Patent ID: 12258818

DESCRIPTION OF EMBODIMENTS

The following description and the drawings sufficiently illustrate specific embodiments to enable those skilled in the art to practice them. Other embodiments may incorporate structural, logical, electrical, process, and other changes. Portions and features of some embodiments may be included in, or substituted for, those of other embodiments. Embodiments set forth in the claims encompass all available equivalents of those claims.

FIG.1shows an example of a directional drill100. The directional drill100includes a drill stem110including an attached sonde housing, and a drill head112for 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. A directional drill vice120is further shown at a front end of the directional drill100. Additional aspects of the directional drill vice120are described in more detail below.

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 movable track. 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.3shows a front view of an example drill stem vice120. The drill stem vice120includes a base302. A first gripping device310and a second gripping device330are shown coupled to the base302. The first gripping device310is shown with a first pair of actuators312,314. In operation, each of the first pair of actuators312,314forces a respective gripping jaw into engagement with a surface of a drill stem segment, or removes the respective gripping jaws from contact with the drill stem segment. This operation will be shown in more detail in subsequent figures.

FIG.4shows a rear view of the drill stem vice120. In this view, the second gripping device330is shown to include a second pair of actuators332,334. Similar to the first gripping device310, in operation, each of the second pair of actuators332,334forces a respective gripping jaw into engagement with a surface of a drill stem segment, or removes the respective gripping jaws from contact with the drill stem segment.

Although pairs of actuators are shown associated with both the first gripping device310and the second gripping device330, the invention is not so limited. In other examples, a single actuator may operate the first gripping device310, and a single actuator may operate the second gripping device330. In the example shown, the actuators are hydraulic cylinders, however the invention is not so limited. In other examples, other types of actuators, such as solenoids, stepper motors, etc. may be used.

In one example, the second gripping device330is rigidly fixed to the base302, while the first gripping device310is mounted to the base302through a rotation joint306. As shown, the rotation joint306has an axis of rotation that is concentric with a drill string axis304. A rotation actuator308is shown coupled between the base302and the first gripping device310to provide controlled rotation about the rotation joint306.

In a drill stem removal operation, a drill string, composed of multiple drill stem segments, may be located within both the first gripping device310and the second gripping device330along drill string axis304. A connection interface between two adjacent drill stem segments may be aligned between the first gripping device310and the second gripping device330. The rigidly connected second gripping device330may then hold one drill stem segment in place, while the entire first gripping device310is rotated about the rotation joint306, while gripping the adjacent drill stem segment. This rotation of the first gripping device310and the adjacent drill stem segment may loosen, or “break” loose a threaded joint between the adjacent drill stem segments. Once the threaded joint is loosened, the drill head142fromFIGS.1and2may complete the unscrewing process of the drill stem segment and replace the removed drill stem segment into the drill stem magazine144.

In a drill stem extension operation, the first gripping device310may grip an end of the drill stem, while the drill head142fromFIGS.1and2, fetches a new drill stem segment for installation into the drill string. The drill head142may screw the new drill stem segment into the drill string while the first gripping device310holds the drill stem secure. Once the new drill stem segment is installed, the first gripping device310may be released, and the drill stem may be extended in a normal drilling operation until the next new drill stem segment is needed.

The example drill stem vice120shown inFIGS.3and4further includes a slot309to permit sideways loading and unloading of drill stem segments into and out of the drill stem vice120.FIGS.3and4show the slot309extending adjacent to only the second gripping device330. In one example, drill stem segments are only loaded or unloaded from the second gripping device330, and sideways access to the first gripping device310is not needed. In the examples shown, the slot309is oriented upward to permit vertical loading into the drill stem vice120, however the invention is not so limited. Other orientations of the slot309, such as sideways, left, right, downward, or at other angles are also within the scope of the invention.

Using the vertical orientation of the slot309shown inFIGS.3and4, and the drill stem magazine144being located substantially over a center of the directional drill100, the directional drill100becomes more stable. Weight from the drill stem magazine144and the drill stem segments is more centered over the directional drill100. Further, using the vertically oriented slot309and drill stem magazine144configuration shown, a more simple mechanism may be used to load and unload drill stem segments. In one example, drill stem segments may be loaded and unloaded in a linear range of motion, which reduces complexity of loading an unloading mechanisms, when compared to multiple translations and multiple directions of movement required in other existing directional drill configurations.

In one example a new drill stem segment may be directly loaded sideways into the second gripping device330of the drill stem vice120. The second gripping device330may then clamp onto the new drill stem segment and hold it secure while the drill head142screws into the new drill stem segment. In other configurations without a slot309, a new drill stem segment cannot be gripped immediately after being placed in line with the drill stem axis304. In such configurations, a transfer system such as the first linear actuator210and the second linear actuator220, must be made more robust, to hold the new drill stem segment while the drill head142screws into the new drill stem segment. Configurations with a slot309allow the complexity of the transfer system such as the first linear actuator210and the second linear actuator220to be reduced, thus reducing cost and improving reliability of the directional drill100.

FIG.5shows a cross section of the first gripping device310of the drill stem vice120according to one example. In the example ofFIG.5, a first jaw carrier316and a second jaw carrier318are shown. A pair of gripping jaws is shown in place within the first jaw carrier316and the second jaw carrier318. A first jaw313is shown housed within the first jaw carrier316, and a second jaw315is shown housed within the second jaw carrier318. In selected examples, having separate jaws313,315housed within jaw carriers316,318provides an advantage of replace ability. If one or both of the jaws313,315becomes unduly worn, it may be removed from within the jaw carrier316,318and replaced with minimal effort. Although replaceable jaws are shown in this example, the invention is not so limited. Other examples may include jaws that are integral with vice components.

FIG.5further shows a common jaw pivot311. As the name implies, the common jaw pivot311is common to both the first jaw carrier316and the second jaw carrier318. One advantage of a common jaw pivot311includes ease and accuracy of maintaining a drill string segment in concentric relation along the drill stem axis304when a gripping device (first gripping device310and/or second gripping device330) is actuated and holding one or more drill stem segments. In contrast to configurations with independent jaw actuation, it is easier to accurately control jaw location when both jaws are constrained by a common pivot point. Additionally, it is possible to cheaply manufacture a high tolerance single pivot point, compared to the manufacturing cost required to accurately move two separate mechanisms. Further it is easier and cheaper to make a high tolerance pivot point compared to a high tolerance slide joint. Another advantage includes the ability to easily keep the common jaw pivot311free of unwanted debris, compared to other configurations such as more complex linkages or slide configurations.

FIG.5further shows the first actuator312coupled to the first jaw carrier316at a pivot320. Likewise, the second actuator314is coupled to the second jaw carrier318at a pivot322. The arrangement shown inFIG.5, including the common jaw pivot311, pivots320and322, allows for design requirements that may reduce the size of the first actuator312and the second actuator314. The mechanical advantage of the pivot arrangement311,320,322provides the necessary force needed for gripping a drill stem segment without the need for larger actuators.

AlthoughFIG.5only shows a cross section of the first gripping device310, in one example, the second gripping device330is similarly configured. The accuracy and reduced cost provided by both the first gripping device310and the second gripping device330is accentuated when two drill stem segments are both gripped at the same time, and both drill stem segments are more accurately located along the drill stem axis304.

FIG.6shows a flow diagram of a method of directional drilling according to one example of the invention. In operation602, a first pair of gripping jaws is rotated about a first common pivot in a directional drill vice to clamp on a first drill stem segment. In operation604, a second drill stem segment is placed into the directional drill vice, and in operation606, the second drill stem segment is threaded onto the first drill stem segment to form a drill stem coupling.

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

Example 1 includes a directional drill vice. The vice includes a first pair of gripping jaws located in a vice frame, at least one actuating device coupled to the first pair of gripping jaws, and a common jaw pivot coupled to both jaws in the first pair of gripping jaws, the common pivot coupled to the vice frame; wherein both jaws in the first pair of gripping jaws are constrained to only rotational motion about the common jaw pivot.

Example 2 includes the directional drill vice of example 1, wherein the first pair of gripping jaws includes replaceable jaws held in jaw carriers.

Example 3 includes the directional drill vice of any one of examples 1-2, wherein each jaw in the first pair of gripping jaws is actuated by a separate actuating device.

Example 4 includes the directional drill vice of any one of examples 1-3, wherein each jaw carrier includes the common pivot on a first end of the jaw carrier and an actuating device coupled to a second end of the jaw carrier.

Example 5 includes the directional drill vice of any one of examples 1-4, further including a second pair of gripping jaws.

Example 6 includes the directional drill vice of any one of examples 1-5, further including a rotation joint between the first pair of gripping jaws and the second pair of gripping jaws to provide rotation about a drill stem axis, and a rotation actuator to drive relative rotation between the first pair of gripping jaws and the second pair of gripping jaws.

Example 7 includes a directional drill. The directional drill includes a first gripper, including a first pair of gripping jaws located in a vice frame, at least one actuating device coupled to the first pair of gripping jaws, and a first common jaw pivot coupled to both jaws in the first pair of gripping jaws, the first common pivot coupled to the vice frame; wherein both jaws in the first pair of gripping jaws are constrained to only rotational motion about the first common jaw pivot.

The directional drill includes a second gripper, including a second pair of gripping jaws located in a vice frame, at least one actuating device coupled to the second pair of gripping jaws, and a second common jaw pivot coupled to both jaws in the second pair of gripping jaws, the second common pivot coupled to the vice frame; wherein both jaws in the second pair of gripping jaws are constrained to only rotational motion about the second common jaw pivot.

The directional drill includes a slot in the vice frame to allow lateral insertion of a drill stem segment into the first gripper, a rotation joint between the first gripper and the second gripper to provide rotation about a drill stem axis, and a rotation actuator to drive relative rotation between the first gripper and the second gripper.

Example 8 includes the directional drill of example 7, wherein the actuating devices are hydraulic actuating devices.

Example 9 includes the directional drill of any one of examples 7-8, wherein the rotation actuator is a hydraulic rotation actuator.

Example 10 includes the directional drill of any one of examples 7-9, wherein the first gripper is fixed with respect to the vice frame, and the second gripper rotates relative to the vice frame about the rotation joint.

Example 11 includes a method of directional drilling. The method includes rotating a first pair of gripping jaws about a first common pivot in a directional drill vice to clamp on a first drill stem segment, placing a second drill stem segment into the directional drill vice, and threading the second drill stem segment onto the first drill stem segment to form a drill stem coupling.

Example 12 includes the method of example 11, wherein placing the second drill stem segment into the directional drill vice includes laterally inserting the second drill stem through a slot in the directional drill vice.

Example 13 includes the method of any one of examples 11-12, wherein rotating a first pair of gripping jaws about a first common pivot includes actuating the first pair of gripping jaws using two actuators with one actuator for each jaw in the first pair of gripping jaws.

Example 14 includes the method of any one of examples 11-13, further including rotating a second pair of gripping jaws about a second common pivot in the directional drill vice to clamp on the second drill stem segment, while the first pair of gripping jaws are clamped onto the first drill stem segment, and driving relative rotation between the first pair of gripping jaws and the second pair of gripping jaws to break the drill stem coupling loose.

Example 15 includes the method of any one of examples 11-14, wherein driving relative rotation between the first pair of gripping jaws and the second pair of gripping jaws includes holding the second pair of gripping jaws fixed and rotating the first pair of gripping jaws.

The above detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the invention can be practiced. These embodiments are also referred to herein as “examples.” Such examples can include elements in addition to those shown or described. However, the present inventors also contemplate examples in which only those elements shown or described are provided. Moreover, the present inventors also contemplate examples using any combination or permutation of those elements shown or described (or one or more aspects thereof), either with respect to a particular example (or one or more aspects thereof), or with respect to other examples (or one or more aspects thereof) shown or described herein.

In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more than one, independent of any other instances or usages of “at least one” or “one or more.” In this document, the term “or” is used to refer to a nonexclusive or, such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated. In this document, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Also, in the following claims, the terms “including” and “comprising” are open-ended, that is, a system, device, article, composition, formulation, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.

The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments can be used, such as by one of ordinary skill in the art upon reviewing the above description. The Abstract is provided to comply with 37 C.F.R. § 1.72(b), to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment, and it is contemplated that such embodiments can be combined with each other in various combinations or permutations. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.