Air compressor system and method for monitoring an air compressor system
Patent Information
- Application Number
- PCT/US2025/016765
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2025-02-21
- Publication Date
- 2026-08-27
Smart Images
Figure US2025016765_27082026_PF_FP_ABST
Abstract
Description
[0001] P24090W001
[0002] 1
[0003] TITLE
[0004] AIR COMPRESSOR SYSTEM AND METHOD FOR MONITORING AN AIR COMPRESSOR SYSTEM
[0005] TECHNICAL FIELD
[0006] The technology disclosed relates to a method and an air compressor system comprising a safety and monitoring system for monitoring temperature sensors located in the air compressor system.
[0007] BACKGROUND
[0008] Air compressors deliver a source of compressed air that may perform many useful functions. One example of where air compressors are used is for rock drilling rigs. A drilling rig typically comprises a drill bit on a drill string, which is one or more drill rods connected together, that is rotated to drill a hole in the ground.
[0009] In order to flush the cuttings from the hole as it is being drilled, an air compressor system may be used to deliver pressurized air which is communicated downwardly through the drill string to the front face of the drill bit. The cuttings get caught in the airflow from the drill bit and are brought to the surface as the air travels upwardly along the exterior of the drill string. The pressurized air may also serve to cool the cutting elements of the drill bit.
[0010] Compressed air may also be used in percussive drilling where the compressed air is used to reciprocate an impact piston which applies percussive blows from a piston to a rotating drill bit to enhance the cutting action. The piston may be disposed below the ground surface immediately above the drill bit, or it may be disposed on above the surface of the drill hole.
[0011] In many compressed air applications it is common to drive the air compressor by an engine, for example a fuel-driven engine or an electrically driven motor, which may also drive other equipment, such as a hydraulic system which may function to perform the following functions: power hydraulic systems to raise and lower the drill string, rotate the drill string via a gearbox, add drill rods to theP24090W001
[0012] 2
[0013] drill string as drilling progresses, remove drill rods from the drill string as the drill string is being withdrawn from the hole, raise and lower a drilling mast, raise and lower leveling jacks, and propel the drilling rig in the case of a mobile drilling rig. The engine may also drive a hydraulic pump and a cooling fan of a cooling system.
[0014] The compressed air needs of such a rock drilling rig are associated with the supplying of flushing air for flushing cuttings and / or driving the impact piston of a percussive tool and / or other accessories that may be used by the drilling rig. During operation of the drilling rig, there may be no need for pressurized air, such as during the adding or removal of drill rods, relocating the drill rig, setting up the drill rig, etc. Although there is no need during those periods to circulate compressed air to flush cuttings or to reciprocate the impact piston, it still may be necessary to drive the engine that drives both the air compressor and the hydraulics to continue to power the hydraulics.
[0015] The technology disclosed relates to a safety monitoring system for an air compressor system that is suitable for use in a drilling rig. If the temperature in the air compressor becomes too high, this may cause overheating of machine parts and, in a worst-case scenario, the machine starts burning. Therefore, it is important to monitor the temperature in the air compressor system. For redundancy reasons and to achieve certain safety ratings, two temperature sensors must be monitored. The use of two temperature sensors acts as a failsafe. If the two sensors report roughly the same temperature, then you can be confident that this measured temperature is correct. However, if the two temperature sensors start widely differing in their measurements, this indicates e.g. that at least one of the sensors is working incorrectly, and one cannot be sure of the actual temperature.
[0016] In conventional solutions, the temperature differential between measurement values obtained from the two sensors is determined, and when it is greater than a fixed allowed differential temperature tolerance, an emergency stop condition is triggered by a safety and monitoring system. During the emergency stop, the drilling machine remains unusable until the differential between temperatureP24090W001
[0017] 3
[0018] readings of the two temperature sensors is less than the fixed allowed temperature tolerance.
[0019] The at least two temperature sensors can however also report different values due to other reasons. As an example, there may be manufacturing tolerances in the sensors themselves or the positioning of the temperature sensors in the compressor circuit to be monitored can also result in variations in reported values between a first temperature sensor and a second temperature sensor. Therefore, an emergency stop may be triggered by the safety and monitoring system even if it is not actually needed. Continuous emergency stopping and restarting of the system is harsh on the powerpack so unnecessary emergency stops should be avoided.
[0020] The emergency stopping may also cause the drilled hole to collapse and the drill bit to become stuck, as drill cuttings are no longer flushed out of the hole, or as drill cuttings that have been flushed up but not entirely out of the hole drop down and wedge themselves between the drill bit and the rock. This results in a longer drilling time and more effort is needed to complete drilling the hole.
[0021] Moreover, electric machines can take up to 30 minutes before restart is permitted after the differential temperature between the two sensors is back within the fixed allowed differential temperature tolerance. This time-consuming procedure is necessary because the temperature must be allowed to drop in the electric circuitry to satisfy certain safety regulations.
[0022] SUMMARY
[0023] An air compressors system for a rock drilhng rig and a method for monitoring an air compressor system is provided.
[0024] The air compressor system disclosed comprises a safety monitoring system including at least two temperature sensors arranged for measuring a temperature in the air compressor system. A control unit of the safety monitoring system is configured to continuously obtain temperature measurement data from the at least two temperature sensors and, in response to determining that the difference in reported temperature values between at least two of the at least twoP24090W001
[0025] 4
[0026] temperature sensors is greater than an allowed differential tolerance level, produce at least one of a warning of event and an emergency stop of the drilling machine. According to the technology disclosed, the control unit of the safety monitoring system is further configured to adjust the allowed differential tolerance level in reported temperature values between the at least two temperature sensors by increasing the allowed differential tolerance level in response to obtaining at least one indicator of a changed condition expected to cause a significant increase of turbulence in the air compressor system.
[0027] In embodiments, the control unit of the safety monitoring system is configured to increase the allowed differential tolerance level in response to obtaining at least one indicator of a changed condition so that the increased allowed differential tolerance level is proportional to an expected increase of turbulence in the air compressor system.
[0028] In embodiments, the control unit of the safety monitoring system is configured to increase the allowed differential tolerance level in response to obtaining at least one indicator of a changed condition so that the increased allowed differential tolerance level is proportional to an expected difference in temperature readings between the at least two temperature sensors.
[0029] In embodiments, the control unit of the safety monitoring system is configured to increase the allowed differential tolerance level in response to obtaining at least one indicator of a changed condition so that the increased allowed differential tolerance level is proportional to an expected rapid and significant change of the air flowing through an air passage of the air compressor system, for example an expected rapid and significant change of the air flowing into the air compressor.
[0030] In embodiments, the at least one indicator of a changed condition obtained by the control unit of the safety monitoring system is at least one of an indicator of a rapid and significant change of the air flowing into the air compressor, an indicator of a rapid and significant change of the air flowing through another air passage of the air compressor system than in the air compressor an indicator of the start of a powerpack resulting in a compressor rotation, an indicator of engagement or disengagement of a clutch or power take off (PTO) unit resultingP24090W001
[0031] 5
[0032] in a compressor rotation, and an indicator of a changed mode of operation expected to cause a significant increase of turbulence in the air compressor system.
[0033] In embodiments, the control unit of the safety monitoring system is configured to obtain at least one indicator of a changed condition by obtaining at least one control signal, for example a control signal produced by a control system for at least one of controlling and indicating a changed condition that is expected to cause a significant increase of turbulence in the air compressor system. In embodiments, the control unit of the safety monitoring system is configured to obtain at least one control signal produced and / or transmitted by a control system for controlling an amount of air flowing throughthe air compressor system where the control signal itself is an indicator, or comprises at least one indicator, of a changed condition expected to cause a rapid and significant change of the air flowing through the air compressor system. In embodiments, the control system is configured to control the start of a powerpack by producing and / or transmitting a control signal for controlling the start of the powerpack where the control signal is an indicator of a changed condition that is expected to cause a significant increase of turbulence in the air compressor system. The control unit of the safety monitoring system may then be configured to obtain the at least one control signal for controlling the start of the powerpack as an indicator of a changed condition and increase the allowed differential tolerance level in response thereto.
[0034] In embodiments, the control system is configured to at least one of control the engagement and disengagement of a clutch or power take off (PTO) unit by transmitting a control signal for controlling the engagement and disengagement of a clutch or power take off (PTO) unit and that is providing an indicator of a changed condition that is expected to cause a significant increase of turbulence in the air compressor system. The control unit of the safety monitoring system may then be configured to obtain the control signal for controlling the engagement and disengagement of a clutch or power take off (PTO) unit as an indicator of a changed condition and increase the allowed differential tolerance level in response thereto.P24090W001
[0035] 6
[0036] In embodiments, the control system is configured to control a change of mode of operation for the air compressor system by transmitting at least one control signal providing at least one indicator of a changed mode of operation that is expected to cause a significant increase of turbulence in the air compressor system. The control unit of the safety monitoring system may then be configured to obtain the at least one control signal for changing mode of operation as an indicator of a changed condition that is expected to cause a significant increase of turbulence in the air compressor system and increase the allowed differential tolerance level in response thereto.
[0037] In embodiments, the at least two temperature sensors are co-located in the air compressor system. In embodiments, the at least two temperature sensors are co-located in the air compressor system in that they are separated by a distance less than 20 centimetres.
[0038] In embodiments, the at least two temperature sensors are both located in the discharge line of the air compressor system. In embodiments, the at least two temperature sensors are both located in the discharge line at a distance less than 50 centimetres from the air outlet of the air compressor. In aspects, the technology disclosed relates to the use of an air compressor system according to any one of the above-mentioned embodiments in a rock drilling rig for breaking of a mineral substrate, such as in any one of rock drilling, concrete processing, mineral processing, and continuous mining. In aspects, the technology disclosed relates to a rock drilling rig for breaking of a mineral substrate, such as in any one of rock drilling, concrete processing, mineral processing, and continuous mining, comprising an air compressor system according to any of the above-mentioned embodiments.
[0039] In aspects, the technology disclosed relates to a method in an air compressor system for a rock drilling rig, the method comprising:
[0040] - measuring, by each of the at least two temperature sensors, a temperature in the air compressor system to produce temperature measurement data,P24090W001
[0041] 7
[0042] - obtaining, continuously by a control unit of a safety monitoring system, the temperature measurement data from the at least two temperature sensors, the method is further comprising:
[0043] - obtaining, by the control unit of the safety monitoring system, at least one indicator of a changed condition that is expected to cause a significant increase of turbulence in the air compressor system, and
[0044] - adjusting, by the control unit of the safety monitoring system and in response to obtaining the at least one indicator of a changed condition that is expected to cause a significant increase of turbulence in the air compressor system, the allowed differential tolerance level.
[0045] In embodiments, the method further comprising increasing, by the control unit of the safety monitoring system, the allowed differential tolerance level so that the increased allowed differential tolerance level is proportional to the expected rapid and significant change of the air flowing through an air passage of the air compressor system, for example a change of an amount of air per time unit flowing into the air compressor where the change of the amount of air per time unit is controlled by controlling the speed of the air compressor.
[0046] In embodiments, the step of obtaining at least one indicator of a changed condition is comprising obtaining at least one control signal produced by the control system and that comprises at least one indicator of a changed condition that is expected to cause a significant increase of turbulence in the air compressor system.
[0047] In embodiments, the obtaining of at least one indicator of a changed condition is comprising transmitting, by a control system, at least one control signal that provides an indicator of a changed condition that is expected to cause significant increase of turbulence in the air compressor system, and detecting, by the control unit of the safety monitoring system, the at least one control signal that provides the at least one indicator and, in response to obtaining the at least one control signal, adjusting the allowed differential tolerance level by increasing the allowed differential tolerance level.P24090W001
[0048] 8
[0049] In embodiments, the obtaining of at least one indicator of a changed condition is comprising transmitting, by the control system, at least one control signal with at least one indicator of a changed condition that is expected to cause significant increase of turbulence in the air compressor system, and detecting, by the control unit of the safety monitoring system, the at least one control signal comprising the at least one indicator.
[0050] In embodiments, the at least one control signal with at least one indicator of a changed condition that is expected to cause a significant increase of turbulence in the air compressor system is at least one of a control signal for controlling the amount of air flowing through the air compressor system, a control signal for at least one of controlling and indicating the start of a powerpack, a control signal for at least one of controlling and indicating the engagement or disengagement of a clutch or power take off (PTO) unit, and a control signal comprising the indicator of a changed mode of operation that is expected to cause a significant increase of turbulence in the air compressor system.
[0051] BRIEF DESCRIPTION OF THE DRAWINGS
[0052] In the following, the technology disclosed will be described in detail, with reference to exemplifying embodiments and to the enclosed drawings.
[0053] In the drawings:
[0054] FIG. 1 schematically illustrates an example embodiment of an air compressor according to the technology disclosed.
[0055] FIG. 2 illustrates an example embodiment of an air compressor system according to the technology disclosed.
[0056] FIG. 3 illustrates another example embodiment of an air compressor system according to the technology disclosed.
[0057] FIG. 4 is a flow-chart illustrating steps of a method according to an embodiment of the disclosure.P24090W001
[0058] 9
[0059] FIG. 5 schematically illustrates an example of a rockdrill rig configured for comprising an air compressor system according to the technology disclosed.
[0060] The drawings show diagrammatic, exemplifying embodiments of the present disclosure and are thus not necessarily drawn to scale. It shall be understood that the embodiments shown and described are exemplifying and that the disclosure is not limited to these embodiments. It shall also be noted that some details in the drawings may be exaggerated to better describe and illustrate the disclosure. Like reference characters refer to like elements throughout the description, unless expressed otherwise.
[0061] DETAILED DESCRIPTION
[0062] In currently employed air compressor systems for drill rigs, an emergency stop may be triggered by the safety and monitoring system even if it is not actually needed.
[0063] Continuous emergency stopping and restarting of the system is harsh on the powerpack and can cause oil to saturate the compressor air inlet filters so unnecessary emergency stops should be avoided. The emergency stopping may also cause the drilled hole to collapse and the drill bit to become stuck, as drill cuttings are no longer flushed out of the hole, or as drill cuttings that have been flushed up but not entirely out of the hole drop down and wedge themselves between the drill bit and the rock. This results in a longer drilling time and more effort is needed to complete drilling the hole.
[0064] Moreover, it may take a long time before restart is permitted after the differential temperature between the at least two temperature sensors is back within the fixed allowed differential temperature tolerance.
[0065] Therefore, there is a need in the art for an improved air compressor system for a rock drill rig and improved methods of operating an air compressor system for a rock drill rig.
[0066] The basic concept of the technology disclosed relates to an air compressor system and method for adjusting the allowed differential tolerance level inP24090W001
[0067] 10
[0068] reported temperature values between two temperature sensors in response to obtaining at least one indicator of a changed condition expected to cause a significant increase of turbulence in the air compressor system. The technology disclosed is typically using compressor temperature differential control logic to adapt tolerances between the two temperature sensors based on operational conditions.
[0069] The concept further includes obtaining temperature measurements from the two temperature sensors and, in response to determining that the difference in reported temperature values between the two temperature sensors is greater than an allowed differential tolerance level, for example an adjusted / increased allowed differential tolerance level, produce at least one of a warning of event and an emergency stop of the drilling machine.
[0070] In embodiments, the control unit of the safety monitoring system is configured to increase the allowed differential tolerance level in response to obtaining at least one indicator of a changed condition so that the magnitude of the increase in allowed differential tolerance level imposed by the control unit is dependent on, for example proportional to, at least one of an expected increase of turbulence in the air compressor system, an expected difference in temperature readings between the two temperature sensors and an expected rapid and significant change of the air flowing through an air passage of the air compressor system, for example a rapid and significant change of the air flowing into the air compressor. The at least one indicator of a changed condition obtained by the control unit may then be at least one of an indicator of a rapid and significant change of an air flowing through the air compressor system, an indicator of the start of a powerpack resulting in a compressor rotation, an indicator of engagement or disengagement of a clutch or power take off (PTO) unit resulting in a compressor rotation, and an indicator of a changed mode of operation expected to cause a significant increase of turbulence in the air compressor system.
[0071] In various embodiments, the control unit configured to increase the allowed differential tolerance level in response to obtaining at least one indicator of a changed condition may be part of the same control system that is configured toP24090W001
[0072] 11
[0073] control the rotation speed of the air compressor and / or an adjustable valve to thereby increase or decrease the air flow into the air compressor, control the start of a powerpack, control the engaging or disengaging of a clutch, etc., or the control unit may be part of a separate control system from a control system configured to control the airflow into the air compressor, control the start of a powerpack, control the engaging or disengaging of a clutch, etc.
[0074] The raid and significant increase or decrease of the air flow, starting of the powerpack, engaging or disengaging a clutch, etc. , may then be controlled or monitored, for example as part of an existing control system for controlling a powerpack, a clutch, etc. Therefore, detecting that these kinds of changed conditions are occurring may be done based on obtained control signals already present in the currently used control system, for example existing control signals for controlling the start of a powerpack, control signals for controlling the engagement or disengagement of a clutch, etc.
[0075] The air compressor system of the technology disclosed comprises at least two temperature sensors arranged for measuring a temperature in the air compressor system and a control unit configured to continuously obtain temperature measurement data from the at least two temperature sensors and, in response to determining / detecting an upcoming occurrence of a changed condition that is expected to cause a significant increase of turbulence in the air compressor system, for example the start of a powerpack and / or the engagement or disengagement of a clutch, adjust an allowed differential tolerance level in reported temperature values between at least two of the at least two temperature sensors.
[0076] Air compressors deliver a source of compressed air that may perform many useful functions of a drill rig. Some drilling rigs operate as follows. A drill bit of a drill string is rotated to drill a hole in the ground, i.e., in earth and / or rock. To flush the cuttings from the hole as it is being drilled, an air compressor may be used to deliver pressurized air which is communicated downwardly through the drill string to the front face of the drill bit. The cuttings get caught in the airflow from the drill bit and are brought to the surface as the air travels upwardly along the exterior of the drill string. The pressurized air may also serveP24090W001
[0077] 12
[0078] to cool the cutting elements of the drill bit. This is one way that compressed air may be used by drill rigs.
[0079] The air compressor system according to the technology disclosed is suitable for a rock drill rig. The air compressor system then typically comprises an air compressor having an air inlet and an air outlet, a discharge line connected to the air outlet of the air compressor and a receiver, or receiver tank.
[0080] The air compressor is configured to compress air received via the air inlet and to deliver compressed air via the air outlet. The discharge line is configured to receive compressed air from the air compressor through the air outlet of the air compressor. The receiver tank is connected to the discharge line to receive compressed air from the air compressor via the discharge line. The receiver tank is typically configured to store air compressed by the air compressor and provide for oil recirculation. The air compressor may further be connected to or comprise a butterfly valve, configured to regulate an amount of air per time unit flowing into the air compressor and a check valve on the outlet. The rotation speed of the air compressor may further be adjustable to thereby regulate an amount of air flowing into the air compressor and a check valve on the outlet. The air compressor system may then further comprise a control system configured to control the rotation speed of the air compressor to thereby control the amount of air flowing into the air compressor.
[0081] In embodiments, the control unit of the safety monitoring system is configured to obtain an indicator of a changed condition that the rotation speed of the compressor is about to change, which is expected to cause a change in the turbulence in the air compressor system and increase the allowed differential tolerance level between the at least two temperature sensors in response thereto.
[0082] In embodiments, the control system for controlling an amount of air flowing into the air compressor comprises a control unit configured to send control signals for controlling a rotation speed of the air compressor to thereby control the amount of air flowing into the air compressor.
[0083] In embodiments, the control system for controlling a rotation speed of the air compressor is the same control system as the control system for obtainingP24090W001
[0084] 13
[0085] temperature measurement data from the at least two temperature sensors and adjusting the allowed differential tolerance level between the temperature sensors in response to detecting an indicator of a changed condition.
[0086] In embodiments, a first control unit for controlling a rotation speed of the air compressor is part of the same control system as, or is communicatively coupled to, a second control unit of the safety monitoring system for obtaining temperature measurement data from the at least two temperature sensors and adjusting the allowed differential tolerance level between the temperature sensors in response to detecting an indicator of a changed condition.
[0087] In embodiments, the air compressor system of the technology disclosed does not comprise an adjustable input valve and an amount of air per time unit flowing through the air compressor system may instead be regulated and changed by controlling the speed of the air compressor. A control system of the air compressor system may then be configured to control the speed of the air compressor to thereby control the amount of air flowing through the air compressor system. In various embodiments, this control system may then be the same control system for adjusting the allowed differential tolerance level between the at least two temperature sensors in response to obtaining at least one indicator of a changed condition, or it may be a separate control system.
[0088] In certain embodiments, the air compressor system may further comprise an adjustable input valve configured to regulate an amount of air per time unit flowing through an air passage of the air compressor system to thereby regulate the amount of air per time unit flowing into the air compressor. The air compressor system may then further comprise a control system configured to control the adjustable input valve to thereby control the amount of air flowing into the air compressor. Typically, the air compressor system further comprises an oil system configured to provide oil to the air compressor and check valve on or connected to the outlet of the air compressor.
[0089] As previously mentioned in this disclosure, the air compressor system according to the technology disclosed comprises a safety monitoring system comprising two temperature sensors arranged for measuring a temperature in the air compressor system and a control unit configured to continuously obtainP24090W001
[0090] 14
[0091] temperature measurement data from the two temperature sensors and, in response to determining that the difference in reported temperature values between the two temperature sensors is greater than an allowed differential tolerance level, produce a warning of event and / or an emergency stop. The allowed differential tolerance level in reported temperature values between the two temperature sensors is adjusted, typically increased, by the control unit in response to obtaining at least one indicator of a changed condition of the drilling machine that is expected to cause a significant increase of turbulence in the air compressor system.
[0092] The air compressor system comprises an air compressor having an air inlet and an air outlet. The air compressor is configured to compress air from the air inlet and to deliver a volume of compressed air to the air outlet. The air compressor system may further comprise means, for example a valve such as a butterfly valve, configured to control a volume of air produced by the air compressor system and delivered by the air compressor to the discharge line. The means may be called an output control of the air compressor
[0093] system because it controls the volume of air produced by the air compressor system.
[0094] In example embodiments, the air compressor system may further comprise a control system, or control unit, for controlling the adjustable inlet valve. The control system may then be configured to receive a working air requirement and be configured to adjust the output control based on the working air requirement.
[0095] The air compressor system may further comprise a working air outlet valve in communication with the air outlet of the air compressor. The working air outlet may be configured to deliver at least some of the volume of compressed air from the air outlet of the air compressor as a working air when the working air outlet valve is open.
[0096] FIG. 1 schematically illustrates an example embodiment of an air compressor 20 according to the technology disclosed.
[0097] The example embodiment of an air compressor illustrated in FIG. 1 comprises an air inlet 19 and an air outlet 21. The air compressor 20 in FIG. 1 receives airP24090W001
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[0099] via the air inlet 19 and delivers compressed comprises via the air outlet 21. The air compressor 20 further comprises a butterfly valve 25 configured to control a volume of air produced by the air compressor 20. A clutch (not shown) is configured to rotate the air compressor 20 and is used to start and stop the air compressor 20 when not in use. The clutch may then be controlled by a powerpack driven clutch control (not shown). The air flow in the embodiment shown in FIG. 1 is controlled by the butterfly valve 25 arranged between the air inlet 19 and the air compressor 20. In addition to the air compressor 20, FIG. 1 further schematically illustrates a portion of a discharge pipe / line 50 and two temperature sensors 23A, 23B arranged directly outside the air outlet 21, or air compressor discharge pipe connection, of the air compressor 20 in the discharge pipe / line 50, and each configured to measure a temperature of the compressed air and being communicatively connected to a control unit (not shown) .
[0100] FIG. 2 illustrates an example embodiment of an air compressor system according to the technology disclosed.
[0101] FIG. 2 illustrates an example of an air compressor system. The air compressor system 100 in this example embodiment takes air in through a filter 10 and delivers compressed air as working air 44 which in this example is flushing air 44 for a drilling rig operation.
[0102] The basic components of the example embodiments of air compressor system 100 in FIG. 2 include an air compressor having an air inlet 19 and an air outlet 21, a discharge pipe / line 50 connected to the air outlet 21 of the air compressor 20 and a receiver 34, or receiver tank 34. The air compressor system 100 compresses the air with the air compressor 20 and delivers the compressed air as working air 44 which in this example is flushing air 44 for a rock drill rig operation.
[0103] The air compressor 20 in FIG. 2 is configured to compress air received via the air inlet 19 and to deliver compressed air via the air outlet 21. The discharge line 50 is configured to receive compressed air from the air compressor 20 through the air outlet 21 of the air compressor 20. The receiver tank 34 is connected to the discharge line 50 to receive compressed air from the air compressor 20 via the discharge line 50.P24090W001
[0104] 16
[0105] The example embodiment of an air compressor system 100 schematically illustrated in FIG. 2 further comprises an adjustable input valve 25 configured to regulate an amount of air flowing through an air passage of the air compressor system 100 to thereby regulate the amount of air flowing into the air compressor 20, and a control system 22 configured to control the adjustable input valve 25 to thereby control the amount of air flowing into the air compressor 20.
[0106] The air compressor system 100 illustrated in FIG. 2 further comprises a safety monitoring system 110 comprising two temperature sensors 23A, 23B arranged for measuring a temperature in the air compressor system 100 and a control unit 11 configured to continuously obtain temperature measurement data from the two temperature sensors 23A, 23B and, in response to determining that the difference in reported temperature values between the two temperature sensors 23A, 23B is greater than an allowed differential tolerance level, produce a warning of event and / or an emergency stop.
[0107] In the example embodiment schematically illustrated in FIG. 2, the safety monitoring system 110 is a separate system from the control system 22. The example control unit 11 of a safety monitoring system 110 illustrated in FIG.2 is communicatively coupled to the two temperature sensors 23A, 23B to obtain measurement data from the temperature sensors 23 A, 23B. The control unit 11 is further communicatively coupled to a separate control unit 26 of the control system 22 that is configured to control the adjustable input valve 25 to thereby control and regulate an amount of air flowing into the air compressor 20 by increasing or decreasing the air flowing through the adjustable input valve.
[0108] The control unit 11 in FIG. 2 is configured to obtain control signals produced by the control system 22 and, in response to obtaining a control signal that is indicating a changed condition of that is expected to cause a significant increase of turbulence in the air compressor system 100, adjust an allowed differential tolerance level in reported temperature values between the two temperature sensors 23A, 23B.
[0109] The air compressor system 100 illustrated in FIG. 2 comprises two temperature sensors 23A, 23B arranged for measuring a temperature in the air compressor system 100 and the control unit 11 is configured to continuouslyP24090W001
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[0111] obtain temperature measurement data from the two temperature sensors 23A, 23B and, in response to determining that the difference in reported temperature values between the two temperature sensors 23A, 23B is greater than an allowed differential tolerance level, produce a warning of event and / or an emergency stop.
[0112] The two temperature sensors 23A, 23B in FIG. 2 are further and arranged for measuring a temperature in the air compressor system 100 and the control unit 11 may further be configured to continuously obtain temperature measurement data from the two temperature sensors 23A, 23B and, in response to obtaining at least one control signal produced by the control system 22 that is indicating an upcoming occurrence of a changed condition that is expected to cause a significant increase of turbulence in the air compressor system 100, adjust an allowed differential tolerance level in reported temperature values between the two temperature sensors 23A, 23B.
[0113] The air filter 10 may be a filter configured to filter air. The adjustable inlet valve 25 may be an inlet butterfly valve and / or may be biased by a spring to be in a default state of closed. A solenoid (not shown) may be disposed to adjust the adjustable inlet valve 25 to open an adjustable amount to change an amount of air that can flow to the air inlet of the air compressor 19.
[0114] The air compressor in FIG. 2 is driven by an engine 18 and the receiver 34 comprises an air inlet and an air outlet. The working air outlet valve 36 communicate the compressed air from the air outlet of the receiver 35 with a working air application which here is flushing air 44.
[0115] The air compressor system 100 in FIG. 2 is being used by a rock drill rig application. The rock drill rig application drills a drill hole 40 in the ground 400 to produce holes 40 for blasting or to explore for minerals. The rock drill rig application in FIG. 2 includes a drill rod 38, a drill hole 40, a drill bit 42, and flushing air 44.
[0116] The drill rod 38 is a hollow, thick-walled, steel tubing to facilitate the drilling of a drill hole 40. The drill rod 38 may be connectable to other drill rods 38 to form a drill string. The drill bit 42 may be constructed of a hard material such asP24090W001
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[0118] diamond or carbide for drilling in the earth and include a hollow portion (not shown) for conveying the flushing air 44. The flushing air 44 is compressed air from the compressor system 100 that is used to flush the drill hole 40 from the earth crushed by the drill bit 42. In the example drilling application shown in FIG. 2, the drill hole 40 is the hole 40 formed by the operation of drilling by turning the drill bit 42 and drill rod 38. A drilling rig configured to turn the drill rod 38 and drill bit 42 and add new drill rods 38 to a drill string is not illustrated in FIG. 2.
[0119] In operation, the control system 22 is further configured to control the operation of the air compressor system 100. The following is a description of the air compressor system 100 delivering working air here depicted as flushing air 44 when the adjustable air inlet 25 is at least partially open and when the working air outlet valve 36 is open.
[0120] Air flows through the air filter 10 and is filtered by the air filter 10. The air flows through the adjustable air inlet valve 25, which is configured to control the amount of air that can flow through the adjustable air inlet valve 25. The control system 22 controls how open the adjustable air inlet valve 25. By adjusting the adjustable air inlet valve 25, the control system 22 can control the volume of compressed air delivered by the air compressor 20. This may be called throttling the air compressor system 100 by controlling the opening of the adjustable air inlet valve 25.
[0121] In the example embodiment shown in FIG. 2, the air that flows through the adjustable air inlet valve 25 flows into the air inlet 19 of the air
[0122] compressor 20 and is compressed by the air compressor 20, which delivers a volume of compressed air to the air outlet 21 of the air compressor 20. The compressed air then flows through the discharge line 50 and through the nonreturn valve 28. The non-return valve 28 permits oil and air to flow through it in only the direction from the air outlet of the compressor 21 toward the air inlet of the receiver 33.
[0123] The compressed air then flows into the air inlet 33 of the receiver 34 into the receiver 34, or receiver tank. In various embodiments, the receiver 34 may provide multiple functions for the air compressor system 100. First, it mayP24090W001
[0124] 19
[0125] provide for oil recirculation. Second, it may provide a means of storing compressed air so that the air compressor 20 does not have to deliver compressed air all the time when only relatively small amounts of compressed air are required, for example for accessory use through an accessory compressed air supply line (not shown) or when only relatively small amounts of compressed air are required for oil recirculation.
[0126] The compressed air then flows out of the air outlet of the receiver 35 and through the working air outlet valve 36. In some embodiments, the working air outlet valve 36 may be operable by a user of the air compressor system 100 to operate either in an open or closed state. The working air outlet valve 36 in the example embodiment shown in FIG. 2 may be controlled by the control system 22 (not shown). After flowing through the working air outlet valve 36, the compressed air then flows down through the drill rod 38 and through and out the drill bit 42 as flushing air 44. The flushing air 44 flows up the drill hole 40 and aids in removing the parts of the ground 400 that were broken up by the drill bit 42.
[0127] Thus, the air compressor system 100 is configured to deliver working air as flushing air 44. The adjustable air inlet valve 25 may be called an output control of the air compressor system 100 because it controls the volume of air produced by the air compressor system 100. In embodiments, the output control 25 of the air compressor system 100 may, for example, be adjusted by increasing or decreasing the revolutions per minute (RPMs) of the engine 18 of the air compressor 20. The output control of the air compressor may be adjusted by increasing or decreasing a clutch control (not shown) between the engine 18 and the air compressor 20.
[0128] FIG. 3 illustrates another example embodiment of an air compressor system according to the technology disclosed.
[0129] In this embodiment of the technology disclosed, the air compressor system 100 does not comprise an adjustable input valve 25 and an amount of air flowing through the air compressor system is instead controlled by controlling the rotation speed of the air compressor 20.P24090W001
[0130] 20
[0131] The air compressor system 100 illustrated in FIG. 3 further comprises a safety monitoring system 110 comprising two temperature sensors 23A, 23B arranged for measuring a temperature in the air compressor system 100 and configured to continuously obtain temperature measurement data from the two temperature sensors 23A, 23B and, in response to determining that the difference in reported temperature values between the two temperature sensors 23A, 23B is greater than an allowed differential tolerance level, produce a warning of event and / or an emergency stop.
[0132] In the example embodiment schematically illustrated in FIG. 3, the safety monitoring system is a separate system from the control system 22. The control unit 11 of the safety monitoring system 110 in FIG.2 is communicatively coupled to the two temperature sensors 23A, 23B to obtain temperature measurement data from the temperature sensors 23A, 23B. The control unit 11 is further communicatively coupled to the control system 22 and a separate control unit 26 of the control system 22 that is configured to control the rotation speed of the air compressor 20 to thereby control and regulate an amount of air flowing into the air compressor 20.
[0133] The control unit 11 in FIG. 3 is configured to obtain control signals produced by the control system 22 and, in response to obtaining a control signal that is indicating a changed condition that is expected to cause a significant increase of turbulence in the air compressor system 100, adjust an allowed differential tolerance level in reported temperature values between the two temperature sensors 23A, 23B.
[0134] In the example embodiment shown in FIG. 3, the air that flows into the air compressor 20 is regulated by controlling, by the control unit 26 of the control system 22, the rotation speed of the air compressor 20. The air is compressed by the air compressor 20, which delivers a volume of compressed air to the air outlet 21 of the air compressor 20. The compressed air then flows through the discharge line 50 and through the non-return valve 28. The non-return valve 28 permits oil and air to flow through it in only the direction from the air outlet of the compressor 21 toward the air inlet of the receiver 33.P24090W001
[0135] 21
[0136] The compressed air then flows out of the air outlet of the receiver 35 in FIG. 3 and through the working air outlet valve 36. After flowing through the working air outlet valve 36, the compressed air then flows down through the drill rod 38 and through and out the drill bit 42 as flushing air 44. The
[0137] flushing air 44 flows up the drill hole 40 and aids in removing the parts of the ground 400 that were broken up by the drill bit 42.
[0138] FIG. 4 is a flow- chart illustrating steps of a method according to an embodiment of the disclosure.
[0139] A method 400 for monitoring an air compressor system for a rock drill rig is illustrated in Fig. 4. The method 400 comprises the following actions:
[0140] 410: Measuring, by each of two temperature sensors, a temperature in the air compressor system to produce temperature measurement data,
[0141] 420: Obtaining, continuously by a control unit of a safety monitoring system, the temperature measurement data from the two temperature sensors;
[0142] 430: Obtaining, by the control unit of the safety monitoring system, at least one indicator of a changed condition that is expected to cause a significant increase of turbulence in the air compressor system; and
[0143] 440: Adjusting, by the control unit of the safety monitoring system and in response to obtaining the at least one indicator of a changed condition that is expected to cause a significant increase of turbulence in the air compressor system, the allowed differential tolerance level by increasing the allowed differential tolerance level.
[0144] FIG. 5 illustrates schematically an example drill rig 600, or rock drill machine 600, configured for comprising an air compressor 20 as shown in FIG. 1 and an air compressor system 100 as shown in FIG. 2 and FIG. 3, drilling a hole 40 in a mineral substrate 400 in the form of a rock. The rock drill rig 600 illustrated in FIG. 5 comprises a power supply 113, a hydraulic, pneumatic, or electrically actuated arm 510 for at least vertical positioning of the drilling tool 160, such as in response to signals from one or more position sensors (not shown) or similar sensing the distance between the electrodes and the mineral substrate surface.P24090W001
[0145] 22
[0146] The rock drill rig 600 further comprises ground engaging members 520 for moving the rock drilling machine 600 in a direction parallel with the rock 400.
[0147] The technology disclosed further relates to the use of an air compressor system and rock drill rig according to any of the embodiments shown in of the figures 1 to 4 for breaking of a mineral substrate, such as in any one of rock drilling, concrete processing, mineral processing, and continuous mining.
[0148] It is to be understood that the present disclosure is not limited to the embodiments described above and illustrated in the drawings; rather, the skilled person will recognize that many changes and modifications may be made within the scope of the appended claims.
Claims
P24090W00123CLAIMS1. An air compressor system for a rock drilling rig, comprising:a drilling machine,an air compressor having an air inlet and an air outlet, said air compressor is configured to compress air received via the air inlet and to deliver compressed air via the air outlet,a discharge line connected to the air outlet of the air compressor, a control system for controlling an amount of air flowing through the air compressor,a safety monitoring system comprising at least two temperature sensors arranged for measuring a temperature in the air compressor system and a control unit configured to continuously obtain temperature measurement data from at least two of the at least two temperature sensors and, in response to determining that the difference in reported temperature values between the at least two of the at least two temperature sensors is greater than an allowed differential tolerance level, produce at least one of a warning of event and an emergency stop of the drilling machine,wherein the control unit of the safety monitoring system is further configured to adjust the allowed differential tolerance level in reported temperature values between the at least of the at least two temperature sensors by increasing the allowed differential tolerance level in response to obtaining at least one indicator of a changed condition expected to cause a significant increase of turbulence in the air compressor system.
2. The air compressor system of claim 1, wherein the control unit of the safety monitoring system is further configured to increase the allowed differential tolerance level so that the increased allowed differential tolerance level is proportional to an expected rapid and significant change of the air flowing through the air compressor system.
3. The air compressor system of claim 1 or 2, wherein the at least one indicator of a changed condition is at least one of an indicator of a rapid and significant change of the air flowing through an air passage of the airP24090W00124compressor system an indicator of a start of a powerpack resulting in a compressor rotation, an indicator of engagement or disengagement of a clutch or power take off (PTO) unit resulting in a compressor rotation, and an indicator of a changed mode of operation expected to cause a significant increase of turbulence in the air compressor system.
4. The air compressor system of any of the preceding claims, wherein the control unit of the safety monitoring system is further configured to obtain the at least one indicator of a changed condition by obtaining at least one control signal produced by the control system for at least one of controlling and indicating a changed condition that is expected to cause a significant increase of turbulence in the air compressor system.
5. The air compressor system of claim 4, wherein the control unit of the safety monitoring system is configured to obtain at least one control signal transmitted by the control system for controlling an amount of air flowing through the air compressor system where the control signal comprises the at least one indicator of a changed condition in the form of a rapid and significant change of the air flowing through the air compressor6. The air compressor system of any of the preceding claims, wherein the control system is further configured to at least one of control and indicate the start of a powerpack by transmitting at least one control signal with at least one indicator of a changed condition that is expected to cause a significant increase of turbulence in the air compressor system, and wherein the control unit of the safety monitoring system is configured to obtain the at least one control signal with the at least one indicator and increase the allowed differential tolerance level in response thereto.
7. The air compressor system of any of the preceding claims, wherein the control system is further configured to control engagement and disengagement of a clutch or power take off (PTO) unit by transmitting a control signal, and wherein the control unit of the safety monitoring system is configured to obtain the control signal and increase the allowed differential tolerance level in response thereto.P24090W001258. The air compressor system of any of the preceding claims, wherein the control system is further configured to control a change of mode of operation for the air compressor system by transmitting control signals comprising at least one indicator of a changed mode of operation that is expected to cause a significant increase of turbulence in the air compressor system, and wherein the control unit of the safety monitoring system is configured to obtain the at least one control signal with the at least one indicator and increase the allowed differential tolerance level in response thereto.
9. The air compressor system of any of the preceding claims, wherein the control unit of the safety monitoring system is further configured to increase the allowed differential tolerance level so that the increased allowed differential tolerance level is proportional to an expected difference in temperature readings between the at least two of the at least two temperature sensors caused by the changed condition.
10. The air compressor system of any of the preceding claims, wherein the at least two temperature sensors are co-located in the air compressor system.1 l.The air compressor system of claim 10, wherein the at least two temperature sensors are co-located in the air compressor system in that they are separated by a distance less than 20 centimetres.
12. The air compressor system of any of the preceding claims, wherein the at least two temperature sensors are both located in the discharge line of the air compressor system.
13. The air compressor system of claim 12, wherein the at least two temperature sensors are both located in the discharge line at a distance less than 50 centimetres from the air outlet of the air compressor.
14. A method in air compressor system for a rock drilling rig, the air compressor system comprising an air compressor having an air inlet and an air outlet, a discharge line connected to the air outlet of the airP24090W00126compressor, a control system configured to control an amount of air flowing through the air compressor, and a safety monitoring system comprising at least two temperature sensors arranged for measuring a temperature in the air compressor system and a control unit for continuously obtaining temperature measurement data from the at least two temperature sensors and producing at least one of a warning of event and an emergency stop of the drilling machine in response to determining that the difference in reported temperature values between at least two of the at least two temperature sensors is greater than an allowed differential tolerance level for the reported temperature values between the at least two temperature sensors, the method comprising:- measuring, by each of the at least two temperature sensors, a temperature in the air compressor system to produce temperature measurement data,- obtaining, continuously by the control unit of the safety monitoring system, the temperature measurement data from the at least two temperature sensors, the method is further comprising:- obtaining, by the control unit of the safety monitoring system, at least one indicator of a changed condition that is expected to cause a significant increase of turbulence in the air compressor system, and- adjusting, by the control unit of the safety monitoring system and in response to obtaining the at least one indicator of a changed condition that is expected to cause a significant increase of turbulence in the air compressor system, the allowed differential tolerance level by increasing the allowed differential tolerance level.
15. The method according to claim 14, the method further comprising:increasing, by the control unit of the safety monitoring system, the allowed differential tolerance level so that the increased allowed differential tolerance level is proportional to an expected rapid and significant change of air flowing through the air compressor system.
16. The method according to any of claims 14 and 15, wherein the step of obtaining at least one indicator of a changed condition is comprising obtaining at least one control signal produced by the control system andP24090W00127that comprises at least one indicator of a changed condition that is expected to cause a significant increase of turbulence in the air compressor system.
17. The method according to any of claims 14 to 16, wherein the step of obtaining at least one indicator of a changed condition is comprising: transmitting, by the control system, at least one control signal with at least one indicator of a changed condition that is expected to cause significant increase of turbulence in the air compressor system, and detecting, by the control unit of the safety monitoring system, the at least one control signal comprising the at least one indicator.
18. The method according to any of claims 16 and 17, wherein the at least one control signal with at least one indicator of a changed condition that is expected to cause a significant increase of turbulence in the air compressor system is at least one of:a control signal for controlling the amount of air flowing through the air compressor,a control signal for at least one of controlling and indicating the start of a powerpack,a control signal for at least one of controlling and indicating the engagement or disengagement of a clutch or power take off (PTO) unit, anda control signal comprising the indicator of a changed mode of operation that is expected to cause a significant increase of turbulence in the air compressor system.
19. Use of an air compressor system according to any one of claims 1-13 in a rock drilling rig for breaking of a mineral substrate, such as in any one of rock drilling, concrete processing, mineral processing, and continuous mining.
20. A rock drilling rig for breaking of a mineral substrate, such as in any one of rock drilling, concrete processing, mineral processing, and continuousP24090W001mining, comprising an air compressor system according to any one of claims 1-13.