Information
-
Patent Grant
-
6651755
-
Patent Number
6,651,755
-
Date Filed
Thursday, March 1, 200123 years ago
-
Date Issued
Tuesday, November 25, 200320 years ago
-
Inventors
-
Original Assignees
-
Examiners
- Bagnell; David
- Walker; Zakiya
-
CPC
-
US Classifications
Field of Search
US
- 175 45
- 175 40
- 175 24
- 175 26
- 175 62
- 175 61
- 073 15243
- 702 9
- 033 304
- 340 8534
-
International Classifications
-
Abstract
A system and method for controlling a horizontal directional drilling (HDD) machine provides for manually controlling the HDD machine to perform a sequence of HDD machine actions. HDD machine parameters associated with the sequence of HDD machine actions are stored during manual control of the HDD machine. Storing of the HDD machine parameters is subsequently terminated, typically by an operator or HDD machine controller, upon completing the sequence of HDD machine actions. The stored HDD machine parameters define all or part of an executable control program associated with the sequence of HDD machine actions. The control programs may be categorized to define libraries and accessed by users. Selected categorized control programs may be transferred to a memory of the HDD machine or other storage resource for subsequent execution by the HDD machine.
Description
BACKGROUND OF THE INVENTION
The present invention relates generally to the field of underground boring and, more particularly, to a system and method of controlling an underground boring machine through use of macro assistance.
Utility lines for water, electricity, gas, telephone, and cable television are often run underground for reasons of safety and aesthetics. In many situations, the underground utilities can be buried in a trench which is then back-filled. Although useful in areas of new construction, the burial of utilities in a trench has certain disadvantages. In areas supporting existing construction, a trench can cause serious disturbance to structures or roadways. Further, there is a high probability that digging a trench may damage previously buried utilities, and that structures or roadways disturbed by digging the trench are rarely restored to their original condition. Also, an open trench may pose a danger of injury to workers and passersby.
The general technique of boring a horizontal underground hole has recently been developed in order to overcome the disadvantages described above, as well as others unaddressed when employing conventional trenching techniques. In accordance with such a general horizontal boring technique, also referred to as horizontal directional drilling (HDD) or trenchiess underground boring, a boring system is situated on the ground surface and drills a hole into the ground at an oblique angle with respect to the ground surface, A drilling fluid is typically flowed through the drill string, over the boring tool, and back up the borehole in order to remove cuttings and dirt.
After the boring tool reaches a desired depth, the tool is then directed along a substantially horizontal path to create a horizontal borehole. After the desired length of borehole has been obtained, the tool is then directed upwards to break through to the earth's surface. A reamer is then attached to the drill string which is pulled back through the borehole, thus reaming out the borehole to a larger diameter. It is common to attach a utility line or other conduit to the reaming tool so that it is dragged through the borehole along with the reamer.
It can be appreciated that a highly skilled operator is often needed to operate an underground boring machine at a desired level of productivity and safety. Although advancements have been made in excavation machine automation, the presence of a skilled operator remains desirable in order to achieve increased levels of productivity and safety during excavation. Notwithstanding such automation advancements, the present state of the art still requires the skilled operator to manipulate HDD machine controls on a repetitive basis to perform complex and even routine tasks. Such repetition leads to operator fatigue and may reduce overall excavation productivity.
There exists a need in the excavation industry for an apparatus and methodology for increasing the level of boring machine automation. There exists the further need for such an apparatus and methodology that captures the control capabilities of skilled operators and provides a mechanism for sharing such captured control capabilities by other boring machine operators. The present invention fulfills these and other needs.
SUMMARY OF THE INVENTION
The present invention is directed to a system and method of controlling a horizontal directional drilling (HDD) machine. Controlling an HDD machine, according to an embodiment of the present invention, involves manually controlling the HDD machine to perform a sequence of HDD machine actions. HDD machine parameters associated with the sequence of HDD machine actions are stored while manually controlling the HDD machine. Storing of the HDD machine parameters is subsequently terminated, typically by an operator or HDD machine controller, upon completing the sequence of HDD machine actions. The stored HDD machine parameters define all or part of an executable control program associated with the sequence of HDD machine actions. All or some of the controlling, storing, and terminating processes may be performed remotely from or at the HDD machine.
The executable control program may define a wide variety of HDD machine actions or series of actions. For example, the sequence of HDD machine actions may include a sequence of cutting tool or reamer actions, such as a sequence of cutting tool steering actions. The sequence of HDD machine actions may also include a sequence of rod loading or unloading actions. The sequence of HDD machine actions may further include a sequence of mud system actions. The sequence of HDD machine actions may also include a sequence of cutting tool (e.g., boring head or reamer) location detection actions, such as a series of cutting tool orientation movements that enhance cutting tool location detection.
The HDD machine parameters may include parameters associated with operator actuated control inputs for performing the sequence of HDD machine actions. The HDD machine parameters may also include parameters associated with one or more HDD machine operating characteristics. For example, the HDD machine parameters may be associated with a dynamic or kinematic characteristic of the HDD machine, such as parameters associated with one or both of an HDD machine pressure and torque.
According to another embodiment, controlling an HDD machine involves manually controlling the HDD machine to perform a sequence of HDD machine actions, storing HDD machine parameters associated with the sequence of HDD machine actions, and terminating storing of the HDD machine parameters. The stored HDD machine parameters define all or part of an executable control program associated with the sequence of HDD machine actions. The method, according to this embodiment, further involves executing the control program to replicate the sequence of HDD machine actions. The method may further involve testing all or a portion of the control program. The control program may be edited, and all or a selected portion of the control program may be erased.
Executing the control program may involve executing a selected portion of the control program and repeating controlling, storing, and terminating processes to generate a revised portion of the control program. The selected portion of the control program may be replaced with the revised portion. The repeating controlling, storing, and terminating processes may also be repeated to generate a second control program, and the control program and second control program may be executed to replicate sequences of HDD machine actions. One or both of the control program and the second control program may be selected for execution.
In a further embodiment, the controlling, storing, and terminating processes may be repeated to generate a second control program associated with a second HDD machine operating mode. The method may further involve executing the control program associated with a first HDD machine operating mode and the second control program to replicate sequences of HDD machine actions in accordance with the first and second HDD machine operation modes.
The repeating controlling, storing, and terminating processes may also be repeated to generate a second control program, and the second control program may be merged with the control program. For example, the control program may be associated with a first sequence of HDD machine actions, and the controlling, storing, and terminating processes may be repeated to generate a second control program associated with a second sequence of HDD machine actions. The second control program may be merged with the control program to replicate the first and second sequences of HDD machine actions upon execution of the first and second control programs, respectively.
Executing the control program may involve regulating one or more HDD machine characteristics during replication of the sequence of HDD machine actions such that one or more pre-established thresholds are not exceeded. A visual representation of the executed control program may be displayed. In one approach, the process of executing the control program is initiated remotely with respect to the HDD machine.
In accordance with another embodiment of the present invention, controlling an HDD machine involves providing a number of control programs, each of which causes the HDD machine to execute a sequence of pre-defined HDD machine actions. The control programs are categorized, and access to the categorized control programs is provided to users. Selected categorized control programs are transferred to a memory of the HDD machine or other storage resource for subsequent execution by the HDD machine.
Categorizing the control programs may involve arranging the control programs in one or more control program libraries. The control programs may be categorized by associating certain control programs with certain soil-related conditions. Categorizing the control programs may involve categorizing the control programs by associating certain control programs with certain HDD machine productivity specifications. The control programs may also be categorized, for example, by associating certain control programs with certain HDD machine actions.
The certain HDD machine actions may, for example, include a sequence of cutting tool or reamer actions. The certain HDD machine actions may include a sequence of rod loading or unloading actions or a sequence of mud system actions.
In accordance with a further embodiment of the present invention, a system for controlling an HDD machine having a plurality of controls and sensors for controlling the HDD machine provides for the use of a user interface which includes a user input device. The system further includes a memory and a controller coupled to the memory. The controller, in response to a first signal generated by the user input device, receives input signals from one or more HDD machine controls and/or sensors and, in response to a second signal, stores in the memory a set of executable instructions defining a sequence of HDD machine actions developed from the input signals.
The user input device may include a record control that generates one or both of the first and/or second signals. The user input device may also include a playback control that generates a playback signal, such that the controller, in response to the playback signal, executes the set of executable instructions to perform the sequence of HDD machine actions. Further, the user input device may include a pause control that generates a pause signal, such that the controller suspends execution of the set of executable instructions in response to the pause signal. A terminate control may also be provided as part of the user input device that generates a terminate signal, such that the controller terminates execution of the set of executable instructions in response to the terminate signal.
The user interface may include a display. The input device may include an edit control that generates an edit signal, and the controller may graphically present all or selected portions of the set of executable instructions on the display in response to the edit signal. The set of executable instructions may be modified by the controller in response to the edit signal and user inputs received by the user interface.
The user input device may include an erase control that generates an erase signal, and the controller may graphically present all or selected portions of the set of executable instructions on the display in response to the erase signal. The controller may delete all or selected portions of the set of executable instructions in response to the erase signal and user inputs received by the user interface.
The user input device may further include a scan control that generates a scan signal. The controller may graphically present all or selected portions of the set of executable instructions on the display in response to the scan signal. A merge control may be provided as part of the user input device that generates a merge signal. The controller may graphically present all or selected portions of at least two sets of executable instructions on the display and merge all or selected portions of the at least two sets of executable instructions in response to the merge signal. In one configuration, a remote control unit separate from the HDD machine is provided. The remote control unit may house one or more of the user interface, user input device, memory, and/or controller.
In accordance with yet another embodiment of the present invention, controlling an HDD machine involves controlling the HDD machine along an underground path in accordance with a pre-established bore plan. A library of control programs is accessed. Each of the control programs causes the HDD machine to execute a sequence of pre-defined HDD machine actions. A particular control program may be selected from the library of programs. The particular control program may be executed to augment control of the HDD machine along the underground path.
Selecting the particular control program may involve manually or autonomously selecting the particular control program from the library of programs. Selecting the particular control program may, for example, involve autonomously selecting a number of particular control programs from the library of programs to optimize control of the HDD machine.
A change in HDD machine characteristics along the underground path may further be determined, and a second control program may be selected from the library of programs. The second control program may be executed to augment control of the HDD machine along the underground path.
A set of initial HDD machine operating parameters may be input for controlling the HDD machine along the underground path, and execution of the particular control program may involve augmenting the set of initial HDD machine operating parameters.
Controlling the HDD machine may involve autonomously controlling the HDD machine along the underground path in accordance with the pre-established bore plan. Controlling the HDD machine may also involve manually controlling the HDD machine along the underground path in accordance with the pre-established bore plan, wherein execution of the particular control program augments or takes over manual control of the HDD machine.
The above summary of the present invention is not intended to describe each embodiment or every implementation of the present invention. Advantages and attainments, together with a more complete understanding of the invention, will become apparent and appreciated by referring to the following detailed description and claims taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1
is a side view of an underground boring apparatus with which a macro assisted control system and method of the present invention may be practiced;
FIG. 2
is a block diagram of a remote unit operable by a remote operator that cooperates with a controller of a horizontal directional drilling (HDD) machine to implement a macro-assisted control methodology in accordance with an embodiment of the present invention;
FIG. 3A
depicts a control system of an HDD machine that implements a macro assisted mode of operation in accordance with an embodiment of the present invention;
FIG. 3B
depicts a control system of an HDD machine that implements a macro assisted mode of operation in accordance with an another embodiment of the present invention;
FIG. 4
illustrates a control panel of an HDD machine or remote control unit which includes several macro controls and various input/output devices for facilitating macro assisted control of an HDD machine in accordance with an embodiment of the present invention; and
FIGS. 5-13
are flow diagrams depicting various processes associated with macro assisted control of an HDD machine in accordance with several embodiments of the present invention.
While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail hereinbelow. It is to be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the invention is intended to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE EMBODIMENTS
In the following description of the illustrated embodiments, references are made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration, various embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized, and structural and functional changes may be made without departing from the scope of the present invention.
Referring now to the figures and, more particularly to
FIG. 1
, there is illustrated an embodiment of a horizontal directional drilling (HDD) machine which incorporates a macro-assisted control system and methodology of the present invention. The term macro, as used in general terms within the context of the present invention, defines a set or series of user definable instructions which may be carried out by an excavation machine or component in an autonomous or semi-autonomous manner to achieve a desired objective. The term macro is also intended to represent a set or series of computer or combined computer/user definable instructions which may be carried out by an excavation machine or component in an autonomous or semi-autonomous manner to achieve a desired objective.
In the context of certain horizontal direction drilling operations, the term macro is intended to represent a set or series of operator, computer, or combined computer/operator defined instructions which, when executed, causes the HDD machine or an HDD component (e.g., cutting tool locator or guidance system) to operate or alter operation in accordance with the macro. The term macro is also intended to generally represent a set or series of processor or controller defined instructions. The term macro is further intended to represent a set of series of instructions developed by the operator and processor/controller in combination or cooperation.
Operator defined instructions, for example, may be developed through operator manipulation of particular HDD machine/component controls. Electronic, mechanical, hydraulic, and/or manual information associated with operator manipulation of the particular HDD machine/component controls are recorded and stored for re-execution as macro commands or instructions. As mentioned above, the operator defined instructions may be developed partially through operator manipulation and partially by computer or processor assistance (e.g., HDD machine controller refinement of a series of HDD machine/component instructions or operations).
The operator defined instructions may also be developed through computer assistance without operator manipulation of particular HDD machine/component controls, such as by use of computer models, ladder logic, fuzzy logic, artificial intelligence, neural networks or a combination of such techniques. For example, a desired set of HDD machine/component activities may be characterized by a computer model or a set of processor/controller instructions to define a macro. This macro may be executed (or simulated) by the HDD machine or component and subject to refinement or alteration by the HDD machine/component controller/processor. Although this illustrative example represents a highly automated process scenario, the operator may, if desired, intervene in the execution and refinement process as needed or desired.
Turning now to
FIG. 1
, there is illustrated an HDD machine
20
with which the systems and methods of the present invention may be practiced.
FIG. 1
illustrates a cross-section through a portion of ground
10
where a horizontal directional drilling operation takes place. The HDD machine
20
is situated aboveground
11
and includes a platform
14
on which is situated a tilted longitudinal member
16
. The platform
14
is secured to the ground by pins
18
or other restraining members in order to prevent the platform
14
from moving during the drilling or boring operation. Located on the longitudinal member
16
is a thrust/pullback pump
17
for driving a drill string
38
in a forward and/or reverse longitudinal direction. The drill string
38
is made up of a number of drill string members or rods
23
attached end-to-end.
Also located on the tilted longitudinal member
16
, and mounted to permit movement along the longitudinal member
16
, is a rotation motor or pump
19
for rotating the drill string
38
(illustrated in an intermediate position between an upper position
19
a
and a lower position
19
b
). In operation, the rotation motor
19
rotates the drill string
38
which has a cutting head or reamer
42
attached at the end of the drill string
38
.
A typical boring operation takes place as follows. The rotation motor
19
is initially positioned in an upper location
19
a
and rotates the drill string
38
. While the boring tool
42
is rotated, the rotation motor
19
and drill string
38
are pushed in a forward direction by the thrust/pullback pump
17
toward a lower position into the ground, thus creating a borehole
26
.
The rotation motor
19
reaches a lower position
19
b
when the drill string
38
has been pushed into the borehole
26
by the length of one drill string member
23
. With the rotation motor
19
situated at lower position
19
b
, a clamp
41
then grips the drill string
38
to stop all downhole drill string movement. The rotation motor
19
is then uncoupled from the clamped drill string
38
and pulled back to upper location
19
a
. A new drill string member or rod
23
is then added to the drill string
38
either manually or automatically. The HDD controller
50
may coordinate the manipulation of drill rods in cooperation with an automatic rod loader apparatus of a known type, such as those disclosed in U.S. Pat. Nos. 5,556,253 and 6,179,065, which are hereby incorporated herein by reference in their respective entireties. The clamping mechanism then releases the drill string and the thrust/pullback pump
17
drives the drill string
38
and newly added rod
23
into the borehole. The rotation motor
19
is thus used to thread a new drill string member
23
to the drill string
38
, and the rotation/push process is repeated so as to force the newly lengthened drill string
38
further into the ground, thereby extending the borehole
26
.
Commonly, water or other fluid is pumped through the drill string
38
by use of a mud or water pump. If an air hammer is used as the cutting implement
42
, an air compressor is employed to force air/foam through the drill string
38
. The water/mud or air/foam flows back up through the borehole
26
to remove cuttings, dirt, and other debris. A directional steering capability is provided for controlling the direction of the boring tool
42
, such that a desired direction can be imparted to the resulting borehole
26
. Exemplary systems and methods for controlling an HDD machine of the type illustrated in the Figures are disclosed in commonly assigned U.S. Pat. Nos. 5,746,278 and 5,720,354, which are hereby incorporated herein by reference in their respective entireties.
FIG. 2
is a block diagram of a remote unit
100
that cooperates with a controller
50
of a horizontal directional drilling machine (HDDM) to implement a remote macro-assisted control methodology in accordance with an embodiment of the present invention. Many of the components of HDD machine
20
shown in
FIG. 2
are generally representative of those having like numerical references with respect to HDD machine
20
shown in FIG.
1
. The HDD machine shown in
FIG. 1
may be readily retrofitted to include the system components and/or controller software associated with the system of
FIG. 2
in order to implement a macro-assisted control methodology according to the principles of the present invention.
With continued reference to
FIG. 2
, HDD machine
20
includes a main controller or processor, referred to herein as HDDM controller
50
, which controls the operations of HDD machine
20
when operating in several different modes, including a macro-assisted control mode. HDDM controller
50
controls the movement of a cutting head or reamer
42
and drill string
38
by appropriately controlling a thrust/pullback pump
28
, alternatively referred to as a displacement pump
28
, and a rotation pump
30
, each of which is mechanically coupled to the drill string
38
. HDDM controller
50
also controls a fluid pump
58
, alternatively referred to as a “mud” pump, which dispenses a cutting fluid (e.g., water, mud, foam, air) to the cutting head
42
via the drill string
38
.
The HDD machine
20
further includes a clamping apparatus
51
which is used to immobilize the drill string
38
during certain operations, such as when adding or removing a drill rod to/from the drill string
38
. In one operating mode, the HDD controller
50
provides for limited usage of the thrust/pullback pump
28
and rotation pump
30
when operating in a macro-assisted control mode, primarily for enhanced safety reasons. For example, the HDD controller
50
may permit limited thrust/pullback pump
28
and rotation pump
30
usage when initially testing out a given macro. The temporary limits placed on HDD machine operations may be eliminated on a progressive or immediate basis as macro testing continues and proves to meet the desired objectives.
HDDM controller
50
is further coupled to a display
34
and/or a number of mode annunciators
57
. Display
34
may be used to communicate various types of information to the HDD machine operator, such as pump pressures, engine output, boring tool location and orientation data, operating mode information, remote steering and operating requests/commands, and the like. Mode annunciators
57
provide the machine operator with particularized information concerning various functions initiated by or in cooperation with remote unit
100
. Mode annunciators
57
typically include one or more visual, audible, and/or tactile (e.g., vibration) indicators. A transceiver
55
is provided on HDD machine
20
to facilitate the communication of signals and information between HDD machine
20
and remote unit
100
.
Remote unit
100
is preferably configured as a hand-held unit that incorporates manually actuatable controls and control hardware and software (e.g., via machine control unit
108
) which cooperate to control all or a subset of HDD machine activities. In one embodiment, all of the controls and/or switches provided on the hand-held remote unit
100
are readily actuatable by an operator using only one hand, that being the hand holding the remote unit
100
. The remote unit
100
may incorporate ergonomic features that facilitate easy grasping and retention of the unit
100
in the hand, and features that promote easy interaction between the remote user and the remote unit
100
.
In accordance with another embodiment, remote unit
100
may be incorporated into a portable locator or tracking unit
112
as is known in the art. A remote operator may use locator
112
, which incorporates remote unit
100
functionality, to perform conventional tasks, such as scanning an area above the cutting head
42
for purposes of detecting a magnetic field produced by an active sonde provided within the cutting head
42
. In addition to the availability of standard locator functions, various macro learning, testing, and execution functions according to the present invention may be implemented using a locator modified to incorporate remote unit
100
functionality. Examples of such known locators are disclosed in U.S. Pat. Nos. 5,767,678; 5,764,062; 5,698,981; 5,633,589; 5,469,155; 5,337,002; and 4,907,658; all of which are hereby incorporated herein by reference in their respective entireties. These systems may be advantageously modified to include components and functionality described herein to provide for macro-assisted remote control capabilities in accordance with the principles of the present invention.
Remote unit
100
includes a mode selector
104
and a number of mode annunciators
106
. Mode selector
104
permits the remote operator to select one of a number of different standard or macro-assisted operating modes (e.g., Macro-Steering, Macro-Drilling, Macro-Creep, Macro-Rotate, Macro-Push, Macro-Pullback modes), and when implementing boring tool steering changes (manual or macro-assisted) via steering control unit
110
. An indication of the selected mode and other information, such as a warning indication, is communicated to the remote user via mode annunciators
106
. Mode annunciators
106
typically include one or more visual, audible, and/or tactile (e.g., vibration) indicators. Alternatively, or in addition to mode annunciators
106
, remote unit
100
may be provided with a display
103
.
A transceiver
102
of remote unit
100
permits the remote unit
100
to communicate with HDD machine
20
via transceiver
55
of HDD machine
20
. To facilitate communication between remote unit
100
and HDD machine
20
, one or more repeaters may be situated at appropriate locations at the drilling site. The use of repeaters may be desirable or required when hills or other natural or manmade obstructions lie between the remote unit
100
and HDD machine
20
. Repeaters may also be used to provide for increased signal-to-noise (SNR) ratios. Communication between remote unit
100
and HDD machine
20
may be enhanced by using one or more repeaters when drilling boreholes having lengths on the order of thousands of feet (e.g., one mile). Those skilled in the art will appreciate that a number of communication links and protocols may be employed to facilitate the transfer of information between remote unit
100
and HDD machine
20
, such as those that employ wire or free-space links using infrared, microwave, laser or acoustic telemetry approaches, for example.
Referring now to
FIG. 3A
, there is illustrated one embodiment of a control system of an HDD machine for controlling drilling activities during normal operation and for implementing a macro-assisted control methodology in accordance with the principles of the present invention. Although specific control system implementations are depicted in FIG.
3
A and
FIG. 3B
, it will be understood that a control system suitable for effecting a macro-assisted control methodology of the present invention may be implemented using electrical, mechanical, or hydraulic control elements or any combination thereof.
With continued reference to
FIG. 3A
, the operation of a displacement pump
28
and a rotation pump
30
is controlled by HDDM controller
50
. HDDM controller
50
is also coupled to an engine/motor
36
of the HDD machine which provides source power respectively to the displacement and rotation pumps
28
and
30
. A rotation pump sensor
56
is coupled to the rotation pump
30
and HDDM controller
50
, and provides an output signal to HDDM controller
50
corresponding to a pressure or pressure differential, or alternatively, a speed of the rotation pump
30
. A rotation pump control
52
and a displacement pump control
54
provide for manual control over the rate at which drilling or back reaming is performed. During idle periods, the rotation and displacement pump controls
52
and
54
are preferably configured to automatically return to a neutral setting at which no rotation or displacement power is delivered to the cutting head
42
for purposes of enhancing safety. Rotation and displacement pump controls
52
and
54
produce movement/signals that, according to embodiments of the present invention, are recorded during recording of a macro. During execution of a given macro, the recorded movement/signals are used to effectively mimic manually produced rotation and displacement pump control movement/signals.
During normal or macro-assisted operation, modification to the operation of the displacement pump
28
and rotation pump
30
is controlled by HDDM controller
50
. A rotation pump sensor
56
, coupled to the rotation pump
30
and HDDM controller
50
, provides an output signal to HDDM controller
50
corresponding to the pressure or pressure differential, or alternatively, the rotation speed of the rotation pump
30
. A displacement pump sensor
68
, coupled to the displacement pump
28
and HDDM controller
50
, provides an output signal to HDDM controller
50
corresponding to the pressure level of the displacement pump
28
or, alternatively, the speed of the displacement pump
28
.
An operator, either manually or via macro-assisted-operation, typically sets the rotation pump control
52
to a desired rotation setting during a drilling or back reaming operation, and modifies the setting of the displacement pump control
54
in order to change the rate at which the cutting head
42
is displaced along an underground path when drilling or back reaming. The rotation pump control
52
transmits a control signal to an electrical displacement control
62
(EDC
R
) coupled to the rotation pump
30
. EDC
R
62
converts the electrical control signal to a hydrostatic control signal which is transmitted to the rotation pump
30
for purposes of controlling the rotation rate of the cutting head
42
.
The operator also sets, either manually or via macro-assisted operation, the displacement pump control
54
to a setting corresponding to a preferred boring tool displacement rate. The operator may modify the setting of the displacement pump control
54
to effect gross changes in the rate at which the cutting head
42
is displaced along an underground path when drilling or back reaming. The displacement pump control
54
transmits a control signal to a second EDC
64
(EDC
D
) coupled to the displacement pump
28
. EDC
D
64
converts the electrical control signal received from the controller
64
to a hydrostatic control signal, which is then transmitted to the displacement pump
28
for purposes of controlling the displacement rate of the cutting head
42
.
The HDD machine also includes a fluid (air, liquid, foam, or a combination of same) dispensing pump/motor
58
(hereinafter referred to as a liquid dispensing pump) which communicates liquid through the drill string
38
and cutting head
42
for purposes of providing lubrication, power (e.g., air hammer), and enhancing boring tool productivity. The operator, either manually or via macro-assisted operation, generally controls the liquid dispensing pump
58
to dispense liquid, preferably water, a water/mud mixture or a foam, at a preferred dispensing rate by use of an appropriate control lever or knob provided on the control panel
32
shown in FIG.
1
. Alternatively, the dispensing rate of the liquid dispensing pump
58
, as well as the settings of the rotation pump
30
, displacement pump
28
, and engine
36
, may be set and controlled using a configuration input device
60
, which may be a keyboard, keypad, touch sensitive screen or other such input interface device, coupled to HDDM controller
50
. HDDM controller
50
receives the liquid dispensing setting produced by the control lever/knob provided on the control panel
32
or, alternatively, the configuration input device
60
, and transmits an electrical control signal to a third EDC
66
(EDC
L
) which, in turn, transmits a hydrostatic control signal to the liquid dispensing pump
58
.
A feedback control loop, during manual or macro-assisted operation, provides for automatic adjustment to the rate of the displacement pump
28
and rotation pump
30
in response to varying drilling conditions. The feedback control loop further provides for automatic adjustment to the rate at which a drilling fluid is dispensed to the cutting head
42
. HDDM controller
50
communicates the necessary control signals to the displacement pump
28
, rotation pump
30
, and liquid dispensing pump
58
to implement the local and remote steering/remote control methodologies of the present invention.
In
FIG. 3B
, there is illustrated an alternative embodiment of the present invention, in which control of the displacement pump
28
is provided through hydraulic control signals, rather than electrical control signals employed in the embodiment described hereinabove. In accordance with one mode of operation, the operator, either manually or via macro-assisted operation, sets the rotation pump control
52
to an estimated optimum rotation setting for a drilling or reaming operation. The rotation pump control
52
transmits a control signal to a hydraulic displacement control (HDC
R
)
72
which, in turn, transmits a hydraulic control signal to the rotation pump
30
for purposes of controlling the rotation rate of the cutting head or reamer
42
.
Various types of hydraulic displacement controllers (HDC's) use hydraulic pilot signals for effecting forward and reverse control of the pump servo. A pilot signal is normally controlled through a pilot control valve by modulating a charge pressure signal typically between 0 and 800 pounds-per-square inch (psi). HDC
R
72
, in response to the operator changing the setting of the rotation pump control
52
, produces corresponding changes to the forward pilot signal, X
F
80
, and the reverse pilot signal, X
R
82
, thus altering the rate of the rotation pump
30
. Line X
T
81
is a return line from HDC
R
72
to the rotation pump control
52
. Similarly, in response to the operator changing the setting of the displacement pump control
54
, either manually or via macro-assisted operation, the displacement pump control
54
correspondingly alters the forward pilot signal, Y
F
84
, and the reverse pilot signal, Y
R
86
, of HDC
D
74
, which controls the displacement pump
28
, thus altering the displacement rate. Line Y
T
85
is a return line from HDC
D
74
to the displacement pump control
54
.
The hydraulic sensor/controller
73
senses the pressure of the rotation pump
30
or, alternatively, the rotation speed of the rotation pump
30
, by monitoring the flow rate through an orifice to measure rotation, and is operable to transmit hydraulic override signals X
OF
88
and X
OR
90
to the HDC
R
72
, and hydraulic override signals Y
OF
89
and Y
OR
91
to the HDC
D
74
. When, for example, the hydraulic sensor/controller
73
senses that the pressure of the rotation pump
30
has exceeded the upper acceptable pressure limit, P
L
, override signals Y
OF
89
and Y
OR
91
are transmitted to the HDC
D
74
in order to appropriately reduce the cutting head or reamer displacement rate while maintaining the rotation of the cutting head or reamer at a desired rate, such as a substantially constant rate. Once the pressure of the rotation pump
30
has recovered to an acceptable level, the hydraulic sensor/controller
73
instructs HDC
D
74
to increase the displacement rate. The hydraulic sensor/controller
73
may be coupled to an HDDM controller of the type described in connection with
FIG. 3A
or, alternatively, may incorporate the functionality of HDDM controller
50
.
Turning now to
FIG. 4
, there is illustrated an embodiment of a control panel
200
which may be provided at the HDD machine
20
, such as that depicted in
FIGS. 1 and 2
. Alternatively, control panel
200
may be provided on a control apparatus separate from the HDD machine
20
. For example, control panel
200
may be integrated into a portable remote control unit or a portable locator, such as remote unit
100
shown in FIG.
2
.
Control panel
200
includes a number of control and display regions which provide for a high level of operator interaction with the HDD machine
20
and the electronic data acquired and used by the macro processing units of the present invention. A number of operator controls
230
are provided for actuation by an operator during manual, automatic, semi-automatic, or macro control of the HDD machine
20
. Typical operator controls
230
include a variety of levers, switches, and knobs that control the operation of the HDD machine
20
, such as rotation and displacement pump controls
52
and
54
discussed previously. Other types of operator controls
230
may also be provided on the control panel
200
, including those required to effect communication with a remote unit
100
, such as that shown in
FIG. 2
, a locator unit
112
, and/or electronics provided in a cutting head or reamer
42
.
A macro control panel
208
is also provided on main control panel
200
. Within the macro control panel region are a number of controls which are actuatable by an operator. By way of example, the user may actuate various ones of the macro controls provided on panel
208
for purposes of performing various macro-related functions. For example, a record control
210
allows the operator to record a particular series of central functions for storage in memory. An erase control
212
, for example, may be used to erase all or portions of a previously recorded macro. A scan control
214
may be used by the operator to review various steps of a given macro or series of macros.
A given macro, by way of further example, may be selected for scanning or reviewing by the operator. According to one approach, the selected macro may be presented on display
202
of control panel
200
. Various steps that define the selected macro may be presented on display
202
. The macro may be displayed in any number of formats, including, for example, a ladder logic format. Various layers of a given macro may be presented. For example, the main function or series of functions performed by the macro may be further broken down into sub-macros that are performed underneath each of the main functions. These sub-macros may be subject to viewing by use of the scan control
214
. Additional layers of detail may be reviewed by the operator by use of the scan control
214
.
For example, a selected sub-macro may be interrogated to determine which control mechanism, such as which motor, pump, and actuator, sensor, is implicated in the definition of the selected sub-macro. The operator may progress still further into the details of a particular sub-macro by interrogating the operational parameters of a given functional element implicated in the definition of the sub-macro. For example, the inputs, outputs, limits, and status indicators for a particular valve or sensor defined in a given sub-macro may be interrogated and viewed by the operator.
An edit control
216
is also provided on the macro control panel
208
. Upon activating the edit control
216
, the operator may select a desired macro or sub-macro. The edit function allows for the editing of the particular macro or sub-macro, such as by allowing the operator to modify or append to a particular macro. As with the scan operation, various levels of macro and sub-macro detail may be subject to editing and modification by the operator using the edit control
216
.
For example, it is assumed that a series of operator control commands have been recorded so as to define a given macro. The edit control
216
may be activated by the operator to modify, for example, an operating range associated with a given parameter implicated in the macro definition (e.g., range of steering angle, operating temperature threshold, pressure limit, etc.). The operator may modify a given parameter through use of an input device
206
provided on control panel
200
.
The input device
206
provided on control panel
200
may take various forms to accommodate various types of input likely to be received by the operator. By way of example, the input device
206
may take the form of a keyboard, mouse, trackball, touch-screen display icons, and other traditional mechanical user input devices. A microphone for inputting voice commands may also be provided on control panel
200
. In this case, noise cancellation and voice recognition software may be used to increase the efficacy of a voice command input approach, given the likely presence of significant extraneous noise.
A playback control
218
provides for the selection and execution of a selected macro. During playback of a selected macro, a pause control
220
may be actuated to temporarily suspend execution of the selected macro currently being played back. The user may also terminate playback of a selected macro by actuating a terminate control
222
.
A merge control
224
provided on control panel
208
allows the operator to merge together all or selected portions of macros, sub-macros, and/or functions. By way of example, merge control
224
may be actuated to select a first macro and a second macro so that the functionality of the two macros may be merged. In this manner, the functions associated with the two macros may be executed in succession without requiring the operator to select and specifically execute the second of the two macros. Also, merging two macros allows for the selective editing of the merged macro. For example, the functions defining the first and second macro may be ordered as desired to define a merged macro having an operator defined sequence. A merged macro created from two or more existing macros may be stored under a new macro name and subsequently recalled and played back by the operator upon actuation of the playback control
218
.
Merging of macro steps or functions may provide for additional functionality by allowing the operator to select desired functions or sets of functions from two or more macros to define a new macro. Merging macros may also involve combining macro steps associated with a first mode of HDD machine operation with macro steps associated with a second mode of HDD machine operation. In this way, a macro may define operations or functions associated with multiple modes of HDD machine operations.
Control panel
200
may also include a mode control
204
which allows the user to select between a number of different operating modes. For example, a number of predefined operating modes may be defined by a corresponding number of operating mode programs. Each of these operating mode programs may be selected through use of mode control
204
. By way of example, a number of boring mode programs may be stored, each of which defines a set of operating parameters associated with a given type of boring condition. A boring mode associated with rock drilling, for example, may specify a set of HDD machine parameters appropriate for drilling through rock. Another boring mode program may define HDD machine parameters appropriate for drilling through clay, while another boring mode program may configure the HDD machine to operate optimally in sandstone, for example. Each of the mode programs may themselves be subject to editing or modification by the operator, such as by use of a mode edit control similar to the macro edit control
216
shown on control panel
200
.
FIG. 5
shows various steps associated with macro creation and execution in accordance with one embodiment of the present invention. The macro generation and execution procedure
300
depicted in
FIG. 5
is initiated by starting the recording process
302
of the macro. After initiating macro recording, the operator manually performs
304
the desired HDD machine actions. The electronics of the HDD machine monitors and records the operator inputs and/or the control selections and adjustments
306
made by the operator. The process of monitoring and recording operator inputs and/or control selections/adjustments continues until such time as the desired series of actions is deemed completed
308
by the operator. The macro is then stored
310
, preferably in non-volatile alterable memory (e.g., Flash memory, EEPROM).
If the operator desires to record additional macros
312
, the process of starting macro recording
302
, manually performing the desired HDD machine actions
304
, and monitoring and recording of same
306
is repeated until such time as the additional series of actions are completed
308
, which then results in storage of an additional macro
310
. Any number of macros may be recorded by the HDD machine operator, limited only by the amount of memory provided on the HDD machine or other memory used to store the macros (e.g., a personal computer coupled to the HDD machine, smart cards, and memory modules).
The operator may wish to run a particular macro
314
or, alternatively, may simply end the macro procedure
322
after completing the recording operation. If the operator wishes to run a particular macro
314
, a desired macro is selected
316
and subsequently executed
318
. If the operator wishes to run additional macros
320
, the selection and execution steps
316
,
318
are repeated until such time as the operator terminates the macro procedure
322
.
FIG. 6
illustrates various steps associated with recording and executing macros in accordance with another embodiment of the present invention. According to this embodiment, a user starts the macro recording process
342
and then manually performs the desired HDD machine actions
344
. In this embodiment, rather than recording operator inputs and control selections as in the embodiment according to
FIG. 5
, the process of
FIG. 6
involves monitoring and recording of HDD machine parameters.
For example, various HDD machine kinematics and/or dynamics may be recorded, typically by receiving sensor signals from various sensors deployed on the HDD machine, drill string, above-ground locator/repeaters, and/or boring head/reamer. When the desired series of actions is completed
348
, the macro is stored
350
. The user may, if desired, record additional macros
352
. One or more stored macros may be selectively executed
354
,
356
,
358
,
360
as desired by the operator or the macro procedure may be terminated
362
.
FIG. 7
shows various steps associated with the creation and modification of a macro in accordance with a further embodiment of the present invention. According to this embodiment, an operator initiates macro recording
382
and manually performs
384
the desired HDD machine actions that will define the macro. The operator inputs and/or machine parameters are monitored and recorded
386
and, upon completion of the desired HDD machine actions
388
, the macro is stored
390
.
If the operator desires to update the macro
392
, any or all of the HDD machine actions that define the macro subject to updating are performed
394
. The refined HDD machine actions are monitored and recorded
396
, such as by recording of the operator inputs and/or HDD machine parameters. Upon completion
398
of all or selected HDD machine actions, the original macro is replaced by the recently defined macro and stored
400
. The macro procedure may then be terminated
402
by the operator.
In accordance with one approach, an operator may select the macro to be updated or modified, and review the actions that are defined by the selected macro. The steps that are subject to refinement, modification, or replacement may be identified by the operator, such as by identifying macro step designators (e.g., step numbers) or graphically indicating the steps subject to refinement or replacement. This may be accomplished through various known means, including the use of conventional text blocking or identification techniques typically employed by word processing systems, for example.
According to another approach, a given step or series of steps associated with a selected macro may be subject to refinement by use of an averaging technique. For example, a series of steps associated with a previously stored macro may be repeated one or more times by the operator. The original macro steps together with the refined macro steps may be averaged for purposes of refining such macro steps. This process may be subject to iteration until the desired HDD machine response is achieved through the refinement process. It will be appreciated that, having stored a number of similar steps associated with a macro, the operator may selectively include or exclude specific macro step recordings from the averaging or refinement process. Upon completion of the desired series of actions
398
, the refined macro may replace
400
the original stored macro or, alternatively, may be stored under a new macro name, thus preserving the original stored macro.
FIG. 8
illustrates various steps associated with recording a macro in accordance with an embodiment of the present invention. An operator initially selects
422
a pre-established HDD machine operating mode. Such operating modes typically include, for example, various steering modes, rod loading and unloading modes, mud system modes, HDD machine transport modes, thrust and/or rotation modes, cutting tool location/detection modes, and the like. After selecting the desired HDD machine mode, the operator manually performs
424
desired HDD machine actions while recording
426
a macro.
During the macro recording process, a determination is made, typically on a continuous monitoring basis, whether the HDD machine actions are approaching limits associated with the selected operating mode
428
. If, during the macro recording process, the HDD machine actions encroach on the pre-specified limits associated with the given operating mode, the HDD machine actions are automatically limited to avoid exceeding the mode limits
430
. The user may have the option to override the mode limits
432
for a given series of HDD machine actions. In such a case, the mode limits may be overridden by the operator such that the HDD machine actions may exceed the mode limit, but are not permitted to exceed predefined HDD machine safety limits
434
. The macro recording process continues
436
until such time as the desired HDD actions are completed
438
. The macro associated with the HDD machine actions for the selected operating mode is then stored
440
, followed by termination of the macro procedure
442
.
FIG. 9
illustrates various steps associated with the merging of two or more macros in accordance with an embodiment of the present invention. In accordance with a macro merge procedure according to this embodiment, the operator performs
462
the desired drilling actions which are recorded as a first macro, macro (n). Subsequently, additional drilling actions are performed
466
during which an additional macro, macro (n+1), is recorded
468
. The operator may continue performing desired drilling actions so as to optimize
470
a given series of actions, during which subsequent macros may be recorded
468
. After recording (n+1) macros, the operator is given the option to merge
472
all or selected ones of the recorded (n+1) macros. Should the operator enable the merge macro operation, an averaging computation or other merge computation is performed
482
on the parameters that define the macro.
The operator may then test
482
the merged macro, in which case the HDD machine operations are autonomously executed as defined by the merged macro. If the operator is satisfied that the merged macro performs
486
as desired, the merged macro may then be stored
480
for future use. If the operator decides not to merge the macros at step
472
, the last macro of the (n+1) macros may be stored
474
for future use. It is understood that any of the recorded (n+1) macros may be stored for future use in addition to the last stored macro.
FIG. 10
illustrates various steps associated with recording macros for each of the number of distinct drilling actions and then merging the distinct drilling action macros together to produce multiple drilling action macros. According to this approach, an operator performs a given drilling action (n)
502
and records
504
(n+1) macros for the drilling action (n). The operator may then perform a different drilling action (n+1)
506
and record
508
a number of macros (k+1) for the new drilling action (n+1). If desired, the operator may perform additional drilling actions and record
510
one or more macros for each of the additional drilling actions.
The (n+1) macros associated with drilling action (n) may be merged
512
. The (k+1) macros associated with drilling action (n+1) may then be merged
512
. It is understood that individual macros associated with each additional drilling action in connection with step
510
may also be subject to merging at this point. Each of the merged macros may then be tested
516
individually. The individual merged macros may, of course, be subject to editing or modification at this stage. The merged macros may then be tested
518
successively to ensure that the compound set of drilling actions perform as desired. The merged macros, subject to merging operations in step
512
and
514
, may be referred to as a super-macro, which may be subject to testing at step
518
. The super-macro may be modified as desired
520
to fine-tune the drilling actions associated with the super-macro. The super-macro, which is essentially a composite macro, may be stored
522
for future use.
FIG. 11
illustrates various steps associated with the categorization of macros into libraries. It is assumed that a number of macros have been created
542
by one or more operators of one or more HDD machines. The family of macros may be categorized
544
in any number of useful ways. By way of example, each macro, sub-macro, or super-macro may be categorized in terms of HDD machine type or family, operating scenario, drilling action, performance characteristics, and/or soil type and condition, for example. It will be appreciated that other categories for identifying and organizing macros may be useful, and that any given macro may be categorized as having multiple identifiers. The categorized macros may be stored
546
in one or more macro libraries.
Macro libraries are preferably made accessible
548
to HDD machine operators, dealers, integrators and/or manufacturers. For example, libraries of macros may be maintained on one or more servers of a network and made accessible through appropriate interfaces to HDD operators. The macro libraries may be accessed by operators, dealers, manufacturers, and integrators via the World Wide Web or other Internet or proprietary network interface.
An operator or other interested party may gain access to the macro libraries
548
through the appropriate interface, which typically includes satisfying requisite security protocol. The operator may then select
550
a desired macro library or specific macros within particular libraries. The selected macros, sets of macros, or macro libraries may be downloaded
552
to the operator location.
By way of example, selected macros and macro libraries may be downloaded to a personal computer, hand-held personal agent, or other computer resource provided at or accessible to the operator at the operator's location. Alternatively, the selected macros or libraries may be downloaded directly into HDD machine memory
554
. In this scenario, a wireless link, such as a mobile phone link, satellite link, or proprietary wireless link, may be used to establish the transmission of selected macros or macro libraries from the macro server system to the HDD machine memory, which is typically in the field or at a remote location: The downloaded macros or macro libraries may update, replace, or supplement
556
the HDD machine macros already stored in HDD machine memory. The operator of the HDD machine may then gain access
558
to the newly downloaded macros or macro libraries during HDD machine operation.
FIG. 12
illustrates various steps associated with the selection of macros based on HDD machine operating conditions in the field. In accordance with this approach, an operator selects
572
the HDD machine operating scenario best describing the drilling scenario perceived by the operator. Typically, the operating scenarios are preferably defined or accommodated by the predefined operating modes associated with a particular HDD machine.
By way of example, the various operating scenarios or HDD machine modes may encompass machine actions associated with drilling or reamer operations at the entrance or exit pit. Other operating scenarios may be associated with displacing the cutting tool along a straight or curved path. Various steering techniques are also typically defined by selectable operating scenarios or HDD machine modes. The use of a cutting tool or a reamer may be specifically specified by the operator. The type of soil encountered by the cutting tool or reamer may be specified, such as soft, medium, or hard soil, for example. An obstacle avoidance operating scenario may also be selected. Rod threading and unthreading represents additional operating scenarios that may be selectable by the operator. Various operating scenarios or HDD machine modes associated with mud flow, mud characteristics, or mud system performance may also be selectable.
After the operator selects the particular HDD machine operating scenario of interest, the operator is presented with macro selections based on the selected operating scenario
574
. The operator may then select and execute the desired macro
576
. If the action or performance
578
is not acceptable, the operator may select another macro for execution
574
,
576
. If the action or performance associated with the selected macro is acceptable
578
, macro execution may be subject to change by the operator if the operating scenario changes
580
. In such a case, the operator may select a new HDD machine operating scenario at step
572
. If the operating scenario has not changed significantly, macro execution may continue
582
until the desired action or series of actions is completed
584
, at which time the macro procedure may be terminated
586
.
FIG. 13
illustrates various steps associated with the autonomous execution of HDD machine actions in connection with an auto-boring procedure. In accordance with the approach depicted in
FIG. 13
, a bore plan may be developed and programmed for a particular job site. The bore plan may be developed using conventional techniques or by the techniques disclosed in commonly-owned U.S. Pat. No. 6,389,360, entitled “AUTOMATED BORE PLANNING METHOD AND APPARATUS FOR HORIZONTAL DIRECTIONAL DRILLING,” filed on Jan. 13, 2000, which is hereby incorporated herein by reference in its entirety. The predefined bore plan may be loaded into the HDD machine memory
602
. The operator may specify additional initial operating parameters
604
appropriate for the boring operation. The auto-boring procedure may then be initiated
606
. It is assumed for purposes of this and other examples that the location of the cutting tool (e.g., boring head or reamer) is determined and controlled by conventional means or by techniques disclosed in commonly-owned U.S. Pat. Nos. 5,720,354, 5,904,210, 5,819,859, 5,553,407, 5,704,142, and 5,659,985, each of which is hereby incorporated herein by reference in its respective entirety.
The auto-boring procedure determines the operating scenario
602
by comparing the present location of the cutting tool as compared to the planned location of the boring tool as specified by the bore plan loaded in HDD machine memory. For example, initiating the pilot bore will occur at the entrance pit as specified by the bore plan, in which case the appropriate operating scenario at this stage of the drilling operation concerns the entrance pit operating scenario. Having determined the appropriate operating scenario
608
, the macro library associated with the particular operating scenario is accessed
610
. Depending on various operating, performance, and soil factors, for example, the optimal macro for the particular operating scenario defined within the accessed macro library is selected
612
. The selected optimal macro is then executed
614
.
If the actions or performance associated with the executed selected macro is/are not acceptable
616
, the operator may override the macro
618
and manually access an appropriate macro library associated with the particular operating scenario. The manually-selected macro may then be executed
614
. If the actions or performance associated with the selected macro is/are acceptable
616
, drilling operations continue until a new scenario is encountered
624
.
For example, after the cutting tool reaches a predefined depth after passing through the entrance pit as specified by the bore plan, a substantially horizontal path may be dictated by the bore plan. The transition from the initial entrance pit boring operation to substantially horizontal drilling represents a change in the operating scenario. In view of the change of operating scenario
624
, the auto-boring procedure determines the new operating scenario
608
in view of the bore plan and accesses
610
the macro library associated with the new operating scenario. Selection of the optimal macro
612
, execution of same
614
, and operator override steps
618
may then be repeated for the new operating scenario. Each change in operating scenario may result in a repeat of steps
608
-
618
.
If the operator wishes to override a particular macro
618
, the auto-boring mode of operation is discontinued
620
. The operator may then select
622
a particular macro for execution or may operate the HDD machine in a manual mode of operation.
Provided above are several examples of macro-assisted operations for enhancing control of an HDD machine during use in accordance with the principles of the present invention. These examples are intended to enhance an understanding of the present invention, and are not to be regarded as limiting the scope or application of the present invention.
It will, of course, be understood that various modifications and additions can be made to the preferred embodiments discussed hereinabove without departing from the scope of the present invention. Accordingly, the scope of the present invention should not be limited by the particular embodiments described above, but should be defined only by the claims set forth below and equivalents thereof.
Claims
- 1. A method of controlling a horizontal directional drilling (HDD) machine comprising a cutting tool or reamer, the method comprising:initiating a first portion of an operator defineable control program associated with an operator defined sequence of HDD machine actions; sensing a parameter associated with the HDD machine, cutting tool or reamer as the HDD machine replicates the operator defined sequence of HDD machine actions in accordance with the control program; and executing a second portion of the control program in response to the sensed parameter.
- 2. The method of claim 1, wherein the sequence of HDD machine actions comprises a sequence of cutting tool or reamer actions.
- 3. The method of claim 1, wherein the sequence of HDD machine actions comprises a sequence of cutting tool steering actions.
- 4. The method of claim 1, wherein the sequence of HDD machine actions comprises a sequence of rod loading or unloading actions.
- 5. The method of claim 1, wherein the sequence of HDD machine actions comprises a sequence of mud system actions.
- 6. The method of claim 1, wherein HDD machine parameters are associated with the HDD machine actions, and the HDD machine parameters comprise parameters associated with operator actuated control inputs for performing the sequence of HDD machine actions.
- 7. The method of claim 1, wherein HDD machine parameters are associated, with the HDD machine actions, and the HDD machine parameters comprise parameters associated with one or more HDD machine operating characteristics.
- 8. The method of claim 1, wherein HDD machine parameters are associated with the HDD machine actions and define at least part of the executable control program, and the HDD machine parameters comprise parameters associated with a dynamic or kinematic characteristic of the HDD machine.
- 9. The method of claim 1, wherein HDD machine parameters are associated with the HDD machine actions and define at least part of the executable control program, and the HDD machine parameters comprise parameters associated with one or both of an HDD machine pressure and torque.
- 10. The method of claim 1, wherein sensing the parameter associated with the HDD machine is performed remotely with respect to the HDD machine.
- 11. The method of claim 1, wherein sensing the parameter associated with the HDD machine is performed at the HDD machine.
- 12. The method of claim 1, wherein the sensed parameter comprises a pressure parameter.
- 13. The method of claim 1, wherein the sensed parameter comprises a cutting tool or reamer location parameter.
- 14. The method of claim 1, wherein the sensed parameter comprises a cutting tool or reamer orientation parameter.
- 15. A method of controlling a horizontal directional drilling (HDD) machine comprising a cutting tool or reamer, the method comprising:manually controlling the HDD machine to perform a sequence of HDD machine actions; storing, while manually controlling the HDD machine, HDD machine parameters associated with the sequence of HDD machine actions; and terminating storing of the HDD machine parameters, the stored HDD machine parameters defining all or part of an executable control program associated with the sequence of HDD machine actions; executing a first portion of the control program to replicate a first set of HDD machine actions of the sequence of HDD machine actions; sensing, during execution of the control program, a parameter associated with the HDD machine, cutting tool or reamer; and executing, in response to the sensed parameter, a second portion of the control program to replicate a second set of HDD machine actions of the sequence of HDD machine actions.
- 16. The method of claim 15, further comprising testing all or a portion of the control program.
- 17. The method of claim 15, wherein executing the first or second portion of the control program comprises executing a selected portion of the control program and repeating controlling, storing, and terminating to generate a revised portion of the control program, the method further comprising replacing the selected portion of the control program with the revised portion.
- 18. The method of claim 15, further comprising editing the control program.
- 19. The method of claim 15, further comprising erasing all or a portion of the control program.
- 20. The method of claims 15, further comprising repeating controlling, storing, and terminating to generate a second control program, the method further comprising executing the control program and the second control program to replicate sequences of HDD machine actions.
- 21. The method of claim 20, further comprising selecting one or both of the control program and the second control program for execution.
- 22. The method of claim 15, further comprising repeating controlling, storing, and terminating to generate a second control program associated with a second HDD machine operating mode, the method further comprising executing the control program associated with a first HDD machine operating mode and the second control program to replicate sequences of HDD machine actions in accordance with the first and second HDD machine operation modes.
- 23. The method of claim 15, further comprising repeating controlling, storing, and terminating to generate a second control program, the method further comprising merging the second control program with the control program.
- 24. The method of claim 15, wherein the control program is associated with a first sequence of HDD machine actions, the method further comprising repeating controlling, storing, and terminating to generate a second control program associated with a second sequence of the HDD machine actions, and merging the second control program with the control program to replicate the first and second sequences of HDD machine actions upon execution of the first and second control programs, respectively.
- 25. The method of claim 15, wherein executing the control program further comprises regulating one or more HDD machine characteristics during replication of the sequence of HDD machine actions such that one or more pre-established thresholds associated with the sensed HDD machine parameter are not exceeded.
- 26. The method of claim 15, further comprising displaying a visual representation of the executed control program.
- 27. The method of claim 15, wherein at least executing the control program is initiated remotely with respect to the HDD machine.
- 28. The method of claim 15, wherein the sensed parameter comprises a pressure parameter.
- 29. The method of claim 15, wherein the sensed parameter comprises a cutting tool or reamer location parameter.
- 30. The method of claim 15, wherein the sensed parameter comprises a cutting tool or reamer orientation parameter.
- 31. A method of controlling a horizontal directional drilling (HDD) machine, comprising:providing a plurality of control programs, each of the control programs causing the HDD machine to execute a sequence of pre-defined HDD machine actions; categorizing the control programs; providing access to the categorized control programs; transferring selected categorized control programs to a memory of the HDD machine or other storage resource; executing the control programs in a particular sequence to implement a particular HDD machine operation; and sensing, during execution of the control programs, one or more HDD machine parameters to regulate execution of the particular sequence of control programs.
- 32. The method of claim 31, wherein categorizing the control programs comprises arranging the control programs in one or more control program libraries.
- 33. The method of claim 31, wherein categorizing the control programs comprises categorizing the control programs by associating certain control programs with certain soil-related conditions.
- 34. The method of claim 31, wherein categorizing the control programs comprises categorizing the control programs by associating certain control programs with certain HDD machine productivity specifications.
- 35. The method of claim 31, wherein categorizing the control programs comprises categorizing the control programs by associating certain control programs with certain HDD machine actions.
- 36. The method of claim 31, wherein the control programs comprise control programs that define a sequence of cutting tool or reamer actions.
- 37. The method of claim 31, wherein the control programs comprise control programs that define a sequence of rod loading or unloading actions.
- 38. The method of claim 31, wherein the control programs comprise control programs that define a sequence of mud system actions.
- 39. The method of claim 31, wherein the control programs comprise control programs that define a sequence of cutting tool location detection actions.
- 40. The method of claim 31, wherein the control programs defines a sequence of cutting tool orientation movements to facilitate cutting tool detection.
- 41. A system for controlling a horizontal directional drilling (HDD) machine comprising a plurality of controls and sensors for controlling the HDD machine, the system comprising:a user interface comprising a user input device; memory; and a controller coupled to the user interface and memory, the controller, in response to a first signal generated by the user input device, receiving input signals from one or more HDD machine controls and/or sensors in response to an operator defined sequence of HDD machine actions and, in response to a second signal, storing in the memory a set of executable instructions defining the sequence of HDD machine actions developed from the input signals, the controller, in response to an execution signal, sensing one or more parameters associated with the HDD machine as the HDD machine replicates the operator defined sequence of HDD machine actions in accordance with the executable instructions, and regulating execution of a particular sequence of the executable instructions in response to the sensed HDD machine parameters.
- 42. The system of claim 41, wherein the user input device comprises a record control that generates one or both of the first and/or second signals.
- 43. The system of claim 41, wherein the user input device comprises a playback control that generates a playback signal, the controller, in response to the playback signal, executing the particular sequence of executable instructions to perform the sequence of HDD machine actions.
- 44. The system of claim 43, wherein the user input device comprises a pause control that generates a pause signal, the controller suspending execution of the particular sequence of executable instructions in response to the pause signal.
- 45. The system of claim 43, wherein the user input device comprises a terminate control that generates a terminate signal, the controller terminating execution of the particular sequence of executable instructions in response to the terminate signal.
- 46. The system of claim 41, wherein the user interface comprises a display.
- 47. The system of claim 41, wherein the user interface comprises a display and the user input device comprises an edit control that generates an edit signal, the controller graphically presenting all or selected portions of the set of executable instructions on the display in response to the edit signal and modifying the set of executable instructions in response to the edit signal and user inputs received by the user interface.
- 48. The system of claim 41, wherein the user interface comprises a display and the user input device comprises an erase control that generates an erase signal, the controller graphically presenting all or selected portions of the set of executable instructions on the display in response to the erase signal and deleting all or selected portions of the set of executable instructions in response to the erase signal and user inputs received by the user interface.
- 49. The system of claim 41, wherein the user interface comprises a display and the user input device comprises a scan control that generates a scan signal, the controller graphically presenting all or selected portions of the set of executable instructions on the display in response to the scan signal.
- 50. The system of claim 41, wherein the user interface comprises a display and the user input device comprises a merge control that generates a merge signal, the controller graphically presenting all or selected portions of at least two sets of executable instructions on the display and merging all or selected portions of the at least two sets of executable instructions in response to the merge signal.
- 51. The system of claim 41, further comprising a remote control unit separate from the HDD machine, the remote control unit housing one or more of the user interface, user input device, memory, and/or controller.
- 52. The system of claim 41, wherein the one or more sensed parameters comprise a pressure parameter.
- 53. The system of claim 41, wherein the one or more sensed parameters comprise a cutting tool or reamer location parameter.
- 54. The system of claim 41, wherein the one or more sensed parameters comprise a cutting tool or reamer orientation parameter.
- 55. A method of controlling a horizontal directional drilling (HDD) machine, comprising:controlling the HDD machine along an underground path in accordance with a pre-established bore plan; accessing a library of control programs, each of the control programs causing the HDD machine to execute a sequence of pre-defined HDD machine actions; selecting particular control programs from the library of programs; executing the particular control programs in a particular sequence to augment control of the HDD machine along the underground path; and regulating execution of the particular control programs in response to one or more sensed HDD machine parameters.
- 56. The method of claim 55, wherein selecting the particular control programs comprises manually selecting the particular control programs from the library of programs.
- 57. The method of claim 55, wherein selecting the particular control programs comprises autonomously selecting the particular control programs from the library of programs.
- 58. The method of claim 55, wherein selecting the particular control programs comprises autonomously selecting a plurality of particular control programs from the library of programs to optimize control of the HDD machine.
- 59. The method of claim 55, further comprising determining a change in HDD machine characteristics along the underground path, and selecting one or more additional control programs from the library of programs, wherein execution of the one or more additional control programs augments control of the HDD machine along the underground path.
- 60. The method of claim 55, further comprising inputting a set of initial HDD machine operating parameters for controlling the HDD machine along the underground path, wherein execution of the particular control programs augments the set of initial HDD machine operating parameters.
- 61. The method of claim 55, wherein controlling the HDD machine comprises autonomously controlling the HDD machine along the underground path in accordance with the pre-established bore plan.
- 62. The method of claim 55, wherein controlling the HDD machine comprises manually controlling the HDD machine along the underground path in accordance with the pre-established bore plan, further wherein execution of the particular control programs augments or takes over manual control of the HDD machine.
- 63. A method of controlling a horizontal directional drilling (HDD) machine, comprising:manually controlling the HDD machine to perform a sequence of HDD machine actions; storing, while manually controlling the HDD machine, HDD machine parameters associated with the sequence of HDD machine actions; terminating storing of the HDD machine parameters, the stored HDD machine parameters defining all or part of an executable control program associated with the sequence of HDD machine actions; and associating the executable control program with at least a portion of a predefined bore plan.
- 64. The method of claim 63, wherein a first executable control program is associated with a first portion of the predefined bore plan, and a second executable control program is associated with a second portion of the predefined bore plan.
- 65. The method of claim 63, wherein the sequence of HDD machine actions comprises a sequence of cutting tool or reamer actions that facilitate above-ground identification of one or both of a location and an orientation of the cutting tool or reamer.
- 66. The method of claim 63, wherein the sequence of HDD machine actions comprises a sequence of cutting tool or reamer actions that facilitate above-ground identification of a depth of the cutting tool or reamer.
- 67. A method of controlling a horizontal directional drilling (HDD) machine, comprising:manually controlling the HDD machine to perform a sequence of HDD machine actions; storing, while manually controlling the HDD machine, HDD machine parameters associated with the sequence of HDD machine actions, the stored HDD machine parameters defining all or part of an executable control program associated with the sequence of HDD machine actions; executing the control program to replicate the sequence of HDD machine actions; and performing an operation to determine one or more of a location, a depth, and an orientation of a cutting tool or reamer coupled to the HDD machine.
- 68. The method of claim 67, wherein the control program comprises a sequence of above-ground locator actions.
- 69. The method of claim 67, wherein the operation is performed during replication of the sequence of HDD machine actions.
- 70. The method of claim 67, wherein the operation is performed during a pause in the sequence of HDD machine actions.
US Referenced Citations (7)