Drilling Machine Electric Braking and Energy Recovery
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Solution Overview
Problem
Conventional drilling machines face inefficiencies in controlling the lowering speed of the drilling string due to high fuel consumption and instability, leading to destructive impacts and damage to the hole walls, which limits productivity and increases machine downtimes.
Innovation Solution
A drilling machine equipped with a first electric motor and a bidirectional electric power converter system that applies controlled braking to the drilling string, utilizing electric energy storage to recover gravitational potential energy and reduce fuel consumption, and a real-time distributed control system for precise speed control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If hydraulic motor with overcenter valve is used to control lowering speed, then lowering speed control is achieved, but fuel consumption increases and control stability deteriorates
Solution Approach 1:
The patent replaces the hydraulic motor and overcenter valve system with an electric motor system. The electric motor is controlled by a power converter that receives signals from a control unit, eliminating the need for hydraulic fluid and mechanical overcenter valves. This substitution directly reduces fuel consumption while providing more stable and precise control of the lowering speed through electronic regulation.
Solution Approach 2:
The patent changes the control parameter from hydraulic pressure (in the overcenter valve system) to electrical parameters (voltage, current, frequency) that can be precisely regulated by power converters and control units. This parameter change enables more accurate and stable speed control while reducing energy loss and fuel consumption.
2Speed
If hydraulic motor with overcenter valve is used to control lowering speed, then lowering speed control is achieved, but control stability deteriorates causing destructive impacts
Solution Approach 1:
The patent implements a feedback control system where a control unit receives information about the actual lowering speed and compares it with the desired speed. The power converter adjusts the electric motor's operation based on this feedback signal, ensuring stable and precise control. This closed-loop feedback mechanism eliminates the instability and oscillations inherent in hydraulic overcenter valve systems.
Solution Approach 2:
The replacement of the mechanical-hydraulic overcenter valve system with an electric motor and electronic control system eliminates the inherent instability of hydraulic systems. Electric motors provide smoother, more responsive control without the pressure fluctuations and mechanical delays characteristic of hydraulic systems, thereby improving control stability.
3Power
If hydraulic motor is used to move moving device, then movement is achieved, but energy efficiency deteriorates due to pressure drops
Solution Approach 1:
The patent substitutes the hydraulic power transmission system with an electric power transmission system. Electric motors convert electrical energy to mechanical energy with higher efficiency, avoiding the significant pressure drops and energy losses that occur in hydraulic systems during power transmission. This substitution directly improves energy efficiency while maintaining the required movement power.
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 solution significantly reduces fuel consumption, enhances control over the lowering speed, and increases productivity by efficiently managing energy and minimizing damage to the drilling environment.
Implementation Method 1
a first electric motor (22) configured to, in a second operating mode, apply a braking mechanical power on the moving device (21) so as to brake, by means of the flexible tensile element (17), the lowering of the drilling string (12) to reach and maintain a desired controlled lowering speed Vd
Implementation Method 2
a first bidirectional electric power converter device (23) configured to convert an electrical power produced Pmot by the first electric motor (22) into a converted electrical power Pregen
Implementation Method 3
the entire weight of the drilling string (12) acts on the flexible tensile element (17)
Data Source
AI summary
Drilling machine (1) comprising: a supporting structure (3); a drilling string (12); a drilling head (11); a flexible tensile element (17); a moving device (21), mechanically connected to the supporting structure (3) and mechanically associated with the flexible tensile element (17) to hold and move the drilling string (12); at least one first electric motor (22) configured to, in a first operating mode, actuate the moving device (21) so as to lift the drilling string (12), and configured to, in a second operating mode, apply a braking mechanical power on the moving device (21) so as to brake in a controlled manner the lowering of the drilling string (12) to reach and maintain a desired controlled lowering speed (Vd), the at least one first electric motor (22) being also configured to produce an electric power (Pmot); a first bidirectional electric power converter device (23) configured to convert the electric power produced (Pmot) into converted electric power (Pregen); an electric energy transmission network (24) arranged to transmit the converted electric power (Pregen); an electric power use unit (25) arranged to receive said converted electric power (Pregen), the electric power use unit (25) comprising at least one first electric energy storage system (40) and a prime motor (50) configured to generate electric power; a control group (7) configured to send at least one first electric control signal representative of the value of the desired controlled lowering speed (Vd); a control system (60) configured to generate second electric control signals based on such a first electric control signal and send the second electric control signals to the first bidirectional electric power converter device (23) which is configured to control the operation of the first electric motor (22) based on said second electric control signals received from the control system (60), so that the drilling string (12) carries out the lowering at the desired controlled lowering speed (Vd), the control system (60) being of the distributed and real-time type.