Patent Publication Number: US-2010117282-A1

Title: Vise for a directional drilling machine

Description:
This application is being filed on 17 Jan. 2008, as a PCT International Patent application in the name of Vermeer Manufacturing Company, a U.S. national corporation, applicant for the designation of all countries except the US, and Peter C. Rozendaal, a citizen of the U.S., applicant for the designation of the US only, and claims priority to U.S. Provisional Patent Application Ser. No. 60/885,823, filed Jan. 19, 2007. Such provisional application is incorporated herein by reference. 
    
    
     FIELD OF TECHNOLOGY 
     The present invention relates generally to horizontal underground drilling machines. More particularly, the present invention relates to a vise apparatus used with threaded drill pipe. 
     BACKGROUND OF THE INVENTION 
     A variety of vise arrangements for use with horizontal drilling machines exist, including vise jaws having two opposing jaw halves. The jaws are arranged to clamp onto a pipe to either thread or unthread the pipe to another pipe. The vise jaws are clamped to the pipe by hydraulic actuators or cylinders that provide engagement or clamping force. 
     In conventional jaw designs, the maximum torque applied to the gripped pipe, without relative movement between the pipe and the jaws, is directly proportional to the force applied by hydraulic cylinders. The torque effected on the pipe provides torque holding capacity at a threaded connection between the two pipes. Larger pipes require greater torque to effect sufficient torque holding capacity. The drill pipe used in conjunction with the conventional jaw design is limited, typically ranging from 1½ to 3½ inches in outer diameter. 
     Drilling machines utilizing much larger drill pipe and drill tools are becoming available for use in the industry. For example, some drill pipe can range up to about 8 inches in outer diameter. A design that provides greater engagement force to effect sufficient torque holding capacity at a threaded connection between larger pipes is needed. 
     Conventional designs incorporating a latch door arrangement for use on vertical drilling machines have been used to provide sufficient engagement force on larger diameter pipes. These designs, however, are particular to vertical drilling rigs wherein there is ample space in the vicinity of the latch door vise arrangement. A vise apparatus that accommodates large pipe is needed for use on a horizontal drilling machine where space between the ground and a ground support is limited. 
     SUMMARY OF THE INVENTION 
     The disclosure describes a vise apparatus for use on a horizontal drilling machine. The vise apparatus includes a vise die assembly that is pivotally mounted to tong heads of a vise mechanism. The vise die assembly includes a mounting block having a front face and a second face that are oppositely disposed on the mounting block. A vise die having a gripping surface is mounted to each of the first face and the second face of the vise die assembly. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings are included to provide a further understanding of the present invention and are incorporated in and constitute part of this specification. The drawings illustrate exemplary embodiments of the present invention and together with the description serve to further explain the principles of the invention, wherein: 
         FIG. 1  is a front perspective view of a rack assembly for use on a horizontal directional drilling machine in accordance with the principles of this disclosure; 
         FIG. 2  is a side view of the rack assembly of  FIG. 1 ; 
         FIG. 3  is a front view of a vise assembly as shown in  FIG. 1 ; 
         FIG. 4  is a front perspective view of a vise die assembly; and 
         FIG. 5  is a enlarged fragmentary front view of the vise assembly of  FIG. 3 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     With reference now to the various figures in which identical elements are numbered identically throughout, a description of various exemplary aspects of the present invention will now be provided. 
     I. General Operation of the Vise Apparatus in Horizontal Drilling 
     The present invention is directed to a vise apparatus for use on horizontal drilling machines. Horizontal drilling machines typically comprise a rotational drive mechanism, a longitudinal drive mechanism, a vise apparatus, a ground support, and a drill pipe storage/transfer apparatus. The drilling process involves threading together lengths of threaded drill pipe to form a drill string extending from the drilling machine though a bored hole and terminating at a drill bit assembly. The drill string transfers rotational torque and longitudinal thrust from the drive mechanisms to the drill bit assembly. 
     To begin drilling a bore, the drill bit assembly is located near the ground support of the horizontal drilling machine and is attached to a drill string. The drill string initially comprises a first drill pipe that is attached to the rotational drive mechanism and longitudinal drive mechanism. The rotational drive mechanism and longitudinal drive mechanism are typically located at an end opposite the bore location. The first step of boring is thus to attach the drill bit assembly to the first drill pipe. 
     The drill bit assembly is generally larger in diameter than the drill pipe. Conventional designs require that the drill bit assembly be connected to the first drill pipe by manual wrenching. It would be beneficial to connect the drill bit assembly to the first drill pipe by inserting the drill bit assembly into a vise apparatus to aid in the preparations of drilling the bore. The vise apparatus according to the principles of this disclosure provide such utility in an open dimension or adaptable configuration that permits drill bit assemblies to be inserted and clamped into the vise apparatus, as will be described later in detail. 
     Once the drill bit assembly is connected to the first drill pipe, the drill string (the drill bit assembly and the first drill pipe) are rotated and propelled into the ground. As the drill string progresses, a second drill pipe is removed from the storage/transfer apparatus and positioned in alignment with the drill string. Typically the storage/transfer apparatus comprises a magazine wherein the longitudinal axis of the stored drill pipe is parallel to the drill string. Once positioned, the second drill pipe is threaded to the drill string. The process is repeated to extend the length of the bored hole. 
     The drill string is subjected to high torque loads. In directionally controlled applications, the drill string is also subjected to significant bending loads. Proper mating of threaded joints between the drill pipes is critical to the performance of the drill string. To properly “make-up” the threaded joints, significant torque loads must be applied to the outer diameters of the drill pipes. 
     When the bored hole is as long as desired, the drill bit assembly is often changed; or, for a variety of reasons, the drill string is removed from the bored hole. In the latter case, for example, the fixed lengths of drill pipes are subsequently pulled out of the bored hole, unthreaded, and transferred back to storage. Removal of the drill string involves “break-out” of the threaded connections or joints. The break-out torque necessary to break the threaded connection is generally similar or greater than the torque required to initially make-up the threaded joint. 
     Vise configurations of conventional designs involve a lower clamp, an upper clamp, and a driver. The driver is a part of the drilling machine that is longitudinally propelled, typically along a track, and has a male threaded end, or pin end. In make-up operations, the driver advances the drill string along a longitudinal axis until the driver reaches an end of the track. At that point, the lower clamp secures the drill string in a stationary position. The driver rotationally reverses to unthread from a box end (or female threaded area) of the drill string while reversing longitudinally along the track. A new drill pipe is positioned within a loading area either manually or with a rod loader mechanism. The driver changes rotational direction and begins to again longitudinally advance along the track toward the new drill pipe. The pin end of the driver engages a box end (i.e. female threaded-end) of the new drill pipe. As the driver continues to advance longitudinally, a pin end of the new drill pipe engages the box end of the clamped drill string and repeats the process. 
     As a wider variety of tools used in horizontal drilling become available, the need to adapt the vise apparatus to accommodate the various shapes and sizes of tools becomes more important. For instance, some applications insert a relatively short pipe section having the same diameter as the final bored hole into a section of the bored hole to stabilize the soil. This pipe section is commonly known as a slip lining. Because the slip lining has a diameter larger than the diameter of the drill string, the slip lining is typically difficult or impossible to fit within the vise apparatus of conventional designs. 
     Another consideration with regards horizontal drilling concerns the overall arrangement of the drilling machine and vise apparatus in relation to ground. Placement of the drilling machine such that the vise apparatus is as close to the entrance of the bored hole as possible is important to provide maximum support of the drill string. Thus, the opening diameter and the overall envelope of the vise apparatus must ideally accommodate installation of slip lining having a large diameter, yet must be sized for placement that provides drill string support. The vise apparatus according to the principles of this disclosure provides such a feature wherein the design minimizes the cross-sectional size of the overall apparatus assembly while maximizing the opening diameter, as will be described later in detail. 
     In general, the horizontal drilling machine as described by this disclosure comprises of a main chassis assembly having a ground engaging device, tracks, an engine and hydraulic drive unit, an operator&#39;s station, and a main frame. The main chassis assembly of the horizontal drilling machine generally comprises a rack assembly having some type of rod loading and handling device, or pipe magazine. Theses devices ranges from basic transfer mechanisms such as various types of hoists or slings to highly specialized mechanized units specifically designed to manipulate specific rods. 
     Referring to  FIGS. 1 and 2 , a rack assembly  10 , (shown without a pipe magazine) is illustrated. The rack assembly  10  is mounted to a chassis assembly (not shown) of a horizontal drilling machine. The rack assembly  10  comprises a vise apparatus  100 . The vise apparatus  100  according to the principles disclosed could be applied to a variety of machines that utilize clamping devices. 
       FIG. 2  is a side view of the rack assembly  10  and illustrates components that manipulate a drill rod, tube or pipe  36 . The rack assembly  10  includes a front centering assembly  20 , the vise apparatus  100 , and a spindle  30  coupled to a rotational gearbox  40 . The rotational gearbox  40  is mounted to a thrust frame  50  onto which thrust motors  60  are mounted. The trust motors  60  rotationally drive pinion gears  62  that engage rack gears  70 . The resulting rack and pinion gear drive  65  propels the thrust frame  50  forward and backward along rack rails  90  of the rack assembly  10 . The thrust frame  50  therein propels the spindle  30  and the drill string  80  longitudinally, while at the same time the rotational gearbox  40  rotates the drill string  80 . In the alternative, the rack and pinion gear drive  65  may be replaced by cylinder and chain mechanisms or straight cylinder mechanisms to provide longitudinal force to the drill string  80 . 
     The vise apparatus  100  further includes a rotating vise assembly  200 , a fixed vise assembly  300 , a longitudinal positioner  400 , and a rotational vise driver  500 . These components function to operate drilling processes such as, for example, starting and extending the drill string, known as performing the pilot bore process, and retracting the drill string, known as pull-back. 
     II. Operation of the Vise Apparatus: Starting and Extending the Drill String 
     In general, when starting a drilling operation, the drill string will initially consist of only one drill pipe and a drill head assembly. The drill head assembly typically comprises a variety of components such as a drill bit and a sonde housing to hold a radio transmitting device that locates and controls the drill head assembly during the drilling process. 
     Referring again to  FIG. 1 , the drill head assembly (not shown) may be supported by the front centering assembly  20  and the fixed vise assembly  300 , or it may be positioned just beyond the front centering assembly  20 . The front centering assembly  20  includes a drill pipe centering support  22  that may be adjusted vertically to align a centerline  84  of a drill string  80  with an axis  32  of the spindle  30  (shown in  FIG. 2 ). 
     A single drill pipe (not shown) moves from a drill pipe storage location into a drill pipe load area  44 . In the drill pipe load area  44 , the drill pipe is positioned in an axial orientation defined by the longitudinal axis of the spindle  30 . The load area  44  lies generally between a rear plane  202  of the rotating vise assembly  200  and a first end  33  of the spindle  30 . The load area  44  is effectively open when the thrust frame  50  has been moved back along the rack rails  90  such that the rotational gearbox  40  and spindle  30  are fully retracted. In this loading position, the distance between the rear vise plane  202  and the first end  33  of the spindle  30  is greater than the length of the drill pipe (not shown). 
     With the thrust frame  50  in the loading position, the first drill pipe is positioned in the drill pipe load area  44  and held by the drill pipe transfer mechanism (not shown). The rotational gearbox  40  rotates the spindle  30  while the spindle  30  is propelled longitudinally by the thrust frame  50 . As the spindle  30  propels forward, a threaded male end or pin end  34  of the spindle  30  engages female threads of the drill pipe (not shown). 
     If the fixed vise assembly  300  supports the drill head assembly, the drill pipe and the spindle  30  are propelled longitudinally until a threaded front end of this first drill pipe is inserted into the drill head assembly. The rotational gearbox  40  continues to rotate the first drill pipe to thread the first drill pipe to the drill head assembly. The fixed vise assembly  300  holds the drill head assembly stationary while the rotational gearbox  40  controls the level of torque applied to properly make-up the threaded joint between the drill head assembly and the first drill pipe. The same level of torque is, at the same time, applied between the first drill pipe and the spindle  30 . 
     If the drill head assembly is out front of the front centering assembly  20 , the first drill pipe is propelled forward until a front portion extends into the fixed vise assembly  300 . The fixed vise assembly  300  grips the first drill pipe and prevents the first drill pipe from rotating so that proper torque is applied to the joint between the first drill pipe and the spindle  30 . Once the joint is properly torqued, the fixed vise assembly  300  releases the first drill pipe and the first drill pipe is propelled through the front centering assembly  20  where the drill head assembly can be installed. The drill head assembly in this case is typically torqued with some form of hand held wrench. 
     After installing the drill head assembly to the first drill pipe (now referred to as a drill string), the pilot bore process is performed by longitudinally propelling the drill string forward until the joint between the spindle and the drill pipe is located near a middle location  302  between the fixed vise assembly  300  and the rotating vise assembly  200 . The fixed vise assembly  300  securely clamps the drill string and the spindle  30  is rotated in a reverse direction while being propelled backward along the rack rails  90  so that another drill pipe can be positioning in the drill pipe load area  44 . The process of propelling the rotating spindle forward and applying proper torque between the joints of the drill pipes is repeated to effectively extend the drill string. The drill string is extended until the underground drill path reaches a desired distance. Thus the main function of the fixed vise assembly  300  of the vise apparatus  100  in performing the pilot bore process is to hold the drill string in a stationary position while a new drill pipe is positioned and threaded into the drill string. 
     III. Operation of the Vise Apparatus: Retracting the Drill String 
     The pull-back process involves pulling the drill string back through the pilot bore. The thrust frame  50  is reversed in the longitudinal direction to pull the drill string back until a first joint between the last added drill pipe and the remainder of the drill string is located at the middle location  302 . At this position, the fixed vise assembly  300  clamps the drill string. The rotating vise assembly  200  rotates clockwise in an opened, unclamped position, clamps the last added drill pipe at a first location, and rotates counterclockwise to break the joint between the last added drill pipe and the drill string. The rotating vise assembly  200  then opens to release the last added drill pipe. The rotational gearbox  40  reverse rotates while the thrust frame moves back to separate the last added drill pipe from the drill string. Once the last added drill pipe is separated from the drill string the rotating vise assembly  200  clamps the last added drill pipe at a second location. The spindle  30  reverse rotates to break a second joint between the spindle  30  and the last added drill pipe. Once that joint is broken and the last added drill pipe is separated from the spindle  30 , the rotating vise assembly  200  opens and the drill pipe is removed. To continue the process, the spindle  30  translates forward to mate with the drill string still clamped by the fixed vise assembly  300 . The spindle is threaded to the drill string with the proper torque. The fixed vise assembly  300  opens and the drill string is pulled backwards to repeat the break-out procedure. 
     Thus, the functions of the vise apparatus  100  in the pull-back process include breaking the first joint between the drill string and the last added drill pipe, holding the drill pipe while the second joint between the drill pipe and spindle is broken, and holding the drill string while the spindle is re-attached to repeat the break-out procedure. 
     As the vise apparatus  100  has been described in detail in U.S. Pat. No. 6,880,430, assigned to the assignee of the present invention and incorporated herein by reference, further description of the vise apparatus  100  will not be provided herein. 
     IV. Structural Description of the Vise Assembly 
     Referring now to  FIG. 3 , the fixed vise assembly  300  will be described. Since similar structural elements associated with the present invention are found in both the rotating vise assembly  200  and the fixed vise assembly  300  of the vise apparatus  100 , the following description will be made with reference to the fixed vise assembly  300  only. 
     The fixed vise assembly  300  includes a base frame  304 , having a plurality of mounts  306  for mounting the fixed vise assembly  300  to the rack assembly  10 . The fixed vise assembly  300  further includes a fixed vise mechanism, generally designated  308 . The fixed vise mechanism  308  includes first and second arm members  310 ,  312 , first and second actuators  314 ,  316 , which effectuate the opening and closing of the first and second arm members  310 ,  312 , and first and second tong heads  318 ,  320 . While the first and second actuators  314 ,  316  have been shown in the figures as being hydraulic cylinders, it will be understood by those skilled in the art after reviewing the present disclosure that the scope of the present invention is not limited to the use of hydraulic cylinders since various actuators could be used in association with the present invention. 
     The first arm member  310  is pivotally connected to the second arm member  312  and the base frame  304  at pivot  321 . The pivot  321  provides for a scissor type motion between the first arm member  310  and the second arm member  312 . However, while the arm members  310 ,  312  have been shown in  FIG. 3  as being “scissor” members with a pivotal connection, it will be understood by those skilled in the art after reviewing the present disclosure that the scope of the present invention is not limited to the arm members being pivotally connected. 
     The first actuator  314  includes a rod end  322 , which is pivotally connected to the first arm member  310  at rod pivot  324 , and a cylinder end  326 , which is pivotally connected to the second tong head  320  at cylinder pivot  328 . The second actuator  316  includes a rod end  330 , which is pivotally connected to the second arm member  312  at rod pivot  332 , and a cylinder end  334 , which is pivotally connected to the first tong head  318  at cylinder pivot  336 . 
     The first arm member  310  is pivotally connected to the first tong head  318  at tong head pivot  338 , while the second arm member  312  is pivotally connected to the second tong head  320  at tong head pivot  340 . These pivotal connections (i.e. pivot  321 , rod pivots  324 ,  332 , cylinder pivots  328 ,  336 , and tong head pivots  338 ,  340 ) and the first and second actuators  314 ,  316  effectuate the actuation of the vise mechanism  308 . For example, when the rod ends  322 ,  330  of the first and second actuators  314 ,  316  are extended from the cylinder ends  326 ,  334 , the first and second tong heads  318 ,  320  of the vise mechanism  308  approach each other (“close”) defining an opening or pocket  342 . In accord with the principles of this disclosure, the pocket  342  of the vise mechanism  308  is adapted to accommodate a variety of sized drill pipe or drill bit assemblies. When the rod ends  322 ,  330  of the first and second actuators  314 ,  316  are retracted toward the cylinder ends  326 ,  334 , the first and second tong heads  318 ,  320  of the vise mechanism  308  separate from each other, thereby opening the pocket  342 . 
     Referring now to  FIG. 4 , a vise die assembly  344  will now be described. The vise die assembly  344  includes a mounting block  346  having a first face  348  and a second face  350 , with the second face  350  being about parallel to the first face  348 . A groove or slot  352  is defined within each of the first and second faces  348 ,  350 . In the preferred embodiment, the groove  352  extends the length of the faces  348 ,  350  and is adapted to be of a dovetail configuration. However, it will be understood by those skilled in the art after reviewing the present disclosure that the scope of the present invention is not limited to the groove  352  extending the length of the faces  348 ,  350  or having a dovetail configuration. The mounting block  346  further defines a pivot hole  354  that extends through the length of the mounting block  346  in a direction parallel to the first and second faces  348 ,  350 . It will be understood, however, by those skilled in the art that the scope of the present invention is not limited to the pivot hole extending through the length of the mounting block  346 . A vise die, gripping member, or jaw  356 , having a gripping surface  358  is disposed within the groove  352  of the first face  348  and the groove  352  of the second face  350  of the mounting block  346 . The jaws  356  are arranged in the grooves  352  such that the gripping surface  358  of the jaw  356  in the first face  348  faces oppositely the gripping surface  358  of the jaw  356  in the second face  350 . As the gripping surface  358  of jaws  356  are used to contact a drill pipe or drill bit, the jaws  356  are made of steel that is hardened to a desired hardness in order to reduce the wear of the gripping surface. 
     Referring now to  FIG. 5 , at least one vise die assembly  344  is located on each of the tong heads  318 ,  320 . Since each tong head  318 ,  320  includes a vise die assembly  344 , the following description will be made with reference to the first tong head  318  only. It will be understood, however, that this description is also applicable to the vise die assembly  344  associated with the second tong head  320 . The first tong head  318  includes a pivot hole  360  and at least one pivot stop  362 . In the preferred embodiment, however, there are two pivot stops  362  per tong head  318 ,  320 . The vise die assembly  344  is pivotally mounted to the first tong head  318  by a pivot pin  364  that extends through the pivot hole  360  in the first tong head  318  and the pivot hole  354  in the mounting block  346 . In the depicted embodiment, the vise die assembly  344  is mounted between the pair of pivot stops  362  such that the pivot stops  362  cooperate to limit the range of clockwise and counterclockwise pivotal motion of the vise die assembly  344  with respect to the first tong head  318 . The vise die assembly  344  is pivotally mounted to the first tong head  318  such that one of the gripping surfaces  358  of the jaws  356  is facing toward the pocket  342  when the vise mechanism is in the closed position. The pivotal mounting of the vise die assembly  344  allows for better alignment between the gripping surfaces  358  and the drill pipe in the pocket  342 . Proper alignment between the gripping surfaces  358  and the drill pipe is important in order to ensure a more consistent coefficient of friction between the gripping surfaces  358  and the drill pipe. 
     Over time and frequent use, the coefficient of friction between the gripping surfaces  358  and the drill pipe may decrease. This reduction in the coefficient of friction is caused by wear to the gripping surfaces  358 . As the coefficient of friction between the gripping surfaces  358  and the drill pipe deceases, the drill pipe will begin to “slip” in the vise mechanism  308 . If this slippage occurs, it is usually necessary to replace the vise die, which could create a commercial loss due to machine downtime if another vise die is not readily available. The vise die assembly  344  in the present invention, however, has two gripping surfaces  358  per vise die assembly  344 . Therefore, if the drill pipe in the vise mechanism begins to slip due to wear of the gripping surface  358  of the jaw  356  of the first face  348 , the vise die assembly  344  can be disassembled from the tong head  318 ,  320  [e.g. by removing the pivot pin  364 ] and inverted and reassembled such that the gripping surface  358  of the jaw  356  of the second face  348  is now facing the pocket  342  when the vise mechanism  308  is in the closed position. By incorporating two gripping surfaces  358  per vise die assembly  344 , the present invention would reduce machine downtime due to wear of the gripping surfaces  358 . 
     The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.