Carousel Bit Changer Assembly for Compact Drill Rig Automation

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Solution Overview

Problem

Automating the drill bit changing process in mobile drill rigs is challenging due to limited rig space and the need for a compact, reliable, and safe system that can handle extreme conditions, while also reducing human interaction to enhance safety and efficiency.

Innovation Solution

A combined deck wrench and bit changing mechanism that includes a slewing/sliding group, carousel weldment, and bit breaker group, capable of storing and handling multiple bits, and designed to fit within the limited space of a drill rig, allowing for automated bit replacement and storage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual bit changing is performed by mechanic and operator, then bit replacement can be completed, but safety risks increase and efficiency decreases due to human interaction with heavy drill bits in confined spaces

Engineering Contradiction:

ImprovesafetyVSAvoidefficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The automated bit changing system performs bit replacement operations autonomously without human intervention. The mechanism includes automated bit storage, retrieval, and installation components that operate independently, allowing the drill rig to service itself during bit changes, thereby eliminating safety risks associated with manual handling while maintaining operational efficiency

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces the manual mechanical process of bit changing with an automated mechanical system. The automated mechanism uses controlled mechanical components such as grippers, conveyors, and positioning systems to handle and install bits, substituting human operators and eliminating the need for mechanics to manually manipulate heavy drill bits in confined spaces

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If automated bit changing system is implemented, then safety improves and efficiency increases, but rig space requirements increase

Engineering Contradiction:

ImproveefficiencyVSAvoidrig space

Core Design Contradiction:

ProductivityVSArea of stationary object

Solution Approach 1:

The automated bit changing system is designed with nested components where smaller functional units are integrated within larger structural elements. The bit storage carousel is positioned within or adjacent to the deck wrench assembly, and various mechanical components are arranged in a compact, space-efficient configuration that minimizes the overall footprint on the drill rig while maintaining full automation functionality

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The patent utilizes three-dimensional space optimization by arranging components vertically and radially rather than only linearly. The carousel configuration allows bits to be stored in multiple positions around a central axis, and the mechanism uses vertical movement and radial positioning to access and install bits, effectively utilizing available space in multiple dimensions to reduce the system's horizontal footprint

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Area of stationary object

If automated bit changing mechanism is designed to be compact, then rig space is reduced, but system complexity increases

Engineering Contradiction:

Improverig spaceVSAvoidsystem complexity

Core Design Contradiction:

Area of stationary objectVSDevice complexity

Solution Approach 1:

The patent combines multiple functions into integrated assemblies. The deck wrench assembly is merged with the bit storage and handling mechanism, creating a unified system that performs both bit storage and bit installation functions. This consolidation reduces the number of separate components and interfaces, thereby managing system complexity while achieving compact dimensions

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The automated bit changing mechanism is designed with universal components that perform multiple functions. The carousel serves both as a storage structure and as a positioning mechanism, while the gripper system handles both bit retrieval and bit installation. This multi-functionality reduces the number of dedicated components needed, simplifying the overall system while maintaining compact size

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS20260049530A1Automated bit handling and changing system and process

Publication Date: 2026.02.19 SANDVIK MINING & CONSTRUCTION USA LLC

AI summary

A drill bit handling and changing system includes a deck wrench assembly mounted on a deck of a mast of a drill rig and arranged to break the bit from a drill pipe of the rig, and a bit changing mechanism slidably disposed on the deck wrench assembly between a standby position and an engaged position where the bit changing mechanism is centered with the drill bit and/or drill pipe. The bit changing mechanism includes a carousel having a plurality of receptacles, at least one of the receptacles being empty to receive a used drill bit and at least two receptacles holding new drill bits to be connected with the drill pipe after the used drill bit is removed from the drill string. The bit changing mechanism includes a slewing drive arranged to rotate the carousel to present an empty receptacle or a new drill bit to the drill pipe.