# Presentation: 116036

## Drilling Automation

**Dr. Brian Glass**
**Howard Cannon**
**Samantha Domville**

## Drilling is unpredictable

**Discovery** -- hard to predict what’s down there
- Seismic surveys used on Earth
**Rugged** environments
**Matching** drill behavior to lithology... (Sand? Basalt? Tuff? Worn-out bit?)
- Diagnostics and prognostics
**Sticking** (collapses, creep, ice layers...)
**Retrieval** of cores and cuttings up a long, thin hole

- Crater Ejecta
- Volcanic Flows
- Weathering Products
- Sedimentary Deposits

- Basement Fractured
*in situ*

- Self-Compaction Depth

- Steve Clifford 1993

## Drilling Diagnosis Difficult

- Highly uncertain environment
- limited number of measurements
- performance dependant on local strata
- environment changes over time
- Need to react quickly
- Situations require different techniques with associated costs and risks – important to identify the correct state.
- Example: Auger choking versus hard material.

## Current Activities

_**SMD Projects:**_
**MIDP**: (PI: Brian Glass) 3-year development funding for Drilling Automation for Mars Exploration (**DAME**), for software development and field testing of a Honeybee drill at the Haughton Crater Lunar/Mars-analogue site in the High Arctic
**ASTEP**: (PI: Carol Stoker)  3-year **MARTE** field campaign to drill in the unique, highly acidic Rio Tinto bioanalogue site in Spain, with a Honeybee drill
- 		-- subtask provides human-centered computing, remote science operations simulation, drill automation, field wireless communications
**MTP**: (PI: Brian Glass) Adapt DAME-like automation and diagnostic software for a new planetary deep drill being designed for JPL by Swales, beginning in FY05
**ASTID**: (PI: Geoff Briggs) 3-year development funding for a Baker-Hughes/JSC Mars Arctic Deep Drill (**MADD**), targeted towards bit development for cold-region Mars-analog field site tests in the Arctic
- 		-- subtask provides limited heuristic diagnosis and data acquisition, controls and displays
**MIDP**: (PI: Carol Stoker) 3-year development funding for a shallow/near-subsurface, percussive-drilling Mars Underground Mole (**MUM**), based on the ESA Beagle-2 flight hardware design (Note: Code TI (H. Vu) is also the lead for the MUM mechanical redesign work)
- 		 -- subtask provides diagnostics, mole controls and firmware design
_**ESMD Projects:**_
**ECP:** (PI: Jerome Johnson/Army CRREL) Regolith Characterization Project to build a suite of both surface and subsurface (using a modified Honeybee drill) instruments for prospecting lunar ISRU and surveying the subsurface.  Targeted to provide a low-mass suite for use in 2009 or later lunar surface missions.
- 		-- subtask provides software architecture and integration of instruments, executive controller
- ARC/TI is the **drilling automation technology provider of choice for all three of the competing US planetary subsurface vendors** (Honeybee, Baker-Hughes/JSC, and Swales) and also collaborates with the Canadians...

## Drill Automation for Mars Exploration (DAME)

**Description:**
**Purpose: **develop enabling information technologies for planetary subsurface exploration
**Approach: **iterative spiral implementation and field testing of drilling automation
**Deliverables:**
- Low-power, dry Mars-prototype drill, bits modified for Arctic conditions (permafrost)
- Control and automation software
- Dynamic shaft flexural model and dynamic failure models
- Hybrid diagnostic module

**FY04-FY06 Critical Milestones:**
**FY04** Design and fabricate drill; field test to characterize performance, faults
**FY05 **Build diagnostic models of drill; initial diagnostic software; field test in parallel
**FY06 **In-the-loop drill automation tests at analog site

**Co-Investigators / Participants:**
- 	ARC/Code TI, ARC/Code SS, Honeybee Robotics, Georgia Institute of Technology, SETI Institute, QSS, Mars Institute, RIACS
- 	.
**PI:  **Dr. Brian Glass, ARC, (650) 279-4141,  brian.glass@nasa.gov

## 2004 DAME Field Season

- Full-scale Mars-prototype deep drill has been tested for 1st time under field conditions at a high-fidelity Mars-analog site (Haughton Crater).
- Drilled 2.2m in permafrost and regolith-like breccia, July 2004
- Two sites at Haughton Crater on Devon Island in the the Canadian Arctic, operating at Mars-relevant power levels (max150-200W).
- Level 1 milestone completed successfully

## Cognitive Models Comparison to  FDIR Architecture

- Some cognitive models see humans comprised as a team with multiple intelligences -- analytical/classificational, emotional, and reactive selfs
- Balances of these -- theories of autism, etc
- Relevance to planetary surface robotics in replicating/supplementing human functions in exploration
**In our current FDIR automation approach, there are several internal agents with defined roles... **
**Quick reflex ("ow, my hand's on fire!") implemented as very fast rules or sensor limit-checks **
**Fuzzy neural net that takes past training examples of known problems or faults and then perceives incoming data, coming up quickly with the closest match it knows about from its neural weightings**
**Model-based reasoning module which carries around an internal running simulation of how things are supposed to behave (from the physics, or underlying principles). The latter is slowest and gets invoked when there's a novel fault or situation that the other agents can't handle (or by running in parallel, subtleties that they didn't detect)**
**Overall executive takes the hypotheses from the neural or model-based agents, and weighs between them and decides what course of action to invoke and how it can be made to be compatible with higher-level goals.**

## Vibration Classification Module

- Stick-slip-whirl-bounce model describes primary vibration characteristics of system
- Failure modes change model parameters
- Fuzzy-neural learning techniques used to learn model parameters, and help classify system state

## Initial Drill Model

- Control System

- Power Supply

- Motor

- Motorz

- Auger

- Z drive

- Bit

- Z axis encoder

*dz/dt *
*sensed*

*dz/dt*

*dz/dt desired*

***z*

***z*

*F**z*

- Auger Force Sensor

*F**z** *
*sensed*

*dz**bit**/dt*

*F**bit*

- WOB Sensor

- TOB Sensor

***bit*

***bit*

****

****

*power*

*****desired*

*i**sensed*

*WOB, RPM Inputs from Exec*

*dz**floor**/dt*

*dV**cuttings**/dt*
*created** *

*dV**cuttings**/dt*
*ejected** *

- Theta axis encoder

*****sensed*

## Auger Model

- Nominal
- Drag due to carrying material is minimal
- Torque is a function of depth only
- T=Tl+k*depth
- Choked
- Volume of material in auger can be calculated by integrating material displaced and limiting to auger capacity.
- Torque is a function of depth and volume
- Equation derived from Payzone model
- T=Tl+k*depth+K1/K2*exp(k2*vol-1)

## Model Development

- Auger choking selected for initial tests due to high degree of uncertainty, and necessity to predict (can lead to severe reduction in performance & potential freeze-up).
- Initial models show reasonable correlation to events in 2004 field season.
- Further lab tests conducted recently to refine & improve models.

## Leveraging a Common Software Architecture

- MInI Dispatcher

- Contingent Executive

- Telemetry Interface

- Drill Server

- CSHS Server

- BHIS Server

- Borehole
- Science
- Repository

- Drill

- CSHS

- BHIS

- RSI

- Remote Sensor Servers

*Science Data*

*CRL Plan File*

*Commands*

*Ops Data*

*CRL Plan *
*File*

- Execution
- Repository

*Mission Ops*

- MARTE 2005 Configuration

## Leveraging a Common Software Architecture

- MInI Dispatcher

- Contingent Executive

- Drill Server

- Drill

*CRL Plan File*

*Commands*

*Ops Data*

*CRL Plan *
*File*

- Execution
- Repository

- DAME  Configuration

- Hybrid Diagnosis Module

- Vibration Classification Module

## MARTE Instrument Interface (MINI)

- Flexible Middleware that relays commands and data between multiple clients and servers.
- Built on top of CORBA so is relatively platform and OS independent.
- Allows communication without need to share source code.  Clients can query servers for commands and parameters at run time.
- Utility provided which automatically constructs servers from a configuration file.  Working server can be created in minutes.
- GUI provided which allows communication to any MINI server.
- MInI is complete and stable.  Continuous uptimes of over 96 hours demonstrated, with as many as 3  clients and 10 servers.

## Contingent Executive

- Developed at NASA Ames for rover applications.
- Same Executive as that used in 2004 K9 rover field demonstrations
- Takes in a plan via Contingent Rover Language (CRL) – issues commands and retrieves data from other subsystems via MInI
- Plans support contingent & concurrent operation
- Specifies sequential or concurrent tasks.
- Allows specification of temporal relationships between tasks.
- Can specify start and maintenance conditions based on resources and state.
- Can specify plan branches based on resources and state.

## MADD Automation

**JSC/Baker-Hughes advanced inchworm drill**
**Eureka Arctic test site**
**Original task was only data archival, later **
**upscoped to include controls, displays and **
**automation:**
**Data Acquisition Display:**
- Load cell, ROP, extension, % commanded ROP, auger motor speed, auger motor current, auger motor Temp, AFOB Motor Temp, AFOB motor current, anchor motor current
**Alarm / Warning panel with text**
**Motor Controls: (includes Drill, AFOB and Anchor)**
**Speed, Direction, and Enable/Disable**
**Field-test window stability (user control safeguards)**
**Archival of data and field notes**
**Control loops and diagnostic algorithms**

## MADD DAQ Control and Automation

**MADD DAQ Control and Automation**

**Notes:**
kris

## MADD Auger Choking Algorithm

**MADD Auger Choking Algorithm**

- Drill model compared to HB drill model, similar fault modes, Labview controls

**Notes:**
sam

## Summary

**Drilling is a MEPAG objective -- “follow the water”**
**Drilling is difficult on Earth, an art form**
**Automation of drilling is necessary for planetary subsurface exploration**
**Progress made in drill fault detection and recovery, remote operations, controls and in **
**Umbrella software architectures that integrate diagnosis, execution, sensors and instruments on-board**
**Successful field tests at lunar and Mars-analog sites in 2004**

## Backups

## Universal Executive (PLEXIL)

- CASPER Planner
- (on-board)

- PICO Contingent Planner (off-board)

***Universal Executive***

- CLARAty Functional Layer

- Develop a common execution language that supports multiple planning systems (PLEXIL).
- Develop a generalized, robust Universal Executive within the CLARAty Decision Layer framework for PLEXIL based plans.
- Demonstrate the Universal Executive on the K9 rover using plans from both CASPER and the PICO Contingent Planner.

## Plans / FY04 – FY06 DAME milestones

- The first year, the project designed and fabricated a Mars-prototype drill (6/04) and conducted manual drilling operations in the field to characterize fault modes (7/04)
- Second year, a set of initial automation will be tested alongside the drill in an observe-only fashion (8/05)
- Final season, in-the-loop automation tests in the field (7/06)

## Automated Drilling Analogue Field Tests

*Drill hardware and automation software field tests*
*Automation and drill tests on Devon Island (crater, permafrost)*
*Drill and operations, system of systems tests in Spain (subsurface life in rocks)*
*Component tests (Eureka)*
**Reference Mission Class:**
*Human and robotic subsurface exploration; ISRU acquisition*
**Analogue Features**
*Subsurface ice and permafrost (Devon, Eureka, Antarctica)*
*Regolith-like breccia layers (Devon)*
*Absence of vegetation, roots, etc (Devon Eureka, Antarctica)*
*Cold, dusty (gloved human operations) (Devon, Eureka, Antarctica)*
*Unknown subsurface layers/strata (Devon, Spain)*
*Planetary power and mass limits (max 150-200W power)*
*Dry drilling without lubricants*
**Major Accomplishments:**
*Full-scale planetary-prototype deep drill has been tested for 1st time under field conditions at a high-fidelity analogue site (DAME 7/04)*
*Drilled frozen breccia, tested permafrost bit designs*
*Tested automated drill controls*
**Key Lessons Learned**
*Frictional heating in the hole may cause cuttings and ice shards to briefly melt, forming a mud which quickly refreezes and adheres to the bit and bottom-hole assembly, clogging*
*20m depth is possible with planetary-level mass and power*

- Drilling and remote science ops at Rio Tinto, Spain

**Automated Drilling Analogue Field Tests**

- Drill hardware and automation test on Devon Island

## Measurement Set-up

- Bushing

- Shaker

- Load Cell

- Accelerometer 1

- Laser Vibrometer

- Accelerometer 2

- July 28, 2004

## July 28, 2004

- Channel 1: Load cell
- Channel 2: Accelerometer near shaker
- Channel 3: Accelerometer near clamped end
- Channel 4: Laser vibrometer

- File name: Shaker03.mat

- Clamped free configuration

-     28.7500
-   162.5000
-   378.7500
-   567.5000
-   903.7500

- Frequency peaks [Hz]

-     28.7500
-   161.2500
-   378.7500
-   567.5000
-   805.0000

- Frequency peaks [Hz]

- Frequency peaks [Hz]

-     28.7500
-   162.5000
-   378.7500
-   805.0000
-   892.5000