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煤矿井下小直径PDC数字钻头多参数高精度监测方法

A high-precision multi-parameter monitoring method for small-diameter PDC digital drill bit in underground coal mines

  • 摘要: 针对煤矿井下钻进过程中孔底工况感知失真、传统钻机参数监测值与钻头实际工况存在显著偏差等问题,为实现贴近孔底真实破岩状态的多工程参数高精度、实时监测,研制适用于煤矿井下小尺寸防爆数字钻头工程参数测量系统。提出外径为120 mm的防爆数字钻头整体方案,采用MEMS传感器偏置式布局和应变片圆周对称布局的设计,集成应变片、加速度计、内环空压力传感器与温度传感器等多参数传感模块,并通过基于磁耦合原理的无线短传技术实现与随钻测量(MWD)系统的实时数据交互。重点研究小尺寸空间下的多参数高精度测量难题,提出基于应变片全桥布置的钻压与扭矩解耦算法,并系统分析温度变化与内外环空压力差对测量结果的扰动规律,建立综合考虑温度变化及内外环空压力差影响的钻压扭矩解耦模型,最终研制出Φ120 mm防爆数字钻头,实现了钻压(0~150 kN,±1.21% F.S.)、扭矩(0~4 kN·m,±0.94% F.S.)、转速(0~300 r/min)、温度(0~80 ℃)、内环空压力(0~15 MPa)及三向振动(径向、切向、轴向) (±16 g)的高精度同步测量。试验结果表明,经补偿算法优化后,数字钻头在满量程范围内的钻压、扭矩的测量精度分别提高至±1.21% F.S.、±0.94% F.S.。现场试验表明,基于数字钻头实测数据,可有效识别扭矩与钻压突变、横向振动等异常工况;对比数据显示,钻头处实测钻压平均比钻机给进力监测值低9.4 kN,直观揭示了孔壁摩擦等能耗因素,证实了直接获取钻头工况参数的必要性。研究成果为煤矿井下钻进过程的数字化感知、工况识别与智能化控制提供了直接的数据支撑与硬件基础。后续研究可聚焦于基于数字钻头多源数据的钻进状态智能诊断与自适应控制策略,进一步推动煤矿安全高效智能化钻探技术的发展。

     

    Abstract: In response to issues such as distorted perception of downhole conditions and significant deviations between traditional rig monitoring data and the actual working state at the bit during underground coal mine drilling, this research aims to develop a compact, explosion-proof digital drill bit engineering parameter measurement system. The goal is to achieve high-precision, real-time monitoring of multiple parameters that accurately reflect the true rock-breaking conditions at the borehole bottom. An overall design for a small-sized, explosion-proof digital drill bit with an outer diameter of 120 mm was proposed. The design incorporates an offset layout for MEMS sensors and a circumferentially symmetric arrangement for strain gauges. It integrates multi-parameter sensing modules including strain gauges, accelerometers, an inner annulus pressure sensor, and a temperature sensor. Real-time data interaction with the Measurement-While-Drilling (MWD) system is enabled via wireless short-range transmission technology based on magnetic coupling principles. Focusing on the challenge of high-precision multi-parameter measurement within confined spaces, a decoupling algorithm for weight on bit (WOB) and torque based on a full-bridge strain gauge configuration was proposed. The disturbance patterns of temperature variations and differential pressure between inner and outer annuli on measurement results were systematically analyzed. A WOB-torque decoupling model incorporating these factors was established. Ultimately, a Φ120 mm explosion-proof digital drill bit was developed. The developed digital drill bit achieves high-precision synchronous measurement of WOB (0−150 kN, ±1.21% F.S.), torque (0−4 kN·m, ±0.94% F.S.), rotational speed (0−300 r/min), temperature (0−80 ℃), inner annulus pressure (0−15 MPa), and triaxial vibration (radial, tangential, and axial) (±16 g). Experimental results show that after optimization by the compensation algorithm, the measurement accuracy for WOB and torque across the full scale improved to ±1.21% F.S. and ±0.94% F.S., respectively. Field trials demonstrated that the system can effectively identify abnormal conditions such as sudden changes in torque and WOB, as well as lateral vibration based on the measured data. Comparative data revealed that the average WOB measured at the bit was 9.4 kN lower than the feed force monitored at the rig, intuitively highlighting energy consumption factors like borehole wall friction and confirming the necessity of directly acquiring bit working parameters. The research outcomes provide direct data support and a hardware foundation for the digital perception, condition identification, and intelligent control of the drilling process in underground coal mines. Future research can focus on intelligent diagnosis of drilling states and adaptive control strategies based on the multi-source data from the digital drill bit, to further advance the development of safe, efficient, and intelligent drilling technology in coal mines.

     

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