Core tube handling system with kickout tray

Abstract

A kickout tray assembly can be used with exploratory drill rigs. The assembly may include a first pivotable structure mountable on a mast of a drill rig. The first pivotable structure may pivot toward and away from the mast about a first axis oriented parallel to the mast. A second pivotable structure coupled to the first pivotable structure may be pivotable toward and away from the first pivotable structure about a second axis parallel to the first axis. A tray, including a first end coupled to the second pivotable structure and a free second end, may pivot toward and away from the second pivotable structure about a third axis transverse to the second axis proximate to the first end. The tray may be configured to receive and move a core tube toward and away from the mast.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application is based upon and claims priority to U.S. Provisional Application No. U.S. 63 / 387,828, filed on Dec. 16, 2022, which is hereby incorporated by reference herein in its entirety.FIELD

[0002] This disclosure relates to core tube handling systems used with drill rigs and, in particular, to drill rigs configured for core drilling (e.g., diamond exploration drilling).BACKGROUND

[0003] Diamond core drill rigs are used to retrieve core samples from rock strata at depths of up to 1800 meters or more. The core samples can be analyzed to determine if the drilling site has potential for mining operations. Such exploratory rigs can use annular (e.g., annular diamond-impregnated) drill bits attached to the end of hollow drill rods to cut a cylindrical core sample from the solid rock. Core samples can be retrieved using a core tube (also known as an “inner tube” or a “core barrel”), a hollow receptacle positioned within the drill string. As the core is drilled, the core tube can slide over the rock core sample. An overshot, attached to the core tube and to a winch by a cable, may be used to retrieve the core tube from inside the drill string. Retracting the winch can pull the core tube to the surface.

[0004] Once at the surface, the core tube must be maneuvered to a position where the overshot can be removed from the core tube and the core sample removed from the core tube. The challenge is to handle a core tube, which can be 3-6 meters long and weigh 120 kg- 260 kg or more, held by the winch cable. Prior art techniques require the awkward and heavy core tubes to be physically manhandled by the drilling crew. There are clearly physical challenges and safety concerns associated with this process, which requires lifting of heavy weight and working at dangerous heights.SUMMARY

[0005] Disclosed herein, in various aspects, is a core handling system including a kickout tray assembly for moving a free hanging core tube, the kickout tray assembly being attachable to a drill rig having a mast for supporting the core tube. The kickout tray assembly may comprise a first pivotable structure mountable on the mast in an orientation parallel thereto. The first pivotable structure may be pivotable toward and away from the mast about a first axis oriented parallel to the mast. The kickout tray assembly may comprise a second pivotable structure coupled to the first pivotable structure. The second pivotable structure may be pivotable toward and away from the first pivotable structure about a second axis parallel to the first axis. The kickout tray assembly may comprise a tray. The tray may include a first end coupled to the second pivotable structure and a free second end. The tray may be pivotable toward and away from the second pivotable structure about a third axis transverse to the second axis proximate to the first end. The tray may be configured to receive and move the core tube toward and away from the mast.

[0006] The first pivotable structure may be mountable to the mast via at least one first pivoting arm and at least one first actuator that may be configured to move the first pivotable structure relative to the mast about the first axis.

[0007] The at least one first actuator may comprise a first hydraulic cylinder that is pivotably coupled to the mast.

[0008] The first hydraulic cylinder may comprise a rotary actuator or a slew motor.

[0009] The second pivotable structure may be coupled to the first pivotable structure via at least one second pivoting arm and at least one second actuator that may be configured to move the second pivotable structure relative to the first pivotable structure about the second axis.

[0010] The at least one second actuator may comprise a second hydraulic cylinder that is pivotably coupled to the first pivotable structure.

[0011] The second rotating hydraulic cylinder may comprise a rotary actuator or a slew motor.

[0012] The tray may be pivotable (e.g., kicking-out to the front of the drill rig) via at least one third actuator.

[0013] The at least one third actuator may comprise a hydraulic cylinder or a rotary actuator.

[0014] The kickout tray assembly may further comprise a controller. The controller may be configured to cause the at least one first actuator to pivot the first pivotable structure toward or away from the mast about the first axis. The controller may cause the at least one second actuator to pivot the second pivotable structure toward or away from the first pivotable structure about the second axis. The controller may cause the at least one third actuator to pivot the tray toward or away from the second pivotable structure about the third axis.

[0015] The controller may be configured to cause at least one of the at least one first actuator, at least one second actuator, and at least one third actuator to move according to at least one sensor configured to sense a degree of rotation.

[0016] The tray may comprise a V-shaped interior surface.

[0017] The first end and the second end of the tray may each include a ramp.

[0018] The tray may be pivotable between 0-45 degrees with respect to the second axis.

[0019] A drill rig system may comprise a mast. The drill rig system may comprise a kickout tray assembly. The kickout tray assembly may comprise a first pivotable structure mounted on the mast in an orientation parallel thereto. The first pivotable structure may be pivotable toward and away from the mast about a first axis oriented parallel to the mast. The kickout tray assembly may comprise a second pivotable structure coupled to the first pivotable structure. The second pivotable structure may be pivotable toward and away from the first pivotable structure about a second axis parallel to the first axis. The kickout tray assembly may comprise a tray. The tray may include a first end coupled to the second pivotable structure and a free second end. The tray may be pivotable toward and away from the second pivotable structure about a third axis transverse to the second axis proximate to the first end. The tray may be configured to receive and move the core tube toward and away from the mast.

[0020] The drill rig system may further comprise a rod handling system. The rod handling system may comprise a base. The rod handling system may comprise a second tray comprising a first end pivotally attached to the base and a free second end. The rod handling system may comprise a fourth actuator that may be configured to pivot the second tray to elevate the free second end. The free second end of the second tray may be configured to receive at least a portion of the core tube from the kickout tray assembly.

[0021] A method may comprise moving a core tube attached to a drilling apparatus having a mast with a kickout tray assembly. The kickout tray assembly may comprise a first pivotable structure mounted on the mast in an orientation parallel thereto. The first pivotable structure may be pivotable toward and away from the mast about a first axis oriented parallel to the mast. The kickout tray assembly may comprise a second pivotable structure coupled to the first pivotable structure. The second pivotable structure may be pivotable toward and away from the first pivotable structure about a second axis parallel to the first axis. The kickout tray assembly may comprise a tray. The tray may include a first end coupled to the second pivotable structure and a free second end. The tray may be pivotable toward and away from the second pivotable structure about a third axis transverse to the second axis proximate to the first end. The tray may be configured to receive and move the core tube toward and away from the mast.

[0022] Moving the core tube with the kickout tray assembly may comprise pivoting, by a first actuator, the first pivotable structure toward the mast. The second actuator may pivot the second pivotable structure away from the first pivotable structure. The third actuator may pivot the second end of the tray away from the second pivotable structure to receive and move the core tube.

[0023] Moving the core tube with the kickout tray assembly may further comprise pivoting, by the third actuator, the second end of the tray towards the second pivotable structure. The second actuator may pivot the second pivotable structure toward the first pivotable structure. The first actuator may pivot the first pivotable structure away from the mast.

[0024] A controller may cause the first actuator, the second actuator, and the third actuator to move.BRIEF DESCRIPTION OF THE DRAWINGS

[0025] FIG. 1 is an isometric view of an example drill rig and kickout tray assembly in accordance with the present disclosure.

[0026] FIG. 2 is an isometric view of an example mast of the drill rig and the kickout tray assembly.

[0027] FIG. 3 is an isometric views of the example kickout tray assembly in a first position.

[0028] FIG. 4 is an isometric view of the example kickout tray assembly of FIG. 3 in a second position.

[0029] FIG. 5 is an isometric view of the example kickout tray assembly of FIGS. 3 and 4 in a third position.

[0030] FIG. 6 is an isometric view of the example kickout tray assembly of FIGS. 3-5 in a fourth position.

[0031] FIGS. 7A and 7B each show an isometric view of an example tray extension. FIG. 7A shows the tray extension when the example kickout tray assembly is in the third position. FIG. 7B shows the tray extension when the example kickout tray assembly is in the fourth position.

[0032] FIG. 8 is a section view of an exemplary core tube cap.

[0033] FIG. 9 is a block diagram of an operating environment comprising a computing device as disclosed herein for controlling the kickout tray assembly.DETAILED DESCRIPTION

[0034] The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, this invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout. It is to be understood that this invention is not limited to the particular methodology and protocols described, as such may vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention.

[0035] Many modifications and other embodiments of the invention set forth herein will come to mind to one skilled in the art to which the invention pertains having the benefit of the teachings presented in the foregoing description and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

[0036] As used herein the singular forms “a,”“an,” and “the” can include plural referents unless the context clearly dictates otherwise. Use of such singular forms herein is understood to represent disclosure of embodiments in only a single element is provided, as well as alternative embodiments in which a plurality of such elements are provided. For example, unless the context dictates otherwise, use of the term “a bracket” can represent disclosure of embodiments in which only a single bracket is provided, as well as alternative embodiments in which a plurality of such brackets are provided.

[0037] All technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this invention belongs unless clearly indicated otherwise.

[0038] As used herein, the terms “optional” or “optionally” mean that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

[0039] As used herein, the term “at least one of” is intended to be synonymous with “one or more of.” For example, “at least one of A, B and C” explicitly includes only A, only B, only C, and combinations of each.

[0040] Ranges can be expressed herein as from “about” one particular value, and / or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. Optionally, in some aspects, when values are approximated by use of the antecedent “about,” it is contemplated that values within up to 15%, up to 10%, up to 5%, or up to 1% (above or below) of the particularly stated value can be included within the scope of those aspects. Similarly, use of “substantially” (e.g., “substantially parallel”) or “generally” (e.g., “generally planar”) should be understood to include embodiments in which angles are within ten degrees, or within five degrees, or within one degree.

[0041] The word “or” as used herein means any one member of a particular list and, in alternative embodiments, can also include any combination of members of that list, unless context dictates otherwise.

[0042] It is to be understood that unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps or operational flow; plain meaning derived from grammatical organization or punctuation; and the number or type of aspects described in the specification.

[0043] The following description supplies specific details in order to provide a thorough understanding. Nevertheless, the skilled artisan would understand that the apparatus, system, and associated methods of using the apparatus can be implemented and used without employing these specific details. Indeed, the apparatus, system, and associated methods can be placed into practice by modifying the illustrated apparatus, system, and associated methods and can be used in conjunction with any other apparatus and techniques conventionally used in the industry.

[0044] FIG. 1 shows a drill rig system 10, in this example, for core or rock drilling (e.g., using drill bits such as diamond-impregnated drill bits). The drill rig system 10 may include a mast 12 configured to support other components of the drill rig system 10. The mast 12 may have different steel structure designs than the one shown in FIG. 1. The mast 12 may support a rotary head 14 configured to drill a hole to obtain geological samples. A drill string comprising drill rod(s) (e.g., a plurality of drill rods coupled end-to-end) may be drilled into the ground via the rotary head 14. The drill string may transmit the rotational torque and weight from a power source (e.g., the rotary head 14) to a drill bit to drill into the ground / formation below the drill rig system 10. The mast 12 may also support a wireline apparatus 16 that may be mounted in front of, behind, or on top of the mast 12. The wireline apparatus 16 may include a winch and a cable configured to lift and lower a core tube 18 (also referred to as an “inner tube” or “core barrel”) through the drill string and into the drill hole. The core tube 18 may be advanced within and retracted out of the drill string and drill hole to collect a core or rock sample from the formation. The mast 12 may also support a core tube handling assembly, which as further disclosed herein, can comprise a kickout tray assembly 20 that is configured to receive and move a core tube 18 attached to the cable of the wireline apparatus 16. Optionally, the core tube 18 may be attached to an overshot, which is in turn attached to the cable of the wireline apparatus 16.

[0045] As shown in FIG. 1 and FIG. 2, the kickout tray assembly 20 may be mounted on a side of the mast 12. The kickout tray assembly 20 may be mounted on the left or right side of the mast 12 which may allow the assembly 20 to work with different types of rotary heads, such as top-drive and chuck-drive rotary heads. In one aspect, the kickout tray assembly 20 may be mounted on the mast 12 between the winch and wireline roller of the wireline apparatus 16. Additionally, the kickout tray assembly 20 may be mounted on the mast 12 above the clamping / footclamp and breaking device 13 and below the rotary head 14.

[0046] Optionally, if a safety gate 15 is placed around the drill rig system 10, the kickout tray assembly 20 may be mounted on the mast 12 above the safety gate 15. The kickout tray assembly 20 may be configured to pivot into position between the core tube 18 and a front of the mast 12 to move the core tube 18, as shown in FIG. 1.

[0047] FIGS. 3-6 show the kickout tray assembly 20 in various positions as it pivots from the side of the mast 12 to a front of the mast 12 between the free hanging core tube 18 and mast 12. The kickout tray assembly 20 may include a first pivotable structure 22. The first pivotable structure 22 may be mountable on the mast 12. Optionally, the first pivotable structure 22 may be mounted to a beam 19 of the mast 12. The first pivotable structure 22 may be mounted to the mast 12 in an orientation substantially parallel to the mast 12. The kickout tray assembly 20 may also include a second pivotable structure 24 mounted on the first pivotable structure 22 and a tray 26 mounted on the second pivotable structure 24. The first pivotable structure 22 may pivot toward and away from the mast 12 about a first axis 30 substantially parallel to the mast 12. In some aspects, the first pivotable structure 22 may pivot toward and away from the mast 12 by about 90 degrees.

[0048] FIG. 3 shows the kickout tray assembly 20 in a first position (a folded, home position). In the home position, the first pivotable structure 22 can be pivoted away from the mast 12. The first pivotable structure 22 may be pivotably mounted to the mast 12 via at least one pivoting arm 21 and at least one first actuator 25. In one aspect, the at least one first actuator 25 may be coupled to the first pivotable structure 22 and the mast 12 by at least one first bracket 23. Although FIG. 3 shows a first pivotable structure 22 connected to the mast 12 via two pivoting arms 21, fewer or more than two pivoting arms 21 may be used depending on the length of the first pivotable structure 22. Optionally, the pivoting arms 21 may be coupled to the mast 12 via weldment or one or more fasteners. Optionally, in some aspects, the pivoting arms 21 may be fastened to the mast 12 via screws. In these aspects, shims may be used to adjust the position of the pivoting arms 21 with respect to the mast 12. The at least one first actuator 25 may be configured to pivot the first pivotable structure 22 about the first axis 30. In one aspect, the first actuator 25 may comprise a first hydraulic cylinder 27. Optionally, the first hydraulic cylinder 27 may comprise a rotary actuator or a slew motor. Although one first bracket 23 and first actuator 25 are shown in FIG. 3, more than one first bracket 23 and first actuator 25 may be connected to the first pivotable structure 22 to pivot the first pivotable structure 22. In one aspect, the at least one first bracket 23 and first actuator 25 may be positioned adjacent to a pivoting arm 21 to reduce the bending moment in the first pivotable structure 22 upon actuation of the first actuator 25. Optionally, the at least one first bracket 23 and / or the first actuator 25 may be coupled to the mast 12 via weldment or one or more fasteners. Optionally, in some aspects, the at least one first bracket 23 and / or first actuator 25 may be fastened to the mast 12 via screws. In these optional aspects, shims may be used to adjust the position of the at least one first bracket 23 and / or first actuator 25 with respect to the mast 12.

[0049] In one aspect, the first actuator 25 may be controlled by at least one controller 80. The at least one controller 80 may cause the first actuator 25 to pivot the first pivotable structure 22 toward or away from the mast 12. Optionally, the at least one controller 80 may be configured to cause the at least one first actuator 25 to pivot the first pivotable structure 22 according to at least one sensor that is communicatively coupled to the controller 80. The at least one sensor may sense a degree of rotation or a rotational position of the first pivotable structure 22 and signal to a controller 80 the position of the first pivotable structure 22. Exemplary sensors include conventional sensors for sensing rotational position, as are known in the art, such as, for example, optical encoders, proximity switches, momentary switches and the like. For example, in one aspect, the at least one sensor can comprise a momentary switch that compresses when the first pivotable structure 22 reaches a particular position (e.g., the first position). Optionally, the at least one sensor may be coupled to the first pivotable structure 22, the at least one first actuator 25, and / or the pivoting arm(s) 21. In exemplary aspects, the at least one sensor can include a sensor that is coupled to the first pivotable structure 22. Additionally, or alternatively, in some exemplary aspects, the at least one sensor can include a sensor that is coupled to the at least one first actuator 25. Additionally, or alternatively, in still other exemplary aspects, the at least one sensor can include a sensor that is coupled to the pivoting arm 21. Thus, in some exemplary aspects, it is contemplated that the at least one sensor can comprise a plurality of sensors that are distributed among at least two of the first pivotable structure 22, the first actuator 25, and the pivoting arm 21.

[0050] FIG. 4 shows the kickout tray assembly 20 in a second position (a first slew position) wherein the first pivotable structure 22 is pivoted towards the mast 12. As the first pivotable structure 22 pivots, the second pivotable structure 24 and the tray 26 move with the first pivotable structure 22. The first pivotable structure 22 may be pivoted toward the mast 12 to position the second pivotable structure 24 and tray 26 in a location which allows the second pivotable structure 24 and the tray 26 to be pivoted from the side of the mast 12 to the front of the mast 12.

[0051] FIG. 5 shows the kickout tray assembly 20 in a third position (a second slew position behind the drill line) wherein the second pivotable structure 24 is pivoted away from the first pivotable structure 22. The second pivotable structure 24 may be pivotably coupled to the first pivotable structure 22 via at least one second pivoting arm 33 and at least one second actuator 34 that may be configured to pivot the second pivotable structure 24 toward or away from the first pivotable structure 22 about a second axis 32. The second axis 32 may be parallel to, or substantially parallel to, the first axis 30. In some aspects, the second pivotable structure 24 may pivot toward and away from the first pivotable structure 22 by about 90 degrees. In this position, the Kickout tray assembly 20 is positioned behind the drilling line (the centerline of the drill string). Having two pivotable structures, the first pivotable structure 22 and the second pivotable structure 24, allows the kickout tray assembly 20 to be transported and pivoted to different positions with a generally low profile. Said low profile can be particularly beneficial for storage and for transportation to and from a drill site.

[0052] In one aspect, the second actuator 34 may comprise a second hydraulic cylinder 35 that may be pivotably coupled to the first pivotable structure 22. In one example, the second hydraulic cylinder 35 may comprise a rotary actuator or a slew motor. Although FIG. 5 shows two pivoting arms 33 and two second actuators 34, fewer or more pivoting arms 33 and / or second actuators 34 may be used to couple the second pivotable structure 24 to the first pivotable structure 22.

[0053] In one aspect, the second actuators 34 may be controlled by at least one controller 80. The at least one controller 80 may cause the second actuators 34 to pivot the second pivotable structure 24 toward or away from the first pivotable structure 22. Optionally, the at least one controller 80 may be configured to cause the second actuators 34 to pivot the second pivotable structure 24 according to at least one sensor. The at least one sensor may sense a degree of rotation or a rotational position of the second pivotable structure 24 and signal to the controller 80 the position of the second pivotable structure 24. Optionally, the at least one sensor may be coupled to the second pivotable structure 24, the at least one second actuator 34, and / or the pivoting arm(s) 33. In exemplary aspects, the at least one sensor can include a sensor that is coupled to the second pivotable structure 24. Additionally, or alternatively, in some exemplary aspects, the at least one sensor can include a sensor that is coupled to the at least one second actuator 34. Additionally, or alternatively, in still other exemplary aspects, the at least one sensor can include a sensor that is coupled to the pivoting arm 33. Thus, in some exemplary aspects, it is contemplated that the at least one sensor can comprise a plurality of sensors that are distributed among at least two of the second pivotable structure 24, the second actuator 34, and the pivoting arm 33. When the second pivotable structure 24 is pivoted away from the first pivotable structured 22, the second pivotable structure 24, and therefore the tray 26, are positioned in front of the mast 12 thereby positioning the tray 26 between a core tube 18, shown in FIG. 1, and the mast 12.

[0054] FIG. 6 shows the kickout tray assembly 20 in a fourth position (a kickout position) wherein the tray 26 is pivoted away from the second pivotable structure 24. The tray 26 may include a first end 42 coupled to the second pivotable structure 24 and a free second end 44. The first end 42 may be pivotably coupled to the second pivotable structure 24 via a pivotable joint. The second end 44 of the tray 26 may be pivotable toward and away from the second pivotable structure 24 about the first end 42 and about a third axis 40. The third axis 40 may be transverse to or substantially transverse to the second axis 32. In one aspect, the tray 26 may be pivotable via at least one third actuator 46. Optionally, the third actuator 46 may comprise a hydraulic cylinder or a rotary actuator. Although FIG. 6 shows one third actuator 46, the kickout tray assembly 20 may include more than one third actuator 46 to pivot the tray 26. In one aspect, the third actuator 46 may be controlled by the at least one controller 80. The at least one controller 80 may cause the third actuator 46 to pivot the tray 26 toward or away from the second pivotable structure 24. Optionally, the at least one controller 80 may be configured to cause the at least one third actuator 46 to pivot the tray 26 according to at least one sensor. The at least one sensor may sense a degree of rotation or a rotational position of the tray 26 and signal to the controller 80 the position of the tray 26. Optionally, the at least one sensor may be coupled to the tray 26, the at least one third actuator 46, and / or the pivotable joint. In exemplary aspects, the at least one sensor can include a sensor that is coupled to the tray 26. Additionally, or alternatively, in some exemplary aspects, the at least one sensor can include a sensor that is coupled to the at least one third actuator 46. Additionally, or alternatively, in still other exemplary aspects, the at least one sensor can include a sensor that is coupled to the pivotable joint. Thus, in some exemplary aspects, it is contemplated that the at least one sensor can comprise a plurality of sensors that are distributed among at least two of the tray 26, the third actuator 46, and the pivotable joint.

[0055] Feedback from the sensors can be configured for interlocking other drilling functions. For example, axial movement of the drill head can be inhibited while the kickout tray assembly 20 is not in a stowed position (e.g., with the first and second pivotable structures in respective stowed positions at the side of the mast and the second end of the tray pivoted against the second pivotable structure). Further, in some aspects, the rotary head 14 can be configured to pivot between a stowed position (e.g., pivoted upwardly, as illustrated in FIG. 1, or pivoted to the side in embodiments in which the rotary head 14 can be pivoted as such). In these aspects, pivoting of the rotary head 14 into a use position can be inhibited while the tray is not in a stowed position. Still further, in some aspects, the wireline assembly can comprise a roller arm that is pivotable into and away from the drilling line. In these aspects, pivoting of the roller arm can be inhibited while the kickout tray assembly 20 is in a use position (e.g., with the tray 20 in front of the mast).

[0056] The tray 26 may be configured to receive a core tube 18, as shown in FIG. 1. The tray 26 may define a channel to receive the core tube 18. In one aspect, the tray 26 may include an interior surface 48 that defines the channel, which optionally can comprise a V-shape in cross section in planes perpendicular to the second axis 32. The channel or interior surface 48 may be configured to receive various core tube diameters. Optionally, the tray 26 may be reinforced with a frame. The frame may comprise a plurality of steel structures coupled to an exterior surface opposing the channel or interior surface 48. As the tray 26 is pivoted away from the second pivotable structure 24 and the second end 44 extends out, the tray 26 may receive and move the core tube 18 away from the mast 12 as shown in FIG. 1. In one aspect, the tray 26 may pivot about the third axis 40 creating an angle A with respect to the second axis 32. Optionally, angle A may be at least 30 degrees, or at least 40 degrees, or about 45 degrees, or great than 45 degrees. After the tray 26 receives and moves the core tube 18 away from the mast 12, the winch of the wireline apparatus may lower the cable attached to the core tube 18 to allow the core tube 18 to slide down the tray 26. The first end 42 and / or second end 44 of the tray 26 may include ramps. A ramp on the second end 44 can guide the overshot and core tube into the channel of the tray 26. A ramp on the first end 42 can inhibit the core tube 18 and / or overshot from catching on an end of the tray 26 as the core tube 18 is lowered from the tray 26. In one aspect, the second end 44 may include projections 45 configured to further guide the core tube 18 into and out of the tray 26. The tray 26 can comprise bends or flanges that extend along the length of the tray for providing structural support to the tray.

[0057] With reference to FIG. 7A and FIG. 7B, the kickout tray assembly 20 may further include a tray extension 60. The tray extension 60 may be connected or coupled to the first end 42 of the tray 26 and / or to the second pivotable structure 24. In one aspect, the tray extension 60 may be pivotally connected to the first end 42 of the tray 26 to allow the tray extension 60 to remain vertical or substantially vertical along the second axis 32 as the tray 26 pivots out from the second pivotable structure 24. The tray extension 60 may be configured to support the overshot, which may not be supported when using a relatively long core tube (e.g., a 6 meter core tube). The tray extension 60 may also prevent the overshot from getting caught or stuck on the first end 42 of the tray 26 or on other equipment, such as a sled that carries the rotary head 14. As shown, the rotary head 14 can be pivoted away from the drilling line to prevent collision of the tray extension 60 with the rotary head 14.

[0058] With reference to FIG. 8, a cap 52 can be positioned over a lower end 50 of the core tube 18 to prevent damage to the tray 26 or core tube (e.g., without damaging the threads of the core tube) and allow the core tube 18 to slide down the tray 26 more efficiently. Optionally, the cap 52 may be made out of polymer (e.g., plastic). More specifically, the cap 52 may be made out of a high-density polyethylene, ertalon, or cast nylon with oil. In one aspect, the cap 52 may be chamfered or rounded to decrease friction between the core tube 18 and the tray 26 and improve sliding. As the core tube 18 slides away from the drill string and mast 12, the core tube 18 may be maneuvered to a position in front of the drill rig system 10 to allow the overshot to be decoupled from the core tube 18 and / or removal of the core sample from the core tube 18.

[0059] In one aspect, the core tube 18 is slid from the kickout tray assembly 20 to a rod handling system 70 shown in FIG. 1. The rod handling system 70 may be placed in front of the drill rig to take over the full core tube 18 or to present or store an empty core tube 18. The rod handling system 70 may include a base 72 and a second tray 74. The second tray 74 may include a first end 76 pivotally attached to the base 72 and a free second end 78. The rod handling system 70 may also include a fourth actuator 79 that may be configured to pivot the second tray 74 to elevate the free second end 78 to receive at least a portion of the core tube 18 from the kickout tray assembly 20. In one aspect, the fourth actuator 79 may comprise a hydraulic cylinder or a rotary actuator. The core tube 18 may further slide down the second tray 74 of the rod handling system 70 to a position where the overshot, core sample from within the core tube 18, and / or the core tube 18 may be removed. Alternatively, the core tube 18 may be removed from the second tray 74 to another location for the overshot to be removed and / or core sample to be extracted. In one aspect, for example, where no rod handling system 70 is provided, the core tube 18 may be transported and handled using other equipment, such as a vertical tray and / or on a bracket placed in front of the drill rig system 10. Accordingly, as should be understood, the kickout tray assembly 20 can be used with our without a rod handling system 70.

[0060] A method may comprise moving a core tube 18 with a kickout tray assembly 20 attachable to a drill rig system 10 having a mast 12. In one aspect, moving the core tube 18 with the kickout tray assembly 20 may comprise using at least one first actuator 25 to pivot the first pivotable structure 22 toward the mast 12. At least one second actuator 34 may pivot the second pivotable structure 24 away from the first pivotable structure 22. In this position, the second pivotable structure 24 and the tray 26 may be positioned between the core tube 18 and the mast 12.

[0061] Optionally, a sensor may detect the position of the first pivotable structure 22. In one optional aspect, the second actuator 34 can pivot the second pivotable structure 24 only after the sensor senses that the first pivotable structure 22 is pivoted toward the mast 12.

[0062] The overshot or core tube 18 may be connected to the wireline cable of the wireline apparatus 16. The winch may cause the cable to lift the overshot and core tube 18 from the drill string. Optionally, a sensor (e.g., a wireline limiter comprising a forked sensor) can detect that the overshot and / or core tube 18 is being removed from the proximal end of the drill string, and the wireline apparatus 16 can slow lifting of the overshot and core tube. Optionally, an operator can position a cap 52 over the end 50 of the core tube 18. The winch of the wireline apparatus 16 may stop lifting the cable prior to the overshot or core tube 18 reaching the roller system of the wireline apparatus 16 or the wireline apparatus 16 mounted on the mast 12.

[0063] At least one third actuator 46 may be used to pivot the second end 44 of the tray 26 away from the second pivotable structure 24 to receive and move the core tube 18. The cable may be lowered via the winch to lower the core tube 18 down the tray 26. The core tube 18 may slide down the tray 26 away from the mast 12. In one aspect, the core tube 18 may be received by the rod handling system 70 from the tray 26. This method may be used to move the core tube 18 away from the mast 12 of the drill rig system 10 to allow the core tube 18 to be removed from the system 10 and / or to decouple the overshot from the core tube.

[0064] This method may be performed in the reverse order to reload and reposition an empty core tube 18 in a drill string. The method may be performed in the reverse order to reload and reposition an empty core tube 18 in a drill string from the rod handling system 70, or from a tray or one or more brackets in front of the drill rig system 10.

[0065] A method can include stowing the kickout tray assembly 20. For example, the method may include using the at least one third actuator 46 to pivot the second end 44 of the tray 26 towards the second pivotable structure 24. The at least one second actuator 34 may be used to pivot the second pivotable structure 24 toward the first pivotable structure 22. The at least one first actuator 25 may be used to pivot the first pivotable structure 22 away from the mast 12. This aspect of the method may be used to position the kickout tray assembly 20 to a stowed position on the side of the mast 12. With the kickout tray assembly 20 in the stowed position, the drill rig can be operated for drilling purposes. Further, with the kickout tray assembly 20 in the stowed position, the drill rig can be configured for transportation to and from a drill site.

[0066] The system 10 can comprise at least one computing device for controlling operation of the system 10. For example, one or more computing devices can control a plurality of operations, including: moving the at least one first actuator 25, the at least one second actuator 34, and the at least one third actuator 46. In some optional aspects, a single computing device controls a plurality of such operations. In some aspects, the system 10 can comprise a plurality of computing devices that operate in coordination. For example, a first computing device (e.g., a controller 80) can control movement of the first pivotable structure 22 and the second pivotable structure 24, and a second computing device can control movement of the tray 26. Still another computing device can provide an operator with an interface (e.g., at a human machine interface) for permitting an operator to control aspects of the system. Each of said computing devices can optionally be embodied in accordance with the computing device 1001 as further disclosed herein.

[0067] FIG. 9 shows an exemplary operating environment 1000 including an exemplary configuration of a computing device 1001 for use with the system 10 disclosed herein.

[0068] The computing device 1001 may comprise one or more processors 1003, a system memory 1012, and a bus 1013 that couples various components of the computing device 1001 including the one or more processors 1003 to the system memory 1012. In the case of multiple processors 1003, the computing device 1001 may utilize parallel computing.

[0069] The bus 1013 may comprise one or more of several possible types of bus structures, such as a memory bus, memory controller, a peripheral bus, an accelerated graphics port, and a processor or local bus using any of a variety of bus architectures.

[0070] The computing device 1001 may operate on and / or comprise a variety of computer readable media (e.g., non-transitory). Computer readable media may be any available media that is accessible by the computing device 1001 and comprises, non-transitory, volatile and / or non-volatile media, removable and non-removable media. The system memory 1012 has computer readable media in the form of volatile memory, such as random access memory (RAM), and / or non-volatile memory, such as read only memory (ROM). The system memory 1012 may store data such as kickout tray position data 1007 and / or program modules such as operating system 1005 and position control software 1006 (e.g., software for controlling the position of the kickout tray) that are accessible to and / or are operated on by the one or more processors 1003.

[0071] The computing device 1001 may also comprise other removable / non-removable, volatile / non-volatile computer storage media. The mass storage device 1004 may provide non-volatile storage of computer code, computer readable instructions, data structures, program modules, and other data for the computing device 1001. The mass storage device 1004 may be a hard disk, a removable magnetic disk, a removable optical disk, magnetic cassettes or other magnetic storage devices, flash memory cards, CD-ROM, digital versatile disks (DVD) or other optical storage, random access memories (RAM), read only memories (ROM), electrically erasable programmable read-only memory (EEPROM), and the like.

[0072] Any number of program modules may be stored on the mass storage device 1004. An operating system 1005 and drilling software 1006 may be stored on the mass storage device 1004. One or more of the operating system 1005 and drilling software 1006 (or some combination thereof) may comprise program modules and the drilling software 1006. The position data 1007 may also be stored on the mass storage device 1004. The position data 1007 may be stored in any of one or more databases known in the art. The databases may be centralized or distributed across multiple locations within the network 1015.

[0073] A user may enter commands and information into the computing device 1001 using an input device. Such input devices comprise, but are not limited to, a joystick, a touchscreen display, a keyboard, a pointing device (e.g., a computer mouse, remote control), a microphone, a scanner, tactile input devices such as gloves, and other body coverings, motion sensor, speech recognition, and the like. These and other input devices may be connected to the one or more processors 1003 using a human machine interface 1002 that is coupled to the bus 1013, but may be connected by other interface and bus structures, such as a parallel port, game port, an IEEE 1394 Port (also known as a Firewire port), a serial port, network adapter 1008, and / or a universal serial bus (USB).

[0074] A display device 1011 may also be connected to the bus 1013 using an interface, such as a display adapter 1009. It is contemplated that the computing device 1001 may have more than one display adapter 1009 and the computing device 1001 may have more than one display device 1011. A display device 1011 may be a monitor, an LCD (Liquid Crystal Display), light emitting diode (LED) display, television, smart lens, smart glass, and / or a projector. In addition to the display device 1011, other output peripheral devices may comprise components such as speakers (not shown) and a printer (not shown) which may be connected to the computing device 1001 using Input / Output Interface 1010. Any step and / or result of the methods may be output (or caused to be output) in any form to an output device. Such output may be any form of visual representation, including, but not limited to, textual, graphical, animation, audio, tactile, and the like. The display 1011 and computing device 1001 may be part of one device, or separate devices.

[0075] The computing device 1001 may operate in a networked environment using logical connections to one or more remote computing devices 1014a, b, c. A remote computing device 1014a, b, c may be a personal computer, computing station (e.g., workstation), portable computer (e.g., laptop, mobile phone, tablet device), smart device (e.g., smartphone, smart watch, activity tracker, smart apparel, smart accessory), security and / or monitoring device, a server, a router, a network computer, a peer device, edge device or other common network node, and so on. The remote computing devices 1014a, b, c, can perform respective operations of the system 10. For example, one remote computing device 1014a can be a controller of a first pivotable structure 22. One remote computing device 1014b can control a second pivotable structure 24. Logical connections between the computing device 1001 and a remote computing device 1014a, b, c may be made using a network 1015, such as a local area network (LAN) and / or a general wide area network (WAN), or a Cloud-based network. Such network connections may be through a network adapter 1008. A network adapter 1008 may be implemented in both wired and wireless environments. Such networking environments are conventional and commonplace in dwellings, offices, enterprise-wide computer networks, intranets, and the Internet. It is contemplated that the remote computing devices 1014a, b, c can optionally have some or all of the components disclosed as being part of computing device 1001. In various further aspects, it is contemplated that some or all aspects of data processing described herein can be performed via cloud computing on one or more servers or other remote computing devices. Accordingly, at least a portion of the system 1000 can be configured with internet connectivity.Advantages of the Disclosed System

[0076] The disclosed systems and methods can reduce physical operator interaction with heavy core tubes, thereby improving safety during core tube handling.

[0077] The disclosed system can be adapted for use on existing drill rigs.

[0078] The disclosed system can be used with different core tube diameters and lengths.

[0079] The disclosed system can be configured for mounting to either side of a mast.

[0080] The disclosed system can be configured for use with wireline rollers and wireline placement systems.

[0081] The disclosed system can be configured for use with different rotary heads.

[0082] The disclosed system can be compactly stowed against the mast for transportation.

[0083] The disclosed system can be used together with a rod handling system in front of the mast or with manual rod handling including using storage trays and / or brackets in front of the mast.

[0084] Although the foregoing invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, certain changes and modifications may be practiced within the scope of the appended claims.Exemplary Aspects

[0085] In view of the described products, systems, and methods and variations thereof, herein below are described certain more particularly described aspects of the invention. These particularly recited aspects should not however be interpreted to have any limiting effect on any different claims containing different or more general teachings described herein, or that the “particular” aspects are somehow limited in some way other than the inherent meanings of the language literally used herein.

[0086] Aspect 1: A kickout tray assembly for moving a core tube, the kickout tray assembly being attachable to a drill rig having a mast for supporting the core tube, the kickout tray assembly comprising:

[0087] a first pivotable structure mountable on the mast in an orientation parallel thereto, the first pivotable structure being pivotable toward and away from the mast about a first axis oriented parallel to the mast;

[0088] a second pivotable structure coupled to the first pivotable structure, the second pivotable structure being pivotable toward and away from the first pivotable structure about a second axis parallel to the first axis; and

[0089] a tray including a first end coupled to the second pivotable structure and a free second end, the tray being pivotable toward and away from the second pivotable structure about a third axis transverse to the second axis proximate to the first end, wherein the tray is configured to receive and move the core tube toward and away from the mast.

[0090] Aspect 2: The kickout tray assembly according to aspect 1, wherein the first pivotable structure is mountable to the mast via at least one first pivoting arm and at least one first actuator that is configured to move the first pivotable structure relative to the mast about the first axis.

[0091] Aspect 3: The kickout tray assembly according to aspect 2, wherein the at least one first actuator comprises a first hydraulic cylinder that is pivotably coupled to the mast.

[0092] Aspect 4: The kickout tray assembly according to aspect 2, wherein the first hydraulic cylinder comprises a rotary actuator or a slew motor.

[0093] Aspect 5: The kickout tray assembly according to aspect 2, wherein the second pivotable structure is coupled to the first pivotable structure via at least one second pivoting arm and at least one second actuator that is configured to move the second pivotable structure relative to the first pivotable structure about the second axis.

[0094] Aspect 6: The kickout tray assembly according to aspect 5, wherein the at least one second actuator comprises a second hydraulic cylinder that is pivotably coupled to the first pivotable structure.

[0095] Aspect 7: The kickout tray assembly according to aspect 6, wherein the second hydraulic cylinder comprises a rotary actuator or a slew motor.

[0096] Aspect 8: The kickout tray assembly according to aspect 5, wherein the tray is pivotable via at least one third actuator.

[0097] Aspect 9: The kickout tray assembly according to aspect 8, wherein the at least one third actuator comprises a hydraulic cylinder or a rotary actuator.

[0098] Aspect 10: The kickout tray assembly according to aspect 8, further comprising a controller, wherein the controller is configured to:

[0099] cause the at least one first actuator to pivot the first pivotable structure toward or away from the mast about the first axis;

[0100] cause the at least one second actuator to pivot the second pivotable structure toward or away from the first pivotable structure about the second axis; and

[0101] cause the at least one third actuator to pivot the tray toward or away from the second pivotable structure about the third axis.

[0102] Aspect 11: The kickout tray assembly according to aspect 10, wherein the controller is configured to cause at least one of the at least one first actuator, the at least one second actuator, or the at least one third actuator to move according to at least one sensor configured to sense a degree of rotation.

[0103] Aspect 12: The kickout tray assembly according to aspect 1, wherein the tray comprises a V-shaped interior surface.

[0104] Aspect 13: The kickout tray assembly according to aspect 1, wherein the first end and the second end of the tray each include a ramp.

[0105] Aspect 14: The kickout tray assembly according to aspect 1, wherein the tray is pivotable between 0 degrees and 45 degrees with respect to the second axis.

[0106] Aspect 15: A drill rig system comprising:

[0107] a mast; and

[0108] a kickout tray assembly comprising:

[0109] a first pivotable structure mounted on the mast in an orientation parallel thereto, the first pivotable structure being pivotable toward and away from the mast about a first axis oriented parallel to the mast;

[0110] a second pivotable structure mounted on the first pivotable structure, the second pivotable structure being pivotable toward and away from the first pivotable structure about a second axis parallel to the first axis; and

[0111] a tray including a first end mounted on the second pivotable structure and a free second end, the tray being pivotable toward and away from the second pivotable structure about a third axis transverse to the second axis proximate to the first end, wherein the tray is configured to receive and move a core tube toward and away from the mast.

[0112] Aspect 16: The drill rig system according to aspect 15, further comprising a rod handling system, the rod handling system comprising:

[0113] a base;

[0114] a second tray comprising a first end pivotally attached to the base and a free second end; and

[0115] a fourth actuator that is configured to rotate the second tray to elevate the free second end,

[0116] wherein the free second end of the second tray is configured to receive at least a portion of the core tube from the kickout tray assembly.

[0117] Aspect 17: A method comprising:

[0118] moving a core tube with a kickout tray assembly attachable to a drilling apparatus having a mast, the kickout tray assembly comprising:

[0119] a first pivotable structure mounted on the mast in an orientation parallel thereto, the first pivotable structure being pivotable toward and away from the mast about a first axis oriented parallel to the mast;

[0120] a second pivotable structure mounted on the first pivotable structure, the second pivotable structure being pivotable toward and away from the first pivotable structure about a second axis parallel to the first axis; and

[0121] a tray including a first end mounted on the second pivotable structure and a free second end, the tray being pivotable toward and away from the second pivotable structure about a third axis transverse to the second axis proximate to the first end, wherein the tray is configured to receive and move a core tube toward and away from the mast.

[0122] Aspect 18: The method of aspect 17, wherein moving the core tube with the kickout tray assembly comprises:

[0123] pivoting, by a first actuator, the first pivotable structure toward the mast about a first axis;

[0124] pivoting, by a second actuator, the second pivotable structure away from the first pivotable structure about a second axis; and

[0125] pivoting, by a third actuator, the second end of the tray away from the second pivotable structure to receive and move the core tube.

[0126] Aspect 19: The method of aspect 18, wherein moving the core tube with the kickout tray assembly further comprises:

[0127] pivoting, by the third actuator, the second end of the tray towards the second pivotable structure;

[0128] pivoting, by the second actuator, the second pivotable structure toward the first pivotable structure; and

[0129] pivoting, by the first actuator, the first pivotable structure away from the mast.

[0130] Aspect 20: The method of aspect 18 or 19, wherein a controller causes the first actuator, the second actuator, and the third actuator to move.

[0131] Other embodiments of the present disclosure will be apparent to one skilled in the art. As such, the foregoing description merely enables and describes the general uses and methods of the present disclosure. Accordingly, the following claims define the true scope of the present disclosure.

Claims

1. A kickout tray assembly for moving a core tube, the kickout tray assembly being attachable to a drill rig having a mast for supporting the core tube, the kickout tray assembly comprising:a first pivotable structure mountable on the mast in an orientation parallel thereto, the first pivotable structure being pivotable toward and away from the mast about a first axis oriented parallel to the mast;a second pivotable structure coupled to the first pivotable structure, the second pivotable structure being pivotable toward and away from the first pivotable structure about a second axis parallel to the first axis; anda tray including a first end coupled to the second pivotable structure and a free second end, the tray being pivotable toward and away from the second pivotable structure about a third axis transverse to the second axis proximate to the first end, wherein the tray is configured to receive and move the core tube toward and away from the mast.

2. The kickout tray assembly according to claim 1, wherein the first pivotable structure is mountable to the mast via at least one first pivoting arm and at least one first actuator that is configured to move the first pivotable structure relative to the mast about the first axis.

3. The kickout tray assembly according to claim 2, wherein the at least one first actuator comprises a first hydraulic cylinder that is pivotably coupled to the mast.

4. The kickout tray assembly according to claim 2, wherein the first hydraulic cylinder comprises a rotary actuator or a slew motor.

5. The kickout tray assembly according to claim 2, wherein the second pivotable structure is coupled to the first pivotable structure via at least one second pivoting arm and at least one second actuator that is configured to move the second pivotable structure relative to the first pivotable structure about the second axis.

6. The kickout tray assembly according to claim 5, wherein the at least one second actuator comprises a second hydraulic cylinder that is pivotably coupled to the first pivotable structure.

7. The kickout tray assembly according to claim 6, wherein the second hydraulic cylinder comprises a rotary actuator or a slew motor.

8. The kickout tray assembly according to claim 5, wherein the tray is pivotable via at least one third actuator.

9. The kickout tray assembly according to claim 8, wherein the at least one third actuator comprises a hydraulic cylinder or a rotary actuator.

10. The kickout tray assembly according to claim 8, further comprising a controller, wherein the controller is configured to:cause the at least one first actuator to pivot the first pivotable structure toward or away from the mast about the first axis;cause the at least one second actuator to pivot the second pivotable structure toward or away from the first pivotable structure about the second axis; andcause the at least one third actuator to pivot the tray toward or away from the second pivotable structure about the third axis.

11. The kickout tray assembly according to claim 10, wherein the controller is configured to cause at least one of the at least one first actuator, the at least one second actuator, or the at least one third actuator to move according to at least one sensor configured to sense a degree of rotation.

12. The kickout tray assembly according to claim 1, wherein the tray comprises a V-shaped interior surface.

13. The kickout tray assembly according to claim 1, wherein the first end and the second end of the tray each include a ramp.

14. The kickout tray assembly according to claim 1, wherein the tray is pivotable between 0 degrees and 45 degrees with respect to the second axis.

15. A drill rig system comprising:a mast; anda kickout tray assembly comprising:a first pivotable structure mounted on the mast in an orientation parallel thereto, the first pivotable structure being pivotable toward and away from the mast about a first axis oriented parallel to the mast;a second pivotable structure mounted on the first pivotable structure, the second pivotable structure being pivotable toward and away from the first pivotable structure about a second axis parallel to the first axis; anda tray including a first end mounted on the second pivotable structure and a free second end, the tray being pivotable toward and away from the second pivotable structure about a third axis transverse to the second axis proximate to the first end, wherein the tray is configured to receive and move a core tube toward and away from the mast.

16. The drill rig system according to claim 15, further comprising a rod handling system, the rod handling system comprising:a base;a second tray comprising a first end pivotally attached to the base and a free second end; anda fourth actuator that is configured to rotate the second tray to elevate the free second end,wherein the free second end of the second tray is configured to receive at least a portion of the core tube from the kickout tray assembly.

17. A method comprising:moving a core tube with a kickout tray assembly attachable to a drilling apparatus having a mast, the kickout tray assembly comprising:a first pivotable structure mounted on the mast in an orientation parallel thereto, the first pivotable structure being pivotable toward and away from the mast about a first axis oriented parallel to the mast;a second pivotable structure mounted on the first pivotable structure, the second pivotable structure being pivotable toward and away from the first pivotable structure about a second axis parallel to the first axis; anda tray including a first end mounted on the second pivotable structure and a free second end, the tray being pivotable toward and away from the second pivotable structure about a third axis transverse to the second axis proximate to the first end, wherein the tray is configured to receive and move a core tube toward and away from the mast.

18. The method of claim 17, wherein moving the core tube with the kickout tray assembly comprises:pivoting, by a first actuator, the first pivotable structure toward the mast about a first axis;pivoting, by a second actuator, the second pivotable structure away from the first pivotable structure about a second axis; andpivoting, by a third actuator, the second end of the tray away from the second pivotable structure to receive and move the core tube.

19. The method of claim 18, wherein moving the core tube with the kickout tray assembly further comprises:pivoting, by the third actuator, the second end of the tray towards the second pivotable structure;pivoting, by the second actuator, the second pivotable structure toward the first pivotable structure; andpivoting, by the first actuator, the first pivotable structure away from the mast.

20. The method of claim 18, wherein a controller causes the first actuator, the second actuator, and the third actuator to move.

Images