network interruption lasts for more than 3 seconds, a forced switch from remote mode to local mode will be automatically triggered. Perform steps S2-S4 to synchronize the full-state snapshot to the local end and send a network interruption alarm and forced takeover prompt to the local end.

6. The dual-mode control switching method for unattended retrofitting of a rotary drilling rig according to claim 5, characterized in that: After the network is restored, the remote end needs to re-initiate the switch request and complete the three-level arbitration decision and two-factor security verification confirmed by the target end before it can switch to remote mode.

7. The dual-mode control switching method for unattended retrofitting of a rotary drilling rig according to claim 1, characterized in that: In remote control mode: In response to an emergency takeover operation from the local control panel, the vehicle controller immediately freezes remote control commands. Perform a critical safety status review. If the tilt angle is within limits and there is no risk of collision, switch to local mode immediately. If the tilt angle exceeds limits or there is a risk of collision, perform an emergency shutdown.

8. The dual-mode control switching method for unattended retrofitting of a rotary drilling rig according to claim 1, characterized in that: In the three-level arbitration confirmed by the target end, if the first-level arbitration or the second-level arbitration fails, a rejection reason information containing the fault type identifier and real-time sensor data is sent to the initiator of the mode switching request.

9. The dual-mode control switching method for unattended retrofitting of a rotary drilling rig according to claim 1, characterized in that: In step S2, the equipment health status includes self-test results and fault alarm information, which covers at least one of chain breakage, oil leakage, horizontal over-limit, and clamping rod.

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