FIELD OF THE INVENTION

This invention relates to data capturing. In particular, the invention relates to a method of capturing drilling data and to a data capturing device.

BACKGROUND OF THE INVENTION

The inventor is aware of pneumatic and hydraulic rock drills used in mines. In this specification the term rock drill is used to refer to a handheld rock drill as well as a drill rig. However, there is no method of monitoring the performance of such rock drills and of rock drill operators, which leads to unplanned maintenance on such drills and inefficient underground drilling.

In order to avoid unplanned maintenance, rock drills are then serviced and indiscriminately overhauled.

It is an object of the invention to capture time stamped drilling data for use in maintenance planning and performance monitoring.

SUMMARY OF THE INVENTION

In accordance with one aspect of the invention, there is provided a method of capturing drilling data from a rock drill, which includes

receiving an input signal from a sensor, the input signal being proportional to the physical effect generated by the rock drill;

recording a series of input signals from the sensor;

associating the recorded series of input signals with a particular rock drill;

deriving usage data from the recorded series of input signals; and

making the usage data available to a user.

The rock drill may be any one of a pneumatic and hydraulic rock drill, or a drill rig. The sensor may be any one of an impact, noise and inclination sensor. The physical effect generated by the rock drill may be any one of an impact, a noise, and an inclination, depending on the sensor being used.

The recorded series of input signals and the usage data derived therefrom may be time stamped with the use of a Real-Time Clock circuit.

The method may include measuring the impact generated by the rock drill in terms of impact force and frequency. The impact force and frequency may directly be measured or derived from vibration-; noise-; shock-; inductive-; acceleration sensors or any sensor which can sense drilling or drilling movement. In this document the different sensors/methods which can be used is merely referred to by the term“sensor”.

The method may include the prior step of associating a unique equipment identity number with any one of a rock drill, rock drill location and rock drill operator.

The method may include measuring the time for which the rock drill is operational, such as the time from where the rock drill starts to operate, until when the rock drill stops operating. The method may include using this data to determine the total operational time and the total non-operational time of the rock drill. From the sensor data the method may include using this data to determine“on-collar” drilling time and“off- collar” drilling time.

The method may include measuring the angle at which the rock drill is being used and the time for which it is used at a particular angle. The angle at which the drill is being used is measured with an inclination sensor or a micro electro-mechanical systems (MEMS) accelerometer and gyro and can measure this under vibration and shock conditions typical of the rock drilling operation. The angle data is time stamped by using the start and end time of drilling obtained from a signal present from the sensor. The method may include measuring the operational efficiency of the rock drill in terms of the number of holes that were drilled per panel/stope/per section and per shift/operational time. This is achieved by measuring the start and end of drilling operation by reading the time (date- and time stamped) from a real-time clock circuit as soon as the drill starts to operate together with on and off collar drilling cycles- it is possible to count each drilling cycle in terms of a hole being drilled. By accumulating each drill cycle (start and stop together with or without the on and off collar cycles) it is possible to count the number of holes drilled by each drill and operator.

The method may include measuring the operation cycle times, such as on- collar drilling and off-collar drilling times. The on- and off collar drilling operation is determined by the difference in frequency and amplitude being read from the sensor.

The method may include measuring the rock drill performance in terms of rate of penetration per hole drilled. The rate of penetration is determined by the difference in start time of the drill operation and the end time of the operation for each hole drilled. The start time is confirmed by a signal present from the sensor and a signal absent from the sensor. A better resolution of rate of penetration may be obtained by using the time stamped“on-collar” frequency and amplitude data to determine the drill has started and the end time is determined by the time stamped off-collar frequency and amplitude data. The on-collar frequency and amplitude differ from each other in magnitude and order.

The method may include monitoring the rock drill status by measuring the vibration generated by the rock drill and the operational temperature of the rock drill. The method may include measurement of air and water- flow and pressure to determine the drill deterioration and drill condition.

The method may include measuring the Mean Time Between Failure (MTBF) and Mean Time To Repair (MTTR) of the rock drill by reading data from a real time clock and calculating the MTBF and MTTR values. The method may include calculating when the rock drill is due for service by accumulating the operational time of the rock drill. The method may then include providing an audio/visual indication of when the rock drill is due for a service.

The invention extends to a data capturing device, which includes a sensor, operable to generate an input signal representative of an operational parameter of a pneumatic rock drill;

a processor operable to record a series of impact signals from the sensor and to derive usage date from the recorded series of input signals;

a unique identification device, which is associated with a particular rock drill; a communication interface, connected to the processor, operable wirelessly to transmit usage data to a remote receiver.

The sensor may be an impact sensor, operable to generate an input signal representative of the impact of a pneumatic rock drill. The sensor may be an inclinometer operable to determine the angle at which the rock drill is being operated. The sensor may be a vibration sensor, operable to sense vibration of the rock drill to determine when the rock drill is being operated. The sensor may be acoustic sensor to determine when the drill is being operated.

The data capturing device may include a real time clock, operable to measure the time for which the rock drill is being operated.

The processor of the data capturing device may include calculation means operable to calculate any one or more of an accumulated operational time of the rock drill; an“on-collar” drilling time and“off-collar” drilling time; a time for which the rock drill is operated at a particular angle; an operational efficiency of the rock drill in terms of drilling cycles per time interval; the number of holes drilled by each drill and operator; the rate of penetration per hole drilled; the Mean Time Between Failures (MTBF) and Mean Time To Repairs (MTTR) of the rock drill and when the rock drill is due for service.

The invention is now described by way of non-limiting example, with reference to the accompanying figures. FIGURE(S)

In the figure(s):

Figure 1 shows a functional block diagram of a data capturing device in accordance with one aspect of the invention; and

Figures 2 to 5 show presentations of operational data collected in terms of the method of the invention.

In the drawing(s), like reference numerals denote like parts of the invention unless otherwise indicated.

EMBODIMENT OF THE INVENTION

Figure 1 shows a functional block diagram of a data capturing device (10) in accordance with the invention.

The data capturing device (10) is a stand-alone unit with its own power supply in the form of a battery (12) or air/water driven generator for pneumatic/hydraulic drills respectively to power the electronic components of the data capturing device (10). It is to be appreciated that the generator may include any other generator such as induction; piezo or movement energy harvesting generator.

The data capturing device (10) includes a sensor (14), operable to generate an input signal representative of a physical characteristic of a pneumatic/hydraulic rock drill.

The following sensors (14), or other type of sensor, can be installed into the device (10) to measure the required physical characteristics:

• Impact (impulse) sensor- providing impact energy of percussion

• Vibration sensor- providing frequency and amplitude of vibration of the drill

• Acoustic sensor providing acoustic noise data or sound pressure level data from the drill operating (usually micro electro-mechanical systems (MEMS) type) • Shock sensor providing data from the percussion frequency of the drill usually MEMS type)

• Acceleration sensor providing linear movement data of the drill in one to three axes (usually MEMS type)

• Gyro sensor providing rotational movement data on one to three axes (usually MEMS type)

• Temperature measuring drill temperature and can be indication of abnormal friction of parts and that the condition of the drill deteriorates

• Flow sensor- measure water and air flow of the drill

• Pressure sensor- measure water and air pressure of the drill

• Lubrication sensor- measure lubrication of the drill (flow and pressure)

the above sensors may have digital or analogue outputs.

The sensor (14) is connected to a processor (16), which is operable to record a series of signals from the sensor and to derive usage data from the recorded series of input signals. The processor (16) is connected to a non-volatile memory device (18) for storing data, to a real time clock (20) which is operable to keep time and to record the duration for which the rock drill is used or not used.

The data capturing device (10) includes a universal asynchronous receiver-transmitter (22) (UART), a generic communication interface (24), such as a Wi- Fi-, optical-, blue tooth-, Low Power Wide Area Network (LPWAN), such as the LoRa WAN or Ethernet interface and an optical transceiver (28) connected to the processor (16) through which the processor (16) can communicate with an external processing device (26) and to other external devices (not shown).

The data capturing device (10) includes a unique identification code contained in the firmware, which is re-programmable, which is associated with a particular rock drill, in use. In this embodiment, the identification device is in the form of the memory (18) on which is stored a unique identity code.

In use, the data capturing device (10) provides a method of capturing time stamped drilling data from a pneumatic/hydraulic rock drill. The method includes the steps of receiving an input signal from the sensor (14). The input signal is proportional to a physical characteristic of the rock drill in terms of impact force and frequency. The method includes recording a series of input signals from the sensor (14).

The data capturing device (10), and its usage data, being the series of input signals are associated with a particular rock drill.

Once the series of input signals are recorded by the processor (16) and stored in the memory (18), usage data is derived therefrom.

The following usage data, or any other data is collected:

a) Equipment number for the drill (for identification during testing and asset tracking). The unique identification code or equipment number is transferred to the device by means of external communication from an external programmer (such as a personal computer or handheld programming device) (not shown) to the device (10) through a communication interface (22, 24, 28) before operational deployment or through the wireless communication interface during or after operational deployment from the external programmer. The unique identifier code is part of the firmware (software code) programmed into non-volatile memory on the device and can be read back together with the time stamped sensor data collected during drill operation.

b) Equipment location.

The equipment location is transferred by the same means as the unique identifier and also stored in memory on the device (10) and can also be re-programmed through a communication interface (22, 24, 28) by the externa programmer.

c) Operator.

The operator code is transferred by the same means as above unique identifier and equipment location as described above.

d) Equipment operational hours as measured by the real time clock.

The real time clock is set initially (to start keeping real time e.g. year; month; day; hour; minute; second) through a communication interface (22, 24, 28) and will keep time as long as the power source /battery is present and powered. The real time clock is read as soon as data is obtained and the data is then“time stamped” and stored in memory together with the time when the data was captured. e) Angle at which the equipment operates (e.g drilling angle against drilling time).

The angle at which the drill is being used is measured with an inclination sensor or a micro electro-mechanical systems (MEMS) accelerometer and gyro and can measure this under vibration and shock conditions typical of the rock drilling operation. The angle data is time stamped by using the start and end time of drilling obtained from a signal present from the sensor.

f) Data to determine operational efficiency (e.g. how many holes have been drilled per panel/stope/per section per shift/operational time) Drills are allocated (per unique equipment number) to a panel/stope and section- the time stamped data per unique equipment number then provides information of which shift it was in operational use, in which section it was operated and what the operational time of the drill was.

g) Different operation cycle times (e.g on-collar; off collar drilling times)

h) Total operational time

i) Total non-operational time

j) Equipment performance monitoring e.g. (rate of penetration per hole drilled) k) Equipment health monitoring (vibration; temperature over against operated)

L) Equipment reliability monitoring such as Drill Mean Time Between Failure (MTBF); Mean Time To Repair (MTTR) and other reliability parameters

m) Indication that the equipment is due for service by means of an audio/visual indication when the equipment reach its service due date/operational time/end of life time.

In use, the data capturing device (10) is loaded with executable code, which, when executed stores a unique drill/equipment ID number, the location of equipment deployment, the operator or any other required data related to the equipment. The device will record shock and vibration, inclination, acceleration or any data required to monitor the performance of the equipment or the operator through digital and analogue sensors to monitor starting of the operational process and ending of the operational process.

The data capturing device (10) will also store equipment and operator performance data or any data that may be required to monitor the operation or the equipment and or operator under use. Operator performance will be measured by assessing off collar drill time- if the off collar drill time exceeds the average of all operators off collar drill time- the drill is running without drilling. Further the total drilling time and rate of penetration will give an indication of operator efficiency.

The data is stored in the non-volatile Flash memory (18) to be exported through different communication interfaces, such as serial communication interfaces (RS 232, RS 422, RS 485) or through wireless communication interfaces such as WiFi, Near Field Communication, Blue Tooth; Lora or Optic communication to a remote receiver.

The data capturing device (10) can include an optical interface such as a visible spectrum LED to provide an indication of the rock drill operational data and service due date.

Figure 2 shows operational data including a graph of the drill angle, the shaft, section and stope at which the drill was operated and the operator and drill identification data. The average angle at which the drill was operated, the rate of penetration, the hole number, drill run time and drill off time.

Figure 3 shows a graph of the number of holes drilled per panel.

Figure 4 shows the rate of penetration per hole.

Figure 5 shows a spreadsheet of the drill rig numbers and the visits to a customer, the workshop and the stores. The total days in operation of each drill rig is also shown.

The present invention provides a novel method of capturing drilling data and a novel data capturing device, which is unique in its application as an electronic hour meter and performance monitoring device. The application to monitor a rock drill or rock drill rig and to monitor operator performance provides a unique application to underground equipment and works. The method provides a unique application to track drilling equipment and their operational data.