A parametric study for the design of an optimized ultrasonic-percussive planetary drill tool

Traditional rotary drilling for planetary rock sampling, in situ analysis, and sample return are challenging because the axial force and holding torque requirements are not necessarily compatible with lightweight spacecraft architectures in low-gravity environments. This paper seeks to optimize an ultrasonic percussive drill tool to achieve rock penetration with lower reacted force requirements, with a strategic view toward building an ultrasonic planetary core drill (UPCD) device. The UPCD is a descendant of the ultrasonic/sonic driller/corer technique. In these concepts, a transducer and horn (typically resonant at around 20 kHz) are used to excite a toroidal free mass that oscillates chaotically between the horn tip and drill base at lower frequencies (generally between 10 Hz and 1 kHz). This creates a series of stress pulses that is transferred through the drill bit to the rock surface, and while the stress at the drill-bit tip/rock interface exceeds the compressive strength of the rock, it causes fractures that result in fragmentation of the rock. This facilitates augering and downward progress. In order to ensure that the drill-bit tip delivers the greatest effective impulse (the time integral of the drill-bit tip/rock pressure curve exceeding the strength of the rock), parameters such as the spring rates and the mass of the free mass, the drill bit and transducer have been varied and compared in both computer simulation and practical experiment. The most interesting findings and those of particular relevance to deep drilling indicate that increasing the mass of the drill bit has a limited (or even positive) influence on the rate of effective impulse delivered

Push-and-Twist Drillstring Assemblies

Deep drilling using a rigid drillstring requires the assembly and disassembly of multiple drill pipes. The interfaces between these pipes provide a challenge for automation because they must transmit large drilling forces and movements while, at the same time, minimise the actions and forces that are needed to make or break the interface. A geometry which can address these requirements has been suggested by the authors. This approach would use a push-and-twist bayonet system to engage drill pipes, with torque transmission through the bayonet studs. A variety of L-shaped and T-shaped bayonet paths have been proposed to ensure that separation of specific drill pipes can be achieved through a combination of clockwise and counter-clockwise rotation and single-point clamping. Sustained drills into a variety of media are used to show that percussive impulses are transmitted across the interface, whilst ensuring that the drill interface is able to withstand the shock loading associated with hammer-drilling. These tests are repeated and contrasted to control experiments using a single-piece control drillstring, which allows the performance of the interface and any degradation over time to be quantified. Results suggest that the bayonet-style connection performs well with no significant performances losses encountered or structural degradation noted

Development of a switchable system for longitudinal and longitudinal-torsional vibration extraction

High-frequency/low-frequency drilling is an attractive technology for planetary exploration tools, and one which has seen considerable innovation in the techniques used to ensure rotation of the front-end cutting bit. This rotation is essential to prevent tooth imprintation in hard materials, and extracting the rotation from the high-frequency or ultrasonic system has obvious benefits in terms of simplicity and robustness. However, extracting the rotation from an ultrasonic horn raises the possibility of bit-walk if it is used to operate a coring device and the authors therefore propose an ultrasonic horn which uses an excitation applied to a single input surface to yield torsional and longitudinal vibration on two physically separated output surfaces. By engaging with the two output surfaces, longitudinal vibration can be extracted to achieve initial percussive drilling, even where a coring bit is applied, and the torsional output can subsequently be added to prevent tooth imprintation once the coring bit has settled into the site in question. In this manner, the horn provides a mechanism whereby high-frequency/low-frequency drilling technique can be applied to coring operations without the need for an exceptionally robust drill structure capable of resisting bit-walk forces

Ultrasonic Planetary Core Drill: Overview and Results from Field Trial

In the effort to explore the subsurface of terrestrial bodies, we seek to obtain better samples from ever greater depths. Many organisations are working towards technologies that can achieve this goal whilst ensuring compatibility with the likely requirements of planetary landers in terms of mass, power, and dimensions. The Ultrasonic Planetary Core Drill (UPCD) was an FP7 funded project which aimed to develop such a planetary sub-surface sample acquisition system, developing the required drill hardware and testing it in a Mars analogue environment in Antarctica. The objective was to reach 30cm and containerise the samples using the least possible power, while operating at low weight-on-bit. This has been broadly achieved within a conceptually-deployable package

Development of a robust mating system for use in the autonomous assembly of planetary drill strings

Volume-constrained robotic missions seeking to obtain samples from beneath a planetary subsurface may wish to use a rigid drill string consisting of multiple, individual drill bit sections connected together, as opposed to a single, lengthy drill bit. To ensure that drill strings can be assembled and disassembled reliably, it is essential that a robust connection system be used. The authors propose a geometry that seeks to address the requirements of such a mating interface. The proposed solution is based on the bayonet interface, using L- and T-shaped so-called female grooves and male studs connected and disconnected together through a series of clockwise and counterclockwise rotations and single-point clamping events. This routine allows the transfer of both percussion through the drill string and torque in both directions of rotation, while permitting the accurate disconnection of individual drills bits at the required location. Sustained laboratory and field drilling operations suggest that bayonet-style connections offer a reliable solution to the problem of autonomous assembly and disassembly of drill strings in a planetary exploration setting. This paper discusses the development of such a connection system, based on the bayonet connection, which has been implemented in the overall architecture of the Ultrasonic Planetary Core Drill (UPCD). The design trade-off study, which sought to evaluate the use of the bayonet system in comparison with the more conventional screw thread interface, will be discussed, alongside experimental results from percussion transmission testing and drill string assembly testing

Development of a switchable system for longitudinal and longitudinal-torsional vibration extraction

High-frequency/low-frequency drilling is an attractive technology for planetary exploration tools, and one which has seen considerable innovation in the techniques used to ensure rotation of the front-end cutting bit. This rotation is essential to prevent tooth imprintation in hard materials, and extracting the rotation from the high-frequency or ultrasonic system has obvious benefits in terms of simplicity and robustness. However, extracting the rotation from an ultrasonic horn raises the possibility of bit-walk if it is used to operate a coring device and the authors therefore propose an ultrasonic horn which uses an excitation applied to a single input surface to yield torsional and longitudinal vibration on two physically separated output surfaces. By engaging with the two output surfaces, longitudinal vibration can be extracted to achieve initial percussive drilling, even where a coring bit is applied, and the torsional output can subsequently be added to prevent tooth imprintation once the coring bit has settled into the site in question. In this manner, the horn provides a mechanism whereby high-frequency/low-frequency drilling technique can be applied to coring operations without the need for an exceptionally robust drill structure capable of resisting bit-walk forces

Enabling technologies for the subsurface exploration of the solar system

Future robotic exploration missions within the Solar System, focussing on either scientific discovery or the emerging field of In-Situ Resource Utilisation (ISRU), shall require the development of technologies which are capable of exploring to ever-greater depths beneath the planetary surface. In order to achieve these ambitious goals, advances in the existing state of the art in robotic sampling are required. This Ph.D. presents findings on the development of novel solutions within this field. The development of the Ultrasonic Planetary Core Drill (UPCD), a system based upon the ultrasonic-percussive drill technique, was designed with a Mars Sample Return (MSR) objective at the core of the development. Breakthroughs in autonomous control and the robotic assembly of drill strings were required in order to meet the requirements set. The system was tested at Coal Nunatak, Antarctica, in December 2016. A rotary-percussive drilling system for use in extracting subglacial bedrock samples from Earth’s Polar Regions was developed. Making use of technologies devised in the UPCD project, this collaboration with the British Antarctic Survey (BAS) required a low resource approach to the problem in order to ensure compatibility with existing BAS systems and logistical constraints. Building upon technologies developed and confidence generated in previous systems, the subglacial bedrock was industrialised into what became the Percussive Rapid Access Isotope Drill (P-RAID). This system underwent initial field trials at the Skytrain Ice Rise, Antarctica in January 2019 with the intention to further develop the system for full deployment

Wood wasp inspired space and earth drill

In this chapter, we explain why the low gravity encountered on Mars or on the Moon and the low mass of the probes, landers and rovers that carry drilling devices limit classical drilling techniques. Novel boring solutions optimised in mass and power consumption are thus needed for space applications. Biologists have identified the wood wasp, an insect that is capable of "drilling" into wood to lay its eggs. A low mass and low power system, like an insect, capable of drilling into wood is of the highest interest for planetary drilling and terrestrial drilling alike. The general working principle of the wood wasp drill ("dual reciprocating drilling") will be exposed and the potential benefits of imitating the wood wasp for planetary drilling will be highlighted. Since the nature of wood is highly fibrous but the nature of extraterrestrial and terrestrial soils are not, it is necessary to adapt the wood wasp ovipositor to our target soils. A test bench to evaluate the influence of the different geometries and operational parameters was produced and is presented here. The dual reciprocating drilling experimental results obtained on this test bench are also highlighted. They should lead to a new and enhanced model and comprehension of dual-reciprocating-drilling

Percussive Augmenter of Rotary Drills for Operating as a Rotary-Hammer Drill

A percussive augmenter bit includes a connection shaft for mounting the bit onto a rotary drill. In a first modality, an actuator percussively drives the bit, and an electric slip-ring provides power to the actuator while being rotated by the drill. Hammering action from the actuator and rotation from the drill are applied directly to material being drilled. In a second modality, a percussive augmenter includes an actuator that operates as a hammering mechanism that drives a free mass into the bit creating stress pulses that fracture material that is in contact with the bit

Intelligent Drilling and Coring Technologies for Unmanned Interplanetary Exploration

The robotic technology, especially the intelligent robotics that can autonomously conduct numerous dangerous and uncertain tasks, has been widely applied to planetary explorations. Similar to terrestrial mining, before landing on planets or building planetary constructions, a drilling and coring activity should be first conducted to investigate the in-situ geological information. Given the technical advantages of unmanned robotics, utilizing an autonomous drill tool to acquire the planetary soil sample may be the most reliable and cost-effective solution. However, due to several unique challenges existed in unmanned drilling and coring activities, such as long-distance time delay, uncertain drilling formations, limited sensor resources, etc., it is indeed necessary to conduct researches to improve system’s adaptability to the complicated geological formations. Taking drill tool’s power consumption and soil’s coring morphology into account, this chapter proposed a drilling and coring characteristics online monitoring method to investigate suitable drilling parameters for different formations. Meanwhile, by applying pattern recognition techniques to classify different types of potential soil or rocks, a drillability classification model is built accurately to identify the current drilling formation. By combining suitable drilling parameters with the recognized drillability levels, a closed-loop drilling strategy is established finally, which can be applied to future interplanetary exploration