U.S. patent application number 12/463588 was filed with the patent office on 2010-11-11 for method and system for automated earth boring drill bit manufacturing.
This patent application is currently assigned to BAKER HUGHES INCORPORATED. Invention is credited to Glynn R. BARTLETT, David K. LUCE, Alan J. MASSEY, Crystal A. PARROTT, Sean W. WIRTH.
Application Number | 20100282026 12/463588 |
Document ID | / |
Family ID | 43061550 |
Filed Date | 2010-11-11 |
United States Patent
Application |
20100282026 |
Kind Code |
A1 |
LUCE; David K. ; et
al. |
November 11, 2010 |
METHOD AND SYSTEM FOR AUTOMATED EARTH BORING DRILL BIT
MANUFACTURING
Abstract
A method and system for manufacturing a earth boring tool,
comprising placing a tool in a positioner of an system which then
conforms the tool to a model through the performance of a plurality
of processing steps thereon. The positioner may move the tool in
two axis. The system may include a manipulator which performs each
of the processing steps. Alternatively, the system may include a
plurality of manipulators, each performing a different one of the
processing steps. The processing steps may include various shaping,
cleaning, painting, and packaging steps. The processing steps may
be performed without removing the tool from the positioner. The
tool may be repositioned in the positioner during or between
processing steps. For example, performing the processing steps may
comprise performing one or more of the process steps, repositioning
the tool in the positioner, and re-performing the one or more of
the process steps.
Inventors: |
LUCE; David K.; (Splendora,
TX) ; WIRTH; Sean W.; (Spring, TX) ; MASSEY;
Alan J.; (Houston, TX) ; PARROTT; Crystal A.;
(Helotes, TX) ; BARTLETT; Glynn R.; (Borne,
TX) |
Correspondence
Address: |
LOCKE LORD BISSELL & LIDDELL LLP
600 TRAVIS SUITE 2800
HOUSTON
TX
77002-3095
US
|
Assignee: |
BAKER HUGHES INCORPORATED
Houston
TX
|
Family ID: |
43061550 |
Appl. No.: |
12/463588 |
Filed: |
May 11, 2009 |
Current U.S.
Class: |
76/108.1 |
Current CPC
Class: |
B23P 15/28 20130101 |
Class at
Publication: |
76/108.1 |
International
Class: |
B21K 5/04 20060101
B21K005/04 |
Claims
1. A method of manufacturing a earth boring tool, the method
comprising the steps of: providing at least a partial computer
model of at least a portion of finished earth boring tool to an
automated manufacturing system; placing a tool in a positioner of
the system; causing the system to conform the tool to the model
through the performance of a plurality of processing steps
thereon.
2. The method of claim 1, wherein the positioner moves the tool in
at least one axis.
3. The method of claim 1, wherein the system further includes a
manipulator which performs the processing steps.
4. The method of claim 1, wherein the system further includes a
plurality of manipulators, each performing a different one of the
processing steps.
5. The method of claim 1, wherein the performance of the processing
steps comprises: performing one or more of the process steps;
repositioning the tool in the positioner; and re-performing the one
or more of the process steps.
6. The method of claim 1, the processing steps include: removing an
outer mold shell from the tool; removing casting mold material from
the tool; and shaping the tool.
7. The method of claim 1, the processing steps include: cleaning
the tool; masking predetermined portions of the tool; and painting
exposed portions of the tool.
8. The method of claim 1, the processing steps include: preparing
the tool for paint; painting the tool; and curing the paint.
9. The method of claim 1, the processing steps include: painting
the tool; curing the paint; and preparing the tool for
shipment.
10. The method of claim 1, the processing steps include: applying a
shank protecting material to a shank of the tool; applying a label
to the tool; and packaging the tool.
11. The method of claim 1, wherein each of the plurality of
processing steps are performed without removing the tool from the
positioner.
12. A method of manufacturing a earth boring tool, the method
comprising the steps of: providing at least a partial computer
model of a finished earth boring tool to an automated manufacturing
system; placing a tool in a positioner of the system; causing the
system to conform the tool to the model through the performance of
at least one of a plurality of first processing steps selected from
the group consisting of-- removing casting mold material from the
tool, machining the tool, and grinding the tool; causing the system
to conform the tool to the model through the performance of at
least one of a plurality of second processing steps selected from
the group consisting of-- preparing the tool for paint, painting
the tool, and curing the paint; causing the system to conform the
tool to the model through the performance of at least one of a
plurality of third processing steps selected from the group
consisting of-- applying a shank protecting material to a shank of
the tool, applying a label to the tool, and packaging the tool.
13. The method of claim 12, wherein the positioner moves the tool
in two axis.
14. The method of claim 12, wherein the system further includes a
first manipulator which performs the first processing steps, a
second manipulator which performs the second processing steps, and
a third manipulator which performs the third processing steps.
15. The method of claim 12, wherein the system further includes a
plurality of manipulators, each performing a different one of the
processing steps.
16. The method of claim 12, wherein the performance of the
processing steps comprises: performing one or more of the process
steps; repositioning the tool in the positioner; and re-performing
the one or more of the process steps.
17. The method of claim 12, wherein each of the processing steps of
each of the plurality of processing steps are performed without
removing the tool from the positioner.
18. A method of manufacturing a earth boring tool, the method
comprising the steps of: providing a computer model of a finished
earth boring tool to an automated manufacturing system; placing a
tool in a two axis positioner of the system; causing the system to
conform the tool to the model through the performance of at least
one of a plurality of first processing steps selected from the
group consisting of-- removing casting mold material from the tool,
machining the tool, and grinding the tool; wherein performing at
least one of the first processing steps comprises-- performing one
or more of the process steps, repositioning the tool in the
positioner, and re-performing the one or more of the process steps;
causing the system to conform the tool to the model through the
performance of at least one of a plurality of second processing
steps selected from the group consisting of-- preparing the tool
for paint, painting the tool, and curing the paint; wherein
performing at least one of the second processing steps comprises--
performing one or more of the process steps, repositioning the tool
in the positioner, and re-performing the one or more of the process
steps; causing the system to conform the tool to the model through
the performance of at least one of a plurality of third processing
steps selected from the group consisting of-- applying a shank
protecting material to a shank of the tool, applying a label to the
tool, and packaging the tool.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] None.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO APPENDIX
[0003] Not applicable.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The inventions disclosed and taught herein relate generally
to earth boring drill bits; and more specifically relate to
manufacturing earth boring drill bits.
[0006] 2. Description of the Related Art
[0007] U.S. Pat. No. 6,209,420 discloses a "method of fabricating
rotary-type drill bits, drilling-related structures, and other
articles of manufacture. The method includes fabricating a
machinable matrix, machining the matrix, and dispersing a binder
material throughout the matrix. The matrix of the rotary-type drill
bit may be fabricated by layered-manufacturing techniques or by
disposing a particulate or powdered material into a mold and
binding the particles together with a resin or by sintering. The
matrix may have the desired dimensions and features, the
approximate dimensions and features, or lack desired dimensions or
features of a drilling-related structure or other article of
manufacture. The matrix is machined to correct any anisotropies or
imperfections of the matrix, to refine features of the matrix, or
to define the features in the matrix. The machined matrix may be
infiltrated with a binder material to define a drill bit body."
[0008] There are also several separate examples of automated
processes, such as grinding, cleaning, shaping, masking, painting,
curing, packaging, and labeling, in disparate industries and as
applied to disparate products, such as U.S. Pat. Nos. 4,830,609,
5,175,018, 5,791,968, 6,270,394, 6,562,139, and 7,386,968.
[0009] The inventions disclosed and taught herein are directed to
an improved method and system for manufacturing earth boring drill
bits.
BRIEF SUMMARY OF THE INVENTION
[0010] The present invention is a method and system for
manufacturing a earth boring tool, comprising providing at least a
partial computer model of a finished earth boring tool to an
automated manufacturing system and placing a tool in a positioner
of the system which then conforms the tool to the model through the
performance of a plurality of processing steps thereon. The
positioner may move the tool in two axis. The system may include a
manipulator which performs each of the processing steps.
Alternatively, the system may include a plurality of manipulators,
each performing a different one of the processing steps. The
processing steps may include removing casting mold material from
the tool, grinding cutter pockets of the tool, grinding junk slots
of the tool, cleaning the tool, masking predetermined portions of
the tool, preparing the tool for paint, painting the tool, curing
the paint, preparing the tool for shipment, applying a protecting
material to a portion of the tool, applying a label to the tool,
and/or packaging the tool. In some embodiments, each of the
plurality of processing steps may be performed without removing the
tool from the positioner. However, in some embodiments, the tool
may be repositioned in the positioner during or between processing
steps. For example, performing the processing steps may comprise
performing one or more of the process steps, repositioning the tool
in the positioner, and re-performing the one or more of the process
steps.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0011] FIG. 1 illustrates a perspective view of a drill bit as
might be designed using a computer aided design (CAD) system
utilizing certain aspects of the present inventions;
[0012] FIG. 2 illustrates a flow chart of various processes that
may be performed utilizing certain aspects of the present
inventions;
[0013] FIG. 3 illustrates a block diagram of an initial cleaning
process utilizing certain aspects of the present inventions;
[0014] FIG. 4 illustrates a block diagram of a shaping process
utilizing certain aspects of the present inventions;
[0015] FIG. 5 illustrates a block diagram of a painting process
utilizing certain aspects of the present inventions; and
[0016] FIG. 6 illustrates a block diagram of a packaging process
utilizing certain aspects of the present inventions.
DETAILED DESCRIPTION
[0017] The Figures described above and the written description of
specific structures and functions below are not presented to limit
the scope of what Applicants have invented or the scope of the
appended claims. Rather, the Figures and written description are
provided to teach any person skilled in the art to make and use the
inventions for which patent protection is sought. Those skilled in
the art will appreciate that not all features of a commercial
embodiment of the inventions are described or shown for the sake of
clarity and understanding. Persons of skill in this art will also
appreciate that the development of an actual commercial embodiment
incorporating aspects of the present inventions will require
numerous implementation-specific decisions to achieve the
developer's ultimate goal for the commercial embodiment. Such
implementation-specific decisions may include, and likely are not
limited to, compliance with system-related, business-related,
government-related and other constraints, which may vary by
specific implementation, location and from time to time. While a
developer's efforts might be complex and time-consuming in an
absolute sense, such efforts would be, nevertheless, a routine
undertaking for those of skill in this art having benefit of this
disclosure. It must be understood that the inventions disclosed and
taught herein are susceptible to numerous and various modifications
and alternative forms. Lastly, the use of a singular term, such as,
but not limited to, "a," is not intended as limiting of the number
of items. Also, the use of relational terms, such as, but not
limited to, "top," "bottom," "left," "right," "upper," "lower,"
"down," "up," "side," and the like are used in the written
description for clarity in specific reference to the Figures and
are not intended to limit the scope of the invention or the
appended claims.
[0018] Particular embodiments of the invention may be described
below with reference to block diagrams and/or operational
illustrations of methods. It will be understood that each block of
the block diagrams and/or operational illustrations, and
combinations of blocks in the block diagrams and/or operational
illustrations, can be implemented by analog and/or digital
hardware, and/or computer program instructions. Such computer
program instructions may be provided to a processor of a
general-purpose computer, special purpose computer, ASIC, and/or
other programmable data processing system. The executed
instructions may create structures and functions for implementing
the actions specified in the block diagrams and/or operational
illustrations. In some alternate implementations, the
functions/actions/structures noted in the figures may occur out of
the order noted in the block diagrams and/or operational
illustrations. For example, two operations shown as occurring in
succession, in fact, may be executed substantially concurrently or
the operations may be executed in the reverse order, depending upon
the functionality/acts/structure involved.
[0019] Computer programs for use with or by the embodiments
disclosed herein may be written in an object oriented programming
language, conventional procedural programming language, or
lower-level code, such as assembly language and/or microcode. The
program may be executed entirely on a single processor and/or
across multiple processors, as a stand-alone software package or as
part of another software package.
[0020] Applicants have created a method and system for
manufacturing a earth boring tool, comprising providing at least a
partial computer model of a finished earth boring tool to an
automated manufacturing system and placing a tool in a positioner
of the system which then conforms the tool to the model through the
performance of a plurality of processing steps thereon. The
positioner may move the tool in two axis. The system may include a
manipulator which performs each of the processing steps.
Alternatively, the system may include a plurality of manipulators,
each performing a different one or more of the processing steps.
The processing steps may include removing casting mold material
from the tool, grinding cutter pockets of the tool, grinding junk
slots of the tool, cleaning the tool, masking predetermined
portions of the tool, preparing the tool for paint, painting the
tool, curing the paint, preparing the tool for shipment, applying a
protecting material to a portion of the tool, applying a label to
the tool, and/or packaging the tool. In some embodiments, each of
the plurality of processing steps may be performed without removing
the tool from the positioner. However, in some embodiments, the
tool may be repositioned in the positioner during or between
processing steps. For example, performing the processing steps may
comprise performing one or more of the process steps, repositioning
the tool in the positioner, and re-performing the one or more of
the process steps.
[0021] In the manufacture of earth boring tools and components,
such as the type having cutting elements fixed in recesses,
accurate cutting element placement is critical. In an as cast or as
initially machined form, there are minor defects that must be
removed to allow accurate placement of the cutting elements, as
well as other defects that may impact the performance of a finished
tool.
[0022] For example, earth boring tools, such as drill bits, may be
cast by infiltrating a binder material throughout a matrix of
particulate material, such as powdered steel or tungsten carbide,
as described in U.S. Pat. No. 6,209,420, which is incorporated
herein by specific reference. While the matrix, or even a steel bit
body blank, may be initially machined, additional imperfections
often arise as or after the tool is cast or otherwise initially
formed.
[0023] Referring now to FIG. 1, an exemplary drill bit 10 is
depicted as modeled by a state-of-the-art computer aided design
(CAD) system. Such systems are well-known and widely used, and a
particularly suitable, commercially available CAD system for
implementation of the present invention is the Pro/ENGINEER,
offered by Parametric Technology Corporation. Drill bit 10, as
shown, includes a variety of external and internal components, such
as bit body 12 that may be secured to a blank (not shown), which is
secured to a tubular bit shank 14 having a threaded pin connection
16 at the free end thereof and six blades or wings 18 carrying
cutting elements 20 placed in cutter pockets 22 and supported from
the rear by inclined buttresses 24. Gage trimmers 26 are set
immediately adjacent and above (as depicted in the drawing figures)
gage pads 28. Blades 18 are separated by generally radially
extending fluid courses 30 leading to junk slots 32, fluid courses
30 and junk slots 32 being provided in operation with drilling
fluid ("mud") from the drill string through bit shank 14
communicating with internal fluid passages leading to nozzles 36 in
cavities 38 opening onto fluid courses 30. Blades 18, fluid courses
30, and the topographical details thereof collectively define what
may be termed the "bit face;" being the surface of the bit in
contact with the undrilled formation at the bottom of the borehole.
The exterior shape of a diametrical cross-section of the bit body
12 taken along the longitudinal bit axis 40 defines what may be
termed the bit or "crown" profile.
[0024] The present invention comprises an automated, and/or
semi-automated, method and system for conforming a rough, or
initially formed, tool to a finished and ready-for-shipment earth
boring tool, such as that discussed above and shown in FIG. 1.
Referring also to FIG. 2, the method may include creating and
providing a complete or partial computer model of the finished
earth boring tool, or portion thereof, to an automated
manufacturing system, as shown in step 2A; placing the tool in one
or more positioners of the system, as shown in step 2B; and causing
the system to conform the tool to a model through the performance
of a plurality of processing steps thereon, as shown in steps 2C,
2D, 2E, 2F, 2G, and 2H.
[0025] More specifically, the drill bit 10 of the present invention
may go through several processing steps, some or all of which may
be automated, semi-automated, and/or manually performed. These
processing steps include casting, mold removal, machining and/or
grinding, shank attachment and/or welding, cutter attachment and/or
brazing, cleaning, one or more quality inspections, marking, paint
preparation, painting, and/or packaging. While most, if not all, of
these processes may be automated according to certain aspects of
the present invention, only a subset of these processing steps will
be discussed below in an effort to aid in understanding the
invention.
[0026] Furthermore, the system of the present invention will be
described as a single system, with one or more sub-systems to
accomplish various tasks. However, it should be understood that the
system of the present invention may be implemented as one or more
independent sub-systems. Finally, in one embodiment of the present
invention, each of the processing steps may be automatically
performed upon the tool, without manually removing the tool from
the positioner. For example, the tool may be automatically
repositioned within the positioner. Alternatively, the tool may be
semi-automatically or manually repositioned within the positioner,
as needed. In still other alternative embodiments, the tool is
manually placed in the positioner for one or more of the processing
steps, removed from the positioner for manual performance of one or
more of the processing steps, and then replaced in the same or a
different positioner for one or more of the processing steps. Thus,
the present invention provides for automated and/or semi-automated
performance of multiple, if not all, of the processing steps
required to fabricate the bit 10.
[0027] In one embodiment, the positioner may secure the tool in a
stationary position. For example, a stationary positioner may
function similarly to a rigidly secured vise. Alternatively, the
positioner may move the tool along, and/or rotate the tool about,
one, two, or three dimensions, or axis. For example, the positioner
may include a turn-table and/or a multi-dimensional robotic arm.
The tool may be transferred from one positioner to another, with or
without one or more processing steps being performed manually.
Alternatively, one or more of the processing steps may be performed
without removing the tool from a single positioner. In any case,
the tool may be repositioned in the positioner(s) during or between
processing steps, as shown in step 2I. For example, performing the
processing steps may comprise performing one or more of the process
steps, repositioning the tool in the positioner, and re-performing
the one or more of the process steps. This would allow the process
step(s) to be performed on an otherwise inaccessible portion of the
tool that might otherwise be blocked by the positioner.
[0028] The system may include one or more manipulators which
perform one, several, or each of the processing steps. For example,
the manipulator may incorporate interchangeable attachments for
each of the processing steps. The attachments may be automatically
and/or manually exchanged. Alternatively, the system may include a
plurality of manipulators, each performing a different one or more
of the processing steps. For example, the positioner may move the
tool to an appropriate one of the manipulators and/or the
appropriate manipulator may come to the positioner and tool.
[0029] The system may be a single automated machine or multiple
integrated automated machines and/or sub-systems, and may be
integrated with other sub-systems. The system may include automated
elements as well as manual elements. For example, the system may
include an automated, semi-automated, and/or manual waste
reclamation sub-system, running along-side various other processes
and/or sub-systems.
[0030] As discussed above, the processing steps may include various
casting, mold removal, machining and/or grinding, shank attachment
and/or welding, cutter attachment and/or brazing, cleaning, one or
more quality inspections, marking, paint preparation, painting,
and/or packaging steps. More specifically, referring also the FIG.
3, initial cleaning processes 3A may include disassembly of a mold
used to cast the tool 3B and/or removal of the mold material 3C.
For example, after the tool is initially cast using a manual
process and/or a mold assembly, the positioner may be used to
capture the mold assembly containing the tool and move it to a
station that grips and disassembles the mold components. More
specifically, the system may capture a binder head and orient the
tool to a position where there is access to remove a mold component
assembly, which may include an outer mold shell, and then remove
any remaining mold material.
[0031] These initial cleaning processes, as well as other
processes, may be performed by one or more automated,
semi-automated, or manual sub-systems. The system may also include
an automated and/or manual mold component recovery sub-system. The
system may further include an automated and/or manual mold
component evaluation and disposition sub-system. These sub-systems
may be integrated and operate in synchronization, or may be
independently controlled to operate as needed.
[0032] In any case, the system may include sensors to assist with
positioning and/or evaluation of the mold and/or tool. For example,
evaluation sensors may be capable of evaluating dimensional
measurements, oxidation levels, and the structural integrity of the
tool. The sensors may operate by machine vision, structured light,
laser scanning, and/or probe sensing. Evaluation information may be
stored and utilized for ultimate disposition of the tool.
[0033] The manipulator may remove mold material and/or flashing
from the mold assembly by crushing, blasting, wheel impact or a
combination thereof. Blasting media may include any combination of
water, abrasive water, shot, walnut shell, garnet, glass bead,
metal oxides, and/or dry ice pellets. The manipulator may use any
combination of rotating and/or impacting material removal tools
such as wire wheels, wheel-type blasting, fiber wheels, hammer
mills, and/or needle scaling.
[0034] As discussed above, the manipulator may be moved relative to
the mold assembly, held in the positioner, and/or the mold assembly
can be moved relative to the manipulator. The relative motion can
be derived from CAD data and or sensor feedback. For example, a CAD
model may be used to automatically or semi-automatically create
algorithms consisting of positioner and manipulator relative motion
paths and attachment control commands.
[0035] Referring also the FIG. 4, the shaping processes 4A may
include machining 4B, grinding 4C, or otherwise shaping the blades
18, cutter pockets 22, fluid courses 30, and/or junk slots 32.
Faces of blades 18 may be ground to remove matrix projections that
would interfere with identification of cutter pocket locations. The
cutter pockets 22 themselves may be ground to a final size and
shape to accept the cutter elements 20. Thus, the cutter pockets 22
may be validated to insure proper fit, such as by using surface
mapping, or sensory feedback. Corrections may be affected through
further shaping through manual or automatic processes. Similarly,
the fluid courses 30, and/or junk slots 32 may be ground to ensure
proper flow of the drilling fluid and cuttings.
[0036] The shaping process may have portions that are automated and
portions that are manual. More specifically, as discussed above,
the shaping processes may be performed by one or more automated,
semi-automated, or manual sub-systems. The system may also include
an automated and/or manual waste recovery, evaluation, and/or
recycling sub-system.
[0037] Grinding types that may be used include diamond, rock,
garnet wheels, honing wheels, and/or cubic boron nitride (CBN).
Grinding shapes that may be used include spherical, cylindrical,
disk, and/or cone. Additionally, other grinding types and/or shapes
may be used.
[0038] The system may utilize fixed patterns and/or adaptive
patterns for shaping, as well as the other processes performed
during manufacturing. For example, the system may use the CAD data
and/or surface mapping to create grinding manipulator paths.
Surface mapping techniques such as laser scanning, structured light
and/or contact probing could be used to attain a surface map of the
earth boring tool as well as cutting element pocket location,
obstructions, graphite inclusions, matrix inclusions, and/or major
casting deviations, etc. For example, linear displacement tools may
be used to attain dimensional information of the earth boring tool.
Additionally, or alternatively, force feedback may be used to
adaptively control the shaping process. For example, the system may
use torque, lateral side forces, and/or longitudinal end
forces.
[0039] At this point, or virtually any other point in
manufacturing, the tool may be marked. For example, tool marking
may be done using an automated, semi-automated, or manual device.
Marking can be accomplished with laser etch, impact, grinding,
magnetic coding, RFID, flame spray, stencil, and/or chemical etch
techniques.
[0040] Referring also the FIG. 5, the painting processes 5A may
include various cleaning 5B, masking 5C, painting 5D, and/or curing
5E processes. As discussed above, the system may include single or
multiple manipulators to systematically and consistently clean
and/or apply surface treatments. Various degrees of manipulation
and automation may be used. More specifically, as discussed above,
the painting processes may be performed by one or more automated,
semi-automated, or manual sub-systems. The system may also include
an automated and/or manual waste recovery, evaluation, and/or
recycling sub-system.
[0041] A single rotational axis positioner holding the earth boring
tool or component coupled with a single linear axis manipulator
with a paint and/or cleaning attachment could accomplish simple
tool shapes. For complex shaped earth boring tools a two axis
positioner holding the earth boring tool coupled with a multi-axis
manipulator with the cleaning and/or painting attachment would
allow for more complex manipulator, or attachment, to tool surface
orientation. Thus, in one preferred embodiment, a two axis
positioner holds the earth boring tool for a multi-axis manipulator
with various paint preparation and paint application
attachments.
[0042] As discussed above, the system may reposition the tool
within the positioner during and/or between processes. For example,
the system may clean, or otherwise process, the tool where
accessible then reposition the tool within the positioner. The
system may then clean, or otherwise process, the earth boring tool
or component where access was constrained in the previous setup.
The system may then apply masking if necessary, and to locations
that are accessible. The earth boring tool would then be
repositioned in the positioner in its original orientation. The
system may then apply masking to areas inaccessible in the second
earth boring tool orientation.
[0043] At this point, the basic surface prep, masking, and
temperature can be inspected. The inspection may be conducted
automatically, or semi-automatically, with sensors, or may be
conducted manually. In either case, the tool may remain in the
positioner, be removed from the positioner, and/or be moved to
another positioner for inspection.
[0044] The results of this inspection, may be used in the decision
to paint, re-prep, or alert for operator review. In the case where
the decision is made to paint, the system may use a single paint
gun with multiple paint feed stocks or multiple paint attachments
each with one or more paint feed stocks. Masks can be applied and
removed as necessary to attain selective multi-tone coatings. In
each case, the tool may be repositioned in the positioner, such
that the positioner allows access to portions of the tool to be
painted. The earth boring tool may then be inserted into a curing
oven or atmospheric control chamber where temperature and pressure
may be used to increase the efficiency of or the resulting quality
of the curing process.
[0045] More specifically, an automated or semi-automated cleaning
process may include blasting, vapor degreasing, washing, steam
washing, and/or solvent cleaning. Blasting media may include any
combination of water, abrasive water, shot, walnut shell, garnet,
glass bead, metal oxides, and dry ice pellets. As discussed above,
the earth boring tool cleaning my include any combination of moving
the earth boring tool and/or the cleaning attachment using an
automated or semi-automated system. As also discussed above, earth
boring tool cleaning can be enhanced in that systematic cleaning
paths may be created automatically based on CAD data and utilized
to reduce waste.
[0046] Automated or semi-automated masking of cutting elements 20
and/or cutter pockets 22 may include magnetic, adhesive stickers,
tape, grease coating, and/or water soluble paste as masking agents.
In some cases cutter faces of the cutting elements 20 are not
masked prior to paint. Alternatively, the cutting elements 20 may
be repainted for contrast with the rest of the earth boring
tool.
[0047] Automated or semi-automated masking of nozzle orifices 38
may include screw in plugs, press in plugs and/or drop in plugs.
Automated or semi-automated masking of the earth boring tool may be
accomplished by inserting the tool 10 into a sleeve or installing a
sleeve over the section or portion to be masked. An adjustable or
multiple concentric sleeves could be used to adapt to varying
diameters of earth boring tool sections that require masking.
Shadow masks can be used where multiple paints are used on the
earth boring tool.
[0048] As discussed above, and as with other manufacturing
processes, automated or semi-automated masking of earth boring bit
may include locating areas to be masked with vision sensing devices
and/or CAD data. Similarly, automated or semi-automated cleaning,
masking, painting, and/or curing may be accomplished with the
movement of the earth boring tool under a stationary or moving
attachment, and/or moving the attachment relative to the stationary
or moving earth boring tool.
[0049] Painting, or coating, processes may be performed with an
automated or semi-automated sub-system or technique, such as spray,
dip, electrostatic powder coat, brush, roller, and/or flame spray.
Automated or semi-automated painting of earth boring tools may be
accomplished with one or more of the following coating
types--epoxy, enamel, powder, latex, polyurethanes, and alkyd.
Automated or semi-automated painting of earth boring tools may
utilize one or more of the following coating delivery systems:
dynamic mixing, pressure pots, canister, can, cartridge, bells,
nozzles, reciprocators, automation. This painting process may be
performed with a temperature controlled environment, an
atmospherically controlled chamber, and/or a barometrically
controlled chamber.
[0050] To decrease the curing time of an earth boring tool or
component, heat may be applied to the earth boring tool, or portion
thereof, prior to painting. Methods of preheating the earth boring
tool may include convection oven, induction coil, radiant heat,
flame, hot liquid tank, and/or hot liquid pressurized tank. These
methods may be utilized with or without a color additive. The
curing rate may be controlled in a barometric pressure chamber.
[0051] Referring also the FIG. 6, the packaging processes 6A may
include applying protective materials to select portions of the
tool 6B, labeling the tool 6C, and/or boxing or crating the tool
6D. Applying protective materials may comprise automated or
semi-automated application of grease, wax, plastic, or other
protective material to select portions of the tool, such as the
shank. Such protective application may be accomplished through
brushing, injecting, spraying, and/or dipping. Applying a more
rigid shank protector, through automated or semi-automated
installation, may be accomplished with vacuum, gripping, and/or
magnetic techniques. Furthermore, a heat shrinkable material may be
installed over the shank of the tool or component then heat
activated to shrink down over the threads providing protection.
[0052] Labels may be applied to earth boring tools, components and
their respective boxes using an automated or semi-automated
sub-system. This sub-system may be the same sub-system that applies
paint or separate therefrom. Labels may be printed based on CAD
and/or other production control data and applied to the earth
boring tool or component by the automated or semi-automated
sub-system. The sub-system may use structured light, laser
scanning, and/or CAD data to locate an appropriate position for the
label on the earth boring tool or component.
[0053] Labels can be printed directly on the earth boring tool.
Alternatively, or additionally, plain, or white, labels may be
applied to the earth boring tool or component, identifying
information being printed on the label, with the label on the tool.
Alternatively, or additionally, Labels may be printed in batches
and selected manually based on CAD or production control data and
applied to the earth boring tool or component manually, by the
automated system and/or by some semi-automated sub-system.
[0054] Similarly, an automated or semi-automated sub-system may be
used to apply protective packaging materials and/or peripheral
items to the tool as required by CAD or production control data and
then place the tool in an appropriate shipping container. This
sub-system may pick and place a lid onto the container and secure
the container. This sub-system may also pick and secure an
appropriate label on the container.
[0055] It can be seen that the system of the present invention may
yield less cutting element recess geometric and dimensional
variances and more accurate cutting element recess location
relative to the design intent. The system of the present invention
may also create more consistent higher quality surface treatments
and more consistent surface finishes. The system of the present
invention may also reduce labor cost and move operators away from
potential safety hazards, as well as permit the use of materials
that are potentially hazardous to human operators.
[0056] Other and further embodiments utilizing one or more aspects
of the inventions described above can be devised without departing
from the spirit of Applicant's invention. For example, an entire
tool may be processed at once, or together, or individual
components of a tool may be processed individually. Further, the
various methods and embodiments of the present invention can be
included in combination with each other to produce variations of
the disclosed methods and embodiments. Discussion of singular
elements can include plural elements and vice-versa.
[0057] The order of steps can occur in a variety of sequences
unless otherwise specifically limited. The various steps described
herein can be combined with other steps, interlineated with the
stated steps, and/or split into multiple steps. Similarly, elements
have been described functionally and can be embodied as separate
components or can be combined into components having multiple
functions.
[0058] The inventions have been described in the context of
preferred and other embodiments and not every embodiment of the
invention has been described. Obvious modifications and alterations
to the described embodiments are available to those of ordinary
skill in the art. The disclosed and undisclosed embodiments are not
intended to limit or restrict the scope or applicability of the
invention conceived of by the Applicants, but rather, in conformity
with the patent laws, Applicants intend to fully protect all such
modifications and improvements that come within the scope or range
of equivalent of the following claims.
* * * * *