Automated mast control for drilling

Abstract

A control system and method for automating the positioning of a mast in a drilling machine is disclosed herein. The machine operator can enter a desired mast angle into the control system and the control system can position/reposition the mast until the mast is within an acceptable range of the desired mast angle such that the mast can be successfully locked at the desired mast angle. An automated calibration process can be used to calibrate the mast prior to positioning the mast at the desired mast angle and compensate for any difference between the measured mast angle and a default mast angle.

What is claimed is: 
     
         1 . A method of automating positioning of a mast in a drilling machine at various angles, the method comprising:
 (a) entering a desired mast angle into an input module of the machine, the input module connected to an electronic control module (ECM) of the machine;   (b) moving the mast using the ECM;   (c) measuring an angle of the mast using a measuring device in communication with the ECM;   (d) determining with the ECM whether the measured mast angle is within an acceptable range of the desired mast angle;   (e) if the measured angle is within the acceptable range, attempting to lock the mast at the measured mast angle using the ECM;   (f) if the measured angle is not within the acceptable range, repeating the step above of moving the mast using the ECM until the measured mast angle is within the acceptable range;   (g) determining with the ECM whether the mast is successfully locked; and   (h) if the mast is not successfully locked, repeating steps (b)-(g).   
     
     
         2 . The method of  claim 1  wherein moving the mast using the ECM includes raising or lowering the mast relative to a stowed position of the mast on the drilling machine. 
     
     
         3 . The method of  claim 2  wherein raising the mast includes actuating a raise mast solenoid with the ECM. 
     
     
         4 . The method of  claim 2  wherein lowering the mast includes actuating a lower mast solenoid with the ECM. 
     
     
         5 . The method of  claim 1  wherein measuring an angle of the mast using a measuring device includes measuring the mast angle with a sensor, and the mast angle is measured relative to a vertical position of the mast, the vertical position generally perpendicular to a stowed position. 
     
     
         6 . The method of  claim 1  wherein determining with the ECM whether the mast is successfully locked includes using a proximity sensor to determine whether a locking pin is sufficiently engaged with a hole corresponding to the mast positioned at the desired mast angle. 
     
     
         7 . The method of  claim 1  further comprising:
 before step (b), unlocking the mast with the ECM unless the mast is in a stowed, unlocked position. 
 
     
     
         8 . The method of  claim 1  further comprising:
 if the mast is locked in step (g), relaying confirmation of successful lock to an output display. 
 
     
     
         9 . The method of  claim 1  further comprising:
 prior to performing steps (a)-(h), calibrating the mast to compensate for any discrepancies between the measured mast angle and a default mast angle at a particular mast position. 
 
     
     
         10 . The method of  claim 9  wherein calibrating the mast comprises:
 moving the mast to a vertical position, the vertical position generally perpendicular to a stowed position and correlating to a first pin position, additional pin positions correlating to various angles of the mast relative to the vertical position and at equally spaced increments; 
 measuring a mast angle at the vertical position using the measuring device; 
 adjusting a default mast angle for the first pin position based on a value of the measured mast angle at the vertical position; and 
 adjusting a default mast angle for each additional pin position based on the value of the measured mast angle at the vertical position. 
 
     
     
         11 . The method of  claim 10  wherein the additional pin positions are spaced from the first pin position at 5 degree increments. 
     
     
         12 . The method of  claim 1  wherein in step (h), repeating steps (b)-(g) is performed until the mast is locked or until the ECM times out. 
     
     
         13 . A method for automating position of a mast in a drilling machine, the method comprising:
 (a) entering a desired mast angle into an electronic control panel of the drilling machine, the electronic control panel in communication with an electronic control module (ECM) of the machine, the desired mast angle selected from a plurality of default mast angles that correspond to an angle of the mast relative to a vertical position of the mast and are at equally spaced increments to one another;   (b) unlocking the mast with the ECM unless the mast is in a stowed, unlocked position;   (c) engaging a raise mast solenoid or a lower mast solenoid with the ECM to activate raising or lowering of the mast;   (d) measuring an angle of the mast at a particular mast position and relaying the measured mast angle to the ECM;   (e) determining with the ECM whether the measured mast angle is within an acceptable range of the desired mast angle;   (f) if measured mast angle within acceptable range, activating a lock solenoid with the ECM to attempt to lock the mast at the particular mast position;   (g) if measured mast angle outside of acceptable range, repeating steps (c)-(e) until the measured mast angle is within acceptable range;   (h) determining whether the mast is locked and relaying to the ECM;   (i) if locked, displaying an output on the electronic control panel confirming successful lock; and   (j) if not locked, repeating steps (c)-(h) until locked or until the ECM times out.   
     
     
         14 . The method of  claim 13  further comprising:
 prior to performing steps (c)-(j), 
 moving the mast to the vertical position; 
 measuring the mast angle at the vertical position and relaying the measured mast angle to the ECM; and 
 adjusting each of the default mast angles in the plurality of default mast angles based on the measured mast angle at the vertical position. 
 
     
     
         15 . The method of  claim 13  wherein the plurality of default mast angles are spaced at 5 degree increments. 
     
     
         16 . The method of  claim 13  wherein activating a lock solenoid comprises engaging a locking pin with one of a plurality of holes on a bottom portion of a mast housing, each of the plurality of holes corresponding to a default mast angle from the plurality of default mast angles. 
     
     
         17 . A control system for positioning of a mast in a drilling machine, the control system comprising:
 an electronic control module (ECM) configured to receive, store and execute instructions for operation of the mast;   a control panel coupled to the ECM and configured to receive user inputs from a user of the machine and display outputs from the ECM;   a first electrohydraulic circuit configured to raise or lower the mast in response to instructions from the ECM;   a mast angle sensor in communication with the ECM and configured to measure an angle of the mast and relay the measured mast angle to the ECM;   a second electrohydraulic circuit configured to lock or unlock the mast in response to instructions from the ECM; and   a locking sensor in communication with the ECM and configured to detect whether the mast is in a locked position and relay to the ECM,   wherein the control panel is configured to receive a desired mast angle from the user, the desired mast angle is communicated to the ECM, and the ECM controls operation of the first and second hydraulic circuits to position and lock the mast at the desired mast angle.   
     
     
         18 . The control system of  claim 17  wherein the first electrohydraulic circuit includes a raise mast solenoid and a lower mast solenoid. 
     
     
         19 . The control system of  claim 17  wherein the second electrohydraulic circuit includes a locking mast solenoid to engage a locking pin with a hole on the mast, the hole is selected form a plurality of holes and each hole corresponds to a predetermined angle of the mast. 
     
     
         20 . The control system of  claim 17  wherein the ECM is configured to perform a calibration of the mast prior to positioning and locking the mast at the desired mast angle, and the calibration accounts for any difference between a measured mast angle and a default mast angle at a particular mast position.