Drilling Machine Power Control System
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Solution Overview
Problem
Horizontal directional drilling machines face engine overload issues due to combined power demands from multiple hydraulic pumps, leading to potential engine stalling and performance degradation.
Innovation Solution
A control system and method that monitors hydraulic fluid pressure and flow rates from rotation, thrust, and mud pumps, calculates total power draw, and adjusts power distribution to prevent engine overload by moderating the mechanical energy draw from each pump based on thresholds, ensuring the engine operates within its capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple hydraulic pumps (rotation, thrust, and mud pumps) operate simultaneously to perform drilling functions, then the drilling machine can execute complex boring operations, but the engine may become overloaded when combined power demand exceeds available capacity
Solution Approach 1:
The system dynamically adjusts pump power draw based on real-time engine load conditions. The controller continuously monitors engine parameters and modulates hydraulic pump operation to match available engine capacity, enabling the system to adapt between full-power operations and power-constrained modes without stalling
Solution Approach 2:
The system changes operational parameters of hydraulic pumps (flow rate, pressure) based on engine load conditions. When engine capacity is sufficient, pumps operate at full demand; when capacity is exceeded, the controller reduces pump parameters to prevent overload while maintaining essential drilling functions
2Productivity
If the engine operates at maximum capacity to meet peak power demands, then drilling operations can proceed at full speed, but the engine may stall when power demand temporarily exceeds capacity
Solution Approach 1:
The controller proactively monitors engine load and anticipates overload conditions before they cause stalling. By detecting approaching power capacity limits, the system pre-adjusts pump power draw to prevent engine stall, maintaining continuous operation without interruption
Solution Approach 2:
The system implements closed-loop feedback by continuously monitoring engine parameters (RPM, load, temperature) and adjusting hydraulic pump operation in response. This real-time feedback mechanism prevents engine stall by correcting power imbalance before it becomes critical
3Ease of operation
If manual control is used to manage power distribution among pumps, then operator flexibility is maintained, but uncoordinated energy distribution occurs leading to inefficient power utilization
Solution Approach 1:
The controller acts as an intermediary between the operator and hydraulic pumps. It receives operator commands and automatically coordinates power distribution among pumps based on engine capacity and operational priorities, eliminating manual coordination issues while preserving operator intent and flexibility
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
Prevents engine overload by dynamically managing power distribution among pumps, maintaining stable operation and preventing unpredictable energy diminishment, thus enhancing the reliability and efficiency of horizontal directional drilling processes.
Implementation Method 1
a rotation pump that draws upon the mechanical energy output by the engine to operate a rotation motor that rotates a drill string by pressurization of a rotation hydraulic fluid circuit
Implementation Method 2
a thrust pump that draws upon the mechanical energy output by the engine to operate a thrust motor that longitudinally moves the drill string by pressurization of a thrust hydraulic fluid circuit
Implementation Method 3
a mud pump that draws upon the mechanical energy output by the engine to operate a mud motor that delivers fluid through the drill string by pressurization of a mud hydraulic fluid circuit
Data Source
AI summary
The present disclosure is directed to methods and apparatuses for controlling pump power draw from an engine in horizontal directional drilling. Various embodiments of the invention are directed to a horizontal directional drilling machine that comprises an engine that outputs mechanical energy, a rotation pump that draws upon the mechanical energy output by the engine to operate a rotation motor that rotates a drill string, a thrust pump that draws upon the mechanical energy output by the engine to operate a thrust motor that longitudinally moves the drill string, a mud pump that draws upon the mechanical energy output by the engine to operate a mud motor that delivers fluid through the drill string, and control circuitry comprising a controller and memory, the processor configured to execute program instructions stored on the memory, processor execution of the stored program instructions causing the control circuitry to calculate a rotation pump power draw from the engine, calculate a thrust pump power draw from the engine, calculate a mud pump power draw from the engine, calculate a total power draw based on the rotation pump power draw, the thrust pump power draw and the mud pump power draw, compare the total power draw to a threshold, and decrease mechanical energy draw of each of the rotation pump, the thrust pump, and the mud pump from the engine based on the total power draw exceeding the threshold.