AU2020205242B2 - Collar control system for mobile drilling machines - Google Patents

Abstract

#$%^&*AU2020205242B220250925.pdf##### Abstract COLLAR CONTROL SYSTEM FOR MOBILE DRILLING MACHINES A collar control system and methods for mobile drilling machines are disclosed. One method may include: automatically initiating rotation of a drill bit based on collar settings; automatically feeding the drill bit at a feed rate to form an initial hole at a predetermined reaming increment; and automatically retracting the drill bit from the initial hole when the predetermined reaming increment is achieved, but prior to reaching a collar depth. Another method may include: measuring values of multiple drill bit inputs at a predetermined sample depth region during the collar operation; storing average values for each of the drill bit inputs over the predetermined sample depth region; monitoring values of the drill bit inputs when the drill bit moves beyond the predetermined sample depth region; and ending the collar operation prior to a desired collar depth when any of the monitored values change by a predetermined threshold. Abstract COLLAR CONTROL SYSTEM FOR MOBILE DRILLING MACHINES 2020205242 14 Jul 2020 A collar control system and methods for mobile drilling machines are disclosed. One method may include: automatically initiating rotation of a drill bit based on collar settings; automatically feeding the drill bit at a feed rate to form an initial hole at a predetermined reaming increment; and automatically retracting the drill bit from the initial hole when the predetermined reaming increment is achieved, but prior to reaching a collar depth. Another method may include: measuring values of multiple drill bit inputs at a predetermined sample depth region during the collar operation; storing average values for each of the drill bit inputs over the predetermined sample depth region; monitoring values of the drill bit inputs when the drill bit moves beyond the predetermined sample depth region; and ending the collar operation prior to a desired collar depth when any of the monitored values change by a predetermined threshold. !"#$%& 205 2;.1475CW12 20 20 20 52 42 1 4 Ju l 2 02 0 FIG. 1 15 W 08 09 288 18 52 200 200 oo ++ CARD12 210 ot Com 98 88 23 22 14 EO 34 288 OL 26 2020205242 16 24 14 Jul 2020 19-0364AU011/4

Description

205 2;.1475CW12 14 Jul 2020 14 Jul 2020 1/4 19-0364AU01

24

16 2020205242

2020205242

26

OL

288

34 EO

14 22

23 98 88 ot om C

210 CARD 12 + + 200 o o 200

52 288 18

09

08

W 15

!"#$%& FIG. 1

1

2020205242 14 Jul 2020 Description Description

COLLAR CONTROL COLLAR CONTROLSYSTEM SYSTEMFOR FORMOBILE MOBILEDRILLING DRILLING MACHINES MACHINES

Technical Field Technical Field

[0001] The The

[0001] present present disclosure disclosure relates relates generally generally to to mobile mobile drillingmachines, drilling machines, andand more more

particularly, to particularly, to aa collar collar control controlsystem system for for suchsuch machines. machines.

Background Background

[0002] Mobile

[0002] Mobile drilling drilling machines, machines, such such as blasthole as blasthole drilling drilling machines, machines, are are typically typically used used forfor

drilling blastholes drilling blastholesfor formining, mining,quarrying, quarrying,dam dam construction, construction,and and road road construction, construction,among other among other

uses. The uses. The process process of excavating of excavating rock, rock, or material, or other other material, by blasthole by blasthole drilling comprises drilling comprises using the using the blastholedrill blasthole drill machine machineto to drill drill a plurality a plurality of of holes holes intointo the the rockrock and filling and filling the holes the holes with with explosives. The explosives. Theexplosives explosivesare aredetonated detonatedcausing causingthe therock rocktotocollapse collapse and andrubble rubbleofofthe the collapse collapse is is then then removed andthe removed and the new newsurface surfacethat that is is formed is reinforced. formed is Manycurrent reinforced. Many currentblasthole blastholedrilling drilling machines machines utilize utilize rotary rotary drill drill rigs,mounted rigs, mounted on a on masta that mastcan that canblastholes drill drill blastholes anywhereanywhere from 6 from 6 inches to2222inches inches to inchesin in diameter diameter and depths and depths up to up to 180 180 feet or feet more.or more.

[0003] Blasthole

[0003] Blasthole drilling drilling machines machines may may also also include include an automatic an automatic drilling drilling mode. mode. The The automatic drilling automatic drilling mode mayinclude mode may includeananautomatic automaticcollar collaroperation. operation. For For example, example, thethe ground ground

surface may surface maybe be fractured fractured and/or and/or may include may include loose material loose material (e.g., left (e.g., material material from aleft from previous a previous blast) such blast) suchthat thatitit is is difficult difficult to formananinitial to form initialhole holefor fordrilling. drilling.TheThe collar collar operation, operation, or or collaring, may collaring, may include include forming forming an initial an initial hole hole at at reduced reduced drill settings drill settings (e.g., reduced (e.g., reduced drill rotation drill rotation

speedand speed andfeed feed rate) rate) before before initiating initiating the the drilling drilling operation operation to drill to drill a hole. a hole. Therefore, Therefore, collaring collaring

maybe may beused usedtoto set set aa base for for the the hole. hole. During collaring, loose During collaring, loosematerial materialmay may accumulate ontop accumulate on top of the of the drill drill bit bit causing thedrill causing the drill bit bit to to clog clogand/or and/orairairpressure pressure to to increase increase as the as the hole hole depthdepth

increases andmaymay increases and result result in ain a jam. jam. Further, Further, ininstances, in some some instances, thedepth the collar collar maydepth be setmay be set by the by the

operator or predetermined, operator in which predetermined, in which case case the the depth depth may maynot notcorrespond correspondtotothe theactual actual required required collar depth. collar depth.

[0004] U.S.U.S.

[0004] Patent Patent Application Application Publication Publication No. No. 2011/0108323, 2011/0108323, published published on May on 12,May 201112, 2011 ("the '323 ("the '323publication"), publication"), describes describes a system a system for drilling for drilling a borehole a borehole that receives that receives information information

fromthe from thedrill drillrig rig that that relates relates totoatat least least one onedrill drillparameter. parameter.The The system system of the of thepublication '323 '323 publication monitorsa penetration monitors a penetration raterate during during a first a first phasephase of collaring of collaring andinitiates and then then initiates a seconda phase secondof phase of collaring when the penetration rate falls below a predetermined level for a predetermined period 26 Aug 2025 of time. The first phase of collaring advances the drill bit to a predetermined depth and the second phase of collaring retracts the drill bit above the surface. However, the ’323 publication does not disclose mitigating or preventing jams and clogs prior to collaring to the predetermined depth. Further, the system of the ’323 publication may include an overall longer drilling operation due to the second phase of collaring of retracting the drill bit above the surface prior to beginning the drilling operation. 2020205242

[0005] The systems and methods of preferred embodiments of the present disclosure may address or solve one or more of the problems set forth above and/or other problems in the art, and/or provide a useful alternative. The scope of the current disclosure, however, is defined by the attached claims, and not by the ability to solve any specific problem.

[0005A] Reference to any prior art in the specification is not an acknowledgement or suggestion that this prior art forms part of the common general knowledge in any jurisdiction or that this prior art could reasonably be expected to be combined with any other piece of prior art by a skilled person in the art.

Summary

[0005B] According to a first aspect of the invention there is provided a method for automated control of a collar operation of a mobile drilling machine using a drill bit mounted on a drill string, comprising: automatically initiating rotation of the drill bit at a rotation speed based on collar settings, wherein the collar settings include at least a set collar depth; automatically feeding the drill bit to form an initial hole at a predetermined reaming increment, the predetermined reaming increment being a distance that is a fraction of the set collar depth; automatically retracting the drill bit from the initial hole when the predetermined reaming increment is reached; and repeating, until the set collar depth is reached, the steps of (i) automatically feeding the drill bit to increase a depth of the initial hole by the predetermined reaming increment and (ii) retracting the drill bit from the initial hole after the depth of the initial hole has increased by the predetermined reaming increment.

[0005C] According to a second aspect of the invention there is provided a mobile drilling machine, comprising: a mast including a mast frame; a rotary head movably mounted on the mast frame, the rotary head controllable to rotate a drill bit mounted on a drill string at a rotation speed, wherein the rotary head is further controllable to move up and down the mast frame to feed the drill bit at a feed speed; and a controller configured to: automatically initiate rotation of the drill bit at a rotation speed based on collar settings for a collar operation, wherein the collar 26 Aug 2025 settings include at least a set collar depth; automatically feed the drill bit to form an initial hole at a predetermined reaming increment, the predetermined reaming increment being a distance that is a fraction of the set collar depth; automatically retract the drill bit from the initial hole when the predetermined reaming increment is reached; and repeat, until the set collar depth is reached, the steps of (i) automatically feeding the drill bit to increase a depth of the initial hole by the predetermined reaming increment and (ii) retracting the drill bit from the initial hole after the depth of the initial hole has increased by the predetermined reaming increment. 2020205242

[0005D] According to a third aspect of the invention there is provided a method for automated control of a collar operation of a mobile drilling machine using a drill bit mounted on a drill string, comprising: automatically initiating rotation of the drill bit at a rotation speed based on collar settings, wherein the collar settings include at least a set collar depth; automatically feeding the drill bit at a feed rate to form an initial hole; measuring values of multiple drill bit inputs at a predetermined sample depth region during the collar operation; storing average values for each of the drill bit inputs over the predetermined sample depth region; monitoring values of the drill bit inputs when the drill bit moves beyond the predetermined sample depth region; and ending the collar operation prior to the set collar depth when any of the monitored values change by a predetermined threshold.

[0006] In one embodiment, a method for automated control of a collar operation of a mobile drilling machine using a drill bit mounted on a drill string is disclosed. The method may include: automatically initiating rotation of the drill bit at a rotation speed based on collar settings; automatically feeding the drill bit at a feed rate to form an initial hole at a predetermined reaming increment; and automatically retracting the drill bit from the initial hole when the predetermined reaming increment is achieved, but prior to reaching a collar depth.

[0007] In another embodiment, a mobile drilling machine is disclosed. The mobile drilling machine may include: a mast including a mast frame; a rotary head movably mounted on the mast frame, the rotary head controllable to rotate a drill bit mounted on a drill string at a rotation speed, wherein the rotary head is further controllable to move up and down the mast frame to feed the drill bit at a feed speed; and a controller configured to: automatically initiate rotation of the drill bit at a rotation speed based on collar settings; automatically feed the drill bit at a feed rate to form an initial hole at a predetermined reaming increment; and automatically retract the drill bit from the initial hole when the predetermined reaming increment is achieved, but prior to reaching a collar depth.

3a

[0008] In yet another embodiment, a method for automatically adjusting a collar depth during 26 Aug 2025

a collar operation of a mobile drilling machine including a drill bit mounted on a drill string is disclosed. The method may include: measuring values of multiple drill bit inputs at a predetermined sample depth region during the collar operation; storing average values for each of the drill bit inputs over the predetermined sample depth region; monitoring values of the drill bit inputs when the drill bit moves beyond the predetermined sample depth region; and ending the collar operation prior to a desired collar depth when any of the monitored values change by a predetermined threshold. 2020205242

[0009] In yet another embodiment, a mobile drilling machine is disclosed. The mobile drilling machine may include: a mast including a mast frame; a rotary head movably mounted on the mast frame, the rotary head controllable to rotate a drill bit mounted on a drill string at a rotation speed, wherein the rotary head is further controllable to move up and down the mast frame to feed the drill bit at a feed speed; and a controller configured to: measure values of multiple drill bit inputs at a predetermined sample depth region during a collar operation; store average values for each of the drill bit inputs over the predetermined sample depth region; monitor values of the drill bit inputs when the drill bit moves beyond the predetermined sample depth region; and end the collar operation prior to a desired collar depth when any of the monitored values change by a predetermined threshold.

[0009A] By way of clarification and for avoidance of doubt, as used herein and except where the context requires otherwise, the term "comprise" and variations of the term, such as "comprising", "comprises" and "comprised", are not intended to exclude further additions, components, integers or steps.

Brief Description of the Drawings

[0010] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate various exemplary embodiments and together with the description, serve to explain the principles of the disclosure.

[0011] FIG. 1 illustrates a schematic side view of a drilling machine with an exemplary collar control system, according to aspects of the disclosure.

[0012] FIG. 2 illustrates a schematic view of the exemplary collar control system of the drilling machine of FIG. 1.

3b

[0013] FIG. 3 is a flowchart depicting an exemplary collar reaming function of the collar 26 Aug 2025

control system if FIGs. 1 and 2.

[0014] FIG. 4 is a flowchart depicting an exemplary automatic collar depth adjustment function of the collar control system of FIGs. 1 and 2.

Detailed Description

[0015] Both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the features, as claimed. As used 2020205242

herein, the terms “comprises,” “comprising,” “having,” including,” or other variations thereof, are intended to cover a non-exclusive inclusion such that a process, method, article, or apparatus

4

2020205242 14 Jul 2020 that comprises that comprisesa list a listofofelements elements doesdoes not include not include only elements, only those those elements, but may but may include include other other elementsnotnot elements expressly expressly listed listed or inherent or inherent to such to such a process, a process, method,method, article, article, or apparatus. or apparatus.

Further, relative Further, relativeterms, terms,such such as,as, forfor example, example, "about," "about," "substantially," "substantially," "generally," "generally," and and "approximately" "approximately" are are usedused to indicate to indicate a possible a possible variation variation of ±10% of in a 10% invalue. stated a stated value.

[0016] FIG.FIG.

[0016] 1 illustratesa aschematic 1 illustrates schematic side side view view of of an an exemplary exemplary drilling drilling machine machine 10. 10. The The

disclosure herein may disclosure be applicable may be applicable to to any type of any type of drilling drillingmachine, machine, however, reference will however, reference will be be

madebelow made belowparticularly particularlytoto aa mobile mobileblasthole blasthole drilling drilling machine. Asshown machine. As shownin in FIG. FIG. 1, 1,mobile mobile drilling machine drilling 10 may machine 10 mayinclude includea aframe frame12, 12,machinery machinery14,14, andand a drillingmast a drilling mast16. 16.Frame Frame 12 12 maybe may besupported supportedonona aground ground surfacebyby surface a a transportmechanism, transport mechanism, such such as crawler as crawler tracks tracks 18.18.

Crawler tracks Crawler tracks 18 18 may mayallow allowmobile mobiledrilling drillingmachine machine10 10 to to maneuver maneuver about about the the ground ground surface surface

to aa desired to desiredlocation locationforfora adrilling drillingoperation. operation. Frame Frame 12 may 12 may include further further one include one or more or more jacks 20 jacks 20 for supporting for and leveling supporting and leveling mobile drilling machine mobile drilling 10 on machine 10 onthe the ground groundsurface surface during duringthe the drilling drilling operation. Frame operation. Frame1212may may support support thethe machinery machinery 14, 14, which which may may include include engines, engines, motors, motors,

batteries, pumps, batteries, pumps, air aircompressors, compressors, aa hydraulic hydraulic fluid fluidstorage storagetank tank38 38(shown (shown schematically in FIG. schematically in FIG.

1) and/or 1) and/or any any other equipment necessarytoto power equipment necessary powerand andoperate operatemobile mobile drillingmachine drilling machine10.10.

Frame1212may Frame may furthersupport further supportananoperator operatorcab cab22, 22,from fromwhich which a user,ororoperator, a user, operator,may may maneuver maneuver

andcontrol and controlmobile mobile drilling drilling machine machine 10 via 10 an via andevice input input 40, device such 40, suchinterfaces as user as user interfaces and and displays. It displays. It isisunderstood understood that thatinput inputdevice device40 40may may be be located located remote from mobile remote from mobiledrilling drilling machine1010such machine suchthat thatmobile mobiledrilling drilling machine machine1010may may be be controlled controlled remotely. remotely.

[0017] As further

[0017] As further shown shown in FIG. in FIG. 1, drilling 1, drilling mast mast 16 may 16 may include include a mast a mast frameframe 24 which 24 which may may support aa drill support drill motor motor assembly, assembly, or rotary rotary head head 26, 26, movably mountedonon movably mounted themast the mast frame frame 24.24.

Rotaryhead Rotary head 26 26 may may couple couple to, andto, and may be may be controllable controllable to rotate, to a rotate, a drill drill string 28 string 28 ofpipe of drilling drilling pipe segmentson on segments which which a drill a drill bitmay bit 30 30 be may be mounted mounted for into for drilling drilling into the the ground ground surface for surface collar, for collar, as further as further described describedbelow. below. Mobile Mobile drilling drilling machine machine 10 may 10 may include anyinclude type of any drilltype of drill bit 30, such bit 30, such as aa rotary as rotary drill drill bit, bit, aa claw drill bit, claw drill bit, aa down-the-hole bit, down-the-hole bit, etc.Rotary etc. Rotary head head 26 may26 be may be any any type of type of rotary head, rotary head,such such as as a hydraulic a hydraulic rotary rotary head head or theor the like. like. Rotary Rotary head 26 head 26 may may further further include a include a hydraulicfluid hydraulic fluidline line(not (notshown) shown) for receiving for receiving hydraulic hydraulic fluid. fluid. The The hydraulic hydraulic fluid fluid may be usedmay be used to rotate to rotate aa shaft shaft of ofrotary rotaryhead head2626 on on which which the drill the drill string string 28 is28 is connected connected for rotating for rotating the the drill drill string 28 string 28 (and (andthus thusrotating rotating drillbitbit30). drill 30).TheThe hydraulic hydraulic fluid fluid line line of of rotary rotary head 26head 26 may be may be coupled to coupled to aa hydraulic hydraulic valve 32 (shownschematically 32 (shown schematicallyininFIG. FIG.1)1)for for controlling controlling the the amount, and amount, and

flow rate, of flow rate, ofthe thehydraulic hydraulicfluid into fluid rotary into head rotary 26.26. head In In thethe exemplary exemplaryembodiment, hydraulic embodiment, hydraulic

valve 32 valve 32 may maybebelocated locatedononthe thehydraulic hydraulic fluid fluid storage storage tank tank 38. 38. However, However,hydraulic hydraulicvalve valve3232 maybebelocated may located anywhere anywhere along along the hydraulic the hydraulic fluid fluid line linerotary of the of thehead rotary head 26, as 26, as necessary. necessary.

5

2020205242 14 Jul 2020

[0018] Drilling

[0018] Drilling mast mast 16 may 16 may further further include include a hydraulic a hydraulic feedfeed cylinder cylinder 34 (located 34 (located within within mast mast

frame 24) frame 24) connected connectedtotorotary rotary head head 26 26via via aa cable cable and and pulley pulley system system(not (not shown) shown)for formoving moving rotary head rotary head 26 up and 26 up and down downalong alongthe themast mastframe frame 24.24. As As such, such, when when hydraulic hydraulic feedfeed cylinder cylinder 34 34 is extended, is extended, hydraulic hydraulic feed feed cylinder cylinder 34 34 may exert aa force may exert force on on rotary rotary head head 26 26 for for pulling-down pulling-down

rotary head rotary head 26 along mast 26 along mast frame frame24. 24. Likewise, Likewise,when when hydraulic hydraulic feed feed cylinder cylinder 34 34 is is retracted, retracted,

hydraulicfeed hydraulic feed cylinder cylinder 34 may 34 may exert exert a force a force on head on rotary rotary 26 head 26 for up for hoisting hoisting up rotary rotary head 26 head 26 along mast along mast frame frame24. 24. Thus, Thus,hydraulic hydraulicfeed feedcylinder cylinder3434may maybe be controllableto tomove controllable move rotary rotary head head

26 up 26 up and and down downthe themast mastframe frame 24 24 such such thatdrill that drillbit bit 30 on drill 30 on drill string string2828may may be be pulled-down pulled-down

towards, and towards, and into, into, the the ground surface or ground surface or hoisted hoisted up up from from the the ground surface. As ground surface. Asused usedherein, herein, the the term"feed" term "feed"in inthethe context context of the of the feedfeed cylinder cylinder 34 includes 34 includes movementmovement ofstring of the drill the drill string 28 in 28 in either direction either direction(up (uporordown). down). Hydraulic Hydraulic feed cylinder feed cylinder 34 mayhydraulic 34 may include includefluid hydraulic fluid lines (not lines (not shown)for shown) for receiving receiving and and conveying conveyinghydraulic hydraulicfluid fluidtoto and andfrom fromthe thefeed feedcylinder cylinder34. 34. The The hydraulicfluid hydraulic fluidmay may be used be used to actuate to actuate hydraulic hydraulic cylinder cylinder 34 such 34 such that a rodthat a rod of cylinder of hydraulic hydraulic cylinder 34 may 34 maybebeextended extendedororretracted. retracted. The Thehydraulic hydraulicfluid fluidline line of of hydraulic hydraulic cylinder cylinder 34 34 may be may be

coupled to coupled to hydraulic hydraulic valves valves 36 36 (shown (shownschematically schematicallyininFIG. FIG.1)1)for forcontrolling controlling the the amount, amount, and and flow rateand flow rate andpressure, pressure, of of thethe hydraulic hydraulic fluidfluid into into hydraulic hydraulic cylinder cylinder 34. exemplary 34. In the In the exemplary embodiment,hydraulic embodiment, hydraulicvalve valve3636 may may be be located located on on thethe hydraulic hydraulic fluid fluid storagetank storage tank38. 38. However,hydraulic However, hydraulicvalve valve3636may may be be located located anywhere anywhere along along the the hydraulic hydraulic fluid fluid line line of of thethe

hydrauliccylinder hydraulic cylinder 34,34, as necessary. as necessary. It is It is understood understood that hydraulic that hydraulic fluid mayfluid may be any beofany type type of hydraulicfluid, hydraulic fluid,such suchas as hydraulic hydraulic oil oil or the or the like. like.

[0019] FIG.FIG.

[0019] 1 shows 1 shows the drill the drill string string 28 28 located located in in hole50. hole 50.TheThe hole hole 50 50 includes includes a collar a collar

portion5252atata atop portion topportion portion of of thethe hole, hole, and and a bottom a bottom of the of the54hole hole 54 desired (e.g., (e.g., desired depth ofdepth hole). of hole).

As shown As shownbybythe thearrows arrowsininFIG. FIG.1,1,drill drill string string 28 28 can can rotate, rotate,and andmove move up and down up and down(e.g. (e.g. feed feed andretract/hoist) and retract/hoist)such such thatdrill that drillbit bit3030rotates rotatesandand moves moves up andup and respectively. down, down, respectively. Drill bit Drill 30 bit 30 can also can alsoreciprocate reciprocate(e.g. (e.g.when when a down-the-hole a down-the-hole drill drill bit is bit is used). used). Further Further drill28string drill string may 28 may include water include and air water and air lines lines (not (notshown) shown) for for supplying supplying water water and/or and/or compressed air through compressed air throughthe the drill bit 30 to the hole 50. drill bit 30 to the hole 50.

[0020] FIG.FIG.

[0020] 2 illustratesa aschematic 2 illustrates schematic view view of of thethe exemplary exemplary collar collar control control system system 200200 of the of the

drilling machine drilling of FIG. machine of 1. Control FIG. 1. Control system system200 200may may include include inputs inputs 212-224, 212-224, controller controller 210,andand 210,

outputs230-236. outputs 230-236.The The inputs inputs may include may include sensor sensor input, input, inputs, operator operator inputs,inputs, or stored or stored for inputs, for example,bitbitinformation example, information 212, 212, desired desired hole settings hole settings 214, 214, feed feed rate rate rotation limits, limits, rotation speedairlimits, speed limits, air pressurelimits pressure limitsand and torque torque limits, limits, bit bit air air pressure pressure 216, 216, pulldown pulldown force force 218, 218, rotation rotation torque 220, torque 220, feed rate feed rate 222, 222, and and rotation rotationspeed speed 224. 224. Such sensors, operation Such sensors, operation input, input, or or stored storedinputs inputsmay may be be

obtained using obtained using any any conventional conventionalsystem system(sensors, (sensors,user userinputs, inputs, etc.) etc.) The outputs may The outputs mayinclude, include, for for

6

2020205242 14 Jul 2020 example, aa feed example, feed command command 230, 230, airair supply supply command command 232, 232, drilldrill string string rotation rotation command command 234, 234, and and watering command watering 236. command 236.

[0021] Controller

[0021] Controller 210 210 may may embody embody a single a single microprocessor microprocessor or multiple or multiple microprocessors microprocessors that that mayinclude may includemeans meansforformonitoring monitoring operation operation of of thedrilling the drilling machine machine1010andand issuinginstructions issuing instructions to components to components ofofmachine machine10.10.ForFor example, example, controller controller 210210 may may include include a memory, a memory, a secondary a secondary

storage device, a processor, such as a central processing unit or any other means for storage device, a processor, such as a central processing unit or any other means for

accomplishinga atask accomplishing task consistent consistent with with the the present present disclosure. disclosure. The memory The memory or or secondary secondary storage storage

device associated with controller 210 may store data and/or software routines that may assist device associated with controller 210 may store data and/or software routines that may assist

controller 210 controller 210 in in performing its functions. performing its functions. Further, Further,the thememory or secondary memory or secondarystorage storagedevice device associated with associated controller 210 with controller 210 may also store may also store data data received received from the various from the various inputs inputs 102 102

associated with associated mobile drilling with mobile drilling machine 10. Numerous machine 10. Numerous commercially commercially available available microprocessors microprocessors

can be configured to perform the functions of controller 210. It should be appreciated that can be configured to perform the functions of controller 210. It should be appreciated that

controller 210 controller 210 could could readily readily embody embody a ageneral generalmachine machinecontroller controllercapable capableofofcontrolling controlling numerousother numerous othermachine machine functions.Various functions. Various other other known known circuits circuits may may be associated be associated with with

controller 210, including signal-conditioning circuitry, communication circuitry, hydraulic or controller 210, including signal-conditioning circuitry, communication circuitry, hydraulic or

other actuation circuitry, and other appropriate circuitry. other actuation circuitry, and other appropriate circuitry.

[0022] As shown

[0022] As shown in Fig. in Fig. 2, controller 2, controller 210210 may may also also store store certain certain limits limits 238238 associated associated with with

drilling machine 10. These limits may include one or more of rotation speed limits, air pressure drilling machine 10. These limits may include one or more of rotation speed limits, air pressure

limits, and torque limits. Feed rate limits may include maximum limits for the feed rate of the limits, and torque limits. Feed rate limits may include maximum limits for the feed rate of the

drill bit 30. Rotation speed limits may include maximum limits for the rotation speed of the drill drill bit 30. Rotation speed limits may include maximum limits for the rotation speed of the drill

bit 30. bit 30. Air Air pressure pressure limits limitsmay may include include maximum limitsforforananamount maximum limits amountof of airairpressure pressureprovided provided for the drill for the drill bit bit 30. Torquelimits 30. Torque limits maymay include include maximum maximum limits forlimits for rotational rotational torque torque on the drillon the drill

bit 30. bit 30. These limits 238 These limits maybebeprovided 238 may providedtotocontroller controller 210 210 in in any any conventional conventionalmanner mannerandand maymay

be configurable. be configurable.

[0023] Bit Bit

[0023] information information input input 212 212 may may include include a user a user inputinput of bit of bit typetype andand a weight a weight on the on the bitbit

per diameter. Bit type may include, for example, a rotary drill bit, a claw drill bit, a down-the per diameter. Bit type may include, for example, a rotary drill bit, a claw drill bit, a down-the-

hole bit, or any other type of drill bit. The weight on the bit per diameter may be determined by hole bit, or any other type of drill bit. The weight on the bit per diameter may be determined by

a user input of the diameter of the bit. The user input may be received from an input device 40, a user input of the diameter of the bit. The user input may be received from an input device 40,

such as such as aa computing device, number computing device, numberpad, pad,ororthe thelike. like.

[0024] HoleHole

[0024] settings settings input input 214214 may may include, include, for for example, example, a desired a desired collar collar depth, depth, reaming reaming

increments, sampledepth, increments, sample depth, and anddesired desiredhole hole depth. depth. Desired Desiredcollar collardepth depthmay maybebethethedesired desireddepth depth in which the front end, or collar, of the hole 50 is drilled. Reaming increments may be depth in which the front end, or collar, of the hole 50 is drilled. Reaming increments may be depth

7

2020205242 14 Jul 2020 increments by which increments by whichthe thehole holemay maycollared. collared.Sample Sample depth depth region region may may be abe a small small region region (e.g., (e.g.,

betweentwo between twopredetermined predetermined depths) depths) of of thethecollar portion5252ofofhole collarportion 50. Desired hole 50. Desiredhole holedepth depthmay may be the be the desired desireddepth depth in in which which the hole the hole 50 is 50 is drilled drilled duringduring the automatic the automatic drilling drilling operation. operation.

These inputs These inputs 214 214 may maybebeprovided provided byby thethe operatorofofthe operator themobile mobiledrilling drillingmachine machine10,10,and/or and/orbebe preset by preset by the the manufacturer of the manufacturer of the machine, service personnel, machine, service personnel, or or engineers associated associated with the with the

machine10. machine 10.Further, Further,such suchvalues valuesmay maybe be presetand preset and non-configurable, non-configurable, or or configurable. configurable.

[0025] Bit Bit

[0025] air air pressure pressure input input 216 216 maymay be abesensor a sensor for for detecting detecting and/or and/or communicating communicating a neta net force acting force actingononanan airair supply supply line. line. Forces Forces acting acting on theon airthe air supply supply line mayline mayair include include air pressure. pressure. Bit air Bit airpressure pressureinput input216 216 may may be be an an air air pressure pressure sensor sensor configured configured to to communicate communicate ananair air pressuresignal pressure signalindicative indicative of of airair pressure pressure of the of the air supply air supply line line on theon the bit drill drill30bit to 30 to controller controller

210. For 210. For example, example, an pressure an air air pressure sensorsensor may be may be inlocated located the airin the air supply supply line linetheadjacent adjacent drill the drill bit 30 bit so asasto 30 so to detect detectpressure pressureof of fluid fluid (e.g.,air) (e.g., air)within within thethe airair supply supply line. line. Bit Bit air pressure air pressure inputinput

216 may 216 mayalso alsoderive deriveair air pressure pressure information information from fromother othersources, sources, including including other other sensors. sensors.

[0026] Pulldown

[0026] Pulldown forceforce inputinput 218 be 218 may may be a sensor a sensor or other or other mechanism mechanism configured configured to to detect detect and/or communicate and/or communicatea pulldown a pulldown force force acting acting on on thethe drillbit drill bit 30. 30. The Thepulldown pulldown forceacting force actingonon the drill the drill bit bit 30 30 may may bebe the the force force exerted exerted by hydraulic by the the hydraulic feed cylinder feed cylinder 34 the 34 through through rotary the headrotary head 26 to 26 to the the drill drill bit bit 30. 30. AsAssuch, such, thethe pulldown pulldown force force may bemay be derived derived from aofpressure from a pressure the of the hydraulic feed hydraulic feed cylinder. cylinder. Pulldown Pulldownforce forceinput input218 218may maybe be a sensorforfordetecting a sensor detectinga anet net force force acting on acting on the the hydraulic hydraulic feed feed cylinder cylinder 34, 34, which which maybe controlled by may be controlled by controller controller 210. 210. Forces Forces acting on acting on the the hydraulic hydraulic feed feed cylinder cylinder 34 34 may include aa head may include head end end pressure pressure and andaarod rod end endpressure. pressure. For example, For example,pulldown pulldownforce forceinput input218 218maymay be be oneone or or more more pressure pressure sensors sensors configured configured to to communicatea pressure communicate a pressuresignal signaltotocontroller controller 210. 210. The Thepressure pressuresensors sensorsmay maybe be disposed disposed within within a a hydraulicfluid hydraulic fluidline, line,atata apump pump of the of the hydraulic hydraulic fluid fluid tankor36, tank 36, in aorhead in aofhead of the hydraulic the hydraulic feed feed cylinder34. cylinder 34.Further, Further, pulldown pulldown force force input input 218 may218 maya include include weight ofa the weight drillof the drill string 28 onstring the 28 on the drill bit drill bit 30. Assuch, 30. As such,thethepressure pressure signals signals may may be added be added to the ofweight to the weight of the the drill drill28string string acting28 acting on the on the drill drillbit bit30.30.Alternatively, Alternatively,anyanysensor associated sensor with associated pulldown with pulldown force forceinput input218 218may may be be

disposedininother disposed other locations locations relative relative to the to the hydraulic hydraulic feed cylinder feed cylinder 34. Pulldown 34. Pulldown force inputforce 218 input 218 mayalso may also derive derive pulldown pulldownforce forceinformation informationfrom from other other sources,including sources, includingother othersensors. sensors.

[0027] Rotation

[0027] Rotation torque torque input input 220 220 may may be or be one one or more more sensors sensors or other or other mechanism mechanism configured configured

to detect to detect and/or communicate and/orcommunicate a rotation a rotation torque torque of thebitdrill of the drill 30.bit One30. One torque or more or more torque sensors sensors maybebephysically may physically associated associated withdrill with the the bit drill30bit or 30 mayor bemay be a virtual a virtual sensor sensor used used to acalculate to calculate a rotation torque rotation torque based based on sensed parameters on sensed parameters such suchasas rotation rotation speed speed of of the the rotary rotary head head 26 26 and and

pressure at pressure at the the rotary rotaryhead head 26. 26. As As such, rotation rotation torque torque input input220 220 may include one may include one or or more more

2020205242 14 Jul 2020 sensors (e.g., a speed sensor) for detecting rotation speed of the rotary head 26 (and thus the drill sensors (e.g., a speed sensor) for detecting rotation speed of the rotary head 26 (and thus the drill

bit 30) and a sensor (e.g., a pressure sensor) for detecting pressure of a fluid supply to the rotary bit 30) and a sensor (e.g., a pressure sensor) for detecting pressure of a fluid supply to the rotary

head 26. head 26. The Thespeed speedsensor sensormay may be be disposed disposed on on or or near near thethe rotaryhead rotary head 26 26 andand thethe pressure pressure

sensor may be disposed within a fluid supply line of the rotary head 26. Alternatively, any sensor may be disposed within a fluid supply line of the rotary head 26. Alternatively, any

sensor associated with rotation torque input 220 may be disposed in other locations relative to sensor associated with rotation torque input 220 may be disposed in other locations relative to

the rotary head 26 and/or drill bit 30. Rotation torque input 220 may also derive rotation torque the rotary head 26 and/or drill bit 30. Rotation torque input 220 may also derive rotation torque

information from information fromother other sources, sources, including including other other sensors. sensors.

[0028] FeedFeed

[0028] raterate input input 222222 may may be a be a sensor sensor or other or other mechanism mechanism configured configured to detect to detect and/orand/or

communicatea feed communicate a feedrate rateofofthe the drill drill bit bit30. 30.Feed Feed rate rateinput input222 222may communicatea afeed may communicate feedrate rate signal indicative of a feed rate of the drill bit 30 to controller 210. For example, feed rate input signal indicative of a feed rate of the drill bit 30 to controller 210. For example, feed rate input

222 may 222 maymonitor monitora arotation rotationspeed speedofofa asheave sheaveofofthe the cable cable and andpulley pulley system systemfor formoving movingrotary rotary head 26 head 26 up up and anddown downalong along thethe mast mast frame frame 24.24. FeedFeed raterate input input 222222 maymay embody embody a conventional a conventional

rotational speed detector (e.g., a rotary encoder) having a stationary element rigidly connected to rotational speed detector (e.g., a rotary encoder) having a stationary element rigidly connected to

a mounting bracket of the sheave that is configured to sense a relative rotational movement of the a mounting bracket of the sheave that is configured to sense a relative rotational movement of the

sheave (e.g., of a shaft of the sheave). The stationary element may be a magnetic or optical sheave (e.g., of a shaft of the sheave). The stationary element may be a magnetic or optical

element mounted element mountedtotothe themounting mounting bracket bracket of of thethesheave sheave andand configured configured to to detectrotation detect rotationofofanan indexing element (e.g., a toothed tone wheel, an embedded magnet, a calibration stripe, teeth of a indexing element (e.g., a toothed tone wheel, an embedded magnet, a calibration stripe, teeth of a

timing gear, etc.) connected to rotate with the shaft of the sheave. A sensor of feed rate input timing gear, etc.) connected to rotate with the shaft of the sheave. A sensor of feed rate input

222 may 222 maybebelocated locatedadjacent adjacentthe the indexing indexingelement elementand andconfigured configured to to generatea signal generate a signaleach eachtime time the indexing the element (or indexing element (or aa portion portion thereof) thereof) passes passes near near the thestationary stationaryelement. element. The The signal signal may may

be directed to controller 210, which may use the signal to determine a number of shaft rotations be directed to controller 210, which may use the signal to determine a number of shaft rotations

of the sheave, occurring within fixed time intervals, and use this information to determine the of the sheave, occurring within fixed time intervals, and use this information to determine the

feed rate value. feed rate value.Feed Feed raterate input input 222 222 mayderive may also also derive feed feed rate rate information information from other from other sources, sources,

including other sensors. including other sensors.

[0029] Rotation

[0029] Rotation speed speed input input 224 224 may may be be a sensor a sensor (e.g., (e.g., a speed a speed sensor) sensor) thatthat maymay be be configured to detect a rotation speed of the drill bit 30. Rotation speed input 224 may configured to detect a rotation speed of the drill bit 30. Rotation speed input 224 may

communicate a rotation speed signal indicative of a rotation speed of the drill bit 30 to controller communicate a rotation speed signal indicative of a rotation speed of the drill bit 30 to controller

210. For 210. Forexample, example,rotation rotationspeed speedinput input224 224may may monitor monitor thethe rotationspeed rotation speed of of therotary the rotaryhead head 26. Rotation 26. Rotation speed speedinput input224 224may mayembody embody a conventional a conventional rotational rotational speed speed detector detector having having a a stationary element rigidly connected to the rotary head 26 that is configured to sense a relative stationary element rigidly connected to the rotary head 26 that is configured to sense a relative

rotational movement of the rotary head 26 (e.g., of a rotational portion of the rotary head 26 that rotational movement of the rotary head 26 (e.g., of a rotational portion of the rotary head 26 that

is operatively connected to the rotary head 26, such as a shaft of the rotary head 26 or the drill is operatively connected to the rotary head 26, such as a shaft of the rotary head 26 or the drill

string 28 string 28 mounted onthe mounted on the rotary rotary head head 26). 26). The Thestationary stationary element elementmay maybe be a magnetic a magnetic or or optical optical

element mounted element mountedtotoa ahousing housingofofthe therotary rotary head headassembly assemblyandand configured configured to to detectrotation detect rotationofofanan

9

2020205242 14 Jul 2020 indexing element indexing element (e.g., (e.g., a toothed a toothed tone tone wheel, wheel, an embedded an embedded magnet, a magnet, a calibration calibration of a teeth of a stripe, teethstripe,

timing gear, etc.) connected to rotate with the shaft of the rotary head 26. A sensor of rotation timing gear, etc.) connected to rotate with the shaft of the rotary head 26. A sensor of rotation

speed input speed input 224 224 may maybebelocated locatedadjacent adjacentthe the indexing indexingelement elementand andconfigured configured to to generatea generate a signal each time the indexing element (or a portion thereof) passes near the stationary element. signal each time the indexing element (or a portion thereof) passes near the stationary element.

The signal The signal may maybebedirected directed toto controller controller 210, 210, which mayuse which may usethe thesignal signal to to determine determine aa number numberofof shaft rotations of the rotary head 26, occurring within fixed time intervals, and use this shaft rotations of the rotary head 26, occurring within fixed time intervals, and use this

information to information to determine determine the the rotation rotation speed speed value. Rotation speed value. Rotation speedinput input 224 224may mayalso alsoderive derive rotation speed information from other sources, including other sensors. rotation speed information from other sources, including other sensors.

[0030] For For

[0030] outputs outputs of control of control system system 200,200, feedfeed command command 230 230 may mayactuation cause cause actuation of the of the hydraulic feed hydraulic feed cylinder cylinder 34 34 and maycause and may causea achange changeofofposition positionofofrotary rotary head head 2626upupand anddown down along the along the mast frame 24. mast frame 24. AsAssuch, such,feed feedcommand command230 230 may control may control the feed the feed rate rate of drill of drill bitbit3030 into into and and out out of of the thehole hole50. 50. Air Air supply supply command 232 command 232 maymay cause cause actuation actuation of aofvalve a valve in in thethe air air

supply line supply line of of the the rotary rotaryhead head26. 26. As As such, such, air airsupply supply command command 2626 may may control control airair pressure pressure

exerted on the drill bit 30. Drill string rotation command 234 may cause actuation of the valve exerted on the drill bit 30. Drill string rotation command 234 may cause actuation of the valve

of hydraulic of hydraulic fluid fluid line lineofofthe rotary the head rotary 26.26.AsAssuch, head such,drill drillstring rotation string command rotation command234 234may may

control the rotation speed of the drill string 28 (and thus the drill bit 30). Watering command control the rotation speed of the drill string 28 (and thus the drill bit 30). Watering command

236 may 236 maycause causeactuation actuationofofaavalve valveofofthe the watering watering line. line. As As such, such, the the watering watering command command 236 236

maycontrol may control water waterpressure pressure and andamount amountof of waterofof water thewatering the wateringline. line.

[0031] FIG.FIG.

[0031] 3 provides 3 provides an exemplary an exemplary collar collar reaming reaming function function 300the 300 for forautomatic the automatic collarcollar

operation. The operation. Thecollar collar reaming reamingfunction function300 300may maybe be selectivelyenabled selectively enabledbyby an an operatorviaviainput operator input device 40. device 40. Alternatively, Alternatively, the the collar collar reaming reaming function function may be set may be set to to always be enabled always be enabled such such that that collar reaming collar occurs during reaming occurs during every every collar collar operation. Thus, collar operation. Thus, collar reaming function 300 reaming function 300may may include initiating include initiatingcollaring collaringwith withreaming reaming increments increments when collar reaming when collar reamingisis enabled enabled (step (step 310). 310). When collar reaming is enabled, controller 210 may initiate drill rotation at collar settings (step When collar reaming is enabled, controller 210 may initiate drill rotation at collar settings (step

312). The collar settings may include a rotation speed and feed rate lower than a rotation speed 312). The collar settings may include a rotation speed and feed rate lower than a rotation speed

and feed rate during the non-collar drilling operation (hereinafter "drilling operation"), and may and feed rate during the non-collar drilling operation (hereinafter "drilling operation"), and may

include water and air supplied to the drill bit 30, but with more water and less air than the drilling include water and air supplied to the drill bit 30, but with more water and less air than the drilling

operation. For operation. For example, example,controller controller 210 210may mayprovide provide a drill string a drill string rotation rotation command 234 command 234 to to

initiate initiate rotation of drill rotation of drill string 28 atat the string 28 the lower lowerrotation rotationspeed speed thanthan for non-collar for the the non-collar drilling drilling of theof the

hole. hole.

[0032] WhenWhen

[0032] the drill the drill rotation rotation is is at at thecollar the collar settings, settings, controller controller210 210 may then provide may then provide aa feed feed command 230 to feed the drill bit 30 (e.g., at the lower feed rate) to the ground to a command 230 to feed the drill bit 30 (e.g., at the lower feed rate) to the ground to a

predetermined increment and then automatically retract the drill bit 30 from the hole (step 314). predetermined increment and then automatically retract the drill bit 30 from the hole (step 314).

10

2020205242 14 Jul 2020 The predetermined The predeterminedincrement is isless increment lessthan thanthe the set set collar depth. For collar depth. For example, the predetermined example, the predetermined increment maybebe200mm increment may 200mm and and the set the set collar collar depth depth maymay be 1,600mm. be 1,600mm. It is It is understood understood that these that these

increments are exemplary increments are exemplaryonly onlyand andthat thatother otherincrements incrementstotothe the collar collar may beimplemented may be implementedandand

the increments the maybebedifferent. increments may different. Further, Further, the the increments increments may mayinclude includeonly onlyone oneincrement, increment,twotwo increments, or or more than two more than twoincrements. increments.This Thisprocess process may may be be repeated repeated to to increase increase thethe collar collar

depthbybythethepredetermined depth predetermined increments increments until until the the desired desired collar collar depth is depth is (step achieved achieved 316 - (step Yes). 316 - Yes). Aswill As willbebedetailed detailed below below with with respect respect to 4, to FIG. FIG. the 4, the collar collar depth depth may be amay be a via set value set value via operator operator input or aa predetermined input value stored predetermined value stored in in the the memory memory ofofcontroller controller 210, 210, or or the collar collardepth depth may be may be

a variable a valuedetermined variable value determined in real in real time time basedbased on the on the values sensed sensedofvalues of the the collar collar operation. operation.

Further, ifif the Further, the last last increment increment is is lessthan less than a predetermined a predetermined threshold threshold (e.g., 50mm), (e.g., 50mm), controllercontroller 210 210 mayproceed may proceed directly directly to step to step 318 without 318 without retracting retracting thebit the drill drill 30 bit from30 thefrom hole.the hole.

[0033] WhenWhen

[0033] the collar the collar depthdepth is achieved, is achieved, controller controller 210210 may may retract retract the the drillbit drill bit3030from fromthe the bottomofof bottom thehole the hole (step (step 318), 318), but but not necessarily not necessarily out ofout the of the The hole. hole. Thereaming collar collarfunction reaming function 300(and 300 (andthethecollar collaroperation) operation) may may be be discontinued discontinued when the when collar the collar depth depth is met is met and the drilland bit the drill bit 30 is 30 is retracted retracted (step (step318) 318)prior prior to to feeding feeding the the drill drill for for drilling drilling (step (step 320)320) fordrilling for the the drilling operation.ForFor operation. example, example, when when the collar the collar depth depth is is met, controller met, controller 210 may 210 may retract retract drill bit 30drill bit 30 slightly from slightly fromthe thebottom bottom of the of the hole, hole, and transition and transition the drill the drill fordrilling for the the drilling operation operation (e.g. (e.g. increase the increase therotation rotationspeed, speed, increase increase the the feed feed rate,rate, decrease decrease watering, watering, and increase and increase air supplyair to supply to the drill bit 30). the drill bit 30).

[0034] FIG.FIG.

[0034] 4 provides 4 provides an exemplary an exemplary automatic automatic collarcollar depthdepth adjustment adjustment function function 400thefor 400 for the automatic collar automatic collar operation. The automatic operation. The automaticcollar collar depth depth adjustment adjustmentfunction function400 400may maybe be an an automaticpart automatic part of of thethe collar collar function, function, or may or may be a function be a function that isthat is enabled enabled and by and disabled disabled the by the operatorororother operator otherentity entityassociated associated withwith the drilling the drilling machine machine 10. the 10. During During collarthe collar operation, operation, the the automatic collar automatic collar depth depth adjustment function 400 adjustment function 400may mayinclude includemeasuring measuring values values of multiple of multiple drill drill

bit inputs bit at aa predetermined inputs at predetermined sample sample depth depth region region that is that less is lessthethan than set the set depth collar collar(step depth (step 410). 410). For example, For example,controller controller 210 210 may mayreceive receivevalues valuesofofinputs inputs216-224 216-224during duringthethecollar collaroperation, operation, e.g. bit e.g. bit air air pressure, pulldown pressure, pulldown force, force, rotation rotation torque, torque, feed feed rate,rate, and/or and/or rotation rotation speed. speed. The The predeterminedsample predetermined sampledepth depthregion region may may be be a small a small region region (e.g.,between (e.g., betweentwotwo predetermined predetermined

depths) of the depths) the collar collarportion portion52 52of ofhole hole50. 50.InInone oneexample example the the sample region may sample region maybebelocated located approximatelyatat aa midpoint approximately midpointofofthe the collar collar depth, depth, for forexample a region example a region of 400-600 400-600mmmm forfor a 1a 1

meter collar meter collar depth. The predetermined depth. The predeterminedsample sample depth depth region region maymay be input be input by operator by an an operator or may or may

be determined be andstored determined and storedbybythe the manufacturer, manufacturer,ananengineer, engineer,ororother other personnel personnelassociated associatedwith with the operation the operationofof drillingmachine drilling machine 10. 10.

11

2020205242 14 Jul 2020

[0035] Controller

[0035] Controller 210 210 may may then then storestore values values for each for each drill drill bitbit inputover input overthe thesample sampledepth depth region (step region (step 412). For example, 412). For example, controller controller 210 210 may mayaverage averagemultiple multiplemeasured measured values values over over the the

sample depthregion sample depth regionfor for each each input input 216-224. 216-224. When When the the drillbit drill bit3030isis moved movedbeyond beyond thethe sample sample

depthregion, depth region,andand hashas notnot yet yet reached reached thecollar the set set collar depth,depth, controller controller 210 may 210 mayvalues monitor monitor of values of the drill the drill bit bit inputs (step 414). inputs (step 414).ForFor example, example, afterafter the average the average values values have have been beencontroller stored, stored, controller 210 will 210 will continue continue to to receive receive inputs inputs 216-224 as the collar 216-224 as collaroperation operation continues continues beyond the sample beyond the sample depth region. depth region.

[0036] The The

[0036] monitoring monitoring may continue may continue until until one orone or more more of theof the monitored monitored valuesvalues changes changes by a by a predeterminedthreshold predetermined threshold(step (step 416). 416). The Thepredetermined predetermined threshold threshold maymay include include a percentage a percentage or or set value. set value. For For example, the predetermined example, the predeterminedthreshold thresholdmay may correspond correspond to to a 20% a 20% change change from from the the stored average stored averagevalue, value, or may or may be anbe an absolute absolute value for value change change for the the input input 216-224 216-224 (e.g. a feed (e.g. rate a feed rate change of change ofgreater greater than 2mm/s), or even 2mm/s), or evenmerely merelybebeananabsolute absolutevalue valuealone alonefor forthe the input input 216-224 216-224 in the in post-sampling the post-sampling region region that that is indicative is indicative of anof an expected expected change change from the from the average average value. value. Further, the Further, the monitoring monitoring may maycontinue continueuntil untilone oneorormore moreofofthe themonitored monitored values values changes changes by by thethe

predeterminedthreshold predetermined thresholdfor for aa predetermined predeterminedamount amount of of time.ForFor time. example, example, the the predetermined predetermined

amountofoftime amount timemay maybebeoneone second. second. In In some some embodiments, embodiments, each input each input 216-224 216-224 may include may include a a predeterminedweight predetermined weightfactor factorthat that controller controller 210 stores when 210 stores the monitored when the monitoredvalues valuesfor forthe the corresponding input corresponding input216-224 216-224changes changes by by thethe predetermined predetermined threshold. threshold. The The predetermined predetermined

weight factor weight factor may maybe bedifferent different for for each each input 216-224. Themonitoring 216-224. The monitoringmaymay continue continue until until a sum a sum

of the of the stored stored predetermined weight factors predetermined weight factors exceeds exceeds aa predetermined predeterminedvalue. value.For Forexample, example, thethe

predeterminedweight predetermined weightfactor factorfor for each each input input 216-224 216-224may may be be a fractionsuch a fraction suchthat thatthe the monitoring monitoring continuesuntil continues untilthe thestored stored predetermined predetermined weightweight factors factors sum tothan sum to greater greater thantoor1.equal or equal to 1.

[0037] WhenWhen

[0037] one one or or more more of theof the monitored monitored inputs inputs 216-224 216-224 changeschanges by the predetermined by the predetermined

threshold,controller threshold, controller210210 maymay endcollar end the the collar operation operation prior toprior to reaching reaching the setdepth, the set collar collar anddepth, and then may then maybegin beginthe thedrilling drilling operation operation (step (step 418). 418). For example, controller 210 example, controller mayend 210 may endthe thecollar collar operationwhen operation whenany any of values of the the values of bitof bitpressure air air pressure inputpulldown input 216, 216, pulldown force force input 218, input or 218, or rotation torque rotation torque input input 220 220 changes (increases) by changes (increases) by more than 20% more than 20%forforone onesecond. second.Likewise, Likewise, controller 210 controller 210maymay end end the collar the collar operation operation when when any anyvalues of the of theof values ofinput feed rate feed 222 rateorinput 222 or rotation speed rotation speed input 224 changes (decrease) 224 changes (decrease) by by more morethan than20% 20%forfor one one second. second.

Industrial Applicability Industrial Applicability

[0038] The The

[0038] disclosed disclosed aspects aspects of collar of collar control control system system 200 200 of the of the present present disclosure disclosure maymay be be used in used in any drilling machine any drilling having aa collar machine having collar mode. mode.

12

2020205242 14 Jul 2020

[0039] As used

[0039] As used herein, herein, the the terms terms automated automated and automatic and automatic are used are used to describe to describe functions functions that that

are done are donewithout without user user intervention. intervention. Thus, Thus, the automatic the automatic collar operation, collar operation, as well as as well the as the various various functions functions ofof FIGs. FIGs. 3-4, 3-4, maymay all proceed all proceed without without user intervention. user intervention.

[0040] SuchSuch

[0040] a collar a collar control control system system 200 200 may may help help decrease decrease the chances the chances of a or of a jam jamclog or clog duringthe during thecollar collaroperation operation and and may may also enable also enable a overall a faster faster overall drillingdrilling operation operation due to due to decreased collar decreased collar time. For example, time. For example,the the disclosed disclosed system system200 200may may allow allow an an operator operator to to input input

desired hole desired holesettings settingsandand trigger trigger (either (either manually manually or automatically) or automatically) theoperation. the collar collar operation. The The disclosed disclosed system 200may system 200 mayreceive receivevarious varioussensor sensorinputs, inputs,asas described describedabove, above,and andcontrol controlfeed feed rate, drill rate, drill string string rotation, rotation, air air supply, andwatering supply, and watering supply supply functions functions to automatically to automatically collar acollar hole a hole at reaming at increments reaming increments to desired to the the desired collar collar depth depth settings settings and/or and/or to automatically to automatically adjust the adjust collar the collar depth settings. depth settings. Such Such aa system system 200 200may maycreate createa amore moreintuitive intuitiveoperator operator control control and andmay mayallow allow more autonomy more autonomyof of thethedrilling drilling machine machine10.10.Thus, Thus, thethe collarcontrol collar controlsystem system200200 of of thepresent the present disclosure disclosure may help operators may help operators execute execute the the collar collar operation operation and mayhelp and may helptoto reduce, reduce, or or avoid, avoid, jamsororclogs jams clogs during during the the collar collar operation, operation, while while decreasing decreasing overall drilling overall drilling time. time.

[0041]It will

[0041] It will be apparent be apparent to skilled to those those skilled in the in the art thatart that various various modifications modifications and and variations variations can be can madetoto the be made the disclosed disclosed system systemwithout withoutdeparting departingfrom fromthe thescope scopeofofthe thedisclosure. disclosure. Other Other embodiments embodiments of disclosure of the the disclosure will will be be apparent apparent to thosetoskilled those in skilled infrom the art the consideration art from consideration of of the specification the specificationand and practice practice of the of the invention invention disclosed disclosed herein.herein. It is intended It is intended that the that the specification specification and and examples be considered examples be consideredasas exemplary exemplaryonly, only,with witha atrue truescope scopeand andspirit spirit of of the the invention being indicated by being indicated by the the following claims. following claims.

Claims (20)

Claims 26 Aug 2025

1. A method for automated control of a collar operation of a mobile drilling machine using a drill bit mounted on a drill string, comprising: automatically initiating rotation of the drill bit at a rotation speed based on collar settings, wherein the collar settings include at least a set collar depth; automatically feeding the drill bit to form an initial hole at a predetermined reaming increment, the predetermined reaming increment being a distance that is a fraction of 2020205242

the set collar depth; automatically retracting the drill bit from the initial hole when the predetermined reaming increment is reached; and repeating, until the set collar depth is reached, the steps of (i) automatically feeding the drill bit to increase a depth of the initial hole by the predetermined reaming increment and (ii) retracting the drill bit from the initial hole after the depth of the initial hole has increased by the predetermined reaming increment.

2. The method of claim 1, wherein the predetermined reaming increment includes a first increment to a first hole depth, and repeating the steps of automatically feeding the drill bit and automatically retracting the drill bit includes: automatically feeding the drill bit at a second increment to a second hole depth, wherein the second hole depth is greater than the first hole depth, but less than a collar depth, and automatically retracting the drill bit from the second hole depth when the second hole depth is achieved.

3. The method of claim 1 or 2, further including: ending the collar operation once the set collar depth is reached; automatically retracting the drill bit from the bottom of the hole while still remaining partially inside the hole; and transitioning to a drilling operation.

4. The method of any one of claims 1-3, wherein transitioning to a drilling operation includes: automatically increasing the rotation speed of the drill bit for the drilling operation; and automatically feeding the drill bit at an increased feed rate for the drilling 26 Aug 2025 operation.

5. The method of any one of claims 1-4, further including: measuring values of multiple drill bit inputs at a predetermined sample depth region during the collar operation; storing average values for each of the drill bit inputs over the predetermined sample depth region; 2020205242

monitoring values of the drill bit inputs when the drill bit moves beyond the predetermined sample depth region; and ending the collar operation prior to the set collar depth when any of the monitored values change by a predetermined threshold.

6. The method of claim 5, wherein the predetermined sample depth region is less than the set collar depth.

7. The method of claim 5 or 6, further including: ending the collar operation prior to the set collar depth when any of the monitored values change by the predetermined threshold for a predetermined amount of time.

8. The method of any one of claims 5-7, wherein each of the drill bit inputs includes a predetermined weight factor, wherein the method further includes: storing the predetermined weight factor for a respective drill bit input when the monitored value for the respective drill bit input changes by the predetermined threshold; summing the stored predetermined weight factors; and ending the collar operation prior to the set collar depth when the summed predetermined weight factors exceeds a predetermined threshold.

9. The method of any one of claims 1-8, further including: monitoring values of multiple drill bit inputs over a predetermined sample depth region during the collar operation; and ending the collar operation prior to the set collar depth when any of the monitored values change by a predetermined threshold beyond the predetermined sample depth region.

10. The method of any one of claims 1-9, wherein the predetermined reaming 26 Aug 2025

increment is less than or equal to one-eighth of the set collar depth.

11. A mobile drilling machine, comprising: a mast including a mast frame; a rotary head movably mounted on the mast frame, the rotary head controllable to rotate a drill bit mounted on a drill string at a rotation speed, wherein the rotary head is further controllable to move up and down the mast frame to feed the drill bit at a feed speed; and 2020205242

a controller configured to: automatically initiate rotation of the drill bit at a rotation speed based on collar settings for a collar operation, wherein the collar settings include at least a set collar depth; automatically feed the drill bit to form an initial hole at a predetermined reaming increment, the predetermined reaming increment being a distance that is a fraction of the set collar depth; automatically retract the drill bit from the initial hole when the predetermined reaming increment is reached; and repeat, until the set collar depth is reached, the steps of (i) automatically feeding the drill bit to increase a depth of the initial hole by the predetermined reaming increment and (ii) retracting the drill bit from the initial hole after the depth of the initial hole has increased by the predetermined reaming increment.

12. The mobile drilling machine of claim 11, wherein the controller is further configured to: measure values of multiple drill bit inputs at a predetermined sample depth region during the collar operation; store average values for each of the drill bit inputs over the predetermined sample depth region; monitor values of the drill bit inputs when the drill bit moves beyond the predetermined sample depth region; and end the collar operation prior to the set collar depth when any of the monitored values change by a predetermined threshold.

13. The mobile drilling machine of claim 12, wherein the predetermined threshold includes a percentage or set value.

14. The mobile drilling machine of claim 12 or 13, wherein the controller is further configured to: end the collar operation prior to the set collar depth when any of the monitored values change by the predetermined threshold for a predetermined amount of time.

15. The mobile drilling machine of any one of claims 12-14, wherein each of the drill bit inputs includes a predetermined weight factor, and wherein the controller is further 2020205242

configured to: store the predetermined weight factor for a respective drill bit input when the monitored value for the respective drill bit input changes by the predetermined threshold; sum the stored predetermined weight factors; and end the collar operation prior to the set collar depth when the summed predetermined weight factors exceeds a predetermined threshold.

16. The mobile drilling machine of any one of claims 11-15, wherein the controller is further configured to: automatically retract the drill bit from the initial hole when the predetermined reaming increment is achieved, but prior to reaching the set collar depth.

17. The mobile drilling machine of claim 16, wherein the predetermined reaming increment is a first increment to a first hole depth, and the controller is further configured to: after automatically retracting the drill bit from the initial hole, automatically feed the drill bit at a second increment to a second hole depth, wherein the second hole depth is greater than the first hole depth, but less than the set collar depth; and automatically retract the drill bit from the second hole depth when the second hole depth is achieved.

18. The mobile drilling machine of any one of claims 11-17, wherein the controller is further configured to: automatically retract the drill bit when the set collar depth is achieved; automatically increase the rotation speed of the drill bit for the drilling operation; and automatically feed the drill bit at an increased feed rate for the drilling operation.

19. The mobile drilling machine of any one of claims 11-18, wherein the controller is further configured to: monitor values of multiple drill bit inputs over a predetermined sample depth region during the collar operation; and end the collar operation prior to the set collar depth when any of the monitored values change by a predetermined threshold beyond the predetermined sample depth region; automatically increasing the rotation speed of the drill bit for the drilling 2020205242

operation; and automatically feeding the drill bit at an increased feed rate for the drilling operation.

20. A method for automated control of a collar operation of a mobile drilling machine using a drill bit mounted on a drill string, comprising: automatically initiating rotation of the drill bit at a rotation speed based on collar settings, wherein the collar settings include at least a set collar depth; automatically feeding the drill bit at a feed rate to form an initial hole; measuring values of multiple drill bit inputs at a predetermined sample depth region during the collar operation; storing average values for each of the drill bit inputs over the predetermined sample depth region; monitoring values of the drill bit inputs when the drill bit moves beyond the predetermined sample depth region; and ending the collar operation prior to the set collar depth when any of the monitored values change by a predetermined threshold.