U.S. patent application number 09/776196 was filed with the patent office on 2001-08-30 for directional drilling components and adaptors.
Invention is credited to Crane, Robert F., Wentworth, Steven W..
Application Number | 20010017222 09/776196 |
Document ID | / |
Family ID | 26793547 |
Filed Date | 2001-08-30 |
United States Patent
Application |
20010017222 |
Kind Code |
A1 |
Wentworth, Steven W. ; et
al. |
August 30, 2001 |
Directional drilling components and adaptors
Abstract
An adapter usable for interconnection of a pair of drill
components according to the invention includes an elongated adapter
body having a first end and a second end, wherein the first end
includes one of (1) a tubular wall defining a socket that opens
outwardly at one end of the adapter and having at least one
transverse opening therethrough configured to receive a removable
retainer for mechanically interlocking a projection in the socket,
and (2) the projection which fits into the socket, which projection
has at least one transverse opening therein to receive the
removable retainer. The second end includes a connecting portion
different from the projection and the tubular wall defining the
socket, such as a threaded projection or recess. The adapter
preferably has a lengthwise fluid passage through it suitable for
passing lubricating drilling fluid through the adapter to a drill
head or back reamer. The socket (1) of the first end preferably has
a series of spaced splines arranged in an arcuate formation around
the socket, which splines extend in a lengthwise direction of the
adapter and can engage a series of grooves in an adjoining
component in a manner effective to prevent relative rotation
between the adapter and an adjoining component. If splines are used
in this manner, complementary splines and grooves are also formed
on the projection (2) if the first end is male. An adapter of this
kind can be used to interconnect a component having a pinned,
projection and socket connector with another type of connector that
is less easy to couple and uncouple manually, such as an API
threaded connection.
Inventors: |
Wentworth, Steven W.;
(Brookfield, WI) ; Crane, Robert F.; (Oconomowoc,
WI) |
Correspondence
Address: |
Philip G. Meyers
Philip G. Meyers Intellectual Property Law, P.C.
Suite 114
3121 Cross Timbers Road
Flower Mound
TX
75028
US
|
Family ID: |
26793547 |
Appl. No.: |
09/776196 |
Filed: |
February 2, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09776196 |
Feb 2, 2001 |
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09616177 |
Jul 14, 2000 |
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09776196 |
Feb 2, 2001 |
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09373121 |
Aug 12, 1999 |
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09373121 |
Aug 12, 1999 |
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09212042 |
Dec 15, 1998 |
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6148935 |
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60097694 |
Aug 24, 1998 |
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Current U.S.
Class: |
175/19 ; 175/320;
175/385 |
Current CPC
Class: |
E21B 7/064 20130101;
E21B 17/046 20130101; Y10T 403/7033 20150115; E21B 47/017 20200501;
E21B 47/01 20130101; E21B 10/573 20130101; E21B 10/26 20130101;
E21B 10/60 20130101; E21B 7/06 20130101; E21B 10/56 20130101 |
Class at
Publication: |
175/19 ; 175/320;
175/385 |
International
Class: |
E21B 021/00 |
Claims
1. An adapter usable for interconnection of a pair of drill
components, comprising an elongated adapter body having a first end
and a second end, wherein the first end includes one of: (1) a
tubular wall defining a socket that opens outwardly at one end of
the adapter and having at least one transverse opening therethrough
configured to receive a removable retainer for mechanically
interlocking a projection in the socket, and a series of spaced
splines are arranged in an arcuate formation around the socket,
which splines extend in a lengthwise direction of the adapter and
can engage a series of grooves in an adjoining component in a
manner effective to prevent relative rotation between the adapter
and an adjoining component; and (2) the projection which fits into
the socket, which projection has at least one transverse opening
therein to receive the removable retainer; and the second end
includes a connecting portion different from the projection and the
tubular wall defining the socket.
2. The adapter of claim 1, wherein the second end is a threaded
male projection.
3. The adapter of claim 1, wherein the second end is a threaded
female hole.
4. The adapter of claim 2, wherein the first end is the tubular
wall defining the socket.
5. The adapter of claim 2, wherein the first end is the
projection.
6. The adapter of claim 3, wherein the first end is the tubular
wall defining the socket.
7. The adapter of claim 3, wherein the first end is the
projection.
8. A sonde housing assembly, comprising: an elongated tubular
housing having an internal chamber for mounting an electronic
locating device for transmitting a signal indicating orientation or
location of the sonde housing assembly, a front end connecting
portion configured for mechanical engagement of the front end of
the sonde housing to a first drill head component, and a rear end
connecting portion configured for mechanical engagement of the rear
end of the sonde housing to a second drill head component; and an
adapter usable for interconnection of one end of the sonde housing
to another drill component, comprising an elongated adapter body
having a first end and a second end, wherein the first end includes
one of (1) a tubular wall defining a socket that opens outwardly at
one end of the adapter and having at least one transverse opening
therethrough configured to receive a removable retainer for
mechanically interlocking a projection in the socket and (2) the
projection which fits into the socket, which projection has at
least one transverse opening therein to receive the removable
retainer, and the second end includes a connecting portion
different from the projection and the tubular wall defining the
socket, wherein the connecting portion of the adapter is configured
for mechanical engagement with one of the front and rear connecting
portions of the sonde housing.
9. The sonde housing assembly of claim 8, wherein the first end of
the adapter is the tubular wall defining a socket.
10. The sonde housing assembly of claim 8, wherein the tubular wall
defining a socket further has a series of spaced splines arranged
in an arcuate formation around the socket, which splines extend in
a lengthwise direction of the adapter and can engage a series of
grooves in an adjoining component in a manner effective to prevent
relative rotation between the adapter and an adjoining
component.
11. The sonde housing assembly of claim 8, wherein the rear end
connecting portion of the sonde housing has a threaded recess, and
the connecting portion of the second end of the adapter has a
threaded male projection which engages the threaded recess.
12. A back reamer assembly, comprising: a back reamer including a
frontwardly tapering conical portion suitable for enlarging an
existing hole and a front end connecting portion at the front of
the conical portion for mechanical engagement of the front end of
the back reamer to another drill head component; and an adapter
usable for interconnection of the front end of the back reamer to
another drill component, comprising an elongated adapter body
having a first end and a second end, wherein the first end includes
one of (1) a tubular wall defining a socket that opens outwardly at
one end of the adapter and having at least one transverse opening
therethrough configured to receive a removable retainer for
mechanically interlocking a projection in the socket and (2) the
projection which fits into the socket, which projection has at
least one transverse opening therein to receive the removable
retainer, and the second end includes a connecting portion
different from the projection and the tubular wall defining the
socket, wherein the connecting portion of the adapter is configured
for mechanical engagement with the front connecting portion of the
back reamer.
13. The back reamer assembly of claim 12, wherein the first end of
the adapter is the tubular wall defining a socket.
14. The back reamer assembly of claim 12, wherein the tubular wall
defining a socket further has a series of spaced splines arranged
in an arcuate formation around the socket, which splines extend in
a lengthwise direction of the adapter and can engage a series of
grooves in an adjoining component in a manner effective to prevent
relative rotation between the adapter and an adjoining
component.
15. The back reamer assembly of claim 12, wherein the front end
connecting portion of the back reamer has a threaded recess, and
the connecting portion of the second end of the adapter has a
threaded male projection which engages the threaded recess.
Description
RELATED APPLICATIONS
[0001] This application is a continuation-in-part of Wentworth et
al. Ser. No. 09/616,177, filed Jul. 14, 2000, pending. This
application is also a continuation-in-part of Wentworth et al. Ser.
No. 09/373,121, filed Aug. 12, 1999, pending, which was a
continuation-in-part of Wentworth et al. Ser. No. 09/212,042, filed
Dec. 15, 1998, U.S. Pat. No. 6,148,935, which claims priority of
provisional application Serial No. 60/097,694, filed Aug. 24,
1998.
TECHNICAL FIELD
[0002] The invention relates to directional boring and, in
particular to improved joints and adapters for interconnection of
tools utilized in directional boring.
BACKGROUND OF THE INVENTION
[0003] Directional boring apparatus for making holes through soil
are well known. The directional borer generally includes a series
of drill rods joined end to end to form a drill string. The drill
string is pushed or pulled though the soil by means of a powerful
hydraulic device such as a hydraulic cylinder. A drill head for
boring in soil, rock or both is disposed at the end of the drill
string and may include an ejection nozzle for water or other
drilling fluid to assist in boring. Accurate directional boring
necessarily requires information regarding the orientation and
depth of a cutting or boring tool, which almost inevitably requires
that a electronic sensor and transmitting device ("sonde") be
attached to the cutting tool so that the steering direction can be
determined by the operator on the surface. Such a sonde requires a
protective housing, which adds another component to the drill
string, that is typically coupled between the drill bit and drill
string.
[0004] Ideally, drill heads used in horizontal directional drilling
should be coupled in a mounted in a manner that permits rapid
replacement. Tool breakage, changes in strata and similar
circumstances often require on site tool changes and replacements.
If it is desired to first forward drill a pilot hole and then pull
a back reamer through the hole to widen it, it is necessary to
uncouple the sonde housing and drill bit from the drill string in
the exit pit and mount the back reamer in place of these
components. Consequently, couplings or joints that enable rapid
tool changes are very desirable. Additionally, it may be necessary
to interconnect tools and components having different coupling
types. For example, it may be desirable to couple a sonde housing
or similar tool, configured to receive a convention male API
coupling half, to a starter rod utilizing for example the joint
manufactured and sold by Earth Tool Company L.L.C. of Oconomowoc,
Wis. under the SPLINELOK.RTM. trademark. One style of
SPLINELOK.RTM. coupling is described in detail in U.S. Pat. No.
6,148,935, the disclosure of which is incorporated herein by
reference for all purposes.
[0005] As the '935 patent illustrates, the sonde housing is coupled
to adjacent components of the drill head at its ends, and as such
must have connecting end portions for this purpose. The '935 patent
describes an improved joint in two styles that can be used at
either or both ends of a sonde housing. However, this requires
specialized structures, such as transverse holes and optionally
splines, to be machined as part of the sonde housing. It has been
found that the socket portion of the joint between sonde housing
and starter rod illustrated in the '935 patent tends to wear out
more rapidly than the rest of the assembly, and it would be
desirable to replace that portion of the drill head without having
to replace the entire sonde housing. The present invention provides
an adapter and two-piece sonde housing that address these
needs.
SUMMARY OF THE INVENTION
[0006] An adapter usable for interconnection of a pair of drill
components according to the invention includes an elongated adapter
body having a first end and a second end, wherein the first end
includes one of (1) a tubular wall defining a socket that opens
outwardly at one end of the adapter and having at least one
transverse opening therethrough configured to receive a removable
retainer for mechanically interlocking a projection in the socket,
and (2) the projection which fits into the socket, which projection
has at least one transverse opening therein to receive the
removable retainer. The second end includes a connecting portion
different from the projection and the tubular wall defining the
socket, such as a threaded projection or recess. The adapter
preferably has a lengthwise fluid passage through it suitable for
passing lubricating drilling fluid through the adapter to a drill
head or back reamer. The socket (1) of the first end preferably has
a series of spaced splines arranged in an arcuate formation around
the socket, which splines extend in a lengthwise direction of the
adapter and can engage a series of grooves in an adjoining
component in a manner effective to prevent relative rotation
between the adapter and an adjoining component. If splines are used
in this manner, complementary splines and grooves are also formed
on the projection (2) if the first end is male. An adapter of this
kind can be used to interconnect a component having a pinned,
projection and socket connector with another type of connector that
is less easy to couple and uncouple manually, such as an API
threaded connection.
[0007] The invention further provides a sonde housing assembly
wherein a sonde housing body is connected at one end thereof with
the foregoing adaptor. In such a manner, when the adapter becomes
worn, it can be replaced without requiring replacement of the
entire sonde housing. Similarly, a back reamer assembly according
to the invention includes a back reamer connected at its leading
end to the foregoing adaptor.
[0008] A preferred sonde housing assembly of the invention includes
an elongated tubular housing having an internal chamber for
mounting an electronic locating device for transmitting a signal
indicating orientation or location of the sonde housing assembly, a
front end connecting portion configured for mechanical engagement
of the front end of the sonde housing to a first drill head
component, and a rear end connecting portion configured for
mechanical engagement of the rear end of the sonde housing to a
second drill head component. The assembly further includes an
adapter usable for interconnection of one end of the sonde housing
to another drill component, comprising an elongated adapter body
having a first end and a second end, wherein the first end includes
one of (1) a tubular wall defining a socket that opens outwardly at
one end of the adapter and having at least one transverse opening
therethrough configured to receive a removable retainer for
mechanically interlocking a projection in the socket and (2) the
projection which fits into the socket, which projection has at
least one transverse opening therein to receive the removable
retainer, and the second end includes a connecting portion
different from the projection and the tubular wall defining the
socket, wherein the connecting portion of the adapter is configured
for mechanical engagement with one of the front and rear connecting
portions of the sonde housing.
[0009] An "adapter" for purposes of the invention is any device
having different connecting portions at its ends that is used in a
directional drilling head to connect two other components. A
starter rod is a specialized adapter with a large diameter end that
connects to the next component of the drill head and a smaller
diameter end that connects to the lead rod of the drill string,
generally with a threaded API socket as the connecting portion for
joining to the threaded male projection on the front of the drill
string. A drill head for purposes of the present invention refers
to the assembly of components joined end to end at the front of the
drill string for drilling a hole, forward- or back-reaming an
existing hole, pipe bursting and replacement, or the like. Typical
components of the drill head include a unitary bit or bit assembly,
a sonde housing, an impactor for imparting impacts to the bit, a
sonde housing, one or more reamers, a starter rod and other
adapters. These components are joined end-to-end with the starter
rod at the rear end of the drill head during forward drilling
through soil or rock, and at the front of the drill head during
back reaming. It is well known in the art to forward-drill a pilot
hole with a dirt or rock drilling bit, then interchange the drill
bit with a back reamer in the exit pit, then pull and spin the back
reamer through the existing hole to widen it. The joint described
in the '935 patent is convenient for this purpose since it can be
uncoupled manually and safely. The sonde housing is not needed
during back reaming, so it is generally removed and attached
directly to the starter rod. However, if the back reamer has an API
threaded socket at one end, then an adapter is needed to secure it
to the starter rod as described hereafter. These and other aspects
of the invention are described in the detailed description that
follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] In the accompanying drawings, like numerals represent like
elements except where section lines are indicated:
[0011] FIG. 1 is a side view of a drill head including an adapter
according to the invention;
[0012] FIG. 2 is a lengthwise sectional view taken along the line
2-2 in FIG. 1;
[0013] FIG. 3 is a partial enlarged view, partly in phantom, of the
adapter-starter rod connection of FIGS. 1-2;
[0014] FIG. 4 is a side view an back reamer assembly including an
adapter according to the invention;
[0015] FIG. 5 is a side view of the adaptor used in FIGS. 1-4;
[0016] FIG. 6 is a lengthwise sectional view of a second embodiment
of an adaptor according to the invention;
[0017] FIG. 7 is a side view of a third embodiment of an adaptor
according to the invention;
[0018] FIG. 8 is a right side end view of the embodiment of FIG.
7;
[0019] FIG. 9 is a side view of a fourth embodiment of an adaptor
according to the invention;
[0020] FIG. 10 is a side view, partly in section, of a fifth
embodiment of an adaptor according to the invention;
[0021] FIG. 11 is the same view as FIG. 10, with the other end in
section;
[0022] FIG. 12 is a right side end view of the adaptor of FIG. 11;
and
[0023] FIG. 13 is a side view of a sixth embodiment of an adaptor
according to the invention.
[0024] While the making and using of various embodiments of the
present invention are discussed in detail below, it should be
appreciated that the present invention provides many applicable
inventive concepts which can be embodied in a wide variety of
specific contexts. The specific embodiments discussed herein are
merely illustrative of specific ways to make and use the invention
and are not to limit the scope of the invention.
DETAILED DESCRIPTION
[0025] Turning now to FIGS. 1-5, a drill head 10 includes a bit
assembly 11, an elongated tubular sonde housing 12 having a
internal chamber 14 for mounting and retaining an electronic
locating device for transmitting a signal indicating the
orientation or location of the sonde housing, a sonde housing
adapter 13, and a starter rod 15 for mounting the drill head 10 to
the leading end of a drill string. Bit assembly 11 is further
described in co-pending, commonly-assigned U.S. patent application
Ser. No. 09/393,778, filed Sep. 10, 1999, and sonde housing 12 is
further described in co-pending, commonly assigned U.S. patent
application Ser. No. 09/465,479, filed Dec. 16, 1999, the contents
of which applications are hereby incorporated herein by reference.
A wide variety of bits for horizontal directional drilling in rock,
soil or both are known in the art and all are usable in connection
with the sonde housing assembly of the present invention.
Similarly, a variety of sonde housing structures are known in the
art, such as for example the one shown in the foregoing Wentworth
et al. U.S. Pat. No. 6,148,935.
[0026] The sonde housing assembly is in two pieces, including main
sonde housing 12 and adapter 13. It is most convenient to be able
to access the sonde compartment without taking the drill ahead
apart, and as such many sonde housing designs include a side
opening and door 17 that permits removal and replacement of the
sonde. A leading end 18 of the sonde housing 12 is one half of a
mechanical joint or coupling, in this case, a splined projection of
the type described in the '935 patent coupled to a two piece bit
assembly 11 including a headpiece 19 and replaceable bit 20. Rear
end 16 of sonde housing 12 includes a conical recess 25 with a
threaded inner surface 29. In a preferred embodiment, conical
threaded recess 25 is adapted to receive the male end of a standard
API (American Petroleum Institute) type coupling.
[0027] Adapter 13 includes a threaded projection 24 adapted to
threadedly engage threaded recess 25 of sonde housing 12, securing
adapter 13 to sonde housing 12. Adapter 13 has a generally tubular
wall 30 defining a rearwardly-opening socket 32. A plurality of
transverse retainer openings 31 extend through tubular wall 30 for
receiving two pairs of solid retaining pins 33 (FIG. 2), and at
least one set of detent openings 38 for receiving a roll pin detent
39 extend through wall 30, substantially perpendicular to retainer
openings 31. Openings 38 partially intersect retainer openings 31
at a right angle, and pins 33 have an annular groove 42 into which
roll pins 39 fit when pins 33 are fully inserted. The joint remains
assembled in this manner until the roll pins are removed.
[0028] Tubular wall 30 also includes a plurality of splines 56 and
grooves 58 for mating engagement with splines and grooves of the
male end of starter rod 15. The spline and grooves interconnection
aids in passing torque through the joint. A master spline and
groove pair 35 of a different size than the other splines and
grooves are provided in order to key the connection to a particular
orientation. However, if a sufficient number of pins 33 are
provided that can the joint can bear the maximum load encountered
during use, and keying is accomplished in another manner (such as
with a single key and groove connection) then the splines and
grooves can be omitted. It will also be appreciated that the
configuration at either end of adapter 13 and the parts to which it
connects may be reversed, e.g. the male and female ends reversed.
However, since the leading end of the drill string is generally
male and some users may want to directly connect the drill string
to either a sonde housing or back reamer, the embodiment wherein
adapter 13 has a male threaded end as one connecting portion is
preferred. Adapter 13 can then be removed if a direct connection is
desired.
[0029] Both retainer openings 31 and detent openings 38 are
substantially perpendicular to, and preferably laterally offset
from, the central longitudinal axis of drill head 10. This axis
coincides along part of its length with a fluid flow passage 41
used to pass drilling mud, water or the like through the drill
string and drill head and out of the bit or back reamer in order to
lubricate the hole. However, one skilled in the art will recognize
that the portion of flow passage 41 located in adapter 13 could be
relocated to an off-center position so that one or more openings 31
or 38 could extend through the middle of adapter 13 and intersect
the longitudinal axis of the drill head.
[0030] FIG. 4 illustrates a back reamer assembly 60 according to
the invention utilizing adapter 13 attached to a back reamer 64
having a front end configuration matching the rear end of sonde
housing 12, i.e., front end 61 of reamer 64 has a tapered threaded
socket therein. Starter rod 15 connects to adapter 13 in the same
manner as before. Back reamer 64 has an enlarged diameter rear
portion 66 which can be pulled or spun and pulled through soft
earth to widen the initial borehole during the second run. The
forwardly tapering conical midportion 67 of reamer 64 may have a
radially spaced series of longitudinal grooves 68 therein which
have edges 69 useful in grinding away rock if the borehole extends
through a rock formation. Grooves 68 then conduct material back
from the cutting area when reamer 64 functions as a drill bit in
this manner. Fluid outlets 65 receiving fluid from the passages
through the starter rod, adapter and reamer are commonly located in
the bottoms of grooves 68 for aiding in carrying away cuttings.
[0031] A variety of other adapters suited for other connection
styles for use with drill head components such as back reamers and
sonde housings are shown in FIGS. 6 to 13. In FIG. 6, adaptor 50 is
nearly identical to adapter 13, except that it has a mid section 52
of slightly enlarged diameter, and passage 41 has a flared inner
end 59 to better collect fluid fed from the end of the projection
received in the socket.
[0032] FIGS. 7 and 8 illustrate another adapter 70 with a female
end 71 similar that of adapter 60 and an opposite end with a
central tubular shaft 72 with a central hole 73 that can be welded
directly to an adjacent component. Blind holes 74 may be provided
as needed in the side of adapter 70 to receive tungsten carbide
stud inserts.
[0033] FIG. 9 illustrates an adapter 90 with a female end 91
similar that of adapter 13 and an opposite end formed as a
hexagonal shaft 92 for insertion into a sleeve mounted on the
outside of an adjacent component that slides over shaft 92 in a
manner well known in the art and can be secured by means of a screw
or similar fastener set in a hole 93 opening in the side of shaft
92. This type of joint is well known in the art as a low profile
thread connection.
[0034] FIGS. 10-12 show an adapter 100 with a female end 101
similar to that of adapter 13 and a second female end 102 forming a
hexagonal recess 103 for receiving a hexagonal shaft on the end of
an adjoining component. End openings 104 are provided to aid in
welding the hexagonal shaft to the adapter once fully inserted.
[0035] FIG. 13 illustrates an adapter 130 similar to adapter 13,
except that male projections are provided at both ends, i.e., a
male API threaded projection 131 at one end and a projection 132
with transverse pin holes in that is substantially the same as the
male end of starter rod 15 described in connection with FIGS. 1-4
above. Splines 133 and grooves 134 disposed in an annular formation
outside of projection 132 engage mating splines and grooves on the
starter rod or other adjacent part.
[0036] As the foregoing examples illustrate, the adaptor of the
invention provides a means of coupling tools uses in directional
drilling to a variety of adjacent components in different
configurations. Adaptors in accordance with the invention are
particularly useful in coupling drill bits, sonde housings,
reamers, back reamers, starter rods, impactors and similar drill
head components together in a manner that facilitates rapid
replacement of such components while simultaneously providing
joints and couplings with enhanced reliability. Adaptors in
accordance with the invention also provide the operator with
greater flexibility in terms of being able to change drill string
components to meet the particular requirements encountered during
horizontal drilling.
[0037] While certain embodiments of the invention have been
illustrated for the purposes of this disclosure, numerous changes
in the method and apparatus of the invention presented herein may
be made by those skilled in the art, such changes being embodied
within the scope and spirit of the present invention as defined in
the appended claims.
* * * * *