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IIoT-based Instrumentation and Control System for a Lateral Micro-drilling Robot Using Machine Fault Diagnosis and Failure Prognosis

thesis
posted on 2023-10-11, 12:26 authored by Jose A. Solorio CervantesJose A. Solorio Cervantes

This project aimed to develop an instrumentation and control system for a micro-drilling robot based on Industrial Internet of Things (IIoT) technologies. The automation system integrated IIoT technological tools to create a robust automation system capable of being used in drilling operations. The system incorporated industrial-grade sensors, which carried out direct measurements of the critical variables of the process. The indirect variables relevant to the control of the robot were calculated from the measured parameters. The system also considered the telemetry architecture necessary to reliably transmit data from the down-the-hole (DTH) robot to a receiver on the surface. Telemetry was based on wireless communication through long-range radio frequency (LoRa). The system developed had models based on Artificial Intelligence (AI) and Machine Learning (ML) for determining the mode of operation, detecting changes in the process, and changes in drilling variables in critical hydraulic components for the drilling process. Algorithms based on AI and ML models also allowed the user to make better decisions based on the variables' correlation to optimize the drilling process (e.g., dynamic change of flow, pressure, and RPMs based on automatic rock identification). A user interface (UI) was developed, and digital tools to perform data analysis were implemented. Safety assessment in all robot systems (e.g., electrical, hardware, software) was contemplated as a critical design component. The result of this research project provides innovative micro-drilling robots with the necessary technological tools to optimize the drilling process. The system made drilling more efficient, reliable, and safe, providing diagnostic and prognostic tools that allowed planning maintenance based on the actual health of the devices. The system that was developed was tested in a test bench under controlled conditions within a laboratory to characterize the system and collect data that allowed ML models' development, training, validation, and testing. The prototype of a micro-drilling robot installed on the test bench served as a case study to assess the implemented models' reliability and the proposed telemetry.

History

Degree Type

  • Doctor of Philosophy

Department

  • Technology

Campus location

  • West Lafayette

Advisor/Supervisor/Committee Chair

Jose M. Garcia

Additional Committee Member 2

Brittany A. Newell

Additional Committee Member 3

Mark French

Additional Committee Member 4

Nathan C. Schultheiss