U.S. patent application number 14/412941 was filed with the patent office on 2015-07-23 for laser alignment device for use with a drill rig.
The applicant listed for this patent is Precision Alignment Holdings Pty Ltd.. Invention is credited to Jordan O'Reilly.
Application Number | 20150204149 14/412941 |
Document ID | / |
Family ID | 49881166 |
Filed Date | 2015-07-23 |
United States Patent
Application |
20150204149 |
Kind Code |
A1 |
O'Reilly; Jordan |
July 23, 2015 |
LASER ALIGNMENT DEVICE FOR USE WITH A DRILL RIG
Abstract
A laser alignment device for use with a drill rig having an
elongate drill rod, the laser alignment device including a head
unit having at least one laser emitting device to indicate the
drill rod orientation and an inertial measurement device to
indicate at least the azimuth of the at least one laser emitting
device, and an attachment arrangement to attach the head unit to a
drill rig wherein the alignment device is used to align at least
the azimuth of the drill rod relative to one or more survey points.
The attachment arrangement includes a head chuck, tail chuck and
connecting rod which allows the laser emitting device to be located
and orientated in a direction which simulates the drill rod.
Inventors: |
O'Reilly; Jordan; (Yeppoon,
AU) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Precision Alignment Holdings Pty Ltd. |
Yeppoon, QLD |
|
AU |
|
|
Family ID: |
49881166 |
Appl. No.: |
14/412941 |
Filed: |
July 5, 2013 |
PCT Filed: |
July 5, 2013 |
PCT NO: |
PCT/AU2013/000733 |
371 Date: |
January 5, 2015 |
Current U.S.
Class: |
175/45 |
Current CPC
Class: |
E21B 47/024 20130101;
E21B 7/02 20130101; E21B 7/04 20130101; E21B 19/24 20130101; E21D
9/004 20130101 |
International
Class: |
E21B 19/24 20060101
E21B019/24; E21B 47/024 20060101 E21B047/024; E21B 7/04 20060101
E21B007/04 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 5, 2012 |
AU |
2012203948 |
Claims
1. A laser alignment device for use with drill rig having an
elongate drill rod, the laser alignment device including a head
unit having at least one laser emitting device fixed in orientation
to indicate the drill rod orientation, and a gyrocompass to
indicate at least the azimuth of the at least one laser emitting
device, and an attachment arrangement to attach the head unit to a
drill rig wherein the alignment device is used to align at least
the azimuth of the drill rod relative to one or more survey points
by adjusting the position of the drill rig using the at least one
laser emitting device to point to a desired drilling location.
2. A laser alignment device as claimed in claim 1 wherein the
device is also used to align the drill rod to a required drill rod
dip angle.
3. A laser alignment device as claimed in claim 1 wherein the laser
alignment device is provided with a mechanism to locate the drill
rig.
4. A laser alignment device as claimed in claim 1 wherein the least
one laser emitting device points forwardly, that is in the
direction of the drilling.
5. A laser alignment device as claimed in claim 1 wherein an
inclinometer is provided to align the drill rod to a required drill
rod dip angle.
6. A laser alignment device as claimed in claim 1 further including
a display device to display any parameters measured or indicated by
the head unit.
7. A laser alignment device as claimed in claim 1 wherein a spindle
including a bearing race is provided as a part of said attachment
arrangement in order to allow the gyrocompass of the head unit to
self-position.
8. A laser alignment device as claimed in claim 1 wherein said
attachment arrangement includes a head chuck, a tail chuck and a
connecting rod located between the head chuck and tail chuck.
9. A laser alignment device as claimed in claim 8 wherein said head
chuck is attached to the connecting rod and said tail chuck is
removably attached to said connecting rod at an opposite end to the
head chuck and is movable along at least a portion of the length of
the connecting rod.
10. A laser alignment device as claimed in claim 8 wherein the head
chuck is substantially conical in shape.
11. A laser alignment device as claimed in claim 8 wherein the head
chuck is substantially frustoconical.
12. A laser alignment device as claimed in claim 8 wherein said
connecting rod is mounted permanently to the head chuck and is
received through the tail chuck in order that the tail chuck can be
removed from the connecting rod and also moved along the length of
the connecting rod.
13. A laser alignment device as claimed in claim 8 wherein a
threaded portion is provided at least partially along the length of
the connecting rod of sufficient length in order to fit the head
chuck and tail chuck on either side of a collar drives.
14. A laser alignment device as claimed in claim 8 wherein the tail
chuck is substantially conical in shape.
15. A laser alignment device as claimed in claim 8 wherein the tail
chuck is substantially frustoconical.
16. A laser alignment device as claimed in claim 14 wherein the
tail chuck is oriented in a reverse direction to the head
chuck.
17. A laser alignment device as claimed in claim 8 wherein the tail
chuck includes a bore extending through the tail chuck.
18. A laser alignment device for use with drill rig having an
elongate drill rod, the laser alignment device including a. a head
unit having at least one laser emitting device to indicate the
drill rod orientation; b. an inertial device to indicate at least
the azimuth of the at least one laser emitting device, and c. an
attachment arrangement to attach the head unit to a drill rig
wherein the alignment device is used to align at least the azimuth
of the drill rod relative to one or more survey points wherein the
position of the drill rig is adjusted to align at least the azimuth
of the drill rod relative to one or more survey points and the
laser emitting device is maintained in a fixed orientation
indicating the orientation of the drill rod using the at least one
laser emitting device to point to a desired drilling location.
19. A laser alignment device as claimed in claim 18 wherein the
head unit is permanently attached to a drill rig.
20. A laser alignment device as claimed in claim 18 wherein the
inertial device is permanently attached to a drill rig.
21. A laser alignment device as claimed in claim 18 wherein at
least one of the head unit and the inertial device transmit
alignment information to an electronic graphic display remote from
the head unit and the inertial device.
22. A drill rig including a laser alignment device as claimed in
claim 19 linked to drive apparatus such that drilling parameters
can be entered into a control panel or other computing device to
enable the drill rig to move to a location corresponding to the
entered parameters.
23. A drill rig as claimed in claim 22 wherein display and control
software is provided on a display device capable of transmission of
control information to the drive apparatus such that a visual
display of a drill site can be produced on the display device and
control instructions can be issued from the display device to the
drive apparatus to navigate the drill rig to a hole location
allowing both navigation and alignment of the drill rig.
24. A method of aligning a drill rig having an elongate drill rod
using a laser alignment device including a head unit having at
least one laser emitting device to indicate the drill rod
orientation an inertial device to indicate at least the azimuth of
the at least one laser emitting device, and an attachment
arrangement to attach the head unit to a drill rig the method
including the steps of adjusting the position or orientation of the
drill rig for the required azimuth and dip angle to ensure the
correct positioning and using the at least one laser emitting
device maintained in a fixed orientation pointing to indicate the
orientation of the drill rod to ensure the drill rod points to a
desired drilling location.
Description
TECHNICAL FIELD
[0001] The present invention relates to alignment devices and
particularly to those which can be used to align drilling rigs to
ensure correct drilling azimuth and/or dip angle.
BACKGROUND ART
[0002] In mining, whether underground or surface mining (e.g.
diamond mining, goldmining etc), once the mine has been formed,
exploratory drill holes are typically then formed to try to locate
ore bodies. These drill holes can have a length of up to 1 km bur
are usually much shorter.
[0003] Initially, geologists will determine the likely location of
an ore body or seam. The mine geologist will design the mine and
the location of the exploratory holes and the surveyors will place
survey markers in appropriate locations marking the intended hole
positions. The survey markers will comprise a first mark on one
wall of the mine and a second mark on an opposed wall of the mine.
The markers are usually small reflective squares pinned to the mine
wall. A "string line" between the two markers will show exactly the
direction that the drilling apparatus will need to drill. This is
known technology. For surface mines, a pair of pegs or markers
inserted into the ground are typically used.
[0004] The direction typically includes the two components
"elevation" and the "azimuth". The elevation is the angle to the
horizontal at which the drill rod is oriented and the azimuth is
the degree or direction about a vertical axis that the drill rod is
oriented.
[0005] Ensuring the correct "elevation" is usually not a great
problem as the drill rig can quite easily be angled upwardly or
downwardly to the correct elevation. However, ensuring the correct
"azimuth" has been a problem to date and even a small error in the
azimuth can cause rejection of the bore hole.
[0006] Once the survey markers have been completed, a drill rig is
positioned to drill the required core samples. The drill rig is
usually a very large self-propelled apparatus. A typical apparatus
comprises a wheeled or tractor vehicle which has a forwardly
extending boom arm and attached to the boom arm is a drill rig. The
drill rig is attached to the boom arm such that it can adopt any
required angle (in FIGS. 1 and 2 the drill rig is pointing
downwardly)
[0007] This type of apparatus is well-known and there are many
different sizes and types of such apparatus, such as that
illustrated in FIG. 3 for example which is an example of a
skid-steered self-propelled rig.
[0008] Once the drill rig is roughly in position (determined by the
survey markers), it needs to be very accurately adjusted to the
survey markers. Once the adjustment is complete, the drill rig is
secured in position and this is usually done by bolting the drill
rig to the mine floor using a known type of feed frame positioner.
For larger rigs, the weight of the rig can be sufficient to
maintain the position.
[0009] The drill rig is then turned on to drill the required
hole.
[0010] The present invention is directed to a laser unit device
that can be used to very accurately correctly adjust the azimuth of
the rig prior to bolting (securing) the rig into position.
Preferably, the laser unit device is a gyroscopically aligned laser
unit device.
[0011] Conventionally, string lines are used to align the rig prior
to securement of the rig into position. That is, a string line is
stretched between the survey markers on the opposed walls of the
mine shaft. The apparatus is then positioned as close as possible
to the string line and is aligned with the string line (that is the
drill rig is aligned to be parallel with the string line to get the
correct azimuth). Because of the size and shape of the apparatus,
it is not possible to place the apparatus against the string line
and usually the apparatus will be some distance away from the
string line. For a "normal" sized apparatus, the apparatus will
still be about 1 m away from the string line but for a larger
apparatus, this can be between 3 to 4 m from the string line. A
measuring tape is then used to accurately measure the distance
between the front and the rear of the apparatus and the string line
to ensure that the apparatus is exactly parallel with the string
line such that when a hole is drilled, the hole will be at the
correct azimuth.
[0012] In practice, it is difficult to obtain the level of accuracy
that is demanded by the geologists using this known technique of
string lines and measuring tapes. Once a pilot hole is collared,
and it reaches its first survey mark (normally at approximately 5
to 15 meters) a survey tool is then inserted into the drilled hole.
This survey tool normally provides a reading of both the elevation
and the azimuth of the pilot hole. The driller then checks this
against the hole plans and if not exactly correct, the hole will
need to be redone.
[0013] The cost of drilling each hole can be many thousands of
dollars and it is not unknown for the cost to be about $100,000 per
hole. A drilling contractor is not paid for a "rejected" hole.
[0014] In the present specification, the term "drill rig" is not
intended to be limiting and includes any type of drill or surface
rig adapted to drill a hole in any type of mine including a surface
or underground mine.
[0015] It will be clearly understood that, if a prior art
publication is referred to herein, this reference does not
constitute an admission that the publication forms part of the
common general knowledge in the art in Australia or in any other
country.
SUMMARY OF INVENTION
[0016] The present invention is directed to a laser alignment
device, which may at least partially overcome at least one of the
abovementioned disadvantages or provide the consumer with a useful
or commercial choice.
[0017] With the foregoing in view, the present invention in one
broad form, resides broadly in a laser alignment device for use
with a drill rig having an elongate drill rod, the laser alignment
device including a head unit having at least one laser emitting
device, the laser devices movable in one plane only, an attachment
means to attach the head unit to a drill rig and an adjustable
assembly to adjust the positioning of the head unit relative to the
drill rod, wherein the alignment device is used to align at least
the azimuth of the drill rod relative to a desired orientation.
[0018] In an alternative, the invention resides in a laser
alignment device for use with a drill rig having an elongate drill
rod, the laser alignment device including a head unit having at
least one laser emitting devices, the laser devices movable in one
plane only, an attachment means to attach the head unit to a drill
rig and an adjustable assembly to adjust the positioning of the
head unit relative to the drill rod, wherein the alignment device
is used to align at least the yaw of the drill rod relative to a
desired orientation.
[0019] The least one laser emitting device may be a rotating or
static laser capable of projecting a laser beam. The desired
orientation can be indicated in any way including through the use
of survey points or simply as an angle with appropriate descriptive
information.
[0020] In a preferred embodiment, the laser alignment device will
align the pitch and the yaw of the drill rod, or put another way,
the inclination and azimuth of the drill rod. Normally, a laser
device will be used to align the azimuth or yaw of a drill rod
relative to survey marks to ensure that the drill rod is on the
correct heading. In addition or in the alternative, bearing devices
may be used once a laser beam device has established the
alignment.
[0021] An inclinometer, clinometer, gyroscope, sensors laser
detectors repeaters or any type of device may be used to ensure
that the drill rod has the correct inclination or tilt angle.
[0022] The device of the present invention can be used in
underground situations or above ground, surface situations.
[0023] With the foregoing in view, the present invention in a
second form, resides broadly in a laser alignment device for use
with a drill rig having an elongate drill rod, the laser alignment
device including a head unit having at least a pair of laser
emitting devices mounted independently to one another thereon, each
of the laser devices movable in one plane only and oriented in
substantially opposite directions to one another, an attachment
means to attach the head unit to a drill rig and a length
adjustable assembly to adjust the separation distance between the
head unit and the drill rod, wherein the alignment device is used
to align at least the azimuth of the drill rod relative to survey
marks.
[0024] Typically, the lasers will be used to align or adjust the
drill rod to the correct elevation or angle as well as azimuth.
[0025] As discussed above, it is typically difficult to obtain the
level of accuracy of alignment of the drill that is demanded by the
geologists and surveyors using the known technique of string lines
and measuring tapes. The present invention obviates the need for
string lines and droppers and measuring tapes and increases the
accuracy of the alignment of the drill rig and thereby the
precision of the holes which is drilled.
[0026] Preferably the alignment of the drill rig takes place prior
to securing the drilling rig in position to drill the hole.
[0027] The drill rig in relation to which the device of the present
invention is used normally includes a pair of parallel steel feed
rails. A carriage is provided which normally slides relative to the
rails.
[0028] The device of the present invention will normally be
attached to the feed rails although it may be attached to any
portion of the drill rig. Any mechanism of attachment may be used
but the preferred form of attachment is a secure attachment but one
which is also easily removable as the device will normally be
removed prior to commencement of the drilling.
[0029] Preferred methods of attachment include pin and slot or
clamping arrangements but most preferred is a magnetic attachment.
A magnetic attachment increase utility of the device as the device
can be attached to any metal portion of the drill rig according to
the preference the user.
[0030] The device will typically be temporarily attached to the
drill rig during the alignment phase of the operation of preparing
the drill rig for use and will be removed prior to operation of the
drill rig. The device will normally remain in place until after the
drill rig has been secured in position to limit the chance that the
drill rig moves accidentally during the fixing process and to check
the alignment of the drill rig.
[0031] The device of the present invention includes a head unit.
The head unit typically mounts the pair of opposed laser pointing
devices in a removable manner. Alternatively, the head unit may
mount a single rotating laser device.
[0032] Any laser pointing devices may be used. Each of the laser
pointing devices are typically held by a laser holding means. The
laser holding means are typically attached relative to one another.
Each laser pointing device can be moved relative to one another via
a hinge or pivot or the like extending through both
[0033] Each laser holding means will typically clamp or receive the
laser pointing devices in a threaded engagement.
[0034] Each laser holding means is preferably provided with a
finger tab extending at an angle to the holding means. These finger
tabs typically allow each laser to be moved so to point to the
survey marks during the alignment process.
[0035] The laser holding means may be "sandwiched" between a
backing plate and a front plate. Each of the plates and typically
the laser holding means itself will be provided with at least one
magnetic strip. The respective magnetic strips will preferably
function to magnetically clamp the laser holding means to hold the
laser holding means in position once aligned with the survey marks
or pegs. A pair of arcuate openings may be provided through the
front plate through which the finger tabs extend.
[0036] Although the abovementioned magnetic means is preferred, any
releasable attachment means can be used.
[0037] Importantly, each of the laser devices move only in a plane
which is substantially vertical, such that the laser pointing
devices can move up and down only and not side to side. The head
unit will therefore also be parallel to the foot portion.
[0038] The attachment means of the head unit is preferably
associated with attachment means to attach the head unit relative
to the drill rig.
[0039] Preferably an actuable electromagnet attachment will be
used. The attachment means will also typically be length adjustable
to adjust the distance between the drill rig in general and the
drill rod in particular and the head unit.
[0040] The length adjustment means will typically include a rod or
arm assembly which is length adjustable. Located at one end of the
arm assembly will normally be the head unit and at the opposite end
will be a foot to attach the arm assembly to the drill rig. The arm
assembly may be length adjustable in any manner including
telescopically or through the provision of a number of arm portions
which are attachable relative to one another.
[0041] There is also typically an ability to move the head unit
upwardly and downwardly relative to the rig.
[0042] There may also be a "remote control" variation. To explain,
sometimes, the drilling rigs are operated by a single person.
Larger rigs are medium-sized having a control cabin to operate the
boom arm and various other components. As the laser unit is
attached to the drill rig, it may become difficult for a sole
operator to (a) operate the entire drill rig from the cabin while
at the same time (b) needing to leave the cabin constantly keep
check on the laser unit. Therefore, a remote-control laser unit
where the lasers might be attached to some form of motor or other
type of driving mechanism to adjust the lasers and where the
telescopic arm can be extended and retracted by remote-control may
be provided. The laser unit could then be operated from the
cabin.
[0043] A further option is to have an alarm (which could be a
light) which lights up when the lasers are correctly aligned. To do
so, a reflective strip may be placed on the survey marker and if
the laser beam is correctly aligned, the laser beam will bounce off
the reflective strip and back to a sensor provided on the laser
unit which would then activate the alarm when the laser is
correctly aligned. An audio alarm may be provided although a mine
is a very noisy environment and a visual alarm is probably of most
benefit.
[0044] A further option is to have a digital inclinometer attached
to the laser unit (typically to the telescopic rod). This can then
allow the correct elevation or inclination of the drill rig to be
quickly determined, and together with the two lasers (to determine
the azimuth), the drill rig can be correctly orientated. By having
the inclinometer attached to the laser unit, it can also be removed
prior to operation of the drill rig.
[0045] In another form, the invention resides in a laser alignment
device for use with a drill rig having an elongate drill rod, the
laser alignment device including a head unit having at least one
laser emitting device to indicate the drill rod orientation and an
inertial measurement device to indicate at least the azimuth of the
at least one laser emitting device, and an attachment arrangement
to attach the head unit to a drill rig wherein the alignment device
is used to align at least the azimuth of the drill rod relative to
one or more survey points.
[0046] Typically, the laser alignment device will be used to align
the drill rig whilst the drill rod is not mounted to the drill rig.
The laser alignment device will typically be mounted to the drill
rig in place of the drill rod and the at least one laser emitting
device is used to indicate the orientation of the drill rod once
the drill rod is attached or mounted to the drill rig. The laser
alignment device is removed from the drill rig once the drill rig
has been aligned and replaced with a drill rod which is then used
to drill the hole.
[0047] However, the alignment device can be used to align the drill
rig whilst the drill rod is mounted to the drill rig.
[0048] Typically, the laser alignment device will provide an
indication of the drill rod dip as well as the azimuth. Still
further, it is preferred that the laser alignment device be
provided with a mechanism to locate the drill rig as well as
provide the azimuth and dip angle of the drill rod.
[0049] The head unit of the laser alignment device of a preferred
embodiment includes at least one laser emitting device located at
least parallel to the drill rod, but preferably mounted relative to
the drill rig in the position which the drill rod normally occupies
during operation. As mentioned above, the head unit is therefore
preferably mounted in place of the drill rod with the drill rod
temporarily removed from the rig during alignment. In this way, the
laser emitting device can be used to ensure that the drill rod
(once fitted) will be oriented as required.
[0050] Typically, the least one laser emitting device points
forwardly, that is in the direction of the drilling but the at
least one laser emitting device or another laser emitting device
can point rearwardly or in both directions. For example a rotating
laser device can be used.
[0051] Typically, the at least one laser emitting device is fixed
relative to the head unit such that any emission from the device is
in a fixed direction. Typically, the least one laser emitting
device is mounted substantially in line with the drive of the drill
rod. The method of accomplishing end this may differ according to
the drill rig.
[0052] For example, surface drilling typically uses a survey peg or
similar to indicate the drilling location. The at least one laser
emitting device of the present invention is preferably used to
point to that location while the required azimuth and dip angle of
the drill rod are established. Typically, the laser emitting device
is maintained pointing at the desired point whilst the position
and/or orientation of the drill rig is adjusted for the required
azimuth and dip angle to ensure the correct positioning. In this
embodiment, the at least one laser emitting device takes the place
of the drill rod or in other words, indicates that position and/or
orientation of a virtual drill rod which indicates the position
and/or orientation that the actual drill rod will assume when
attached to the drill rig.
[0053] The head unit of this embodiment of the present invention
preferably includes an inertial measurement device or unit to
indicate at least the azimuth of the at least one laser emitting
device on the basis that orienting the beam from the laser emitting
device will have the effect of orienting the drill rig so that the
drill rod is properly aligned once the drill rod is attached to the
drill rig.
[0054] The type of inertial measurement device used is not
essential but a gyrocompass or similar is preferred and a
particularly preferred type is a fiber optic gyrocompass. The
inertial measurement device or unit may use a combination of
accelerometers and gyroscopes, sometimes also magnetometers. Recent
developments allow for the production of inertial measurement
device or unit-enabled GPS devices. An inertial measurement device
(navigation system) provides position relative to a given reference
(often GPS) but will continue to provide a position reference when
GPS is not available. GPS is an aiding sensor to an inertial
navigation system. This is particularly useful in tunnels, inside
buildings, or when electronic interference is present. In some
cases an inertial measurement device may be aligned with a GPS
system in order to provide latitude and/or longitude or other
location data.
[0055] The inertial measurement device may indicate a measure of
the azimuth or simply indicate when the beam of the at least one
laser emitting device is aligned with a particular azimuth. An
azimuth is normally measured in degrees, typically from the North
direction but any units may be used.
[0056] The head unit may also include a device to measure the dip
angle or ensure the dip angle of the at least one laser emitting
device (or beam) is correct. Typically, a suitable device is an
inclinometer although other devices such as accelerometers may be
used instead of or in addition thereto. If a single device can
provide both functions (azimuth and dip angle), then a single
device may be used or separate devices may be provided in a single
head unit.
[0057] Typically, the devices are integrated into a single head
unit such that all three parameters (location, azimuth and dip
angle) can be used to correctly position and orient the at least
one laser emitting device (or beam) which is subsequently replaced
by the drill rod.
[0058] The laser and gyroscope/azimuth alignment device may be
either co-located or be located separately on the drill rig and the
alignment between the two devices calculated and used as an offset
such that the two devices can function together as if co-located in
the tool body.
[0059] According to alternatives of the present invention, the head
unit can be positioned parallel to the drill rod rather than
replacing the drill rod and the same methodology used albeit
allowing for the separation distance between the head unit and a
drill rod.
[0060] A display device can be used to display the parameters
measured or indicated by the head unit. Typically, a tablet PC or
other computing device can be used for this purpose. Typically
these devices include a display screen as well as at least one, and
typically a variety of communication possibilities and pathways
including WIFI, Bluetooth.RTM., WLAN, LAN, USB and serial
communications, and/or other communications pathways such as those
used by mobile telephony and the like. The display device will
typically also be capable of operating software to assist with the
location and orientation of the drill rig and rod, both prior to
drilling and preferable also during the drilling operation to
ensure that the drilling not only begins at the correct location
and orientation but also that it remains on target.
[0061] A particularly appropriate series of devices is the Leica
iCON tablet devices. These devices are wireless and can function
remotely from the head unit. Typically, the head unit and/or the
device will include a GPS locator in order to assist with
positioning of the drill rig and drill rod. Other appropriate
devices are computer tablets which may be connect by wireless or
hard wired communications to other components.
[0062] Each of the devices integrated into the head unit (or if
attached separately) may be independently actuable and/or powered
so that any device is not required to be powered down or off.
Preferably, the devices also report information and communicate
data to/from one or more display devices and/or storage
servers.
[0063] Typically, the at least one laser emitting device is located
in line with the position of the drill rod and the remaining
devices can be offset from the position of the drill rod and either
attached to the housing or integrated into the housing containing
the at least one laser emitting device.
[0064] The device of the present invention also includes an
attachment arrangement to attach the head unit to drill rig.
Normally, the attachment arrangement is adapted to attach the head
unit to the drill rig in place of the drill rod. Typically, drill
rigs are one of two main types, namely either an end drive or a
collar drive.
[0065] When applied in an end drive configuration, namely where a
drive is provided at one end of a drill rod, an adapter is
preferably provided to attach the device to the drive. Typically,
the adapter will attach directly to the drive and to the housing of
the head unit.
[0066] Typically, the adapter will mount the device to the drill
rig such that the at least one laser emitting device is coaxial
with the drive.
[0067] A spindle may be provided in or as part of the adapter or
separately. Typically, the spindle will attach between the head
unit and the drive. The spindle will typically include a bearing
race in order to allow the inertial measurement device of the head
unit to self-position and/or level. Preferably, the order of
mounting to the drive of the drill rig will be the adapter then the
spindle then the housing of the head unit.
[0068] When applied in a collar drive configuration, namely where
the drill rod is typically received through a generally cylindrical
opening and driven by a drive provided in the cylindrical opening,
the spindle as provided above may still be provided. Typically, the
attachment arrangement will include a mounting system which will
allow the at least one laser emitting device to be located and
oriented in a direction which simulates the drill rod which has
typically been removed from the drill rig and replaced with the
device of the present invention.
[0069] It is particularly preferred that a centering attachment
arrangement is provided. In a particularly preferred embodiment,
the attachment arrangement will include a head chuck, a tail chuck
and a connecting rod located between the two chucks. Typically, the
head chuck is attached to the connecting rod and the tail chuck is
removably attached to the connecting rod at an opposite end to the
head chuck and is movable along at least a portion of the length of
the connecting rod.
[0070] Typically, the head chuck is generally conical in shape as
this allows the chuck to centre within the collar drive opening.
Normally, the preferred shape will have a larger end surface which
is typically circular and a smaller end surface, also typically
circular joined by a generally conical sidewall. In preferred
configurations, the head chuck will be frustoconical.
[0071] The conical shape of the head chuck may be defined by a
solid member or alternatively and more preferred, by framework of
ribs provided to define the conical shape, but reduce the amount of
material used and/or the weight of the head chuck.
[0072] The head chuck of the preferred attachment arrangement will
normally have an attachment portion for the attachment of the
spindle or directly to the head unit of the device. The attachment
portion will normally be in the larger end surface. Typically, the
attachment portion will include a threaded opening which will allow
engagement with a preferred rigid threaded portion provided on the
spindle.
[0073] Normally, the connecting rod is mounted centrally, extending
from the smaller end surface of the head chuck. Preferably, the
connecting rod is permanently attached to the head chuck.
[0074] The connecting rod will typically be elongate and normally
substantially circular in cross-section although any
cross-sectional shape can be used. The connecting rod is typically
mounted permanently to the head chuck but is received through the
tail chuck in order that the tail chuck can be removed from the rod
and also moved along the length of the rod.
[0075] Appropriate features will be provided on the rod and/or the
tail chuck to allow the fixing of the position of the tail chuck on
the connecting rod at a variety of positions along the length of
the connecting rod in order to control the separation distance
between the head chuck and the tail chuck.
[0076] One simple mechanism for achieving this is to provide a
threaded portion at least partially along the length of the
connecting rod. Normally, the threaded portion will be of
sufficient length in order to fit the head chuck and tail chuck on
either side of a variety of collar drives from different drill rig
manufacturers. In a particularly preferred embodiment, the threaded
portion will extend from the end of the connecting rod furthest
from the head chuck to approximately half to 3/4 of the length of
the connecting rod. In some embodiments, the entire rod can be
threaded.
[0077] The tail chuck is similar in many respects to the head chuck
it is typically oriented in the reverse direction with the small
end surface facing the small end surface of the head chuck. This
results in the converging conical surfaces of both the head and
tail chuck facing one another.
[0078] Typically, the tail chuck will include a bore extending
through the tail chuck, from the smaller end surface to the larger
end surface. According to a preferred embodiment, the bore will be
internally threaded in order to engage with the preferably threaded
connecting rod although the fixing mechanism used to fix the
position of the tail chuck relative to the rod will largely
determine the configuration of the fixing mechanism provided on the
tail chuck, if any.
[0079] In order to ensure that the hole drilled remains on line, an
alignment detector attachment and system can be provided. The
alignment tool discussed above can be used with a laser alignment
detector attachment as a part of a system to ensure that the hole
remains online as it is drilled as well as at setup.
[0080] Therefore, as an alternative aspect, the present invention
may reside in a drill rod alignment detector system including a
laser device mounted relative to a drill rig for indicating a drill
rod orientation and an alignment detector device adapted to be
placed at least partially in a partially drilled hole and having a
laser point detection portion that detects where a laser light
point of the laser device strikes the face of the detector enabling
calculation of the position of the drill rod in relation to the
centre of the partially drilled hole.
[0081] Normally, the alignment tool discussed above is used during
the original rig setup and the alignment tool is then removed from
the drill rig. According to this aspect of the present invention,
normally, after the hole is drilled to a sufficient indicated
depth, the alignment tool can be reattached to the drill rig.
Normally, no changes are made to the rig setup during this process,
that is the alignment is not adjusted. The alignment detector
attachment is then typically placed into the hole which has been
partially drilled and the alignment tool or laser is directed at
the alignment detector attachment.
[0082] The alignment detector attachment will preferably provide
data to a display device outside the whole of the orientation of
the laser and thereby of the drill rod in order to allow adjustment
of the alignment tool and thereby adjustment of the drill rod to
ensure correct drilling.
[0083] This alignment detector attachment preferably includes a
laser point detection plate (typically an optical detection array)
that detects where the laser light point strikes the face of the
detector and will calculate this position in relation to the centre
of the drilled hole, normally in two axes.
[0084] The orientation of the laser point detection plate in
relation to the orientation of the alignment tool is preferably
measured by rotational alignment detectors, which may be
inclinometers measuring one or two axes or other similar
inclination measuring device.
[0085] The alignment detector attachment is typically centred in
the drilled hole by a mechanical centering mechanism. This will
usually be a length of machined rod--similar to a drill rod and
either of the same diameter as the drill rod used to drill the
hole, or extended to this diameter using collars, extensions,
bushes or similar devices.
[0086] This information or sufficient data to allow a visual
representation of the orientation of the laser is preferably
transmitted to a display device outside the hole. Transmission of
this information may be by wireless communication means or by way
of a hard wired connection. The information is then processed in
software running on the display device to compensate for any
rotation of the alignment tool within the hole. An image is
preferably generated and displayed on the display in an easy to
read information display depicting the angular offset of the hole
from the centre line of the drill in two axes.
[0087] The alignment detector attachment will preferably be self
centering in the hole and also be capable of self centering in a
hole of any larger size. The alignment detector attachment will
preferably have a detector allowing for positional and/or
rotational alignment relative to the alignment tool or to determine
alignment relative to the alignment tool.
[0088] For surface drilling applications the gyrocompass preferred
for underground use may be replaced by an inertial navigation
system (INS). This INS will preferably receive an input from
available GPS/DGPS/RTK GPS navigation systems.
[0089] Display software provided on a display device will
preferably utilise the navigation data output by the INS to plot
the position of the drill rig--with offsets preferably included to
navigate the centre of the drill on a generated map/or grid display
of the drill site and surrounds.
[0090] The navigation position provided by the INS can normally be
plotted within a few centimetres dependent upon the accuracy of the
available GPS signal. The display will preferably allow zooming in
to allow correct positioning of the rig.
[0091] The software will access a database of desired or required
hole locations to provide coordinates for each hole to the display
allowing an operator to correctly position the drill rig. Each hole
will be able to be selected as a navigation waypoint and displayed
on the map/grid display.
[0092] Further, the software is preferably able to log all data and
display onto the display device. The software will also preferably
communicate with a server or similar device to maintain back up
data in relation to hole set ups as well as real time recording of
movements between holes and hole set ups. This will preferably
allow an operator to access and preferably view data in relation to
the past, present or future drilling activities for planning or
review purposes.
[0093] A variety of information will preferably be accessible via
the system software including shift reports, pre starts, drill hole
run recording, and/or survey results. In addition, it is preferred
that photos also can be taken of drilled ground, equipment or
anything and used in daily shift reporting such as safety issues,
damage to equipment, hazards and the like.
[0094] Information can be used or recorded as required by clients
or drill companies. This information can typically be downloaded or
sent directly via the display device or any type of recording or
display device each day or when need to a server that processes and
stores information for later use.
[0095] Preferably, software is provided that can also be used when
a laser device and a gyrocompass type device are mounted separately
on rig to transmit information to a display device which is either
separate from the drill rig (such as a tablet computer or similar
device) or mounted relative thereto. Any of the components can be
mounted separately on the drill rig and communicate (via wireless
or wired connections) to a remote computing device, on the rig or
not.
[0096] A fully automated option may also be provided with a mobile
drill rig integrated with drill rig hydraulics and software such
that the location of the rig and each drill hole is programmed into
software allowing the rig to self-navigate to each location and
then align itself using the components described herein making set
up fully automated. In this case, an operator would simply upload
or enter required information and the drill rig in conjunction with
gyrocompass/navigational devices/software will automatically move
to required location, align itself and begin the drilling
operation.
[0097] Laser beam, can go from a single dot and using internal
lenses can adjust to any diameter required. This laser can then be
used to identify where hole is going to be drilled, collared,
bored. Once set up, use of the laser beam can show circular
reference to hole diameter that is going to be drilled. Also, use
of a laser can assist with reinterring drill holes simply adjust
laser beam to hole diameter or slightly bigger this helps operator
see a circular beam around drill hole.
[0098] Any of the features described herein can be combined in any
combination with any one or more of the other features described
herein within the scope of the invention.
[0099] The reference to any prior art in this specification is not,
and should not be taken as an acknowledgement or any form of
suggestion that the prior art forms part of the common general
knowledge.
BRIEF DESCRIPTION OF DRAWINGS
[0100] Various embodiments of the invention will be described with
reference to the following drawings, in which:
[0101] FIG. 1 is a perspective photograph of a conventional boom
operated drill rig in operation.
[0102] FIG. 2 is a perspective photograph of the drill rig
illustrated in FIG. 1 from an alternative angle.
[0103] FIG. 3 is a side elevation view of a conventional skid-based
drill rig in the installed configuration and anchored to the
floor.
[0104] FIG. 4 is a schematic isometric view of a device of the
present invention according to a preferred embodiment.
[0105] FIG. 5 is a perspective view of a drill rig with a laser
alignment device according to a first embodiment temporarily
attached to the drill rig.
[0106] FIG. 6 is a perspective view of a drill rig with a laser
alignment device according to a second embodiment temporarily
attached to the drill rig.
[0107] FIG. 7 is a group of views illustrating a device and
components thereof according to a preferred embodiment.
[0108] FIG. 8 is an exploded perspective view of an alternative
attachment mechanism for the device of the present invention.
[0109] FIG. 9 is a side view of the attachment mechanism
illustrated in FIG. 8 in the assembled condition.
[0110] FIG. 10 is a schematic top view showing the alignment of a
drilling rig using the present invention.
[0111] FIG. 11 is a schematic side view of the arrangement
illustrated in FIG. 12.
[0112] FIG. 12 is a schematic perspective view of a drilling rig
with the device according to a preferred embodiment attached and
aligned.
[0113] FIG. 13 is a further schematic perspective view of a
drilling rig with the device according to a preferred embodiment
attached and aligned.
[0114] FIG. 14a is a view from above of a drill rig with alignment
device of a preferred embodiment prior to alignment.
[0115] FIG. 14b is a view from above of a drill rig with alignment
device of a preferred embodiment after alignment.
[0116] FIG. 15 is an isometric view of another variation of the
present invention that allows the alignment of the drilling rig to
the marker points without having to implicitly align the laser
beams to the marker tags.
[0117] FIG. 16a is a view from above of a preferred embodiment of
device of the present invention mounted to a tripod to reference
bearings for aligning a drill rig.
[0118] FIG. 16b is a view from above of the device illustrated in
FIG. 16a transferred to a cradle mounted on a drilling rig.
[0119] FIG. 16c is a detailed view of a compass dial on the device
illustrated in FIG. 16a showing orientation.
[0120] FIG. 16d is a detailed view of a compass dial on the device
illustrated in FIG. 16c with the outer dial zeroed.
[0121] FIG. 16e is a detailed view of a compass dial on the device
illustrated in FIG. 16b with the outer dial indicating zero and
therefore aligned.
[0122] FIG. 17 is an axonometric view of a preferred embodiment of
an alternative aspect of the present invention.
[0123] FIG. 18 is a view from the rear of the device illustrated in
FIG. 17 in a partially exploded configuration.
[0124] FIG. 19 is an exploded axonometric view of the device
illustrated in FIG. 17.
[0125] FIG. 20 is an axonometric view of the device illustrated in
FIG. 17 attached to an Atlas Copco.RTM. Diamec MCRU6 drill rig.
[0126] FIG. 21 is an axonometric view of the device illustrated in
FIG. 17 attached to an Atlas Copco.RTM. Diamec U8 drill rig.
[0127] FIG. 22 is an axonometric view of the device illustrated in
FIG. 17 attached to an Atlas Copco.RTM. top drive drill rig.
[0128] FIG. 22A is a detailed view of the drill drive portion of
the rig illustrated in FIG. 22 showing the attachment of the device
thereto.
[0129] FIG. 23 is an axonometric view of the device illustrated in
FIG. 17 attached to a DE 130 drill rig.
[0130] FIG. 24 is an axonometric view of the device illustrated in
FIG. 17 attached to a Sandvik top drive drill rig.
[0131] FIG. 25 is a schematic illustration of generated and
displayed image of a drill hole pattern and the indicative movement
of a drill rig relative thereto to a drilling position according to
a preferred embodiment of the present invention.
[0132] FIG. 26 is a schematic illustration of one possible system
configuration showing communications pathways between elements of
the system according to a preferred embodiment of the present
invention.
[0133] FIG. 27 is a schematic illustration of an
alignment/orientation detector according to a preferred embodiment
of the present invention.
[0134] FIG. 27A is a detailed view of the detector plate
illustrated in FIG. 27 showing the laser point.
[0135] FIG. 27B is a detailed view of the detector plate
illustrated in FIG. 27 showing the output display according to a
preferred embodiment of the present invention.
DESCRIPTION OF EMBODIMENTS
[0136] According to a preferred embodiment, a laser device for use
with a drilling rig and a drill rig with the device attached, are
provided.
[0137] A conventional drill rig is illustrated in FIG. 3. The
drilling rig itself is of a commercial type and basically comprises
a pair of parallel steel feed rails 10 which will typically have a
length of between 1.5 m up to 6 m. A carriage 11 slides over the
top of each feed rail, and can reciprocate between the retracted
position illustrated above and an extended position where the
carriage has been moved to the front of the feed rails 10. A
hydraulic ram 12 powers the carriage between its positions. On top
of the carriage is a high speed hydraulic rotating apparatus 13.
The rotating apparatus will typically rotate at speeds of between
1000-10,000 rpm. A drill rod (not illustrated) passes into the
front opening of the rotating apparatus and is rotated by the
rotating apparatus. In a front part of the drill rig is a
"centraliser" 14 through which the rods pass and the function of
the centraliser is to keep the rods aligned and to minimise
"wobble". A hydraulic piston 15 is associated with the centraliser.
The piston extends to lock the drill rod when the drill rod has
stopped rotating.
[0138] In FIG. 5 and FIG. 6, the drill rig is exactly the same but
the laser unit is slightly different in how the laser unit is
attached to the drill rig.
[0139] Turning now to the laser unit, the various parts are
illustrated in FIG. 7.
[0140] Basically, the laser unit is temporarily attached to the
drill rig during the alignment process and is then removed prior to
operation of the drill. Usually, the laser unit will also remain in
place as the drill rig is secured in position just in case there is
any inadvertent movement during the securing process. Once the rig
is secured, the laser unit is removed and the drilling begins.
[0141] It is envisaged that the laser unit will be a separate
device that can be attached to any commercial type of drilling rig.
Therefore, the inventor believes that a magnetic attachment of the
laser unit to the rig will be most versatile as this means that the
laser unit can simply be magnetically clamped to any commercial
rig. It also allows the laser unit to be clamped at any suitable
position on the rig.
[0142] In practice, it is envisaged that in most circumstances, the
laser unit will be attached to one of the feed frames of the
drilling rig this being illustrated in FIG. 5 and FIG. 6. The feed
frames are made of steel.
[0143] FIG. 5 best illustrates the attachment of the laser unit.
According to an embodiment illustrated generally by 20A, the laser
unit has a base member 20 in which is positioned a strong magnet. A
switch is positioned on the base unit and turning the switch causes
the strong magnet to turn inside the base member between a magnetic
clamping position and a free position where the entire laser unit
can be removed. The invention advises that this type of device is
known.
[0144] FIG. 6 illustrates an alternative attachment 20B of the
laser unit which does not use the magnet. Instead, a more
conventional fastener arrangement is used. A disadvantage with this
alternative attachment is that it does require fasteners or
something equivalent to be welded or otherwise attached to the feed
frames which can result in projections that can form "snagging
points" which is somewhat undesirable.
[0145] While a magnetic attachment is desirable, other forms of
attachments may also be used such as temporary clamps, a pin and
slot arrangement, fasteners, possibly the use of straps and the
like. The inventor also does not see any reason to limit exactly
where the laser unit is attached to the drill rig. In practice, the
attachment will most probably be on the feed frame but this need
not be so.
[0146] A rod 21 extends outwardly from the mounting plate or
mounting block. The rod in the particular embodiment is length
adjustable and this can be done by making the rod telescopic. The
length of the rod should be sufficient to allow the lasers to align
with the survey marks on the mine shaft wall.
[0147] As a typical drill rig can be placed no closer than about 1
m to the "string lines" which are presently in use, it is
considered that the rod should at least the extendable to about 1
m. For the smaller drilling rigs, the rod should be extendable from
at least 20 cm up to 1.5 m and for the larger drilling rigs the rod
may need to be longer such as between 1.5 m up to 4 m.
[0148] Usually two rod designs will be used, one being telescopic
for the smaller units and therefore being extendable between 20 cm
up to 1.5 m and a second rod design which can extend between 1.5 m
up to 4 m and which can be used for the larger units.
[0149] Attached to the end of the rod are two oppositely pointing
lasers. An advantage of the present invention is that two lasers
22, 23 (see FIG. 7) are used which point in the opposite direction.
Each laser can be commercially available laser can be screwed into
a laser holder. Therefore, there will be two laser holders as
well.
[0150] The laser holders are attached to each other by a fastener
24 and importantly each holder (and therefore each laser) can hinge
or pivot relative to each other.
[0151] Each laser holder is provided with a finger tab 25, 26. This
enables each laser to be gripped and moved depending on the survey
markers. Each laser holder is also provided with a magnetic
strip.
[0152] The laser holders are "sandwiched" between a backing plate
27 (see for instance, FIG. 6 and which can be made of thin metal or
plastic) and a front plate 28. The backing plate also contains
magnetic strips (see FIG. 7). These magnetic strips will
magnetically clamp to the magnetic strip on each laser holder. In
this manner, once a particular laser holder has been aligned with a
survey mark, it will be held in place by the magnetic strip 30 on
the backing plate attaching to the magnetic strip on the laser
holder. The front plate 28 is provided with a pair of arcuate
openings 29 through which the finger tabs 25, 26 extend and
allowing rotation of the lasers 22, 23.
[0153] The advantage of the "twin" lasers may be better illustrated
with reference to FIGS. 10 and 11 which are rough schematic views.
FIG. 10 is a top view looking down on the apparatus and what can be
seen is the self-propelled wheeled or tractor vehicle 30, the boom
arm 31 and the drilling rig 32. Also shown in FIG. 10 and in FIG.
11 are the two markers 33 and 34. In the side view (FIG. 11), it
can be seen that one of the markers (e.g. 33) is in an upper part
of the mine wall while the other marker (34) is at the bottom of
the mine wall. This is not unusual, but if using string tines, it
becomes very difficult to try to perfectly align the drill rig with
the string line.
[0154] When using the twin lasers, (see particularly FIG. 11), the
front laser can be pivoted upwardly to target the upper marker 33
while the rear laser can be pivoted downwardly to target the lower
marker 34. When looking at this in plan (FIG. 10) it looks like a
straight line but when looking at this in side view (FIG. 11) it
can be seen that the two lasers are at an angle relative to each
other. Importantly however the lasers still project a "straight"
line when viewed in plan (FIG. 10) and this allows the drill rig 34
to be aligned with the lasers to be perfectly parallel thereto.
That is, the front of the drill rig 35 and the rear of the drill
rig 36 must be exactly the same distance away from the imaginary
line formed by the lasers (see FIG. 10). Any deviation may result
in the formed hole being rejected. This deviation can be seen as
the "azimuth" and therefore the main function of the laser unit is
to ensure that there is no deviation in the azimuth that is
required.
[0155] The "elevation" can be seen as the angle of the drill rig
from the horizontal (e.g. the mine floor) this can be easily
adjusted by the apparatus. Thus, when looking at FIG. 6, it can be
seen that the drilling rig has not yet been correctly "elevated"
such that the drilling rig will ultimately drill a hole next to the
upper marker 33. Once the all important "azimuth" of the drill rig
has been aligned, the drill rig is secured (e.g. bolted to the
floor) and then the elevation of the drill rig can be adjusted
using the hydraulics of the apparatus.
[0156] For this reason, it is quite important that the lasers can
only move up and down but cannot move from side to side. Any side
to side movement can compromise the correct azimuth which is
undesirable. It is also quite important that the lasers are exactly
parallel to the drilling rig when the laser unit is attached
thereto. The inventor advises that the drilling rigs are very
precise and that the feed frames on the drilling rig are exactly
parallel to the drilling rods. Thus, attachment of the laser unit
to a feed frame will result in the lasers projecting a laser beam
which is exactly parallel to the drilling rods. It also seems
important in the manufacture of the laser units that the laser
holders are exactly parallel to the Magnetic mounting block wall
mounting frame.
[0157] FIG. 4 is an isometric view of the head unit 50 of a laser
device according to a further preferred embodiment including lights
37 which are activated once the correct azimuth is reached. Also
illustrated is an alternative method of connecting the head unit to
the rod for simple and easy attachment and removal.
[0158] The head unit 50 is provided with a bore therethrough. A
collar 38 is located in the bore. The rod 21 of the device is
provided with an internally threaded end portion into which a
threaded fastener 39 is received. The threaded fastener 39 extends
through the collar 38 located in the head unit 50 and attaches the
head unit 50 to the rod 21 quickly and easily. An o-ring 40 or
similar is provided to minimise unwanted rotation of the head unit
50 relative to the rod 21.
[0159] A further embodiment of the present invention is illustrated
in FIG. 13 showing a drilling rig 80 fitted with a cradle 82 at the
rear of the boom 81. The cradle 82 in turn holds a removable laser
unit 83 comprising a rotating or static laser 85 capable of
projecting a laser beam 84 to the extremities of the front and rear
walls of the tunnel. The unit 83 will also contain a clinometer to
take pitch readings and a device that will capture the yaw of the
rig. The laser unit is set up so that the beam emitted runs
parallel to the drill shaft. This means that when the drill rig 80
is moved to a position where the laser beam is aligned to the front
marker tag 86 and rear marker tag 87 on the front and rear walls,
as illustrated in FIG. 14A, the drill rig is in the correct
alignment for drilling, illustrated in FIG. 14B.
[0160] The cradle 82 is fitted with a removable extender section
88, which can be stored safely when not in use. It also has a
geared rack 89 incorporated to allow the head unit 83 to be moved
in and out remotely. This function is to allow the fine-tuning
which may be required to compensate for the movement of the rig 80
relative to the marker points.
[0161] If on the rare occasion the drill rig 80 isn't able to be
positioned close enough to the marker points for the laser beams to
reach the markers then alignment can be approximated by eye and the
fine-tuning can be done by measuring the distances between the
laser beam 84 and the tag at the front 86 and back 87 markers.
[0162] The clamp on cradle 82 has adjustable fixing points so it
can be adapted to the majority of drill rigs used in this
application.
[0163] The preferred embodiment illustrated in FIG. 15 is another
variation of the present invention that allows the alignment of the
drilling rig to the marker points without having to implicitly
align the laser beams to the marker tags.
[0164] This embodiment has all of the functionality of the
embodiment illustrated in FIG. 13 but adds a bearing device such as
a compass or gyrocompass that allows the operator to align the rig
80 according to a bearing taken from the site plans or by repeating
a bearing from a remote reading obtained by aligning the compass to
the front 86 and back 87 markers. A laser/compass unit 90 including
both a laser unit and a compass or bearing unit is provided.
[0165] This embodiment does not require an extended support system
or the ability to move the laser/compass unit 90 relative to the
rig 80 (as used in the previous embodiment) as there is no need to
align the laser to the marker points when the unit is fixed to the
rig.
[0166] In use a remote reading is translated to or taken from the
compass from the alignment of the compass to the marker points on
the front and back walls, using a laser beam 84. This reading can
be translated to the rig 80 by taking the laser/compass unit 90
with the reading on it and fixing it to the drilling rig 80. The
actual reading can be translated to the rig or a marker can be used
to capture the zero point on the compass when aligned to the marker
tags and then the rig can be aligned to the zero point defined by
that marker.
[0167] For example, as illustrated in FIG. 16A, a laser/compass
unit 90 is mounted on a tripod and using the laser being aligned
with the front and rear markers, a true bearing from the tripod
mounted laser/compass unit 90 reads 45.degree.. An outer dial of
the compass of the preferred embodiment can then be rotated to read
0.degree..
[0168] As illustrated in FIG. 16B, the laser/compass unit 90 can
then be transferred to the cradle 82 mounted on the drilling rig 80
entity drill rig is then rotated until the compass again shows the
zero reading. The drill rig 80 will be parallel to the market
points when the compass read zero as illustrated in FIG. 16E.
[0169] If the readings are to be taken from site plans then the
compass should be calibrated to the site plans before any readings
can be translated to the drilling rig. This would need to
compensate for specific site grids that may be a fixed number of
degrees off true north. In these situations the bearing may be a
simple translation of the bearing dictated on the plans to the rig.
Alternatively a true north reading can be translated directly to
the rig with any site anomalies being accounted for in the
bearing.
[0170] In order for the operator of the drilling rig to align the
drilling shaft with the marker points he/she estimates the correct
proximity to the front marker and then rotates the rig until the
required bearing is met. The bearing devices used will need to be
impervious to any external influences that may affect its accuracy,
such as magnetic effects which are typically present in underground
mines.
[0171] The compass, gyrocompass or any type of bearing
reader/repeater and inclination reader (clinometer) can also be
used to align any type of surface drill rig or any type of drilling
equipment that needs aligning. Alternatively a true north bearing
gyrocompass can be used to align the drill rig or equipment to the
required azimuth and a clinometer can be used to determine the
depth, or the gyrocompass can be set to a particular mine grid
depending on the user's requirements that can be fixed to the mast
of the rig or side or any part of the rig or equipment.
[0172] It is intended that the mobile units are stored safely and
transported to the rig when required.
[0173] In an alternative embodiment illustrated in FIGS. 17 to 24,
the laser alignment device 150 includes a head unit 101 having a
laser emitting device 107 to indicate the drill rod orientation and
a gyrocompass 102 to indicate at least the azimuth of the laser
emitting device. An attachment arrangement 105 is provided to
attach the head unit 101 to a drill rig 103.
[0174] In this form, the laser alignment device is used to align
the drill rig whilst the drill rod is removed from the drill rig.
The laser alignment device is mounted to the drill rig in place of
the drill rod and the laser emitting device is used to indicate the
orientation of the drill rod once the drill rod is attached or
mounted to the drill rig. The laser alignment device is removed
from the drill rig once the drill rig has been aligned and replaced
with a drill rod which is being used to drill the hole.
[0175] The laser alignment device of this embodiment provides an
indication of the drill rod dip as well as the azimuth.
[0176] The head unit 101 of the laser alignment device of this
embodiment includes one laser emitting device mounted relative to
the drill rig in the position which the drill rod normally occupies
during operation. As mentioned above, the head unit is therefore
preferably mounted in place of the drill rod with the drill rod
temporarily removed from the rig during alignment. In this way, the
laser emitting device can be used to ensure that the drill rod
(once fitted) will be oriented as required. The position of the
unit on a number of different drill rigs is illustrated in FIGS. 20
to 24.
[0177] The laser emitting device points forwardly, that is in the
direction of the drilling and emits a beam in that direction 104.
As illustrated in FIGS. 20 to 24, the laser emitting device is
mounted substantially in line with the drive of the drill rod. The
methods of accomplishing this differ according to the drill
rig--and more precisely, the type of drive the drill rig uses.
[0178] The head unit of this embodiment includes a gyrocompass 102
to indicate at least the azimuth of the laser emitting device on
the basis that orienting the laser emitting device will have the
effect of orienting the drill rod once the drill rod is attached to
the drill rig. The gyrocompass will normally be battery powered and
wirelessly transmit information to a tablet computer for display to
an operator. A cover 108 is normally provided to cover connectors
and wireless transmitter.
[0179] Typically, the devices are integrated into a single head
unit as illustrated in FIGS. 17 to 19 such that all three
parameters (location, azimuth and dip angle) can be used to
correctly position and orient the laser emitting device which is
subsequently replaced by the drill rod.
[0180] Each of the laser emitting device 107 and the gyrocompass
102 integrated into the head unit is independently actuable and
powered so that any device is not required can be powered down or
off. As illustrated in FIG. 19, two power switches 106, one for
each device are provided.
[0181] The attachment arrangement 105 is adapted to attach the head
unit 101 to the drill rig 103 instead of the drill rod. Typically,
drill rigs are one of two main types, namely either an end drive as
illustrated in FIGS. 22 and 24 or a collar drive as illustrated in
FIGS. 20, 21 and 23.
[0182] When applied in an end drive configuration, namely where a
drive is provided at one end of a drill rod, an adapter 110 is
provided to attach the drive and to the housing of the head unit
101 such that the laser emitting device 107 is coaxial with the
drive.
[0183] In the embodiments illustrated in FIGS. 22 and 24, the
adapter 110 is attached to a spindle 109 including a bearing race
111 in order to allow the gyrocompass 102 of the head unit 101 to
self level.
[0184] When applied in a collar drive configuration as illustrated
in FIGS. 20, 21 and 23, where the drill rod is typically received
through a generally cylindrical opening and driven by a drive
provided in the cylindrical opening, the spindle 109 as described
above is still provided. In this form, a preferred embodiment of
the attachment arrangement allows the laser emitting device to be
located and oriented in a direction which simulates the drill rod
which has typically been removed from the drill rig and replaced
with the device of the present invention.
[0185] In the preferred embodiment illustrated in FIGS. 17 to 19,
the attachment arrangement includes a head chuck 112, a tail chuck
113 and a connecting rod 114 located between the two chucks 112,
113. The head chuck 112 is attached to the connecting rod 114 and
the tail chuck 113 is removably attached to the connecting rod 114
at an opposite end to the head chuck 112 and is movable along at
least a portion of the length of the connecting rod 114.
[0186] Typically, the head chuck 112 is generally conical or
frustoconical in shape as this allows the chuck to centre within
the collar drive opening. The illustrated head chuck 112 has a
larger end surface which is typically circular and a smaller end
surface, also typically circular joined by a generally conical
sidewall.
[0187] The conical shape of the head chuck is defined by a
framework of ribs provided to define the conical shape, but reduce
the amount of material used and/or the weight of the head
chuck.
[0188] The head chuck 112 illustrated has an attachment portion 115
for the attachment of the spindle 109 or directly to the head unit
of the device. The attachment portion 115 is normally be in the
larger end surface and in the illustrated embodiment includes a
threaded opening which allows engagement with a correspondingly
threaded portion 116 provided on the spindle 109.
[0189] The connecting rod 114 is permanently attached centrally
extending from the smaller end surface of the head chuck 112.
[0190] The connecting rod 114 is elongate is received through the
tail chuck 113 in order that the tail chuck. 113 can be removed
from rod 114 and also moved along the length of the rod 114.
[0191] A threaded portion is provided at least partially along the
length of the connecting rod 114. Normally, the threaded portion
will be of sufficient length in order to fit the head chuck 112 and
tail chuck 113 on either side of a variety of collar drives from
different drill rig manufacturers.
[0192] The tail chuck 113 is similar in many respects to the head
chuck 112 it is typically oriented in the reverse direction with
the small end surface facing the small end surface of the head
chuck 112. This results in the converging conical surfaces of both
the head and tail chuck facing one another.
[0193] The tail chuck 113 includes a bore extending through the
tail chuck 113, from the smaller end surface to the larger end
surface. The bore is internally threaded in order to engage with
the threaded connecting rod 114.
[0194] In use, regardless of whether the drill rig is used in a
surface application or underground, an indicator such as a peg 117
or survey mark or similar to is used to indicate the drilling
location. The laser emitting device 107 of the device is used to
point to that location while the position of the drill rig is
adjusted to achieve the required azimuth and dip angle of the drill
rod. Typically, the laser emitting device 107 is maintained
pointing at the desired point whilst the position or orientation of
the drill rig is adjusted for the required azimuth and dip angle to
ensure the correct positioning. In this embodiment, the laser
emitting device 107 takes the place of the drill rod or in other
words, indicates that position and/or orientation of a virtual
drill rod which indicates the position and/or orientation that the
actual drill rod will assume when attached to the drill rig.
[0195] Illustrated in FIG. 25 is a schematic example of a generated
and displayed image of a drill hole pattern 30 showing the movement
of a drill rig 103 relative thereto into a final position.
[0196] For surface drilling applications the gyrocompass preferred
for underground use is replaced by an inertial navigation system
(INS). This INS will preferably receive an input from available
GPS/DGPS/RTK GPS navigation systems. A general system configuration
is illustrated in FIG. 26.
[0197] The system as illustrated includes a drill rig 103 with
alignment tool as previously explained and with an INS rather than
a gyrocompass which accordingly creates an alignment and
positioning tool 31. The INS can receive data from a satellite
based location system including one or more satellites 32 such as
UPS, GLONASS or other system. The alignment and positioning tool 31
also communicates with some form of display, usually on a computing
device 33 which can be either mounted to the drill rig 103 or
separate therefrom to allow an operator the freedom of movement.
This computing device 33 will normally be adapted for two way
communication and/or data transfer with a remote server 34.
[0198] Display software provided on the computing device 33 such as
a tablet or similar will utilise the navigation data output by the
INS to plot the position of the drill rig 103 relative to the
required holes and preferably down to the level of navigating to
the centre of the drill on a generated map/or grid display of the
drill site and surrounds such as that illustrated in FIG. 25.
[0199] The navigation position provided by the INS can normally be
plotted within a few centimetres dependent upon the accuracy of the
available (GPS) signal. The display will preferably allow zooming
in to allow correct positioning of the rig 103 and the drill rod to
form the holes as required.
[0200] The software will access a database of desired or required
hole locations located on the server 34 to provide coordinates for
each hole to the display, allowing an operator to correctly
position the drill rig 103. Each hole (illustrated by "o" on FIG.
25 will be able to be selected as a navigation waypoint and
displayed on the map/grid display allowing a rig 103 to be moved
relative to drilling pattern to a final drilling position 35 as
illustrated in FIG. 25.
[0201] Further, the software is preferably able to log all data and
display onto the display device. The software will also preferably
communicate with a server 34 or similar device to maintain back up
data in relation to hole set ups as well as real time recording of
movements between holes and hole set ups. This will preferably
allow an operator to access and preferably view data in relation to
the past, present or future drilling activities for planning or
review purposes.
[0202] To allow the operator to ensure that the hole drilled
remains on line, an alignment detector attachment and system can be
provided such as is illustrated in FIG. 27. The alignment tool head
unit 101 with laser device discussed above can be used with a laser
alignment detector attachment as a part of a system to ensure that
the hole 37 in the surface 38 remains online as it is drilled as
well as at setup.
[0203] Normally, the alignment tool head unit 101 discussed above
is used during the original rig setup and the alignment tool head
unit 101 is then removed from the drill rig. According to the
preferred embodiment illustrated in FIG. 27, normally, after the
hole 37 is drilled to a sufficient depth (generally at least 300 mm
and normally at any depth or depths following that), the alignment
tool head unit 101 can be reattached to the drill rig. Normally, no
changes are made to the rig setup during this process, that is the
alignment is not adjusted. The alignment detector attachment 36 is
then typically placed into the hole 37 which has been partially
drilled and the laser is directed at the alignment detector
attachment 36.
[0204] The alignment detector attachment 36 provides data to a
display 50 outside the hole 37 of the orientation of the laser and
thereby of the drill rod in order to allow adjustment of the
alignment tool and thereby adjustment of the drill rod to ensure
correct drilling angle and/or direction is maintained. The display
50 may be on the rig or on a portable computer device such as a
tablet or similar.
[0205] This alignment detector attachment 36 of the preferred
embodiment includes a laser point detection plate (typically an
optical detection array) that detects where the laser light point
strikes the face of the detector as illustrated in FIG. 27B and
will calculate this position in relation to the centre of the
drilled hole, normally in two axes and provide for this to be
illustrated for an operator as seen in FIG. 27A. A quantitative
measure of the precision of alignment may also be represented on
the display.
[0206] The orientation of the laser point detection plate in
relation to the orientation of the alignment tool is preferably
measured by rotational alignment detectors, which may be
inclinometers measuring one or two axes or other similar
inclination measuring device.
[0207] The alignment detector attachment 36 is centred in the
drilled hole 37 by a mechanical centering mechanism. This will
usually be a length of machined rod--similar to a drill rod and
either of the same diameter as the drill rod used to drill the
hole, or extended to this diameter using collars, extensions,
bushes or similar devices.
[0208] This information or sufficient data to allow a visual
representation of the orientation of the laser is preferably
transmitted to a display device outside the hole. Transmission of
this information may be by wireless communication means or by way
of a hard wired connection. The information is then processed in
software running on the display device to compensate for any
rotation of the alignment tool within the hole. An image such as
that illustrated in FIG. 27A can be generated and displayed on the
display in an easy to read information display depicting the
angular offset of the hole 37 from the centre line of the drill in
two axes.
[0209] The alignment detector attachment 36 is typically self
centering in the hole and also be capable of self centering in a
hole of any larger size. The alignment detector attachment 36 will
preferably have a detector allowing for positional and/or
rotational alignment relative to the alignment tool or to determine
alignment relative to the alignment tool.
[0210] 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.
[0211] Reference throughout this specification to "one embodiment"
or "an 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.
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