A machine to generate micro-cracks in the rock using a sonic vibrator to enhance subsequent deep drilling operation and a process for the same

Abstract

ABSTRACT A machine to generate micro-cracks in the rock using a sonic vibrator to enhance subsequent deep drilling operation and a process for the same The invention discloses a self-propelled device/machine with a sonic vibrator that makes tiny fissures/micro-cracks in the rock that goes vertically through tunnel ceilings or walls that enhances subsequent deep drilling operation. The said machine comprising a drill bit (102) to penetrate rock efficiently; Two motion controllers (103, 104) are configured, one (103) is positioned to hold the upper section steady while the bottom section climbs and other (104) hold the bottom section steady during drilling. The machine is further configured with an ultra sonic wave generator (105) which produces different frequency waves to create micro-cracks in the rock to make subsequent deep drilling easier. A hydraulic lift (106) is disposed to adjust the height and position of the machine components to ensure optimal contact with the rock surface. The drill machine (100) is connected to an electric wire (107) for power supply and securely placed against the tunnel walls by a structural support (108) which is supported by height adjustable rod (109). Fig 1.

Specification

Description:A machine to generate micro-cracks in the rock using a sonic vibrator to enhance subsequent deep drilling operation and a process for the same.

FIELD OF INVENTION
The present invention relates to a machine to generate micro-cracks in the rock using a sonic vibrator to enhance subsequent deep drilling operation. The invention discloses a machine that emulates caterpillar-like movement along walls or to the ceiling in a tunnel, generating micro-cracks in the rock using a sonic vibrator resulting reduction in mechanical resistance enhancing subsequent rock drilling process.

BACKGROUND OF THE INVENTION AND PRIOR ARTS
Tunnel and mine drilling have traditionally relied on heavy machinery and hydraulic systems to penetrate dense rock formations. These methods often require large, powerful drill bits and systems to overcome the mechanical resistance posed by hard rock. However, this approach presents several challenges, including high energy consumption, complex maintenance requirements, and reduced manoeuvrability, especially in confined spaces. Conventional drilling techniques have focused on brute force to break through rock. While effective, these methods are energy-intensive, slow, and lead to significant wear and tear on drilling components. As a result, drilling operations often face downtime due to the need for frequent equipment repairs or replacements. Additionally, traditional systems require significant human intervention, adding to labour costs and project timelines. Recent advancements in drilling technology such as ultrasonic drilling, uses high-frequency vibrations to weaken rock structures by creating small cracks, which allow the drill to penetrate with less resistance. This approach not only speeds up the drilling process but also reduces the strain on the equipment, extending the life of drill bits and other components. By focusing on external power sources and leveraging the benefits of ultrasonic vibrations, this drilling technology can offer more precise, faster, and cost-efficient solutions for tunnel construction and deep drilling operations.

Patent US-5896938-A describes a portable drilling system that uses an electrohydraulic method to create pressure waves for drilling holes in materials like rock. A drill stem, connected to a flexible cable, is powered by electrical pulses from a generator. This setup allows for efficient drilling in confined spaces, such as tunnel roofs, where traditional methods are impractical. The system offers improved drilling efficiency compared to conventional drills, making it particularly useful for underground mining and construction applications. The inclusion of a jackleg support facilitates the advancement of the drill during operation.

Patent US-3978930-A relates to a drilling apparatus designed for continuous borehole formation in mining operations. It incorporates a thrust force accumulator that enables consistent drilling during the alternating activation of borehole anchors. The system uses a conventional drill motor and bit combined with a piston and cylinder mechanism. This setup, along with a force-accumulating compression spring, ensures uninterrupted drill progression, improving efficiency over traditional intermittent drilling methods. The accumulator stores energy during the anchor engagement phase, releasing it to advance the drill bit, thus maintaining a steady drilling pace.

Patent US-4436455-A features a compact drilling machine designed for maneuvering in low-ceiling mines tunnels. It utilizes an electric-powered carriage with a low profile, comparable to the height of its rubber tires. The drill rig includes a variable-length boom and a motorized auger that can be positioned in three dimensions for drilling at various angles, including near the tunnel floor. The system's short wheelbase allows it to position transversely across the tunnel to drill holes for ceiling supports. A retraction feature for the power line ensures it doesn't tangle during operation.

Patent CN-106801607-B details a mechanism for a rock tunnelling machine that includes a drill with enhanced mobility and stability. The drilling machine is mounted on a sliding seat, allowing for precise reciprocating motion driven by a pressurization power mechanism. It incorporates a circumferential mobile mechanism for movement along the tunnel's circumference and a longitudinal moving mechanism for axial movement. This design efficiently utilizes limited space and reduces the system's overall weight and vibration, making it suitable for various Tunnel Boring Machines (TBM). The machine is designed to provide flexibility and stability during drilling operations, improving efficiency and reducing maintenance costs.

Patent CS-243439-B1 pertains to a tunnelling machine designed for creating small-diameter tunnels, specifically less than 4 meters in diameter. The machine includes a drill head mounted on a rotating bearing body, which transitions into a main frame with a spreading mechanism and a conveyor for the excavated rock. Key features include a ring with longitudinal and transverse guides that allow a sliding carriage to move and position reinforcement segments in the confined space behind the drilling head. This mechanism enables the automatic placement of tunnel reinforcements, reducing the need for manual labour and enhancing safety and efficiency in narrow tunnel spaces.

(Kotwica, 2018) This paper discusses innovative mining tools, holders, and heads designed for road headers used in tunnelling and gallery drilling in hard rock. Traditional tools, like tangential-rotary picks, wear out quickly in hard rock. To address this, the AGH UST in Krakow developed new tools, including crown picks and asymmetrical mini disk tools, along with a lubricated holder to reduce wear. Laboratory and field tests showed that these innovations significantly reduced tool wear and dust production while maintaining output quality. The research led to the creation of mining heads equipped with these new tools, which proved effective in various tests and showed potential for improved efficiency and durability in hard rock mining operations.

(Cao et al., 2020) This study investigates how vibration measurement while drilling (VMWD) technology can be used to better identify geological anomalies in coal mines that are submerged. Traditional methods like drilling and geophysical prospecting, while useful, have limitations in precision and operational convenience. The VMWD technology involves continuous monitoring of drilling tool vibrations using sensors placed near the drill bit or on the drill pipe. By analysing the vibration signals, the strength and composition of the rock can be determined, aiding in the identification of lithology and geological structures without the need for core samples. Field experiments demonstrated that this method effectively differentiates rock strengths, aligning well with traditional core drilling results, and shows promise for improving the safety and efficiency of coal mine operations.

(Cheluszka, 2020) This paper focuses on the optimization of cutting process parameters for increased efficiency by developing an automatic control system for boom-type road headers used in tunnel and roadway drilling. Manual control of these machines often results in suboptimal performance, particularly in hard rock environments, leading to high energy consumption and excessive wear. The proposed automatic system adjusts the cutting parameters based on real-time dynamic load information, significantly reducing energy usage and improving the efficiency and durability of the equipment. Simulations and laboratory tests confirmed that the system enhances mining efficiency by up to 50% and decreases dynamic loads and vibrations, paving the way for the future automation and robotization of road headers.
(Ding et al., 2021) This paper describes an innovative method for locating geological strata while drilling, using an R-20 rotary drilling rig for granite site experiments. The system monitors and records key drilling parameters such as axial pressure, drilling rate, rotation speed, flushing fluid pressure, and torque. The study finds that these parameters vary in their sensitivity to changes in formation structure, with drilling rate being the most predictive, followed by axial pressure, torque, rotation speed, and flushing fluid pressure. The research introduces a prediction formula based on drilling specific energy to estimate formation structure and compressive strength, demonstrating higher accuracy compared to single-parameter methods. The findings suggest that this energy-based approach can effectively predict rock and soil characteristics, thereby enhancing the efficiency and safety of geotechnical projects.

(Zhou et al., 2024) This work introduced a novel method for increasing the effectiveness of rock-breaking in deep drilling and mining operations: ultra-high-frequency particle impact rock-breaking (UPIRB). This method makes use of ultrasonic vibrations. This method involves small-sized particles generating ultra-high frequency and high impact stress on rock samples, significantly promoting rock degradation. Comparative studies between UPIRB and traditional ultrasonic vibration rock-breaking (UVRB) demonstrated that UPIRB delivers more than ten times the impact stress, reduces rock-breaking time from minutes to seconds, and increases efficiency nearly tenfold. The results show that UPIRB, due to its high-frequency impact and minimal contact area, quickly and effectively breaks rocks, overcoming the limitations of UVRB and offering a promising solution for energy exploration in complex geological environments.

OBJECTS OF THE INVENTION
- Therefore, it is an object of the invention to propose a machine to generate micro-cracks in the rock using a sonic vibrator to enhance subsequent deep drilling operation, which is capable of reducing mechanical resistance and significantly enhances speed and efficiency of subsequent deep drilling operation.

- Another object of the invention is to propose a machine to generate micro-cracks in the rock using a sonic vibrator to enhance subsequent deep drilling operation, which is able to provide a caterpillar-like movement of the machine enabling a steady progress without frequent stops or manual adjustments, thus boosting efficiency and shortening project timeless.

- A still another object of the invention is to propose a machine to generate micro-cracks in the rock using a sonic vibrator to enhance subsequent deep drilling operation, which is cost effective and a reliable solution for deep drilling in tunnel walls, simplifying operation and maintenance cost and overcoming the drawbacks of traditional rock drilling techniques.

SUMMARY OF THE INVENTION
The creativity behind this tunnel walls drilling machine (100) rests on a unique caterpillar-like mechanism propelled by two sets of motion controllers (103, 104) ensuring precise and progressive drill movements. It works in tandem with an ultrasonic wave generator (105) tasked with creating micro-cracks within the rock, thus dual processes. When tunnelling commences, external support is needed initially but not for long once the machine is completely inside the hole, it self-navigates within the tunnel walls using its own system. This approach not only boosts efficiency in penetrating rocks but also curtails unnecessary strain on the drill bit (102). The lightweight design and external power supply through an electric cable (107) make sure that this machine is not burdened with maintaining onboard power sources, as required by traditional hydraulic tunnel drilling machines that are bulky and intricate demanding extensive maintenance efforts. The drill bit (102) begins to penetrate the rock (101), assisted by the ultrasonic wave generator (105) which induces the micro-crack in the rock, making it easier to subsequent rock drilling.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Fig.1 - shows a caterpillar vibra sonic drill machine (100) according to invention

Fig 2 - Shows a core drilling machine bit (200) having a cutting edge (201), a slot (202) for removal of excess material during drilling and a arbor (203) to hold the drill bit securely,

Fig.3 - Shows a solid drill bit (300) to create long hollow holes in tunnel walls with multiple cutting edges (301), a slot (302) and an arbor (303) similar to Fig.2.


DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION:

The Caterpillar VibraSonic Drill Machine introduces a novel approach to tunnel walls drilling by integrating a caterpillar-like movement mechanism with an ultrasonic vibration system. Unlike traditional drilling machines, this design utilizes external electric power via an electric wire, thereby eliminating the complexities associated with onboard power sources and hydraulic systems. The machine employs two sets of motion controllers to ensure stability: the first set (103) holds the upper portion while the bottom climbs, and the second set secures the bottom during drilling. The ultrasonic wave generator creates micro-cracks in the rock, significantly reducing drilling resistance and enhancing efficiency. This innovative combination of technologies, including a hydraulic lift and a specialized drill bit, offers a more efficient and controlled method for tunnel drilling, particularly in challenging geological conditions.

The Caterpillar VibraSonic Drill Machine is an advanced drilling machine designed to penetrate rock efficiently using a combination of caterpillar-like movement and ultrasonic vibrations. This machine is externally powered by electricity, eliminating the need for onboard power sources.

The stone/rock represented by (101) will be drilled through by the caterpillar vibra sonic drill machine (100) producing cracks with ultrasonic vibrations.

The machine (100) comprising of a drill bit (102) which is the primary cutting tool of the machine, designed to penetrate rock and stone efficiently; a motion controller (103) positioned to hold the upper portion of the machine steady while the bottom portion climbs like a caterpillar ensuring stability and precise movement during the climbing process, another motion controller (104) that holds the bottom portion of the machine in place during the drilling operation. It maintains stability and control, allowing for effective drilling; an ultra sonic wave generator (105) that produces different frequency waves to create micro-cracks in the rock, facilitating subsequent drilling easier by reducing the force required by the drill bit, a hydraulic lift (106) to adjust the height and position of the machine components, ensuring optimal contact with the rock surface and aiding in the caterpillar-like movement of the machine an electric wire (107) to supply power to the caterpillar vibra sonic drill machine (100) enabling its various components to function without the need for onboard power sources; a structural support (108) to support the caterpillar vibra sonic drill machine (100) to keep it secured against the tunnel walls, during operation; a height adjustable rod (109) to provide support to the structure (108), allowing height adjustment to ensure the machine to maintain proper engagement with the tunnel walls. The tunnel floor is represented by (110) which provides the base for the drilling activities.

The present invention relates to a caterpillar-like tunnel walls drilling machine designed to improve the efficiency and safety of tunnel construction. This machine, referred to as the Caterpillar VibraSonic Drill Machine (100), leverages a combination of advanced mechanical and ultrasonic technologies to penetrate hard rock efficiently while minimizing the need for heavy hydraulic systems and long drill bits.

Operation
The drilling process begins with the machine requiring external support (108) to position itself at the start of the tunnel (mechanized or manual depending upon the size of the drill). Once the Caterpillar VibraSonic Drill Machine (100) enters the hole, it self-propagates using its internal mechanisms, thereby eliminating the need for external support. The process is as follows:

Initial Setup and Support:
The machine is initially externally supported (108) while it is in its initial position; support is not needed once the machine is fully engaged in the tunnel wall or celling.
The drill bit (102) begins to penetrate the rock (101), assisted by the ultrasonic wave generator (105) which induces micro-cracks in the rock, making it easier to drill through.

Incremental Movement and Drilling:
The two sets of motion controllers (103, 104) drive screws that hold different portions of the machine in place during various stages.
Motion controllers (103) hold the upper section while the bottom section climbs.
Motion controllers (104) hold the bottom section steady during drilling.
The hydraulic lift (106) helps in adjusting the machine's position and angle, ensuring precise drilling.


Self-Propagation:
As the machine progresses, it utilizes its caterpillar-like mechanism to move forward incrementally without requiring additional external support.
The electric wire (107) supplies continuous power to the machine, enabling uninterrupted operation.

Continuous Drilling:
Due to the combined action of ultrasonic wave-induced fracturing and mechanical penetration, the machine continues to advance and effectively drills through the rock.

This design not only simplifies the operation and maintenance of the machine, but also reduces operating costs and improves productivity. The technological advancement and economic importance of this invention make it an unnoticeable improvement over the existing state-of-the-art tunnel walls drilling machines, providing a more efficient, economical and practical solution for tunnel construction.

The invention utilizes a machine that emulates caterpillar-like movement along walls or to the ceiling in a tunnel. This machine generates micro-cracks in the rock using a sonic vibrator, which reduces mechanical resistance and significantly enhances drilling speed and efficiency. Powered externally through a long wire, this machine eliminates the need for onboard power sources. This design choice simplifies the machine, reducing its weight and maintenance requirements, while ensuring a continuous energy supply that minimizes downtime and allows for uninterrupted drilling operations.

The caterpillar-like movement of the machine enables steady progress without frequent stops or manual adjustments, thus boosting efficiency and shortening project timelines. The combination of micro-cracking technology and the machine's streamlined design offers a cost-effective and reliable solution for deep drilling in tunnel walls. The machine's precise and progressive movements are controlled by dual motion controllers, working in conjunction with an ultrasonic wave generator, which enhances rock penetration efficiency and reduces drill bit strain. The lightweight construction and reliance on an external power source mean the machine avoids the complications and maintenance demands of traditional hydraulic systems. This innovative design not only simplifies operation and maintenance but also cuts operating costs and improves overall productivity. This invention is an important advancement solution for deep drilling in tunnel walls because it addresses and overcomes the drawbacks of traditional drilling techniques, supplying a workable, affordable, and effective tunnel and mines solution.

ADVANTAGES OVER THE EXISTING METHODS AND DEVICES

The Caterpillar VibraSonic Drill Machine offers several distinct advantages and improvements over existing methods, devices, and materials in tunnel walls drilling. First, its combination of mechanical penetration and ultrasonic wave technology significantly enhances drilling efficiency by creating micro-cracks in the rock, facilitating easier and faster penetration. This reduces wear on the drill bit and minimizes downtime for maintenance. Second, the machine's compact design and elimination of bulky hydraulic systems enable it to operate effectively in confined spaces, which is not feasible with traditional hydraulic tunnel drills. Third, the self-propagating mechanism, which requires external support only at the initial drilling phase, improves operational safety and reduces the need for continuous manual adjustments. This feature not only streamlines the drilling process but also decreases labour costs and the risk of human error. Additionally, the machine's reliance on external electricity via a long wire instead of onboard power sources or complex hydraulic systems further reduces operational costs and simplifies maintenance. Overall, the Caterpillar VibraSonic Drill Machine offers superior efficiency, reduced operational and maintenance costs, and enhanced safety, making it a significant advancement in tunnel drilling technology. , Claims:WE CLAIM:

1. A machine (100) to generate micro-cracks in the rock, using a sonic vibrator to enhance subsequent deep drilling operation, the said machine comprising;
- a drill bit (102) to work as the primary cutting tool of the machine configured to penetrate rock and stone efficiently;
- a motion controller (103) configured in a position to hold the upper portion of the machine (100) steady while the bottom portion climbs like a caterpillar, ensuring stability and precise movement during the climbing process;
- another motion controller (104) configured to hold the bottom portion of the machine in place during operation, maintaining stability and control for effective drilling;
- an ultra-sonic wave generator (105);
- a hydraulic lift (106);
- an electric wire to supply power to the caterpillar vibrasonic drill machine (100) to enable its various components to function without the need for onboard power sources;
- a structural support (108) to keep the caterpillar vibra sonic drill machine (100) secured against the tunnel walls during operation;
- a height adjustable rod (109) to provide support to the structure (108), allowing height adjustment to ensure the machine maintains proper engagement with the tunnel walls;
characterized in that,
the ultrasonic wave generator (105) produces different frequency waves to create micro-cracks in the rock to facilitate easier drilling, reducing the force required by the drill bit in subsequent deep drilling operation, wherein the hydraulic lift (106) is disposed to adjust the height and position of the machine components, ensuring optimal contact with the rock surface and aiding in the caterpillar-like movement of the machine (100), moving forward incrementally without requiring additional external support.

2. A process to generate micro-cracks in the rock by the machine (100) using a sonic vibrator, the said process comprising the steps of;
- ensuring external support (108) to position the machine (100) at the start of the tunnel to begin the drilling operation;
- arranging the drill machine (100) to enter the hole and allowing to self-propagate using the internal mechanism of the machine (100) , eliminating the need for external support (108);
- disposing a motion controller (103) to hold the upper section of the machine steady while the bottom portion climbs like a caterpillar, ensuring stability and precise movement during the climbing process;
- disposing another motion controller (104) to hold the bottom portion of the machine in place during drilling operation maintaining stability and control for effective drilling;
- configuring a hydraulic lift (106);
- configuring an ultra-sonic wave generator (105);
- arranging an electric wire to supply power to the caterpillar vibra sonic drilling machine (100) enabling the machine components to function;
- providing structural support (108) to support the machine (100);
- providing height adjustable rod (109) to support the structure (108);
- configuring a drill bit (102),
wherein,
the drill bit (102) begins to penetrate the rock (101) assisted by the ultrasonic wave generator (105) inducing micro-cracks in the rock, making it easier for subsequent drilling, wherein the hydraulic lift adjusts the machine's position and angle, ensuring optimal contact with the rock surface, wherein, as the machine progresses, it utilizes its caterpillar-like mechanism forward incrementally without requiring additional support.

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