Abstract:
A method and system for controlling a horizontal directional drilling machine having a boring tool. A rate of rotation and a rate of thrust are selected by an operator. Controls allow an automatic boring operation mode to be initiated to maintain the selected rate of rotation and thrust without further input from the operator. Periodically, when the rotation and thrust are interrupted, such as to modify the drill string, the automatic boring operation mode is interrupted. The automatic boring operation mode may be resumed without requiring the operator to select the rate of rotation and rate of thrust. The rate of rotation is resumed before the rate of thrust to reduce drill string shock loads and increase drilling performance.

Description:
FIELD OF THE INVENTION 
   The present invention relates generally to underground boring machines and methods for controlling underground boring. More particularly, the present invention relates to underground boring machines for use in horizontal directional drilling and to an improved method of, and apparatus for, automatic control of boring functions. 
   BACKGROUND OF THE INVENTION 
   Utility lines for water, electricity, gas, telephone and cable television are often run underground for reasons of safety and aesthetics. Sometimes, the underground utilities are buried in a trench that is then back filled. However, trenching can be time consuming and can cause substantial damage to existing structures or roadways. Consequently, alternative techniques such as horizontal directional drilling (“HDD”) are becoming increasingly popular. 
   A typical horizontal directional drilling machine includes a frame on which is mounted a rotational drive mechanism that can be slidably moved along the longitudinal axis of the frame, to rotate a drill string about its longitudinal axis while sliding along the frame to advance the drill sting into, or withdraw it from, the ground. The drill string comprises one or more drill rods attached together in a string. 
   A boring tool is installed onto the end of the drill string furthest away from the horizontal HDD machine. For example, a drill bit is used when the drill string is being advanced into the ground where there is no existing hole. Similarly, a back reamer is used to enlarge a bored hole and is used when the drill string is being withdrawn after a hole is cut. These boring tools may include a wide variety of soil cutting devices tailored for specific formations. Examples include cutting edges that shear the soil and compression elements that concentrate longitudinal force from the drill string onto a concentrated area to fracture the ground when boring in rock conditions. In either case, the operation of the boring tools includes both rotational and longitudinal (or thrust) motion. 
   Boring machines include controls that allow the operator to control both the rotational movement and the longitudinal movement, also referred to as thrust, of the drill string and consequently of the boring tool. Typically, the magnitude of the rotational movement and thrust movement are proportional to the position of the controls. The optimum setting of rotational movement and thrust movement depends on various factors such as the soil conditions, the formation, and the type of boring tool. It is therefore necessary for the operator to establish the optimum setting based on each unique boring situation. However, in some situations the soil conditions can change rapidly, particularly as the boring tool advances through the soil and encounters soils of different densities and types, such as clay soil and rocks. Under these circumstances, an operator may be not be able to adjust the settings quickly enough to compensate for these variations. U.S. Pat. No. 5,746,278, to Bischel, herein incorporated by reference, discloses a control system that automatically adjusts the rotational movement and thrust movement settings, independently from the inputs of the operator. 
   In some conditions, the boring process requires maintaining consistent values of the rotational and thrust movement settings, which in turn requires the operator to maintain the controls in the appropriate position for relatively long periods of time. It can be difficult, however, for the operator to accurately maintain the positions of the controls for relatively long periods of time without becoming fatigued or losing attentiveness. In these conditions, the control system can be set to automatically maintain the boring parameters once the operator has determined the optimum levels of rotation and thrust. A control system configured in this way allows the operator to first manually set the desired rotational movement and thrust movement parameters, and then to maintain this state by depressing a separate control (such as a switch) that causes the control system to maintain these settings when the operator lets go of the controls. Although the controls typically return to their neutral positions (the position where the rotational and thrust movement are set to zero), the rotation and thrust movement settings are maintained automatically at the preferred operating state. 
   The boring operation must generally, however, be periodically interrupted, such as when a drill rod needs to be added to the drill string during boring or when a drill rod needs to be removed from the drill string during backreaming. When the boring process is resumed, the drill bit must be transitioned from a stationary state to a drilling state. A drilling state may generally be defined as including rotation and thrust against the soil. To accomplish this, the control system may further be configured to resume the rotational movement and thrust movement parameters that were present before the boring operation was interrupted. However, when the control system attempts to quickly resume the rotational and thrust movement settings, high loads can be encountered in the boring tool and drill string. These high loads can damage the boring tool and drill string and lead to poor drilling performance. Therefore, there is a need for an optimized boring resumption process and an apparatus for implementing the same. 
   SUMMARY OF THE INVENTION 
   One aspect of the invention includes a method for controlling an underground boring tool. The method includes setting a rate of rotation of the boring tool and setting an axial thrust of the boring tool. As indicated above, the set rate of rotation and axial thrust of the boring tool are generally interrupted periodically, such as to add a drill rod to the drill string. Following the interruption, the set rate of rotation of the boring tool is resumed first before the set axial thrust of the boring tool is resumed at a set rate of increasing axial thrust. While the term periodically is used herein to describe the interruptions in the drilling state, it will be appreciated, however, only one such interruption of the drilling state and a resumption is necessary to practice the principles of the present invention. 
   A further aspect of the invention includes an apparatus for controlling an underground boring tool. The apparatus includes a hydraulic system for imparting rotational motion to the drill string at a controllable speed of rotation or to generate a controllable level of torque, in response to the position of a first control, and thrusting motion at a controllable speed or to generate a controllable level of axial thrust force, in response to the position of a second control, to a boring tool at the distal end of the drill string. The apparatus also includes a third control for generating a rotation setting signal and a thrust setting signal in response to the position of the controls, an indicator for generating an automatic boring mode signal, and a fourth control for generating an automatic boring mode cancel signal. Furthermore, the apparatus includes a controller for receiving input signals including rotation and thrust setting signals, automatic boring mode signals, and automatic boring mode cancel signals from the controls, for generating rotational motion and thrusting motion control signals in response to the input signals, and for communicating said motion control signals to operatively control said hydraulic system. 
   Yet another aspect of the invention includes an apparatus for controlling an underground boring tool. The apparatus includes a hydraulic system for imparting rotational motion at a controllable speed of rotation or to generate a controllable level of torque, in response to the position of a first control, and thrusting motion at a controllable speed or to generate a controllable level of axial thrust, in response to the position of a second control, to a boring tool. The apparatus also includes a third control for generating a rotation setting signal and a thrust setting signal in response to the position of the controls, a fourth operator actuated control that generates a signal for incrementing and decrementing a rotational motion setting, and a fifth operator actuated control that generates a signal for incrementing and decrementing an axial thrust setting. The apparatus also includes a controller for receiving input signals from the first, second, third, fourth, and fifth operator actuated controls, for generating rotational motion and axial thrust control signals in response to the input signals, and for communicating said motion control signals to operatively control said hydraulic system. 
   While the invention will be described with respect to preferred embodiment configurations and with respect to particular devices used therein, it will be understood that the invention is not to be construed as limited in any manner by either such configuration or components described herein. Also, while the particular types of hydraulic pumps and motors are described herein, it will be understood that such particular mechanisms are not to be construed in a limiting manner. Instead, the principles of this invention extend to any environment in which automatically maintaining and/or resumption of a drilling state with predetermined rotation and axial thrust settings are desired. These and other variations of the invention will become apparent to those skilled in the art upon a more detailed description of the invention. 
   The advantages and features which characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. For a better understanding of the invention, however, reference should be had to the drawings which form a part hereof and to the accompanying descriptive matter, in which there is illustrated and described a preferred embodiment of the invention. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The accompanying drawings, which are incorporated herein and constitute a part of the specification, illustrate several aspects of the invention and together with the description, serve to explain the principles of the invention. A brief description of the drawings is as follows: 
       FIG. 1  illustrates a horizontal directional drilling machine; 
       FIG. 2  illustrates the operator control station of a horizontal directional drilling machine according to the principles of the present invention; 
       FIG. 3  illustrates a control lever of the operator control station of  FIG. 2 ; 
       FIG. 4  illustrates a label identifying the function of the controls found on the control lever of  FIG. 3 ; 
       FIG. 5  illustrates controls found on the right side of the operator control station of  FIG. 2 ; 
       FIG. 6  illustrates a display according to the principles of the present invention; 
       FIG. 7  illustrates the rates of increase of rotational movement and axial thrust when a boring process is resumed; and 
       FIG. 8  is a flow diagram of a method of resuming automatic control of boring functions. 
   

   DETAILED DESCRIPTION 
   With reference now to the various drawing figures in which identical elements are numbered identically throughout, a description of various exemplary aspects of the present invention will now be provided. The preferred embodiments are shown in the drawings and described with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the embodiments disclosed. 
   A horizontal directional drilling machine  20 , illustrated in  FIG. 1 , includes a frame  22  on which is mounted a rotational drive mechanism  30  that is slidably moved along a longitudinal axis of the frame  22 . In one embodiment, horizontal directional drilling machine  20  includes a rear stabilizer  26  and front stabilizer  27  for positioning and stabilizing the machine  20  at the drilling site, and a wheel assembly  24  for supporting the machine during transport between job sites. A drill string  18  comprises a boring tool  42  designed to engage the soil and one of more drilling rods  38  that transmit forces from machine  20  to the boring tool  42 . The rotational drive mechanism  30  typically includes a gearbox and a drive spindle that rotates the drill string  18  about its longitudinal axis, the rotational power being preferably provided by hydraulic motor  216 . The horizontal directional drilling machine  20  also includes a thrust drive mechanism  28  that typically includes gears or sprockets to move the drive mechanism  28  up and down the frame  22  to advance the drill sting  18  into, or withdraw it from, the soil. The thrust power is preferably provided by hydraulic motor  217 . In some embodiments, an engine  36  drives hydraulic pumps  16  and  17 , which pressurize fluid that is transferred to hydraulic motors  216  and  217 . 
   The hydraulic systems can be either open loop where the fluid is transferred from a hydraulic reservoir  14  through the pumps to the motors  216 ,  217  and back to the reservoir  14 , or they can be hydrostatic where the fluid is substantially in a closed loop—being transferred between the pump and the motor. In either system the pumps  16 ,  17  and motors  216 ,  217  are matched, such that by controlling the flow rate of the hydraulic fluid, the speed of rotation of the output shafts of the motors is controlled and can be inferred. The pumps are typically variable displacement pumps capable of producing variable output flow rates, proportional to an electrical current provided by a control system. The output speed of the pumps is proportional to the output flow rates. While the speed can be controlled, the pressure of the hydraulic fluid can be monitored to infer the torque being generated by the motor, which is directly proportional to the longitudinal force or rotational torque being generated. Other embodiments are possible, for instance wherein rotational and thrust drive mechanisms could be actuated by different hydraulic drives (e.g., such as hydraulic cylinders). 
   Some embodiments may also include a water flow mechanism that transmits water through the drill string  18  to the vicinity of the boring tool  42 , where the water flow entrains cut soil particles and removes them from the hole. The horizontal directional drilling machine  20  may also include a greaser for lubricating various moving components (not shown). 
     FIG. 2  illustrates an exemplary operator control station  100  for a horizontal directional drilling machine  20 . Operator control station  100  includes rotational control  110  and thrust control  130  that provide inputs to a controller  150 . Many embodiments of controls  110  and  130  are usable. For example, in one usable embodiment, each of controls  110  and  130  comprise a control lever. In such an embodiment, control levers  110 ,  130  each produce an electrical signal that is proportional to the position of the control lever relative to a center position. The electrical signal is provided as an input to a controller  150 . 
   In one embodiment, when the control lever  110 ,  130  is moved away from the center position, the electrical signal that is generated corresponds to increased rotational torque (and/or rate of rotational movement) or axial thrust force (and/or rate of axial movement), respectively. As the control lever  110 ,  130  is moved closer toward the center position, the generated electrical signal corresponds to decreased rotational torque (and/or rate of rotational movement) or axial thrust force (and/or rate of axial movement), respectively. In one embodiment, when the control lever  110  is moved in the forward direction, away from the operator (best seen in  FIG. 3 , with the direction designated at  200 ), the generated electrical signal corresponds to counter-clockwise rotational movement of the drill string, as viewed looking at the end of the drill string. Alternatively, when the control lever  110  is moved in the backwards direction, toward the operator (best seen in  FIG. 3 , with the direction designated at  201 ), the electrical signal that is generated corresponds to the opposite direction, clockwise rotational movement. Likewise, in one embodiment, when control lever  130  is moved forward, away from the operator, the electrical signal that is generated corresponds to forward movement of the drill string into the soil. Alternatively, when control lever  130  is moved in the backwards direction, toward the operator, the electrical signal that is generated corresponds to backwards movement of the drill string back toward the machine. 
   When either of control lever  110 ,  130  is in the center position, the electrical signal that is generated corresponds to a neutral condition where the rotational or thrust movement respectively is set to zero. A spring or other biasing mechanism is provided to return each of the control levers to the center position, so that if an operator does not hold the lever, it returns to its centered, neutral position such that the rotational or thrust motion settings are set to zero. 
   The controller  150  generates outputs, in response to various inputs, to control the hydraulic system. The system includes the hydraulic pumps  16  and  17  of the drilling machine  20 . The hydraulic motors  216 ,  217  are driven by the hydraulic fluid in a known manner to create rotational and thrust movement of the boring tool  42  and drill string  18 . As noted above, this control is typically a variable electrical current, wherein a certain electrical current will cause the pump to create a certain hydraulic flow rate. The output shaft of the motor thereby rotates at a certain speed of rotation. This is typically independent of the pressure in the fluid. The control systems are typically designed to provide speed control that is independent of load. The control systems typically further include pressure transducers  226  and  227  that provide feedback to the control system indicating the pressure in the circuits, and can further include speed sensors  236  and  237  for measuring the output speed of the motors  216  and  217 , respectively. 
     FIG. 3  illustrates the rotational movement control  110  in more detail, showing the various control switches that are mounted on the control, as well as the forward  200  and backward  201  directions.  FIG. 4  illustrates a visually perceptible display (e.g., a sign) that indicates the functions of each of the control switches located on the control  110  to the operator. Control  110  includes switches  112 ,  118 ,  120 , and  122 , each of which generates an electrical signal when actuated, such as by being pressed. Control switch  112  may be called a SET switch. When SET switch  112  is actuated, an electrical signal is sent to controller  150  activating an automatic boring mode (also called auto boring mode). When controller  150  receives a signal from SET switch  112 , the rotational movement and thrust movement parameters are set within the controller to the values established by the positions of controls  110 ,  130  at the time that the SET switch  112  is actuated. The preferred technique includes setting a value for the speed of rotation, while setting a value for the pressure in the axial thrust circuit, as will be explained in more detail later. Thereafter, controller  150  automatically maintains the boring parameters of rotational movement and thrust movement at the set values without further input from the operator. Preferably, the operator then may release control levers  110 ,  130 , which will then automatically return to the neutral position within a short period of time, without affecting the boring operation, thereby reducing operator fatigue. The auto boring mode will be deactivated if either the rotation handle  110  or the thrust handle  130  is subsequently moved from the neutral position. It will be appreciated that as an alternative embodiment or as an option, it may be possible to deactivate the system by actuating the SET switch (or some other switch), when the system is currently activated. 
   In one embodiment, rotational movement control  110  also includes control switches  114  and  116  which control the water flow functions for injecting water into a bored hole to remove cuttings from the hole. Rotational movement control  110  also includes control switches  118  and  120  to control the speed of the engine  36 , and control switch  122  to control a greaser (not shown). 
     FIG. 6  illustrates a display  170  for the control system that includes a light  172  that is energized when an auto boring mode is active (e.g., to help alert the user on the status of the system). This light  172  is energized after the SET switch  112  is activated and a rotation setting and a thrust setting are defined, so as to enter the auto boring mode. Light  172  is deactivated if the auto boring mode is not active. 
     FIG. 5  illustrates additional control switches on the right side of the operator control station  100 . In one embodiment, control station  100  includes switches  140 ,  142  that are in electrical communication with controller  150 . Switch  140  has a neutral position, a first operative position, and a second operative position. In one embodiment, switch  140  is spring-loaded to the neutral position, so that when the switch is placed in either the first or second operative positions and then released, switch  140  will return to the neutral position. When switch  140  is in the neutral position, switch  140  has no effect on the boring operation. When switch  140  is placed in the first operative position, such as where switch  140  is rotated clockwise away from the neutral position, and when the auto bore mode is activated, an electrical signal is sent to controller  150  to increase the rotational pressure or movement setting by a predefined increment. Similarly, when switch  140  is placed in the second operative position, such as where switch  140  is rotated counterclockwise away from the neutral position, and when the auto bore mode is activated, an electrical signal is sent to controller  150  to decrease the rotational pressure or movement setting by a predefined decrement. 
   Operation of switch  142  is similar. Switch  142  has a neutral position, a first operative position, and a second operative position. In one embodiment, switch  142  is spring-loaded to the neutral position, so that when the switch is placed in either the first or second operative positions and then released, switch  142  will return to the neutral position. When switch  142  is in the neutral position, switch  142  has no effect on the boring operation. When switch  142  is placed in the first operative position, such as where switch  142  is rotated clockwise away from the neutral position, and when the auto bore mode is activated, an electrical signal is sent to controller  150  to increase the axial thrust pressure setting by a predefined increment. Similarly, when switch  142  is placed in the second operative position, such as where switch  142  is rotated counterclockwise away from the neutral position, and when the auto bore mode is activated, an electrical signal is sent to controller  150  to decrease the axial thrust pressure setting by a predefined decrement. 
   During the boring or backreaming processes the system then acts to maintain rotation of the drill string at the selected speed of rotation, independent of the rotational pressure setting and axial pressure setting, and will automatically vary the axial thrust speed as necessary to attempt to maintain the selected pressure in the rotation circuit, or to maintain a set amount of force at the boring tool. In consistent formations maintaining a constant force on the drill bit will result in a constant/consistent torque on the drill bit, and will maximize drilling efficiency. In formations that vary, this same control technique is also effective. 
   It may be necessary to interrupt the auto boring mode, such as when it is required to add or remove a drill rod from the drill string. There are several ways in which the auto boring mode may be interrupted. The machine  20  may be configured so that when the auto boring mode is activated, as indicated by light  172 , any further motion of controls  110 ,  130  sends an electrical signal to controller  150  that causes controller  150  to interrupt the auto boring mode. Alternatively, other switches or controls may be provided or adapted so as to provide an electrical signal to the controller  150  to interrupt the auto boring mode. One example is a control function related to breaking the connection between the drive chuck of the rotational drive  30  and the drill string. When a drill rod has been completely inserted, and the rotational drive is at the end of the frame  22 , then the rotational drive must be unthreaded from the drill string and moved back to the opposite end of the frame so that another drill rod can be added. This action is required when the rotational drive is located at certain positions along the frame, for instance at the extreme opposite ends. Thus, an interrupt signal can be provided automatically by a sensor that measures the position of the thrust drive. When the interrupt signal is received it may also automatically cancel other functions such as the water flow. 
   The operator control station  100  also includes switch  144  that is in electrical communication with controller  150 . Switch  144  may be called a RESUME switch. When the auto boring mode has been interrupted, the operator may actuate switch  144  to resume the auto boring mode. Switch  144  then sends an electrical signal to controller  150  that causes controller  150  to resume the auto boring mode at the same settings as existed prior to the auto boring mode being interrupted. 
   A preferred method which implements the principles of the present invention is shown in  FIG. 8 , where the method is generally designated at  800 . At block  801 , a rate of rotation is of the boring tool  42  is set. The axial thrust of the boring tool  42  is set at block  802 . At block  803 , the set rates of rotation and axial thrust are interrupted, while at block  804 , the resume process is implemented. 
   Many embodiments of the resume process are usable. The resume process of the present invention initiates drilling operation in a manner that minimizes unnecessary vibration and stress in the drill string and drilling tool.  FIGS. 7 and 8  illustrate one usable embodiment of the resume process. The resume process begins (at time equal to 0 seconds) when the switch  144  is depressed to initiate the resume process, sending an electrical signal to the controller  150 . The controller  150  will activate the rotational drive mechanism so as to bring the boring tool to the set value of rotational movement, the set rate of rotation. At the same time, preferably the water flow is automatically restarted (not shown). The resumption of rotational movement occurs rather quickly, usually in about one second. During the time that the rotation is being resumed, controller  150  does not activate the thrust drive mechanism. In this way, the boring tool  42  will resume rotation to the set rate of rotation while there is little or no longitudinal thrust loading or movement. This operation is advantageous because it produces a smooth rotational acceleration without shock loading of the boring tool and drill string. There are additional benefits to reestablish water flow to the cutting tool prior to new cuttings being generated from axial movement of the drill string. 
   After the rotational movement setting is attained, approximately one second after the rotation is started, the controller  150  then beings to apply thrust force to the drill string. However, rather than rapidly increasing the thrust force to the set value, the thrust force is increased from zero to the set value, the set axial thrust, at a predetermined rate. In one usable embodiment, the thrust force is applied at a first constant rate of 25% of the set axial thrust force setting per second for three seconds, from the time of one second after the resume process is initiated to the time of four seconds after the resume process is initiated. Thus, having increased by 25% of the thrust force setting for three (3) seconds, the amount of thrust force applied at this point will be 75% of the thrust force setting. The thrust force is then applied at a second constant rate of 12.5% per second for two seconds. Under this resumption example, from the time of four (4) seconds after the resume process is initiated to the time of six (6) seconds after the resume process is initiated, the thrust force is increased from 75% of the set value to 100% of the set value. Thus, at six (6) seconds after the resume process is initiated, the boring tool will be operating both at the set rate of rotation and the set axial thrust. 
   An alternative embodiment includes increasing the axial thrust force at a single predetermined rate, such as 25% of the set axial thrust force per second for four (4) seconds. It will be appreciated that other rates may also be used, and that the rates provided herein are presented as preferred embodiments, and not as limitations. 
   While particular embodiments of the invention have been described with respect to its application, it will be understood by those skilled in the art that the invention is not limited by such application or embodiment or the particular components disclosed and described herein. It will be appreciated by those skilled in the art that other components that embody the principles of this invention and other applications therefor other than as described herein can be configured within the spirit and intent of this invention. The arrangement described herein is provided as only one example of an embodiment that incorporates and practices the principles of this invention. Other modifications and alterations are well within the knowledge of those skilled in the art and are to be included within the broad scope of the appended claims.