US 11,753,922 B1
Control systems and methods to enable autonomous drilling
Stephen Buerger, Albuquerque, NM (US); Anirban Mazumdar, Atlanta, GA (US); Steven James Spencer, Albuquerque, NM (US); Timothy James Blada, Albuquerque, NM (US); Jiann-Cherng Su, Albuquerque, NM (US); Elton K. Wright, Rio Rancho, NM (US); Adam Foris, Albuquerque, NM (US); and David W. Raymond, Edgewood, NM (US)
Assigned to National Technology & Engineering Solutions of Sandia, LLC, Albuquerque, NM (US)
Filed by National Technology & Engineering Solutions of Sandia, LLC, Albuquerque, NM (US)
Filed on Mar. 18, 2022, as Appl. No. 17/698,213.
Application 17/698,213 is a continuation of application No. 17/157,614, filed on Jan. 25, 2021, granted, now 11,280,173.
Application 17/157,614 is a continuation in part of application No. 15/880,109, filed on Jan. 25, 2018, granted, now 10,900,343, issued on Jan. 26, 2021.
Int. Cl. E21B 44/08 (2006.01); E21B 1/38 (2006.01); E21B 49/00 (2006.01)
CPC E21B 44/08 (2013.01) [E21B 1/38 (2020.05); E21B 49/003 (2013.01); E21B 2200/22 (2020.05)] 17 Claims
OG exemplary drawing
 
1. A method for autonomously controlling a drilling system comprising:
applying a predetermined force setpoint to a first controller; applying a predetermined rotary speed to a second controller;
applying a first controller output and a second controller output to a drilling process module; measuring a plurality of outcome parameters of the drilling process module;
receiving drilling process inputs from downhole sensor data and processing and process outcome parameters;
estimating a plurality of rock parameters associated with a rock type;
comparing the estimated rock parameters with a database of rock profiles; determining whether a change in the outcome parameters have occurred which indicate that a change in the drilled material has occurred;
searching the database rock profiles for optimal operating conditions in response to determining that a change in the material being drilled is indicated;
generating an updated set of drilling parameters corresponding to the optimal operating conditions rock parameters in response to the comparing of database rock profiles by executing machine-executable instructions stored in a computer;
transmitting the updated set of drilling parameters comprising the force setpoint and rotary speed setpoint;
adjusting the drilling parameters by subtracting measured drilling parameters from the updated set of drilling parameters; and
generating adjusted drilling parameter setpoints for predetermined force and predetermined angular velocity; and
determining whether the adjusted drilling parameter setpoints are approaching stall conditions;
wherein the step of determining stall conditions further comprises:
monitoring the torque;
determining that the torque exceeds a predetermined torque;
reducing the target weight on bit by an amount determined by a barrier function configured to respond more rapidly to material changes.