Directional Drill Securing Device and Method

This application is a continuation of U.S. patent application Ser. No. 18/228,327, filed Jul. 31, 2023, which is a continuation of U.S. patent application Ser. No. 17/349,309, filed Jun. 16, 2021, issued as U.S. Pat. No. 11,713,624, which is a continuation of U.S. patent application Ser. No. 15/880,001, filed Jan. 25, 2018, issued as U.S. Pat. No. 11,066,877, all of which are incorporated by reference herein in their entireties.

Embodiments described herein generally relate to horizontal directional drills and methods. Specific examples may include securing systems for horizontal directional drills.

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 secure the directional drill in place during a bore. It is further desirable to have a securing system that is configurable for different soil conditions, and uses less energy to use.

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. Additional aspects of the stake down systemare described in more detail below. A directional drill viceis further shown at a front end of the directional drill.

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 drill carriage 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 stakedown deviceaccording to one example. The stakedown deviceincludes a plurality of stake implements that are adapted to be located together on one lateral side of the drill carriage. In the example shown, the stakedown deviceincludes a first staking implement, and a second staking implement. Additional detail of the respective staking implements,are shown in cross section in.

The first staking implementincludes a first auger, and the second staking implementincludes a second auger. Although spiral auger flights are shown in, the invention is not so limited. Other staking implements such as spikes or claws etc, are within the scope of the invention.

The stakedown deviceincludes a proximal end, and a distal end. In operation, the staking implements,are selectively driven into or out of the soil along a range of motion. In one example, one or more actuators such as hydraulic cylinders may be used to drive the staking implements,along the range of motion. Although hydraulic cylinders actuators are described, other examples of actuators include, but are not limited to, gear driven actuators, rack and pinion actuators, electric actuators, etc.

In the example shown, a pair of hydraulic cylinders,are utilized. In the example shown, a first hydraulic cylinderis mounted with a piston facing the distal endof the stakedown device, and a second hydraulic cylinderis mounted with a piston facing the proximal endof the stakedown device.

One advantage of using a pair of hydraulic cylinders includes the ability to select a depth for the augers,in a middle portion of the range of motion. While other systems of actuation may also be capable of selectable depth, the use of the pair of hydraulic cylinders,provides depth selection ability without the use of more expensive components. Hydraulic cylinders are relatively inexpensive and more reliable compared to other actuators such as gear driven actuators. Another advantage of using a pair of hydraulic cylinders over the use of a single hydraulic cylinder includes reduced cost and improved reliability. The shorter length of each cylinder,reduces the cost of the actuation system over a single, larger, hydraulic cylinder, and reduces the likelihood of a long piston bending due to high stress during operation.

In the auger examples shown in, each staking implement,includes a rotating spindle,. The rotating spindles,are coupled to the augers,and rotate within distal bearing assemblies,. At the proximal endof the stakedown device, a respective pair of drive gears,are shown. Although a gear drive is illustrated as an example device for rotating the rotating spindles,, the invention is not so limited. Other examples include, but are not limited to, hydraulic motors, electric motors, belt drive, chain drive, etc.

A drive motoris shown incoupled to the drive gears,of the staking implements,. In operation, rotation of the rotating spindles,and the attached augers,is accomplished by engaging the drive motor. Then extension or retraction of the staking implements,is accomplished by actuation of one or more of the hydraulic cylinders,.

A plurality of smaller augers are easier to drive into the soil than a single large auger of equal auger surface area. In one example, by using a plurality of smaller augers, a similar staking force is achieved with a lower force required to drive the augers. In one example, an equal driving force is used to drive multiple augers, and an increased staking force is achieved as a result of using multiple augers. Again, while augers are used as an example other staking implements may be used with similar gains in efficiency.

shows a stakedown deviceaccording to one example. The stakedown deviceincludes a single stake implementthat is adapted to be located on one lateral side of the drill carriage. In the example shown, the stakedown deviceincludes a staking implement, and an actuator to drive the staking implement. The stakedown deviceincludes a proximal end, and a distal end.

The staking implementincludes an auger. Similar to the examples discussed above in, although spiral auger flights are shown in, the invention is not so limited. Other staking implements such as spikes or claws etc, are within the scope of the invention. A spindleis attached between a drive gearand the auger. In the example shown, the spindleis housed in an distal bearing assembly. Additional detail of the staking implementis shown in cross section in.

In operation, the staking implementis selectively driven into or out of the soil along a range of motion. In the example shown, a pair of actuators,drive the staking implementalong the range of motion. Although hydraulic cylinders actuators are described, other examples of actuators include, but are not limited to, gear driven actuators, rack and pinion actuators, electric actuators, etc.

A drive motorand drive motor gearis shown incoupled to drive gearof the staking implement. In operation, rotation of the spindleand the attached augeris accomplished by engaging the drive motor. Then extension or retraction of the staking implement, is accomplished by actuation of one or more of the hydraulic cylinders,.

In the example directional drillshown in, a single staking implement (similar to staking implement) is shown on a first lateral side of the drill carriage frame, and two staking implements (similar to staking implements,) are shown on a second lateral side of the drill carriage frame. However, the invention is not so limited. In other examples, multiple staking implements are located on both the first side and the second side of the drill carriage frame. As discussed above, a plurality of smaller augers are easier to drive into the soil than a single large auger of equal auger surface area. In one example, a number of staking implements on each lateral side of the drill carriage frameis equal. In other examples, a first lateral side of the drill carriage includes a larger number of stake implements than the second lateral side.

One advantage of having a different number of staking implements on different lateral sides of a drill carriage includes the potential for several staking level options. For example, in loose soil conditions, all staking implements on both lateral sides may be used. The higher number of staking implements provides a higher staking force to accommodate the loose soil conditions. In hard soil conditions, it may be difficult to drive a staking implement into the soil. In this example, it may be desirable to drive only a single staking implement into the soil. Using examples of staking devices shown, in intermediate conditions, it may be desirable to drive an intermediate number of staking implements into the soil.

In the example of, three staking implements from both lateral sides of the directional drillmay be used in loose soil. One staking implement from a single side of the directional drillmay be used for hard soil conditions, and two staking implements from the other single side of the directional drill may be used in intermediate conditions.

shows an example of an orientation of staking implements according to one embodiment of the invention. In the diagram of, a drill stemis shown by intel without other directional drill components, in order to illustrate orientation. The drill stempasses through a planeat point. The planeis shown to illustrate an orientation of a first staking implementand a second staking implementwith respect to each other, and the drill stem. In one example, the planemay be oriented perpendicular to a ground surface. In one example, the planemay be oriented perpendicular to an axis of the drill stem. In one example, the planemay be fixed with respect to a directional drill. In one example, the planemay be adjustable in orientation with respect to a directional drill.

The dashed lines shown inare used to represent axes of staking implements as they are driven into the ground. Examples of staking implements that travel into the ground along the dashed lines,ofmay include the staking implementsandas shown in either or both.

The example ofshows the first staking implementand the second staking implementare not parallel to one another. Further, in the example of, the first staking implementand the second staking implementare both within the plane, and are angled with respect to one another, and are not parallel.shows that in one example, a bottom end of the first staking implementand the second staking implementare separated by a lower distance. A top end of the first staking implementand the second staking implementare separated by an upper distance.shows the lower distanceis less than the upper distance. In this example, as the first staking implementand the second staking implementare driven into the soil, they will converge in the ground underneath the drill stem. One advantage of angling the staking implements,towards each other includes less likelihood of accidentally hitting a buried utility. Another advantage of angling the staking implements,towards each other includes improved holding strength. It has been found that in selected soil conditions, locating adjacent auger flights from two adjacent augers approximately 0.5 to 1.0 times an auger flight diameter from each other provides increased holding strength. Selecting an angle of the staking implements,provides the ability to manufacture a directional drill for a given auger diameter with optimal holding strength.

In addition to angling staking implements beneath a drill stem, the same formula of adjacent staking implements may be used for two or more staking implements on the same side of a drill stem, such as shown inabove. As discussed above, locating adjacent auger flights from two adjacent augers approximately 0.5 to 1.0 times an auger flight diameter from each other provides increased holding strength over a single auger of equal auger flight area. In one example, any two augers, on any side of a drill stem, are located adjacent one another with auger flights from two adjacent augers approximately 0.5 to 1.0 times an auger flight diameter from each other. This configuration reduces driving force to deploy the augers over a single auger of equal auger flight area. Further, this configuration provides more holding force than a single auger of equal auger flight area. In one example, two augers are angled to provide this desired spacing. In other examples, the two adjacent augers are driven parallel to one another, but located such that flights from two adjacent augers approximately 0.5 to 1.0 times an auger flight diameter from each other.

shows an example flow diagram of a method of operation according to one embodiment. In operation, a drill carriage and a rotating spindle coupled to the drill carriage are positioned, along a drilling axis. In operation, an optional desired number of stake implements are selected from a plurality of stake implements located on both a first lateral side of the drill carriage and a second lateral side of the drill carriage wherein the first lateral side of the drill carriage includes a larger number of stake implements than the second lateral side. In operation, the directional drill is staked down using the selected number of stake implements.

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

Example 1 includes a directional drill. The directional drill includes a drill carriage, a rotating spindle coupled to the drill carriage, wherein the rotating spindle is adapted to translate along a surface of the drill carriage, and a stakedown system coupled to an end of the drill carriage. The stakedown system includes a first stake implement located on a first lateral side of the drill carriage, and a plurality of second stake implements located on a second lateral side of the drill carriage, opposite the first lateral side.

Example 2 includes the directional drill of example 1, wherein the first stake implement includes a plurality of first stake implements located on the first lateral side.

Example 3 includes the directional drill of any one of examples 1-2, wherein the plurality of first stake implements includes two first stake implements.

Example 4 includes the directional drill of any one of examples 1-3, wherein the plurality of second stake implements includes two second stake implements.

Example 5 includes the directional drill of any one of examples 1-4, wherein the first stake implement includes an auger.

Example 6 includes the directional drill of any one of examples 1-5, wherein the plurality of second stake implements includes at least one auger.

Example 7 includes the directional drill of any one of examples 1-6, wherein the plurality of second stake implements each include an auger.

Example 8 includes a directional drill. The directional drill includes a drill carriage, a rotating spindle coupled to the drill carriage, wherein the rotating spindle is adapted to translate along a surface of the drill carriage, and a stakedown system coupled to an end of the drill carriage. The stakedown system includes a plurality of stake implements located on both a first lateral side of the drill carriage and a second lateral side of the drill carriage, wherein the first lateral side of the drill carriage includes a larger number of stake implements than the second lateral side.

Example 9 includes the directional drill of example 8, wherein the first lateral side of the drill carriage includes one stake implement.

Example 10 includes the directional drill of any one of examples 8-9, wherein the second lateral side of the drill carriage includes two stake implements.

Example 11 includes the directional drill of any one of examples 8-10, wherein the plurality of stake implements includes at least one auger.

Example 12 includes the directional drill of any one of examples 8-11, wherein the plurality of second stake implements each include an auger.

Example 13 includes a method of operating a directional drill, including positioning a drill carriage and a rotating spindle coupled to the drill carriage along a drilling axis, selecting an optional desired number of stake implements from a plurality of stake implements located on both a first lateral side of the drill carriage and a second lateral side of the drill carriage wherein the first lateral side of the drill carriage includes a larger number of stake implements than the second lateral side, and staking down the directional drill using the selected number of stake implements.

Example 14 includes the method of example 13, wherein selecting an optional desired number of stake implements includes selecting a single stake implement on the first lateral side of the drill carriage.

Example 15 includes the method of any one of examples 13-14, wherein selecting an optional desired number of stake implements includes selecting two stake implements on the second lateral side of the drill carriage.

Example 16 includes the method of any one of examples 13-15, wherein staking down the directional drill includes rotating at least one auger into the ground.

Example 17 includes a directional drill, including a drill carriage, a rotating spindle coupled to the drill carriage, wherein the rotating spindle is adapted to translate along a surface of the drill carriage, and a stakedown system coupled to an end of the drill carriage. The stakedown system includes a first stake implement located on a first lateral side of the drill carriage, and a second stake implement located on a second lateral side of the drill carriage, opposite the first lateral side, wherein the first stake implement is angled with respect to the second stake implement.

Example 18 includes the directional drill of example 17, wherein the first stake implement and the second stake implement are angled towards each other beneath a drill stem axis.

Example 19 includes the directional drill of any one of examples 17-18, wherein the first stake implement and the second stake implement are angled towards each other within a plane.