Flat Tape Winch for Accurate Drilling Depth Measurement
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Solution Overview
Problem
Current drilling operations face challenges in accurately measuring the rate of penetration (ROP) of drill bits, particularly in hard rock drilling, due to the inefficiencies of using round section cables which lead to tangling, wear, and inaccurate depth measurements, and the need for complex spooling guide mechanisms, as well as the manual and unreliable nature of existing ROP calculation methods.
Innovation Solution
A system utilizing a flat, spirally wound tape as a load-bearing member that deploys and retracts from a spool, equipped with sensors to measure ROP, which calculates and provides real-time data on drill bit advancement, allowing for automatic control of drilling parameters like weight on bit, torque, and RPM, and includes a wireless communication system for remote data processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If round section cable is used as load bearing member, then lifting and lowering loads can be achieved, but the cable does not readily overlay one winding onto another on the winch drum, requiring complex spooling guide mechanisms
Solution Approach 1:
The patent replaces the traditional round section cable with a flat tape as the load bearing member. This flat tape can be wound directly onto the drum in neat, non-overlapping layers without requiring complex spooling guide mechanisms. The flat geometry allows the tape to lay flat against previous windings, eliminating the tangling and overlapping problems inherent with round cables.
2Strength
If round section cable is used, then load bearing function is achieved, but the cable takes up a great deal of space on the drill rig
Solution Approach 1:
The flat tape design significantly reduces the space required on the drill rig compared to round section cable. The tape can be wound more compactly on the drum and requires less lateral space for spooling operations. The reduced cross-sectional area of the flat tape allows for more efficient use of available space on the drilling equipment.
3Device complexity
If manual methods are used to calculate rate of penetration, then simplicity is maintained, but accuracy and reliability of ROP measurement deteriorates
Solution Approach 1:
The patent replaces manual calculation methods with an automated sensor-based measurement system. Sensors directly measure the rate of penetration by detecting changes in drum rotation speed and tape payout rate, providing real-time accurate ROP data without requiring manual measurements or calculations. This automated system eliminates human error and provides continuous monitoring.
Solution Approach 2:
The measurement system incorporates feedback mechanisms where sensors continuously monitor drum rotation and tape payout, automatically adjusting and recording ROP measurements. This feedback loop ensures accurate real-time measurement and recording of drilling progress, eliminating the inaccuracies associated with manual timing and measurement methods.
4Reliability
If spooling guide mechanism is added to manage cable windings, then cable tangling is prevented, but cost, complexity and weight of the winch increase
Solution Approach 1:
By using flat tape instead of round cable, the patent eliminates the need for complex spooling guide mechanisms that add significant weight to the winch. The flat tape's geometry allows it to be wound directly onto the drum without guides, automatically maintaining proper layering and preventing tangling without the additional mechanical components required for cable management.
Data Source
AI summary
Winch (304) has a load bearing tape (305) to advance into a borehole (307). Hole depth can be determined by subtracting a sensed height (310) above ground surface (311) from total depth (312) measured. Can include a height above ground sensor (314) and a tape distance measurer (316). Depth of water or watery mud or muddy water (320) can be sensed, such as by a pressure sensor (326) on a weight or in a sensor device at or near the tape leading end. A heater (309) can warm the tape. A cover or housing (313) can be provided for the winch or spool. The tape can include wires or fibre optics (336) embedded in or applied to a surface of the tape (305) and/or apertures or embedded or surface applied markers/indicators (338) along a length thereof e.g. for reading by an optical or magnetic sensor.