Drill Head Positioning via Sheave Sensor Calibration
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Solution Overview
Problem
Current systems for determining the position of a drill head in drilling machines, such as blasthole drilling machines, often provide inaccurate information due to slippage or jumping of the cable on the pulley system, which can lead to inaccuracies in depth measurements and operational challenges.
Innovation Solution
A method and system that involves retrieving and calibrating the rotational position of a sheave using a sheave sensor, dynamically determining the drill head position based on the sheave's rotational position, and storing this information during shutdown events, while also using proximity sensors to validate and correct the position data, ensuring accurate positioning even after potential cable slippage or movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a cable pulley system is used to move the drill head up and down the mast, then the drill head can be positioned at various depths, but cable slippage or jumping occurs causing inaccurate position information
Solution Approach 1:
A sheave sensor is introduced as an intermediary device between the cable pulley system and the position determination system. The sensor detects the rotational position of the sheave, providing a reliable intermediate measurement that can be converted to drill head position without being directly affected by cable slippage. This intermediary approach allows the system to maintain accurate position information even when the cable experiences slippage or jumping.
Solution Approach 2:
The patent replaces direct mechanical position measurement methods with a sensor-based detection system. Instead of relying solely on mechanical cable tension or drill head location sensors that are vulnerable to slippage, the system uses a sheave sensor to detect rotational position, which can be reliably converted to depth information. This substitution of measurement methodology eliminates the accuracy problems associated with direct mechanical measurement in cable-driven systems.
2Reliability
If stored rotational position data is used to determine drill head position, then position information can be maintained during operation, but inaccuracies accumulate due to cable slippage
Solution Approach 1:
The system continuously monitors the rotational position of the sheave through the sheave sensor and uses this feedback to dynamically determine the drill head position. By continuously updating the position information based on real-time sensor data rather than relying on stored data that may have accumulated errors, the system maintains both continuity and accuracy of position information throughout the drilling operation.
Solution Approach 2:
The system performs preliminary calibration of the sheave sensor to establish an accurate baseline relationship between sheave rotation and drill head position before the drilling operation begins. This preliminary action ensures that the conversion from rotational position to depth information is accurate from the start, preventing error accumulation during subsequent operation.
3Productivity
If the cable pulley system is used for drill head movement, then drilling operations can be performed, but operational errors occur due to inaccurate position data
Solution Approach 1:
The sheave sensor serves as a reliable intermediary that provides accurate position information to the control system, enabling operational functions to proceed with confidence. By having a trustworthy source of position data, the system can reliably perform operations such as coupling and decoupling drill pipe at specific depths without the uncertainty introduced by cable slippage.
Solution Approach 2:
The patent replaces unreliable mechanical position indication with sensor-based detection that is not affected by cable slippage. This substitution ensures that operational functions dependent on position information (such as automated coupling/decoupling operations) can be performed reliably, maintaining both productivity and operational reliability simultaneously.
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
This approach enhances the accuracy of drill head positioning, reduces operational errors, and enables more precise control of drilling operations by accounting for cable slippage and movement, thereby improving the reliability of drilling machine functions.
Implementation Method 1
measuring the rotational position of the at least one sheave using a sheave sensor
Data Source
AI summary
Systems and methods for drill head position determination are disclosed. A method for determining a position of a drill head of a drilling machine may include: retrieving a stored rotational position of at least one sheave and a stored position of the drill head; measuring the rotational position of the at least one sheave using a sheave sensor; initially calibrating the rotational position of the at least one sheave before the drill head moves; dynamically determining the position of the drill head based on the rotational position of the at least one sheave while the drill head is moved; and storing the rotational position of the at least one sheave and the position of the drill head during a shutdown event of the drilling machine.