Drill Rig Rod Handling Conveyor Automation
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Solution Overview
Problem
Existing drill rigs face inefficiencies in handling drill rods, particularly in deep diamond core drilling, leading to high cycle rates and potential injuries due to manual handling, and existing rod handling systems like rod pushers cause uneven rope spooling and other issues.
Innovation Solution
A rod handling apparatus for drill rigs featuring a conveyor assembly with a linkage system, drive assembly, and winch mechanism that automates the handling of drill rods, allowing for secure attachment and detachment from the drill string, minimizing manual handling and injuries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual handling of drill rods is used, then flexibility and simplicity are maintained, but productivity is reduced and safety risks increase
Solution Approach 1:
The conveyor assembly is equipped with its own drive assembly that includes a winch mechanism, allowing it to autonomously transport drill rods along the mast without requiring manual intervention or external hoisting equipment. The conveyor can independently position itself and perform rod handling operations.
Solution Approach 2:
The conveyor assembly acts as an intermediary device between the drill rod storage area and the drill string assembly point. It mediates the transfer of drill rods by providing a controlled, automated conveyance system that bridges the gap between manual operations and the drilling process.
2Ease of operation
If rod pushers are used to assist drill rod movement, then ease of operation is improved, but harmful factors are introduced through uneven rope spooling
Solution Approach 1:
The patent replaces the rod pusher's mechanical pushing action with a conveyor-based system that uses controlled winching and belt conveyance. This substitution eliminates the rope spooling issues inherent in pusher systems while maintaining the ability to assist drill rod movement throughout the mast height.
Solution Approach 2:
The conveyor assembly serves as an intermediary that provides controlled, gradual movement of drill rods through the mast, replacing the direct pusher-to-rod interaction that causes rope spooling problems. The conveyor mediates the force application to ensure uniform and controlled rod advancement.
3Productivity
If automated conveyor assembly is implemented, then productivity and safety are improved, but device complexity increases
Solution Approach 1:
The conveyor assembly is designed as a multi-functional unit that combines rod conveyance, self-positioning via winch, and integration with the drill rig's existing hoisting system. This universal design allows a single device to perform multiple operations that would otherwise require separate systems, justifying the complexity through functional consolidation.
Solution Approach 2:
The patent merges the conveyor mechanism with the drill rig's existing mast structure and hoisting winch system. The conveyor's drive assembly integrates with the rig's available infrastructure, combining multiple functions into a unified system that leverages existing components rather than requiring entirely separate systems.
4Productivity
If main haul winch is used for rod extraction, then existing equipment is utilized, but productivity is limited by winch capacity and cycle time
Solution Approach 1:
The conveyor assembly performs preliminary actions by pre-positioning drill rods along the mast and maintaining them in ready positions before they are needed for drilling operations. This preliminary preparation eliminates waiting time and allows the main haul winch to operate continuously at full capacity without interruption for rod retrieval.
Solution Approach 2:
The conveyor system enables continuous useful action by maintaining a steady supply of drill rods in position throughout the mast, allowing the drilling operation to proceed without interruption. The conveyor operates continuously to feed rods as needed, eliminating the stop-start nature of traditional winch-based rod retrieval and ensuring uninterrupted drilling progress.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The apparatus reduces manual handling of drill rods, enhances efficiency in rod handling operations, and minimizes injuries by providing a fully automated system that ensures secure and efficient attachment and detachment of drill rods.
Implementation Method 1
a winch assembly for winching the guide trolley along the pair of rails
Implementation Method 2
conveying a drill rod up and/or down the drill rig mast
Data Source
Figure 1
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AI summary
The present invention relates to a rod handling apparatus for a drill rig including a drill rig mast and a hoisting winch. The rod handling apparatus including: a base assembly; a frame assembly coupled to the base assembly, the frame assembly including a pair of rails along which a conveyor assembly is adapted to travel along; and, the conveyor assembly adapted to be coupled to the hoisting winch for conveying a drill rod up and/or down the drill rig mast such that the drill rod is attachable to and/or detachable from a drill string.