Virtual Brake Spindle Control for Non-Rotating Drill Steering
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Solution Overview
Problem
Horizontal directional drilling systems face challenges in maintaining the angular position of the spindle assembly during drilling operations, particularly when advancing the drill string without rotation, which is necessary for steering the drill bit.
Innovation Solution
A system comprising a spindle assembly, motor, sensor, and controller that utilizes a virtual brake condition to maintain the desired angular position of the spindle assembly by actuating the motor based on signals from the sensor, allowing for precise control and steering without physical rotation brakes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a physical rotation brake is used to maintain spindle assembly angular position, then the angular position control is achieved, but the device complexity and mechanical wear increase
Solution Approach 1:
The patent replaces the mechanical rotation brake system with an electrical control system. The controller receives clock position signals from the sensor and actuates the motor to rotate the spindle assembly to the desired orientation, eliminating the need for physical brake components while achieving the same angular position control function.
Solution Approach 2:
The invention extracts and removes the physical brake component from the system. By using the motor alone to both rotate and hold the spindle assembly at desired positions, the patent eliminates the brake subsystem, reducing device complexity and mechanical wear points while maintaining angular position control capability.
2Ease of operation
If a physical rotation brake is used to prevent spindle rotation during steering, then steering control is achieved, but mechanical wear and maintenance requirements increase
Solution Approach 1:
The patent substitutes the mechanical brake system with an electrical control mechanism. The controller actuates the motor to maintain the spindle assembly at the desired clock position during steering operations, eliminating mechanical wear and maintenance requirements while preserving steering control functionality.
Solution Approach 2:
The motor serves dual functions: rotating the spindle assembly during drilling and holding it at the desired position during steering. This self-service approach eliminates the need for a separate brake system, reducing maintenance requirements while maintaining ease of operation for steering control.
3Productivity
If the spindle assembly rotates during advancement, then drilling efficiency improves, but the drill bit cannot be steered accurately
Solution Approach 1:
The patent implements dynamic control of the spindle assembly rotation. The controller receives real-time clock position signals from the sensor and continuously actuates the motor to maintain the desired orientation during advancement, enabling the system to switch between rotation for drilling and position holding for steering as needed.
Solution Approach 2:
The system uses feedback from the sensor that determines the clock position of the spindle assembly. The controller compares the actual position with the desired orientation and actuates the motor accordingly, enabling precise drill bit steering by preventing unwanted rotation during advancement while maintaining drilling efficiency.
Data Source
AI summary
A brake system for maintaining an angular position of a spindle assembly. A pump-powered motor drives rotation of a spindle on the machine. When no rotation is desired, the spindle will slow, then stop at a desired angular orientation. A rotational sensor will determine the clock position, and a controller compares that to a desired angular orientation. If an error tolerance is exceeded, the motor will rotate the spindle back to the desired orientation.