Automatic well drilling device

Abstract

There is provided an automated drilling device (10) comprising: a platform (12); a drill pipe loading assembly (14) disposed on the platform (12) and including a carriage (16) for receiving a drill pipe segment (18) and a carrier assembly (20) configured to automatically displace and orient the drill pipe segment (18) from the carriage (12) to a vertical position for engagement with a drill string. The apparatus (10) further includes a drilling mast (22) disposed on the platform (12) and including a rotary head drive (24) movable along the mast (22) to effect drilling and a drill rod operator (26) configured to automatically receive the drill rod segment (18) from the carrier assembly (20), align and connect it with a drill string of the rotary head drive (24), and to move the drill rod segment (18) from the carrier assembly (20). To facilitate automated drilling by an automated drilling device (10).

Description

Technical Field

[0001] The present invention generally relates to the field of drilling, and more particularly, to an automatic drilling device and related drilling methods. Background Art

[0002] The following discussion of the background art is intended only to assist in understanding the present invention. The discussion is not an acknowledgement or admission that any of the material referred to is or was ever part of the common general knowledge as at the priority date of the application.

[0003] As is known in the art, a drilling rig is an integrated system for drilling a well, such as an oil well or a water well. Drilling rigs can also be used to sample underground mineral deposits, test the physical properties of rock, soil, and groundwater, and can be used to install underground fabricated items, such as underground utilities, instruments, tunnels, or wells. Drilling rigs can be mobile devices mounted on trucks, tracks, or trailers, or more permanent structures on land or offshore. The term "drilling rig" generally refers to equipment commonly used to penetrate the surface of the Earth's crust.

[0004] The drill string on a drilling rig is a column or string of drill pipes that usually deliver drilling fluid through a mud pump and transmit torque to the drill bit through a top drive. Drill pipe generally forms the main part of the drill string from the drill bit back up to the surface. Each section of drill pipe usually consists of a long pipe section with a specified outer diameter. Each end of the drill pipe section is usually threaded, which allows each drill pipe section to be paired with an adjacent section through the appropriate male and female threads.

[0005] Drilling with a drill rig is often a labor-intensive and often dangerous task due to the large number of drill pipe sections that need to be handled to connect to (or disconnect from) the drill string as it penetrates the ground (or subsequently removed after drilling is completed). The drilling mast or derrick also typically includes a top drive for rotating the drill string, as well as various other mechanical components, making the drilling rig a dangerous area for personnel due to the movement and displacement of equipment, often resulting in personal injury or even death.

[0006] In particular, automatic threading and unthreading of drill pipe sections is necessary to achieve automated drilling, but this presents particular difficulties because correct threading alignment is necessary to achieve automated drilling without manual monitoring or management. There are semi-automatic drilling rigs, such as that described in WO 2010 / 046757 A1 of FRASTE SPA, which shows a semi-automatic drilling rig that requires manual monitoring and adjustment during the drilling process. Manual management of the FRASTE SPA system can be found in https: / / www.youtube.com / watch?v= FN5VFU6AxY .

[0007] In particular, the device disclosed in the document of FRASTE SPA requires manual control, in particular during the screwing and unscrewing of drill pipe segments, wherein manual monitoring is required to align the screwing of one drill pipe segment with another in order to perform drilling. FRASTE SPA also describes the use of a conventional so-called double breakout clamp or locking assembly, which usually has two hydraulic jaws for simultaneously clamping the drill pipe segment to facilitate screwing. Specifically, such a double breakout clamp is specially designed to allow unscrewing of a stuck drill pipe segment, wherein the hydraulic jaw sets are rotated relative to each other to loosen the stuck drill pipe threads.

[0008] In view of this, the applicant has recognized the need for a safer and less labor-intensive drilling device, particularly a drilling device that can automatically and accurately thread drill rods without human intervention, and the present invention is conceived based on this purpose. Summary of the invention

[0009] According to a first aspect of the present invention, there is provided an automatic drilling device, comprising:

[0010] platform;

[0011] a drill pipe loading assembly disposed on the platform and comprising a cradle for receiving a drill pipe segment and a carrier assembly configured to automatically displace and orient the drill pipe segment from the cradle into a vertical position for engagement with a drill string; and

[0012] A drilling mast is disposed on the platform and includes a rotary head drive movable along the mast to achieve drilling and a drill rod operator, the drill rod operator being configured to automatically receive the drill rod segment from the carrier assembly, align it with the drill string of the rotary head drive and connect it with the drill string of the rotary head drive to facilitate automatic drilling by the automatic drilling device.

[0013] Those skilled in the art will appreciate that as part of the overall operation of the drilling rig, the operation of the carrier assembly and the drill pipe operator is generally reversible to remove the drill pipe segment from the well. Therefore, the description of such drilling operations herein includes the reverse order as appropriate.

[0014] In one embodiment, the platform comprises a mobile platform, such as a flatbed truck, a tracked platform, or the like.

[0015] In one embodiment, the mobile platform comprises an automated platform or an autonomous driving platform.

[0016] In one embodiment, the platform comprises energy supply means for the drill rod loading assembly and the drilling mast, such as an internal combustion engine and electric, pneumatic and / or hydraulic generators and / or actuators for providing energy to the components of the drilling apparatus.

[0017] In one embodiment, the drilling arrangement comprises an automatic loader configured to automatically load drill rod segments from a drill rod supply onto the carriage.

[0018] In one embodiment, the drill pipe supply comprises a truck loaded with a supply of drill pipe sections.

[0019] In one embodiment, the automated loader comprises an automated platform or an autonomous driving platform.

[0020] In one embodiment, the automatic loader comprises a robotic arm disposed on the drill rod supply and configured to automatically load the drill rod segments from the drill rod supply onto the carriage.

[0021] In one embodiment, the cradle of the drill rod loading assembly comprises at least two pipe roller cradles for receiving drill rod segments in a substantially horizontal position.

[0022] In one embodiment, the drilling mast is disposed laterally of the bracket.

[0023] In one embodiment, the handler assembly includes a mechanism configured to capture a drill pipe segment in the cradle, hoist the captured drill pipe segment into a substantially vertical orientation, and rotate the vertical drill pipe segment from adjacent the cradle toward the drill string.

[0024] In one embodiment, the mechanism of the carrier assembly is configured to move the vertical drill rod segments laterally beneath the rotary head drive.

[0025] In one embodiment, the drilling mast is pivotally mounted on the platform such that the mast is deployable between a transport position in which the mast is located adjacent the platform and a drilling position in which the mast is in a substantially vertical position to enable drilling.

[0026] In one embodiment, the drill rod manipulator includes at least two layered pairs of rod clamps, each selectively configured to clamp or release an end of a drill rod segment to facilitate automatic threaded interconnection of successive drill rod segments.

[0027] Typically, the two stacked pairs of rod clamps are coaxially rotatably arranged relative to each other about a drill rod segment within the drill rod handler to facilitate threaded interconnection of successive drill rod segments.

[0028] In one embodiment, the drill rod operator includes at least one rod aligner stacked on the pair of rod clamps and configured to align an end of a drill rod segment with an end of a subsequent drill rod segment to facilitate automatic threaded interconnection of the drill rod segments.

[0029] In one embodiment, the rod aligner includes a rod drum for abutting the drill rod segment to allow the aligner to laterally move the end of the drill rod segment while the drill rod segment is able to move longitudinally through the drill rod manipulator.

[0030] In one embodiment, the automatic drilling device includes a control system, which includes sensors for sensing the relative positions of drill rod segments and supplementarily controlling the energy supply device, actuator, automatic loader, carrier assembly and / or drill rod operator as needed to facilitate automatic drilling by the automatic drilling device.

[0031] According to a second aspect of the present invention, there is provided a drilling method, the method comprising the following steps:

[0032] An automatic drilling device is provided, which includes a platform and a drill rod loading assembly, a drilling mast is disposed on the platform and includes a rotary head drive movable along the mast to achieve drilling, and the drill rod loading assembly is disposed on the platform and includes a bracket for receiving a drill rod segment;

[0033] automatically displacing and orienting the drill pipe segment from the cradle to a vertical position for engagement with the drill string of the rotary head drive by an automated handler assembly on the platform;

[0034] automatically receiving, aligning and connecting a drill rod section from the carrier assembly to the drill string of the rotary head drive via a drill rod handler of the drilling mast; and

[0035] A well is drilled using the drill string.

[0036] In one embodiment, the platform comprises a mobile platform, such as a flatbed truck, a tracked platform, or the like.

[0037] In one embodiment, the platform comprises energy supply means for the drill rod loading assembly and the drilling mast, such as an internal combustion engine and electric, pneumatic and / or hydraulic generators and / or actuators for providing energy to the components of the drilling apparatus.

[0038] In one embodiment, the method comprises the step of automatically loading drill rod segments from a drill rod supply onto the carriage by an automatic loader.

[0039] In one embodiment, the drill rod supply comprises a truck loaded with a batch of drill rod segments.

[0040] In one embodiment, the automatic loader comprises a robotic arm disposed on the drill rod supply and configured to automatically load the drill rod segments from the drill rod supply onto the carriage.

[0041] In one embodiment, the carriage of the drill rod loading assembly comprises at least two rod drum carriages for receiving drill rod segments in a substantially horizontal position.

[0042] In one embodiment, the drilling mast is disposed laterally of the bracket.

[0043] In one embodiment, the handler assembly includes a mechanism configured to capture a drill pipe segment in the cradle, hoist the captured drill pipe segment into a substantially vertical orientation, and rotate a vertical drill pipe segment from adjacent the cradle toward the drill string.

[0044] In one embodiment, the mechanism of the carrier assembly is configured to move the vertical drill rod segments laterally beneath the rotary head drive.

[0045] In one embodiment, the drilling mast is pivotally mounted on the platform such that the mast is deployable between a transport position in which the mast is located adjacent the platform and a drilling position in which the mast is in a substantially vertical position to enable drilling.

[0046] In one embodiment, the drill rod manipulator comprises at least two pairs of rod clamps stacked on top of each other, each of the pairs of rod clamps being configured to clamp or release an end of a drill rod segment to facilitate automatic threaded interconnection of successive drill rod segments.

[0047] Typically, the two stacked pairs of rod clamps are coaxially rotatably arranged relative to each other about a drill rod segment within the drill rod handler to facilitate threaded interconnection of successive drill rod segments.

[0048] In one embodiment, the drill rod operator includes at least one rod aligner stacked on the pair of rod clamps and configured to align an end of a drill rod segment with an end of a subsequent drill rod segment to facilitate automatic threaded interconnection of the drill rod segments.

[0049] In one embodiment, the rod aligner includes a rod drum for abutting the drill rod segment to allow the aligner to laterally move the end of the drill rod segment while the drill rod segment is able to move longitudinally through the drill rod manipulator.

[0050] According to another aspect of the present invention, there is provided an automated drilling method, comprising the step of drilling by the automated drilling device according to the first aspect of the present invention.

[0051] According to another aspect of the present invention there is provided an automated drilling apparatus and associated drilling method, substantially as described and / or illustrated herein. BRIEF DESCRIPTION OF THE DRAWINGS

[0052] The description will be made with reference to the accompanying drawings, in which:

[0053] Figure 1 is a schematic rear perspective view of an automatic drilling device according to various aspects of the present invention;

[0054] Figure 2 for Figure 1 A schematic side view of an automated drilling apparatus of FIG. 1 showing the drilling mast in a transport position;

[0055] Figure 3 for Figure 1 A schematic rear perspective view of an automated drilling apparatus showing a drilling mast in a drilling position;

[0056] Figure 4 for Figure 3 A schematic rear view of an automatic drilling device;

[0057] Figure 5 for Figure 1 A schematic side view of a drill pipe loading assembly of an automatic drilling device;

[0058] Figure 6 for Figure 5 A schematic close-up view of a handler assembly of a drill pipe loading assembly;

[0059] Figure 7 for Figure 8 A schematic side view of a carrier assembly vertically lifting a drill pipe segment;

[0060] Figure 8 for Figure 7 A schematic close-up view of a carrier assembly grabbing a drill pipe segment;

[0061] Fig. 9 for Figure 7 A schematic rear perspective view of a carrier assembly of FIG.

[0062] Fig.10 for Figure 7A schematic rear view of a carrier assembly of the drill bit, the carrier assembly rotating a vertical drill pipe segment from a bracket toward the drill string;

[0063] Fig.11 for Fig.10 a schematic close-up view of a carrier assembly of , showing an actuator for laterally moving a vertical drill pipe segment below a rotary head drive;

[0064] Fig.12 for Fig.11 A schematic rear view of a carrier assembly of FIG.

[0065] Fig.13 for Fig.12 A schematic rear perspective view of a carrier assembly of FIG.

[0066] Fig.14 is a schematic top rear perspective view of an automated drilling apparatus having drill pipe segments interconnected with a drill string;

[0067] Fig.15 A schematic diagram of a drill rod operator for an automatic drilling device;

[0068] Fig.16 for Fig.15 A schematic top perspective view of a drill pipe manipulator of , showing a pair of stacked rod clamps coaxially rotatable about a drill string to facilitate automatic threaded interconnection of drill pipe segments;

[0069] Fig.17 for Fig.16 A schematic perspective view of a drill rod manipulator of , wherein the rod clamp pair and the rod aligner are in line with each other;

[0070] Figures 18 to 22 For screwing drill pipe segments together Fig.15 A schematic side view of a drill pipe manipulator;

[0071] Fig.23 is a schematic diagram of an automatic drilling device including an automatic loader; and

[0072] Fig.24 for Fig.23 Schematic diagram of the automatic loader. DETAILED DESCRIPTION

[0073] More features of the present invention are fully illustrated in the following description of several non-limiting embodiments. This description is included only for the purpose of illustrating the present invention to those skilled in the art. It should not be construed as a limitation to the broad overview, disclosure or description of the present invention described above.

[0074] In the accompanying drawings included to illustrate features of an exemplary embodiment or multiple embodiments, the same reference numerals are used to identify the same components in all figures. In addition, features, mechanisms and aspects that are well known and understood in the art will not be described in detail again, as these features, mechanisms and aspects will be within the scope of understanding of those skilled in the art.

[0075] In summary, the present invention provides an automatic drilling device 10 that facilitates automatic drilling by automatically supplying drill pipe segments 18 from a drill pipe supply device 32 to a drilling mast 22 having a rotary head drive 18, wherein a drill string is connected to the rotary head drive, as is known in the art, such a drill string includes a plurality of drill pipe segments 18, and the drill pipe segments 18 are connected in sequence to lengthen the drill string as the well is drilled deeper.

[0076] In a typical embodiment, the automated drilling apparatus 10 generally includes a platform 12, a drill rod loading assembly 14, and a drilling mast 22 having a rotary head drive 24 movable along the mast 22 to achieve drilling, and a drill rod handler 26, which cooperate to facilitate automated drilling as described herein.

[0077] Referring to the drawings, an example of an automated drilling device 10 is currently shown, which includes a platform 12 supporting other components, as described below. The platform 12 may include a mobile platform, such as a flatbed truck, a crawler platform, etc. In other embodiments, the platform 12 may be a fixed platform.

[0078] In a typical embodiment, the platform 12 includes energizing means 28 for the drill pipe loading assembly 14 and the drilling mast 22, such as an internal combustion engine and an electric, pneumatic and / or hydraulic generator and / or actuator for providing energy to the components of the drilling device 10. In an exemplary embodiment, as shown in the drawings, the various components are energized or actuated by electric, pneumatic and / or hydraulic actuators. When the platform 12 is movable, such as on a truck, it may also include stabilizers, etc. for stabilizing the platform 12. It will be appreciated by those skilled in the art that the various components may be actuated by various means as needed, and such means are within the purview of those skilled in the art.

[0079] In one embodiment, in the case where the platform is mobile, the platform may include an automated or self-driving vehicle platform configured to position the drilling device to a desired location in an automated manner. Similarly, the automatic loader 30 may include an automated or self-driving vehicle platform to position the drill pipe supply device 32 relative to the drilling device 10 to a desired location.

[0080] The apparatus 10 further includes a drill rod loading assembly 14 disposed on the platform 12 and including a cradle 16 for receiving a drill rod segment 18. The drill rod loading assembly 14 further includes a carrier assembly 20 configured to automatically displace and orient the drill rod segment 18 from the cradle 16 to a vertical position for engagement with a drill string of a rotary head drive 24.

[0081] In one embodiment, the carriage 16 of the drill rod loading assembly 14 includes at least two rod drum carriages for receiving the drill rod segments 18 in a substantially horizontal position. One or more of the rod drum carriages may be powered to move the drill rod segments 18 along the carriage 16 as needed to facilitate handling by the carrier assembly 20.

[0082] In an exemplary embodiment, the carriage 16 is laterally disposed with the drilling mast 22, which maximizes the use of available space on the platform 12. This lateral arrangement also allows the carriage 16 to be positioned to receive drill pipe segments 18 from one side of the platform 12. In such an embodiment, the carrier assembly 20 includes a mechanism configured to grab a drill pipe segment 18 in the carriage 18, hoist the grabbed drill pipe segment 18 into a substantially vertical orientation, and rotate the vertical drill pipe segment 18 from near the carriage 16 toward the drill string at the mast 22. Additionally, in one embodiment, the mechanism of the carrier assembly 20 is configured to move the vertical drill pipe segment 18 laterally under the rotary head drive 24. These handling steps are more clearly shown in FIG. Figures 5 to 12 middle.

[0083] As will be appreciated by those skilled in the art, the carrier assembly 20 may take many forms, but typically includes a pipe gripper mounted on a pivotable and rotatable frame to carry the drill pipe segments 18 as previously described. Similarly, movement of the carrier assembly 20 is accomplished by a variety of actuators to actuate the carrier assembly 20 as desired. Such actuators may include pneumatic, hydraulic, and / or electromechanical actuators known in the art, and are typically powered by a power supply 28.

[0084] The apparatus 10 also includes a drilling mast 22 disposed on the platform 12 and including a rotary head drive 24 that can be moved along the drilling mast 22 to enable drilling, as is known in the art. In one embodiment, the drilling mast 22 is pivotally disposed on the platform 12 so that the mast 22 can be deployed between a transport position, in which the mast 22 is located near the platform, and a drilling position, in which the mast 22 is in a substantially vertical position to enable drilling. For example, when the platform 12 is on a truck, the mast 22 can be lowered to be closer to the platform for transportation, and it can also be deployed to a vertical position when drilling.

[0085] Importantly, the drilling mast 22 includes a drill rod handler 26 that is configured to automatically receive, align, and connect drill rod segments 18 from the carrier assembly 20 with the drill string of the rotary head drive 24 to facilitate automated drilling by the automated drilling apparatus 10. While conventional so-called double-breakaway clamps are known to be used in drilling rigs to clamp and loosen stuck drill rod threads during drill rod extraction, the drill rod handler 26 in the drilling apparatus 10 is specifically configured for automated alignment between drill rod segments, particularly during threading of such drill rod segments (rather than simple unthreading, as with conventional double-breakaway clamps).

[0086] Although the drill rod operator 26 can have a variety of forms, in an exemplary embodiment, the drill rod operator 26 includes at least two rod clamp pairs 36 stacked on top of each other, each rod clamp pair 36 configured to clamp or release the ends of the drill rod segments 18 to facilitate the automatic threaded interconnection of successive drill rod segments 18. Importantly, each of the at least two rod clamp pairs 36 is configured to function independently of the other rod clamp pairs, as described in more detail below, for example, the rod clamp pairs do not operate in unison like conventional double-split pliers. As shown in the accompanying drawings, the rod clamp pairs 36 generally include two opposing clamping portions actuated by a suitable actuator to clamp or release the drill rod segments.

[0087] To achieve threaded engagement of the drill rod segments 18, two stacked pairs of rod clamps 36 are coaxially rotatably arranged relative to each other around such drill rod segments 18 within the drill rod handler 26 to facilitate threaded interconnection of successive drill rod segments 18. Fig.16 As more clearly shown, the rod clamp pairs 36 can be individually and independently operated and coaxially rotated relative to each other by suitable actuators. For example, Figures 18 to 22 The stacked rod clamp pairs 36 are shown to cooperate to screw the upper drill rod segment into the lower drill rod segment. As shown in the drawings, the corresponding rod clamp pairs 36 clamp the corresponding drill rod segments 18 (upper and lower) respectively to allow the rotation of the rotary head drive to rotate the upper drill rod segment to be screwed onto the lower drill rod segment of the drill string. The operation of the drill rod operator 26 is also reversible to separate or loosen the drill rod segments from each other.

[0088] Importantly, in one embodiment, the drill rod handler 26 also includes at least one rod aligner 38 that is stacked on (and / or located below) the rod clamp pair 36 and is configured to align the end of one drill rod segment 18 with the end of a subsequent drill rod segment 18, as described to facilitate automatic threaded interconnection of the drill rod segments. In an exemplary embodiment, the rod aligner 38 includes a rod drum for abutting the drill rod segment to move the end of the drill rod segment laterally while the drill rod segment passes longitudinally through the drill rod handler 26. In this way, the rod aligner 38 aligns the corresponding drill rod segments for individual clamping and threading by the stacked rod clamp pair 36.

[0089] In this manner, utilizing independently operable rod clamp pairs 36 to selectively clamp separate upper and lower drill rod segments, combined with rod aligner 38 to align the drill rod segments, enables apparatus 10 to automatically align and bolt or unbolt drill rod segments without requiring human intervention.

[0090] In one embodiment, Fig.23 and 24 An example of this embodiment is shown, the drilling device 10 also includes an automatic loader 30, which is configured to automatically load drill pipe segments 18 from a drill pipe supply device 32 onto the bracket 16. In one embodiment, the drill pipe supply device 32 includes a truck loaded with a batch of drill pipe segments 18. In one embodiment, the automatic loader 30 includes a robotic arm 34, which is disposed on the drill pipe supply device 32 and is configured to automatically load the drill pipe segments from the drill pipe supply device onto the bracket 16. As with the platform 12, the automatic loader 30 may also include a suitable power supply device 28. As described above, both the platform 10 and the automatic loader 30 may include self-driving, automated vehicle platforms to facilitate automatic autonomous drilling.

[0091] The automatic drilling device 10 generally also includes a control system 40, which includes sensors for sensing the relative positions of the drill rod segments 18, and supplementarily controls the energy supply device 28, actuator, automatic loader 30, carrier assembly 20, rotary head drive 24 and / or drill rod operator 26 as needed to facilitate the automatic drilling device 10 to perform automatic drilling.

[0092] As will be appreciated by those skilled in the art, such a control system 40 with appropriate sensors may take many forms. For example, in one embodiment, a programmable logic controller (PLC) and appropriate proximity sensors, limit sensors, and / or computer vision sensors may be used to determine the position and motion of the components. Those skilled in the art will also appreciate that reference to "computer vision" generally refers to any applicable technology for building an artificial system for acquiring information from images or multi-dimensional data, and any applicable configuration for processing how a computer or similar processing system can obtain a high-level and / or detailed understanding from a digital image or video, i.e., automating the tasks that a human vision system can accomplish, as is well known in the computer and vision engineering fields.

[0093] In particular, the control system 40 is generally configured to accurately monitor and track the positions of the components of the drill rod handler 26, such as the rod clamp pair 36 and the rod aligner 38, to achieve proper alignment and threading of the individually manipulable drill rod segments, as described above.

[0094] It will also be appreciated by those skilled in the art that the operation of the automatic loader 30, loading assembly 12, carrier assembly 20, rotary head drive 24, and drill pipe handler 26 (as part of the overall operation of the drilling apparatus 10) is generally reversible to remove the drill pipe segments 18 from the well. Therefore, the description of such drilling operations herein includes the reverse sequence, as appropriate, to automatically remove and store the drill pipe segments 18.

[0095] It should be understood by those skilled in the art that the present invention includes a related drilling method. The method generally includes the steps of providing an automatic drilling device 10, the automatic drilling device including a platform 12 with a drilling mast 22, the drilling mast 22 is arranged on the platform 12 and includes a rotary head drive 24 that can move along the mast 22 for drilling, and a drill pipe loading assembly 14 is arranged on the platform 12 and includes a bracket 16 for receiving a drill pipe segment 18.

[0096] The method also includes automatically shifting and orienting the drill pipe segment 18 from the cradle 16 to a vertical position by an automated carrier assembly 20 on the platform to engage with the drill string of the rotary head drive 24, and automatically receiving the drill pipe segment 18 from the carrier assembly 20 by a drill pipe manipulator 26, aligning and connecting it with the drill string of the rotary head drive 24, and then using the drill string to drill.

[0097] Similar to the automatic drilling device 10 described above, the drilling method is also applicable to removing the drill string from the wellbore, wherein the steps for drilling can generally be reversible to remove the drill pipe segment 18 from the drill string. Therefore, although these reversible operations are not described in detail here, they are obvious to those skilled in the art.

[0098] Applicants consider it particularly advantageous that the present invention provides an automated drilling apparatus 10 that reduces the labor intensive nature of conventional drilling methods while also removing personnel from potentially hazardous working environments during such drilling operations.

[0099] The optional embodiments of the present invention may also be considered to broadly include the parts, elements and features mentioned or indicated herein, individually or collectively, in any or all combinations of two or more parts, elements or features; and where certain specific integers are mentioned, there are known equivalents in the technical field to which the present invention belongs, and these known equivalents are considered to be incorporated herein as if they were set forth separately. In the exemplary embodiments, well-known processes, well-known equipment structures and well-known technologies are not described in detail because they are easily understood by those skilled in the art.

[0100] The use of the terms "a," "an," "said," "the," and / or similar referents when describing various embodiments (especially in the context of the claimed subject matter) should be understood to include both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms "comprising," "having," "including," and "containing" should be understood as open-ended terms (i.e., meaning "including, but not limited to") unless otherwise indicated. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items. Language in the specification should not be construed to indicate that any non-claimed subject matter is essential to the practice of the claimed subject matter.

[0101] For ease of description, spatially relative terms such as "inside", "outside", "below", "below", "lower", "above", "upper", etc. may be used herein to describe the relationship of one element or feature relative to another element or feature shown in the figures. The spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation shown in the figures.

[0102] It should be understood that references to "one example" or "an example" or similar exemplary language (e.g., "for example") herein are not exclusive. Thus, one example may illustrate certain aspects of the invention, while other aspects are illustrated in different examples. These examples are intended to assist those skilled in the art in practicing the invention and are not intended to limit the overall scope of the invention in any way unless the context clearly indicates otherwise. After reading this application, changes (e.g., modifications and / or enhancements) to one or more of the embodiments described herein may become apparent to a person of ordinary skill in the art. The inventors expect that skilled technicians will adopt these variations as needed, and the inventors intend that the claimed subject matter can be implemented in a manner different from that specifically described herein.

[0103] Any method steps, processes, and operations described herein should not be construed as necessarily requiring their execution in the particular order discussed or illustrated, unless specifically indicated as an order of execution. It should also be understood that additional or alternative steps may be employed.

Claims

1. An automatic drilling device, comprising: platform; a drill pipe loading assembly disposed on the platform and comprising a cradle for receiving a drill pipe segment and a carrier assembly configured to automatically displace and orient the drill pipe segment from the cradle into a vertical position for engagement with a drill string; as well as a drilling mast disposed on the platform and including a rotary head drive movable along the mast to effect drilling and a drill rod operator configured to automatically receive, align and connect the drill rod segments from the carrier assembly with a drill string of the rotary head drive to facilitate automated drilling by the automated drilling device; wherein the drill rod operator comprises at least two pairs of rod clamps stacked on top of each other, each of the rod clamp pairs being independently and selectively configured to clamp or release ends of two separate drill rod sections to facilitate automatic threaded interconnection of such two consecutive drill rod sections; and Wherein, the drill rod operator includes at least one rod aligner stacked on the rod clamp pair, and the rod aligner is configured to align the end of one drill rod segment with the end of a subsequent drill rod segment.

2. The drilling apparatus according to claim 1, wherein the platform comprises a mobile platform, such as a flatbed truck, or a crawler platform.

3. The drilling device according to claim 1 or 2, wherein: The platform comprises energy supply means for the drill rod loading assembly and the drilling mast, such as internal combustion engines and electric, pneumatic and / or hydraulic generators and / or actuators for providing energy to the components of the drilling apparatus.

4. A drilling arrangement according to any one of claims 1 to 3, comprising an automatic loader configured to automatically load drill rod segments from a drill rod supply device onto the carriage.

5. The drilling device according to claim 4, wherein: The drill rod supply comprises a truck loaded with a batch of drill rod segments.

6. The drilling device according to claim 4 or 5, wherein: The automatic loader includes a robotic arm disposed on the drill rod supply and configured to automatically load drill rod segments from the drill rod supply onto the carriage.

7. The drilling device according to any one of claims 1 to 6, wherein: The carriage of the drill rod loading assembly includes at least two rod drum carriages for receiving drill rod segments in a substantially horizontal position.

8. The drilling device according to any one of claims 1 to 7, wherein: The drilling mast is arranged laterally of the bracket.

9. The drilling device according to any one of claims 1 to 8, wherein: The handler assembly includes a mechanism configured to capture a drill pipe segment in the cradle, hoist the captured drill pipe segment into a substantially vertical orientation, and rotate the vertical drill pipe segment from adjacent the cradle toward the drill string.

10. The drilling device according to claim 9, wherein: The mechanism of the carrier assembly is configured to move the vertical drill rod segments laterally beneath the rotary head drive.

11. The drilling device according to any one of claims 1 to 10, wherein: The drilling mast is pivotably mounted on the platform such that the mast can be deployed between a transport position in which the mast is located adjacent the platform and a drilling position in which the mast is in a substantially vertical position to enable drilling.

12. The drilling device according to any one of claims 1 to 11, wherein: The two stacked pairs of rod clamps are coaxially rotatably arranged relative to each other about a drill rod segment within the drill rod handler to facilitate threaded interconnection of successive drill rod segments.

13. The drilling device according to any one of claims 1 to 12, wherein: The rod aligner includes a rod drum for abutting a drill rod segment to allow the aligner to laterally move an end of the drill rod segment while the drill rod segment is able to move longitudinally through the drill rod handler.

14. The drilling device according to any one of claims 1 to 13 comprises a control system, wherein the control system includes sensors for sensing the relative positions of drill pipe segments and supplementarily controlling the energy supply device, platform, actuator, automatic loader, carrier assembly and / or drill pipe operator as needed to facilitate automatic drilling by the automatic drilling device.

15. The drilling device according to claim 14, wherein: The control system is configured to accurately monitor and track the positions of the at least two rod clamp pairs 36 and the rod aligner 38 to enable automatic alignment and threading of individually manipulable drill rod segments.

16. A method of drilling a well, the method comprising the following steps: Providing an automatic drilling device according to any one of claims 1 to 15; automatically displacing and orienting drill pipe segments from the carriages to a vertical position for engagement with the drill string of the rotary head drive by an automated handler assembly on the platform; automatically receiving, aligning and connecting a drill pipe segment from the carrier assembly to a drill string of the rotary head drive via a drill pipe handler of the drilling mast; as well as A well is drilled using the drill string.

Images