AUTOMATED MAST CONTROL FOR DRILLING

- Caterpillar Inc.

A control system and method for automating the positioning of a mast in a drilling machine is disclosed herein. The machine operator can enter a desired mast angle into the control system and the control system can position/reposition the mast until the mast is within an acceptable range of the desired mast angle such that the mast can be successfully locked at the desired mast angle. An automated calibration process can be used to calibrate the mast prior to positioning the mast at the desired mast angle and compensate for any difference between the measured mast angle and a default mast angle.

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Description
TECHNICAL FIELD

This disclosure relates to rotary/blast hole drilling machines. More particularly, this disclosure relates to automated mast calibration and control for adjusting the position of the mast of the drilling machine.

BACKGROUND

Rotary/blast hole drilling machines are utilized in surface mining operations where the mast drilling machine drills bores in rocks and other materials in desired locations. The drilling machine commonly includes a mast that is stationed on a mainframe of the machine and hydraulically connected thereto. In operation, a lift system moves the mast from the transport position (stowed position) to an operation or drilling position. When in a drilling position the vehicle functions as a counterweight or base for the mast to prevent the mast from tipping over, causing significant damage and danger. Once the mast is in the desired drilling position, one or more locking mechanisms can be used to lock the mast in position.

The lift system rotates the mast about a pivot axis from the stowed position to the drilling position. When in the drilling position, the mast is generally perpendicular to the ground (assuming a level ground surface) and perpendicular to the stowed position. As such, the drilling position can also be referred to as a vertical position. Additionally, drilling can be performed with the mast at an angle between the vertical and stowed positions.

A machine operator of the drilling machine can use one or more joysticks or other components for raising and lowering the mast, as well as locking and unlocking the mast. In an example, a locking pin can be used to lock the mast at various angles by engaging with one of a plurality of holes corresponding to a desired mast angle. The location of the holes can be inexact, due at least in part to manufacturing tolerances, and the operator may have to make multiple adjustments before the mast is locked via successful engagement of the locking pin in the selected hole.

SUMMARY OF THE INVENTION

In an example, a method is provided for automating positioning of a mast in a drilling machine at various angles. The method includes entering a desired mast angle into an input module of the machine that is connected to an electronic control module (ECM), moving the mast using the ECM, measuring an angle of the mast using a measuring device in communication with the ECM, and determining with the ECM whether the measured mast angle is within an acceptable range of the desired mast angle. If the measured mast angle is within the acceptable range, the method includes attempting to lock the mast at the measured mast angle using the ECM and determining with the ECM whether the mast is successfully locked. If the measured mast angle is not within the acceptable range, the method includes repeating the step above of moving the mast using the ECM until the measured mast angle is within the acceptable range. In some instances, the method can further comprise calibrating the mast, prior to performing the steps above, to compensate for any discrepancies between the measured mast angle and a default mast angle at a particular mast position.

In another example, a method is provided for automating mast position of a mast in a drilling machine. The method includes entering a desired mast angle into an electronic control panel of the drilling machine, the electronic control panel in communication with an electronic control module (ECM) of the machine. The desired mast angle is selected from a plurality of default mast angles that correspond to an angle of the mast relative to a vertical position and are at equally spaced increments to one another. The method includes unlocking the mast with the ECM (unless the mast is in a stowed, unlocked position), engaging a raise mast solenoid or a lower mast solenoid with the ECM to activate raising or lowering of the mast, measuring an angle of the mast at a particular mast position and relaying the measured mast angle to the ECM, and determining with the ECM whether the measured mast angle is within an acceptable range of the desired mast angle. If the measured mast angle is within acceptable range, the method includes activating a lock solenoid with the ECM to attempt to lock the mast at the particular mast position. If the measured mast angle is outside of acceptable range, the method includes repeating the steps of engaging the raise or lower mast solenoid and measuring the angle, until the measured mast angle is within acceptable range. The method includes determining whether the mast is locked and relaying to the ECM. If locked, the method includes displaying an output on the electronic control panel confirming successful lock. If not locked, the method includes repeating the above steps until locked or until a system timeout.

In yet another example, a control system is provided for positioning of a mast in a drilling machine. The control system includes an electronic control module (ECM) configured to receive, store and execute instructions for operation of the mast, a control panel coupled to the ECM and configured to receive user inputs from a user of the machine and display outputs from the ECM, and a first electrohydraulic circuit configured to raise or lower the mast in response to instructions from the ECM. The control system includes a mast angle sensor in communication with the ECM and configured to measure an angle of the mast and relay the measured mast angle to the ECM. The control system includes a second electrohydraulic circuit configured to lock or unlock the mast in response to instructions from the ECM, and a locking sensor in communication with the ECM and configured to detect whether the mast is in a locked position and relay to the ECM. The control panel is configured to receive a desired mast angle from the user, the desired mast angle is communicated to the ECM, and the ECM controls operation of the first and second hydraulic circuits to position and lock the mast at the desired mast angle.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an example drilling machine having a mast in a vertical position.

FIG. 2 is a side view of a portion of the drilling machine in FIG. 1 with the mast in a stowed position.

FIG. 3 is side view of a portion of the mast in the vertical position and a deck on the drilling machine.

FIG. 4 is a perspective view of a portion of the mast assembly under the deck.

FIG. 5 is a perspective view of an opposing portion of the mast assembly under the deck.

FIG. 6 is a side view of a portion of the mast in the vertical position.

FIG. 7 is a schematic of a control system for positioning of the mast.

FIG. 8 is a flowchart of an example process for calibrating default mast angles for the mast.

FIG. 9 is a flowchart of an example process for automated positioning of the mast.

 DETAILED DESCRIPTION

The present application is directed to a control system and method for positioning the mast of a drilling machine at a particular angle selected from a plurality of predetermined mast angles. The control system can facilitate successful locking of the mast at the particular angle with less operator adjustments. The control system can facilitate calibration of the mast prior to positioning the mast at the particular angle. The calibration can be continuously updated while the machine is operating by supplying measured mast angle data to the control system each time that the mast is repositioned and locked at one of the predetermined mast angles.

FIG. 1 illustrates a drilling machine 10 that includes, among other things, a mast assembly 12 with a mast 14 that extends from a first end 16 to a second end 18. The mast 14 is shown in FIG. 1 in a vertical, operating position and can be moved to a transport or stowed position (see FIG. 2).

The mast assembly 12 can be coupled to a vehicle portion 20 of the drilling machine 10 that facilitates transport of the mast assembly 12. The mast 14 can include a support framework that supports an operational implement that can include, for example, a drill. The mast assembly 12 can include a mast pivot system configured to pivot the mast 14 from the stowed position to the vertical position and vice-versa.

The mast assembly 12 can include a support plate 24 (see FIG. 2) that can include a plurality of openings or holes 26 for receiving a pin to lock the mast 14 at predetermined angles. Each hole 26 can correlate to a pre-determined angle of the position of the mast 14. When the locking pin is engaged with one of the holes 26, undesired movement of the mast 14 can be prevented. The locking pin is described further below in reference to FIGS. 4 and 5.

Typically drilling can be performed with the mast 14 at the vertical position such that the mast 14 is generally perpendicular to a horizontal plane that is generally parallel with a level ground surface. During operation, circumstances exist in which the mast 14 can be orientated at an angle that is less than 90 degrees relative to the horizontal plane. The particular angle selected can depend, for example, on the type of material or surface that is being drilled.

For purposes herein, the angle of the mast 14 is described as the angle relative to the vertical position. For example, a mast angle of 5 degrees, as used herein, refers to an acute angle which is 5 degrees from the vertical position of the mast and 85 degrees from the horizontal plane. The mast angle is also described herein as corresponding to a position of the locking pin.

In the example shown in FIG. 3, the support plate 24 includes seven holes 26 that correspond to a pin locking the mast 14 at seven different angles. Each pin hole can be spaced at five degree increments (0, 5, 10, 15, 20, 25 and 30 degrees). In an example, a second plate can be located opposite to the support plate 24 shown in FIG. 2. The second support plate can include holes that match with the holes 26 on the plate 24, and a second locking pin can be used with the second support plate.

FIG. 3 shows a portion of a deck 28 of the drilling machine 10. When the mast 14 is moved from the stowed position in FIG. 2 to the vertical position, the support plate 24 can extend into an opening 30 in the deck 28 such that the support plate 24 resides under the deck 28 in the vertical position.

The mast assembly 12 can include first and second locking pins such that each locking pin engages with one of the two support plates. Specifically, the locking pins engage with the holes on the support plates to secure the mast 14 once the desired mast angle is reached. FIG. 4 shows a first locking pin 32 located under the deck 28 of the machine 10. FIG. 5 shows a second locking pin 34 located under the deck 28 on an opposing side of the mast 14. As the first and second locking pins 32, 34 extend into the holes on each of the two support plates, the locking pins 32, 34 extend inward toward one another. In an example, the first and second locking pins 32, 34 can be electro-hydraulically controlled. FIG. 4 also shows locking sensors 33 which are described below.

The mast assembly 12 is described herein as having two support plates and two corresponding locking pins. However, it is recognized that the mast assembly 12 does not require two support plates (on opposing sides of the mast assembly). In another example, one support plate and one locking pin can be used for locking the mast 14. The mast assembly 12 is described herein as having seven holes 26 on the support plate 24. It is recognized that the support plate 24 can include more or less than the seven holes 26 shown in FIG. 2. It is recognized that the holes 26 can be configured to position the mast at alternative angles to the seven angles provided herein (0, 5, 10, 15, 20, 25 and 30) or at a different increment, rather than the example increment of 5 degrees.

Fluid hoses 35 as shown in FIG. 5 can be connected to an electrohydraulic valve that can control fluid supplied to the system for moving the locking pin 34. Similar fluid hoses are shown in FIG. 4 for connection to an electrohydraulic valve for controlling the locking pin 32. The electrohydraulic valves for the locking pins 32, 34 can be connected to corresponding solenoids for actuation of the locking pins 32, 34.

One or more locking sensors 33 can be used to detect whether the mast 14 is successfully locked (i.e. whether the locking pin 32, 34 is sufficiently engaged with the mast 14 to prevent movement of the mast 14). In an example, the one or more locking sensors 33 can include a proximity switch. The system for the second locking pin 34 can include one or more locking/proximity sensors that are configured similar to the one or more sensors 33 in FIG. 4. If the locking pin 32, 34 is not fully engaged with the hole 26 on the support plate 24, the locking sensors 33 can relay to the ECM that the mast 14 was not successfully locked or pinned.

FIG. 6 illustrates a portion of the mast assembly 12 opposite to the side of the mast assembly 12 shown in FIG. 3. FIG. 6 shows two mast cylinders 36 for supporting the mast 14 in the vertical position and controlling its movement. FIG. 6 shows a mast angle sensor 38 for measuring an angle of the mast 14 relative to the vertical position. The measured mast angle can be relayed to the ECM and displayed such that the machine operator can track the measured mast angle. The measured mast angle can be tracked independent of whether the mast is locked or unlocked.

Valve bank 40 includes one or more electrohydraulic valves for controlling the mast cylinders 36. The valves 40 of the valve bank can be connected to solenoids for extending or retracting the mast cylinders 36, depending on intended movement of the mast 14. When the mast 14 is being raised, the cylinders 36 can extend. When the mast 14 is being lowered, the cylinders 36 can retract.

FIG. 7 illustrates a control system 50 for automated positioning of the mast. The automated control system and method of the present application includes two processes—(1) calibration and (2) automated mast positioning. Each of these processes can be used in combination or independent of one another. Neither process relies on the other.

The control system 50 can include an electronic control module (ECM) 52 configured for communication with a control panel 54 of the drilling machine. In an example, the control panel 54 can be located inside an operator cab of the drilling machine. The control panel 54 can receive user inputs, such as a desired mast angle, and communicate such user inputs to the ECM 52. The ECM 52 can relay outputs to the control panel 54, such as successful lock or failure to lock. In an example, such outputs can be displayed on the control panel 54.

The ECM 52 can engage one or more raise/lower solenoids 56 to provide an electrohydraulic signal to move the mast (via the mast cylinders 36), depending on the starting position of the mast and the desired mast angle. The mast angle sensor 38 (see FIG. 6) can connected to the ECM 52 and relay the measured mast angle to the ECM as the mast is being moved. The ECM 52 can engage one or more lock/unlock solenoids 58 to provide an electrohydraulic signal to move the one or more locking pins for engagement with the pin holes on the mast assembly. The one or more locking sensors 33 (see FIG. 4) can determine whether the one or more locking pins is sufficiently engaged with the selected hole and relay such determination to the ECM 52, such that the ECM 52 can conclude whether the mast is successfully locked.

The drilling machine can have one or more electronic control units, which can include the ECM 52. The ECM 52 can be an embedded system that controls machine electrical systems and/or other subsystems of the machine. The ECM 52 can be communicatively connected to other components of the drilling machine and configured to send and receive data, sensor or other analog signals, and other information between various other electronic control units of the machine.

The ECM 52 can include software, hardware, and combinations of hardware and software configured to execute a number of functions attributed to the components of the drilling machine described herein. The ECM 52 can include an analog, digital, or combination analog and digital controllers having a number of components. As examples, the ECM 52 can include integrated circuit boards or ICB(s), printed circuit boards PCB(s), processor(s), data storage devices, switches, relays, etcetera. Examples of processors can include any one or more of a microprocessor, a controller, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field-programmable gate array (FPGA), or equivalent discrete or integrated logic circuitry.

The ECM 52 can include storage media to store and/or retrieve data or other information, for example, signals from sensors, including locking sensors 33 and mast angle sensor 38. Examples of non-volatile storage devices include magnetic hard discs, optical discs, floppy discs, flash memories, or forms of electrically programmable memories (EPROM) or electrically erasable and programmable (EEPROM) memories. Examples of volatile storage devices include random access memories (RAM), dynamic random access memories (DRAM), static random access memories (SRAM), and other forms of volatile storage devices. The data storage devices can be used to store program instructions for execution by processor(s) of the ECM 52.

The ECM 52 can be configured to communicate with other components of the drilling machine via various wired or wireless communications technologies and components using various public and/or proprietary standards and/or protocols. Examples of transport mediums and protocols for electronic communication between components of the machine include Ethernet, Transmission Control Protocol/Internet Protocol (TCP/IP), 802.11 or Bluetooth, or other standard or proprietary transport mediums and communication protocols.

In an example, the ECM 52 can be the main control unit of the machine. In an example, the control system 50 can include additional electronic control units, such as, for example, an engine control module, a transmission control module, and an implement control module associated with one or more implements coupled to and operable from the machine. The various components of the machine can be connected to the ECM 52 via a wired or wireless connection. The ECM 52 can control additional features and components of the machine, in addition to the mast calibration and positioning. Updates to the ECM 52 can be installed onto the ECM 52, using, for example, hardware flashing. Software changes can be made to the ECM 52 to reflect a particular design of the machine or changes made after the machine was assembled. For example, although a design with two locking pins 32, 34 (one on each side of the mast 14) is described above, it is recognized that in other examples, the machine can include only one locking pin. The software in the ECM 52 can be updated to accommodate a single locking pin design.

Calibration:

A calibration process as described herein can be used to improve accuracy of the mast angle during mast positioning. Although the mast angle sensor 38 is relied on to provide the mast angle, various factors can contribute to inaccuracies in the measured mast angle provided by the mast angle sensor 38. Such factors can include, for example, electrical noise, drifting, and manufacturing tolerances. The calibration process can be performed prior to mast positioning and can be applied to each of the mast angles corresponding to the locking pin holes 32, 34. Moreover, the calibration data can be updated as applicable for a particular mast angle whenever the mast 14 is locked at such particular angle. As such, calibration updates can be continually performed as the mast 14 goes through operation and is moved to different angles.

The calibration process can include performing calibration based on the vertical position of the mast 14, which generally corresponds to a mast angle of zero degrees or an angle close to zero degrees. The mast assembly 12 can be designed such that the mast 14 cannot move beyond the vertical position. In other words, the mast 14 is designed such that it cannot be positioned at an obtuse angle relative to the stowed position. Since the vertical position represents a stopping position that the mast 14 cannot move beyond, the vertical position can be used as a reference point in the calibration process. Before measuring an actual mast angle, the locking pin 32, 34 can attempt to engage with the first pin hole. Assuming successful locking, the mast angle sensor 38 can then measure the actual mast angle at the vertical position. Ideally, the measured mast angle at the vertical position is zero. If the value is not zero, through the calibration process disclosed herein, such value can be used to adjust the default mast angle at the vertical position. For example, if the measured mast angle at the vertical position is −2 degrees, the default mast angle for the first pin position can be adjusted from −2 to 0 degrees. As another example, if the actual mast angle at the vertical position is 1 degree, the default mast angle for the first pin position can be adjusted from 1 to 0 degrees.

In an example, the control panel 54 of the machine can include a feature on the display panel for calibrating the mast. Once the mast is positioned and pinned at the vertical position, the operator can touch that feature on the display. At that point, the measured mast angle (−2 or +1 for the examples provided above) at the vertical position is changed to 0 degrees. The measured mast angle at the vertical position becomes the reference point for the other pin positions, since the spacing between adjacent pins is fixed.

Once the first pin hole (correlating to the vertical position) is calibrated, the remaining default mast angles for the other pin positions (5, 10, 15, 20, 25 and 30 degrees) can be adjusted based on the measured mast angle for the first pin hole. The next pin hole is five degrees away from the first pin hole, thus the uncalibrated second pin position is −2+5, which equals 3 degrees. Based on the measured mast angle at the vertical position being −2 degrees, the system is calibrated by adding two degrees to each pin position. In other words, two degrees is added to the uncalibrated value and thus the second pin position is adjusted from 3 degrees to 5 degrees. For each subsequent pin position, two degrees is added to the uncalibrated pin position. In the other example provided above in which the measured mast angle at the vertical position is 1 degree, 1 degree is subtracted from each of the uncalibrated values to obtain the adjusted pin position.

The two examples provided above are shown in Table 1 below.

TABLE 1 Calibration adjustments to default mast angle Measured Mast Angle Adjusted at Vertical Uncalibrated default Position Pin Position mast angle −2 −2 0 3 5 8 10 13 15 18 20 23 25 28 30 1 1 0 6 5 11 10 16 15 21 20 26 25 31 30

FIG. 8 is a flow chart depicting an example process 100 in accordance with the present application for calibrating a mast angle for the mast of a drilling machine, to compensate for any discrepancies between a measured mast angle and a default mast angle. The process 100 can include at 102 that the ECM moves the mast from a stowed position to a vertical position. The vertical position can correspond to a first pin position at or close to zero degrees. The process can include at 104 that the ECM activates the extend locks solenoid to lock the mast at the first pin position. The process can include at 106 that the mast angle sensor measures the mast angle in the vertical/first pin position and relays the measured mast angle to the ECM. The process can include at 108 that the ECM adjusts the default mast angle for the first pin position based on the measured mast angle at the vertical/first pin position. For example, if the measured mast angle at the vertical position is −2 degrees, the default mast angle is adjusted from −2 degrees to zero degrees. The process can include at 110 that the ECM adjusts the default mast angle for the remaining pin positions, based on the measured mast angle at the first pin position. Using the example above in which the measured mast angle at the first pin position is −2 degrees, the second pin position is 5 degrees from the first pin position and the uncalibrated pin position of 3 degrees is adjusted to 5 degrees. Similarly, the third pin position at 8 degrees is adjusted to 10 degrees.

Once the initial calibration process is performed, the steps in FIG. 8 may not need to be repeated unless there are updates to the software for the ECM or the ECM is replaced. As described below, calibration updates can be provided to the ECM each time the mast is successfully locked at a particular pin position. Using the same example as provided above in which the third pin position is 8 degrees (and calibrated/adjusted to 10 degrees), if during operation the pin is successfully locked at the third pin position and the actual value measured by the mast angle sensor is 8.5 degrees, the ECM can further calibrate the third pin position such that the pin position at 8.5 degrees has an adjusted default mast angle of 10 degrees. If the mast is manually positioned, such calibration updates can still be collected and stored within the ECM. If it is determined that the mast angle sensor is tampered with or mounted incorrectly, the adjusted mast angles can be reset to the default positions corresponding to each of the pin positions.

The calibration process 100 can be utilized regardless of whether automated mast positioning is used during operation of the drilling machine.

Automated Mast Positioning:

An automated mast positioning process can be used to position the mast at a desired mast angle. The desired mast angle can be selected from one of the predetermined default angles that correspond to the plurality of locking pin holes on the mast assembly. The automated mast positioning process can reduce the number of times that the machine operator has to engage the joystick or other machine components used in adjusting the position of the mast.

FIG. 9 is a flow chart depicting an example process 200 in accordance with the present application for positioning the mast of the drilling machine. The process 200 can include at 202 that the machine operator enters a desired mast angle into an input module of the drilling machine. The input module can be connected to the ECM of the machine. The desired mast angle can be selected from the predetermined default angles that correspond to the locking pin holes on the mast assembly. The process can include at 204 that the ECM unlocks the mast (removes the locking pin from the hole on the support plate) such that the mast can be ready to move up (raise) or down (lower), unless the mast is in the stowed position in which case the mast does not need to be unlocked. Next, the process can include at 206 that the ECM activates a raise mast solenoid or lower mast solenoid to raise or lower the mast to the desired mast angle. An electrohydraulic signal can be applied to actuate and drive the raise or lower mast solenoid.

At 208, the mast angle sensor can measure the mast angle and relay the measured mast angle to the ECM. The ECM determines whether the measured mast angle is within a target range of the desired mast angle. If the measured mast angle is not within the target range, at 210 the ECM raises or lowers the mast (depending on whether the measured mast angle is too high or too low) in a second attempt and the process steps represented by 208 and 210 are repeated until the measured mast angle is within range of the desired mast angle.

A rate of movement of and/or a hydraulic force applied to the raise mast solenoid or the lower mast solenoid can depend in part on the angle differential between the desired mast angle and the position of the mast at the start of the process 200. As the mast gets closer to the desired mast angle, the ECM can slow down the raise or lower mast solenoid. Similarly, if additional attempts are needed for the mast to be within the target range of the desired mast angle, the ECM can control the rate of movement of the mast to avoid overcorrecting or overcompensating for not being within the target range.

If the measured mast angle is within target at 208, then at 212 the ECM can activate the extend locks solenoid to engage the locking pin with the hole corresponding to the desired mast angle. At 214, one or more lock sensors can determine whether the mast is successfully locked and relay the output to the ECM. If the locking pins sufficiently engage the hole, at 216 the mast can be considered locked and an output display connected to the ECM can provide confirmation of a successful lock. At 214, the ECM can also update the adjusted default mast angle based on the measured mast angle at which the mast successfully locked at a particular pin position. Thus updating the calibration data each time the mast successfully locks at a particular position can further improve the precision at each of the pin positions. It is recognized that the process 200 does not require that the mast be calibrated prior to performing the steps in FIG. 9 or that any calibration be updated at 214.

If, on the other hand, the one or more lock sensors determine at 214 that the mast is not successfully locked, the steps of raising or lowering the mast and then attempting to pin can be repeated as necessary or until the system times out or shuts down. In an example, the system can timeout after a predetermined time period of attempted locking without a successful lock. In another example, the system can timeout after a predetermined number of attempts. At that point, the machine operator may attempt to manually position and pin the mast or the machine operator may investigate whether there is a potential problem with the locking pin or other component on the mast assembly.

The methods and systems disclosed herein for automated position of a mast in a drilling machine can be included in the ECM of new machines as the machines are built and assembled. In addition, the methods and systems disclosed herein can be incorporated into existing machines that are already being used in the field. The updated software and/or hardware can be installed onto the existing ECM or the ECM can be replaced.

INDUSTRIAL APPLICABILITY

Example machines in accordance with the present application can be used in a variety of applications for surface mining or hard rock mining. As a drilling machine begins operation, the calibration process can be used to determine if the default mast angle at the various pin locations is equal to a measured mast angle at the corresponding pin location. The calibration process can be performed by moving the mast of the drilling machine to the vertical position and measuring the mast angle at the vertical position. The measured mast angle at the vertical position can then be used to adjust the default mast angle at the other pin positions. Calibration can continually be updated as the mast is locked at various pin positions.

The automated positioning process described herein can be used to more easily or efficiently position the mast at a particular mast angle. Instead of multiple operator adjustments to the position of the mast and multiple pin locking attempts, the operator can enter the desired mast angle and the control system can perform the positioning process and provide confirmation to the operator when the machine is successfully locked at the desired mast angle. In raising or lowering the mast, the control system can control a rate of movement of the mast as a function of the change in angle and overcorrections can be minimized. The control system can be configured to time out after a predetermined time period or predetermined number of attempts without successful locking and the operator can take over manual positioning of the mast.

The above detailed description is intended to be illustrative, and not restrictive. The scope of the disclosure should, therefore, be determined with references to the appended claims, along with the full scope of equivalents to which such claims are entitled.

Claims

1. A method of automating positioning of a mast in a drilling machine at various angles, the method comprising:

(a) entering a desired mast angle into an input module of the machine, the input module connected to an electronic control module (ECM) of the machine;
(b) moving the mast using the ECM;
(c) measuring an angle of the mast using a measuring device in communication with the ECM;
(d) determining with the ECM whether the measured mast angle is within an acceptable range of the desired mast angle;
(e) if the measured angle is within the acceptable range, attempting to lock the mast at the measured mast angle using the ECM;
(f) if the measured angle is not within the acceptable range, repeating the step above of moving the mast using the ECM until the measured mast angle is within the acceptable range;
(g) determining with the ECM whether the mast is successfully locked; and
(h) if the mast is not successfully locked, repeating steps (b)-(g).

2. The method of claim 1 wherein moving the mast using the ECM includes raising or lowering the mast relative to a stowed position of the mast on the drilling machine.

3. The method of claim 2 wherein raising the mast includes actuating a raise mast solenoid with the ECM.

4. The method of claim 2 wherein lowering the mast includes actuating a lower mast solenoid with the ECM.

5. The method of claim 1 wherein measuring an angle of the mast using a measuring device includes measuring the mast angle with a sensor, and the mast angle is measured relative to a vertical position of the mast, the vertical position generally perpendicular to a stowed position.

6. The method of claim 1 wherein determining with the ECM whether the mast is successfully locked includes using a proximity sensor to determine whether a locking pin is sufficiently engaged with a hole corresponding to the mast positioned at the desired mast angle.

7. The method of claim 1 further comprising:

before step (b), unlocking the mast with the ECM unless the mast is in a stowed, unlocked position.

8. The method of claim 1 further comprising:

if the mast is locked in step (g), relaying confirmation of successful lock to an output display.

9. The method of claim 1 further comprising:

prior to performing steps (a)-(h), calibrating the mast to compensate for any discrepancies between the measured mast angle and a default mast angle at a particular mast position.

10. The method of claim 9 wherein calibrating the mast comprises:

moving the mast to a vertical position, the vertical position generally perpendicular to a stowed position and correlating to a first pin position, additional pin positions correlating to various angles of the mast relative to the vertical position and at equally spaced increments;
measuring a mast angle at the vertical position using the measuring device;
adjusting a default mast angle for the first pin position based on a value of the measured mast angle at the vertical position; and
adjusting a default mast angle for each additional pin position based on the value of the measured mast angle at the vertical position.

11. The method of claim 10 wherein the additional pin positions are spaced from the first pin position at 5 degree increments.

12. The method of claim 1 wherein in step (h), repeating steps (b)-(g) is performed until the mast is locked or until the ECM times out.

13. A method for automating position of a mast in a drilling machine, the method comprising:

(a) entering a desired mast angle into an electronic control panel of the drilling machine, the electronic control panel in communication with an electronic control module (ECM) of the machine, the desired mast angle selected from a plurality of default mast angles that correspond to an angle of the mast relative to a vertical position of the mast and are at equally spaced increments to one another;
(b) unlocking the mast with the ECM unless the mast is in a stowed, unlocked position;
(c) engaging a raise mast solenoid or a lower mast solenoid with the ECM to activate raising or lowering of the mast;
(d) measuring an angle of the mast at a particular mast position and relaying the measured mast angle to the ECM;
(e) determining with the ECM whether the measured mast angle is within an acceptable range of the desired mast angle;
(f) if measured mast angle within acceptable range, activating a lock solenoid with the ECM to attempt to lock the mast at the particular mast position;
(g) if measured mast angle outside of acceptable range, repeating steps (c)-(e) until the measured mast angle is within acceptable range;
(h) determining whether the mast is locked and relaying to the ECM;
(i) if locked, displaying an output on the electronic control panel confirming successful lock; and
(j) if not locked, repeating steps (c)-(h) until locked or until the ECM times out.

14. The method of claim 13 further comprising:

prior to performing steps (c)-(j),
moving the mast to the vertical position;
measuring the mast angle at the vertical position and relaying the measured mast angle to the ECM; and
adjusting each of the default mast angles in the plurality of default mast angles based on the measured mast angle at the vertical position.

15. The method of claim 13 wherein the plurality of default mast angles are spaced at 5 degree increments.

16. The method of claim 13 wherein activating a lock solenoid comprises engaging a locking pin with one of a plurality of holes on a bottom portion of a mast housing, each of the plurality of holes corresponding to a default mast angle from the plurality of default mast angles.

17. A control system for positioning of a mast in a drilling machine, the control system comprising:

an electronic control module (ECM) configured to receive, store and execute instructions for operation of the mast;
a control panel coupled to the ECM and configured to receive user inputs from a user of the machine and display outputs from the ECM;
a first electrohydraulic circuit configured to raise or lower the mast in response to instructions from the ECM;
a mast angle sensor in communication with the ECM and configured to measure an angle of the mast and relay the measured mast angle to the ECM;
a second electrohydraulic circuit configured to lock or unlock the mast in response to instructions from the ECM; and
a locking sensor in communication with the ECM and configured to detect whether the mast is in a locked position and relay to the ECM,
wherein the control panel is configured to receive a desired mast angle from the user, the desired mast angle is communicated to the ECM, and the ECM controls operation of the first and second hydraulic circuits to position and lock the mast at the desired mast angle.

18. The control system of claim 17 wherein the first electrohydraulic circuit includes a raise mast solenoid and a lower mast solenoid.

19. The control system of claim 17 wherein the second electrohydraulic circuit includes a locking mast solenoid to engage a locking pin with a hole on the mast, the hole is selected form a plurality of holes and each hole corresponds to a predetermined angle of the mast.

20. The control system of claim 17 wherein the ECM is configured to perform a calibration of the mast prior to positioning and locking the mast at the desired mast angle, and the calibration accounts for any difference between a measured mast angle and a default mast angle at a particular mast position.

Patent History
Publication number: 20200131856
Type: Application
Filed: Oct 31, 2018
Publication Date: Apr 30, 2020
Applicant: Caterpillar Inc. (Deerfield, IL)
Inventors: Ahsan Shahid (Peoria, IL), Hyppolite Kuissi (Peoria, IL)
Application Number: 16/177,083
Classifications
International Classification: E21B 15/04 (20060101); E21B 7/02 (20060101);