Patent Publication Number: US-2019186211-A1

Title: Pipe management system for negative angle drilling

Description:
TECHNICAL FIELD 
     The present disclosure is directed to a pipe management system and, more particularly, is directed to a pipe management system for negative angle drilling. 
     BACKGROUND 
     Excavating is employed to create mines, quarries, etc., in order to obtain desirable material such as ore or stone. In addition to using various types of heavy excavating equipment, drill-and-blast operations are commonly used to fragment material so it can be loaded and hauled. For example, overburden may need to be removed in order to reach the desirable material. Drill-and-blast operations may include drilling different types of blast holes, and some blast holes, for example pre-split holes, may require negative angle drilling. For example, pre-split holes are drilled in a “bench” of an excavation typically at an angle, referred to as a “negative angle,” that aligns with the slope of a “highwall” of the excavation, for example 5 to 15 degrees from a vertical direction. 
     Current drill-and-blast operations employ platform based drills to bore production holes, but not for boring pre-split holes which must be formed close to the highwall and substantially at the negative angle of the highwall in order to maintain the desired slope of the highwall as the depth of the bench is increased and the height of the highwall is increased. Since current platform based drills are not capable of drilling at the required negative angle of the highwall, the usual drill-and-blast operation will employ various dedicated pre-split drills that are usually boom mounted drills. Accordingly, a drill-and-blast operation in an open pit mine ordinarily may require a diverse fleet of drilling machines in order to form the different types of required holes. 
     During a drilling operation with a platform based drill, sections of drill pipe may be added to a drill column in order to increase the depth of drilling, and later removed as the drill column is disassembled. Various systems for managing drill pipe have been developed to manipulate and stabilize the drill pipe both during drilling and when adding or removing sections of drill pipe. Such drill pipe management systems typically include pipe handling equipment that requires substantial space, either externally of the mast or within the mast. Platform based drills capable of drilling blast holes at negative angles may enable drilling of all the various types of blast holes, including production and pre-split holes. Drilling negative angle holes with an open side of the mast inclined downwardly presents pipe management issues, particularly since gravity tends to work against pipe alignment as the mast tilts to negative angles. Current pipe management systems have not proven adequate for negative angle drilling. 
     There exists a need for a relatively simple and cost-effective pipe management system that occupies minimum space and effectively handles drill pipe as it is installed and removed from the drill column. It would be both beneficial and desirable to provide the mast of a drilling machine capable of negative angle drilling with a system that will both occupy minimum space and support negative angle drilling and that can hold and maintain drill pipe stable during both positive and negative angle drilling as well as vertical drilling. It would be both beneficial and desirable to provide a platform based drill that is capable of boring both vertical and positive angle production holes, is capable of boring negative angle pre-split holes, and includes support structure sufficient to accommodate pipe handling and management with a mast tilted at a negative angle. 
     One type of drilling machine used for drill and blast operations is disclosed in U.S. Pat. No. 5,931,238 issued to Gilmore et al. on Aug. 3, 1999 (“the &#39;238 patent”). The &#39;238 patent discloses a blast hole drill with a drill head mounted on a mast and a pipe carousel on the drill deck. A drill pipe handling system includes an arm assembly that transfers a drill pipe from a position on a pipe carousel to a position adjacent the mast. The arm assembly includes a single jaw pipe grasping assembly and a double jaw grasping assembly to hold a drill pipe as it is transferred by the arm assembly. 
     While the drilling machine of the &#39;238 patent may be useful for some drilling purposes, the &#39;238 patent does not disclose a pipe management system that supports negative angle drilling. In addition, the drill pipe handling system disclosed in the &#39;238 patent may be unduly complicated and adapted only to drilling machines where drill pipes are stored in horizontal position on the deck. Furthermore, the drill pipe handling system disclosed in the &#39;238 patent requires a substantial amount of space in order to manipulate between a pipe loading and pipe storage position. Accordingly, the system of the &#39;238 patent may not be suitable for drilling operations where the pipe carousel is positioned parallel to the mast. 
     The disclosed pipe management system for negative angle drilling of the present disclosure solves one or more of the problems set forth above and/or other problems of the prior art. 
     SUMMARY 
     In one aspect, the present disclosure is directed to a pipe handling system for a platform based drill comprising a drilling platform including a frame structure having a first end, a second end opposite the first end, and first and second opposite sides. The pipe handling system for a platform based drill may include a mast supported on a pivotal connection to the drilling platform permitting the mast to be pivotally adjusted to a negative drilling angle whereby an upper portion of the mast leans in a first direction extending toward the first end of the frame structure and away from the second end of the frame structure, the mast including a length direction and having an open cross-section with a concave side facing in the first direction, and a convex side facing in a second direction opposite to the first direction. The pipe handling system also may include a pipe handling unit mounted to the concave side of the mast and configured to support a drill pipe within the mast when the mast is pivotally adjusted to the negative drilling angle. 
     In another aspect, the present disclosure is directed to a pipe handling unit on a mast of a drilling platform and may include a mast having a length direction and a generally C-shaped cross section including a back element and first and second side elements partially enclosing a space within the mast, and including an open front. The pipe handling unit may be within the space and may include a first support linkage having first and second ends and pivotally attached at the first end to the first side element, and a second support linkage having first and second ends and pivotally attached at the first end to the second side element. 
     In yet another aspect, the present disclosure is directed to a method of managing drill pipe to support negative angle drilling with a drilling machine including a mast having a length direction and a generally C-shaped cross section with a back element and first and second side elements partially enclosing a space, and including an open front. The method may include pivoting the mast to a negative angle with the mast leaning from a vertical direction toward the direction of the open front and away from the back element. The method also may include moving in the length direction of the mast a pair of opposed arcuate support elements that are partially cylindrical about axes extending parallel to the length direction of the mast. The method also may include, while moving the pair of opposed arcuate support elements, maintaining the axes extending parallel to the length direction of the mast to engage and support a section of drill pipe. The method also may include moving the pair of opposed arcuate support elements again in the length direction of the mast. The method also may include, while moving the pair of opposed arcuate support elements again, maintaining the opposed arcuate support elements parallel to the length direction of the mast to release the section of drill pipe. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates an exemplary platform based drill supported on a bench adjacent a highwall of a mine or quarry; 
         FIG. 2  is a perspective view of a portion of a mast mounted at an end of a drilling platform of an exemplary drilling machine; 
         FIG. 3  is a cross section through a mast showing certain details of an exemplary drilling machine with a pipe rack carousel in a loading/unloading position; 
         FIG. 4  is a cross section through a mast showing certain details of an exemplary drilling machine with a pipe rack carousel in a position withdrawn from the drill column; 
         FIG. 5  is a perspective view of a pipe handling unit in a mast; 
         FIG. 6  is another perspective view of a pipe handling unit in a mast; 
         FIG. 7  is a perspective view of certain details of an exemplary platform based drill including a pipe handling unit engaging a drill pipe section; 
         FIG. 8  is another perspective view of certain details of an exemplary platform based drill including a pipe handling unit engaging a drill pipe section; 
         FIG. 9  is another perspective view of certain details of an exemplary platform based drill including a pipe handling unit in disengaged position; and 
         FIG. 10  is a flow chart for an exemplary method according to the disclosure. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  illustrates certain aspects of the disclosure including one environment in which the disclosed machine may be employed and in which the disclosed method may be realized. The environment illustrated in  FIG. 1  is an excavation  10 , such as an open pit mine, quarry, etc. Such an excavation  10  commonly is formed by a combination of excavating and haulage techniques with various types of excavating machines and haulage vehicles, and drill-and-blast techniques using drilling machines and explosives. At the various levels reached in the course of formation of excavation  10 , the surface on which working equipment rests may be designated a bench  12 , and an adjacent wall of the excavation  10  rising above the bench  12  may be designated a highwall  14 . For purposes of this disclosure, bench  12  may be said to include a bench surface  13 , and highwall  14  may be said to include a face  15 . Face  15  typically may form an obtuse angle with bench surface  13 , and face  15  typically may slope at an acute angle α relative to vertical direction  17   
       FIG. 1  diagrammatically illustrates a stripped-down version of an embodiment of a platform based drill  16  showing only certain basic components. Platform based drill  16  may include a drilling platform  18  which in turn may include, among other things that are not illustrated in  FIG. 1 , a frame structure  20 . Drilling platform  18  may be supported and leveled, for example during a drilling operation, by a plurality of vertically adjustable supports, such as vertically adjustable support  22 . Platform based drill  16  also may include an operator station  28  which may house suitable controls and provide accommodations for personnel. Frame structure  20  may include a first end  32  and a second end  34  that is opposite first end  32 . In addition, frame structure  20  may include two opposite sides, the view in  FIG. 1  showing first side  33 . Platform based drill  16  also may include a mast  30  extending in a length direction A and supporting drilling equipment. 
     During the course of forming excavation  10 , bench  12  may be drilled and blasted in order to aid further removal of overburden and/or desirable ore material, for example. A common practice is to attempt to maintain face  15  of highwall  14  at an angle α relative to vertical direction  17  that is commensurate with maintaining stability of highwall  14 . For example, an exemplary angle α of slope for face  15  of highwall  14  may be on the order of 15 degrees from vertical direction  17 . Mast  30  may be supported and mounted for pivotal movement adjacent first end  32  and adjacent a lower portion  29  of mast  30 , permitting mast  30  to be pivotally adjusted to a negative drilling angle equivalent to angle α whereby an upper portion  31  of mast  30  leans in a first direction extending toward first end  32  of frame structure  20  and away from second end  34  of frame structure  20 . 
     As illustrated in  FIG. 1 , when mast  30  of platform based drill  16  is pivotally adjusted to the negative drilling angle α, mast  30  will be substantially parallel to face  15  of highwall  14 . In this orientation wherein mast  30  is substantially parallel to face  15  of highwall  14 , a series of pre-split holes, such as pre-split hole  36 , may be drilled at the negative angle of face  15  and closely adjacent highwall  14  in order to facilitate blasting and maintaining of face  15  of highwall  14  at a desirably stable angle as excavation proceeds. The term “negative angle” is employed to designate an angle of a mast  30  relative to a drilling platform  18  of a drilling machine wherein upper end  31  of the mast  30  leans away from, or outbound of, the drilling machine in a direction away from the non-drilling end (i.e., second end  34  in  FIG. 1 ) of the drilling platform  18 . Operator station  28  also may be located adjacent first end  32  and proximate mast  30  permitting a drilling operation and pivotal adjustment of mast  30  to be readily visible to an operator. 
       FIG. 2  is a perspective view of platform based drill  16  adjacent first end  32  of frame structure  20  with certain machine components removed in order to better illustrate certain other components.  FIG. 2  illustrates lower portion  29  of mast  30  and with mast  30  inclined from the vertical direction  17  ( FIG. 1 ) at a negative angle similar to that diagrammatically illustrated in  FIG. 1 . First end  32  may include an opening  48  within frame structure  20 . Mast  30  may extend within opening  48  and may be pivotally mounted, for example via a pivotal connection  49 , to frame structure  20 . Opening  48  may be centrally located between first side  33  and second side  35  of frame structure  20 . Mast  30  may include a baseplate  60 , and baseplate  60  may include a drill hole  61 . Mast  30  may be formed with a cross-section that may be characterized as an open cross-section with a concave side  38  facing in a first direction B extending toward first end  32  of frame structure  20  and away from second end  34  ( FIG. 1 ) of frame structure  20 , and an opposing convex side  39  facing in a second direction C opposite to first direction B. Pipe handling unit  70  is visible in  FIG. 2  mounted to concave side  38  of mast  30  and will be described in more detail subsequently. 
       FIGS. 3 and 4  illustrate cross-sections taken through an exemplary embodiment of mast  30  with the view in  FIGS. 3 and 4  being toward lower portion  29  ( FIGS. 1 and 2 ) and baseplate  60  of mast  30 . The open cross-sectional shape of mast  30  may include back element  42  and first and second side elements  44  and  46  which may diverge at a suitable angle from back element  42  as illustrated. Accordingly, the cross-section of mast  30  may include an open front  67  that may have a greater width than back element  42 . However, it is within the scope of this disclosure and it is contemplated that the open cross-section of mast  30  also may include a cross-section in which first and second side elements  44  and  46  do not diverge from back element  42 , but instead are perpendicular to back element  42  with the open front being of the same width as back element  42 . In addition, it is within the scope of this disclosure and it is contemplated that the open cross-section of mast  30  could be curved such that back element  42  and first and second side elements  44  and  46  form parts of the curve. In either alternative form, back element  42  and first and second side elements  44  and  46  may form elements of concave side  38  and convex side  39 , described previously, of mast  30 . The open cross-sectional shape of mast  30  also may be characterized as generally C-shaped inasmuch as, whether formed with diverging first and second side elements  44 ,  46 , with first and second side elements  44 ,  46  perpendicular to back element  42 , or entirely curved, the cross-sectional shape is similar to and resembles the letter “C.” 
     A pipe rack carousel  62  may be suitably mounted adjacent mast  30  and may include holders  63  for a plurality of drill pipe sections, such as drill pipe section  66  illustrated at drill column  65 . Pipe rack carousel  62  may be mounted to swing about a pivot rod  64 , for example mounted to baseplate  60  of mast  30 , to move a drill pipe section  66  to or from drill column  65 . Pipe rack carousel  62  is illustrated in  FIG. 3  as pivoted to a position for transferring a drill pipe section  66  to or from drill column  65 , while pipe rack carousel  62  is illustrated in  FIG. 4  as pivoted to a rest position withdrawn from drill column  65 . Pipe handling unit  70  is illustrated in  FIG. 3  engaging and holding a drill pipe section  66  at drill column  65 , while pipe handling unit  70  is illustrated in  FIG. 4  in a rest position withdrawn from contact with drill pipe section  66 . 
       FIGS. 5 and 6  are perspective views, each taken at a slightly different angle from the other, of pipe handling unit  70  mounted to concave side  38  of mast  30  and configured to support a drill pipe section  66  ( FIG. 3 , for example) within mast  30  when mast  30  is adjusted to any of a vertical position, a positive drilling angle, or a negative drilling angle. As described in connection with  FIGS. 3 and 4 , concave side  38  of mast  30  may include back element  42  and first and second side elements  44  and  46 . Pipe handling unit  70  may include a first support linkage  52 , and a second support linkage  56 . First support linkage  52  may be pivotally attached at its first end  53  to first side element  44 , and pivotally connected at its second end  54  to first arcuate support element  72 . Second support linkage  56  may be pivotally attached at its first end  57  to second side element  46 , and pivotally connected at its second end  55  to second arcuate support element  74 . As illustrated in  FIGS. 5 and 6 , first and second arcuate support elements  72 ,  74  each may be formed with partially cylindrical surfaces  68 ,  69 , that are cylindrical about axes extending parallel to the length direction A of mast  30 . 
     First support linkage  52  may include first arm  75  and second arm  76  spaced from each other along length direction A of mast  30  with first arm  75  being parallel to second arm  76 . Similarly, second support linkage  56  may include first arm  77  and second arm  78  spaced from each other along length direction A of mast  30  with first arm  77  being parallel to second arm  78 . A first mast bracket  79  and a first support element bracket  80  may be associated with first support linkage  52  and its first and second arms  75 ,  76 . Similarly, a second mast bracket  81  and a second support element bracket  82  may be associated with second support linkage  56  and its first and second arms  77 ,  78 . First mast bracket  79  may be fixed to first side element  44  on concave side  38  of mast  30 . In like manner, second mast bracket  81  may be fixed to second side element  46 . First support element bracket  80  may be fixed to first arcuate support element  72 , and second support element bracket  82  may be fixed to second arcuate support element  74 . First and second arms  75 ,  76  of first support linkage  52  may be pivotally connected to first mast bracket  79  via pivotal connections  83 ,  84  at first end  53  of first support linkage  52 , and may be pivotally attached to first support element bracket  80  via pivotal connections  87 ,  88  at second end  54  of first support linkage  52 . First and second arms  77 ,  78  of second support linkage  56  may be pivotally connected to second mast bracket  81  via pivotal connections  85 ,  86  at first end  57  of second support linkage  56 , and may be pivotally attached to second support element bracket  82  via pivotal connections  89 ,  90  at second end  55  of second support linkage  56 . 
     One of first and second arms  75 ,  76 , for example second arm  76 , of first support linkage  52 , and one of first and second arms  77 ,  78 , for example second arm  78 , of second support linkage  56 , may include an aperture  97 ,  98  for connection of a suitable actuator, for example a hydraulic cylinder. First and second actuators  40 ,  41 , not shown in  FIGS. 5 and 6  but visible in  FIGS. 3 and 4 , may be connected between one of first and second side elements  44 ,  46  and one of apertures  97 ,  98  in one of second arms  76 ,  78  for pivoting first and second support linkages  52 ,  56 . 
     As will be apparent from the foregoing description and  FIGS. 5 and 6 , for example, first and second arms  75 ,  76  of first support linkage  52  along with first mast bracket  79  and first support element bracket  80  form a parallelogram linkage assembly. Accordingly, upon movement of first and second arms  75 ,  76  of first support linkage  52  via first actuator  40  in length direction A of mast  30  about pivotal connections  83 ,  84 , the parallelogram arrangement will ensure that first arcuate support element  72  will maintain an orientation with the axis of partially cylindrical surface  68  of first arcuate support element  72  parallel to length direction A of mast  30 . In like manner, upon movement of first and second arms  77 ,  78  of second support linkage  56  via second actuator  41  in length direction A of mast  30  about pivotal connections  85 ,  86 , the parallelogram arrangement will ensure that second arcuate support element  74  will maintain an orientation with the axis of partially cylindrical surface  69  of second arcuate support element  74  parallel to length direction A of mast  30 . 
     As more clearly illustrated in  FIG. 6 , first arm  75  of first support linkage  52  may be pivotally attached to first mast bracket  79  at two laterally spaced and coincident pivotal connections. Accordingly, first arm  75  may be attached to first mast bracket  79  at pivotal connection  83  as previously described, and also to adjacent pivotal connection  93  via branch element  94  fixed to first arm  75 . In this embodiment, pivotal connection  84  for second arm  76  thus is a third pivotal connection for first support linkage  52  that is between the two laterally spaced and coincident pivotal connections  83 ,  93  and spaced from the two laterally spaced and coincident pivotal connections  83 ,  93  in length direction A of mast  30 . Similarly, first arm  77  of second support linkage  56  may be pivotally attached to second mast bracket  81  at two laterally spaced and coincident pivotal connections. Accordingly, first arm  77  may be attached to second mast bracket  81  at pivotal connection  85  as previously described, and also to adjacent pivotal connection  95  via branch element  96  fixed to first arm  77 . Pivotal connection  86  for second arm  78  thus is a third pivotal connection for second support linkage  56  that is between the two laterally spaced and coincident pivotal connections  85 ,  95  and spaced from the two laterally spaced and coincident pivotal connections  85 ,  95  in length direction A of mast  30 . 
       FIGS. 7-9  are perspective views of mast  30  and associated features including pipe rack carousel  62  described in connection with  FIGS. 3 and 4 , and including deck wrench  58  employed to hold a drill pipe section  66  against rotation during addition or removal of another drill pipe section  66 , and to support a drill pipe section that is disengaged from the gearbox (not shown) or drill column  65 . In  FIG. 7 , first and second support linkages  52 ,  56  are illustrated in a position in which first and second arcuate support elements  72 ,  74  (only second arcuate support element  74  being visible in  FIG. 7 ) engage and support a drill pipe section  66  as it is being transferred to drill column  65  or removed from drill column  65  and loaded onto pipe rack carousel  62 . 
       FIG. 8  shows pipe rack carousel  62  pivoted away from drill column  65  and illustrates first and second support linkages  52 ,  56  in a position in which first and second arcuate support elements  72 ,  74  engage and support a drill pipe section  66  with an attached drill bit  50 .  FIG. 9  illustrates first and second support linkages  52 ,  56  in a disengaged position pivoted away from drill column  65  with first and second arcuate support elements  72 ,  74  adjacent side elements  44 ,  46  of mast  30 . It is readily apparent from viewing  FIG. 9  together with  FIG. 8 , for example, that first and second arcuate support elements  72 ,  74  remain in positions parallel to the length direction A of mast  30  at both the engagement position with a drill pipe section  66  illustrated in  FIG. 8 , and in the fully disengaged position illustrated in  FIG. 9 . 
     INDUSTRIAL APPLICABILITY 
     The disclosed pipe management system for negative angle drilling facilitates handling of drilling pipe in a platform based drill where a mast is capable of being pivoted to a negative angle for negative angle drilling. The disclosed open cross-section mast having the concave open side facing in the same direction that the mast leans during negative angle drilling is made more feasible and cost effective by being provided with the disclosed drill pipe handling system. While gravity tends to work with drill pipe when drilling vertically, gravity works against drill pipe during negative angle drilling by pulling it toward the open or concave side of the mast, particularly during loading drill pipe sections into the drill column and removing drill pipe sections from the drill column. 
     Advantageously, the disclosed pipe management system for negative angle drilling operates to fully support drill pipe and maintain it in alignment with the drill hole associated with the mast. In addition, the disclosed pipe management system for negative angle drilling facilitates loading and unloading drill pipe sections between the drill column and the carousel. The pipe handling unit is housed entirely within the mast itself and occupies a minimum of space thereby avoiding interference with other components associated with the mast. Also, the movement of the pipe handling unit along the length direction of the mast via a parallelogram linkage assembly involves a minimum of movement from a position engaging a drill pipe section to a disengaged position, and therefore requires less space for movement. 
     An exemplary method according to the disclosure of managing drill pipe to support negative angle drilling with a drilling machine including a mast having a length direction and a generally C-shaped cross section with a back element and first and second side elements partially enclosing a space and including an open front, is diagrammatically illustrated via flowchart  100  in  FIG. 10 . Referring to  FIG. 10 , the exemplary method may include, at box  102 , pivoting the mast to a negative angle with the mast leaning from a vertical direction toward the direction of the open front and away from the back element. 
     At box  104 , a pair of opposed arcuate support elements that are partially cylindrical about axes extending parallel to the length direction of the mast are moved in the length direction of the mast. At box  106 , while moving the pair of opposed arcuate support elements, the axes are maintained extending parallel to the length direction of the mast to engage and support a section of drill pipe. At box  108 , the pair of opposed arcuate support elements again are moved in the length direction of the mast. At box  110 , while moving the pair of opposed arcuate support elements again, the axes are maintained extending parallel to the length direction of the mast to release the section of drill pipe. 
     For each moving of the pair of opposed arcuate support elements in the length direction of the mast, at box  112 , parallel arms for each of the pair of opposed arcuate support elements may be moved, the parallel arms being attached to one of the first and second side elements of the mast at a first end of the arms and connected to the arcuate support elements at a second end of the arms. The mast may include a baseplate with a drill hole, and, at box  114 , the section of drill pipe may be supported and maintained in alignment with the drill hole with the pair of opposed arcuate support elements. At box  116 , each moving of the pair of opposed arcuate support elements in the length direction of the mast to support and release the section of drill pipe may be coordinated with loading and unloading the section of drill pipe from a pipe rack carousel and with operation of a deck wrench. 
     Use of the terms “substantially” and “generally” within this specification, (e.g., substantially parallel, generally C-shaped, etc.) is intended to take into account those situations wherein the components and relationships referenced may deviate from an absolute by normal and accepted convention, industry manufacturing tolerances, or industry field tolerances. 
     It will be apparent to those skilled in the art that various modifications and variations can be made in the disclosed pipe management system for negative angle drilling without departing from the scope of the disclosure. Other embodiments of the disclosed pipe management system for negative angle drilling will be apparent to those skilled in the art from consideration of the specification. It is intended that the specification and examples be considered as exemplary only, with a true scope of the disclosure being indicated by the following claims and their equivalents.