Dual-Winch Excavator Control for Synchronized Drill String Extraction
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Solution Overview
Problem
Existing drilling machines using continuous flight auger (CFA) technology face challenges in synchronizing multiple winches for efficient extraction of heavy and long drill strings, leading to potential mechanical damage and inefficiencies due to the use of similar hydraulic transmission types for both main and pull-down winches.
Innovation Solution
A system where the main winch is driven by a closed-circuit hydraulic transmission or electric circuit, while the secondary winch is driven by an open-circuit hydraulic transmission, allowing for synchronized control during combined pulling operations, optimizing energy consumption and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If both main winch and pull-down winch are driven by the same type of hydraulic transmission (open circuit), then the system structure is simple and easy to manufacture, but synchronization control during combined pulling operations is difficult and energy consumption is high
Solution Approach 1:
The patent divides the hydraulic transmission system into two separate segments: the main winch is driven by a closed-circuit hydraulic transmission while the pull-down winch is driven by an open-circuit hydraulic transmission. This segmentation allows each winch to operate with optimized control characteristics, enabling precise synchronization during combined pulling operations while maintaining structural simplicity for manufacturing
Solution Approach 2:
The patent implements dynamic control of the closed-circuit hydraulic transmission for the main winch, allowing real-time adjustment of hydraulic flow and pressure to match the pulling requirements. This dynamic adaptation enables the main winch to synchronize efficiently with the pull-down winch during combined operations, improving overall productivity while reducing energy consumption
2Use of energy by moving object
If the main winch uses closed-circuit hydraulic transmission for efficient control, then energy consumption is reduced and control precision is improved, but the system complexity increases
Solution Approach 1:
The patent applies different hydraulic transmission qualities to different parts of the system: the main winch, which requires precise control and low energy consumption, is equipped with a closed-circuit hydraulic transmission, while the pull-down winch, which has different operational requirements, uses an open-circuit system. This localized optimization achieves energy efficiency where needed without unnecessarily complicating the entire system
Solution Approach 2:
The patent designs the hydraulic transmission system with universal control capabilities that can handle both closed-circuit and open-circuit configurations through a unified control unit. This multi-functionality allows the system to manage the complexity of the closed-circuit transmission for the main winch while maintaining the simplicity of the open-circuit transmission for the pull-down winch, reducing overall system complexity
3Force
If multiple winches are used for extracting heavy drill strings, then extraction force is sufficient, but mechanical stress and potential damage increase due to synchronization issues
Solution Approach 1:
The patent implements a feedback control system that continuously monitors the operational parameters of both the main winch and pull-down winch during combined pulling operations. The control unit receives feedback signals and automatically adjusts the hydraulic transmission parameters to maintain synchronized operation, preventing mechanical stress and potential damage while ensuring sufficient extraction force
Solution Approach 2:
The patent employs prior cushioning by pre-configuring the hydraulic transmission systems with pressure relief valves, flow control mechanisms, and synchronization control algorithms that prevent excessive mechanical stress before it occurs. These protective measures are built into the system design to cushion against potential damage during combined pulling operations
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 enhances the efficiency and control of winches, reducing energy consumption and preventing mechanical stress, ensuring stable and synchronized operation of the winches during extraction processes.
Implementation Method 1
a primary driving circuit, which is a closed hydraulic circuit (201) or an electric circuit, for driving main winch (109)
Implementation Method 2
an open hydraulic circuit (202) for driving secondary winch (111)
Data Source
AI summary
An excavating machine includes an actuation unit for moving the excavator, a main winch and secondary winch for lifting and lowering the actuation unit. A closed hydraulic circuit or an electric circuit drives the main winch. An open hydraulic circuit drives the secondary winch. A first pressure or current sensor measures fluid pressure or, electric current intensity in the hydraulic or electric driving circuit. A second pressure sensor measures fluid pressure in the open hydraulic circuit. A pressure regulator regulates fluid pressure in the open hydraulic circuit. A control unit executes a combined operating condition with the winches applying a force simultaneously and based on values sensed, controls the pressure regulator so the fluid pressure in the open hydraulic circuit, during the combined operating condition, has a target value that is a function of: the fluid pressure in the closed hydraulic circuit or the current in the electric circuit.