Automated Pipe Loading System for Blast Hole Drilling Rigs
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Solution Overview
Problem
Existing drilling tool management systems require a large number of personnel and manual operation, leading to inefficiencies and risks of damage or loss of tools during change-out operations, and are not suitable for automated pipe carousel systems.
Innovation Solution
A pipe loading system with pivotably supported pipe loaders and sensors that automatically index and align drilling tools with the drill string, using a pipe support pod and holding clamp, and an automatic control system to manage the pipe holding clamp's state and ensure safe tool exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual operation of pipe loaders is used for drilling tool change-out, then personnel can directly control the tool replacement process, but a large number of personnel are required and the risk of tool damage or loss increases
Solution Approach 1:
The pipe loading system is configured to automatically detect the presence of drilling tools in pipe holders and autonomously control the opening and closing of pipe holding clamps without requiring manual intervention. The system monitors its own state through sensors and executes loading operations independently, eliminating the need for multiple personnel to manually operate the pipe loaders while maintaining tool safety through automated control protocols
Solution Approach 2:
The patent replaces manual mechanical operation with an automated control system that uses sensors to detect tool presence and automatically actuates the pipe holding clamps. The mechanical system of manually operated pipe loaders is substituted with an automated control mechanism that reduces personnel requirements and minimizes the risk of tool damage or loss during change-out operations
2Ease of operation
If automated pipe loading system is implemented, then operator requirements are simplified and tool safety is improved, but system complexity increases
Solution Approach 1:
The pipe loading system incorporates sensors that automatically detect the presence of drilling tools in pipe holders and provide feedback to the control system. This feedback mechanism enables the system to autonomously determine when pipe holding clamps should be opened or closed, simplifying operator requirements while managing system complexity through intelligent sensing and automated decision-making protocols
3Productivity
If manual drilling tool change-out is performed, then flexibility in operation is maintained, but downtime during tool replacement increases
Solution Approach 1:
The automated pipe loading system enables continuous drilling operations by automatically performing tool change-out operations without requiring manual intervention. The system maintains continuous useful action by seamlessly replacing drilling tools during non-productive periods, minimizing downtime and maximizing drilling efficiency through uninterrupted automated operations
Data Source
AI summary
A pipe loading system for a blast hole drilling rig. The blast hole drilling rig includes a drilling platform, a drill tower supported on the drilling platform, a drill motor supported at an upper end of the drill tower, operatively coupled to a drilling head configured to selectively engage with and rotate a drill pipe, and a pipe loader pivotably supported on the drilling platform and configured to selectively index a drilling tool into coaxial alignment with the drill pipe during a drilling tool change-out operation. The pipe loader includes a pipe support pod at a lower end and a pipe holding clamp at an upper end. Sensors detect a presence of the drilling tool in the pipe holder, an interconnection between the drilling head and the drill pipe, and a state of the pipe holding clamp. The pipe loading system closes the pipe holding clamp when the drilling tool is in the pipe loader and the pipe holding clamp is not in a closed position.