Virtual Brake Control for Spindle Angular Position Holding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Horizontal directional drilling systems face challenges in maintaining the angular position of the spindle assembly during drilling operations, particularly in advancing the drill string without rotation and preventing drift of the carriage, which is essential for steering and maintaining precise bore path alignment.
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, allowing for precise control and positioning without physical brakes, and includes a rotational sensor to determine the clock position and send signals to the controller for motor actuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a physical brake is used to maintain the angular position of the spindle assembly, then the spindle position can be held, but mechanical wear occurs and the system complexity increases
Solution Approach 1:
The patent replaces the mechanical brake system with a virtual brake implemented through software control. The controller monitors the spindle assembly's clock position via a sensor and actuates the motor to maintain the desired orientation without physical contact, thereby eliminating mechanical wear while preserving position-holding functionality.
Solution Approach 2:
The patent creates a virtual copy of the brake function through software logic rather than physical hardware. The virtual brake condition in the controller replicates the position-holding effect of a physical brake by continuously comparing the actual clock position with the desired orientation and making corrective motor actuations as needed.
2Manufacturing precision
If a physical brake is used to prevent carriage drift, then positioning accuracy is improved, but mechanical components experience wear and require maintenance
Solution Approach 1:
The patent eliminates mechanical wear by substituting the physical brake with a virtual brake implemented through software control. The controller continuously monitors the spindle assembly's clock position and actuates the motor to maintain the desired orientation, achieving precise bore path alignment without mechanical contact or associated wear.
Solution Approach 2:
The virtual brake system is self-regulating, using feedback from the clock position sensor to automatically adjust motor actuation and maintain precise positioning. This eliminates the need for mechanical brakes and their associated maintenance requirements while continuously ensuring accurate bore path alignment.
3Measurement precision
If continuous motor actuation is used to maintain spindle orientation, then positioning precision is improved, but energy consumption increases
Solution Approach 1:
The virtual brake system operates by periodically monitoring the clock position and making corrective motor actuations only when deviations from the desired orientation are detected. This intermittent operation, triggered by position errors rather than continuous operation, maintains high positioning precision while significantly reducing energy consumption compared to continuous motor actuation.
Solution Approach 2:
The system uses feedback from the clock position sensor to determine when motor actuation is necessary. The controller compares the actual position with the desired orientation and only actuates the motor when a deviation is detected, creating an energy-efficient closed-loop control system that maintains precision without continuous energy input.
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.