Abstract:
A biased door member is provided in an external wall of a drill rod supply magazine mounted on a horizontal directional drilling (HDD) machine. The door member swings inwardly from a first position parallel to the external wall to a second position within the distal column. At least one cut-out is formed in the external wall at the bottom of the retaining guides located at the longitudinal ends of the magazine. The cut-out creates a window through which the added drill rod is inserted. In operation, a drill rod is moved through the biased door member and window cut-outs into the distal column. The pocket of a rod transfer mechanism is positioned below the last column, and a rod lifter lowers the added drill rod into the pocket. The rod transfer mechanism then moves the added drill rod into alignment with the drill string.

Description:
FIELD OF THE INVENTION 
   The present invention relates generally to equipment used for horizontal ground boring; more specifically to a method and apparatus for manipulating drill rod used in horizontal directional drilling; and more particularly still to a method and apparatus for loading drill rod into a drill rod storage magazine mounted on a horizontal directional drill. 
   BACKGROUND 
   Horizontal directional drilling, commonly referred to as HDD, is a process used in applications such as installing utilities underground. Generally the first step in the HDD process includes boring a pilot hole. In this step a bore hole is created that extends underground—generally horizontally or parallel to the surface of the earth—starting at a launch point and ending at a termination point. 
   The bore hole is created by a boring machine that rotates and pushes a drill string through the ground. A drill bit is attached to the leading end of the drill string. The drill string is formed by connecting individual drill rods together end-to-end. The connection between the rods is made up, and subsequently broken in a later step, by the boring machine. A typical boring machine includes a gearbox that connects to the drill string, a drill rod storage magazine, and a rod loading mechanism. The rod loading mechanism moves the individual drill rods from the storage magazine into alignment with the drill string and the gearbox where the individual drill rod is connected to and made a part of the drill string. 
   Rod loading mechanisms typically include a rod transfer mechanism that moves the rod from the storage magazine and positions it with one end in alignment with the drill string and the other end in alignment with the gearbox. The drill rods are typically long, and are stored with their longitudinal axes parallel to one another. There are generally several separated, parallel columns in the storage magazine for storing the drill rods, with each subsequent column further from the drill string. Accordingly, the rod loading magazine is generally heavy and bulky. 
   The drill rod storage magazine may be interchangeable with other magazines. In this type of arrangement, once all of the drill rods stored in a first magazine are used, the empty first magazine can be replaced with a full second magazine. In this manner, a longer drill string may be formed. However, because of the weight of the magazine, special equipment such as a back-hoe, front end loader or other hydraulic equipment capable of lifting the magazine must generally be employed to remove the empty first magazine and replace it with a full second magazine (e.g., the second magazine has an additional supply of drill pipe located therein). 
   A drawback exists, however, with these systems since there are occasions when only one (or a relatively few) additional drill rods are required for the drill string. Also, there may be instances when the necessary power equipment is not available to lift and replace the magazine. Still further, there may be instances when specific drill pipe is desired to be inserted into the drill string. Therefore, there is a need in the art for a method and apparatus for selectively loading drill rod into a magazine. The present invention overcomes the shortcomings of the prior art and addresses these needs in the art. 
   SUMMARY 
   The present invention generally relates to a method and apparatus for loading a drill rod magazine. One aspect of the invention relates to an apparatus and method for loading the drill rod magazine while the magazine is mounted on the HDD boring machine. A second aspect of the invention relates to an apparatus and method for loading drill rod into a drill rod magazine at a point in the magazine that is distal from the drill string. A third aspect of the invention relates to selectively providing individual drill rods from a location external to the magazine for delivery to the drill string by a pipe handling mechanism. 
   In one embodiment constructed according to the principles of the present invention, there is provided a biased door member in an external wall of the distal most storage column of the magazine. The door member swings inwardly thereby retaining drill rod initially stored in the distal most column and avoiding inadvertent discharge of drill rods through the door member. The door member preferably physically swings from a first position parallel to the external wall to a second position within the last column. 
   Retaining guides located at each end of the magazine keep the drill rods organized within columns. However, at least one cut-out is formed in the external wall at the bottom of the retaining guide at each end of the magazine. The cut-out creates a window through which added drill rod is inserted into the magazine. In the preferred embodiment, two cut-outs are provided—with one located at each end of the magazine. 
   Optionally, two or more support arms may be located on the exterior of the external wall of the magazine for supporting drill rod prior to inserting the same into the magazine. In this case, suitable stops may be included at the distal ends of the support arms to retain the drill rod in position. 
   In operation, a drill rod is placed onto the support arm in anticipation of loading a drill rod into the magazine. The drill rod is then moved through the biased door member into the last column of the magazine. The ends of the added drill rod fit through the window cut-outs. The pocket of the rod transfer mechanism is positioned below the last column, and a rod lifter lowers the added drill rod into the pocket. The rod transfer mechanism then moves the added drill rod into alignment with the drill string. 
   Therefore, according to one aspect of the invention, there is provided a horizontal directional drilling machine, comprising: a boring assembly defining a drill string axis comprising a rack frame with an upper end and a lower end, a gearbox configured to travel along the rack frame from the upper end to the lower end, and a vise assembly at the lower end; a drill rod storage magazine mounted on the horizontal directional drilling machine and adjacent the boring assembly, the storage magazine including a plurality of columns defined by retaining guides located at opposing ends of the storage magazine, and further including a biased member located on an external wall of the storage magazine distal to the drill string through which drill rod is selectively loaded; and a pair of drill pipe transfer mechanisms configured to transfer drill pipe from the storage magazine to drill string. 
   According to another aspect of the invention, there is provided a drill rod storage magazine, the magazine comprising: a supporting structure; a plurality of columns defined within the supporting structure by retaining guides located at opposing ends of the supporting structure; and a plurality of biased members located on an external wall of the supporting structure through which drill rod is selectively loaded. 
   According to yet another aspect of the invention, there is provided a method for selectively loading drill rod into a storage magazine of a horizontal directional drill machine, the method comprising: pivotally mounting a plurality of biased members onto an external wall of a storage magazine located on the directional drill machine, the storage magazine including retaining guides located at opposing ends of the storage magazine to form storage columns; forming at least one window into at least one of the retaining guides through which drill rod can be inserted into the column formed by the respective retaining guides; and loading drill rod through the biased members and windows into the magazine. 
   While the invention will be described with respect to preferred embodiment configurations and with respect to particular devices used therein, it will be understood that the invention is not to be construed as limited in any manner by either such configuration or components described herein. Also, while particular types of transfer mechanisms and storage magazines are described herein, it will be understood that such particular mechanisms and magazines are not to be construed in a limiting manner. Instead, the principles of this invention extend to any environment in which selective loading of a drill rod magazine is desired. These and other variations of the invention will become apparent to those skilled in the art upon a more detailed description of the invention. 
   The advantages and features which characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. For a better understanding of the invention, however, reference should be had to the drawings which form a part hereof and to the accompanying descriptive matter, in which there is illustrated and described a preferred embodiment of the invention. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is an elevated side plan view illustrating the basic components of a horizontal directional drill device including a magazine constructed in accordance with the principles of the present invention; 
       FIG. 2  is a first perspective partial view of a portion of the horizontal directional drilling machine and the magazine illustrating the location of the bias members, windows, and transfer mechanism; 
       FIG. 3  is a second perspective partial view of the magazine and the horizontal directional drilling device; 
       FIGS. 4   a - 4   d  are a schematic cross-section view illustrating the operation of a biased member, rod lifter and blocking mechanism; 
       FIG. 5  schematically illustrates the biased member in the shut or first position; and 
       FIG. 6  is an elevated side plan view of an embodiment of a horizontal directional drill device according to the principles of the present invention. 
   

   DETAILED DESCRIPTION 
   Reference will now be made in detail to exemplary aspects of the present invention which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers are used throughout the drawings to refer to the same or like parts. In order to more clearly describe the invention, a description of the magazine loading method and apparatus will be deferred pending a brief overview of a typical horizontal directional drill and a transfer member for moving drill rod from a magazine to the drill string (and vice versa). 
     FIG. 1  illustrates a typical horizontal directional drill  10  including a main frame  14 , a rack frame  18 , a gearbox  20  that is arranged and configured to move back and forth along the longitudinal axis of the rack frame. Spindle  21  can be independently rotated clockwise or counterclockwise. A rod magazine  22  located generally above and to the side of the rack frame stores drill rods. Pipe transfer mechanism is arranged and configured to move the drill rod from the magazine  22  to a position in line with the drill string. A vise assembly  28  is located at the opposing end of the horizontal directional drill  10  from the gearbox  20 . Accordingly, in operation, the pipe transfer mechanism  24  supports and transfers individual drill rod from the magazine  22  and into alignment with the drill string  23  (best seen in  FIG. 2 ) and spindle  21  of gearbox  20 . 
   While not specifically shown, it will be appreciated that an operator console, controls, and a prime mover are also included as part of the horizontal directional drill  10 , as well as other well known components that operate in their customary and known manner. Further, it will be appreciated that the drill rod may be referred to herein as both drill rod and drill pipe. Such terms are used interchangeably herein and are not meant to denote a different type or work piece or structure. Still further, as used herein, the term lower refers to a position closer/nearer to the surface of the ground, while upper refers to a position that is relatively further from the ground. 
   Referring now to  FIGS. 1 ,  2  and  3 , the magazine  22  of the drilling apparatus  10  includes a box-shaped frame  54  having a plurality of retaining members  56 . The members  56  divide the magazine  22  into a plurality of columns  56 - 60 . The column  56  nearest the drill string  23  is referred to as a first or proximal column. The column  60  farthest from the drill string  23  is referred to as an end or distal column. Each of the columns  57 - 60  may contain a plurality of pipes (e.g., best seen in  FIG. 4   a ) with the pipes aligned vertically within each of the columns  56 - 60  and with the pipe axes parallel to the drive axis of the drill string  23 . The columns  56 - 60  each physically have a width approximately equal to the width of one of the pipes  28  (best seen in  FIG. 4   a ). 
   Now referring to  FIG. 3 , the magazine  22  has a bottom end  62  that is open such that the spaces between the retaining members  56  define a plurality of discharge openings. In a preferred embodiment, the drill rod or pipes  28  are gravity discharged through the openings. 
   In the example shown, the magazine  22  has five columns each containing a plurality of pipes. It will be appreciated that the magazine  22  can be provided with more or fewer columns and with more or fewer pipes per column. Also, the magazine  22  can be configured such that the columns are adapted to discharge pipes through a single discharge opening. Consequently, separate discharge openings are not required for each column. Additionally, the magazine can be configured to define a single open bin for holding pipes, and one or more discharge openings to enable pipes to be removed from the bin. Furthermore, non-gravity feed magazines can also be used. 
   As previously noted, two transfer members  46  are used to convey pipes between the magazine  22  and the drill string  23 . As shown in  FIG. 3 , the drill string  23  is coaxial with the drill rod  28  and the spindle  21 . The pipe transfer members  46  each have substantially identical configurations and are simultaneously moved between a retracted orientation (e.g., as shown in  FIG. 4   b ) and an extended orientation (shown in  FIG. 4   a ). 
   In  FIGS. 4   a - 4   d , only one of the pipe transfer members  46  is shown. The illustrated pipe transfer member  46  includes a pipe receiving region  64  positioned at an end  65  of the pipe transfer member that is closest or proximal to the drill string  23 . When the pipe transfer member  46  is in the retracted orientation of  FIG. 4   b , the pipe receiving region  64  is preferably located beneath the magazine  22  (e.g., directly beneath a selected one of the magazine storage columns and associated discharge opening). By contrast, when the pipe transfer member  46  is in the extended orientation of  FIG. 4   a , the pipe receiving region  64  is positioned at the drive axis of the drill string  23 . As so positioned, a pipe held within the pipe receiving region  64  is preferably placed in coaxial alignment with the drill string axis. 
   As shown in  FIGS. 4   a - 4   d , the pipe transfer member  46  is slidably mounted on a lower track  66 . A gear rack  72  is secured to the bottom of the pipe transfer member  46 . The gear rack  72  fits within an elongated slot defined by the track  66 . The rack  72  cooperates with a drive gear  73 , such as a pinion gear driven by a hydraulic motor, to move the pipe transfer member  46  between the extended and retracted orientations. 
   Referring still to  FIGS. 4   a - 4   d , the pipe transfer member  46  includes a top pipe retaining surface  76  that is used to block the discharge openings. The retaining surface  76  prevents pipes from being discharged from the columns  56 - 60  when such columns contain pipes, and the pipe receiving region  64  of the pipe transfer member  46  is not positioned below a selected one of the columns  57 - 60 . The pipe transfer member  46  also includes a lower platform  78  that is recessed relative to the pipe retaining surface  76 . Both the lower platform  78  and the pipe retaining surface  76  are covered by wear strips preferably made of a suitable plastic-type material. 
   The lower platform  78  is positioned at the end  65  of the pipe transfer member  46  that is closest to the drill string  23 . Referring to  FIG. 4   a , the lower platform  78  includes a top surface  82  that is aligned generally along a horizontal plane. The pipe transfer member  46  also includes an upright wall  84  positioned adjacent the pipe receiving region  64 . The lower platform  78  and the upright wall  84  cooperate to define a partial pocket at the pipe receiving region  64 . 
   To unload a pipe from the first column  57  of the magazine  26 , the pipe transfer members  46  are moved to the retracted position such that the pipe receiving regions  64  are located directly beneath the appropriate discharge opening. With the pipe transfer members  46  so positioned, pipe lifts  52  are lowered causing the lower most pipe in the first column  56  to move through the discharge opening into the pipe receiving regions  64 . The pipe retaining surfaces  76  of the pipe transfer members  46  prevent any other pipes from being discharged through any of the other discharge openings. 
   After the pipe has been loaded into the pipe receiving regions  64 , the pipe transfer members  46  are moved toward the extended orientation. As the pipe receiving regions  64  move from beneath the magazine  22 , devices which help retain and guide the pipe into the drill string axis may be implemented. For example, assist arms (not shown) may move and/or magnets (if any) may be activated. The magnetic attraction provided by the magnets resists lateral movement of the pipe within the partial pockets of the pipe transfer members  46  thereby inhibiting the pipe from falling out of the partial pockets during transfer of the pipe. The magnets also inhibit the pipe from sliding along its axis as the pipe is transferred. For example, during drilling operations, the track  30  and magazine  26  are commonly inclined. Therefore, the pipe may have a tendency to slide downward along its axis unless somehow restrained. 
   With the pipe aligned with the drill string  23  axis, the spindle  21  of the drive head  20  can be threaded into the pipe, and the pipe can be drilled into the ground. After the pipe has been coupled to the spindle  21 , the pipe transfer members  46  are preferably retracted. Hence, the pipe is laterally displaced from the pipe receiving regions  64  as the pipe transfer members  46  are retracted. The pipe transfer members  46  are then moved back to a retracted position such that another pipe from the first column  56  can be loaded into the pipe receiving regions  64 . 
   In unloading the magazine  22 , the sequence of steps described above are repeated until all of the pipes contained in the first column  56  have been selected. Thereafter, the same procedure is repeated with respect to the second column  57 , the third column  58 , the fourth column  59 , and the fifth column  60  until all of the pipes from the magazine  22  have been selected. 
   To load the magazine, the pipe transfer members  46  are extended to receive a pipe from the drill string  23  and the pipe is uncoupled from the spindle  21  and other pipes in the drill string. The uncoupled pipe is loaded into the pipe receiving pocket  64  of the pipe transfer members  46 . With the pipe so oriented, the pipe transfer members  64  are moved from the extended orientation toward the retracted orientation. The pipe transfer members  46  are then oriented such that the pipe receiving regions  64  are positioned beneath the fifth column  60 . Next, the pipe lifts  52  are used to lift the pipe from the pipe receiving regions  64 , through the discharge opening and into the fifth column  60 . The pipe transfer members  46  are then moved back to the extended orientation to receive another pipe from the drill string  23 , and the pipe lifts  52  are lowered. Thereafter, the sequence is repeated until the fifth column  60  has been filled. After the fifth column  60  has been filled, the same process is repeated with respect to the fourth column  59 , the third column  58 , the second column  57  and the first column  56  until the entire magazine  22  has been filled. 
   It will be appreciated that the loading and unloading sequences will depend upon the particular magazine configuration being used. Consequently, the disclosed unloading and loading cycles are being provided as examples that are not intended to limit the scope of the present invention For example, in one alternate embodiment, individual, separately actuated pipe stops can be used at each of the discharge openings. For such an embodiment, pipes can be loaded into or unloaded from any of the columns  56 - 60  at any given time. Therefore, any type of loading or unloading sequence can be used (i.e., the columns can be loaded or unloaded in any order or even randomly). 
   For those wishing a more detailed discussion of the construction and operation of pipe transfer mechanisms  46 , reference may be had, for example, to U.S. Pat. No. 6,332,502, with such patent being incorporated herein and made a part hereof by reference. 
   Returning now to  FIG. 2  and the description of a preferred magazine loading method and apparatus, a biased member  200  is shown as hinged on top of the external wall  201  of the storage magazine  22 . Preferably, the external wall  201  is that wall that is most distal from the drill string  23 . A spring  202  is connected between a flange  203  of the biased member  200  so as to rotate the biased member  200  about the hinge  204 . The spring  203  normally biases the biased member  200  into a first position where it is flush or generally adjacent to the mean plane formed by the external wall  201 . In this position, the biased member closes the opening into the storage magazine  22 . This position results in drill rod in distal column  60  helping urge biased member  200  against the external wall  201 —thereby retaining the drill rod within the magazine  22 . 
   In  FIG. 3 , the biased member  200  is shown in an open position with the spring  202 , the flange  203  and the hinge  204 . The pipe transfer mechanism  46 , however, is in a retracted position and the pipe lifting arms  52  are lowered. Also shown is a section of drill rod  28  in line with the drill string  23 . Cut-out  205  is shown in the external guide member  207  at the lower end of the magazine  22 . The cut-out  205  forms a window through which drill rod may be selectively loaded into the magazine  22 . 
   Turning now to  FIGS. 4   a - 4   d , a schematic cross-section view is illustrated looking toward the up-hill end of the horizontal directional drill  10 . In  FIG. 4   a , the transfer mechanism  46  is shown in the extended position. In this position it would normally block all of the columns  56 - 60  of the magazine  22  while delivering a drill rod to the drill string  23 . Still referring to  FIG. 4   a , the biased member  200  is shown in the open or second position where it is rotated so that it extends into the magazine  22 , and more specifically within the distal column  60 . In this position, drill rod  28  may be placed into the magazine  22  within the distal column  60 . As noted above, a window  205  is sized and defined in the guide member  207  of the magazine  22 . 
   It will be appreciated that if drill rods are located in the distal column  60 , then the biased member  200  cannot be opened. It will be further appreciated that while only one biased member  200  is shown in  FIG. 1 , a second biased member may also located at the opposing end of the magazine  22  (best seen in  FIG. 6 ). The biased member  200  is thereby comprised of a plurality of doors though which the drill rod is selectively inserted. Still further, additional biased members may be included at intermediate positions of the magazine  22 . The biased members  22  may be constructed of steel, rigid plastic, and other metals and materials which are suitable for withstanding the forces exerted by a column of drill rods. 
   A single window  205  may be provided at one end of the magazine or, alternatively, a second window may be provided at the opposite end of the magazine. In the case where a single window is provided, the drill rod  28  can be first inserted into the down-hill end of the magazine  22  by stabbing one end into distal column  60 . That end becomes a fixed end. The opposing end (or free end) of drill rod  28  can then be rotated into the magazine  22  through the biased members  200  and the window  205 . It will be appreciated that the single window  205  may also be formed in the down-hill end of the magazine. In the case of two windows  205 , such windows are preferably formed in opposing ends of the magazine such that drill rod  28  can be placed within the magazine without rotating the drill rod  28 . Accordingly, such windows  205  are preferably arranged and configured to have an opening of at least the outer diameter of the drill rod  28  and to be spaced apart from one another to accommodate the length of the drill rod  28 . 
     FIG. 4   b  illustrates the transfer mechanism  46  in a retracted position. When the pipe lifting arms  52  are lowered, the inserted drill rod  28  will be lowered into the receiving pocket  64  of the transfer mechanism  46 . Subsequently, the inserted drill rod  28  can be transferred to the drill string  23 .  FIG. 4   c  shows the pipe lifting arms  52  lowered, the biased member  200  in the second position and the transfer mechanism  46  in its retracted position.  FIG. 4   d  illustrates the transfer mechanism in its extended position with the biased member open. 
     FIG. 5  illustrates the transfer mechanism  46  in the retracted position, the pipe lifting arms  52  in an upward position, and the biased member  200  in a closed or a first position. 
   Drill rod  28  may also be selectively removed from the magazine  22  during the process of moving drill rods from the drill string  23  into the magazine  22 . 
   While particular embodiments of the invention have been described with respect to its application, it will be understood by those skilled in the art that the invention is not limited by such application or embodiment or the particular components disclosed and described herein. It will be appreciated by those skilled in the art that other components that embody the principles of this invention and other applications therefor other than as described herein can be configured within the spirit and intent of this invention. The arrangement described herein is provided as only one example of an embodiment that incorporates and practices the principles of this invention. Other modifications and alterations are well within the knowledge of those skilled in the art and are to be included within the broad scope of the appended claims.