Directional Drill Vice and Method

This application is a continuation of U.S. patent Ser. No. 18/223,242, filed Jul. 18, 2023, which application is a continuation of U.S. patent Ser. No. 17/209,775, filed Mar. 23, 2021, which is a continuation of U.S. patent Ser. No. 16/985,360, filed Aug. 5, 2020, which is continuation of U.S. patent Ser. No. 15/879,987, filed Jan. 25, 2018, which claims the benefit of priority of U.S. Provisional Application 62/501,412, filed May 4, 2017, all of which are hereby incorporated by reference in their entirety.

Embodiments described herein generally relate to directional drilling. Specific examples may include drill stem vices for adding or removing segments from a drill string.

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

It is desirable to have a reliable system to add and remove segments of drill stem. It is further desirable to reduce cost of the directional drill.

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.

shows an example of a directional drill. The directional drillincludes a drill stemincluding an attached sonde housing, and a drill headfor piercing the ground and leading a directional drill bore operation. A drill stem loaderis shown coupled to the directional drill. The drill stem loaderis configured to pick drill stem segments (or drill rods) from a drill stem magazine and add stem segments to the stemduring a boring operation. The drill stem loaderis further configured to remove stem segments from the drill stemand 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 supplyis coupled to the directional drillto drive the drill stem, and to operate other aspects of the directional drill. A cockpitis further included in the directional drill, the cockpitincluding a number of controllers and gauges to control and monitor a drilling operation. In on example, a track systemis included on the directional drillto move and position the directional drill. A stake down systemis also shown coupled to a front end of the directional drillin the example of. A directional drill viceis further shown at a front end of the directional drill. Additional aspects of the directional drill viceare described in more detail below.

shows a portion of a directional drillfrom, with a number of components removed to reveal more detail of a directional drill stem loaderaccording to an embodiment of the invention. The drill stem loaderincludes a drill stem magazine, having a number of individual drill stem segmentsloaded into the magazine.

A first linear actuatorand a second linear actuatorare shown adjacent to the drill stem magazine. In one example, the linear actuators,are 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 viceincludes a slot that coordinates with the first linear actuatorand a second linear actuatorto load a drill stem segment laterally into the directional drill vice.

A drill headis shown at a rear of the drill stem loader. The drill headis mounted to a carriage framealong a movable track. In one example, a drill fluid supply systemis coupled to the directional drill, adjacent to the drill head. During a drilling operation, the drill headis operated to both rotate the drill stem, and to drive the drill stemforward into the ground. The drill stem viceis shown at a front end of the drill stem loader. During a drilling operation, the directional drill viceselectively holds or releases individual segments of the drill stemto 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).

shows a front view of an example drill stem vice. The drill stem viceincludes a base. A first gripping deviceand a second gripping deviceare shown coupled to the base. The first gripping deviceis shown with a first pair of actuators,. In operation, each of the first pair of actuators,forces 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.

shows a rear view of the drill stem vice. In this view, the second gripping deviceis shown to include a second pair of actuators,. Similar to the first gripping device, in operation, each of the second pair of actuators,forces 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 deviceand the second gripping device, the invention is not so limited. In other examples, a single actuator may operate the first gripping device, and a single actuator may operate the second gripping device. 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 deviceis rigidly fixed to the base, while the first gripping deviceis mounted to the basethrough a rotation joint. As shown, the rotation jointhas an axis of rotation that is concentric with a drill string axis. A rotation actuatoris shown coupled between the baseand the first gripping deviceto provide controlled rotation about the rotation joint.

In a drill stem removal operation, a drill string, composed of multiple drill stem segments, may be located within both the first gripping deviceand the second gripping devicealong drill string axis. A connection interface between two adjacent drill stem segments may be aligned between the first gripping deviceand the second gripping device. The rigidly connected second gripping devicemay then hold one drill stem segment in place, while the entire first gripping deviceis rotated about the rotation joint, while gripping the adjacent drill stem segment. This rotation of the first gripping deviceand 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 headfrommay complete the unscrewing process of the drill stem segment and replace the removed drill stem segment into the drill stem magazine.

In a drill stem extension operation, the first gripping devicemay grip an end of the drill stem, while the drill headfrom, fetches a new drill stem segment for installation into the drill string. The drill headmay screw the new drill stem segment into the drill string while the first gripping deviceholds the drill stem secure. Once the new drill stem segment is installed, the first gripping devicemay 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 viceshown infurther includes a slotto permit sideways loading and unloading of drill stem segments into and out of the drill stem vice.show the slotextending adjacent to only the second gripping device. In one example, drill stem segments are only loaded or unloaded from the second gripping device, and sideways access to the first gripping deviceis not needed. In the examples shown, the slotis oriented upward to permit vertical loading into the drill stem vice, however the invention is not so limited. Other orientations of the slot, such as sideways, left, right, downward, or at other angles are also within the scope of the invention.

Using the vertical orientation of the slotshown in, and the drill stem magazinebeing located substantially over a center of the directional drill, the directional drillbecomes more stable. Weight from the drill stem magazineand the drill stem segments is more centered over the directional drill. Further, using the vertically oriented slotand drill stem magazineconfiguration 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 deviceof the drill stem vice. The second gripping devicemay then clamp onto the new drill stem segment and hold it secure while the drill headscrews into the new drill stem segment. In other configurations without a slot, a new drill stem segment cannot be gripped immediately after being placed in line with the drill stem axis. In such configurations, a transfer system such as the first linear actuatorand the second linear actuator, must be made more robust, to hold the new drill stem segment while the drill headscrews into the new drill stem segment. Configurations with a slotallow the complexity of the transfer system such as the first linear actuatorand the second linear actuatorto be reduced, thus reducing cost and improving reliability of the directional drill.

shows a cross section of the first gripping deviceof the drill stem viceaccording to one example. In the example of, a first jaw carrierand a second jaw carrierare shown. A pair of gripping jaws is shown in place within the first jaw carrierand the second jaw carrier. A first jawis shown housed within the first jaw carrier, and a second jawis shown housed within the second jaw carrier. In selected examples, having separate jaws,housed within jaw carriers,provides an advantage of replace ability. If one or both of the jaws,becomes unduly worn, it may be removed from within the jaw carrier,and 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.

further shows a common jaw pivot. As the name implies, the common jaw pivotis common to both the first jaw carrierand the second jaw carrier. One advantage of a common jaw pivotincludes ease and accuracy of maintaining a drill string segment in concentric relation along the drill stem axiswhen a gripping device (first gripping deviceand/or second gripping device) 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 pivotfree of unwanted debris, compared to other configurations such as more complex linkages or slide configurations.

further shows the first actuatorcoupled to the first jaw carrierat a pivot. Likewise, the second actuatoris coupled to the second jaw carrierat a pivot. The arrangement shown in, including the common jaw pivot, pivotsand, allows for design requirements that may reduce the size of the first actuatorand the second actuator. The mechanical advantage of the pivot arrangement,,provides the necessary force needed for gripping a drill stem segment without the need for larger actuators.

Althoughonly shows a cross section of the first gripping device, in one example, the second gripping deviceis similarly configured. The accuracy and reduced cost provided by both the first gripping deviceand the second gripping deviceis 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 axis.

shows a flow diagram of a method of directional drilling according to one example of the invention. In operation, 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 operation, a second drill stem segment is placed into the directional drill vice, and in operation, 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.