Bidirectional Data Transfer Through Mud?

June 10, 2024 by Dave Rowntree 30 Comments

We take easy communications for granted these days. It’s no bother to turn on a lightbulb remotely via a radio link or sense the water level in your petunias, but how does a drilling rig sense data from the drill head whilst deep underground, below the sea bed? The answer is with mud pulse telemetry, about which a group of researchers have produced a study, specifically about modelling the signal impairments and strategies for maintaining the data rate and improving the signal quality.

If you’re still confused, mud pulse telemetry (MPT) works by sending a modulated pressure wave vertically through the column of mud inside the drilling tube. It’s essential to obtain real-time data during drilling operations on the exact angle and direction the drill bit is pointing (so it can be corrected) and details of geological formations so decisions can be made promptly. The goal is to reduce drilling time and, therefore, costs and minimize environmental impact — although some would strongly argue about that last point.

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Mining And Refining: Fracking

June 5, 2024 by Dan Maloney 52 Comments

Normally on “Mining and Refining,” we concentrate on the actual material that’s mined and refined. We’ve covered everything from copper to tungsten, with side trips to more unusual materials like sulfur and helium. The idea is to shine a spotlight on the geology and chemistry of the material while concentrating on the different technologies needed to exploit often very rare or low-concentration deposits and bring them to market.

This time, though, we’re going to take a look at not a specific resource, but a technique: fracking. Hydraulic fracturing is very much in the news lately for its potential environmental impact, both in terms of its immediate effects on groundwater quality and for its perpetuation of our dependence on fossil fuels. Understanding what fracking is and how it works is key to being able to assess the risks and benefits of its use. There’s also the fact that like many engineering processes carried out on a massive scale, there are a lot of interesting things going on with fracking that are worth exploring in their own right.
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An unfastened piece of pipe in a drill press, rotating away

Drill Press Piece Fastening 101

April 17, 2022 by Arya Voronova 16 Comments

What are the options you have for securing your workpiece to the drill press table? [Rex Krueger] shows us that there’s plenty, and you ought to know about them. He goes through the disadvantages of the usual C-clamps, and shows options like the regular drill press vice and a heavy-duty version that even provides a workpiece tilting mechanism, and points out small niceties like the V-grooves on the clamps helping work with round stock. For larger pieces, he recommends an underappreciated option — woodworkers’ wooden handscrew clamps, which pair surprisingly well with a drill press. Then, he talks about the hold-down drill press clamps, a favourite of his, especially when it comes to flat sheets of stock like sheet metal or plastic.

As a bonus for those of us dealing with round stock, he shows a V-block he’s made for drilling into its side, and round stock clamp, made by carefully drilling a pair of wooden hand screw clamps, for when you need to drill into a dowel from its top. The ten-minute video is a must watch for anyone not up to speed on their drill press piece fastening knowledge, and helps you improve your drilling game without having skin in it.

We’ve covered a few ingenious and unconventional drill piece fastening options before, from this wise held down by repurposed bicycle quick-release parts, to an electromagnetic wise that left our readers with mixed opinions.

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Extraterrestrial Excavation: Digging Holes On Other Worlds

March 27, 2019 by Dan Maloney 15 Comments

We humans are good at a lot of things, but making holes in the ground has to be among our greatest achievements. We’ve gone from grubbing roots with a stick to feeding billions with immense plows pulled by powerful tractors, and from carving simple roads across the land to drilling tunnels under the English Channel. Everywhere we go, we move dirt and rock out of the way, remodeling the planet to suit our needs.

Other worlds are subject to our propensity for digging holes too, and in the 50-odd years that we’ve been visiting or sending robots as our proxies, we’ve made our marks on quite a few celestial bodies. So far, all our digging has been in the name of science, either to explore the physical and chemical properties of these far-flung worlds in situ, or to actually package up a little bit of the heavens for analysis back home. One day we’ll no doubt be digging for different reasons, but until then, here’s a look at the holes we’ve dug and how we dug them.

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Superdeep Borehole Samples Create Non-boring Music

October 19, 2018 by Bryan Cockfield 14 Comments

In the 1970s, the Soviet Union decided to dig a hole for science. Not just any hole, the Kola Superdeep Borehole reached a depth of over 12 kilometers, the deepest at the time and the second deepest today by just a few meters. Since this was one of the few holes dug this deep that wasn’t being drilled for oil, the project was eventually abandoned. [Dmitry] was able to find some core samples from the project though, and he headed up to the ruins of the scientific site with his latest project which produces musical sounds from the core samples.

The musical instrument uses punched tape, found at the borehole site, as a sort of “seed” for generating the sounds. Around the outside of the device are five miniature drilling rigs, each holding a piece of a core sample from the hole. The instrument uses the punched tape in order to control the drilling rigs, and the sound that is created is processed by the instrument and amplified, which creates some interesting and rather spooky sounds. The whole thing is controlled by an Arduino Mega.

Not only does the project make interesting sounds from a historically and scientifically significant research station and its findings, but the project has a unique and clean design that really fits its environment at the abandoned facility. The other interesting thing about this project is that, if you want to make the trek, anyone can go explore the building and see the hole for themselves. If you’re wondering about the tools that could be used to make a hole like this, take a look at this boring project.

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These Gorgeous Robot Parts Are Hand-Made

April 7, 2018 by Donald Papp 12 Comments

[Dickel]’s robot MDi #4 has been in progress for several years, but what we wanted to draw your attention to is the way the parts have been fabricated and what kind of remarkable results are possible with careful design, measurement, cutting, and finishing. Much of MDi #4 was made by hand-cutting and drilling sheets of high impact polystyrene (HIPS) with a utility knife and layering them as needed. Epoxy and aluminum provide gap filling and reinforcement of key sections, and fiberglass took care of one of the larger sections.

The process [Dickel] follows is to prototype using cardboard first. Parts are then designed carefully in CAD, and printed out at a 1:1 scale and glued to sheets of polystyrene. Each sheet is cut and drilled by hand as necessary. Layers are stacked and epoxied, embedding any hardware needed in the process. Two examples of embedding hardware include sealing captive nuts into parts with epoxy, or using aluminum to add reinforcement. After some careful sanding, the pieces look amazing.

Scroll down a bit on that project page and you’ll see plenty of great photos of the process [Dickel] used. A video highlighting the head and a video showing the careful work that goes into making each part are embedded below.

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Your Work Won’t Move With A Magnetic Drill Press Vise

September 8, 2017 by Dan Maloney 32 Comments

Setting up your workpiece is often the hardest part of any machining operation. The goal is to secure the workpiece so it can’t move during machining in such a way that nothing gets in the way of the tooling. Magnetic chucks are a great choice for securely and flexibly holding down workpieces, as this simple shop-built electromagnetic vise shows.

It looks like [Make It Extreme] learned a thing or two about converting microwave oven transformers to electromagnets when they built a material handling crane for the shop. Their magnetic vise, designed for a drill press but probably a great choice for securing work to a milling machine, grinder, or even a CNC router, has a simple but sturdy steel frame. Two separate platforms slide on the bed of the vise, each containing two decapitated MOTs. Wired to mains power separately for selective control and potted in epoxy, the magnets really seem to do the job. The video below shows a very thick piece of steel plate cantilevered out over one magnet while having a hole cut; that’s a lot of down force, but the workpiece doesn’t move.

Like the idea of a shop-made vise but would rather go the old-fashioned way? Check out [Make It Extreme]’s laminated bench vise, which also makes an appearance in this video.

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