Drill bushing retention

Abstract

A drill machine may include a drill deck having an opening for performing drilling operations. The drill machine may also include an outer bushing with a first flange and an inner bushing configured for being sleevably arranged within the outer bushing. The inner bushing may include an outer peripheral surface and a second flange arranged on a top end thereof and extending radially outward beyond the outer peripheral surface. The drill machine may also include a bit basket configured to retain the outer bushing and a deck wrench configured to retain the inner bushing. A method of drilling operations where the position of the inner bushing or sleeve is retained by the deck wrench is also provided.

Description

TECHNICAL FIELD

[0001] The present application relates generally to drilling equipment. More particularly, the present application relates to guides such as sleeves or bushings in a deck of a drill machine. Still more particularly, the present application relates to retention of the guides in a deck of a drill machine.BACKGROUND

[0002] Drills such as rotary drills or other down-the-hole (DTH) drills may include one or more guides for guiding drill pipe through the deck of the drill as it is driven into the ground below the drill. In some cases, multiple sizes of guides may be provided where a first guide is used to guide the drill bit and / or hammer through the deck and second smaller guide is used to guide drill pipe through the deck. That is, the drill bit and hammer may have a larger diameter than the drill pipe so a larger guide may be used for the drill bit and hammer while a smaller diameter guide may be used for the drill pipe. During drilling and, in particular, during hoisting of the drill string either during drilling or after completion of drilling, the guides can be dislodged.SUMMARY

[0003] In one or more examples, a drill machine may include a ground engaging system configured for supporting the drill machine relative to a supporting surface and for moving the drill machine across the supporting surface. The drill machine may also include a a frame supported by the ground engaging system and a drill deck arranged on the frame and having an opening for performing drilling operations with a drill string extending in a longitudinal direction through the opening. The drill machine may also include an outer bushing arranged in the drill deck at the opening, where the outer bushing has an outer portion with a first flange and an inner portion configured to rotate relative to the outer portion. The drill machine may also include an inner bushing configured for being sleevably arranged within the outer bushing and having an outer peripheral surface and a second flange arranged on a top end thereof and extending radially outward beyond the outer peripheral surface. The drill machine may also include a bit basket configured to articulate laterally relative to the opening between a retracted position and an intermediate position where a portion of the bit basket is positioned directly above and in close proximity with a portion of the first flange and a deck wrench configured to articulate laterally relative to the opening between a retracted position and an intermediate position where a portion of the deck wrench is positioned directly above and in close proximity with a portion of the second flange.

[0004] In one or more examples, an inner bushing or sleeve for drilling operations may include a lower portion having a through bore sized to sleevably receive a drill pipe and having an outer peripheral surface configured for insertion into an outer bushing arranged in an opening in a drill deck of a drilling machine. The inner bushing or sleeve may also include a flange arranged on a top end of the inner bushing or sleeve and extending radially outward beyond the outer peripheral surface.

[0005] In one or more other examples, a method of drilling may include advancing a drill bit and hammer through an outer bushing in a drill deck of a drill machine. The method may also include advancing a drill string including the drill bit, the hammer, and a drill pipe through the outer bushing such that an inner bushing or sleeve arranged on the drill pipe engages the outer bushing. The inner bushing or sleeve may have an outer peripheral surface and a flange extending radially outward beyond the outer peripheral surface. The method may also include arresting longitudinal motion of the inner bushing or sleeve through engagement of the inner bushing or sleeve with the outer bushing. The method may also include actuating a deck wrench to move the deck wrench laterally relative to the drill string and into position above the flange of the inner bushing or sleeve. The method may also include performing drilling operations. Still further, the method may include maintaining a longitudinal position of the inner bushing or sleeve using the deck wrench engaged with the flange of the inner bushing or sleeve.DESCRIPTION OF THE DRAWINGS

[0006] FIG. 1 is a perspective view of a drill machine, according to one or more examples.

[0007] FIG. 2 is a cross-sectional view of the drill machine of FIG. 1, according to one or more examples.

[0008] FIG. 3 is a close-up view of the cross-section of FIG. 2, where the drill string passes through a deck of the drill machine and an inner sleeve is poised for insertion into an outer sleeve, according to one or more examples.

[0009] FIG. 4A is a perspective view of where the drill string passes through the deck and the inner sleeve is inserted into the outer sleeve, according to one or more examples.

[0010] FIG. 4B is an additional close-up view of the cross-section of FIG. 2, where the inner sleeve is inserted into the outer sleeve like in FIG. 4A, according to one or more examples.

[0011] FIG. 5 is a close-up view thereof showing retention of the inner sleeve by a deck wrench, according to one or more examples.

[0012] FIG. 6 is a perspective view of the inner sleeve, according to one or more examples.

[0013] FIG. 7 is a top view thereof.

[0014] FIG. 8 is a cross-sectional view thereof.

[0015] FIG. 9 is a close-up view of the cross-section of FIG. 2 showing a bit basket in a first non-retention position, according to one or more examples.

[0016] FIG. 10 is an addition view thereof with the bit basket in a second retention position, according to one or more examples.

[0017] FIG. 11A is a perspective view of another example of an inner sleeve, according to one or more examples.

[0018] FIG. 11B is a cross-sectional view thereof.

[0019] FIG. 12A is a perspective view of still another example of an inner sleeve, according to one or more examples.

[0020] FIG. 12B is a cross-sectional view thereof.

[0021] FIG. 13A is a perspective view of still another example of an inner sleeve, according to one or more examples.

[0022] FIG. 13B is a cross-sectional view thereof.

[0023] FIG. 14 is a diagram depicting a method of operation of a drill machine, according to one or more examples.DETAILED DESCRIPTION

[0024] FIG. 1 is a perspective view of a drill machine 100 such as a rotary drill or other down-the-hole drill. The drill machine 100 may include a frame 102, a ground engaging system 104 for supporting the frame 102 relative to a supporting surface such as the ground and for moving the drill machine 100 across the supporting surface. The ground engaging 104 system may include a track system, for example, or a system of wheels and / or tires may be provided. The drill machine may include a drill deck 106 supported by the frame and providing a support platform for personnel to manage drilling operations, access equipment on the drill machine, manage pipe delivery, and the like. An operator station 108 may also be provided including an operator cabin equipped with controls for operating the drill machine 100. The drill machine 100 may also include a power source 110 such as a gasoline-powered or diesel-powered combustion engine or an electrical power supply (e.g., battery or electrical cord) and an electrical motor may be provided. The drill machine 100 may include a pneumatic system 112 powered by the drill machine power source 110 and configured to provide pneumatic power to the drill of the drill machine 100. For example, the pneumatic system 112 may include a compressor adapted to deliver compressed air to a tank or directly to the drill. The compressed air may be used by the drill to drive a hammer and / or rotate the drill string and / or drill bit at the bottom of the drill string. The pneumatic system 112 may also supply compressed air to other aspects of the machine. While a pneumatic system 112 has been described for operating the drill, a hydraulic system 114 may additionally, or alternatively, be provided. In one or more example, the hydraulic system 114 may be powered by the power source 110 and may be used to produce and deliver hydraulic power to one or more cylinders on the drill machine, such as a hydraulic cylinder for raising and / or lowering a mast of the drill machine. Still other equipment and / or features may be provided on the drill machine.

[0025] With continued reference to FIG. 1 and further reference to FIG. 2, the drill machine may include a mast 116 extending upward from the deck 106 of the drill machine 100. The mast 116 may be configured for supporting long lengths of drill string including a drill bit 118, a hammer 120, and multiple lengths of drill pipe 122 strung together to form a drill string 124. Moreover, the mast 116 may be configured for supporting the drill string 124 in a vertical arrangement and, as such, the mast 116 may extend from the deck 106 of the drill machine 100 to a relatively high height above the deck 106. The position of the mast 116 may define a well center position based on where the drill string 124 is positioned when suspended from the mast 116. As suggested, the mast 116 may be pivotable relative to the deck 106 from a stowed or generally horizontal position to a deployed or generally vertical position. The deployment may be performed by a hydraulic cylinder or cylinders and the mast 116 may be pivotably coupled to the drill machine 100 at or near the drill deck 106 such that extension of the hydraulic cylinder pivots the mast 116 from the stowed position to the deployed position. The mast 116 may be equipped with a hoist system 126 and / or a block and tackle system for raising or lowering the drill string 124 into and / or out of the drill hole. The mast 116 may also include a rotary head or other system for rotating the drill string and the rotary head may be part and parcel with the hoist system 126.

[0026] The drill machine 100 may also include drill string handling equipment at or near the drill deck 106. For example, as shown in FIG. 3 as well as FIG. 4A, the drill machine may be equipped with a deck wrench 128. The deck wrench 128 may be positioned adjacent to the well center 130 position and may be actuatable to engage and disengage the drill string 124 by moving laterally toward and away from well center 130. The actuation of the deck wrench 128 may be hydraulic, pneumatic, electric, or another actuation system may be provided. As shown in FIG. 4A, the drill string 124 may include necked down flat sections 132 that are configured for engagement by the deck wrench 128. The deck wrench 128 may include a main body 134 with two extending fingers 136 having opposing and generally flat inward facing surfaces defining a generally rectangular slot when viewed from above. The deck wrench 128 may be actuated toward well center 130 such that the opposing flat inward facing surfaces pass alongside the flat sections 132 of the drill string 124 to hold a portion of the drill string 124 against rotation. The rotary head or other rotational system may rotate drill pipe 122 or other portions of the drill string 124 above the section being held against rotation by the deck wrench 128 to threadably engage or disengage one section of the drill string 124 with or from another. The deck wrench 128 may also include a generally flat bottom surface extending along the bottom of the main body and the extending fingers. The deck wrench 128 may be arranged on the drill deck 106 or the deck wrench 128 may be offset a distance above the drill deck 106. In one or more examples, the deck wrench 128 may be arrange such that the bottom surface of the deck wrench 128 is approximately 140 mm to approximately 190 mm above the drill deck or from approximately 160 mm to approximately 175 mm above the drill deck or the bottom surface of the deck wrench may be approximately 167 mm, 168 mm, 169 mm, or 170 mm above the drill deck. Still other spacings of the deck wrench above the drill deck may be provided.

[0027] In addition to the deck wrench 128, the drill string handling equipment may include a bit basket 138. As shown in FIGS. 3, 4B, and 5 as well as FIGS. 9 and 10, the bit basket 138 may be arranged at or near the deck 106 of the drill machine 100 and, like the deck wrench 128, may be operable to move into position at well center 130 and retract away from well center 130. The bit basket 138 may primarily be used when performing maintenance on and / or changing out drill bits 118. That is, the drill string 124 may be raised above the deck 106 and the bit basket 138 may be moved into position below the drill string 124 allowing the bit 118 to be lowered and set on the bit basket 138. The bit basket may, thus, support the weight of the bit 118 allowing the bit 118 to be changed out with another bit and / or serviced. In one or more examples, bit basket 138 may include a generally flat bottom plate with a generally flat bottom surface. The bit basket 138 may also include an apron plate that may be secured to a top side of the bottom plate with thumb screws or other manually operable fasteners. The apron plate may include a relatively large central opening for seatingly receiving the drill bit 118. The central opening may include a perimeter having contours adapted to match the profile of the toothed or working side of the drill bit 118 such that the drill bit 118 may seat in the bit basket 138 and be held generally stable and stationary against rotation. The bottom plate and apron may be secured to one another and may rest on a track to guide the motion of the bit basket 138 laterally toward and away from well center 130. A hydraulic cylinder, pneumatic cylinder, or other actuation device may be coupled to the bottom / apron plate to advance and retract the bit basket 138 laterally toward and away from well center 130. In one or more examples, the bit basket 138 may be arranged at the surface of the drill deck 106 or it may be spaced above the drill deck 106 like the deck wrench 128. In one or more examples, the bottom surface of the bottom plate of the bit basket 138 may be generally flush with the drill deck surface.

[0028] Turning now to FIGS. 3, 4A, and 4B, the mast 116 may support a drill string 124 in a vertical fashion such that it may be lowered and used to drill into the ground below the drill machine 100. Before and during drilling, the drill string 124 may pass through the deck 106 of the drill machine 100. In one or more examples, one or more guides may be arranged in the deck 106 of the drill machine 100 to guide the drill string as it passes through the deck 106. As shown in FIG. 3, for example, a guide in the form of an outer bushing 140 may be provided and a guide in the form of an inner bushing or sleeve 142 may be provided. Each guide may be configured to accommodate different portions of the drill string 124 based on the diameter of the respective portions of the drill string 124. In particular, the outer bushing 140 may be adapted to accommodate the drill bit 118 and hammer 120 while the inner bushing or sleeve 122 may be adapted to accommodate lengths of drill pipe 122 above or behind the hammer 120 and the drill bit 118.

[0029] As shown in FIG. 3, the outer bushing or sleeve 140 may be arranged in the deck 106 of the drill machine. The outer bushing 140 may be sized and configured to allow the drill bit 118 and hammer 120 to pass therethrough. The outer bushing or sleeve 140 may also be configured to accommodate rotation of the drill string 124 relative to the deck 106. For example, as shown in a closer view of FIG. 5, the outer bushing 140 may include a two-part system having a bearing or series of bearings 144 arranged therebetween to allow an inner portion 146 of the bushing 140 to rotate relative to an outer portion 148. For example, one or more bearing races may be provided by circumferential grooves in an inner surface of the outer portion 148 of the bushing 140 and in an outer surface of the inner portion 146 of the bushing 140. Ball bearings may be arranged in the races to allow the inner portion 146 to rotate relative to the outer portion 148. The outer portion 148 of the bushing may include a key or keyway that corresponds to a keyway or key in the drill deck 106 which may prevent rotation of the outer portion 148 of the bushing 140 relative to the deck 106. In one or more examples, the inner portion 146 of the bushing 140 may extend below the outer portion and may include a cuttings deflector 150.

[0030] As shown, the outer portion 148 of the bushing may include a flange 152 on an upper portion thereof that extends radially outward beyond an outer surface 154 of the outer portion 148 of the outer bushing 140. This radially outward extending portion of the flange 152 may be adapted for engaging a supporting surface of the deck 106 to prevent the bushing 140 from falling through the deck 106. In one or more examples, an annular recess may be provided on the drill deck 106 around the drilling hole to allow the top surface of the outer bushing 140 to lie flush with the deck surface 106. The flange 152 may also include a radially inward extending portion 156 having a downward extending lip for closing off the upper end of the annular joint 158 between the inner and outer portions 146 / 148 of the outer bushing 140. In one or more examples, an upper annular surface of the inner portion of the outer bushing may include a chamfered, angled, or conical surface 160 configured to guide the drill bit 118 and / or hammer 120 toward a central position as it enters the bushing 140. The conical surface 160 may extend upward and radially outward of the lip extending down from the flange 152 on the upper portion. As discussed in more detail below, the conical surface 160 may also function to interface with a corresponding conical surface on the inner bushing / sleeve 142 to prevent the inner bushing / sleeve 142 from falling through the outer bushing 140.

[0031] With continued reference to FIGS. 3-4B and FIG. 5, the inner bushing or sleeve 142 is shown. For example, in FIG. 3, the inner bushing or sleeve 142 is shown arranged on the drill pipe 122 above the hammer 120 and spaced well above the drill deck 106. As the drill string 124 advances through the drill deck 106, the inner bushing or sleeve 142 may advance downward and engage the outer bushing 140 as shown in FIGS. 4A and 4B. As shown in FIG. 5, downward motion of the inner bushing or sleeve 142 may be arrested when an outer chamfered or conical surface 162 on the inner bushing or sleeve 142 engages the conical surface 160 on a top portion of the inner portion 146 of the outer bushing 140. In some examples, as shown, the downward motion of the inner bushing or sleeve 142 may be arrested before a flange 164 on the inner bushing or sleeve 142 reaches the drill deck 106 or comes into contact with the top of the outer bushing 140. In any case, the inner bushing or sleeve 142 may include an upper flange 164 that extends radially outward beyond an outer circumferential surface of the inner bushing or sleeve 142.

[0032] More particularly, as shown in FIGS. 6-8, the inner bushing or sleeve 142 may be a generally cylindrical sleeve adapted to fit within and sleevably engage the outer bushing 140 while providing a cylindrical interior bore 166 for receiving a drill pipe portion of the drill string 124. The interior bore 166 may have a diameter 167 ranging from approximately 130 mm to approximately 155 mm or from approximately 140 mm to approximately 145 mm or an interior bore diameter of approximately 142 mm or approximately 143 mm may be provided. As shown, the inner bushing or sleeve 142 may include a lower end 168 for engaging the outer bushing 140, an offsetting portion 170, and an upper portion 172. The lower end 168 may have a length adapted to extend generally fully through the outer bushing 140, it may include an outer diameter 174 adapted to sleevably engage the inner surface of the outer bushing 140, and it may include a tapered tip 176. The outer diameter 174 of the lower portion 168 may range from approximately 170 mm to approximately 190 mm or from approximately 175 mm to approximately 185 mm or a diameter of approximately 180 mm may be provided. The lower portion 168 may extend upward from the tapered tip 176 to the offsetting portion 170 and a conical surface 162 may be provided on an outside surface of the inner bushing 142 at the transition between the lower portion 168 and the offsetting portion 170. This conical surface 162 may be sized and shaped to abut the conical surface 160 on the upper end of the inner portion 146 of the outer bushing 140 thereby preventing the inner bushing or sleeve 142 from falling through and / or advancing too far through the outer bushing 140. The lower end 168 may have a length ranging from approximately 170 mm to approximately 210 mm or from approximately 180 mm to approximately 200 mm or a length of 189 mm or 190 mm may be provided. The tapered tip 176 may have a length 177 ranging from approximately 40 mm to 60 mm or from approximately 45 mm to 55 mm or a length of approximately 50 mm may be provided. The length 178 of the lower portion 168 including the transition portion may range from approximately 180 mm to approximately 210 mm or from approximately 190 mm to approximately 200 mm or a length of approximately 194 mm or 195 mm may be provided.

[0033] The offsetting portion 170 may extend further upward from the lower portion 168 and may be adapted to accommodate and / or makeup the distance from the top of the drill deck 106 to a bottom side of the deck wrench 128. In particular, the offsetting portion 170 may extend upward out of and beyond an upper surface of the outer bushing 140 and the length thereof may be particularly selected to accommodate the relationship of the deck wrench 128 to the drill deck 106 as well as the distance below the drill deck 106 of the conical surface 160 of the inner portion 146 of the outer bushing 140. The particular length of the offsetting portion is discussed below along with the overall length of the inner bushing 142. The offsetting portion 170 may have an inner diameter matching that of the lower portion 168 and may have an outer diameter 180 that is slightly larger than the outer diameter of the lower portion 168 as defined by the conical surface 162 transition between the lower portion 168 and the offsetting portion 170. The outer diameter 180 of the offsetting portion 170 may range from approximately 180 mm to approximately 200 mm or from approximately 185 mm to approximately 195 mm or a diameter of approximately 190 mm, 191 mm, or 192 mm may be provided.

[0034] The upper portion 172 of the inner bushing or sleeve 142 may include a flange 164. The flange 164 may extend radially outward beyond an outer peripheral surface 182 of the offsetting portion 170. That is, the flange 164 may extend radially outward beyond the outside diameter 180 of the offsetting portion 170. In some cases, the flange 164 may extend radially outward beyond the outer peripheral surface of the lower portion 168. That is, in some examples, the offsetting portion 170 may be omitted and the flange 164 extends beyond an outer peripheral surface of the lower portion in these examples. In one or more examples, the flange 164 may be a separate annular piece that is attached to the offsetting portion 170 (or the lower portion 168 when the offsetting portion is omitted) at a seam. The separate annular piece 164 may be welded onto the upper portion of the inner bushing or sleeve 142. In one or more examples, the annular flange 164 may be a retrofit piece that is welded to an existing inner bushing or sleeve 142. The upper portion 172 may also include a chamfered surface 184 on an inner circumferential edge of the offsetting portion 170, which may function to guide the drill string through the bushing 142. That is, while the outer surface of the drill string 124 may be generally cylindrical and smooth, portions of the drill string 124 may include flat spots or recesses that may allow the drill string 124 to sway or vary from a longitudinal centerline. As these portions of the drill string 124 pass through the bushing 142, the chamfered surface 184 may assist in recentering the drill string 124. In one or more examples, the annular flange 164 on the inner bushing or sleeve 142 may have an outer diameter 165 ranging from approximately 230 mm to approximately 290 mm, or from approximately 250 mm to approximately 270 mm, or from approximately 255 mm to approximately 265 mm, or a outer flange diameter of approximately 260 mm may be provided. In one or more examples, the outer flange diameter 165 of the inner bushing or sleeve 142 may be smaller than the outer flange diameter of the outer bushing 140. Additionally, and in some cases, where an offsetting portion 170 of the inner bushing 142 is omitted and the flange 164 of the inner bushing 142 rests on or nests in the flange 152 of the outer bushing 140, some portion of the flange 152 on the outer bushing 140 may still be exposed radially beyond the flange 164 of the inner bushing 142 to allow for engagement by the bit basket 138 or other hold down mechanism. While the flange 164 on the inner bushing 142, or the flange 152 of the outer bushing 140, has been said to be annular and to have an outer diameter, other shaped flanges may also be provided such as square, rectangular, triangular, oval, or other shapes.

[0035] The overall length 186 of the inner bushing or sleeve 142 may range from approximately 375 mm to approximately 425 mm or from 390 mm to approximately 410 mm or a length of approximately 400 mm may be provided. As such, and when giving consideration to the length of the lower portion 168, the offsetting portion 170 may have a length ranging from approximately 190 mm to approximately 220 mm or from approximately 200 mm to approximately 210 mm or a length of approximately 205 mm may be provided.

[0036] The flange 164 of the inner bushing or sleeve 142 may range from approximately 10 mm to approximately 20 mm, or from approximately 15 mm to approximately 17 mm, or a thickness of 16 mm may be provided. However, as shown in FIGS. 11A-13B, a thicker flange may also be provided. That is, the thickness of the flange may be such as to form a collar on the upper portion of the inner sleeve or bushing. As shown in FIGS. 11A-11B, an inner bushing or sleeve 242 may include a solid thicker flange 264 in lieu of the flange 164 described. The other aspects of the bushing or sleeve 242 may be the same or substantially the same as the bushing or sleeve 142, but the flange 264 may extend downward along the upper portion 272 for a much larger distance than the flange 164. For example, as shown, the flange 264 may have a length extending along the bushing or sleeve 242 ranging from approximately 120 mm to approximately 150 mm, or from approximately 130 mm to approximately 140 mm, or a length of approximately 135 mm may be provided.

[0037] FIGS. 12A-12B show yet another example of an inner bushing or sleeve 342 where the flange 364 is formed from a cylindrical plate 367 and upper / lower offsetting annular spacers 365. Here, the flange 364 may have the same or similar dimensions as the flange 264, but may be hollow due to the use of the cylindrical plate 367 and the offsetting spacers 365. This may provide for a generally lighter weight inner bushing or sleeve 342 as compared with the bushing or sleeve 242 with the solid flange 264. In one or more examples, the cylindrical plate 367 and / or the spacers 365 may have a thickness ranging from approximately 10 mm to approximately 20 mm, or from approximately 15 mm to approximately 17 mm or a thickness of approximately 16 mm may be provided. The annular width of the spacers 365 may be as such to make up the space between the outer surface of the upper portion 372 of the inner bushing or sleeve 342 and the inside surface of the cylindrical plate 367.

[0038] Still another example of an inner bushing or sleeve 442 is shown in FIGS. 13A-13B. Here, a top annular ring 464A may be provided that is the same or similar to the flange 164 of inner bushing or sleeve 142. However, additional annular rings 464B / C may be provided to establish an outer envelope that is akin to the outer envelope of the flanges 264 and 364. That is, as shown in FIGS. 13A and 13B, two additional annular rings 464B / 464C may be provided along the length of the upper portion 472 of the inner bushing or sleeve 442 where the lower 464C of the two annular rings is positioned at a location similar to the bottom of the flanges 264 / 364. That is, the annular ring 464C may be spaced along the upper portion 472 such that a bottom surface thereof is spaced from the top surface of the top annular ring 464A by a distance ranging from approximately 120 mm to approximately 150 mm, or from approximately 130 mm to approximately 140 mm, or a length of approximately 135 mm. The additional annular ring 464B may be centered between the top annular ring 464A and the lower annular ring 464C. The resulting spacing between the top annular ring 464A and the intermediate annular ring 464B as well as the spacing between the intermediate annular ring 464B and the lower annular ring 464C may be less than the thickness of the deck wrench 128. As such, for purposes of the discussion below relating to the encounter of the deck wrench with the flange, the three pieces 464A, 464B, and 464C, may function as and be considered parts of the same flange. That is, and more generally, the term “flange” should be considered to include the examples 164, 264, and 364, as well as the combination of the annular rings 464A to 464C.

[0039] These latter examples of the inner bushing or sleeve (e.g., 242, 342, 442) may provide for the ability to verify the position of the inner bushing or sleeve using the deck wrench. That is, for example, the inner bushing or sleeve may sometimes get hung up as it is carried into the outer sleeve and may sometimes not move into a fully seated position in the outer sleeve. If this occurs with the inner bushing or sleeve 142, which has the relatively thin flange 164, the flange 164 may remain above the deck wrench. If this occurs, the deck wrench may move into position to hold the inner bushing or sleeve down, but it may actually move into position below the flange 164 rather than above it due to the sleeve 142 being hung up. Moreover, there may not be any indication that anything is wrong (i.e., nothing obstructs the movement of the deck wrench). In some cases, where the inner sleeve is hung up such that the flange 164 is within the thickness of the deck wrench, the deck wrench may encounter the flange 164, which may indicate that the inner sleeve is not fully seated in the outer sleeve. For purposes of covering a wider range of positions of the inner sleeve that also provide an indication of a non-fully seated inner sleeve, the extended flanges of the sleeves 242, 342, and 442 may be provided. For example, where the inner sleeve is hung up and the flange 164 would otherwise be arranged above the deck wrench, the extended flanges of sleeves 242, 342, and 442 may be encountered by the deck wrench when it moves into position to hold the sleeve down. This may provide the operator with an indication that the inner sleeve is not in a proper position.

[0040] The drill machine 100 may include a controller 188 (see FIG. 1) configured for controlling the drill system of the drill machine 100 and performing drilling operations. In one or more examples, the controller 188 may be part and parcel to the electronic control module of the drill machine 100 or a separate controller may be provided. The controller 188 may be configured to control operation of the hoist or other system 126 for lifting and lowering the drill string. The controller 188 may also be configured to control the rotary system to control rotation of the drill string. Still further, the controller 188 may be configured to control the pneumatic or other fluid power system for performing the drilling operations, for controlling the hammer 120, and for controlling the drill bit 118. The controller may, still further, be configured for controlling the deck wrench 128 and the bit basket 138. In one or more examples, the controller 188 may include computer implemented instructions stored thereon for performing the method of drilling 200 described in more detail below. That is, the controller 188 may include the computer readable storage medium having computer implemented instructions stored thereon. The controller 188 may also include a processor configured for reading and implementing the instructions.

[0041] It is to be appreciated that while particular bushing and sleeve dimensions and ranges have been described, other dimensions and ranges may be applicable where different sizes of drill pipe are used. Those of skill in the art will appreciate the adjustments that may be made to the dimensions and ranges to accommodate other drill pipe sizes, other drill rigs, etc.Industrial Applicability

[0042] In operation and use, a method of drilling 200 may be provided where one or more tools on the drill machine 100 are used in conjunction with features of the outer bushing 140 and / or the inner bushing 142 to hold them in place during drilling operations. For example, the method 200 may include advancing 202 a drill bit and hammer through the outer bushing in the drill deck. The method may also include arranging 204 an inner bushing or sleeve on a length of drill pipe above / behind the hammer and the method may include threadably engaging 206 the drill pipe with the hammer. The method may also include advancing 208 the drill string including the drill bit, the hammer and the drill pipe such that the inner bushing, riding on the drill pipe and behind the hammer, sleevably engages the outer bushing. The method may include arresting 210 longitudinal motion of the inner bushing or sleeve through engagement of the inner bushing or sleeve with the outer bushing. In some examples, this may include arresting longitudinal motion of the inner bushing or sleeve by engagement of the opposing conical surfaces of the inner bushing or sleeve and the outer bushing. That is, the transitional conical surface between the lower portion of the inner bushing or sleeve and the offsetting portion of the inner bushing or sleeve may engage the conical surface at the top of the inner portion of the outer bushing. In other examples, arresting motion of the inner bushing or sleeve may occur by way of engagement of the flange on the inner bushing or sleeve with the top of the outer bushing. That is, for example, where an offsetting portion of the inner bushing or sleeve is not provided, the inner bushing or sleeve may advance fully into the outer bushing until the flange of the inner bushing or sleeve meets the top of the outer bushing.

[0043] The method may also include actuating 212 the bit basket to move the bit basket laterally relative to the drill string and into a position above the flange of the outer bushing as shown in FIG. 10. This position may be an intermediate position of the bit basket. That is, normal operation of the bit basket may generally include moving between a fully retracted position clear of any / all aspects of the drill string (see FIG. 9) and a fully extended position where the bit basket is in position at well center and below a drill string that has been removed from the drill deck. As shown in FIG. 10, the intermediate position of the bit basket may be between the fully retracted position and the fully extended position and, in particular, may be in a position where the bit basket is arranged in a position above one edge of the flange of the outer bushing, but remains clear of the inner bushing. That is, the bit basket may be spaced from the outer surface of the drill string by a distance equal to at least the thickness of the inner bushing, but may be spaced from the outer surface of the drill string by at least the width of the flange on the inner bushing.

[0044] The method may also include actuating 214 the deck wrench to move the deck wrench laterally relative to the drill string and into position above the flange of the inner bushing or sleeve. This position may be an intermediate position of the deck wrench. That is, normal operation of the deck wrench may generally include moving between a fully retracted position clear of any / all aspects of the drill string and a fully extended position where the deck wrench is in position around the drill string to engage flat surfaces of the drill string and prevent rotation of a portion of the drill string. As shown in FIGS. 4A, 4B, and 5, the intermediate position of the deck wrench may be between the fully retracted position and the fully extended position and, in particular, may be in a position where the longitudinally extending fingers of the deck wrench are arranged in position above the flange of the inner bushing or sleeve, but are clear of interference with the drill string. In some cases, where, for example, the inner sleeve has not moved into a fully seated position with the outer sleeve, actuating the deck wrench may cause the deck wrench to encounter the flange of the inner sleeve. In these cases, a pressure relief valve on the deck wrench may be used to prevent damaging the inner sleeve with the deck wrench. Moreover, responsive to the deck wrench not extending to its hold down position, the controller may actuate an alert to the operator that the inner sleeve is not in the proper position. This may allow the operator to run the drill string up and / or down in an effort to free up the inner sleeve and get it to seat in its proper position in the outer sleeve. Other remedial measures may also be taken by the operator.

[0045] The method may also include performing 216 drilling operations with the bit basket and / or the deck wrench holding respective bushings in placed. That is, the drill string may be continually or periodically advanced, rotated, and / or hoisted while the bit basket and / or deck wrench are in position above respective flanges of the outer / inner bushings. As such, when the drill string is manipulated the outer and inner bushings may remain generally longitudinally stationary relative to the drill deck and may remain generally longitudinally stationary with respect to each other. This may be particularly advantageous during hoisting when the inner / outer bushings may have a tendency to hang onto the drill string and ride upward with the drill string. During drilling including advancing, rotating, and / or hoisting, longitudinal slippage between the drill string and the bushings may occur at the interface between the drill string and the inside surface of the inner bushing or sleeve. The inner bushing or sleeve may rotate with the drill string and with the inner portion of the outer bushing where rotation between the inner portion of the outer bushing and the outer portion of the outer bushing is accommodated by the bearings in the outer bushing. The present system and method may, thus, be effective to maintain the inner / outer bushings in proper position during drilling operations, which may provide for better control of the position and / or angle of the drill string and may prolong the useful life of the bushings and one or more portions of the drill string.

[0046] It is to be appreciated that where the offsetting portion of the inner bushing is provided, the inner bushing may be longer than a normal inner bushing and may also be heavier than a normal inner bushing. The longer length may be helpful as the drill string slides through the bushing and, in particular, may help to prevent hanging up on the drill string at the flattened portions. That is, the longer length of the inner bushing may help to prevent misalignment of the bushing as the flattened portions of the drill pipe pass through it because the longer length may help to ensure that some portion of the bushing is engaged with a round portion of the drill pipe on one side of the flattened portion or the other. Since the bushing may remain better aligned with the drill pipe as the flattened portions pass through it, the bushing may have a lower tendency to hang up on the drill pipe and may be more likely to allow the drill pipe to pass readily through the bushing. Still further, the longer length of the bushing may make the bushing heavier as compared with shorter bushings. The heavier weight of the bushing may help to cause the bushing to more readily engage the outer bushing as the bushing is carried downward toward the outer bushing. Still other advantages of the present inner bushing or sleeve design may be appreciated.

[0047] The above detailed description is intended to be illustrative, and not restrictive. The scope of the disclosure should, therefore, be determined with references to the appended claims, along with the full scope of equivalents to which such claims are entitled.

Examples

Embodiment Construction

[0024]FIG. 1 is a perspective view of a drill machine 100 such as a rotary drill or other down-the-hole drill. The drill machine 100 may include a frame 102, a ground engaging system 104 for supporting the frame 102 relative to a supporting surface such as the ground and for moving the drill machine 100 across the supporting surface. The ground engaging 104 system may include a track system, for example, or a system of wheels and / or tires may be provided. The drill machine may include a drill deck 106 supported by the frame and providing a support platform for personnel to manage drilling operations, access equipment on the drill machine, manage pipe delivery, and the like. An operator station 108 may also be provided including an operator cabin equipped with controls for operating the drill machine 100. The drill machine 100 may also include a power source 110 such as a gasoline-powered or diesel-powered combustion engine or an electrical power supply (e.g., battery or electrical c...

TECHNICAL FIELD

[0001] The present application relates generally to drilling equipment. More particularly, the present application relates to guides such as sleeves or bushings in a deck of a drill machine. Still more particularly, the present application relates to retention of the guides in a deck of a drill machine.BACKGROUND

[0002] Drills such as rotary drills or other down-the-hole (DTH) drills may include one or more guides for guiding drill pipe through the deck of the drill as it is driven into the ground below the drill. In some cases, multiple sizes of guides may be provided where a first guide is used to guide the drill bit and / or hammer through the deck and second smaller guide is used to guide drill pipe through the deck. That is, the drill bit and hammer may have a larger diameter than the drill pipe so a larger guide may be used for the drill bit and hammer while a smaller diameter guide may be used for the drill pipe. During drilling and, in particular, during hoisting of the drill string either during drilling or after completion of drilling, the guides can be dislodged.SUMMARY

[0003] In one or more examples, a drill machine may include a ground engaging system configured for supporting the drill machine relative to a supporting surface and for moving the drill machine across the supporting surface. The drill machine may also include a a frame supported by the ground engaging system and a drill deck arranged on the frame and having an opening for performing drilling operations with a drill string extending in a longitudinal direction through the opening. The drill machine may also include an outer bushing arranged in the drill deck at the opening, where the outer bushing has an outer portion with a first flange and an inner portion configured to rotate relative to the outer portion. The drill machine may also include an inner bushing configured for being sleevably arranged within the outer bushing and having an outer peripheral surface and a second flange arranged on a top end thereof and extending radially outward beyond the outer peripheral surface. The drill machine may also include a bit basket configured to articulate laterally relative to the opening between a retracted position and an intermediate position where a portion of the bit basket is positioned directly above and in close proximity with a portion of the first flange and a deck wrench configured to articulate laterally relative to the opening between a retracted position and an intermediate position where a portion of the deck wrench is positioned directly above and in close proximity with a portion of the second flange.

[0004] In one or more examples, an inner bushing or sleeve for drilling operations may include a lower portion having a through bore sized to sleevably receive a drill pipe and having an outer peripheral surface configured for insertion into an outer bushing arranged in an opening in a drill deck of a drilling machine. The inner bushing or sleeve may also include a flange arranged on a top end of the inner bushing or sleeve and extending radially outward beyond the outer peripheral surface.

[0005] In one or more other examples, a method of drilling may include advancing a drill bit and hammer through an outer bushing in a drill deck of a drill machine. The method may also include advancing a drill string including the drill bit, the hammer, and a drill pipe through the outer bushing such that an inner bushing or sleeve arranged on the drill pipe engages the outer bushing. The inner bushing or sleeve may have an outer peripheral surface and a flange extending radially outward beyond the outer peripheral surface. The method may also include arresting longitudinal motion of the inner bushing or sleeve through engagement of the inner bushing or sleeve with the outer bushing. The method may also include actuating a deck wrench to move the deck wrench laterally relative to the drill string and into position above the flange of the inner bushing or sleeve. The method may also include performing drilling operations. Still further, the method may include maintaining a longitudinal position of the inner bushing or sleeve using the deck wrench engaged with the flange of the inner bushing or sleeve.DESCRIPTION OF THE DRAWINGS

[0006] FIG. 1 is a perspective view of a drill machine, according to one or more examples.

[0007] FIG. 2 is a cross-sectional view of the drill machine of FIG. 1, according to one or more examples.

[0008] FIG. 3 is a close-up view of the cross-section of FIG. 2, where the drill string passes through a deck of the drill machine and an inner sleeve is poised for insertion into an outer sleeve, according to one or more examples.

[0009] FIG. 4A is a perspective view of where the drill string passes through the deck and the inner sleeve is inserted into the outer sleeve, according to one or more examples.

[0010] FIG. 4B is an additional close-up view of the cross-section of FIG. 2, where the inner sleeve is inserted into the outer sleeve like in FIG. 4A, according to one or more examples.

[0011] FIG. 5 is a close-up view thereof showing retention of the inner sleeve by a deck wrench, according to one or more examples.

[0012] FIG. 6 is a perspective view of the inner sleeve, according to one or more examples.

[0013] FIG. 7 is a top view thereof.

[0014] FIG. 8 is a cross-sectional view thereof.

[0015] FIG. 9 is a close-up view of the cross-section of FIG. 2 showing a bit basket in a first non-retention position, according to one or more examples.

[0016] FIG. 10 is an addition view thereof with the bit basket in a second retention position, according to one or more examples.

[0017] FIG. 11A is a perspective view of another example of an inner sleeve, according to one or more examples.

[0018] FIG. 11B is a cross-sectional view thereof.

[0019] FIG. 12A is a perspective view of still another example of an inner sleeve, according to one or more examples.

[0020] FIG. 12B is a cross-sectional view thereof.

[0021] FIG. 13A is a perspective view of still another example of an inner sleeve, according to one or more examples.

[0022] FIG. 13B is a cross-sectional view thereof.

[0023] FIG. 14 is a diagram depicting a method of operation of a drill machine, according to one or more examples.DETAILED DESCRIPTION

[0024] FIG. 1 is a perspective view of a drill machine 100 such as a rotary drill or other down-the-hole drill. The drill machine 100 may include a frame 102, a ground engaging system 104 for supporting the frame 102 relative to a supporting surface such as the ground and for moving the drill machine 100 across the supporting surface. The ground engaging 104 system may include a track system, for example, or a system of wheels and / or tires may be provided. The drill machine may include a drill deck 106 supported by the frame and providing a support platform for personnel to manage drilling operations, access equipment on the drill machine, manage pipe delivery, and the like. An operator station 108 may also be provided including an operator cabin equipped with controls for operating the drill machine 100. The drill machine 100 may also include a power source 110 such as a gasoline-powered or diesel-powered combustion engine or an electrical power supply (e.g., battery or electrical cord) and an electrical motor may be provided. The drill machine 100 may include a pneumatic system 112 powered by the drill machine power source 110 and configured to provide pneumatic power to the drill of the drill machine 100. For example, the pneumatic system 112 may include a compressor adapted to deliver compressed air to a tank or directly to the drill. The compressed air may be used by the drill to drive a hammer and / or rotate the drill string and / or drill bit at the bottom of the drill string. The pneumatic system 112 may also supply compressed air to other aspects of the machine. While a pneumatic system 112 has been described for operating the drill, a hydraulic system 114 may additionally, or alternatively, be provided. In one or more example, the hydraulic system 114 may be powered by the power source 110 and may be used to produce and deliver hydraulic power to one or more cylinders on the drill machine, such as a hydraulic cylinder for raising and / or lowering a mast of the drill machine. Still other equipment and / or features may be provided on the drill machine.

[0025] With continued reference to FIG. 1 and further reference to FIG. 2, the drill machine may include a mast 116 extending upward from the deck 106 of the drill machine 100. The mast 116 may be configured for supporting long lengths of drill string including a drill bit 118, a hammer 120, and multiple lengths of drill pipe 122 strung together to form a drill string 124. Moreover, the mast 116 may be configured for supporting the drill string 124 in a vertical arrangement and, as such, the mast 116 may extend from the deck 106 of the drill machine 100 to a relatively high height above the deck 106. The position of the mast 116 may define a well center position based on where the drill string 124 is positioned when suspended from the mast 116. As suggested, the mast 116 may be pivotable relative to the deck 106 from a stowed or generally horizontal position to a deployed or generally vertical position. The deployment may be performed by a hydraulic cylinder or cylinders and the mast 116 may be pivotably coupled to the drill machine 100 at or near the drill deck 106 such that extension of the hydraulic cylinder pivots the mast 116 from the stowed position to the deployed position. The mast 116 may be equipped with a hoist system 126 and / or a block and tackle system for raising or lowering the drill string 124 into and / or out of the drill hole. The mast 116 may also include a rotary head or other system for rotating the drill string and the rotary head may be part and parcel with the hoist system 126.

[0026] The drill machine 100 may also include drill string handling equipment at or near the drill deck 106. For example, as shown in FIG. 3 as well as FIG. 4A, the drill machine may be equipped with a deck wrench 128. The deck wrench 128 may be positioned adjacent to the well center 130 position and may be actuatable to engage and disengage the drill string 124 by moving laterally toward and away from well center 130. The actuation of the deck wrench 128 may be hydraulic, pneumatic, electric, or another actuation system may be provided. As shown in FIG. 4A, the drill string 124 may include necked down flat sections 132 that are configured for engagement by the deck wrench 128. The deck wrench 128 may include a main body 134 with two extending fingers 136 having opposing and generally flat inward facing surfaces defining a generally rectangular slot when viewed from above. The deck wrench 128 may be actuated toward well center 130 such that the opposing flat inward facing surfaces pass alongside the flat sections 132 of the drill string 124 to hold a portion of the drill string 124 against rotation. The rotary head or other rotational system may rotate drill pipe 122 or other portions of the drill string 124 above the section being held against rotation by the deck wrench 128 to threadably engage or disengage one section of the drill string 124 with or from another. The deck wrench 128 may also include a generally flat bottom surface extending along the bottom of the main body and the extending fingers. The deck wrench 128 may be arranged on the drill deck 106 or the deck wrench 128 may be offset a distance above the drill deck 106. In one or more examples, the deck wrench 128 may be arrange such that the bottom surface of the deck wrench 128 is approximately 140 mm to approximately 190 mm above the drill deck or from approximately 160 mm to approximately 175 mm above the drill deck or the bottom surface of the deck wrench may be approximately 167 mm, 168 mm, 169 mm, or 170 mm above the drill deck. Still other spacings of the deck wrench above the drill deck may be provided.

[0027] In addition to the deck wrench 128, the drill string handling equipment may include a bit basket 138. As shown in FIGS. 3, 4B, and 5 as well as FIGS. 9 and 10, the bit basket 138 may be arranged at or near the deck 106 of the drill machine 100 and, like the deck wrench 128, may be operable to move into position at well center 130 and retract away from well center 130. The bit basket 138 may primarily be used when performing maintenance on and / or changing out drill bits 118. That is, the drill string 124 may be raised above the deck 106 and the bit basket 138 may be moved into position below the drill string 124 allowing the bit 118 to be lowered and set on the bit basket 138. The bit basket may, thus, support the weight of the bit 118 allowing the bit 118 to be changed out with another bit and / or serviced. In one or more examples, bit basket 138 may include a generally flat bottom plate with a generally flat bottom surface. The bit basket 138 may also include an apron plate that may be secured to a top side of the bottom plate with thumb screws or other manually operable fasteners. The apron plate may include a relatively large central opening for seatingly receiving the drill bit 118. The central opening may include a perimeter having contours adapted to match the profile of the toothed or working side of the drill bit 118 such that the drill bit 118 may seat in the bit basket 138 and be held generally stable and stationary against rotation. The bottom plate and apron may be secured to one another and may rest on a track to guide the motion of the bit basket 138 laterally toward and away from well center 130. A hydraulic cylinder, pneumatic cylinder, or other actuation device may be coupled to the bottom / apron plate to advance and retract the bit basket 138 laterally toward and away from well center 130. In one or more examples, the bit basket 138 may be arranged at the surface of the drill deck 106 or it may be spaced above the drill deck 106 like the deck wrench 128. In one or more examples, the bottom surface of the bottom plate of the bit basket 138 may be generally flush with the drill deck surface.

[0028] Turning now to FIGS. 3, 4A, and 4B, the mast 116 may support a drill string 124 in a vertical fashion such that it may be lowered and used to drill into the ground below the drill machine 100. Before and during drilling, the drill string 124 may pass through the deck 106 of the drill machine 100. In one or more examples, one or more guides may be arranged in the deck 106 of the drill machine 100 to guide the drill string as it passes through the deck 106. As shown in FIG. 3, for example, a guide in the form of an outer bushing 140 may be provided and a guide in the form of an inner bushing or sleeve 142 may be provided. Each guide may be configured to accommodate different portions of the drill string 124 based on the diameter of the respective portions of the drill string 124. In particular, the outer bushing 140 may be adapted to accommodate the drill bit 118 and hammer 120 while the inner bushing or sleeve 122 may be adapted to accommodate lengths of drill pipe 122 above or behind the hammer 120 and the drill bit 118.

[0029] As shown in FIG. 3, the outer bushing or sleeve 140 may be arranged in the deck 106 of the drill machine. The outer bushing 140 may be sized and configured to allow the drill bit 118 and hammer 120 to pass therethrough. The outer bushing or sleeve 140 may also be configured to accommodate rotation of the drill string 124 relative to the deck 106. For example, as shown in a closer view of FIG. 5, the outer bushing 140 may include a two-part system having a bearing or series of bearings 144 arranged therebetween to allow an inner portion 146 of the bushing 140 to rotate relative to an outer portion 148. For example, one or more bearing races may be provided by circumferential grooves in an inner surface of the outer portion 148 of the bushing 140 and in an outer surface of the inner portion 146 of the bushing 140. Ball bearings may be arranged in the races to allow the inner portion 146 to rotate relative to the outer portion 148. The outer portion 148 of the bushing may include a key or keyway that corresponds to a keyway or key in the drill deck 106 which may prevent rotation of the outer portion 148 of the bushing 140 relative to the deck 106. In one or more examples, the inner portion 146 of the bushing 140 may extend below the outer portion and may include a cuttings deflector 150.

[0030] As shown, the outer portion 148 of the bushing may include a flange 152 on an upper portion thereof that extends radially outward beyond an outer surface 154 of the outer portion 148 of the outer bushing 140. This radially outward extending portion of the flange 152 may be adapted for engaging a supporting surface of the deck 106 to prevent the bushing 140 from falling through the deck 106. In one or more examples, an annular recess may be provided on the drill deck 106 around the drilling hole to allow the top surface of the outer bushing 140 to lie flush with the deck surface 106. The flange 152 may also include a radially inward extending portion 156 having a downward extending lip for closing off the upper end of the annular joint 158 between the inner and outer portions 146 / 148 of the outer bushing 140. In one or more examples, an upper annular surface of the inner portion of the outer bushing may include a chamfered, angled, or conical surface 160 configured to guide the drill bit 118 and / or hammer 120 toward a central position as it enters the bushing 140. The conical surface 160 may extend upward and radially outward of the lip extending down from the flange 152 on the upper portion. As discussed in more detail below, the conical surface 160 may also function to interface with a corresponding conical surface on the inner bushing / sleeve 142 to prevent the inner bushing / sleeve 142 from falling through the outer bushing 140.

[0031] With continued reference to FIGS. 3-4B and FIG. 5, the inner bushing or sleeve 142 is shown. For example, in FIG. 3, the inner bushing or sleeve 142 is shown arranged on the drill pipe 122 above the hammer 120 and spaced well above the drill deck 106. As the drill string 124 advances through the drill deck 106, the inner bushing or sleeve 142 may advance downward and engage the outer bushing 140 as shown in FIGS. 4A and 4B. As shown in FIG. 5, downward motion of the inner bushing or sleeve 142 may be arrested when an outer chamfered or conical surface 162 on the inner bushing or sleeve 142 engages the conical surface 160 on a top portion of the inner portion 146 of the outer bushing 140. In some examples, as shown, the downward motion of the inner bushing or sleeve 142 may be arrested before a flange 164 on the inner bushing or sleeve 142 reaches the drill deck 106 or comes into contact with the top of the outer bushing 140. In any case, the inner bushing or sleeve 142 may include an upper flange 164 that extends radially outward beyond an outer circumferential surface of the inner bushing or sleeve 142.

[0032] More particularly, as shown in FIGS. 6-8, the inner bushing or sleeve 142 may be a generally cylindrical sleeve adapted to fit within and sleevably engage the outer bushing 140 while providing a cylindrical interior bore 166 for receiving a drill pipe portion of the drill string 124. The interior bore 166 may have a diameter 167 ranging from approximately 130 mm to approximately 155 mm or from approximately 140 mm to approximately 145 mm or an interior bore diameter of approximately 142 mm or approximately 143 mm may be provided. As shown, the inner bushing or sleeve 142 may include a lower end 168 for engaging the outer bushing 140, an offsetting portion 170, and an upper portion 172. The lower end 168 may have a length adapted to extend generally fully through the outer bushing 140, it may include an outer diameter 174 adapted to sleevably engage the inner surface of the outer bushing 140, and it may include a tapered tip 176. The outer diameter 174 of the lower portion 168 may range from approximately 170 mm to approximately 190 mm or from approximately 175 mm to approximately 185 mm or a diameter of approximately 180 mm may be provided. The lower portion 168 may extend upward from the tapered tip 176 to the offsetting portion 170 and a conical surface 162 may be provided on an outside surface of the inner bushing 142 at the transition between the lower portion 168 and the offsetting portion 170. This conical surface 162 may be sized and shaped to abut the conical surface 160 on the upper end of the inner portion 146 of the outer bushing 140 thereby preventing the inner bushing or sleeve 142 from falling through and / or advancing too far through the outer bushing 140. The lower end 168 may have a length ranging from approximately 170 mm to approximately 210 mm or from approximately 180 mm to approximately 200 mm or a length of 189 mm or 190 mm may be provided. The tapered tip 176 may have a length 177 ranging from approximately 40 mm to 60 mm or from approximately 45 mm to 55 mm or a length of approximately 50 mm may be provided. The length 178 of the lower portion 168 including the transition portion may range from approximately 180 mm to approximately 210 mm or from approximately 190 mm to approximately 200 mm or a length of approximately 194 mm or 195 mm may be provided.

[0033] The offsetting portion 170 may extend further upward from the lower portion 168 and may be adapted to accommodate and / or makeup the distance from the top of the drill deck 106 to a bottom side of the deck wrench 128. In particular, the offsetting portion 170 may extend upward out of and beyond an upper surface of the outer bushing 140 and the length thereof may be particularly selected to accommodate the relationship of the deck wrench 128 to the drill deck 106 as well as the distance below the drill deck 106 of the conical surface 160 of the inner portion 146 of the outer bushing 140. The particular length of the offsetting portion is discussed below along with the overall length of the inner bushing 142. The offsetting portion 170 may have an inner diameter matching that of the lower portion 168 and may have an outer diameter 180 that is slightly larger than the outer diameter of the lower portion 168 as defined by the conical surface 162 transition between the lower portion 168 and the offsetting portion 170. The outer diameter 180 of the offsetting portion 170 may range from approximately 180 mm to approximately 200 mm or from approximately 185 mm to approximately 195 mm or a diameter of approximately 190 mm, 191 mm, or 192 mm may be provided.

[0034] The upper portion 172 of the inner bushing or sleeve 142 may include a flange 164. The flange 164 may extend radially outward beyond an outer peripheral surface 182 of the offsetting portion 170. That is, the flange 164 may extend radially outward beyond the outside diameter 180 of the offsetting portion 170. In some cases, the flange 164 may extend radially outward beyond the outer peripheral surface of the lower portion 168. That is, in some examples, the offsetting portion 170 may be omitted and the flange 164 extends beyond an outer peripheral surface of the lower portion in these examples. In one or more examples, the flange 164 may be a separate annular piece that is attached to the offsetting portion 170 (or the lower portion 168 when the offsetting portion is omitted) at a seam. The separate annular piece 164 may be welded onto the upper portion of the inner bushing or sleeve 142. In one or more examples, the annular flange 164 may be a retrofit piece that is welded to an existing inner bushing or sleeve 142. The upper portion 172 may also include a chamfered surface 184 on an inner circumferential edge of the offsetting portion 170, which may function to guide the drill string through the bushing 142. That is, while the outer surface of the drill string 124 may be generally cylindrical and smooth, portions of the drill string 124 may include flat spots or recesses that may allow the drill string 124 to sway or vary from a longitudinal centerline. As these portions of the drill string 124 pass through the bushing 142, the chamfered surface 184 may assist in recentering the drill string 124. In one or more examples, the annular flange 164 on the inner bushing or sleeve 142 may have an outer diameter 165 ranging from approximately 230 mm to approximately 290 mm, or from approximately 250 mm to approximately 270 mm, or from approximately 255 mm to approximately 265 mm, or a outer flange diameter of approximately 260 mm may be provided. In one or more examples, the outer flange diameter 165 of the inner bushing or sleeve 142 may be smaller than the outer flange diameter of the outer bushing 140. Additionally, and in some cases, where an offsetting portion 170 of the inner bushing 142 is omitted and the flange 164 of the inner bushing 142 rests on or nests in the flange 152 of the outer bushing 140, some portion of the flange 152 on the outer bushing 140 may still be exposed radially beyond the flange 164 of the inner bushing 142 to allow for engagement by the bit basket 138 or other hold down mechanism. While the flange 164 on the inner bushing 142, or the flange 152 of the outer bushing 140, has been said to be annular and to have an outer diameter, other shaped flanges may also be provided such as square, rectangular, triangular, oval, or other shapes.

[0035] The overall length 186 of the inner bushing or sleeve 142 may range from approximately 375 mm to approximately 425 mm or from 390 mm to approximately 410 mm or a length of approximately 400 mm may be provided. As such, and when giving consideration to the length of the lower portion 168, the offsetting portion 170 may have a length ranging from approximately 190 mm to approximately 220 mm or from approximately 200 mm to approximately 210 mm or a length of approximately 205 mm may be provided.

[0036] The flange 164 of the inner bushing or sleeve 142 may range from approximately 10 mm to approximately 20 mm, or from approximately 15 mm to approximately 17 mm, or a thickness of 16 mm may be provided. However, as shown in FIGS. 11A-13B, a thicker flange may also be provided. That is, the thickness of the flange may be such as to form a collar on the upper portion of the inner sleeve or bushing. As shown in FIGS. 11A-11B, an inner bushing or sleeve 242 may include a solid thicker flange 264 in lieu of the flange 164 described. The other aspects of the bushing or sleeve 242 may be the same or substantially the same as the bushing or sleeve 142, but the flange 264 may extend downward along the upper portion 272 for a much larger distance than the flange 164. For example, as shown, the flange 264 may have a length extending along the bushing or sleeve 242 ranging from approximately 120 mm to approximately 150 mm, or from approximately 130 mm to approximately 140 mm, or a length of approximately 135 mm may be provided.

[0037] FIGS. 12A-12B show yet another example of an inner bushing or sleeve 342 where the flange 364 is formed from a cylindrical plate 367 and upper / lower offsetting annular spacers 365. Here, the flange 364 may have the same or similar dimensions as the flange 264, but may be hollow due to the use of the cylindrical plate 367 and the offsetting spacers 365. This may provide for a generally lighter weight inner bushing or sleeve 342 as compared with the bushing or sleeve 242 with the solid flange 264. In one or more examples, the cylindrical plate 367 and / or the spacers 365 may have a thickness ranging from approximately 10 mm to approximately 20 mm, or from approximately 15 mm to approximately 17 mm or a thickness of approximately 16 mm may be provided. The annular width of the spacers 365 may be as such to make up the space between the outer surface of the upper portion 372 of the inner bushing or sleeve 342 and the inside surface of the cylindrical plate 367.

[0038] Still another example of an inner bushing or sleeve 442 is shown in FIGS. 13A-13B. Here, a top annular ring 464A may be provided that is the same or similar to the flange 164 of inner bushing or sleeve 142. However, additional annular rings 464B / C may be provided to establish an outer envelope that is akin to the outer envelope of the flanges 264 and 364. That is, as shown in FIGS. 13A and 13B, two additional annular rings 464B / 464C may be provided along the length of the upper portion 472 of the inner bushing or sleeve 442 where the lower 464C of the two annular rings is positioned at a location similar to the bottom of the flanges 264 / 364. That is, the annular ring 464C may be spaced along the upper portion 472 such that a bottom surface thereof is spaced from the top surface of the top annular ring 464A by a distance ranging from approximately 120 mm to approximately 150 mm, or from approximately 130 mm to approximately 140 mm, or a length of approximately 135 mm. The additional annular ring 464B may be centered between the top annular ring 464A and the lower annular ring 464C. The resulting spacing between the top annular ring 464A and the intermediate annular ring 464B as well as the spacing between the intermediate annular ring 464B and the lower annular ring 464C may be less than the thickness of the deck wrench 128. As such, for purposes of the discussion below relating to the encounter of the deck wrench with the flange, the three pieces 464A, 464B, and 464C, may function as and be considered parts of the same flange. That is, and more generally, the term “flange” should be considered to include the examples 164, 264, and 364, as well as the combination of the annular rings 464A to 464C.

[0039] These latter examples of the inner bushing or sleeve (e.g., 242, 342, 442) may provide for the ability to verify the position of the inner bushing or sleeve using the deck wrench. That is, for example, the inner bushing or sleeve may sometimes get hung up as it is carried into the outer sleeve and may sometimes not move into a fully seated position in the outer sleeve. If this occurs with the inner bushing or sleeve 142, which has the relatively thin flange 164, the flange 164 may remain above the deck wrench. If this occurs, the deck wrench may move into position to hold the inner bushing or sleeve down, but it may actually move into position below the flange 164 rather than above it due to the sleeve 142 being hung up. Moreover, there may not be any indication that anything is wrong (i.e., nothing obstructs the movement of the deck wrench). In some cases, where the inner sleeve is hung up such that the flange 164 is within the thickness of the deck wrench, the deck wrench may encounter the flange 164, which may indicate that the inner sleeve is not fully seated in the outer sleeve. For purposes of covering a wider range of positions of the inner sleeve that also provide an indication of a non-fully seated inner sleeve, the extended flanges of the sleeves 242, 342, and 442 may be provided. For example, where the inner sleeve is hung up and the flange 164 would otherwise be arranged above the deck wrench, the extended flanges of sleeves 242, 342, and 442 may be encountered by the deck wrench when it moves into position to hold the sleeve down. This may provide the operator with an indication that the inner sleeve is not in a proper position.

[0040] The drill machine 100 may include a controller 188 (see FIG. 1) configured for controlling the drill system of the drill machine 100 and performing drilling operations. In one or more examples, the controller 188 may be part and parcel to the electronic control module of the drill machine 100 or a separate controller may be provided. The controller 188 may be configured to control operation of the hoist or other system 126 for lifting and lowering the drill string. The controller 188 may also be configured to control the rotary system to control rotation of the drill string. Still further, the controller 188 may be configured to control the pneumatic or other fluid power system for performing the drilling operations, for controlling the hammer 120, and for controlling the drill bit 118. The controller may, still further, be configured for controlling the deck wrench 128 and the bit basket 138. In one or more examples, the controller 188 may include computer implemented instructions stored thereon for performing the method of drilling 200 described in more detail below. That is, the controller 188 may include the computer readable storage medium having computer implemented instructions stored thereon. The controller 188 may also include a processor configured for reading and implementing the instructions.

[0041] It is to be appreciated that while particular bushing and sleeve dimensions and ranges have been described, other dimensions and ranges may be applicable where different sizes of drill pipe are used. Those of skill in the art will appreciate the adjustments that may be made to the dimensions and ranges to accommodate other drill pipe sizes, other drill rigs, etc.Industrial Applicability

[0042] In operation and use, a method of drilling 200 may be provided where one or more tools on the drill machine 100 are used in conjunction with features of the outer bushing 140 and / or the inner bushing 142 to hold them in place during drilling operations. For example, the method 200 may include advancing 202 a drill bit and hammer through the outer bushing in the drill deck. The method may also include arranging 204 an inner bushing or sleeve on a length of drill pipe above / behind the hammer and the method may include threadably engaging 206 the drill pipe with the hammer. The method may also include advancing 208 the drill string including the drill bit, the hammer and the drill pipe such that the inner bushing, riding on the drill pipe and behind the hammer, sleevably engages the outer bushing. The method may include arresting 210 longitudinal motion of the inner bushing or sleeve through engagement of the inner bushing or sleeve with the outer bushing. In some examples, this may include arresting longitudinal motion of the inner bushing or sleeve by engagement of the opposing conical surfaces of the inner bushing or sleeve and the outer bushing. That is, the transitional conical surface between the lower portion of the inner bushing or sleeve and the offsetting portion of the inner bushing or sleeve may engage the conical surface at the top of the inner portion of the outer bushing. In other examples, arresting motion of the inner bushing or sleeve may occur by way of engagement of the flange on the inner bushing or sleeve with the top of the outer bushing. That is, for example, where an offsetting portion of the inner bushing or sleeve is not provided, the inner bushing or sleeve may advance fully into the outer bushing until the flange of the inner bushing or sleeve meets the top of the outer bushing.

[0043] The method may also include actuating 212 the bit basket to move the bit basket laterally relative to the drill string and into a position above the flange of the outer bushing as shown in FIG. 10. This position may be an intermediate position of the bit basket. That is, normal operation of the bit basket may generally include moving between a fully retracted position clear of any / all aspects of the drill string (see FIG. 9) and a fully extended position where the bit basket is in position at well center and below a drill string that has been removed from the drill deck. As shown in FIG. 10, the intermediate position of the bit basket may be between the fully retracted position and the fully extended position and, in particular, may be in a position where the bit basket is arranged in a position above one edge of the flange of the outer bushing, but remains clear of the inner bushing. That is, the bit basket may be spaced from the outer surface of the drill string by a distance equal to at least the thickness of the inner bushing, but may be spaced from the outer surface of the drill string by at least the width of the flange on the inner bushing.

[0044] The method may also include actuating 214 the deck wrench to move the deck wrench laterally relative to the drill string and into position above the flange of the inner bushing or sleeve. This position may be an intermediate position of the deck wrench. That is, normal operation of the deck wrench may generally include moving between a fully retracted position clear of any / all aspects of the drill string and a fully extended position where the deck wrench is in position around the drill string to engage flat surfaces of the drill string and prevent rotation of a portion of the drill string. As shown in FIGS. 4A, 4B, and 5, the intermediate position of the deck wrench may be between the fully retracted position and the fully extended position and, in particular, may be in a position where the longitudinally extending fingers of the deck wrench are arranged in position above the flange of the inner bushing or sleeve, but are clear of interference with the drill string. In some cases, where, for example, the inner sleeve has not moved into a fully seated position with the outer sleeve, actuating the deck wrench may cause the deck wrench to encounter the flange of the inner sleeve. In these cases, a pressure relief valve on the deck wrench may be used to prevent damaging the inner sleeve with the deck wrench. Moreover, responsive to the deck wrench not extending to its hold down position, the controller may actuate an alert to the operator that the inner sleeve is not in the proper position. This may allow the operator to run the drill string up and / or down in an effort to free up the inner sleeve and get it to seat in its proper position in the outer sleeve. Other remedial measures may also be taken by the operator.

[0045] The method may also include performing 216 drilling operations with the bit basket and / or the deck wrench holding respective bushings in placed. That is, the drill string may be continually or periodically advanced, rotated, and / or hoisted while the bit basket and / or deck wrench are in position above respective flanges of the outer / inner bushings. As such, when the drill string is manipulated the outer and inner bushings may remain generally longitudinally stationary relative to the drill deck and may remain generally longitudinally stationary with respect to each other. This may be particularly advantageous during hoisting when the inner / outer bushings may have a tendency to hang onto the drill string and ride upward with the drill string. During drilling including advancing, rotating, and / or hoisting, longitudinal slippage between the drill string and the bushings may occur at the interface between the drill string and the inside surface of the inner bushing or sleeve. The inner bushing or sleeve may rotate with the drill string and with the inner portion of the outer bushing where rotation between the inner portion of the outer bushing and the outer portion of the outer bushing is accommodated by the bearings in the outer bushing. The present system and method may, thus, be effective to maintain the inner / outer bushings in proper position during drilling operations, which may provide for better control of the position and / or angle of the drill string and may prolong the useful life of the bushings and one or more portions of the drill string.

[0046] It is to be appreciated that where the offsetting portion of the inner bushing is provided, the inner bushing may be longer than a normal inner bushing and may also be heavier than a normal inner bushing. The longer length may be helpful as the drill string slides through the bushing and, in particular, may help to prevent hanging up on the drill string at the flattened portions. That is, the longer length of the inner bushing may help to prevent misalignment of the bushing as the flattened portions of the drill pipe pass through it because the longer length may help to ensure that some portion of the bushing is engaged with a round portion of the drill pipe on one side of the flattened portion or the other. Since the bushing may remain better aligned with the drill pipe as the flattened portions pass through it, the bushing may have a lower tendency to hang up on the drill pipe and may be more likely to allow the drill pipe to pass readily through the bushing. Still further, the longer length of the bushing may make the bushing heavier as compared with shorter bushings. The heavier weight of the bushing may help to cause the bushing to more readily engage the outer bushing as the bushing is carried downward toward the outer bushing. Still other advantages of the present inner bushing or sleeve design may be appreciated.

[0047] The above detailed description is intended to be illustrative, and not restrictive. The scope of the disclosure should, therefore, be determined with references to the appended claims, along with the full scope of equivalents to which such claims are entitled.

Examples

Embodiment Construction

[0024]FIG. 1 is a perspective view of a drill machine 100 such as a rotary drill or other down-the-hole drill. The drill machine 100 may include a frame 102, a ground engaging system 104 for supporting the frame 102 relative to a supporting surface such as the ground and for moving the drill machine 100 across the supporting surface. The ground engaging 104 system may include a track system, for example, or a system of wheels and / or tires may be provided. The drill machine may include a drill deck 106 supported by the frame and providing a support platform for personnel to manage drilling operations, access equipment on the drill machine, manage pipe delivery, and the like. An operator station 108 may also be provided including an operator cabin equipped with controls for operating the drill machine 100. The drill machine 100 may also include a power source 110 such as a gasoline-powered or diesel-powered combustion engine or an electrical power supply (e.g., battery or electrical c...

Claims

1. A drill machine, comprising:a ground engaging system configured for supporting the drill machine relative to a supporting surface and for moving the drill machine across the supporting surface;a frame supported by the ground engaging system;a drill deck arranged on the frame and having an opening for performing drilling operations with a drill string extending in a longitudinal direction through the opening;an outer bushing arranged in the drill deck at the opening, the outer bushing having an outer portion with a first flange and an inner portion configured to rotate relative to the outer portion;an inner bushing configured for being sleevably arranged within the outer bushing and comprising:a lower portion having a through bore sized to sleevably receive a drill pipe and having a first outer peripheral surface defining a first outer diameter and configured for insertion into the outer bushing;an offsetting portion arranged on a top end of the lower portion and having a second outer peripheral surface defining a second outer diameter larger than the first outer diameter; anda second flange arranged on a top end of the offsetting portion and extending radially outward beyond the second outer peripheral surface;a bit basket configured to articulate laterally relative to the opening between a retracted position and an intermediate position where a portion of the bit basket is positioned directly above and in close proximity with a portion of the first flange; anda deck wrench configured to articulate laterally relative to the opening between a retracted position and an intermediate position where a portion of the deck wrench is positioned directly above and in close proximity with a portion of the second flange.

2. The drill machine of claim 1, wherein the offsetting portion is configured to hold the second flange above the outer bushing by an offset distance.

3. The drill machine of claim 2, wherein the offset distance is selected to place the second flange slightly below the deck wrench.

4. The drill machine of claim 2, further comprising a transition between the lower portion and the offsetting portion of the inner bushing, the transition comprising a conical surface configured to interface with a corresponding conical surface on the outer bushing.

5. The drill machine of claim 1, further comprising a controller configured to control the articulation of the bit basket and the deck wrench.

6. An inner bushing or sleeve for drilling operations, comprising:a lower portion having a through bore sized to sleevably receive a drill pipe and having a first outer peripheral surface defining a first outer diameter and configured for insertion into an outer bushing arranged in an opening in a drill deck of a drilling machine;an offsetting portion arranged on a top end of the lower portion and having a second outer peripheral surface defining a second outer diameter larger than the first outer diameter; anda flange arranged on a top end of the offsetting portion and extending radially outward beyond the second outer peripheral surface.7-8.

9. The inner bushing or sleeve of claim 6, further comprising a transition between the lower portion and the offsetting portion in the form of a conical surface.

10. The inner bushing or sleeve of claim 9, wherein the top end of the offsetting portion comprises a chamfered inner peripheral surface.

11. The inner bushing or sleeve of claim 6, wherein the lower portion comprises a conical tip.

12. The inner bushing or sleeve of claim 7, wherein the flange is an annular element that is sleeved around the offsetting portion and welded thereto.

13. The inner bushing or sleeve of claim 7, wherein the lower portion has a length and the offsetting portion has a length approximately the same as the lower portion.

14. A method of drilling, comprising:advancing a drill bit and hammer through an outer bushing in a drill deck of a drill machine;advancing a drill string including the drill bit, the hammer, and a drill pipe through the outer bushing such that an inner bushing or sleeve arranged on the drill pipe engages the outer bushing, the inner bushing or sleeve comprising:a lower portion having a through bore sized to sleevably receive the drill pipe and having a first outer peripheral surface defining a first outer diameter and configured for insertion into the outer bushing;an offsetting portion arranged on a top end of the lower portion and having a second outer peripheral surface defining a second outer diameter larger than the first outer diameter; anda flange arranged on a top end of the offsetting portion and extending radially outward beyond the second outer peripheral surface;arresting longitudinal motion of the inner bushing or sleeve through engagement of the inner bushing or sleeve with the outer bushing;actuating a deck wrench to move the deck wrench laterally relative to the drill string and into position above the flange of the inner bushing or sleeve;performing drilling operations; andmaintaining a longitudinal position of the inner bushing or sleeve using the deck wrench engaged with the flange of the inner bushing or sleeve.

15. The method of claim 14, wherein arresting longitudinal motion of the inner bushing or sleeve comprises engaging the outer bushing with the flange of the inner bushing or sleeve.

16. The method of claim 14, wherein arresting longitudinal motion of the inner bushing or sleeve comprises engaging the outer bushing with a transition of the inner bushing or sleeve such that the flange of the inner bushing or sleeve is offset above a top of the outer bushing by an offset distance.

17. The method of claim 14, further comprising actuating a bit basket to move the bit basket laterally relative to the drill string and into position above a flange of the outer bushing.18-20. (canceled)21. The inner bushing or sleeve of claim 6, wherein the offsetting portion is configured to hold the flange above the outer bushing by an offset distance.

22. The inner bushing or sleeve of claim 21, wherein the offset distance is configured to position the flange slightly below a deck wrench of a drill machine.

23. The inner bushing or sleeve of claim 21, further comprising a transition between the lower portion and the offsetting portion, the transition comprising a conical surface configured to interface with a corresponding conical surface on the outer bushing.

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