Drilling Solutions

Garland, TX

Tower Sensor Redesign

PV-351
Version 3.0

Written By:
Bryan Pepper
Ted Aikman

For:
New Product Development, IR Drilling Solutions
Aquila Mining Systems, LTD

Date:
20 Mar 2004
Revision History:

Description Ver. Date By

Initial Release 1.0 2-4-02 Pepper

Minor updates per discussions with Aquila. 2.0 5-4-02 Pepper
Update to remove upper stop switch 2.0 3-29-04 Aikman
Revise to current design and description 2.0 10-11-04 Aikman

1 References ________________________________________________________________________2
2 Introduction _______________________________________________________________________2
3 Hardware Design___________________________________________________________________2
3.1 Design Constraints_____________________________________________________________2
3.2 Head Detection Sensors_________________________________________________________3
4 Software Design ___________________________________________________________________4
4.1 Interlocks ____________________________________________________________________4
4.1.1 Added Interlocks____________________________________________________________4
4.1.2 Interlock Priority____________________________________________________________4
4.1.3 Automatic Rod Catcher_______________________________________________________4
4.1.4 Affected Interlocks/Faults_____________________________________________________5
4.2 Switch Faults _________________________________________________________________5
4.3 Rod Support__________________________________________________________________6

1
1 References
The following software configuration files were used as references. (Refer to latest
versions.)
FaultCtrlAngle.cfg, FaultCtrlCompressor.cfg, FaultCtrlFeed.cfg, FaultCtrlIndex.cfg,
FaultCtrlJack.cfg, FaultCtrlLube.cfg, FaultCtrlPropel.cfg, FaultCtrlState.cfg,
FaultCtrlSwing.cfg, FaultCtrlTower.cfg, FaultCtrlVert.cfg,
FaultCtrlWater.cfg, FaultCtrlWrench.cfg, FaultDCU.cfg, FaultECM.cfg,
FaultFilter.cfg, FaultPower.cfg, FaultStop.cfg, FaultTempSensor.cfg

2 Introduction
The Pit Viper 351 drill contains many sensing devices within the tower. These
sensors detect the position of the rotary head, carousel, rod support, and tower pins.
The resulting data is sent to the central computer to control interlocks and to provide
important information to the operator.

When compared with other large blasthole drills, the Pit Viper has several notable
differences in rotary head detection:

Sensor Quantity: The Pit Viper has many more interlocks. Naturally, more
interlocks created a need for more tower sensors.

Sensor Type: The Pit Viper uses a combination of inductive proximity switches
and traditional mechanical limit switches.

3 Hardware Design

3.1 Design Constraints

The following constraints dictate the overall design:

Simplify. Use the least amount of sensors without sacrificing critical interlocks.

When possible, use limit switches. Due to past experience, limit switch failure
modes are known. Limit switches are successfully being used on similar IR
drilling products.

When possible, avoid detecting the head directly. Less vibration and mechanical
failure occur in other detectable areas (i.e. travelling sheaves).

Wire switches normally closed. This will create a safe failure mode if power is
lost to the sensors.

Use redundant switches for upper-tower head deceleration and rod support safe
zone.

Because the PV-351 combines the rod catcher and support into one device,
automatic rod catcher operation must be retained.

Calibration of the Aquila DM-0 system requires absolute head detection in at
least one position on the tower.

2
3.2 Head Detection Sensors
The system will contain five head position switches. A summary of the design layout
is shown in Table A, Switch Layout.

Table A, Switch Layout

ID Type Config Detection Function
SW2 Limit N.C. Travelling Sheaves Decelerate upward feed
(relative) when nearing top.
SW3 Limit N.C Travelling Sheaves Decelerate upward feed
. (relative) when nearing top.
(Redundant)
SW4 Limit N.O. Head Open/Close rod catcher and
(absolute) calibrate Aquila DM-0
module.
SW5 Limit N.C. Travelling Sheaves Stop feed if rod catcher is
(relative) closed and head in unsafe
zone.
SW6 Limit N.C. Travelling Sheaves Stop feed if rod catcher is
(relative) closed and head in unsafe
zone. (Redundant).

Based on the constraints of Section 4.1, the sensor layout results in the following:

SW2 and SW3 will function as upper deceleration switches. The switches will be
limit switch style and will detect the travelling sheave carriage, both switches will
trigger simultaneously. Both switches will be wired normally closed.

SW4 will trigger the automatic rod catcher open/close functionality and calibrate
the Aquila DM-0 system. The switch will be limit switch style and will detect the
travelling sheave carriage. The switch will be wired normally open.

SW5 and SW6 will function as rod catcher protection switches. The switches will
be limit switch style and will detect the travelling sheave carriage, both switches
will trigger simultaneously. Both switches will be wired normally closed.

3
4 Software Design

4.1 Interlocks

4.1.1 Added Interlocks

If SW2 activates, limit feed speed upwards.

If SW3 activates, limit feed speed upwards.

If SW4 is activated, clear the feed latch.

If SW4 activates and if vertical drilling and if head is travelling downwards, open
rod catcher until the Rod Catcher Open switch activates (contacts close).

If SW4 activates and if in vertical drilling mode and if head is travelling upwards,
close the rod catcher until the Rod Catcher Closed switch activates.

If SW4 activates and if in angle drilling mode and if head is travelling upwards,
close the rod catcher until the Jaw Closed switch activates.

If SW4 activates and head is travelling upwards, calibrate Aquila DM-0 system to
upward calibration value.

If SW5 activates, set the feed latch.

If SW6 activates, set the feed latch.

If feed latch is set and if Rod Catcher Open switch is not active, stop feed.
Display Rod Catcher Not Retracted on the CC. (By-passable)

If feed latch is set, disable rod catcher/support functionality in the engage
direction. Display Rotary Head in Rod Support Zone. (By-passable)

If the carousel stowed switch is not activated, limit feed pressure. (By-passable)

Upon shutdown of the central computer, the value of the feed latch shall be
stored. The value shall be reloaded upon power-up. If the value is not
successfully reloaded, de-activate the feed. Display Tower Interlock State
Unknown. The secondary description shall read Open the Rod
Catcher/Support. Once the rod support is open (stowed), the fault may be
cleared. (By-passable)

All other interlocks involving feed should be removed.

4.1.2 Interlock Priority

Any interlock that inhibits feed has the highest priority.

4.1.3 Automatic Rod Catcher

The pipe handling screen shall have a virtual button to toggle on/off the automatic
rod catcher functionality. The default setting will be ON. If the operator chooses to
turn off automatic rod catcher mode, a pop-up screen will appear for verification. If
drill state is changed, automatic rod catcher mode will be set to default (ON).

4
4.1.4 Affected Interlocks/Faults
The faults listed below are current faults that will be affected or deleted based on the
new design.

Fault ID 101, Carousel not stowed. Limit feed force.

Fault ID 104, Breakout wrench not fully open (not stowed). Stop feed.

Fault ID 105, Rod catcher not retracted (not open). Stop feed.

4.2 Switch Faults

If Rod Catcher Open switch is active and if Rod Catcher Closed switch is
active, stop feed and display Rod Support Proximity Switch Fault. (By-
passable)

If Rod Catcher Open switch is active and if Jaw Closed switch is active, stop
feed and display Rod Support Proximity Switch Fault. (By-passable)

If more than one head detection switch is simultaneously active, stop feed and
display Multiple Tower Switches Activated. (By-passable)
Exceptions: 1. Do not consider SW2 and SW3 combination. 2. Do not consider
SW5 and SW6 combination. 3. Do not consider SW1 and SW2 combination.

While feeding down, if SW2 triggered but SW3 does not trigger within + 6 in. of
encoder value, display Deceleration Switch Fault.

While feeding down, if SW3 triggered but SW2 does not trigger within + 6 in. of
encoder value, display Deceleration Switch Fault.

While feeding up, if SW2 triggered but SW3 does not trigger within 6 in. of
encoder value, display Deceleration Switch Fault.

While feeding up, if SW3 triggered but SW2 does not trigger within 6 in. of
encoder value, display Deceleration Switch Fault.

While feeding down, if SW5 triggered but SW6 does not trigger within + 6 in. of
encoder value, display Rod Catcher Interference Switch Fault.

While feeding down, if SW6 triggered but SW5 does not trigger within + 6 in. of
encoder value, display Rod Catcher Interference Switch Fault.

While feeding up, if SW5 triggered but SW6 does not trigger within 6 in. of
encoder value, display Rod Catcher Interference Switch Fault.

While feeding up, if SW6 triggered but SW5 does not trigger within 6 in. of
encoder value, display Rod Catcher Interference Switch Fault.

If SW1 is triggered but SW2 is not triggered, display Deceleration Switch Fault.

If SW1 is triggered but SW3 is not triggered, display Deceleration Switch Fault.

5
4.3 Rod Support
To insure proper automatic operation and functional interlocks, the switches on the rod
support shall be monitored relative to proper sequence and relationship.
The following matrix indicates acceptable states:
Jaw closed Arm closed Arm open
1 1 0
0 1 0
0 0 1

The following matrix indicates un-acceptable states: Initiate level 2 fault

Jaw closed Arm closed Arm open
1 1 1
1 0 1
0 1 1
0 0 0