Kelly Rod Position Detection in Soil Drilling Machines
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Solution Overview
Problem
The existing soil drilling machines using mechanical locking kelly rods face challenges in accurately detecting the correct interlocking positions of kelly rods, relying heavily on operator experience, which leads to inefficiencies, wear, and reduced productivity due to misalignment and manual torque application.
Innovation Solution
A system equipped with sensors and a control unit to detect the position of kelly rods and provide precise indications to the operator for correct alignment, using sensors like laser distance measurers and proximity sensors to calculate and signal the mechanical locking positions, thereby simplifying the operation and increasing productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If mechanical locking kelly rods are used to transmit thrust, then the applicable thrust is improved, but the difficulty of detecting and measuring the locking position worsens
Solution Approach 1:
The patent implements a detection system with sensors (magnetic, optical, or mechanical) that provide real-time feedback on the relative positions of kelly rods. The control unit processes sensor signals to determine when locking features are properly aligned, giving the operator feedback on whether the locking position has been achieved. This resolves the detection difficulty by providing measurable position information without changing the mechanical locking mechanism itself.
Solution Approach 2:
The patent replaces manual operator judgment and experience-based detection with an automated sensor-based detection system. Magnetic sensors detect the position of ferromagnetic locking features, while optical sensors can detect visual markers. This substitution eliminates the need for operator experience in detecting locking positions and provides objective, measurable position data.
2Device complexity
If manual torque application is used to achieve alignment, then the device complexity is reduced, but the productivity decreases
Solution Approach 1:
The detection system allows the operator to perform preliminary alignment actions based on real-time position information from sensors. The system identifies when locking features are approaching proper alignment, allowing the operator to apply torque at the optimal moment. This preliminary detection and guidance reduces the time and number of attempts needed to achieve proper locking, thereby increasing productivity without adding complex automated alignment mechanisms.
3Ease of operation
If operator experience is relied upon for alignment detection, then the ease of operation is maintained, but the measurement precision worsens
Solution Approach 1:
The system maintains ease of operation by providing clear feedback signals (visual, auditory, or haptic) that guide the operator through the alignment process. The control unit processes sensor data and presents simplified information to the operator, such as LED indicators or display messages, rather than requiring the operator to interpret raw sensor data. This feedback mechanism enables precise position detection while keeping the operation simple and intuitive.
Solution Approach 2:
The patent substitutes subjective operator judgment with objective sensor-based measurement. Magnetic sensors provide precise detection of ferromagnetic locking features' positions, and optical sensors can detect visual markers with high accuracy. This substitution eliminates the variability and imprecision inherent in human perception while maintaining ease of operation through automated signal processing and clear output indicators.
4Ease of operation
If repeated alignment attempts are made, then the ease of operation is preserved, but the loss of time increases
Solution Approach 1:
The detection system performs preliminary assessment of the locking position before the operator commits to a drilling action. By providing real-time position information, the system allows the operator to make informed decisions about whether alignment is sufficient, reducing the need for repeated attempts. The control unit can predict upcoming alignment events based on sensor data trends, allowing the operator to prepare and act at the optimal moment, thereby minimizing downtime.
Solution Approach 2:
The system provides continuous feedback on locking position, enabling the operator to monitor alignment progress in real-time. This feedback loop allows the operator to make small adjustments based on position information rather than attempting full alignment cycles repeatedly. The control unit can provide predictive information about upcoming alignment events, allowing the operator to time their actions optimally and reduce the number of attempts needed, thereby reducing downtime while preserving operational simplicity.
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 system enhances operator precision, reduces wear on kelly rods and machinery, and increases drilling efficiency by providing real-time feedback on the correct alignment of kelly rods, minimizing downtimes and improving overall productivity.
Implementation Method 1
a first sensor (35) is configured to detect a first information representing the position assumed by rotary (10) along mast (5)
Implementation Method 2
a second sensor (33) is configured to detect a second information representing the fact that drill string (20) is at least partly supported by rotary (10)
Data Source
AI summary
A system and method detect at least one mechanical locking position of a drill string in a soil drilling machine. According the system and method, there are: a sensor apparatus which is configured to detect first data indicating the position assumed by the top of the drill string and second data indicating the position assumed by the bottom of the drill string. A control unit calculates the estimated length of the drill string based on the data and to compare the estimated length with a reference length value. A pair of kelly rods is in a mechanical locking position; and a signaling apparatus is configured to signal when the estimated length corresponds to a reference length value.