SYSTEM AND METHOD FOR HANDLING DRILL RODS

Abstract

A system for handling drill rods comprising: a rod carrier comprising a cassette body configured for storing at least one drill rod and an actuating mechanism configured to move the drill rod between a first position in the cassette body and a second position; a drilling rig comprising a mast adapted to receive the drill rod; and a manipulator configured to move the drill rod between the second position and the mast, wherein the system for handling drill rods also comprises at least one control unit configured to allow the manipulator to determine the location of the rod carrier and/or the drill rod and to direct handling of the drill rod between the second position and the mast.

Claims

1. A system for handling drill rods comprising: a rod carrier comprising a cassette body configured for storing at least one drill rod and an actuating mechanism configured to move the drill rod between a first position in the cassette body and a second position; a drilling rig comprising a chassis, and a mast adapted to receive the drill rod; and a manipulator including a gripper adapted to grip the drill rod, the manipulator being configured to move the drill rod between the second position and the mast, the manipulator adapted for movement relative to the chassis along a track located on a surface of the chassis, wherein the system for handling drill rods also comprises at least one control unit configured to allow the manipulator to determine the location of the rod carrier and/or the drill rod and to direct handling of the drill rod between the second position and the mast.

2. The system for handling drill rods according to claim 1, wherein the manipulator comprises a robotic arm.

3. The system for handling drill rods according to claim 1, wherein the rod carrier and the drilling rig are configured for movement independently of one another.

4. The system for handling drill rods according to claim 1, wherein the rod carrier is fixedly or removably connected to the drilling rig.

5. The system for handling drill rods according to claim 1 wherein the rod carrier is mounted on the drilling rig.

6. The system for handling drill rods according to claim 1 wherein the drill rod exits the cassette body into a drill rod holder associated with the rod carrier.

7. The system for handling drill rods according to claim 6 wherein the drill rod holder is configured for movement relative to the cassette body to deliver the drill rod into the second position.

8. The system for handling drill rods according to claim 6 or claim 7 wherein the rod carrier is provided with a pair of drill rod holders.

9. A method for handling drill rods comprising: a. positioning a rod carrier and a drilling rig in relative proximity to one another; b. moving a drill rod from a first position in a body of the rod carrier to a second position; c. moving a manipulator including a gripper adapted to grip the drill rod into the vicinity of the drill rod; d. gripping the drill rod with the gripper; and e. moving the drill rod to the mast of the drilling rig by moving the manipulator relative to a chassis of the drilling rig along a track located on a surface of the chassis.

10. The method of handling drill rods according to claim 9, wherein the rod carrier and the drilling rig are moved into relative proximity to one another via a controller operated by an operator.

11. The method of handling drill rods according to claim 9 wherein, when the rod carrier and the drilling rig are positioned in relative proximity to one another, the manipulator is capable of retrieving the drill rod from the rod carrier and moving the drill rod to the mast.

12. The method of handling drill rods according to claim 9, further comprising the step of connecting the drill rod to a drill rod string in the mast of the drilling rig to form an extended drill rod string.

13. The method of handling drill rods according to claim 9. further comprising disconnecting a drill rod from an extended drill rod string, moving the manipulator into the vicinity of the drill rod, gripping the drill rod with the manipulator, moving the drill rod from the drilling rig to the rod carrier, and placing the drill rod in the body of the rod carrier.

14. A method for handling drill rods comprising: a. positioning a rod carrier and a drilling rig in relative proximity to one another; b. moving a manipulator including a gripper adapted to grip the drill rod into the vicinity of the rod carrier; c. retrieving a drill rod from the rod carrier using the manipulator; d. moving the drill rod to the mast of the drilling rig by moving the manipulator relative to a chassis of the drilling rig along a track located on a surface of the chassis.

15. A system for handling drill rods comprising: a rod carrier comprising a cassette body configured for storing at least one drill rod; a drilling rig comprising a chassis, and a mast adapted to receive the drill rod; and a manipulator including a gripper adapted to grip the drill rod, the manipulator being configured to move the drill rod between the rod carrier and the mast, wherein the system for handling drill rods also comprises at least one control unit configured to allow the manipulator to determine the location of the rod carrier and/or the drill rod and to direct handling of the drill rod between the rod carrier and the mast by moving the manipulator relative to the chassis of the drilling rig along a track located on a surface of the chassis.

16. The system for handling drill rods according to claim 15, wherein the manipulator comprises a robotic arm.

17. The system for handling drill rods according to claim 15, wherein the rod carrier and the drilling rig are configured for movement independently of one another.

18. The system for handling drill rods according to claim 15, wherein the rod carrier is fixedly or removably connected to the drilling rig.

19. The system for handling drill rods according to claim 15 wherein the rod carrier is mounted on the drilling rig.

20-22. (canceled)

Description

BRIEF DESCRIPTION OF DRAWINGS

[0102] Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows:

[0103] FIG. 1 illustrates an isometric view of a system for handling drill rods comprising a rod carrier and a drilling rig according to an embodiment of the present invention.

[0104] FIG. 2 illustrates an isometric view of a system for handling drill rods comprising a rod carrier and a drilling rig according to an embodiment of the present invention.

[0105] FIG. 3 illustrates an isometric view of a rod carrier according to an embodiment of the present invention.

[0106] FIG. 4 illustrates an isometric view of a rod carrier according to an embodiment of the present invention.

[0107] FIG. 5 illustrates an isometric view of a drilling rig according to an embodiment of the present invention.

[0108] FIG. 6 illustrates an isometric view of a drilling rig according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE DRAWINGS

[0109] FIGS. 1 and 2 illustrate isometric views of a system for handling drill rods according to an embodiment of the present invention. The system for handling drill rods is generally indicated by arrow 100. The system for handling drill rods 100 comprises a rod carrier 1 comprising a cassette body 2 configured for storing drill rods 3. In FIG. 1, the rod carrier 1 is provided with an actuating mechanism 4 configured to move a drill rod 3 between a first position 5a within the cassette body 2 and a second position 5b external to the cassette body 2 for subsequent pickup.

[0110] The drill rods 3 in the first position 5a within the cassette body 2 are stacked on top of one another in a plurality of channels 20. Drill rods 3 to be moved from the channels 20 to the second position 5b are retrieved from the bottom of the channels 20 by the actuating mechanism 4. The actuating mechanism 4 comprises a pair of rod lifters 21 adapted to lift the retrieved drill rod 3a, the rod lifters 21 being associated with a chain drive mechanism 22 that moves the retrieved drill rod 3a between the first position 5a and the second position 5b.

[0111] The system for handling drill rods 100 also comprises a drilling rig 6 comprising a mast 7 to which drill rods 3 are connected in order to drill holes into a desired orientation for drilling and a manipulator (indicated generally by arrow 8) comprising a gripper 9 configured for gripping the retrieved drill rod 3a and a robotic arm 10 configured to position the gripper 9 in the vicinity of the rod carrier 1 in order to retrieve the drill rod 3a from the rod carrier 1 and move it between the second position 5b and the drilling rig 6 for a drill operation such as attaching to a drill rod string (not shown in these Figures) to the mast 7 or detaching the drill rod 3a from a drill rod string (not shown in these Figures) from the mast 7.

[0112] The rod carrier 1 and the drilling rig 6 each move independently of one another via endless tracks (8 and 8a respectively).

[0113] Movement of the manipulator 8 relative to the track 23 is driven by powerpack 25. The powerpack 25 also drives operation of the drill.

[0114] FIG. 3 illustrates an isometric view of a rod carrier 1 according to an embodiment of the present invention. The rod carrier 1 includes a cassette body 2 in which are stored a plurality of drill rods 3. In this embodiment, the drill rods 3 are stored in channels 20 within the cassette body 2.

[0115] When the rod carrier 1 is in a location where it is to be used (or, for instance, on uneven or unstable ground) stabiliser legs 12 may be deployed to help maintain the rod carrier 1 in position

[0116] A motor 11 drives the endless track 8 of the rod carrier 1 to provide for movement of the rod carrier 1. The motor 11 also drives the actuating mechanism 4 to deliver drill rods 3 from the first position in the storage position in the rod carrier body 2 and the second position 5b for pickup by the robotic arm 10.

[0117] In the embodiment of the invention shown in FIG. 3, the retrieved drill rod 3a exits the cassette body 2 at the side thereof and is received a drill rod holder 30. The retrieved drill rod 3a is retrieved from the drill rod holder 30 by the manipulator (not shown in this Figure).

[0118] The drill rod holder 30 is adapted for movement relative to the cassette body 2. As best seen in FIG. 4, the drill rod holder 30 is adapted to move so that a portion of the drill rod holder 30 and the retrieved drill rod 3a projects forwards of the cassette body 2. In this way, if the drilling rig (not shown in this Figure) and, more specifically, the manipulator (not shown in this Figure) is unable to reach the drill rod 3a when the drill rod holder 30 is in the position shown in FIG. 3, the drill rod holder 30 can be moved relative to the cassette body 2 as shown in FIG. 4 so as to place the drill rod 3a within reach of the manipulator (not shown in this Figure).

[0119] FIG. 5 illustrates an isometric view of a drilling rig 6 according to an embodiment of the present invention. The drilling rig 6 includes a chassis 24 to which is mounted a drive portion in the form of a motor 27. The motor 27 drives the endless track 8a to provide for movement of the drilling rig 6. The drilling rig 6 is stabilised in an operating position by hydraulically activated stabiliser legs 12a.

[0120] The manipulator 8 is mounted on a track 23 that is in turn mounted on the chassis 24. The manipulator 8 is adapted for movement relative to the track 23. In this way, the manipulator 8 can retrieve a drill rod 3 from the rod carrier (not shown in this Figure) regardless of the position of the rod carrier relative to the drilling rig 6. For instance, the manipulator 8 can move along the track 23 relative to the chassis 24 in order to move the manipulator 8 within reach of the rod carrier (not shown in this Figure) so that the robotic arm 10 can be actuated to retrieve a drill rod 3 from the rod carrier.

[0121] Movement of the manipulator 8 relative to the track 23 is driven by powerpack 25. In the embodiment of the invention shown in FIG. 4, the powerpack 25 actuates motor 31 to drive a base 26 on which the manipulator 8 is positioned relative to the track 23 via a rack and pinion mechanism.

[0122] A control unit 32 allows the rod carrier 1 and the drilling rig 6 to communicate with one another. It is envisaged that the rod carrier 1 and the drilling rig 6 may communicate with one another so that the manipulator 8 can determine the precise location of the rod carrier 1 and, more specifically, the precise location of the drill rod 3 to be retrieved. In this way, the manipulator 8 may move relative to the chassis 24 of the drilling rig 6 in order to move into relatively close proximity to the rod carrier 1 (and the drill rod 3) so that the manipulator 8 may retrieve the drill rod 3 from the rod carrier 1 and move it to the mast 7.

[0123] FIG. 6 illustrates an isometric view of a drilling rig 6 according to an embodiment of the present invention. In this Figure, it may be more clearly seen that the gripper 9 comprises at least two grip wheels 9a for gripping a drill rod 3. The movement of the robotic arm 10 has 7 degrees of freedom (7 DOF) to enable its movement during drill rod handling.

[0124] In the present specification and claims (if any), the word ‘comprising’ and its derivatives including ‘comprises’ and ‘comprise’ include each of the stated integers but does not exclude the inclusion of one or more further integers.

[0125] Reference throughout this specification to ‘one embodiment’ or can embodiment' means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases ‘in one embodiment’ or in an embodiment' in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

[0126] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims (if any) appropriately interpreted by those skilled in the art.