Carousel Drilling System for Rapid Tool Changeovers
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Solution Overview
Problem
Existing carousel drilling systems are inefficient and labor-intensive when switching between different drill tools and extenders, requiring manual removal and reattachment of long, heavy drill tools and extenders, which is time-consuming and requires substantial manpower.
Innovation Solution
The system includes a drill tower with a pivotable carousel that supports multiple drill extenders and tools, featuring primary and secondary breaker plates to facilitate quick attachment and detachment of drill extenders and tools, allowing for rapid changeovers with minimal effort and time, by providing additional engagement points to restrain and release the drilling devices during the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual removal and reattachment of drill tools and extenders is used, then the drilling operation can continue, but the process is time-consuming and requires substantial manpower
Solution Approach 1:
The system segments the drill string into modular components (drill tools and extenders) that can be independently handled and quickly exchanged. The carousel divides drill extenders into individual slots, allowing selective retrieval without moving the entire drill string, thus reducing tool change time while maintaining drilling continuity.
Solution Approach 2:
Drill extenders are pre-positioned in the carousel in ready-to-use configurations. The carousel maintains a supply of pre-assembled drill extender combinations, so when a tool change is needed, the next extender is already positioned and can be rapidly attached without time-consuming assembly operations.
2Productivity
If manual removal and reattachment of drill tools and extenders is used, then the drilling operation can continue, but substantial manpower is required
Solution Approach 1:
The carousel acts as an intermediary device between the drill string and the drill tools. It provides mechanical support and positioning for drill extenders, reducing the manual effort needed to handle heavy tools. The breaker plate mechanism serves as a mediator that automatically engages and disengages extenders, minimizing the physical strain on operators.
Solution Approach 2:
The system incorporates self-servicing features where the drill string's own weight and the breaker plate mechanism facilitate the attachment and detachment processes. The breaker plate automatically engages with the drill extender's flats to prevent rotation during threading, and the heavy extenders are lowered under their own weight rather than requiring manual lifting.
3Productivity
If drill extenders are made long (25-30 feet) to reduce frequency of changes, then fewer changes are needed, but shifting and handling becomes more difficult
Solution Approach 1:
The system segments the handling task by providing a carousel with multiple slots, each holding a separate drill extender. This allows operators to work with one extender at a time in a controlled manner, rather than attempting to move multiple long extenders simultaneously. The modular slot design breaks down the handling complexity into manageable discrete actions.
Solution Approach 2:
The carousel serves as an intermediary support structure that bears the weight and provides stable positioning for long drill extenders. The breaker plate acts as a mediator that provides mechanical advantage during attachment, using the extender's own geometry (flats) to create leverage points that reduce the effort needed to handle and position the long extenders.
Data Source
AI summary
A method and apparatus for carousel drilling, which includes a drill tower having a rotatable drive motor at the top, and a carousel pivotably attached with respect to the drill tower and capable of supporting four elongated drilling devices, at least certain of which are drill extenders capable of attachment to, and detachment from, a drilling tool. A retainer plate is located at the upper end portion of the carousel to receive and retain the drilling devices in a generally vertical orientation when the drill tower and the carousel are raised to a generally vertical orientation for operative drilling. A primary breaker plate is provided for individually receiving and engaging each drilling device at the lower end portion of the carousel. A secondary breaker plate is located above the primary breaker plate for individually receiving the four drilling devices.