US007954558B2

(12) United States Patent (10) Patent N0.: US 7,954,558 B2

Lane et a1. (45) Date of Patent: Jun. 7, 2011

(54) DEVICES AND METHODS FOR POWER (56) References Cited

CONTROL IN HORIZONTAL DIRECTIONAL
DRILLING U.S. PATENT DOCUMENTS
4,008,004 A * 2/1977 Shaw .......................... .. 417/216

(75) Inventors: Philip R. Lane, Pella, IA (US); Douglas 4,763,473 A 8/1988 Ziplies et a1.
2001/0050186 A1 12/2001 Wilson et a1.
Peirce, Pleasant Hill, IA (US) 2006/0185899 A1 * 8/2006 Alft et a1. ...................... .. 175/24

FOREIGN PATENT DOCUMENTS

(73) Assignee: Vermeer Manufacturing Company,
Pella, IA (US) DE 9402360 U1 12/1994
W0 WO 97/47858 12/1997
Notice: Subject to any disclaimer, the term of this * cited by examiner
patent is extended or adjusted under 35 Primary Examiner * David J Bagnell
U.S.C. 154(b) by 127 days. Assistant Examiner * James G Sayre
(74) Attorney, Agent, or Firm * HollingsWorth & Funk,
(21) Appl. N0.: 12/252,ss3 LLC
(57) ABSTRACT
(22) Filed: Oct. 16, 2008 The present disclosure is directed to methods and apparatuses
for controlling pump poWer draW from an engine in horizon
(65) Prior Publication Data tal directional drilling. Various embodiments of the invention
are directed to a horizontal directional drilling machine that
US 2009/0095527 A1 Apr. 16, 2009 comprises an engine that outputs mechanical energy, a rota
tion pump that draWs upon the mechanical energy output by
Related US. Application Data the engine to operate a rotation motor that rotates a drill string,
a thrust pump that draWs upon the mechanical energy output
(60) Provisional application No. 60/999,325, ?led on Oct. by the engine to operate a thrust motor that longitudinally
16, 2007. moves the drill string, a mud pump that draWs upon the
mechanical energy output by the engine to operate a mud
motor that delivers ?uid through the drill string, and control
(51) Int. Cl. circuitry comprising a controller and memory, the processor
E21B 44/00 (2006.01) con?gured to execute program instructions stored on the
E21B 3/00 (2006.01) memory, processor execution of the stored program instruc
E21B 7/04 (2006.01) tions causing the control circuitry to calculate a rotation pump
E21B 44/06 (2006.01) poWer draW from the engine, calculate a thrust pump poWer
draW from the engine, calculate a mud pump poWer draW
E21B 44/04 (2006.01) from the engine, calculate a total poWer draW based on the
E21B 44/02 (2006.01) rotation pump poWer draW, the thrust pump poWer draW and
F16D 31/02 (2006.01) the mud pump poWer draW, compare the total poWer draW to
(52) US. Cl. .......................................... .. 175/25; 60/431 a threshold, and decrease mechanical energy draW of each of
(58) Field of Classi?cation Search .................. .. 175/61, the rotation pump, the thrust pump, and the mud pump from
175/62, 162, 170, 202, 203; 60/431, 449, the engine based on the total poWer draW exceeding the
60/428 threshold.
See application ?le for complete search history. 18 Claims, 3 Drawing Sheets
US. Patent Jun. 7, 2011 Sheet 1 013 US 7,954,558 B2
US. Patent Jun. 7, 2011 Sheet 2 of3 US 7,954,558 B2

205 ~\_ 206 i\ 207 \

Rotator) KThrust ) Mud )
_/ ‘ '/ '

2083 2093
Sensor Sensor

260K 261 262 Sensor

J
201x 210
202w 203w 204w
Engine Rotation Pump Thrust/Pull Pump Mud Pump
25 o\ 251‘) l 253\
Rotation Thruswuu Mud
Input Input Input
t v
4D
Rotation Power Mud Power
—|’\—>
211/ 2131
> Thrust Power

215 \ 212/’ 4
Total Power

t
214\ Compare

200
(/
Figure 2
 US 7,954,558 B2
1 2
DEVICES AND METHODS FOR POWER Another technique associated With horizontal directional
CONTROL IN HORIZONTAL DIRECTIONAL drilling, often referred to as push reaming, involves attaching
DRILLING a reamer to the drill string at the entry side of a borehole after
the boring tool has exited at the exit side of the borehole. The
RELATED APPLICATIONS reamer is then pushed through the borehole While the drill
rods being advanced out of the exit side of the borehole are
This application claims the bene?t of Provisional Patent individually disconnected at the exit location of the borehole.
Application Ser. No. 60/999,325, ?led on Oct. 16, 2007, to A push reaming technique is sometimes used because it
Which Applicant claims bene?t of priority under 35 U.S.C. advantageously provides for the recycling of the drilling ?uid.
§l 19(e), and Which is incorporated herein by reference in its The level of direct operator interaction With the drill string,
entirety. such as is required to disconnect drill rods at the exit location
of the borehole, is much greater than that associated With
FIELD OF THE INVENTION traditional horizontal directional drilling techniques.
SUMMARY OF THE INVENTION
The present invention relates generally to methods and
equipment used for horizontal ground boring; more speci? The present disclosure relate to a system and method of
cally to a method and apparatus for managing pump poWer automatically avoiding engine overload in HDD. Horizontal
draW from an engine. directional drilling machines can include an engine that poW
20 ers a number of hydraulic motors. For example, one hydraulic
BACKGROUND OF THE INVENTION motor can be use to thrust or pull the drill string, another
hydraulic motor can be used to rotate the drill string, and yet
Utility lines for Water, electricity, gas, telephone, and cable another hydraulic motor can be used to run a mud pump. The
television are often run underground for reasons of safety and hydraulic motors draW poWer from the engine through sepa
aesthetics. In many situations, the underground utilities can 25 rate pumps and hydraulic ?uid circuits. The present invention
be buried in a trench Which is then back-?lled. Although provides a control method and system that prevents the
useful in areas of neW construction, the burial of utilities in a engine from being overloaded by the multiple hydraulic
trench has certain disadvantages. In areas supporting existing pumps.
construction, a trench can cause serious disturbance to struc Various embodiments of the invention are directed to a
tures or roadWays. Further, there is a high probability that 30 horizontal directional drilling machine that comprises an
digging a trench may damage previously buried utilities, and engine that outputs mechanical energy through a rotation
that structures or roadways disturbed by digging the trench shaft, a rotation pump that draWs upon the mechanical energy
are rarely restored to their original condition. Also, an open output by the engine through rotation of the rotation shaft to
trench may pose a danger of injury to Workers and passersby. operate a rotation motor that rotates a drill string by pressur
The general technique of boring a horizontal underground 35 ization of a rotation hydraulic ?uid circuit betWeen the rota
hole has recently been developed in order to overcome the tion pump and the rotation motor, a thrust pump that draWs
disadvantages described above, as Well as others unaddressed upon the mechanical energy output by the engine through
When employing conventional trenching techniques. In rotation of the rotation shaft to operate a thrust motor that
accordance With such a horizontal boring technique, also longitudinally moves the drill string by pressurization of a
knoWn as horizontal directional drilling (HDD) or trenchless 40 thrust hydraulic ?uid circuit betWeen the thrust pump and the
undergroundboring, a boring system is situated on the ground thrust motor, a mud pump that draWs upon the mechanical
surface and drills a hole into the ground at an oblique angle energy output by the engine through rotation of the rotation
With respect to the ground surface. shaft to operate a mud motor that delivers ?uid through the
The HDD process includes a pilot hole-boring step. In this drill string by pressurization of a mud hydraulic ?uid circuit
step a bore hole is created that extends undergroundigener 45 betWeen the mud pump and the mud motor, a rotation hydrau
ally horizontally or generally parallel to the surface of the lic ?uid sensor that outputs a rotation pressure signal indica
earthistarting at a launch point and ending at a termination tive of hydraulic ?uid pressure Within the rotation hydraulic
point. The bore hole is created by positioning a boring ?uid circuit, a thrust hydraulic ?uid sensor that outputs a
machine to rotate and push a drill string through the ground. thrust pressure signal indicative of hydraulic ?uid pressure
A drill bit is attached to the leading end of the drill string. The 50 Within the thrust hydraulic ?uid circuit, a mud hydraulic ?uid
drill string is created by connecting individual drill rods sensor that outputs a mud pressure signal indicative of
together end-to-end from a supply of drill rods stored on the hydraulic ?uid pressure Within the mud hydraulic ?uid cir
boring machine. The connection betWeen the rods is made up, cuit, a sensor that outputs a rotation signal indicative of rota
and subsequently broken in a later step, by the boring tion rate of the rotation shaft, and control circuitry comprising
machine. 55 a processor and memory, the processor con?gured to execute
A drilling ?uid can be ?oWed through the drill string, over program instructions stored in the memory, processor execu
the boring tool, and back up the borehole in order to remove tion of the stored program instructions causing the control
cuttings and dirt. After the boring tool reaches a desired depth, circuitry to control poWer draW of the rotation pump from the
the tool is then directed along a substantially horizontal path mechanical energy output by the engine, control poWer draW
to create a horizontal borehole. After the desired length of 60 of the thrust pump from the mechanical energy output by the
borehole has been obtained, the tool is then directed upWards engine, control poWer draW of the mud pump from the
to break through to the earth’s surface. A reamer is then mechanical energy output by the engine, calculate a rotation
attached to the drill string Which is pulled back through the pump poWer draW from the engine based on the rotation
borehole, thus reaming out the borehole to a larger diameter. pressure signal and the rotation signal, calculate a thrust
It is common to attach a utility line or other conduit to the 65 pump poWer draW from the engine based on the thrust pres
reaming tool so that it is dragged through the borehole along sure signal and the rotation signal, calculate a mud pump
With the reamer. poWer draW from the engine based on the mud pres sure signal
 US 7,954,558 B2
3 4
and the rotation signal, calculate a total power draW based on operate a rotation motor that rotates a drill string, a thrust
the rotation pump poWer draw, the thrust pump poWer draW pump that draWs upon the mechanical energy output by the
and the mud pump poWer draW, compare the total poWer draW engine to operate a thrust motor that longitudinally moves the
to a threshold associated With output capacity of the engine, drill string, a mud pump that draWs upon the mechanical
and decrease mechanical energy draW from the engine of each energy output by the engine to operate a mud motor that
of the rotation pump, the thrust pump, and the mud pump delivers ?uid through the drill string, and control circuitry
based on the total poWer draW exceeding the threshold. comprising a controller and memory, the processor con?g
Such embodiments may include a user interface compris ured to execute program instructions stored on the memory,
ing a rotation user input con?gured to output a rotation signal processor execution of the stored program instructions caus
based on user input, a thrust user input con?gured to output a ing the control circuitry to calculate a rotation pump poWer
thrust signal based on user input, and a mud user input con draW from the engine, calculate a thrust pump poWer draW
?gured to output a mud signal based on user input, Wherein from the engine, calculate a mud pump poWer draW from the
processor execution of the stored program instructions causes engine, calculate a total poWer draW based on the rotation
the control circuitry to control poWer draW of the rotation pump poWer draW, the thrust pump poWer draW and the mud
pump based on the rotation signal, control poWer draW of the pump poWer draW, compare the total poWer draW to a thresh
thrust pump based on the thrust signal, control poWer draW of old, and decrease mechanical energy draW of each of the
the mud pump based on the mud signal, and Wherein poWer rotation pump, the thrust pump, and the mud pump from the
draW of the rotation pump, poWer draW of the thrust pump, engine based on the total poWer draW exceeding the threshold.
and poWer draW of the mud pump are each moderated from Such embodiments may comprise a ?rst sensor that outputs
user input levels based on the total poWer draW exceeding the 20 a ?rst parameter signal indicative of a ?rst hydraulic ?uid
threshold. parameter of hydraulic ?uid pumped by the rotation pump, a
In such embodiments, processor execution of the stored second sensor that outputs a second parameter signal indica
program instructions may cause the control circuitry to tive of a second hydraulic ?uid parameter of hydraulic ?uid
decrease by a proportional amount the mechanical energy pumped by the thrust pump, and a third sensor that outputs a
draW of each of the rotation pump, the thrust pump, and the 25 third parameter signal indicative of a third hydraulic ?uid
mud pump from the engine based on the total poWer draW parameter of hydraulic ?uid pumped by the mud pump,
exceeding the threshold. Wherein processor execution of the stored program instruc
In such embodiments, processor execution of the stored tions may cause the control circuitry to calculate the rotation
program instructions may cause the control circuitry to pump poWer draW based on the ?rst parameter signal, calcu
decrease the mechanical energy draW of each of the rotation 30 late the thrust pump poWer draW based on the second param
pump, the thrust pump, and the mud pump in different eter signal, and calculate the mud pump poWer draW based on
amounts based on the total poWer draW exceeding the thresh the third parameter signal.
old. In such embodiments, the ?rst hydraulic ?uid parameter
Such embodiments may comprise an engine temperature may be hydraulic ?uid ?oW rate output by the rotation pump,
sensor that outputs a temperature signal indicative of coolant 35 the second hydraulic ?uid parameter may be hydraulic ?uid
temperature of the engine, Wherein processor execution of the ?oW rate output by the thrust pump, and the third hydraulic
stored program instructions may cause the control circuitry to ?uid parameter may be hydraulic ?uid ?oW rate output by the
decrease mechanical energy draW of each of the rotation mud pump.
pump, the thrust pump, and the mud pump from the engine In such embodiments, processor execution of the stored
based on the coolant temperature of the engine exceeding a 40 program instructions may cause the control circuitry to
temperature threshold as indicated by the temperature signal. decrease mechanical energy draW of each of the rotation
Such embodiments may comprise an engine load sensor pump, the thrust pump, and the mud pump from the engine in
that outputs a load signal indicative of load on the engine, equal portion based on the total poWer draW exceeding the
Wherein processor execution of the stored program instruc threshold.
tions may cause the control circuitry to calculate an engine 45 In such embodiments, processor execution of the stored
revolutions per minute parameter based on the rotation signal, program instructions may cause the control circuitry to
and decrease mechanical energy draW of each of the rotation decrease mechanical energy draW of each of the rotation
pump, the thrust pump, and the mud pump from the engine pump, the thrust pump, and the mud pump from the engine in
based on the engine revolutions per minute parameter exceed unequal portion based on the total poWer draW exceeding the
ing a engine revolutions per minute threshold as indicated by 50 threshold.
the rotation signal. Such embodiments may comprise a user interface compris
In such embodiments, processor execution of the stored ing a rotation input con?gured to output a rotation command
program instructions may cause the control circuitry to cal signal, a thrust input command signal, and a mud input com
culate a rotation hydraulic ?uid ?oW rate of hydraulic ?uid in mand signal, Wherein processor execution of the stored pro
the rotation hydraulic ?uid circuit, calculate a thrust hydraulic 55 gram instructions may cause the control circuitry to control
?uid ?oW rate of hydraulic ?uid in the thrust hydraulic ?uid the energy draW of the rotation pump based on the rotation
circuit, calculate a mud hydraulic ?uid ?oW rate of hydraulic command signal, control the energy draW of the thrust pump
?uid in the mud hydraulic ?uid circuit, and Wherein calcula based on the thrust command signal, and control the energy
tion of the rotation pump poWer draW is based on the rotation draW of the mud pump based on the mud command signal,
hydraulic ?uid ?oW rate, calculation of the thrust pump poWer 60 Wherein the energy draW of the rotation pump, the energy
draW is based on the thrust hydraulic ?uid ?oW rate, and draW of the thrust pump, and the energy draW of the mud
calculation of the mud pump poWer draW is based on the mud pump can be each moderated from user input levels by the
hydraulic ?uid ?oW rate. control circuitry based on the total poWer draW exceeding the
Various embodiments of the invention are directed to a threshold.
horizontal directional drilling machine that comprises an 65 Such embodiments may further comprise an engine cool
engine that outputs mechanical energy, a rotation pump that ant temperature sensor con?gured to output a temperature
draWs upon the mechanical energy output by the engine to signal indicative of coolant ?uid temperature of the engine,
 US 7,954,558 B2
5 6
wherein processor execution of the stored program instruc Such embodiments may further include receiving a engine
tions may cause the control circuitry to decrease mechanical coolant temperature signal indicative of engine coolant tem
energy draW of each of the rotation pump, the thrust pump, perature of the engine, and decreasing energy draW of each of
and the mud pump from the engine if the coolant ?uid tem the rotation pump, the thrust pump, and the mud pump from
perature exceeds a temperature threshold based on the tem the engine based on the coolant ?uid temperature exceeding a
perature signal. temperature threshold based on the engine coolant tempera
Various embodiments of the present invention are directed ture signal.
to a method for controlling pump poWer draW from an engine Various embodiments are directed to a horiZontal direc
in a horiZontal directional drilling machine, the method com tional drilling machine having an engine that outputs
prising providing a directional drilling machine having an mechanical energy, a rotation pump that draWs upon the
engine that outputs mechanical energy, a rotation pump that
mechanical energy output by the engine to operate a rotation
draWs upon the mechanical energy output by the engine to
motor that rotates a drill string, a thrust pump that draWs upon
operate a rotation motor that rotates a drill string, a thrust
pump that draWs upon the mechanical energy output by the the mechanical energy output by the engine to operate a thrust
engine to operate a thrust motor that longitudinally moves the motor that longitudinally moves the drill string, a mud pump
drill string, a mud pump that draWs upon the mechanical that draWs upon the mechanical energy output by the engine
energy output by the engine to operate a mud motor that to operate a mud motor that delivers ?uid through the drill
delivers ?uid through the drill string, sensing a ?rst signal string, means for calculating a rotation pump poWer draW
indicative of a ?rst hydraulic ?uid parameter of hydraulic from the engine, means for calculating a thrust pump poWer
?uid pumped by the rotation pump, sensing a second signal 20 draW from the engine, means for calculating a mud pump
indicative of a second hydraulic ?uid parameter of hydraulic poWer draW from the engine, means for calculating a total
?uid pumped by the thrust pump, sensing a third signal poWer draW based on the rotation pump poWer draW, the thrust
indicative of a third hydraulic ?uid parameter of hydraulic pump poWer draW and the mud pump poWer draW, means for
?uid pumped by the mud pump, determining a rotation pump comparing the total poWer draW to a threshold, and means for
poWer draW from the mechanical energy output by the engine 25 decreasing mechanical energy draW of each of the rotation
based on the ?rst signal, determining a thrust pump poWer pump, the thrust pump, and the mud pump from the engine
draW from the mechanical energy output by the engine based based on the total poWer draW exceeding the threshold.
on the second signal, determining a mud pump poWer draW The above summary of the present invention is not
from the mechanical energy output by the engine based on the intended to describe each embodiment or every implementa
third signal, determining a total pump poWer draW based on 30 tion of the present invention. Advantages and attainments,
the rotation pump poWer draW, the thrust pump poWer draW, together With a more complete understanding of the inven
and the mud pump poWer draW, comparing the total pump tion, Will become apparent and appreciated by referring to the
poWer draW to a threshold associated With output capacity of folloWing detailed description and claims taken in conjunc
the engine, and decreasing poWer draW of each of the rotation tion With the accompanying draWings.
pump, the thrust pump, and the mud pump from the engine 35
based on the total pump poWer draW exceeding the threshold. BRIEF DESCRIPTION OF THE DRAWINGS
In such embodiments, the ?rst hydraulic ?uid parameter
may be hydraulic ?uid ?oW rate output by the rotation pump, FIG. 1 illustrates various components of a drilling system
the second hydraulic ?uid parameter may be hydraulic ?uid and a ground cross section shoWing doWn hole boring com
?oW rate output by the thrust pump, and the third hydraulic 40 ponents in accordance With various embodiments of this dis
?uid parameter may be hydraulic ?uid ?oW rate output by the closure;
mud pump. FIG. 2 illustrates a chart shoWing aspects of poWer man
In such embodiments, decreasing poWer draW from the agement in horiZontal directional drilling in accordance With
engine for each of the rotation pump, the thrust pump, and the various embodiments of this disclosure; and
mud pump may further comprise decreasing poWer draW in 45 FIG. 3 illustrates a chart shoWing aspects of poWer man
equal portion betWeen the rotation pump, the thrust pump, agement in horiZontal directional drilling in accordance With
and the mud pump. various embodiments of this disclosure.
In such embodiments, decreasing poWer draW from the While the invention is amenable to various modi?cations
engine for each of the rotation pump, the thrust pump, and the and alternative forms, speci?cs thereof have been shoWn by
mud pump may further comprise decreasing poWer draW in 50 Way of example in the draWings and Will be described in detail
unequal portion betWeen the rotation pump, the thrust pump, herein. It is to be understood, hoWever, that the intention is not
and the mud pump. to limit the invention to the particular embodiments
Such embodiments may further comprise receiving a rota described. On the contrary, the invention is intended to cover
tion input parameter from a ?rst user manipulated input, all modi?cations, equivalents, and alternatives falling Within
receiving a thrust input parameter from a second user manipu 55 the scope of the invention as de?ned by the appended claims.
lated input, receiving a mud input parameter from a third user
manipulated input; DETAILED DESCRIPTION OF VARIOUS
controlling poWer draW by the rotation pump from the EMBODIMENTS
engine based on the rotation input parameter, controlling
poWer draW by the thrust pump from the engine based on the 60 In the folloWing description of the illustrated embodi
thrust input parameter, controlling poWer draW by the mud ments, references are made to the accompanying draWings
pump from the engine based on the mud input parameter, and forming a part hereof, and in Which are shoWn by Way of
modifying each of the rotation input parameter, the thrust illustration, various embodiments by Which the invention
input parameter, and the mud input parameter to decrease may be practiced. It is to be understood that other embodi
poWer draW of each of the rotation pump, the thrust pump, and 65 ments may be utiliZed, and structural and functional changes
the mud pump from the engine based on the total poWer may be made Without departing from the scope of the present
energy draW exceeding the threshold. invention.
 US 7,954,558 B2
7 8
Systems, devices or methods according to the present respective outputs as desired. For example, a joystick can be
invention may include one or more of the features, structures, used by a user to control the thrust/pullback motor 17 output
methods, or combinations thereof described herein. For to advance and retract the drill string 23 . Another joystick can
example, a device or system may be implemented to include be used to control the rotation motor 19. Similarly, a user
one or more of the advantageous features and/or processes control can be employed to control the level of mud delivery
described beloW. It is intended that such a device or system through the drill string. In each of these cases, signals from
need not include all of the features described herein, but may the respective user inputs are received by one or more con
be implemented to include selected features that provide for trollers that control operation of the motors and/ or pumps that
useful structures and/or functionality. poWer the motors.
FIG. 1 illustrates a cross-section through a portion of In various HDD systems several motors are used to rotate
ground 10 Where a HDD boring operation takes place. The the drill string, advance/retract the drill string, and drive mud
underground boring system, generally shoWn as the machine through the drill string. For example, a rotation motor can
12, is situated aboveground 11 and includes a platform 14 on rotate the drill string, a thrust/pull back motor can advance/
Which is situated a tilted longitudinal member 16. The plat retract a drill string, and a mud motor can drive ?uid through
form 14 is secured to the ground by pins 18 or other restrain the drill string. Each of these motors are poWered by hydraulic
ing members in order to resist platform 14 movement during ?uid ?oWing through respective hydraulic ?uid circuits.
the boring operation. Located on the longitudinal member 16 Hydraulic ?uid ?oW in these respective circuits is created by
is a thrust/pullback motor 17 for driving a drill string 22 in a respective pumps draWing mechanical energy from a com
forWard, longitudinal direction as generally shoWn by the mon engine.
arroW. The drill string 22 is made up of a number of drill string 20 For example, a HDD rig may have an engine poWered by
members 23 attached end-to-end. Also located on the tilted electricity or combustible fuel, the engine outputting
longitudinal member 16, and mounted to permit movement mechanical motion (kinetic energy). The mechanical motion
along the longitudinal member 16, is a rotation motor 19 for is draWn upon by separate pumps to force hydraulic ?uid
rotating the drill string 22 (illustrated in an intermediate posi through the respective circuits and poWer the respective
tion betWeen an upper position 1911 and a loWer position 19b). 25 motors. The pumps convert the mechanical motion from the
In operation, the rotation motor 19 rotates the drill string 22 engine (typically rotational motion) to another form of energy
Which has a boring tool 24 attached at the end of the drill (typically hydraulic pressure). The energy converted by the
string 22. pump can then operate the various rotation, thrusting, and
A tracker unit 28 may be employed to receive an informa ?uid delivery functions of the HDD rig.
tion signal transmitted from boring tool 24 Which, in turn, 30 Operating a HDD system distributing poWer in this Way
communicates the information signal or a modi?ed form of can have several advantages. For example, only one engine
the signal to a receiver situated at the boring machine 12. The and fuel input is needed, Whereas other systems may have
boring machine 12 may also include a transmitter or trans separate engines for rotation, thrusting, and mud delivery
ceiver for purposes of transmitting and/or receiving an infor functions. Moreover, a relatively large engine can be used,
mation signal, such as an instruction signal, from the boring 35 alloWing much of the poWer of the engine to be focused on a
machine 12 to the tracker unit 28. Transmission of data and single task When needed. For example, if high speed rotation
instructions may alternatively be facilitated through use of a is needed for certain grinding functions, than a single engine
communication link established betWeen the boring tool 24 HDD rig can devote practically all of its poWer resources to
and central processor 25 via the drill string 22. rotating the drill string. In this Way, a single engine HDD rig
A boring operation can take place as folloWs. The rotation 40 can provide more poWerful drill string rotation, thrust, retrac
motor 19 is initially positioned in an upper location 1911 and tion, or ?uid delivery relative to multiengine embodiments.
rotates the drill string 22. While the boring tool 24 is rotated HoWever, While a single engine HDD rig can manage
through rotation of the drill string 22, the rotation motor 19 poWer resources to ?exibly specialiZe in any one function as
and drill string 22 are pushed in a forWard direction by the needed, multitasking performance can complicate distribu
thrust/pullback motor 17 toWard a loWer position into the 45 tion of poWer from the engine. The engine can become over
ground, thus creating a borehole 26. The rotation motor 19 Whelmed if the draW from each of the pumps combine to
reaches a loWer position 19b When the drill string 22 has been demand more than the engine can deliver. For example, a user
pushed into the borehole 26 by the length of one drill string may manipulate a joystick controlling rotation of the drill
member 23. A neW drill string member 23 is then added to the string to demand that the rotation pump poWering the rotation
drill string 22 either manually or automatically, and the rota 50 motor output at 100% of its capacity While the user also
tion motor 19 is released and pulled back to the upper location manipulates another joystick controlling thrust of the drill
1911. The rotation motor 19 is used to thread the neW drill string to demand that the thrust pump poWering the thrust
string member 23 to the drill string 22, and the rotation/push motor output at 70% of its capacity, exceeding the total
process is repeated so as to force the neWly lengthened drill amount of poWer that the engine can deliver. In such a case,
string 22 further into the ground, thereby extending the bore 55 engine output can decline, or the engine can stall, causing
hole 26. Commonly, Water or other ?uid is pumped through unpredictable and uncoordinated diminishment of energy to
the drill string 22 (often in a mixture refereed to herein as the motors via the pumps.
mud) by use of a mud motor. If an air hammer is used, an air Method and system embodiments of the present disclosure
compressor is used to force air/foam through the drill string address these and other problems by monitoring parameters
22. The mud or air/foam ?oWs back up through the borehole 60 from the pumps, calculating a total poWer demand by the
26 to remove cuttings, dirt, and other debris and improve motors, comparing the total demand to the poWer output
boring effectiveness and/ or e?iciency. A directional steering capacity of the engine, and moderating control signals to the
capability is typically provided for controlling the direction pumps to prevent overdraWing poWer from the engine.
of the boring tool 24, such that a desired direction can be FIG. 2 illustrates an embodiment for managing pump draW
imparted to the resulting borehole 26. 65 from an engine in a HDD system 200. Engine 201 converts
Manual controls can be used to control the rotation motor storable energy, such as gasoline, to mechanical energy, and
19, thrust/pullback motor 17, and mud motor to provide outputs the mechanical energy in the form of rotation. The
 US 7,954,558 B2
10
rotation pump 202, thrust/pull pump 203, and mud pump 204 to a % of its respective capacity. For example, if the rotation
each piggyback on one another. The rotation pump 202, pump 202 is operating at 60% of its capacity, the thrust pump
thrust/pull pump 203, and mud pump 204 each can be inde 203 is operating at 20% of its capacity, and the mud pump 204
pendently controlled by control signals to variably draW upon is operating at 15% of its capacity, then each of these pumps
the mechanical energy output by the engine 201. 202-204 could be destroked by 10% of their respective oper
Depending on hoW much energy each motor 202-204 ating capacities.
draWs from the engine 201 based on control signals, the In some embodiments, the pumps 202-204 could be
rotation motor 205, thrust motor 206, and mud motor 207 can destroked based on their current operating levels, such as a
be controlled to respectively rotate a drill string, advance/ percentage of current operating level. For example, poWer
retract the drill string, and deliver ?uid through the drill draW is calculated 211-213 for each pump 202-204. There
string. For example, the rotation pump 202 responds to con fore, each pump 202-204 could be destroked by a percentage
trol signals to draW some amount of mechanical energy from (e.g., 20%) of their respective current operating poWer levels.
the engine 201 output to circulate hydraulic ?uid in a rotation In this Way, a pump draWing 30 horse poWer Would be limited
hydraulic ?uid circuit 260. The pressure of hydraulic ?uid to 24 horse poWer if the poWer draW of each pump Was
created by the rotation pump 202 in the rotation hydraulic decreased by 20% based on total motor draW exceeding a
?uid circuit 260 is used by the rotation motor 205 to rotate the threshold.
drill string. Likewise, the pressure of hydraulic ?uid created In some embodiments, the pumps 202-204 could be
by the thrust pump 203 in the thrust hydraulic ?uid circuit 261 destroked a standard amount based on poWer. For example,
is used by the thrust motor 206 to advance/retract the drill poWer draW for each pump 202-204 could be decrease by a
string, and the pres sure of hydraulic ?uid created by the mud 20 horsepoWer or Watt amount as determined by the poWer cal
pump 203 in the mud hydraulic ?uid circuit 262 is used by the culations 211-213 for each pump 202-204, the poWer draW
mud motor 207 to deliver a ?uid through the drill string and amount reduced irrespective of the poWer draW for any indi
into the bore hole. vidual pump.
The different hydraulic ?uid circuits 260-262 alloW for In some embodiments, poWer draW for each pump could be
different pres suriZations and ?oW rates respectively appropri 25 linearly or exponentially decreased until the calculated total
ate for the rotation motor 205, thrust motor 206, and mud motor draW 215 falls back beloW a threshold 214, and those
motor 207. Sensors 208-210 respectively monitor parameters control parameters levels input to the pumps 202-204 When
of the respective hydraulic circuits 260-262. The sensors 208 the total motor draW 215 fell beloW the threshold 214 main
210 can sense various parameters associated With motor out tained.
puts, such as hydraulic pressure (pounds per square inch; PSI) 30 In some embodiments, the function of one pump may be
and hydraulic ?uid ?oW rate (gallons per minute; GPM), favored relative to other pumps, such that the other pumps are
among others. Sensors 208-210 provide feedback informa destroked before, and/or in greater amount, than the favored
tion concerning these parameters to monitoring circuits 211 pump. Such unequal poWer draW reduction can preserve the
213, respectively. Information from the engine 201, such as function associated With the favored pump, such as drill string
revolutions per minute of the output shaft feeding the pump 35 rotation, thrust, or mud delivery. For example, running mud
202-204, can also be provided to the monitoring circuits through the bore hole at all times can be a critical function in
211-213. some HDD applications, as the mud can clear aWay cuttings
The respective energy draWs from the rotation pump 202, and act as a lubricant, thereby reducing machine stress. In
thrust/pull pump 203, and mud pump 204 are controlled in such applications, it can be valuable to preserve output of the
part by control signals from the rotation input 250, thrust/pull 40 mud motor 207 relative to the outputs of the rotation motor
input 251, and mud input 253, respectively. The input infor 205 and the thrust/pull motor 206. This can be accomplished
mation is also provided to each of the respective monitoring by reducing draW by the non-favored pumps before reducing
circuits 211-213. draW from the favored pump (e.g., mud pump 204 is only
The monitoring circuits 211-213 can respectively use the destroked if the rotation pump 202 and thrust/pull pump 203
information provided by the sensors 208-210, pumps 202 45 have already been destroked and a total poWer threshold is
204, and control inputs 250-253 to respectively calculate still being exceeded). In some embodiments, the favored
poWer draW on the engine 201 from each of the pumps 202 pump is destroked at the same time as the non-favored pump,
204. The poWer draW information is then summed 215 and but is destroked a lesser amount (e.g., a lesser amount of % of
compared 214 to information associated With the engine 201. pump or motor capacity or current operating level, or a lesser
For example, one or more thresholds can be saved in memory 50 amount of a predetermined poWer decrement relative to the
and the total poWer draW calculation 215 can be compared other non-favored pumps/motors). In some embodiments, all
214 to the threshold. The threshold can be associated With the pumps can be destroked at the same time but at different rates.
maximum poWer output of the engine 201, such as 95% of the For example, the mud and thrust pump poWer draWs could be
maximum poWer output of the engine 201. decreased to 10% of user input While the rotation pump could
A total poWer draW 215 exceeding a threshold 214 associ 55 be decreased to only 50% of user input.
ated With the maximum poWer output of the engine 201 can After the pump 202-204 draWs are reduced based on total
indicate that the poWer draW is about to exceed engine 201 poWer draW 215 exceeding a threshold 214, it is expected that
capacity, threatening to stall the engine 201 or otherWise the respective calculated poWer draWs 211-213 Would be
degrade engine 201 performance. The HDD system 200 can reduced, as Well as the total poWer draW 215 from the engine
respond to this by reducing the control inputs 250-253, mod 60 201. HoWever, if the total poWer draW 215 continues to exceed
erating the motors 202-204 (e.g., decreasing poWer draW), a threshold after some time, or a higher threshold is exceeded,
Which can override user input directing rotation, thrust, and then pump 202-204 poWer draWs can further be reduced using
mud delivery. more aggressive steps, such as greater poWer draW decre
The pump poWer draW reduction from the engine 201 can ments, until the total poWer draW 215 falls beloW a threshold
be done uniformly for each pump 202-204. In some cases, 65 to an acceptable amount Within engine 201 output capacity.
When a total draW 215 threshold is reached 214 each of the As total poWer draW 215 falls beloW the threshold, control
pumps 202-204 could be destroked an amount corresponding signals from the inputs 250-253 can be moderated or fully
 US 7,954,558 B2
11 12
restored to better match the user intended inputs and allow the The pump controllers (e.g., rotation pump controller 304,
pumps 202-204 to draw as much power from the engine 201 thrust/pull controller 324, and mud pump controller 330) can
as indicated by the user via controls. execute algorithms to manage the user input and the control
FIG. 3 illustrates various aspects of the present disclosure. ler 316 setting. For example, a joystick input % (e.g., 0-100%)
According to various embodiments, measured variables are can be multiplied by a poWer limit % received from the
used to calculate the amount of horse poWer that each pump of controller 316 (e.g., 0-100%). If 80% rotation poWer level is
a plurality draWs from an engine. The depicted embodiment input 302 and the controller 316 is limiting pump output to
of FIG. 3 includes three hydrostatic pumps: a rotation pump 90% of input 302, then the rotation pump controller 304 can
305 driving the rotation of the drill string, a thrust/pull pump command the rotation pump 305 to output 72% of capacity
323 driving the thrust and/or pullback of the drill string, and (e.g., using algorithm: (input % from user)*(destroke % from
a mud pump 313 that facilitates delivery of ?uids in the bore controller)/100:pump poWer draW % of capacity of pump).
hole, such as a mud mixture. The operation of the rotation The thrust/pull pump 313 and thrust/pull pump 323 can be
pump 305 is controlled by rotation pump controller 304, similarly controlled to manage user inputs and controller 316
Which receives control signals from input control 302 (e.g., limits. In some embodiments, the drill mode unit 301 input
interfacing With a user joystick/rotation handle), drill mode may set the rotation pump 305 output level, in Which case the
unit 301 (e.g., based on an automatic drill mode setting) via controller 316 can limit the rotation pump 305 output in
logic circuit 303, and controller 316. The operation of the similar fashion to hoW the user input 302 is limited. The drill
thrust/pull pump 323 is controlled by thrust/pull pump con mode unit 326 input associated With thrust, and a drill mode
troller 324, Which receives control signals from input control unit input associated With mud delivery, can be limited by the
327 (e.g., interfacing With a user joystick-thrust/pull handle), controller in the same Ways as the drill mode unit 301 input.
drill mode unit 326 (e.g., based on an automatic drill mode
In some embodiments, the controller 316 can limit opera
setting) via logic circuit 325, and controller 316. Operation of tion of the rotation, thrust/pull, and mud pumps based on
the mud pump 330 can be similarly controlled by a user input engine load 317 and/or engine coolant temperature 318. In
and drill mode unit (not pictured). 25 such cases, if the engine load 317 and/or engine coolant
Each of the pumps consumes some amount of poWer from temperature 318 exceeds a threshold then the controller 316
an engine. The poWer consumed by each pump can be esti can control the rotation pump controller 304, mud pump
mated by the folloWing equation: controller 330, and thrust/pull pump controller 324 to limit
operation of the rotation pump 305, mud pump 313, and the
Hydraulic Pump PoWer:((((Engine RPM/C2)><C1)><% 30 thrust/pull pump 324 in any manner discussed herein (e.g.,
of hydraulic ?uid ?oW)><Hydraulic Fluid PSI)/
1741 >“C3));Wherein:C1:Rated Engine RPM; When total poWer draW by the pumps exceeds a threshold).
C2:Actual Pump output ?oW-rate(GPM)at Rated For example, if the engine is operating at 2400 RPM and the
Engine RPM;and C3:Hydraulic Pump Overall engine RPM then decreases to 1900 RPM and no decrease in
Ef?ciency(e.g.,O.90:90%). engine rotational output Was expected, then the draW from the
As shoWn in the above equation, the rotation pump poWer 35 pumps 305, 313, and 323 can be decreased as discussed
calculation 309 depends on the hydraulic pressure 306, herein based on the sensed RPM droop.
hydraulic ?uid ?oW 307 from the rotation pump, and engine In some embodiments an operator uses a left joystick input
RPM 308. The mud pump poWer calculation 314 depends on 302 to control the rotation of the drill string and a right
the hydraulic pressure 311, hydraulic ?uid ?oW 312 from the joystick input 327 to control the thrust or pull force applied to
mud pump, and engine RPM 310. The thrust pump poWer 40 the drill string. Control signals from the left joystick are sent
calculation 323 depends on the hydraulic pressure 321, through a pro?le function to the rotation pump and control
hydraulic ?uid ?oW 322 from the thrust pump, and engine signals from the right joystick are sent through a pro?le
RPM 320. Each of the rotation pump poWer calculation 309, function to a thrust/pull pump. Essentially, the left and right
mud pump poWer calculation 314, and thrust pump poWer joysticks are used by the operator to input his or her desired
calculation 323 are summed to calculate a total poWer 315 45 actions to the horiZontal drilling machine.
demand. A controller 316 compares the total poWer 315 In some embodiments, a horse poWer limiter PI loop deter
demand to one or more stored thresholds, such as maximum mines, based on input data, Whether the engine is overloaded.
engine output. In some embodiments, controller 316 runs a If the engine is overloaded, a control signal from the joysticks
proportional integral loop to compare total poWer 316 param to the respective hydraulic pumps is adjusted. In the depicted
eter to an engine parameter. 50 embodiments the horse poWer draW from each of the pumps is
In the event that the controller 3 1 6 determines that the total calculated based on the sensed engine revolutions per minute
poWer 315 draW from the pumps 304, 313, and 324 exceeds a (RMP), hydraulic ?uid pressure (PSI), and hydraulic ?uid
threshold, the controller 316 can loWer the poWer inputs for ?oW rate. The horse poWer draW from each of the pumps and
the rotation pump controller 304, thrust/pull pump controller the total horse poWer draW can be sent to the HP limiter PI
324, and mud pump controller 330. The poWer output and the 55 loop. The loop prevents the user from requesting from the
engine poWer consumption of the rotation pump 305 can be pumps more poWer than the engine is able to deliver.
completely controlled by the user control 302 and/or drill While operating in drill mode, hydraulic system poWer
mode unit 3 01 until the threshold is reached, at Which time the requirements of a HDD machine may exceed engine output
controller 316 Will limit the poWer output and the engine poWer capabilities. In effort to reduce or avoid engine over
poWer consumption of the rotation pump 305. The poWer 60 load the present disclosure provides control system. One
output and the engine poWer consumption of the thrust/pull embodiment of the control system is con?gured to monitor
pump 324 can be completely controlled by the user control hydraulic poWer, engine percent load (J 1939), and engine
327 and/or drill mode unit 326 until the threshold is breached, coolant temperature.
at Which time the controller 316 Will limit the poWer output If any of these three variables are above their respective
and the engine poWer consumption of the rotation pump 323. 65 limits the control signal to the hydraulic system are modu
The poWer output and the engine poWer consumption of the lated to control the ‘above-limit’ variable. As the ‘above
mud pump can be similarly controlled. limit’ variable falls back beloW its respective limit the control
 US 7,954,558 B2
13 14
system allows the control signals to the hydraulic system to control circuitry comprising a processor and memory, the
rise back up their original values. processor con?gured to execute program instructions
Embodiments of the invention can use a controller having stored in the memory, processor execution of the stored
memory coupled to a processor to perform the methods and program instructions causing the control circuitry to
functions described here. Memory can be a computer read control poWer draW of the rotation pump from the
able medium encoded With a computer program, software, mechanical energy output by the engine, control poWer
computer executable instructions, instructions capable of draW of the thrust pump from the mechanical energy
being executed by a computer, etc, to be executed by circuitry, output by the engine, control poWer draW of the mud
such as processor of a machine controller. For example, pump from the mechanical energy output by the engine,
memory can be a computer readable medium storing a com calculate a rotation pump poWer draW from the engine
puter program, execution of the computer program by pro based on the rotation pressure signal and the rotation
cessor causing a HDD system to perform the steps referenced signal, calculate a thrust pump poWer draW from the
herein, such as those concerning managing pump poWer draW engine based on the thrust pressure signal and the rota
from an engine. tion signal, calculate a mud pump poWer draW from the
The discussion and illustrations provided herein are pre engine based on the mud pressure signal and the rotation
sented in an exemplary format, Wherein selected embodi signal, calculate a total poWer draW based on the rotation
ments are described and illustrated to present the various pump poWer draW, the thrust pump poWer draW and the
aspects of the present invention. Systems, devices, or meth mud pump poWer draW, compare the total poWer draW to
ods according to the present invention may include one or a threshold associated With output capacity of the
more of the features, structures, methods, or combinations 20 engine, and decrease mechanical energy draW from the
thereof described herein. For example, a device or system engine of each of the rotation pump, the thrust pump, and
may be implemented to include one or more of the advanta the mud pump based on the total poWer draW exceeding
geous features and/or processes described beloW. A device or the threshold, the processor executing the stored pro
system according to the present invention may be imple gram instructions to cause the control circuitry to
mented to include multiple features and/ or aspects illustrated 25 decrease the mechanical energy draW of each of the
and/ or discussed in separate examples and/or illustrations. It rotation pump, the thrust pump, and the mud pump in
is intended that such a device or system need not include all of different amounts based on the total poWer draW exceed
the features described herein, but may be implemented to ing the threshold.
include selected features that provide for useful structures, 2. The horizontal directional drilling machine of claim 1,
systems, and/ or functionality. 30 further comprising a user interface comprising:
Although only examples of certain functions may be a rotation user input con?gured to output a rotation signal
described as being performed by circuitry for the sake of based on user input;
brevity, any of the functions, methods, and techniques can be a thrust user input con?gured to output a thrust signal based
performed using circuitry and methods described herein, as on user input; and
Would be understood by one of ordinary skill in the art. 35 a mud user input con?gured to output a mud signal based
on user input, Wherein processor execution of the stored
We claim: program instructions causes the control circuitry to con
1. A horizontal directional drilling machine having poWer trol poWer draW of the rotation pump based on the rota
control, comprising: tion signal, control poWer draW of the thrust pump based
an engine that outputs mechanical energy through a rota 40 on the thrust signal, control poWer draW of the mud
tion shaft; pump based on the mud signal, and Wherein poWer draW
a rotation pump that draWs upon the mechanical energy of the rotation pump, poWer draW of the thrust pump, and
output by the engine through rotation of the rotation poWer draW of the mud pump are each moderated from
shaft to operate a rotation motor that rotates a drill string user input levels based on the total poWer draW exceed
by pressurization of a rotation hydraulic ?uid circuit 45 ing the threshold.
betWeen the rotation pump and the rotation motor; 3. The horizontal directional drilling machine of claim 1,
a thrust pump that draWs upon the mechanical energy out Wherein processor execution of the stored program instruc
put by the engine through rotation of the rotation shaft to tions causes the control circuitry to decrease by a proportional
operate a thrust motor that longitudinally moves the drill amount the mechanical energy draW of each of the rotation
string by pressurization of a thrust hydraulic ?uid circuit 50 pump, the thrust pump, and the mud pump from the engine
betWeen the thrust pump and the thrust motor; based on the total poWer draW exceeding the threshold.
a mud pump that draWs upon the mechanical energy output 4. The horizontal directional drilling machine of claim 1,
by the engine through rotation of the rotation shaft to further comprising an engine temperature sensor that outputs
operate a mud motor that delivers ?uid through the drill a temperature signal indicative of coolant temperature of the
string by pressurization of a mud hydraulic ?uid circuit 55 engine, Wherein processor execution of the stored program
betWeen the mud pump and the mud motor; instructions causes the control circuitry to decrease mechani
a rotation hydraulic ?uid sensor that outputs a rotation cal energy draW of each of the rotation pump, the thrust pump,
pressure signal indicative of hydraulic ?uid pressure and the mud pump from the engine based on the coolant
Within the rotation hydraulic ?uid circuit; temperature of the engine exceeding a temperature threshold
a thrust hydraulic ?uid sensor that outputs a thrust pressure 60 as indicated by the temperature signal.
signal indicative of hydraulic ?uid pressure Within the 5. The horizontal directional drilling machine of claim 1,
thrust hydraulic ?uid circuit; further comprising an engine load sensor that outputs a load
a mud hydraulic ?uid sensor that outputs a mud pressure signal indicative of load on the engine, Wherein processor
signal indicative of hydraulic ?uid pressure Within the execution of the stored program instructions causes the con
mud hydraulic ?uid circuit; 65 trol circuitry to calculate an engine revolutions per minute
a sensor that outputs a rotation signal indicative of rotation parameter based on the rotation signal, and decrease
rate of the rotation shaft; and mechanical energy draW of each of the rotation pump, the
 US 7,954,558 B2
15 16
thrust pump, and the mud pump from the engine based on the ?oW rate output by the rotation pump, the second hydraulic
engine revolutions per minute parameter exceeding a engine ?uid parameter is hydraulic ?uid ?oW rate output by the thrust
revolutions per minute threshold as indicated by the rotation pump, and the third hydraulic ?uid parameter is hydraulic
signal. ?uid ?oW rate output by the mud pump.
6. The horizontal directional drilling machine of claim 1, 10. The horiZontal direction drilling machine of claim 7,
Wherein processor execution of the stored program instruc Wherein processor execution of the stored program instruc
tions causes the control circuitry to calculate a rotation tions causes the control circuitry to decrease mechanical
hydraulic ?uid ?oW rate of hydraulic ?uid in the rotation energy draW of each of the rotation pump, the thrust pump,
hydraulic ?uid circuit, calculate a thrust hydraulic ?uid ?oW and the mud pump from the engine in equal portion based on
rate of hydraulic ?uid in the thrust hydraulic ?uid circuit, the total poWer draW exceeding the threshold.
calculate a mud hydraulic ?uid ?oW rate of hydraulic ?uid in 11. The horiZontal direction drilling machine of claim 7,
the mud hydraulic ?uid circuit, and Wherein calculation of the further comprising a user interface comprising a rotation
rotation pump poWer draW is based on the rotation hydraulic input con?gured to output a rotation command signal, a thrust
?uid ?oW rate, calculation of the thrust pump poWer draW is input command signal, and a mud input command signal,
based on the thrust hydraulic ?uid ?oW rate, and calculation Wherein processor execution of the stored program instruc
of the mud pump poWer draW is based on the mud hydraulic tions causes the control circuitry to control the energy draW of
?uid ?oW rate. the rotation pump based on the rotation command signal,
7. A horizontal directional drilling machine having poWer control the energy draW of the thrust pump based on the thrust
control, comprising: command signal, and control the energy draW of the mud
an engine that outputs mechanical energy; 20 pump based on the mud command signal, Wherein the energy
a rotation pump that draWs upon the mechanical energy draW of the rotation pump, the energy draW of the thrust
output by the engine to operate a rotation motor that pump, and the energy draW of the mud pump are each mod
rotates a drill string; erated from user input levels by the control circuitry based on
a thrust pump that draWs upon the mechanical energy out the total poWer draW exceeding the threshold.
put by the engine to operate a thrust motor that longitu 25 12. The horiZontal directional drilling machine of claim 7,
dinally moves the drill string; further comprising an engine coolant temperature sensor con
a mud pump that draWs upon the mechanical energy output ?gured to output a temperature signal indicative of coolant
by the engine to operate a mud motor that delivers ?uid ?uid temperature of the engine, Wherein processor execution
through the drill string; and of the stored program instructions causes the control circuitry
control circuitry comprising a controller and memory, the 30 to decrease mechanical energy draW of each of the rotation
processor con?gured to execute program instructions pump, the thrust pump, and the mud pump from the engine if
stored on the memory, processor execution of the stored the coolant ?uid temperature exceeds a temperature threshold
program instructions causing the control circuitry to based on the temperature signal.
calculate a rotation pump poWer draW from the engine, 13. A method for controlling pump poWer draW from an
calculate a thrust pump poWer draW from the engine, 35 engine in a horiZontal directional drilling machine, the
calculate a mud pump poWer draW from the engine, method comprising:
calculate a total poWer draW based on the rotation pump providing a directional drilling machine having an engine
poWer draW, the thrust pump poWer draW and the mud that outputs mechanical energy, a rotation pump that
pump poWer draW, compare the total poWer draW to a draWs upon the mechanical energy output by the engine
threshold, and decrease mechanical energy draW of each 40 to operate a rotation motor that rotates a drill string, a
of the rotation pump, the thrust pump, and the mud pump thrust pump that draWs upon the mechanical energy
from the engine based on the total poWer draW exceeding output by the engine to operate a thrust motor that lon
the threshold, Wherein processor execution of the stored gitudinally moves the drill string, a mud pump that
program instructions causes the control circuitry to draWs upon the mechanical energy output by the engine
decrease mechanical energy draW of each of the rotation 45 to operate a mud motor that delivers ?uid through the
pump, the thrust pump, and the mud pump from the drill string;
engine in unequal portion based on the total poWer draW sensing a ?rst signal indicative of a ?rst hydraulic ?uid
exceeding the threshold. parameter of hydraulic ?uid pumped by the rotation
8. The horiZontal direction drilling machine of claim 7, Pump;
further comprising: 50 sensing a second signal indicative of a second hydraulic
a ?rst sensor that outputs a ?rst parameter signal indicative ?uid parameter of hydraulic ?uid pumped by the thrust
of a ?rst hydraulic ?uid parameter of hydraulic ?uid Pump;
pumped by the rotation pump; sensing a third signal indicative of a third hydraulic ?uid
a second sensor that outputs a second parameter signal parameter of hydraulic ?uid pumped by the mud pump;
indicative of a second hydraulic ?uid parameter of 55 determining a rotation pump poWer draW from the
hydraulic ?uid pumped by the thrust pump; and mechanical energy output by the engine based on the
a third sensor that outputs a third parameter signal indica ?rst signal;
tive of a third hydraulic ?uid parameter of hydraulic determining a thrust pump poWer draW from the mechani
?uid pumped by the mud pump, Wherein processor cal energy output by the engine based on the second
execution of the stored program instructions causes the 60 signal;
control circuitry to calculate the rotation pump poWer determining a mud pump poWer draW from the mechanical
draW based on the ?rst parameter signal, calculate the energy output by the engine based on the third signal;
thrust pump poWer draW based on the second parameter determining a total pump poWer draW based on the rotation
signal, and calculate the mud pump poWer draW based on pump poWer draW, the thrust pump poWer draW, and the
the third parameter signal. 65 mud pump poWer draW;
9. The horiZontal direction drilling machine of claim 8, comparing the total pump poWer draW to a threshold asso
Wherein the ?rst hydraulic ?uid parameter is hydraulic ?uid ciated With output capacity of the engine; and
 US 7,954,558 B2
17 18
decreasing power draw of each of the rotation pump, the decreasing energy draW of each of the rotation pump, the
thrust pump, and the mud pump from the engine based thrust pump, and the mud pump from the engine based
on the total pump poWer draW exceeding the threshold, on the coolant ?uid temperature exceeding a tempera
Wherein decreasing poWer draW from the engine for each ture threshold based on the engine coolant temperature
of the rotation pump, the thrust pump, and the mud pump 5 signal.
further comprises decreasing poWer draW in unequal 18. A horizontal directional drilling machine having poWer
portion betWeen the rotation pump, the thrust pump, and control, comprising:
the mud pump. an engine that outputs mechanical energy;
14. The method of claim 13, Wherein the ?rst hydraulic a rotation pump that draWs upon the mechanical energy
?uid parameter is hydraulic ?uid ?oW rate output by the 10 output by the engine to operate a rotation motor that
rotation pump, the second hydraulic ?uid parameter is rotates a drill string;
hydraulic ?uid ?oW rate output by the thrust pump, and the a thrust pump that draWs upon the mechanical energy out
third hydraulic ?uid parameter is hydraulic ?uid ?oW rate put by the engine to operate a thrust motor that longitu
output by the mud pump. dinally moves the drill string;
15. The method of claim 13, Wherein decreasing poWer a mud pump that draWs upon the mechanical energy output
draW from the engine for each of the rotation pump, the thrust by the engine to operate a mud motor that delivers ?uid
pump, and the mud pump further comprising decreasing through the drill string;
poWer draW in equal portion betWeen the rotation pump, the means for calculating a rotation pump poWer draW from the
thrust pump, and the mud pump. engine;
16. The method of claim 13, further comprising: 20 means for calculating a thrust pump poWer draW from the
receiving a rotation input parameter from a ?rst user engine;
manipulated input; means for calculating a mud pump poWer draW from the
receiving a thrust input parameter from a second user engine;
manipulated input; means for calculating a total poWer draW based on the
receiving a mud input parameter from a third user manipu 25 rotation pump poWer draW, the thrust pump poWer draW
lated input; and the mud pump poWer draW;
controlling poWer draW by the rotation pump from the means for comparing the total poWer draW to a threshold;
engine based on the rotation input parameter; and
controlling poWer draW by the thrust pump from the engine means for decreasing mechanical energy draW of each of
based on the thrust input parameter; 30 the rotation pump, the thrust pump, and the mud pump
controlling poWer draW by the mud pump from the engine from the engine based on the total poWer draW exceeding
based on the mud input parameter; and the threshold, the means for decreasing mechanical
modifying each of the rotation input parameter, the thrust energy draW comprising means for decreasing poWer
input parameter, and the mud input parameter to draW from the engine for each of the rotation pump, the
decrease poWer draW of each of the rotation pump, the 35 thrust pump, and the mud pump in unequal portion
thrust pump, and the mud pump from the engine based betWeen the rotation pump, the thrust pump, and the
on the total poWer energy draW exceeding the threshold. mud pump.
17. The system of claim 13, further comprising:
receiving a engine coolant temperature signal indicative of
engine coolant temperature of the engine; and