Directional drill securing device and method

A directional drill securing device and associated methods are shown. Securing devices and methods shown include a plurality of staking devices on a single lateral side of a directional drill. Using examples shown, a lower force is required to drive multiple staking devices than would be needed for a larger staking device of equivalent area.

TECHNICAL FIELD

Embodiments described herein generally relate to horizontal directional drills and methods. Specific examples may include securing systems for horizontal directional drills.

BACKGROUND

Directional drills are used for a number of types of jobs. A bore is made in the ground by piercing with a drill stem. In one use, new pipe may be drawn back through the bore that was formed. In this way, new pipe may be installed without the need to dig a trench in the ground first. For example, a utility line may be installed beneath a roadway without the need to close the road during the installation process. Progress of a directional drill stem may be monitored, and the tip of a drill stem may be steered to direct the bore over long distances. As a bore progresses, commonly, drill stem segments are added to increase a length of the drill stem until the bore reaches its intended destination. After the bore is complete, the drill stem may be retracted from the bore, and drill stem segments may be removed as the drill stem is retracted.

It is desirable to have a reliable system to secure the directional drill in place during a bore. It is further desirable to have a securing system that is configurable for different soil conditions, and uses less energy to use.

DESCRIPTION OF EMBODIMENTS

FIG. 1shows an example of a directional drill100. The directional drill100includes a drill stem110including an attached sonde housing, and a drill bit112for piercing the ground and leading a directional drill bore operation, A drill stem loader140is shown coupled to the directional drill100. The drill stem loader140is configured to pick drill stem segments (or drill rods) from a drill stem magazine and add stem segments to the stem110during a boring operation. The drill stem loader140is further configured to remove stem segments from the drill stem110and replace them in the drill stem magazine after the boring operation is complete, and the drill stem is being retracted from the bore.

A power supply154is coupled to the directional drill100to drive the drill stem110, and to operate other aspects of the directional drill100. A cockpit150is further included in the directional drill100, the cockpit150including a number of controllers and gauges to control and monitor a drilling operation. In on example, a track system152is included on the directional drill100to move and position the directional drill100. A stake down system130is also shown coupled to a front end of the directional drill100in the example ofFIG. 1. Additional aspects of the stake down system130are described in more detail below. A directional drill vice120is further shown at a front end of the directional drill100.

FIG. 2shows a portion of a directional drill100fromFIG. 1, with a number of components removed to reveal more detail of a directional drill stem loader140according to an embodiment of the invention. The drill stem loader140includes a drill stem magazine144, having a number of individual drill stem segments146loaded into the magazine144.

A first linear actuator210and a second linear actuator220are shown adjacent to the drill stem magazine144. In one example, the linear actuators210,220are coupled to a pair of drill stem grippers. Although two linear actuators are shown, the invention is not so limited. Other configurations may include a single linear actuator, or more than two linear actuators. In one example, the directional drill vice120includes a slot that coordinates with the first linear actuator210and a second linear actuator220to load a drill stem segment laterally into the directional drill vice120.

A drill head142is shown at a rear of the drill stem loader140. The drill head142is mounted to a carriage frame143along a drill carriage track145. In one example, a drill fluid supply system160is coupled to the directional drill100, adjacent to the drill head142. During a drilling operation, the drill head142is operated to both rotate the drill stem110, and to drive the drill stem110forward into the ground. The drill stem vice120is shown at a front end of the drill stem loader140. During a drilling operation, the directional drill vice120selectively holds or releases individual segments of the drill stem110to aid in the adding or removal of drill stem segments (by screwing or unscrewing a threaded joint at either end of the drill stem segment).

FIG. 3Ashows a stakedown device300according to one example. The stakedown device300includes a plurality of stake implements that are adapted to be located together on one lateral side of the drill carriage track145. In the example shown, the stakedown device300includes a first staking implement310, and a second staking implement320. Additional detail of the respective staking implements310,320are shown in cross section inFIG. 3B.

The first staking implement310includes a first auger314, and the second staking implement320includes a second auger324. Although spiral auger flights are shown inFIGS. 3A and 3B, the invention is not so limited. Other staking implements such as spikes or claws etc, are within the scope of the invention.

The stakedown device300includes a proximal end302, and a distal end304. In operation, the staking implements310,320are selectively driven into or out of the soil along a range of motion301. In one example, one or more actuators such as hydraulic cylinders may be used to drive the staking implements310,320along the range of motion301. Although hydraulic cylinders actuators are described, other examples of actuators include, but are not limited to, gear driven actuators, rack and pinion actuators, electric actuators, etc.

In the example shown, a pair of hydraulic cylinders332,334are utilized. In the example shown, a first hydraulic cylinder332is mounted with a piston facing the distal end304of the stakedown device300, and a second hydraulic cylinder334is mounted with a piston facing the proximal end302of the stakedown device300.

One advantage of using a pair of hydraulic cylinders includes the ability to select a depth for the augers314,324in a middle portion of the range of motion301. While other systems of actuation may also be capable of selectable depth, the use of the pair of hydraulic cylinders332,334provides depth selection ability without the use of more expensive components. Hydraulic cylinders are relatively inexpensive and more reliable compared to other actuators such as gear driven actuators. Another advantage of using a pair of hydraulic cylinders over the use of a single hydraulic cylinder includes reduced cost and improved reliability. The shorter length of each cylinder332,334reduces the cost of the actuation system over a single, larger, hydraulic cylinder, and reduces the likelihood of a long piston bending due to high stress during operation.

In the auger examples shown inFIGS. 3A and 3B, each staking implement310,320includes a rotating spindle312,322. The rotating spindles312,322are coupled to the augers314,324and rotate within distal bearing assemblies313,323. At the proximal end304of the stakedown device300, a respective pair of drive gears311,321are shown. Although a gear drive is illustrated as an example device for rotating the rotating spindles312,322, the invention is not so limited. Other examples include, but are not limited to, hydraulic motors, electric motors, belt drive, chain drive, etc.

A drive motor340is shown inFIG. 3Acoupled to the drive gears311,321of the staking implements310,320. In operation, rotation of the rotating spindles312,322and the attached augers314,324is accomplished by engaging the drive motor340. Then extension or retraction of the staking implements310,320is accomplished by actuation of one or more of the hydraulic cylinders332,334.

A plurality of smaller augers are easier to drive into the soil than a single large auger of equal auger surface area. In one example, by using a plurality of smaller augers, a similar staking force is achieved with a lower force required to drive the augers. In one example, an equal driving force is used to drive multiple augers, and an increased staking force is achieved as a result of using multiple augers. Again, while augers are used as an example other staking implements may be used with similar gains in efficiency.

FIG. 4Ashows a stakedown device400according to one example. The stakedown device400includes a single stake implement410that is adapted to be located on one lateral side of the drill carriage track145. In the example shown, the stakedown device400includes a staking implement410, and an actuator to drive the staking implement410. The stakedown device400includes a proximal end402, and a distal end404.

The staking implement410includes an auger414. Similar to the examples discussed above inFIGS. 3A and 3B, although spiral auger flights are shown inFIGS. 4A and 4B, the invention is not so limited. Other staking implements such as spikes or claws etc, are within the scope of the invention. A spindle412is attached between a drive gear411and the auger414. In the example shown, the spindle412is housed in an distal bearing assembly413. Additional detail of the staking implement410is shown in cross section inFIG. 4B.

In operation, the staking implement410is selectively driven into or out of the soil along a range of motion401. In the example shown, a pair of actuators430,434drive the staking implement410along the range of motion401. Although hydraulic cylinders actuators are described, other examples of actuators include, but are not limited to, gear driven actuators, rack and pinion actuators, electric actuators, etc.

A drive motor440and drive motor gear442is shown inFIGS. 4A and 4Bcoupled to drive gear411of the staking implement410. In operation, rotation of the spindle412and the attached auger414is accomplished by engaging the drive motor440. Then extension or retraction of the staking implement410, is accomplished by actuation of one or more of the hydraulic cylinders430,434.

In the example directional drill100shown inFIG. 1, a single staking implement (similar to staking implement410) is shown on a first lateral side of the drill carriage frame143, and two staking implements (similar to staking implements310,320) are shown on a second lateral side of the drill carriage frame143. However, the invention is not so limited. In other examples, multiple staking implements are located on both the first side and the second side of the drill carriage frame143. As discussed above, a plurality of smaller augers are easier to drive into the soil than a single large auger of equal auger surface area. In one example, a number of staking implements on each lateral side of the drill carriage frame143is equal. In other examples, a first lateral side of the drill carriage includes a larger number of stake implements than the second lateral side.

One advantage of having a different number of staking implements on different lateral sides of a drill carriage includes the potential for several staking level options. For example, in loose soil conditions, all staking implements on both lateral sides may be used. The higher number of staking implements provides a higher staking force to accommodate the loose soil conditions. In hard soil conditions, it may be difficult to drive a staking implement into the soil. In this example, it may be desirable to drive only a single staking implement into the soil. Using examples of staking devices shown, in intermediate conditions, it may be desirable to drive an intermediate number of staking implements into the soil.

In the example ofFIG. 1, three staking implements from both lateral sides of the directional drill100may be used in loose soil. One staking implement from a single side of the directional drill100may be used for hard soil conditions, and two staking implements from the other single side of the directional drill may be used in intermediate conditions.

FIG. 5Ashows an example of an orientation of staking implements according to one embodiment of the invention. In the diagram ofFIG. 5A, a drill stem510is shown by itself without other directional drill components, in order to illustrate orientation. The drill stem510passes through a plane502at point512. The plane502is shown to illustrate an orientation of a first staking implement520and a second staking implement522with respect to each other, and the drill stem510. In one example, the plane502may be oriented perpendicular to a ground surface. In one example, the plane502may be oriented perpendicular to an axis of the drill stem510. In one example, the plane502may be fixed with respect to a directional drill. In one example, the plane502may be adjustable in orientation with respect to a directional drill.

The dashed lines shown inFIGS. 5A and 5Bare used to represent axes of staking implements as they are driven into the ground. Examples of staking implements that travel into the ground along the dashed lines520,522ofFIGS. 5A and 5Bmay include the staking implements300and400as shown in either or bothFIGS. 3A, 3B, and 4A, 4B.

The example ofFIG. 5Ashows the first staking implement520and the second staking implement522are not parallel to one another. Further, in the example ofFIG. 5A, the first staking implement520and the second staking implement522are both within the plane502, and are angled with respect to one another, and are not parallel.FIG. 5Bshows that in one example, a bottom end of the first staking implement520and the second staking implement522are separated by a lower distance524. A top end of the first staking implement520and the second staking implement522are separated by an upper distance526.FIG. 5Bshows the lower distance524is less than the upper distance526. In this example, as the first staking implement520and the second staking implement522are driven into the soil, they will converge in the ground underneath the drill stem510. One advantage of angling the staking implements520,522towards each other includes less likelihood of accidentally hitting a buried utility. Another advantage of angling the staking implements520,522towards each other includes improved holding strength. It has been found that in selected soil conditions, locating adjacent auger flights from two adjacent augers approximately 0.5 to 1.0 times an auger flight diameter from each other provides increased holding strength. Selecting an angle of the staking implements520,522provides the ability to manufacture a directional drill for a given auger diameter with optimal holding strength.

In addition to angling staking implements beneath a drill stem, the same formula of adjacent staking implements may be used for two or more staking implements on the same side of a drill stem, such as shown inFIG. 1above. As discussed above, locating adjacent auger flights from two adjacent augers approximately 0.5 to 1.0 times an auger flight diameter from each other provides increased holding strength over a single auger of equal auger flight area. In one example, any two augers, on any side of a drill stem, are located adjacent one another with auger flights from two adjacent augers approximately 0.5 to 1.0 times an auger flight diameter from each other. This configuration reduces driving force to deploy the augers over a single auger of equal auger flight area. Further, this configuration provides more holding force than a single auger of equal auger flight area. In one example, two augers are angled to provide this desired spacing. In other examples, the two adjacent augers are driven parallel to one another, but located such that flights from two adjacent augers approximately 0.5 to 1.0 times an auger flight diameter from each other.

FIG. 6shows an example flow diagram of a method of operation according to one embodiment. In operation602, a drill carriage and a rotating spindle coupled to the drill carriage are positioned, along a drilling axis. In operation604, an optional desired number of stake implements are selected from a plurality of stake implements located on both a first lateral side of the drill carriage and a second lateral side of the drill carriage wherein the first lateral side of the drill carriage includes a larger number of stake implements than the second lateral side. In operation606, the directional drill is staked down using the selected number of stake implements.

To better illustrate the method and apparatuses disclosed herein, a non-limiting list of examples is provided here:

Example 1 includes a directional drill. The directional drill includes a drill carriage, a rotating spindle coupled to the drill carriage, wherein the rotating spindle is adapted to translate along a surface of the drill carriage, and a stakedown system coupled to an end of the drill carriage. The stakedown system includes a first stake implement located on a first lateral side of the drill carriage, and a plurality of second stake implements located on a second lateral side of the drill carriage, opposite the first lateral side.

Example 2 includes the directional drill of example 1, wherein the first stake implement includes a plurality of first stake implements located on the first lateral side.

Example 3 includes the directional drill of any one of examples 1-2, wherein the plurality of first stake implements includes two first stake implements.

Example 4 includes the directional drill of any one of examples 1-3, wherein the plurality of second stake implements includes two second stake implements.

Example 5 includes the directional drill of any one of examples 1-4, wherein the first stake implement includes an auger.

Example 6 includes the directional drill of any one of examples 1-5, wherein the plurality of second stake implements includes at least one auger.

Example 7 includes the directional drill of any one of examples 1-6, wherein the plurality of second stake implements each include an auger.

Example 8 includes a directional drill. The directional drill includes a drill carriage, a rotating spindle coupled to the drill carriage, wherein the rotating spindle is adapted to translate along a surface of the drill carriage, and a stakedown system coupled to an end of the drill carriage. The stakedown system includes a plurality of stake implements located on both a first lateral side of the drill carriage and a second lateral side of the drill carriage, wherein the first lateral side of the drill carriage includes a larger number of stake implements than the second lateral side.

Example 9 includes the directional drill of example 8, wherein the first lateral side of the drill carriage includes one stake implement.

Example 10 includes the directional drill of any one of examples 8-9, wherein the second lateral side of the drill carriage includes two stake implements.

Example 11 includes the directional drill of any one of examples 8-10, wherein the plurality of stake implements includes at least one auger.

Example 12 includes the directional drill of any one of examples 8-11, wherein the plurality of second stake implements each include an auger.

Example 13 includes a method of operating a directional drill, including positioning a drill carriage and a rotating spindle coupled to the drill carriage along a drilling axis, selecting an optional desired number of stake implements from a plurality of stake implements located on both a first lateral side of the drill carriage and a second lateral side of the drill carriage wherein the first lateral side of the drill carriage includes a larger number of stake implements than the second lateral side, and staking down the directional drill using the selected number of stake implements.

Example 14 includes the method of example 13, wherein selecting an optional desired number of stake implements includes selecting a single stake implement on the first lateral side of the drill carriage.

Example 15 includes the method of any one of examples 13-14, wherein selecting an optional desired number of stake implements includes selecting two stake implements on the second lateral side of the drill carriage.

Example 16 includes the method of any one of examples 13-15, wherein staking down the directional drill includes rotating at least one auger into the ground.

Example 17 includes a directional drill, including a drill carriage, a rotating spindle coupled to the drill carriage, wherein the rotating spindle is adapted to translate along a surface of the drill carriage, and a stakedown system coupled to an end of the drill carriage. The stakedown system includes a first stake implement located on a first lateral side of the drill carriage, and a second stake implement located on a second lateral side of the drill carriage, opposite the first lateral side, wherein the first stake implement is angled with respect to the second stake implement.

Example 18 includes the directional drill of example 17, wherein the first stake implement and the second stake implement are angled towards each other beneath a drill stem axis.

Example 19 includes the directional drill of any one of examples 17-18, wherein the first stake implement and the second stake implement are angled towards each other within a plane.

Example 20 includes the directional drill of any one of examples 17-19, wherein the plane is oriented substantially perpendicular to a ground surface.

Example 21 includes the directional drill of any one of examples 17-20, wherein the first stake implement and the second stake implement are both augers having auger flight diameters.

Example 22 includes the directional drill of any one of examples 17-21, wherein the first stake implement and the second stake implement are configured to converge beneath the drill stem axis at a distance between auger flights of about 0.5 and 1.0 times the flight diameter.