Drill Rig Control System for Borehole Defect Mitigation
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Solution Overview
Problem
Existing methods for drilling blastholes in mining and quarrying operations face challenges in achieving consistent quality due to factors like geologic structure, size, spacing, and post-drilling events such as cave-ins, which result in non-compliant blastholes and compromise the efficiency of the blasting process.
Innovation Solution
A system comprising a drill rig with an air injection system, water injection system, and a control system that monitors drill parameters and implements defect mitigation routines, such as air pressure protection, rotary stall protection, and end-of-hole spin-out routines, to ensure compliance with desired specifications and minimize post-drilling issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the number of blastholes is increased to cover larger areas, then the productivity increases, but the likelihood of non-compliant holes due to post-drilling events such as cave-ins increases
Solution Approach 1:
The system performs preliminary stabilization by applying grout or other stabilizing materials to the borehole wall during or immediately after drilling, before the borehole is fully completed or before post-drilling events can occur. This preventive action reduces the likelihood of cave-ins and maintains compliance throughout the blasting operation.
Solution Approach 2:
The system applies stabilizing materials such as grout to cushion and protect the borehole wall from collapse. This creates a protective barrier that prevents cave-ins and maintains the structural integrity of the borehole, ensuring compliance is maintained even when drilling large numbers of holes.
2Productivity
If drilling speed is increased to improve productivity, then the time per blasthole decreases, but the quality and compliance of blastholes deteriorates
Solution Approach 1:
The system continuously monitors drilling parameters such as torque, rotation speed, and depth during the drilling process. This real-time feedback allows the system to detect deviations from specifications and automatically adjust drilling parameters or trigger remedial actions to maintain blasthole quality and compliance even at high drilling speeds.
Solution Approach 2:
The system automatically detects and corrects drilling deviations through integrated sensors and control mechanisms. The drilling rig self-adjusts parameters or triggers stabilization routines without external intervention, maintaining quality standards while operating at high speeds.
3Manufacturing precision
If extensive monitoring and defect mitigation routines are implemented to improve blasthole quality, then the compliance rate increases, but the device complexity and operational time increase
Solution Approach 1:
The system automatically monitors drilling parameters and triggers defect mitigation routines without requiring external intervention. The integrated control system self-manages the entire process from monitoring to correction, reducing the need for additional complex equipment while maintaining high compliance rates.
Solution Approach 2:
The system combines multiple functions—monitoring, detection, and defect mitigation—into a single integrated control system. By merging these functions, the system achieves high compliance rates without proportionally increasing device complexity, as the same hardware performs multiple roles.
4Reliability
If defect mitigation routines are applied to all blastholes to ensure compliance, then the quality consistency improves, but the time and resources required increase
Solution Approach 1:
The system applies defect mitigation routines selectively based on real-time monitoring of drilling parameters. When parameters indicate potential defects, the system triggers appropriate mitigation routines. This partial application approach maintains quality consistency by addressing only the holes that need intervention, rather than applying routines to all holes uniformly.
Solution Approach 2:
The system performs preliminary stabilization during or immediately after drilling based on monitored parameters. By applying stabilization proactively when needed rather than reactively after problems occur, the system maintains quality consistency while minimizing the time and resources required for remediation.
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
The system significantly increases both initial and long-term borehole quality by selectively implementing defect mitigation routines, reducing cave-ins and ensuring that a higher percentage of blastholes conform to specifications, thereby enhancing the efficiency and reliability of the blasting process.
Implementation Method 1
The drill rig includes an air injection system
Implementation Method 2
The drill rig includes a water injection system
Data Source
AI summary
A system for drilling a borehole according to the present invention includes a drill rig and a control system. The drill rig includes a drill, an air injection system and a water injection system. The control system, which is operatively associated with the drill rig, receives information from the drill rig that relates to at least one drill parameter. The control system processes information relating to the drill parameter, determines whether the drill parameter is within a predetermined specification for the monitored drill parameter, chooses a hole defect mitigation routine based on the monitored drill parameter when the monitored drill parameter is outside the predetermined specification, and controls the drill rig to implement the chosen hole defect mitigation routine.