Drill Bit Wear Estimation via Percussion Frequency Monitoring
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Solution Overview
Problem
Rock drilling efficiency is hindered by the inability to accurately estimate drill bit wear, leading to premature replacement and excessive wear on drilling equipment, as existing methods lack effective monitoring of percussion frequency and wear state during percussive drilling processes.
Innovation Solution
A method and system that estimate drill bit wear by determining the percussion frequency using accelerometers or pressure signals, inputting this data into a model representation to output the wear state, allowing for timely replacement and optimizing drilling efficiency by normalizing percussion frequency with respect to fluid pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If drill bit wear is not monitored, then drilling operations continue without interruption, but drill bit wear leads to reduced drilling efficiency and increased equipment damage
Solution Approach 1:
The system continuously monitors percussion frequency and feeds this information back to the control unit, which compares it against reference values to determine wear state. This closed-loop feedback enables real-time detection of drill bit wear without interrupting drilling operations, resolving the contradiction between continuous productivity and maintaining reliability.
Solution Approach 2:
The patent replaces traditional mechanical wear measurement methods with a sensor-based system that measures percussion frequency electronically. Accelerometers or pressure sensors detect vibrations and convert them to electrical signals, which are then processed to determine wear state, eliminating the need for physical inspection while maintaining accuracy.
2Reliability
If drill bit replacement is performed frequently, then equipment reliability is maintained, but unnecessary replacements increase operational costs and reduce productivity
Solution Approach 1:
The system performs preliminary detection of wear state by continuously monitoring percussion frequency before the drill bit reaches critical wear levels. The control unit compares current frequency against reference values and alerts operators in advance, enabling planned replacements at optimal moments rather than reactive replacements, thus maintaining reliability while maximizing productivity.
3Measurement precision
If percussion frequency monitoring is implemented, then accurate wear estimation is achieved, but system complexity and measurement requirements increase
Solution Approach 1:
The patent introduces a control unit as an intermediary that simplifies the monitoring system by integrating sensor data acquisition, signal processing, and wear determination in one component. The control unit receives signals from accelerometers or pressure sensors, compares them against reference values, and outputs wear state information, reducing overall system complexity while maintaining measurement precision.
4Reliability
If existing wear monitoring methods are used, then equipment wear is not detected, but timely replacement cannot be determined
Solution Approach 1:
The system establishes a feedback loop where percussion frequency is continuously measured, compared against reference values, and used to determine current wear state. This real-time feedback enables operators to know precisely when replacement is needed, eliminating guesswork and ensuring replacements occur at optimal moments, thus maintaining reliability while minimizing time loss.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables accurate estimation of drill bit wear, reducing unnecessary replacements and equipment wear, thereby improving drilling efficiency and extending the lifespan of drilling components by providing real-time wear monitoring and predictive maintenance.
Implementation Method 1
a percussion device, such as a hammer device, repeatedly strikes the drill bit, directly, or via a drill string, to transfer percussive pulses to the drill bit and further into the rock
Implementation Method 2
determining a percussion frequency of the percussion device
Implementation Method 3
the percussion frequency may be determined from pressure variations occurring in hydraulic or pneumatic pressure signals
Data Source
AI summary
A method for estimating wear of a drill bit in percussive rock drilling. A percussion device is configured for generating shock waves in a drill bit for breaking rock. The method includes, during drilling determining a percussion frequency of the percussion device; and estimating wear of the drill bit based on the determined percussion frequency of the percussion device and a model representation of the wear of the drill bit as a function of percussion frequency, wherein the model representation is configured to output the estimated wear of the drill bit utilizing the determined percussion frequency as input signal.