Drill String Rotation Sensor Diagnostic System
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Solution Overview
Problem
Current systems for monitoring the rotational alignment of drill strings in blasthole drilling machines lack effective diagnostic verification, leading to potential malfunctions and inaccuracies in pipe segment alignment during extension or removal processes.
Innovation Solution
A drill string rotation angle sensor diagnostic system comprising a first and second rotation angle sensor assembly, an operator interface, and a control module that receives signals from both assemblies to determine if a valid state exists, indicating faults on the operator interface if alignment is incorrect.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If magnetic rotation sensors are used to monitor drill string rotational position, then the ability to determine drill head location and pipe segment alignment is improved, but the system lacks diagnostic verification capability leading to potential undetected malfunctions
Solution Approach 1:
The patent implements a feedback mechanism where the control module continuously receives signals from magnetic rotation sensors, compares actual rotational position readings against expected values, and generates diagnostic alerts when discrepancies indicate sensor malfunction. This closed-loop feedback system enables real-time verification of sensor reliability while maintaining precise measurement capability.
Solution Approach 2:
The control module acts as an intermediary between the magnetic rotation sensors and the drilling operation control system. It receives raw sensor signals, processes them to determine valid rotational positions, and provides both position data and diagnostic status to the operator interface, thereby mediating between measurement and reliability concerns.
2Reliability
If multiple rotation angle sensor assemblies are installed to provide diagnostic verification, then the reliability of sensor malfunction detection is improved, but the device complexity increases
Solution Approach 1:
The patent merges the functions of multiple sensor assemblies and the diagnostic verification system into a single integrated control module. This module receives signals from both sensors, performs comparative analysis, and generates unified diagnostic output, thereby reducing overall system complexity while maintaining the reliability benefits of redundant sensing.
Solution Approach 2:
The control module is designed with multi-functionality, serving both to determine drill string rotational position for alignment control and to provide diagnostic verification of sensor functionality. This universal approach allows a single component to address multiple system needs without proportionally increasing complexity.
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 ensures accurate and quick diagnosis of sensor malfunctions, maintaining precise rotational alignment of drill strings, thereby enhancing operational efficiency and reliability in drilling operations.
Implementation Method 1
The prior art has failed to adequately address this issue. Many drilling machines, such as that disclosed by U.S. Publication No. 2014/0338975 to Hoult, utilize magnetic rotation sensors.
Data Source
AI summary
A drill string rotation angle sensor diagnostic system includes a first rotation angle sensor assembly, a second rotation angle sensor assembly, an operator interface; and a control module. The control module is configured to receive a first signal from the first rotation angle sensor assembly, receive a second signal from the second rotation angle sensor assembly, determine if a valid state exists based on the first signal and the second signal, and indicate a fault on the operator interface if a valid state does not exist.