Automated drill rig

Abstract

An automated drill rig or system (10) comprising a structural base (12), a mast (16) associated with a rod rotation unit (18) and an automatic rod loading arrangement (14). The rod loading arrangement (14) comprises at least a first magazine (26) comprising a plurality of rods (28), a robotic arm (32) and a gripper (34) fitted to the robotic arm (32). The robotic arm (32) and gripper (34) are configured operatively and sequentially to collect one of the plurality of rods (28) from the magazine (26) and present same to the rod rotation unit (18).

Description

[0001] AUTOMATED DRILL RIG

[0002] BACKGROUND TO THE INVENTION

[0003] This invention relates to the field of drilling. More particularly, the present invention relates to an automated drill rig or system, which incorporates an automatic rod loading arrangement. The invention furthermore relates to a method of loading rods onto a rod rotation unit of the drill system.

[0004] The process of drilling holes or shafts, for example in the form of boreholes, wells, holes used for the purpose of geotechnical investigation (exploration drilling) or other the like, into the ground, is well known. Explorative drilling is a crucial process in the mining industry used to assess the presence, quality, and quantity of mineral resources in a given area to determine the economic viability of extracting minerals. The objectives of explorative drilling are mineral deposits identification; ore grade and composition assessment; and ore body structure definition or mapping.

[0005] Conventionally, explorative drilling involves the steps of rotating and advancing drilling rods into the ground, thereby to extract samples at various depths. During the process, drill rods are successively and sequentially threaded onto a top of a rod column, until a predetermined or required depth of the hole is reached.

[0006] The cost associated with explorative drilling represents an operational challenge. The threading of rods is typically a manual process, which is labour intensive and associated with safety concerns.

[0007] Automation of the loading and threading process is typically complicated by a number of factors. For example, known automated gripper mechanisms with which rods could theoretically be collected from a magazine of rods would be bulky and inaccurate. This would, in turn, necessitate relatively large spacings between rods held in the magazine, which would significantly compromise the number of rods held per magazine, the size of the magazine and the frequency with which magazines have to be replaced. Furthermore, inaccurate handling of the rods would negate accurate threading which could lead to thread compatibility issues, damaging or compromising thread integrity, issues with thread synchronisation and the like. To date, automation of rod loading procedures has been inefficient and therefore not suitable for commercial implementation.

[0008] A need therefore exists for improvements in the threading of rods during conventional drilling activities. These improvements relate, among others, to safety, downtime and the removal of human interaction, especially during rod-handling activities. It is accordingly an object of the invention to provide a loading arrangement, drill system incorporating such a loading arrangement and a method of loading a rod that will, at least partially, address the above disadvantages.

[0009] It is also an object of the invention to provide a loading arrangement, drill system incorporating such a loading arrangement and a method of loading a rod which will be a useful alternative to existing arrangements, systems and methods.

[0010] SUMMARY OF THE INVENTION

[0011] In accordance with a first aspect of the invention there is provided a loading arrangement for a drill system comprising a mast and a rod rotation unit, the loading arrangement comprising: at least a first magazine comprising a plurality of rods; a robotic arm; and a gripper fitted to the robotic arm, wherein the robotic arm and gripper are configured operatively and sequentially to collect one of the plurality of rods from the magazine and present same to the rod rotation unit.

[0012] The loading arrangement may comprise a structural base.

[0013] The robotic arm may comprise at least a first and second pivotably interconnected links.

[0014] The first link may be connected by way of a shoulder to a base.

[0015] The shoulder may allow pivoting and revolving displacement of the first link relative to the base.

[0016] The second link may be interconnected to the first link by way of an elbow joint.

[0017] The elbow joint may allow pivoting displacement of the second link relative to the first link.

[0018] The gripper may be fixed relative to an end portion of the second link by means of a wrist joint.

[0019] The elbow joint, second link or wrist joint may facilitate swivelling of the gripper relative to the first link.

[0020] The base of the robot arm may be fixed to and / or supported by the structural base of the loading arrangement.

[0021] The first magazine may comprise a main structure which may facilitate carrying rows of stacks of rods and loading and unloading of rods via an open top thereof.

[0022] First and second end portions of the main structure may comprise inward-facing tracks provided for receiving end portions of the rods. A particular track on the first end portion and a corresponding track on the second end portion may form a pair of facing tracks.

[0023] The tracks may be substantially U-shaped and may extend substantially vertically. Rods received by a particular pair of tracks may form a substantially vertically extending stack of rods. Rods within a stack may physically lie in contact with and on top of one another.

[0024] In some cases, the tracks may be formed between plates or bars extending relative to the end-portions. In use, neighbouring stacks may be spaced apart by a width of the plates or bars forming the tracks.

[0025] The first magazine may be configured with a substantially unobstructed and open side to allow the gripper access to the rods of a stack.

[0026] The first magazine may be configured to carry between 5 and 10 rows of stacks of rods. More particularly, the first magazine may be configured to carry 5, 6, 7, 8, 9 or 10 rows of stacks of rods.

[0027] Each stack may comprise between 8 and 15 rods. More particularly, each stack may comprise 8, 9, 10, 11 , 12, 13, 14 or 15 rods.

[0028] The main structure may further comprise hooking or connection points to facilitate external handling of the magazine.

[0029] The structural base may comprise holding brackets for receiving the first magazine and locating same relative to the structural base. The holding brackets may have open ended top portions to allow loading the magazine there onto from the top. The holding brackets may comprise outward flaring guide portions to facilitate loading of the first magazine from the top.

[0030] The first magazine may comprise at least one reference or teaching point with which a position of the gripper and / or robotic arm may operatively be calibrated relative to the magazine.

[0031] Further in accordance with the first aspect of the invention, the loading arrangement may comprise a second magazine carrying a plurality of rods. The second magazine may, at least in some, if not all, respects mentioned above, be similar or identical to the first magazine.

[0032] The first and second magazines may operatively be located on opposite sides of the robotic arm. The second magazine may be associated with similar holding brackets as the first magazine.

[0033] The gripper may take the form of a gripper assembly comprising a first gripper unit and a second gripper unit.

[0034] The first gripper unit may comprise a plurality of attracting contacts. The attracting contacts may be electromagnetic contacts or pneumatic suction contacts. The attracting contacts may be configurable to attract a rod when placed proximate or in contact with the rod.

[0035] The second gripper unit may comprise a mechanical jaw or clamp arrangement which may be configurable between open and closed configuration. The second gripper unit may be configured to clamp or grab onto a rod when the mechanical jaw or clamp arrangement is configured towards, substantially towards or in the closed configuration.

[0036] The mechanical jaw or clamp arrangement may comprise first and second jaws. The first jaw may comprise a first set of rollers. The second jaw may comprise a second and third set of rollers. The configuration may be such that a clamping force (which may be modulated) may operatively be exerted by the respective sets of rollers on a rod clamped therebetween.

[0037] The respective sets of rollers may be arranged and configured to allow axial rotation of a rod clamped by the second gripper unit. Each roller may therefore be rotatably mounted relative to the respective jaw.

[0038] Furthermore, at least some of the rollers may be driven rollers, which may facilitate operative transmitting of torque to a rod clamped between the respective sets of rollers. The respective jaws may therefore be associated with drive motors which are configured for driving the driven rollers. The drive motors may be hydraulic, electric or pneumatic motors.

[0039] The second gripper unit may comprise a rod supporting guide mechanism, which may have first and second guides. The first and second guides may be arranged and configured operatively to contact, guide and / or support a rod.

[0040] The guides may be substantially U-shaped (when viewed from the side).

[0041] The first and second guides may have different sizes to accommodate the use of rods having different diameters.

[0042] The rod supporting guide mechanism may be rotatable to allow a single one of the first or second guides to be positioned in an operative position at a given time.

[0043] The gripper assembly may be fitted relative to the robotic arm in rotatable fashion, to allow it operatively to be rotated through 180 degrees between a first position, in which the first gripper unit is in an operative position, and a second position, in which the second gripper is in an operative position.

[0044] Further in accordance with the first aspect of the invention, the loading arrangement may comprise a centralizer.

[0045] The centralizer may comprise a centralizer stand with a receiving portion configured for receiving a single rod during an intermediate process of a loading sequence of the loading arrangement.

[0046] The centralizer stand may be supported or fixed pivotably relative to the structural base of the loading arrangement.

[0047] The receiving portion may be associated with an exact and known location relative to the robot arm (which may be determined after calibration). The receiving portion may be configured to locate the rod by receiving same in a particular position and / or orientation only.

[0048] The centralizer may comprise first and second sets of rollers which allow a rod supported thereon to be displaced in an axial direction. More particularly, the first and second sets of rollers may be vertically offset relative to each other, such that a rod operatively supported thereon may be supported slightly offset from a horizontal orientation (allowing the rod to “slide” down under the influence of gravity). The centralizer may further comprise a stopper against which an end of the rod may operatively and positively rests. A proximity sensor may be configured positively to sense a rod which is supported in the particular position and / or orientation.

[0049] In accordance with a second aspect of the invention there is provided a drill system comprising: a main structural base; a loading arrangement according to the first aspect of the invention, wherein the main structural base of the drill system forms a structural base of the loading arrangement; a mast supported relative to the main structural base; and a rod rotation unit supported relative to the mast.

[0050] The mast may be pivotably supported relative to the main structural base, such that an angle of the mast relative to the main structural base may operatively be variable.

[0051] The mast may be supported by a support cylinder / piston arrangement with which an angle of the mast relative to the main structural base may operatively be varied.

[0052] The mast may define a linear base on which the rod rotation unit may be supported. The rod rotation unit may be linearly displaceable relative to the mast.

[0053] The mast may comprise a lattice structure. The mast may be made up of more than one interconnected mast portions which may be configured into a folded configuration when not in use. The mast may be lowered completely when not in use.

[0054] The main structural base may comprise support feet for supporting the system relative to a surface.

[0055] Furthermore, the main structural base may have dimensions roughly comparable to that of a standard shipping container of standard dimensions. All components associated with the drill system may be configured or configurable to fit within a footprint of a standard shipping container when not in use.

[0056] In accordance with a third aspect of the invention there is provided method of loading a rod onto a rod rotation unit of a drill system, the method comprising the steps of: a) providing a loading arrangement in accordance with the first aspect of the invention, the loading arrangement comprising at least a first magazine comprising or carrying a plurality of rods; a robotic arm; and a gripper fitted to the robotic arm; b) using the robotic arm and gripper to collect one of the plurality of rods from the at least first magazine; c) using the robotic arm and gripper to load the rod onto the rod rotation unit. Step b) may comprise at least some of the sub-steps of: b1 ) using the robotic arm to displace the gripper towards the first magazine; b2) configuring the gripper in a first configuration in which a first gripper unit is positioned in an operative position; b3) using the first gripper unit to grip onto a specific rod located in the at least first magazine; b4) displacing the rod towards a centralizer; b5) placing the rod in a predetermined location on the centralizer; b6) releasing the rod from the first gripper unit; b7) using the robotic arm to displace the gripper slightly away from the rod; b8) configuring the gripper in a second configuration in which a second gripper unit is positioned in an operative position; b9) using the second gripper unit to grip onto the specific rod located in the predetermined location on the centralizer; b10) using the robotic arm and gripper to displace the rod towards the rod rotation unit.

[0057] Step c) may include the sub-step of initiating an initial threading process by joining the rod to another rod held relative to the rod rotation unit.

[0058] BRIEF DESCRIPTION OF THE DRAWINGS

[0059] The invention will now be described in more detail, by way of example only, with reference to the accompanying drawings in which:

[0060] Figure 1 shows a top view of an automated drill system in accordance with the invention;

[0061] Figure 2 shows a top perspective view of the automated drill system of Figure 1 ;

[0062] Figure 3 shows a perspective view of a robotic arm and gripper which form part of an automated loading arrangement of the automated drill system of Figure 1 ;

[0063] Figure 4 shows a side view on a loading side of the automated drill system of Figure 1 , the system shown in use;

[0064] Figure 5 shows a side view on a drilling side of the automated drill system of Figure 1 , the system shown in a storage or non-operational configuration;

[0065] Figure 6 shows a side view on a drilling side of the automated drill system of Figure 1 , the system shown in use with a mast pivoted to an oblique angle relative to a surface on which the system is supported;

[0066] Figure 7 shows a side view on a drilling side of the automated drill system of Figure 1 , the system shown in use with a mast pivoted to a perpendicular angle relative to a surface on which the system is supported;

[0067] Figure 8 shows a perspective view of a gripper forming part of the automated drill system of Figure 1 ; and Figure 9 shows a side view of the gripper of Figure 8.

[0068] DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

[0069] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of "including," "comprising," or "having" and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms "mounted", "connected", "engaged" and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings and are thus intended to include direct connections between two members without any other members interposed therebetween and indirect connections between members in which one or more other members are interposed therebetween. Further, "connected" and "engaged" are not restricted to physical or mechanical connections or couplings. Additionally, the words "lower", "upper", "upward", "down" and "downward" designate directions in the drawings to which reference is made. The terminology includes the words specifically mentioned above, derivatives thereof, and words or similar import. It is noted that, as used in this specification and the appended claims, the singular forms "a," "an," and "the," and any singular use of any word, include plural referents unless expressly and unequivocally limited to one referent. As used herein, the term “include” and its grammatical variants are intended to be non-limiting, such that recitation of items in a list is not to the exclusion of other like items that can be substituted or added to the listed items.

[0070] Referring to the drawings, in which like numerals indicate like features, a non-limiting example of a drill system in accordance with the invention, is generally indicated by reference numeral 10. The drill system 10 comprises a main structural base 12 which supports various systems, assemblies and sub-systems and sub-assemblies. As will become apparent from the following, the drill system 10 is configured as an automated drill system. To this end, the drill system 10 includes a loading arrangement 14 which is discussed in greater detail below. Components of the loading arrangement 14 are supported by the main structural base 12, such that the main structural base 12 forms a structural base of the loading arrangement 14. That said, the loading arrangement 14 may alternatively comprise a self-contained unit which may comprise a separate structural base. This will not be discussed further. The system 10 furthermore comprises a mast 16 which is pivotably supported relative to the main structural base 12 and a rod rotation unit 18 which is supported relative to the mast 16. In use, the rod rotation unit 18 is used to rotate and thereby drive rods into the ground in known fashion.

[0071] The mast 16 if fixed relative to the main structural base 12 by means of a top cradle 20. An angle of the mast 16 relative to the main structural base 12 may be adjustable by means of a support ram arrangement (not referenced). A stay 22 may be provided for locking a position or angle of the mast in place.

[0072] The mast 16 comprises a linear base or track on which the rod rotation unit 18 is supported, such that same may be adjusted linearly relative to the mast 16 in use, when driving and advancing rods into the ground.

[0073] Typically, the mast 16 is made up of first and second interconnected mast portions comprising lattice structures. The first and second mast portions are interconnected and can pivot relative to each other to configure the mast 16 into a folded configuration when the system 10 is not in use (facilitating easy transportation of the system 10).

[0074] Adjustable support feet 24 support the main structural base 12 on a working surface. Typically, the support feet 24 comprise hydraulically actuated jacks which enable levelling of the main structural base 12. The use of alternative kinds of support feet, including automatically adjusted or self-levelling support feet is possible. Furthermore, mechanical stabiliser feet (not shown) may additionally be provided and typically positioned after levelling by the support feet 24 has been completed. The mechanical stabiliser feet may support the main structural base 12 in cases where the support feet 24 lose hydraulic pressure or experience hydraulic failure.

[0075] Typically, when not in use and therefore if all relevant systems and sub-systems are configured in a folded configuration, a footprint of the system 10 is similar to, or does exceed, that of a standard shipping container. In this way, the system 10 may be transported between sites by equipment configured for transporting shipping containers. In some cases, the system 10 may be configured for being received within a shipping container. The main structural base 12 therefore has dimensions which are roughly comparable to those of a standard shipping container.

[0076] The loading arrangement 14 comprises at least a first magazine 26 which operatively stores a plurality of rods 28. Even though the system 10 could theoretically operate with a single magazine, a preferred embodiment of the system 10, as shown in the figures, typically also comprises a second magazine 30. The first and second magazines are substantially similar, and any details provided in respect of the first magazine 26 will be taken to apply also to the second magazine 30, unless stated otherwise.

[0077] The loading arrangement 14 furthermore includes a robotic arm 32 and a gripper 34 which is fitted to the robotic arm 32. As discussed more fully below, the robotic arm 32 and gripper 34 are used sequentially to collect one of the rods 28 from one of the magazines (26, 30) and to present same to the rod rotation unit 18.

[0078] The robotic arm 32 may be a conventional robotic arm and may comprise first and second pivotably interconnected links (36, 38). The first link 36 is connected to a base 40 by way of a shoulder joint 42, which allows pivoting and revolving displacement of the first link 36 relative to the base 40.

[0079] The second link 38 is interconnected to the first link 36 by way of an elbow joint 44 which may allow pivoting displacement of the second link 38 relative to the first link 36. The gripper 34 is fixed relative to an end portion of the second link 38 by means of a wrist joint 46. The gripper 34 is configured to be rotatable relative to the first link 36. This may be achieved by either allowing the second link 38 to rotate axially or by allowing the wrist joint 43 to swivel relative to the first link. The base 40 is fixed to and / or supported by the main structural base 12.

[0080] The first magazine 26 comprises a main structure 48 and a first and second end portions (50, 52) supported by brace members 54. Side portions of the first magazine 26 between the braces 54 are substantially open and unobstructed to allow access to the rods 28 stored on the first magazine 26 (and therefore allow loading and unloading thereof using the gripper 34 as discussed more fully below). Even though the side portions are unobstructed, the rods 28 are loaded and unloaded to and from the magazine via an open top-end (as discussed below). The first magazine 26, and in particular the main structure 48, facilitates the carrying of rows 56 of stacks 58 of rods 28.

[0081] The first and second end portions (50, 52) comprise or define inward facing tracks 60 which receive end portions 62 of the rods 28 in use. The tracks 60 extend vertically relative to the end portions (50, 52) and a particular track 60 on one end portion 50 is associated with a particular track 60 on the opposite end portion 52 to form a pair of tracks between which a stack 58 of rods 28 is supported.

[0082] The tracks 60 are substantially U-shaped when viewed from the top and are defined between plates or bars 64. Neighbouring stacks 58 are therefore spaced apart roughly by the width of the plates or bars 64. The individual rods 28 of a particular stack 58 typically rest or lie directly on top of each other and in contact with each other. It will therefore be appreciated that the rods are stored in relatively close proximity to one another within the magazine. The significance of this is discussed more fully below. Generally, however, it will be appreciated that an overall size of the magazine 26 relative to the number of rods 28 carried therein may be optimised by storing the rods 28 in such close proximity. Also, the tracks 60 allow and facilitate the sequential removal of all the rods in a first stack 58 while an adjacent stack 58 remains supported and intact. The size of the magazine 26 and the number of rods 28 carried therein may vary. Typically, the magazine 26 comprises 5 to 10 (for example 7) rows 56 of stacks 58, while each stack 58 comprises 8 to 16 (for example 12) rods 28.

[0083] The main structure 48 includes hooks or connection points (not shown) which allow the magazine 26 to be lifted from and / or placed in position (typically by external means such as a crane). Alternatively, the magazines may be placed in position by means of a tractor-loader backhoe (TLB), forklift or the like. The magazine 26 is therefore supported in position, on top of the main structural base 12. Holding brackets (not shown) are provided to hold the magazine 26 in place relative to the structural base 12. The holding brackets are arranged to interact with corners of the magazine 26 and comprise flared out guide portions and open top ends to facilitate placing of the magazine 26 in position from the top.

[0084] It will be appreciated that the holding brackets may secure and locate the magazine 26 in a very specific location relative to the main structural base 12 and therefore relative to the robotic arm 32. In this way, the positions of the rods relative to the robotic arm 32 is predetermined and known, which facilitates accuracy and efficiency when it comes to the handling of the rods 28 by the robotic arm 32 and gripper 34. More is said about this below.

[0085] The magazine 26 include reference or “teaching” points (not shown) with which a position of the gripper and / or robotic arm 32 may be calibrated. The robotic arm may therefore be equipped with a measuring or sensing device with which a position of the reference or teaching points may be ascertained. It is foreseen that intermittent recalibration of the gripper and / or robotic arm 32 may become necessary over time, as some of the components become slightly worn due to cyclic loads and normal use.

[0086] The first and second magazines (26, 30) are typically located on opposite sides of the robotic arm 32.

[0087] The gripper 34 comprises a gripper assembly made up of a first gripper unit 70 and a second gripper unit 72. The first and second gripper units (70, 72) are typically offset from one another, such that only one can be used at a time. In a preferred embodiment, the first and second gripper units (70, 72) are offset by about 180 degrees from one another, such that rotation of the gripper 34 through 180 degrees may rotate the gripper from a first position, in which the first gripper unit 70 is in an operational position, to a second position, in which the second gripper unit 72 is in an operational position.

[0088] The first gripper unit 70 comprises electromagnetic contacts or contact shoes 74. Therefore, in use, an electrical current is provided to the contact shoes 74 to activate same and cause same to attract a metallic rod 28 by means of electromagnetism. Upon terminating the current, the rod 28 may be released. In an alternative embodiment (not shown), the electromagnetic contact shoes may be replaced by pneumatic suction cups, which may suck onto the rods to grip same. Reference is now made specifically to figures 8 and 9, which show a preferred embodiment of the gripper 34. The second gripper unit 72 comprises a mechanical jaw or clamp 82 arrangement comprising a first and second jaw (84, 86) which are configurable between open and closed configurations. The first jaw 84 is provided with a first set of rollers 88, while the second jaw 86 is provided with a second and third sets of rollers (90, 92). The second gripper unit 72 may therefore be used physically to clamp onto a particular one of the rods, typically, by receiving the rod between the first to third sets of rollers (88, 90, 92). At least some, or all, of the rollers are driven, and may be used to impart a torque onto the rod, as discussed more fully below.

[0089] The second gripper unit 72 also comprises a rod supporting guide arrangement 94 with first and second (substantially U-shaped) guides (96, 98). The first and second guides (96, 98) have different sizes, and one of the first and second guides (96, 98) may be rotated into an operative position, depending on a size of the rod handled by the second gripper unit 72.

[0090] The significance of the fact that the gripper 34 comprises two separate gripper units, and indeed, structurally different gripper units, will become apparent from what follows.

[0091] The loading arrangement 14 also includes a centralizer 76. As discussed more fully below, the centralizer 76 provides an intermediate support for temporarily supporting the rod 28 during the loading process. More particularly, the centralizer 76 provides a support surface on top of which the rod 28 is temporarily placed by the gripper 34 using the first gripping unit 70, to allow the gripper to be rotated into the second position following which the rod 28 is picked up again using the second gripper unit 72. The centraliser therefore facilitates a switch between using the first and second gripper units (70, 72).

[0092] The centralizer 76 comprises a stand 78 which is pivotably fixed relative to the main structural base 12 and a receiving portion 80 on top of which the rod 28 is supported as discussed. The stand 78 may be pivoted out of an operative position when not in use, to limit the physical footprint of the system 10.

[0093] The receiving portion 80 is associated with an exact and known location, position and / or orientation relative to the robot arm and / or the rod rotation unit 18. Therefore, by placing a rod 28 on top of the receiving portion 80, the exact position and orientation of the rod 28 is known. The rod may therefore be located and centralized using the receiving portion 80.

[0094] The receiving portion 80 of the centralizer 76 comprises first and second sets of rollers (not referenced) which are configured to allow a rod supported thereon to roll in an axial direction. Each set of rollers comprises two rollers arranged in a V-shape to allow receiving the rod thereon. The first and second sets of rollers may be vertically offset relative to each other, such that a rod supported thereon is supported slightly offset from a horizontal orientation. The centralizer also comprises a stopper against which an end of the rod operatively and positively rests. When a rod is placed on the receiving portion 80, the sets of rollers cause the rod roll downward under gravity, until the end of the rod contacts the stopper.

[0095] The centralizer furthermore comprises a proximity sensor which is configured positively to sense a rod which is supported in the particular position and / or orientation. The proximity sensor therefore indicates when a rod contacts the stopper. In this way the precise location of the rod is ascertainable.

[0096] In use, a single rod 28 is removed from the magazine 26 according to the following steps:

[0097] Firstly, the gripper 34 is configured into the first position such that the first gripper unit 70 is in the operative position. If the gripper 34 is not yet so configured, the gripper 34 may therefore typically be rotated through 180 degrees.

[0098] Secondly, the robotic arm 32 is manipulated to displace the gripper 34 towards the first magazine 26. The system 10 keeps track of the status of each magazine and therefore displaces the electromagnetic contact shoes 74 towards or even into contact with, the next available rod 28. The use of the robotic arm 32 and the electromagnetic contact shoes 74 of the first gripper unit 70 allow very accurate engagement with the rod 28.

[0099] Thirdly, the electromagnetic shoes 74 are activated to attract or grip onto the rod 28, and same is lifted upward and out of the relevant pair of tracks 60.

[0100] It will be appreciated that the first gripper 70 does not use mechanical clamping means to grip the rods 28. As a direct consequence of this, the rods may be placed in close proximity to each other, and even in direct contact with each other, as aforementioned. The electromagnetic shoes 74 merely require a small contact area to grip a specific one of the rods 28. In the absence of using the first gripper unit 70 to retrieve rods 28 from the magazine 26, spacings between rods 28 would have had to be larger to allow insertion of clamp jaws between rods 28. This would, in turn, have resulted in a lower number of rods 28 carried by the magazine 26 and therefore more frequent magazine changes in use (which would have lowered overall efficiency). The use of the first gripper therefore enables and facilitates larger numbers of rods 28 to be stored in the magazine 26.

[0101] Furthermore, the use of the electromagnetic shoes 74 ensures precise placement of the rods onto the centralizer 76 which is essential for the subsequent loading and drilling processes.

[0102] The incorporation of the centraliser 76 and the electromagnetic first gripper unit 70 is essential for enhancing efficiency of the loading arrangement 14 and the system 10 as a whole, maximizing rod 28 capacity of the magazine 26 and ensuring precise handling of the rods 28 during the downstream loading and drilling operations. This approach therefore streamlines the system 10 as a whole and minimises downtime, ultimately contributing to improved productivity and cost-effectiveness. Following the third step mentioned above, the rod 28 is accurately placed on the receiving portion 80 and the electromagnetic shoes 74 are released. As discussed above, the rod may be displaced under the influence of gravity and may therefore now be in a predetermined position.

[0103] The robotic arm 32 and gripper 34 are moved away slightly and the gripper is reconfigured to place or configure the second gripper unit 72 into the operative position.

[0104] The rod 28 is now gripped by the jaws (or rather, between the first, second and third sets of rollers (88, 90, 92) of the second gripper unit 72 and the rod is displaced towards the rod rotation unit 18.

[0105] The importance of accurate placement and gripping of the rod 28 stems from the complex and precise nature of the loading (or threading) and drilling activities performed by the system 10. It should be noted that simply picking up a rod 28 with a gripper and displacing same directly towards the rod rotation unit 18 would not result in an accurate enough threading process, which could potentially lead to downtime and further inefficiencies. “Regripping” of the rod 28 therefore plays a crucial part in the efficiency of the process. This is because the gripper 34 is involved in the loading process of the rod 28. More particularly, in addition to transporting the rod 28 towards the rod rotation unit 18, the gripper 34 is also used to initiate the treading process of the rod 28 (by exerting the torque on the rod, as aforementioned), which involves joining or coupling the rod 28 to other rods already or previously loaded or threaded. This process requires thread compatibility and alignment of the different rods 28, which can only be achieved by accurately handling the rod 28 as aforementioned.

[0106] The compatibility or alignment of the threads is essential to ensure thread and connection integrity, and to avoid stripping or cross threading the rods 28, which could compromise the structural integrity of the assembled components, leading to potential failures or safety hazards.

[0107] Furthermore, threading involves a coordinated process where the gripper 34, robotic arm 32 and feed cylinder work in tandem. Each component needs to move at a predetermined speed and rate to ensure that the thread is formed correctly. Any substantial or significant misalignment or deviation in the movement of these elements could result in defective threading and subsequently render the rod 28 unusable.

[0108] Once the rod 28 is successfully loaded, the gripper 34 may be released and the loading process outlined above may be repeated for a next sequence of loading.

[0109] Once all the rods 28 of the first magazine 26 are depleted, rods from the second magazine 30 may be loaded. If necessary, the first magazine 26 may in the meanwhile be replaced by a replenished magazine (not shown).

[0110] Alternatively, in some cases, the different magazines (26, 30) may hold rods of different kind and function, and the loading of the rods 28 may be based on the type of rod required for a particular part of the process. For example, the first magazine 26 may be loaded with HQ / NQ and / or NWS Casings. During an initial drilling phase, HQ rods may be used for drilling and to break through a surface layer. The NWS casings, on the other hand, may be inserted to stabilize walls of the hole, ensuring it remains intact during subsequent drilling stages.

[0111] After the initial drilling and casing process, the remainder of the drilling operation is conducted using NQ rods obtained from the second magazine 30.

[0112] It will be appreciated that the above description only provides an example embodiment of the invention and that there may be many variations without departing from the spirit and / or the scope of the invention.

[0113] In some examples, all or most of the hydraulic and drive systems may be arranged in a self- contained "power pack” which may be easily removed from the main support structure and replaced by a standby power pack. This may reduce down-time associated with drive system or hydraulic failures. It is foreseen that the system, as part of the power pack, or separate therefrom, may include one or more hydraulic fluid accumulators, which may supply surplus volumes of pressurised hydraulic fluid to onboard hydraulic systems. This may reduce power supply requirements of motors driving hydraulic pumps, particularly during start-up and transient operating periods. It is believed that the use of the accumulator(s) may positively affect the rate at which hydraulic cylinders, such as those driving the rotation unit, are driven, without requiring larger drive motors.

[0114] It will be easily understood from the present description that the particular features of the present invention, as generally described and illustrated in the figures, can be arranged and designed according to a wide variety of different configurations. In this way, the description of the present invention and the related figures are not provided to limit the scope of the invention but simply represent selected embodiments.

[0115] The skilled person will understand that the technical characteristics of a given embodiment can in fact be combined with characteristics of another embodiment, unless otherwise expressed or it is evident that these characteristics are incompatible. Also, the technical characteristics described one embodiment can be isolated from the other characteristics of this embodiment unless otherwise expressed.

Claims

CLAIMS1 . A loading arrangement for a drill system comprising a mast and a rod rotation unit, the loading arrangement comprising: at least a first magazine comprising a plurality of rods; a robotic arm; and a gripper fitted to the robotic arm, wherein the robotic arm and gripper are configured operatively and sequentially to collect one of the plurality of rods from the magazine and present same to the rod rotation unit.

2. The loading arrangement according to claim 1 , wherein the robotic arm comprises at least a first and second pivotably interconnected links, wherein the first link is connected by way of a shoulder to a base, which shoulder allows pivoting and revolving displacement of the first link relative to the base; the second link is interconnected to the first link by way of an elbow joint which allows pivoting displacement of the second link relative to the first link; the gripper is fixed relative to an end portion of the second link by means of a wrist joint; one of the elbow joint, second link and wrist joint facilitates swivelling of the gripper relative to the first link; and the base of the robot arm is fixed to and / or supported by a structural base of the loading arrangement.

3. The loading arrangement according to claim 1 , wherein the first magazine comprises a main structure which facilitates carrying rows of stacks of rods and loading and unloading of rods via an open top thereof.

4. The loading arrangement according to claim 3, wherein first and second end portions of the main structure comprise inward-facing tracks provided for receiving end portions of the rods, with a particular track on the first end portion and a corresponding track on the second end portion forming a pair of facing tracks.

5. The loading arrangement according to claim 4, wherein the tracks are substantially U- shaped and extend substantially vertically, such that rods received by a particular pair of tracks form a substantially vertically extending stack of rods, with rods within a stack physically lying in contact with and on top of one another.

6. The loading arrangement according to claim 4, wherein the tracks are formed between plates or bars extending relative to the end-portions and wherein, in use, neighbouring stacks are spaced apart by a width of the plates or bars forming the tracks.

7. The loading arrangement according to claim 3, wherein the first magazine is configured with a substantially unobstructed and open side to allow the gripper access to the rods of a stack.

8. The loading arrangement according to claim 3, wherein the first magazine is configured to carry between 5 and 10 rows of stacks of rods, and wherein each stack comprises between 8 and 15 rods.

9. The loading arrangement according to claim 2, wherein the structural base comprises holding brackets for receiving the first magazine and locating same relative to the structural base, wherein the holding brackets have open ended top portions to allow loading the magazine there onto from the top, and wherein the holding brackets comprise outward flaring guide portions to facilitate loading of the magazine from the top.

10. The loading arrangement according to claim 1 , wherein the magazine comprises at least one reference or teaching point with which a position of the gripper and / or robotic arm is operatively calibrated relative to the magazine.1 1. The loading arrangement according to claim 1 , further comprising a second magazine comprising a plurality of rods.

12. The loading arrangement according to claim 11 , wherein the first and second magazines are operatively located on opposite sides of the robotic arm.

13. The loading arrangement according to claim 1 , wherein the gripper takes the form of a gripper assembly comprising a first gripper unit and a second gripper unit.

14. The loading arrangement according to claim 13, wherein the first gripper unit comprises a plurality of attracting contacts in the form of one of i) electromagnetic contacts; and ii) pneumatic suction contacts, and wherein the attracting contacts are configurable to attract a rod when proximate or in contact therewith.

15. The loading arrangement according to claim 13, wherein the second gripper unit comprises a mechanical jaw or clamp arrangement which is configurable between open and closed configurations, wherein the second gripper unit is configured to clamp or grab onto a rod when the mechanical jaw or clamp arrangement is configured towards the closed configuration.

16. The loading arrangement according to claim 15, wherein the mechanical jaw or clamp arrangement comprises first and second jaws, the first jaw comprising a first set of rollers and the second jaw comprising a second and third set of rollers, the configuration such that a modulated clamping force is operatively exerted by the respective sets of rollers on a rod clamped therebetween.

17. The loading arrangement according to claim 16, wherein the respective sets of rollers are arranged and configured to allow axial rotation of a rod clamped by the second gripper unit.

18. The loading arrangement according to claim 16, wherein at least some of the rollers are driven rollers to facilitate operative transmitting of torque to a rod clamped between the respective sets of rollers.

19. The loading arrangement according to claim 13, wherein the second gripper unit comprises a rod supporting guide mechanism, having first and second guides, arranged and configured operatively to contact, guide and / or support a rod.

20. The loading arrangement according to claim 19, wherein the guides are substantially U- shaped.21 . The loading arrangement according to claim 19, wherein the first and second guides have different sizes to accommodate the use of rods having different diameters.

22. The loading arrangement according to claim 19, wherein the rod supporting guide mechanism is rotatable to allow one of the first and second guides to be positioned in an operative position.

23. The loading arrangement according to claim 13, wherein the gripper assembly rotatably fitted relative to the robotic arm to allow the gripper assembly operatively to be rotated through 180 degrees between a first position, in which the first gripper unit is in an operative position, and a second position, in which the second gripper is in an operative position.

24. The loading arrangement according to claim 1 , further comprising a centralizer.

25. The loading arrangement according to claim 24, wherein the centralizer comprises a centralizer stand with a receiving portion configured for receiving a single rod during an intermediate process of a loading sequence of the loading arrangement.

26. The loading arrangement according to claim 25, wherein the centralizer stand is pivotably supported relative to a structural base of the loading arrangement.

27. The loading arrangement according to claim 25, wherein the receiving portion is associated with an exact and known location relative to the robot arm and wherein the receiving portion is configured to locate the rod by receiving same in a particular position and / or orientation only.

28. The loading arrangement according to claim 27, wherein the centralizer comprises first and second sets of rollers which are configured to allow a rod supported thereon to be displaced in an axial direction.

29. The loading arrangement according to claim 28, wherein the first and second sets of rollers are vertically offset relative to each other, such that a rod operatively supported thereon is supported slightly offset from a horizontal orientation.

30. The loading arrangement according to claim 28, wherein the centralizer comprises a stopper against which an end of the rod operatively and positively rests and a proximitysensor which is configured positively to sense a rod which is supported in the particular position and / or orientation.31 . A drill system comprising: a main structural base; a loading arrangement according to claim 1 , wherein the main structural base of the drill system forms a structural base of the loading arrangement; a mast supported relative to the main structural base; and a rod rotation unit supported relative to the mast.

32. The drill system according to claim 31 , wherein the mast: is pivotably supported relative to the main structural base, such that an angle of the mast relative to the main structural base is operatively variable; is supported by a support cylinder / piston arrangement with which an angle of the mast relative to the main structural base is operatively varied; and defines a linear base on which the rod rotation unit is supported in use, such that the rod rotation unit is linearly displaceable relative to the mast.

33. The drill system according to claim 31 , wherein the main structural base: comprises support feet for supporting the system relative to a surface; has dimensions roughly comparable to that of a standard shipping container of standard dimensions, wherein all components associated with the drill system are configured or configurable to fit within a footprint of a standard shipping container when not in use.

34. A method of loading a rod onto a rod rotation unit of a drill system, the method comprising the steps of: a) providing a loading arrangement in accordance with claim 1 , the loading arrangement comprising at least a first magazine comprising a plurality of rods, a robotic arm and a gripper fitted to the robotic arm; b) using the robotic arm and gripper to collect one of the plurality of rods from the at least first magazine; c) using the robotic arm and gripper to load the rod onto the rod rotation unit.

35. The method according to claim 34, wherein step b) comprises the sub-steps of: b1 ) using the robotic arm to displace the gripper towards the first magazine; b2) configuring the gripper in a first configuration in which a first gripper unit is positioned in an operative position; b3) using the first gripper unit to grip onto a specific rod located in the at least first magazine; b4) displacing the rod towards a centralizer;b5) placing the rod in a predetermined location on the centralizer; b6) releasing the rod from the first gripper unit; b7) using the robotic arm to displace the gripper slightly away from the rod; b8) configuring the gripper in a second configuration in which a second gripper unit is positioned in an operative position; b9) using the second gripper unit to grip onto the specific rod located in the predetermined location on the centralizer; b10) using the robotic arm and gripper to displace the rod towards the rod rotation unit.

36. The method according to claim 34, wherein step c) includes the sub-step initiating an initial threading process by joining the rod to another rod held relative to the rod rotation unit.

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