DTH Hammer Pressurized Fluid Flow System Design
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Solution Overview
Problem
Existing pressurized fluid flow systems for DTH hammers suffer from reduced power and energy conversion efficiency due to design complexities, increased manufacturing costs, and wear issues, leading to lower penetration rates and reliability.
Innovation Solution
A pressurized fluid flow system with equal diameter outer sliding surfaces and solid piston design, featuring a cylinder with parallel supply and discharge channels defined by recesses, eliminating the need for holes and channels, which enhances thrust areas and simplifies manufacturing, while integrating an assisted flushing system for improved deep drilling capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional pressurized fluid flow systems are used with complex internal channels and holes in the piston, then fluid control is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The invention extracts the fluid control function from the piston by eliminating all internal channels and holes from the piston structure. Instead, fluid supply and discharge are controlled through external means - specifically through the interaction between the piston's sliding surfaces and the cylinder wall, which contains the fluid passages. This separation simplifies piston manufacturing while maintaining fluid control capability.
Solution Approach 2:
The cylinder wall serves multiple functions: it contains the fluid passages, controls fluid supply to and discharge from the chambers, and provides the sealing surface for the piston. By making the cylinder wall multi-functional, the invention eliminates the need for complex internal piston structure while achieving the same fluid control objectives.
2Force
If piston channels and holes are used for fluid flow control, then fluid distribution is achieved, but thrust area is reduced
Solution Approach 1:
The invention removes all channels and holes from the piston structure, thereby eliminating the thrust area reduction caused by these openings. The fluid control function is extracted to the cylinder wall, allowing the piston to maintain its full cross-sectional area as thrust-bearing surface, which directly increases the effective thrust area and improves penetration rate.
3Manufacturing precision
If complex piston designs with multiple channels are used, then fluid control precision is improved, but manufacturing cost increases
Solution Approach 1:
The invention extracts the fluid control precision requirements from the piston manufacturing process and relocates them to the cylinder manufacturing process. The piston becomes a simple solid component requiring only external cylindrical surfaces, while the cylinder incorporates all fluid passages and control features. This redistribution maintains fluid control precision while dramatically simplifying piston manufacturing and reducing overall cost.
4Volume of moving object
If assisted flushing system is added, then deep drilling capacity is improved, but system complexity increases
Solution Approach 1:
The invention merges the assisted flushing function with the existing fluid supply system by utilizing the same cylinder and piston structure. The flushing channels are integrated into the cylinder wall, and the piston's sliding action simultaneously controls both the main fluid supply and the flushing flow. This integration achieves deep drilling capacity improvement without proportionally increasing system 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
This configuration increases the front and rear thrust areas of the piston, enhancing energy conversion efficiency, reducing manufacturing complexity, and improving the hammer's reliability and deep drilling capacity without compromising penetration rate.
Implementation Method 1
the piston effects a reciprocating movement due to the change in pressure of the pressurized fluid contained in two main chambers, a front chamber and a rear chamber
Implementation Method 2
a pressurized fluid as the means for transmitting power
Implementation Method 3
the drill bit being in contact with the front chamber and adapted to receive the impact of the front end of the piston
Data Source
AI summary
A pressurized fluid flow system for a normal circulation down-the-hole hammer comprises a cylinder coaxially disposed in between an outer casing and a piston which reciprocates due to changes in pressure of pressurized fluid contained inside a front chamber and rear chamber located at opposites sides of the piston, the supply/discharge of fluid to/from these chambers being conducted through sets of supply and discharge channels defined by recesses on the outer surface of the cylinder and arranged in a parallel fashion, the fluid flow into and out of the front and rear chambers being controlled solely by the relative overlap of the piston and the cylinder and channeling of the fluid flow below the inner surface of the cylinder and above the outer surface of the piston. A hammer having this system comprises a drill bit with one or more flushing passages.