Drill Floor Emergency Stop Control for Automatic Collision Avoidance
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Solution Overview
Problem
Existing automated drilling equipment lacks an independent, user-intervention-free system to prevent collisions between personnel and machines, relying on manual intervention through physical buttons or complex software integration, which is costly and inefficient.
Innovation Solution
A programmable logic controller (PLC) system with safety relays and bus couplers is used to detect potential collisions and automatically stop machines in motion without user intervention, integrating after-market hardware to actuate manufacturer-provided emergency stop capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual emergency-stop systems are used, then user control over safety stopping is maintained, but response time is delayed and user intervention is required
Solution Approach 1:
The system performs preliminary detection of potential collision conditions through sensors monitoring machine position and personnel location. When a potential collision is detected, the system prepares to activate the emergency stop function in advance, eliminating the need for manual intervention and reducing response time.
Solution Approach 2:
The emergency stop system operates autonomously by detecting collision risks and automatically activating the stop function without requiring user intervention. The controller monitors sensor inputs and self-activates the emergency stop when predetermined collision conditions are met, making the system self-sufficient in safety operations.
2Adaptability or versatility
If complex software programming is integrated into manufacturer equipment, then customized safety protocols can be implemented, but system complexity and integration cost increase
Solution Approach 1:
The safety system is segmented into independent functional modules: sensor units for detection, a controller for logic processing, and emergency stop actuators for execution. This modular architecture allows customized safety protocols to be implemented through configuration rather than complex software integration, reducing overall system complexity while maintaining adaptability.
Solution Approach 2:
The controller acts as an intermediary between the manufacturer's equipment control system and the safety protocol requirements. It receives inputs from sensors and personnel locations, processes safety logic independently, and activates emergency stops without requiring deep integration into the manufacturer's proprietary software architecture, thereby simplifying integration while maintaining customization capability.
Data Source
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AI summary
Disclosed herein is a computer-implemented collision avoidance method performed on a drill rig floor, the method comprising: receiving a signal indicative of a potential collision between a machine in motion and personnel, the signal indicative of the potential collision being based on (1) image analytics conducted on an image captured by an optical camera disposed to capture images, and/or (2) a positional sensor configured to identify personnel within a predefined or virtual zone associated with the machine; and based on the signal indicative of the potential collision, automatically sending, without user intervention, a signal to the machine such that the machine is stopped or alters course; wherein the machine is stopped or alters course through control by the machine's software.