BREAKOUT SYSTEM FOR A DRILL

Abstract

A breakout system for a drill includes a first wrench, a second wrench, and an actuator for applying a torque to rotate the second wrench relative to the first wrench. The first wrench includes a first clamp member for engaging a portion of a drill string. The first wrench further includes an open side and is supported on a mast of the drill in an orientation to permit viewing the first clamp member from an operator cab of the drill. The second wrench is supported for movement relative to the first wrench. The second wrench includes a second clamp member for engaging another portion of the drill string, includes an open side, and is supported on the mast in an orientation to permit viewing the second clamp member from the operator cab. The first and second clamp members may be configured to pivot outward relative to at least one wrench.

Description

TECHNICAL FIELD

The present disclosure relates to industrial drills, and more particularly to a breakout system on a surface-type mining drill.

BACKGROUND

Industrial drills (e.g., mining drills, oil field drills, drills for exploration, etc.) may be used to drill through rock. A surface-type mining drill typically includes a base, a boom, a drill tower or mast, and an operator cab. This construction is typically configured to support a drill string to extend from the mast into the ground surface to form a borehole. The drill string is typically assembled in the drill by connectable sections to increase the length of the drill string as it penetrates further into the ground. When the hole has been drilled to the desired depth, the sections of the drill string may be raised, disassembled, and removed from the drill.

SUMMARY

A breakout wrench is typically configured to separate the sections of the drill string. During operation, the breakout wrench applies sufficient torque to adjacent sections of the drill string to break apart the sections. The breakout wrench or breakout table may be coupled to the base or the mast at a location in front of the operator cab. An operator may need to monitor the operation of the breakout wrench, and a technician may need to maintain the breakout wrench, in particular when replacing wear parts of the breakout wrench. Many known breakout wrenches are fully enclosed such that clamps and other wearable parts are not easily accessible or visible to a technician or operator. In some cases, the breakout wrench is located on the drill such that an operator in an operator cab does not have a desirable view of the breakout wrench from the cab.

The breakout wrench herein may provide improved visibility to an operator and may provide improved access to interior components for servicing.

In one independent aspect, a breakout system is provided for an industrial drill including a mast. The industrial drill may have a drill string having a drill pipe. The breakout system includes a first wrench, a second wrench, and a wrench actuator for applying a torque to rotate the second wrench relative to the first wrench. The first wrench is designed to be coupled to the mast. The first wrench has a wrench body having a first opening configured to receive the drill string therethrough. The wrench body has an upper portion and a first side wall. The first side wall is pivotably coupled to the upper portion. the second wrench includes a second opening configured to receive the drill string therethrough. The wrench actuator is designed to apply a torque to rotate one of the first wrench and the second wrench relative to the other of the first wrench and the second wrench. The breakout system further includes at least one clamp including a first clamp and a second clamp, wherein at least one of the first clamp and the second clamp is supported on the first side wall of the first wrench for movement relative to the wrench body. The breakout system also includes a clamp actuator for driving the first clamp and the second clamp to engage at least a portion of the drill string passing through the first opening and the second opening.

In some aspects, the at least one clamp member is designed for engaging a portion or section of the drill string. The first wrench further includes an open side. The first wrench is supported on or coupled to the mast in an orientation that permits viewing of the first clamp member from an operator cab through the open side.

In some aspects, the second wrench is supported or coupled to the mast to enable movement relative to the first wrench. The second wrench can also be coupled to the first wrench. The second wrench includes a second opening configured to receive the drill string therethrough and a second clamp member for engaging another portion or section of the drill string. The second wrench further includes a second open side, and the second wrench is supported on or coupled to the mast in an orientation to permit viewing the second clamp member from the operator cab.

In some aspects, the second wrench is configured to rotate relative to the first wrench between approximately 10 degrees and approximately 20 degrees about an axis that is substantially parallel to the drill string. The second open side of the second wrench is configured to move in a direction toward the operator cab as the second wrench is rotated.

In some aspects, the second wrench is configured to rotate relative to the first wrench by at least 10 degrees about an axis that is substantially parallel to the drill string.

In some aspects, the first wrench is secured against movement relative to the mast.

In some aspects, the second open side of the second wrench is configured to move in a direction toward the operator cab as the second wrench is rotated.

In some aspects, the first wrench includes a wrench body, the first clamp member being supported for pivoting movement relative to the wrench body.

In some aspects, the wrench body includes an upper portion or a lower portion and a side wall that is pivotably coupled to the upper portion or pivotably coupled to the lower portion by a hinge, wherein the clamp member is supported on the side wall.

In some aspects, the first clamp member includes a first tool with a first axis and a second tool with a second axis, wherein, during a clamping operation of the first wrench, the first axis is parallel to the second axis, and wherein, during the clamping operation of the first wrench. The first axis and the second axis are arranged at an oblique angle to a longitudinal axis of the industrial machine.

In some aspects, the first clamp member includes a first tool and a second tool, wherein, during a clamping operation of the first wrench, the first tool is at a first orthogonal distance to a longitudinal plane of the mast and the second tool is at a second orthogonal distance to the longitudinal plane of the mast, and wherein the first distance is greater than the second distance.

In some aspects, the first clamp member includes a first tool and a second tool, wherein, during a clamping operation of the first wrench, a first tool location, a second tool location, and a view point in an operator window are arranged in a triangular configuration such that a first angle at the view point is between about 5 degrees and about 45 degrees.

In some aspects, the first clamp member includes a first tool and a second tool, wherein, during a clamping operation of the first wrench, a first tool location and a second tool location are located a third distance apart and in a first vertical plane, and a view point in an operator window is located in a second vertical plane transverse to a longitudinal axis of the industrial machine, wherein, during the clamping operation, a view area of the second vertical plane is defined by the fourth distance, wherein the fourth distance is defined between a first intersection of a first orthogonal line from the first tool location to the second vertical plane and a second intersection of a second orthogonal line from the second tool location to the second vertical plane, and wherein the fourth distance is at least 10 percent of the third distance.

In some aspects, the first clamp member includes a first tool with a first axis and a second tool with a second axis, wherein, during a clamping operation of the first wrench, the first axis is parallel to the second axis, and wherein, during the clamping operation of the first wrench, the first axis and the second axis both extend away from a longitudinal plane of the mast and a transverse plane within which an operator viewpoint of the operator cab is disposed.

In another independent aspect, a breakout system is provided for an industrial drill including a mast. The drill may have a drill string having a drill pipe. The breakout system includes a first wrench, a second wrench, and a wrench actuator for applying a torque to rotate one of the first wrench and the second wrench relative to the other of the first wrench and the second wrench or to rotate the second wrench relative to the first wrench. The first wrench is configured to be coupled to the mast. The first wrench includes a wrench body having a first opening configured to receive the drill string therethrough. The second wrench includes a second opening configured to receive the drill string therethrough. The breakout system further includes at least one clamp configured to engage a portion of the drill string passing through the first opening and the second opening, and a clamp actuator for driving the at least one clamp to engage the portion of the drill string. The clamp actuator is supported for movement relative to the wrench body. Further, the second wrench is supported for movement relative to the first wrench, and the second wrench includes a second clamp for engaging another portion or section of the drill string.

In some aspects, the clamp actuator is supported on the first side wall of the first wrench. The first side wall is designed to pivot outward from the wrench body of the first wrench to provide access to an interior of the wrench body of the first wrench.

In other aspects, the at least one clamp is accessible for service when the first side wall is pivoted outward from the wrench body of the first wrench.

In some aspects, the second wrench has a second wrench body having a lower portion and a second side wall that is pivotably coupled to the lower portion, and the second side wall has a first surface designed to support the second clamp and the second side wall has an opposing second surface designed to support a second clamp actuator.

In some aspects, the first side wall is releasably securable to the upper portion and wherein the second side wall is releasably securable to the lower portion.

In some aspects, the first side wall is designed to pivot outward in a first direction away from the wrench body of the first wrench and towards the mast. The second side wall is designed to pivot outward in a second direction opposite the first direction such that the second side wall is designed to pivot away from the wrench body of the first wrench and away from the mast.

In some aspects, the first side wall is designed to pivot outward in a first direction away from the wrench body of the first wrench and towards the mast. The second side wall is designed to pivot outward in the first direction.

In some aspects, the wrench body includes an upper portion and a side wall that is pivotably coupled to the upper portion, wherein the clamp actuator is supported on the side wall.

In some aspects, the side wall is releasably securable to the upper portion.

In yet another independent aspect, a surface-type drill or surface drill includes a chassis supporting an operator cab, a mast supported on the chassis and configured to support a drill string having a plurality of drill pipe sections, and a breakout system configured to be positioned adjacent the drill string. The breakout system includes a first wrench, a second wrench supported for movement relative to the first wrench, and a wrench actuator for applying a torque to move or rotate the second wrench relative to the first wrench. The first wrench is supported on the mast in an orientation to permit viewing a first clamp member from the operator cab. The first wrench has an opening for receiving the drill string at least partially therethrough and a first clamp member for engaging a portion of the drill string. The first wrench further includes an open side, and the first wrench is viewable from the operator cab. The second wrench includes an opening for receiving the drill string at least partially therethrough and a second clamp member for engaging another portion of the drill string. The second wrench further includes an open side, and the second wrench is supported on or coupled to the mast in an orientation to permit viewing the second clamp member from the operator cab.

In some aspects, the second wrench has a second clamp member, and the second wrench is supported in an orientation to permit viewing the second clamp member from the operator cab.

In some aspects, the first wrench is secured against movement relative to the mast, and the second wrench is configured to rotate relative to the first wrench by at least 10 degrees about an axis that is substantially parallel to the drill string, and the first clamp member and the second clamp member remain in an orientation to permit viewing when the second wrench is in a rotated position relative to the first wrench.

In some aspects, the first clamp member includes a first tool with a first axis and a second tool with a second axis, wherein the first axis is parallel to the second axis during a clamping operation of the first wrench.

In some aspects, the breakout system further includes a clamp actuator designed to actuate the first clamp member to engage at least a portion of the drill string. The clamp actuator is in an orientation to permit viewing from the operator cab.

In some aspects, the clamp actuator and the first clamp member are designed to pivot outward to provide access to an interior of at least one of the first wrench and the second wrench.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of an exemplary surface-type drill including a breakout system.

FIG. 2 is an isometric view of the breakout system supported by or coupled to a mast of the drill shown in FIG. 1.

FIG. 2A is an isometric side view of the breakout system and mast of FIG. 2.

FIG. 3A is an isometric view of the breakout system and mast of FIG. 2, with an upper portion removed from the breakout system for clarity.

FIG. 3B is an isometric view of a breakout system according to another embodiment, with a mast removed and with side walls of the breakout system pivoted toward an open position.

FIG. 4 is an isometric view of the breakout system and mast of FIG. 2 in a first position, with an upper portion removed from the breakout system for clarity.

FIG. 5A is a top view of the breakout system of FIG. 2, in the first position.

FIG. 5B is a top view of the breakout system of FIG. 2, in a second position.

FIG. 6 is a top view of the breakout system of FIG. 5B, with the upper portion removed for clarity.

FIG. 7 illustrates an isometric view of the breakout system of FIG. 2 through an operator cab window.

FIG. 8 is a top view of the operator cab and the breakout system of FIG. 7.

FIGS. 8A-8D are additional views of the operator cab and the breakout system of FIG. 7.

FIG. 9 is an isometric front view of a breakout system according to another embodiment.

FIG. 10 is an isometric side view of the breakout system of FIG. 9.

FIG. 11 is a top view of the breakout system of FIG. 9, with an upper portion removed for clarity.

FIG. 12 is an isometric view of a second wrench body of the breakout system of FIG. 9.

FIG. 13 is an isometric side view of a clamp member of the breakout system of FIG. 9.

DETAILED DESCRIPTION

Before any embodiments are explained in detail, it is to be understood that the disclosure 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 disclosure 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,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.

The following description and accompanying drawings are presented to enable a person skilled in the art to make and use embodiments of the disclosure. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein can be applied to other embodiments and applications without departing from scope of the disclosure. Thus, the disclosure is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of the disclosure. Skilled artisans will recognize the examples provided herein have many useful alternatives and fall within the scope of the disclosure.

Embodiments of the disclosure provide a breakout system for an industrial drill, such as a surface-type drill for mining. More specifically, a breakout system includes one or more wrenches to break apart portions of a drill string and/or drill pipe, and a component or clamping tool of the wrench is supported for pivoting movement to provide a technician and/or operator access to an interior portion of the wrench for servicing. The breakout system further enables an operator of the drill to have visibility of one or more clamps of the breakout system to determine the position of the clamps.

FIG. 1 illustrates an exemplary industrial drill 10 (e.g. a surface-type mining drill, such as a blast hole drill). In the illustrated embodiment, the drill 10 includes a mast 14, a base or chassis 16 (e.g., a machinery house) that supports the mast 14, an operator cab 18 coupled to the chassis 16, and at least one traction element (e.g. crawlers 20) that drive the surface-type drill 10 along a ground surface. The mast 14 may be configured to support a drill string 22 including one more drill pipe sections 24 that, while on the drill 10, can be assembled together for drilling and disassembled after the drilling operation is complete. In some embodiments, the drill 10 may also include a shock sub, a thread, a drill bit, and/or a bit stabilizer. The drill string 22 and/or drill pipe 24 may extend downward (e.g., vertically) through a breakout system 100, and may extend into a borehole in the ground surface.

In some embodiments, the drill 10 may include jacks to support the surface-type drill 10 on the ground surface. The drill 10 also may include a boom for supporting the mast 14 relative to the chassis 16, a drill head motor coupled to the mast 14 that drives a drill head, and/or a coupling that couples the drill head to the drill string 22. Other variations or constructions of the drill 10 are possible.

Referring now to FIG. 2, the breakout system 100 is configured to apply torque to the drill string 22 in order to uncouple components, such as sections of the drill string 22, which have been assembled together through threading, twisting, or other forms of coupling. The assembled sections 24 may be more or less tightly coupled based on multiple factors. For example, the drilling operation itself can tighten sections 24 to adjacent sections 24 of the drill string 22. In some embodiments, the breakout system 100 may be incorporated as an original component of the drill 10; in other embodiments, the breakout system 100 may be provided/installed as a retrofit or additional component for the drill 10.

In the illustrated embodiment, the breakout system 100 is supported on or coupled to the mast 14 of the surface-type drill 10 (for example, by a frame 102 shown in FIG. 2A). The breakout system 100 may be coupled to the mast 14 such that at least a portion of the breakout system 100 is stationary relative to the mast 14. In some embodiments, the frame 102 may be secured against rotation relative to the mast 14. In other embodiments, the frame 102 may provide a removable coupling to the mast 14 to facilitate repair or replacement of the frame 102 and/or the breakout system 100. In other embodiments, the breakout system 100 may be supported in another manner (e.g., coupled to the chassis 16, or removably and/or rotatably coupled to the mast 14). In one embodiment, the breakout system 100 can be oriented substantially perpendicular to the drill string 22. In other embodiments, the breakout system 100 can be oriented at any angle with respect to the drill string 22. Further, in one embodiment, the drill string 22 can pass through the breakout system 100 before passing into the borehole (not shown).

As shown in FIG. 2, the breakout system 100 includes a first wrench 110 and a second wrench 112. In the illustrated embodiment, the first wrench 110 is a lower wrench positioned (e.g., vertically) below the second wrench 112. The second wrench 112 can be an upper wrench.

In one embodiment, the first wrench 110 and the second wrench 112 may be coupled together by a (e.g., wrench) actuator (e.g., a hydraulic cylinder, not shown). In other embodiments, the actuator may be coupled between the second wrench 112 and the mast 14 and/or the frame 102. Actuation of the actuator may drive one or both of the wrenches (e.g., the upper wrench 112) to rotate relative to one another and/or rotate relative with respect to the frame 102 and/or mast 14. For example, the actuator may drive the upper wrench 112 to rotate relative to the lower wrench 110. Furthermore, although two wrenches are shown in the illustrated embodiment, it is possible for the breakout system 100 to include a different number of wrenches.

In the illustrated embodiment, the second wrench 112 is rotatable relative to the first wrench or lower wrench 110, while the lower wrench remains substantially stationary relative to the mast 14. In some embodiments, the first wrench 110 and the second wrench 112 may be rotatable in different directions relative to one another.

In the illustrated embodiment of FIG. 2, the frame 102 is coupled between the mast 14 and at least one wrench (e.g., the lower wrench 110) of the breakout system 100, and the frame 102 secures at least a portion of the wrench 110 (e.g., at a predetermined angle) with respect to the mast 14 or another component of the drill 10. As best shown in FIG. 2A, the frame 102 may be provided as multiple portions or plates (e.g., a first plate 103, a second plate 105, and a third plate 107 coupled between and substantially perpendicular to the first plate 103 and the second plate 105). In the illustrated embodiment of FIG. 2A, the third plate 107 is coupled to the mast 14. In some embodiments, the first plate 103 and/or the second plate 105 may have a trapezoidal shape with a first edge having a length that is substantially the same length as the mast 14 and two additional edges that extend outwardly from the first edge at a (e.g., obtuse) angle. It is to be understood that the first plate 103, the second plate 105, and the third plate 107 may have any suitable shape to couple the breakout system 100 to the mast 14. Additionally, the frame 102 may be provided in any number of portions or plates to facilitate coupling at least one wrench to the mast 14 or another component of the drill 10. In some embodiments, the frame 102 may be formed from a material such as steel or tungsten. Moreover, the frame 102 supports one or more wrenches 110, 112 of the breakout system 100 in an orientation that allows an operator in an operator cab to view and/or have a line of sight (see FIGS. 8, 8A, 8B, 8C, 8D) to at least a portion of an interior portion of at least one wrench 110, 112.

Continuing with FIG. 2, at least one of the wrenches 110, 112 can include an opening 104 that extends therethrough. The opening 104 can be sized and have a shape to receive at least a portion of the drill string 22 therein. In the illustrated embodiment, the opening 104 is provided in a circular shape, although it will be understood that the opening 104 may have any suitable shape.

The first wrench 110 and/or the second wrench 112 may be designed to rotate about an axis 114. The axis 114 can be substantially parallel to the drill string 22 and can extend through the at least one opening 104. In some embodiments, the second wrench 112 is rotatable relative to the first wrench 110 between approximately 10 degrees and approximately 20 degrees about the axis 114. In some embodiments, the second wrench 112 is rotatable relative to the first wrench 110 by at least 10 degrees about the axis 114. In other embodiments, the wrench(es) may rotate at any suitable angle.

As shown in FIG. 2, in the illustrated embodiment, the first wrench 110 may have a first wrench body 120. The first wrench body 120 may include an upper portion or upper plate 121, an (e.g., opposing) lower portion or lower plate 122, a first side or first side plate 124, and an (e.g., opposing) second side panel or second side plate 126. The first side 124 and the second side 126 can extend between the upper portion 121 and the lower portion 122, and each of the first side 124 and the second side 125 can be substantially perpendicular to the upper portion 121 and the lower portion 122. Further, a space can be provided between the upper portion 121 and the lower portion 122.

As shown in FIG. 2A, in some embodiments, the first plate 103 of the frame 102 can form the upper portion 121 of the first wrench body 120, and the second plate 105 of the frame 102 can form the lower portion 122 of the first wrench body 120. In other embodiments, the first plate 103 may be coupled to the upper portion 121 and the second plate 105 may be coupled to the lower portion 122 (e.g., the first plate 103 and the upper portion 121 may be separate components, and the second plate 105 and the lower portion 122 may be separate components, or the first plate 103 and the upper portion 121 may be integrally formed, and the second plate 105 and the lower portion 122 may be integrally formed). In other embodiments, the frame 102 is a support member for the first wrench 110 that rigidly fixes the first wrench 110 to the mast 14. The frame 102 may include a plate bolted or welded to the mast 14. In some embodiments, the plate may be shaped in the form of a hexagon, diamond, or trapezoid. The plate may be reinforced with gussets and include brackets to accept bolts for the connection to the mast. The frame 102 may include at least two arms that connect the first wrench 110 to the mast 14 in some embodiments.

Referring again to FIG. 2, a clamp member 130 is positioned within the space between the upper portion 121 and the lower portion 122. The clamp member 130 is operable to selectively engage an outer surface of the drill string 22. Rather than being fully enclosed, in one embodiment, the wrench body 120 can have at least one side (e.g., a side proximate an operator cab) that is open to permit an operator to view the wrench body 120 and/or the clamp member 130 of the wrench 110. In one embodiment, the clamp member 130 of the first wrench 110 includes a first clamp or clamping tool 132 and an (e.g., opposing) a second clamp or clamping tool 134, where a first surface of the first clamping tool 132 and a second surface of the second clamping tool 134 are actuated toward one another during operation of the clamp member 130.

At least one clamp support can extend between the first clamping tool 132 and the second clamping tool 134 to fix a first housing or a first bracket of the first clamping tool 132 to a second housing or a second bracket of the second clamping tool 134. Also, the first housing or first bracket is coupled to the at least one clamp support by at least one first coupling that allows the first housing or first bracket to rotate relative to the at least one clamp support. Further, the second housing or second bracket is coupled to the at least one clamp support by at least one coupling that allows the second housing or second bracket to rotate relative to the at least one clamp support. Both the first housing and the second housing may be (e.g., substantially rigidly) fixed to the at least one clamp support in an operating position by at least one second coupling. The at least one clamp support may be coupled to the mast 14.

Similarly, the second wrench 112 may have a second wrench body 140. The second wrench body 140 may include an upper portion or upper plate 142, an (e.g., opposing) lower portion or lower plate 144, a first side or first side plate 146, and an (e.g., opposing) second side or second side plate 148. The first side 146 and the second side 148 extend between the upper portion 142 and the lower portion 144, and a space is provided between the upper portion 142 and the lower portion 144, and each of the first side 146 and the second side 148 can be substantially perpendicular to the upper portion 142 and the lower portion 144. Rather than being fully enclosed, the second wrench body 140 can have at least one side (e.g., a side proximate an operator cab) open to permit an operator to view the space and/or a clamp member 150. The clamp member 150 can be positioned within the space between the upper portion 142 and the lower portion 144, and the clamp member 150 is operable to selectively engage at least a portion of an outer surface of the drill string 22.

In another embodiment, the clamp member 150 of the second wrench 112 can include a third clamp or clamping tool 152 and an (e.g., opposing) a fourth clamp or clamping tool 154, where during operation a third surface of the third clamping tool 152 and a fourth surface of the fourth clamping tool 154 can be actuated toward one another. At least one clamp support extends between the third clamping tool 152 and the fourth clamping tool 154 to fix a third housing or a third bracket of the third clamping tool 152 to a fourth housing or a fourth bracket of the fourth clamping tool 154. Also, the third housing or third bracket is coupled to the at least one clamp support by at least one third coupling that allows the third housing or third bracket to rotate relative to the at least one clamp support. Further, the fourth housing or fourth bracket is coupled to the at least one clamp support by at least one coupling that allows the fourth housing or fourth bracket to rotate relative to the at least one clamp support. Both the third housing and the fourth housing may be (e.g., substantially rigidly) fixed to the at least one clamp support in an operating position by at least one fourth coupling. The at least one clamp support may be coupled to the mast 14.

Referring now to FIG. 3A, the first side 146 and/or the second side 148 of the second wrench 112 may be movable relative to the upper portion 142 (FIG. 2) and/or the lower portion 144 of the second wrench 112 (although FIG. 3A depicts the system 100 without the upper portion 142 for clarity). In the illustrated embodiment of FIG. 3A, the first side 146 may be supported by a hinge 170 extending between the upper portion 142 and the lower portion 144, permitting the first side 146 to pivot in a direction away from the axis 114 (FIG. 2). The first side 146 may be releasably secured against the upper portion 142 and the lower portion 144 (e.g., in the position shown in FIG. 3A) by, for example, a fastener or pin. Similarly, the second side 148 may be supported by a hinge 172 extending between the upper portion 142 and the lower portion 144, permitting the second side 148 to pivot in a direction away from the axis 114. The second side 148 may be releasably secured against the upper portion 142 and the lower portion 144 (e.g., in the position shown in FIG. 3A) by, for example, a fastener or pin. In a non-operating state, the first side 146 and the second side 148 may be unsecured and pivoted to an outer position to facilitate service/replacement or visibility of clamp components. In an operating state, the first side 146 and the second side 148 may be secured to substantially prevent each side 146, 148 from pivoting outward and away from the lower portion 144.

In the illustrated embodiment, as shown in FIG. 3A and FIG. 4, the hinge 170 and the hinge 172 are positioned on diagonally opposite corners of the second wrench body 140. Thus, the first side 146 is pivotable outwardly in one direction from the second wrench body 140 and the second side 148 can also be pivoted outwardly from the second wrench body 140 in the same direction (e.g., both the first side 146 and the second side 148 pivot in a clockwise direction as viewed from the top of the wrench body 140).

In some embodiments, as shown in FIG. 3B, the hinge 170 and the hinge 172 may be positioned on the same side of the wrench body 140 such that the first side 146 pivots outwardly from the second wrench body 140 in one direction and the second side 148 pivots outwardly form the second wrench body 140 in another direction, opposite the direction that the first side 146 pivots outwardly from the second wrench body 140 (shown in FIG. 3B). In the embodiment shown in FIG. 3B, the first side 146 can be rotated in a counterclockwise direction away from the second wrench body 140 and/or the axis 114, and the second (e.g., opposing) side 148 may be rotated in a clockwise direction away from the second wrench body 140 and/or the axis 114.

The second wrench 112 can further include a first (e.g., clamp) actuator (e.g., a cylinder) 164 supported on the first side 146 designed to actuate the clamping tool 152 of the second wrench 112 and a second (e.g., clamp) actuator (e.g., a cylinder) 166 supported on the second side 148 designed to actuate the clamping tool 154 of the second wrench 112. In the illustrated embodiment, the actuators 164, 166 can be hydraulic cylinders. An inner end of the first actuator 164 is coupled to the clamping tool 152, and an inner end of the second actuator 166 is coupled to the clamp 154. Operation of the actuators 164, 166 drives the clamping tools 152, 154 to move inwardly toward the axis 114 (FIG. 2), thereby exerting a clamping force on an outer surface of the drill string 22 (FIG. 2). In the illustrated embodiment, the hinge 170 and the hinge 172 are positioned adjacent one side of each clamp 152, 154 to provide a reaction surface as the wrench 112 is rotated and torque is applied to the drill string 22 and/or the drill pipe 24.

It will be understood that the first wrench body 120 includes a similar structure as the second wrench body 140 shown in FIG. 3A. The first wrench 110 includes a first actuator (e.g., a cylinder) 160 supported on the first side 124 driving a first clamping tool 132, and a second actuator (e.g., a cylinder) 162 supported on the second side 126 driving a second clamping tool 134. Moreover, the first wrench body 120 can also include a hinge 168 to support the second side 126 and/or a hinge 167 to support the first side 124. The hinges 167 and/or 168 permit rotating the first side 124 and/or the second side 126 outward in a direction (e.g., the same direction, such as clockwise) away from the axis 114.

Although the hinges 167 and 168 are positioned on diagonally opposite corners of the wrench body 120 as shown in FIGS. 3A, 4, and 6, it is understood that the hinges 167 and 168 can be positioned on the same side of the wrench body 120 (e.g., as shown in FIG. 3B) to facilitate rotating the first side 124 and the second side 126 outwardly from the wrench body 120 and/or the axis 114 in opposite directions (e.g., one side may be rotated in a clockwise direction and the other side may be rotated in a counterclockwise direction).

In some embodiments, an upper portion 121 of the first wrench body 120 and a lower portion 144 of the second wrench body 140 may be spaced apart to avoid rubbing between the first wrench body 120 and the second wrench body 140 and facilitate rotation of the wrench bodies 120, 140 with respect to one another.

In some embodiments, each of the clamping tools 132, 134, 152, and 154 may include at least one of a wear plate, an engaging surface, dies, and/or blocks. During operation of the breakout system 100, the wear plates (not shown) are subject to stress and may need to be serviced or replaced at regular intervals (e.g., approximately every two hundred hours of operation).

Moreover, the breakout system 100 is designed to provide visibility to at least one clamp member 130 and/or clamp member 150 from the operator cab. The first wrench 110 may be oriented at a (e.g., substantially fixed) oblique angle with respect to the mast 14, which can facilitate visibility of one or more components of the first wrench 110 to an operator in the operator cab, and the upper portion 121 and the lower portion 122 of the first wrench 110 can be substantially perpendicular to or positioned at an angle with respect to the mast 14. In addition to visibility of the breakout system 100, when the breakout system 100 is not in operation, an operator or technician may easily access the clamp member 130 and/or the clamp member 150.

During operation of the breakout system 100, as shown in FIGS. 5A and 5B, the first wrench 110 is (e.g., substantially fixed with respect to the mast 14) and the drill string 22 (not shown in FIGS. 5A and 5B) is positioned such that a seam between two sections 24 (not shown) is aligned between the first wrench 110 and the second wrench 112. The clamp member 130 and the clamp member 150 are then actuated to exert a clamping force on each of adjacent pipe section 24. The second wrench 112 is actuated (e.g., rotated) relative to the first wrench 110 and/or relative to the mast 14 to apply a torque and break or loosen the connection and permit the drill pipe sections 24 and/or drill bit to be separated. In some embodiments, the second wrench 112 is rotated about 15 degrees about the axis 114 from a first position (FIGS. 4 and 5A) to a second position (FIGS. 5B and 6). The second wrench 112 may be rotated toward the operator cab 18 (FIG. 8). In other embodiments, the second wrench 112 may be rotated at another angle. Additionally, in alternative embodiments, the first wrench 110 may rotate via the actuator with respect to the second wrench 112.

As shown in FIGS. 7 and 8, the breakout system 100 facilitates visual inspection by an operator positioned in the operator cab 18. A view angle from the operator cab, at least at one point in the operator cab is, in the current embodiment, at least 10 degrees. Further, the percent of a normal view of the breakout system is at least 25 percent, and, in the current embodiment is over 30 percent. The operator may view the first clamp member 130 and/or the second clamp member 150 through the door and/or window of the operator cab 18 via a line of sight 176. The line of sight 176 and the view angle of the breakout system from the operator cab provides the operator a clearer, more direct view each of the first clamp member 130 and the second clamp member 150 of the breakout system 100 to enable improved control of the operation of the drill 10. Furthermore, an operator may have increased visibility to the first clamp member 130 and the second clamp member 150 due to the open sides of the first wrench 110 and/or the second wrench 112, which enables improved control of the machine operation.

This increased visibility reduces potential operator error by reducing the risk that the drill 10 may be operated while one or more of the clamping tools 132, 134, 152, and 154 is incorrectly operated. For example, if an operator believes the clamp members 130, 150 are engaged for a breakout operation but they are not, no breakout torque is applied to the drill pipe. Alternatively, if the operator incorrectly believes the clamp members 130, 150 to be disengaged and attempts to operate the drill, the operation may cause damage to at least one of the dies, die blocks, and clamps and/or clamp cylinders.

During a service/repair event, the first side and second side of each wrench is pivotable (e.g., outward) (e.g., via hinges 167, 168, 170, 172) to provide easy access to the first clamp member 130 and/or the second clamp member 150. When each of the sides 124, 126, 146, and/or 148 is rotated (e.g., outward), each respective clamping tool 132, 134, 152, and/or 154 also may rotate outward. This enables a technician and/or an operator to easily access at least one of or a portion of the first clamp member 130 and the second clamp member 150 from the front and/or sides of the breakout system 100. The access can allow for service and/or maintenance of the breakout system 100 in a tight environment.

The breakout system 100 also provides access to the clamps and clamp members 130, 150 without requiring the removal of one or more sides 124, 126, 146 and/or 148 and without requiring removal of one or more actuators 160, 162, 164, and/or 166 during the repair of the breakout system 100, because one or more sides 124, 126, 146 and/or 148 and/or one or more actuators 160, 162, 164, and/or 166 may rotate outwardly (e.g., away from the axis 114), improving the efficiency for such maintenance. The (e.g., rotating) sides 124, 126, 146, and/or 148 can save time because the operator/technician does not need to remove and/or separate one or more of the sides 124, 126, 146 and/or 148 and/or the actuators 160, 162, 164, and/or 166 from the breakout system 100 to repair and/or replace parts of the breakout system 100, as each actuator 160, 162, 164, and/or 166 may weigh over 100 pounds. Once a repair to the breakout system 100 is complete, at least one of sides 124, 126, 146 and/or 148 may be rotated inward (e.g., toward the axis 114) along its respective hinge 167, 168, 170 and/or 172 and secured (e.g., locked) in place for operation to resume. It may be secured (e.g., with a fastener or pin). Increasing the case and consistency in changing the parts or components of at least one of the breakout system 100, the first wrench 110, and/or the second wrench 112 leads to lower cycle times and higher foot-per-hour drilling performance.

FIGS. 8A-8D are additional top views of the operator cab and the breakout system of FIG. 7. Turning to FIGS. 8A and 8B, in some aspects, the first clamp member 130 and/or the first wrench 110 may include a first tool 50 with a first tool axis 54 and a second tool 52 with a second tool axis 56, wherein during a clamping operation of the first wrench 110, the first tool axis 54 is substantially parallel to the second tool axis 56, and wherein during the clamping operation of the first wrench 110, the first tool axis 54 and the second tool axis 56 are arranged at an oblique tool angle 66 with respect to a longitudinal axis 60 of the industrial machine 10. The axis 60 may be substantially perpendicular to a transverse axis 62 of the industrial machine 10.

In some aspects, the first tool 50 and the second tool 52, during a clamping operation of the first wrench 110, the first tool 50 is at a first orthogonal distance 70 to a longitudinal plane 68 of the mast 14 and the second tool 52 is at a second orthogonal distance 72 to the longitudinal plane 68 of the mast 14. In one aspect, the first orthogonal distance 70 is greater than the second orthogonal distance 72.

Turning to FIG. 8C, in some aspects, during a clamping operation of the first wrench 110, a first tool location, a second tool location, and a view point in an operator window are arranged in a substantially triangular configuration, as shown by the line depicting a vertical plane 76, an orthogonal line 86 (e.g., with respect to the axis 62) depicting the cab operator's viewpoint of the first tool 50 from the operator cab, and a line 74 depicting the cab operator's viewpoint of the second tool 52 from the operator cab, such that a first view angle 64 (e.g., measured or defined between the line 74 and the plane 76) from the operator cab is created. In one embodiment, the first view angle 64 is between about 5 degrees and about 45 degrees.

Turning to FIG. 8D, in some aspects, during a clamping operation of the first wrench 110, a first tool 50 location and a second tool 52 location are located a third distance 80 apart and in the first vertical plane 76, and the view point 74 in an operator window is along a second vertical plane 78 transverse to the longitudinal axis 60 of the industrial machine 10, wherein, during the clamping operation, a view area of the second vertical plane 78 (or the axis 62) is defined by a fourth distance 82, wherein the fourth distance 82 is defined between a first intersection of a first orthogonal line 86 from the first tool location to the second vertical plane 78 and a second intersection of the second orthogonal line 84 from the second tool location to the second vertical plane 78, and wherein the fourth distance 82 is at least 10 percent of the third distance 80.

In some aspects, during a clamping operation of the first wrench 110, the plane 78 is substantially parallel to the axis 62. Also, during a clamping operation of the first wrench 110, the first orthogonal line 86 and the second orthogonal line 84 may be substantially parallel and may be spaced a distance apart from one another. During the clamping operation of the first wrench 110, the line 84 and the line 86 may both extend away from the longitudinal plane 68 of the mast 14 and a transverse plane within which an operator viewpoint of the operator cab is disposed.

FIGS. 9-13 illustrate a breakout system 900 according to another embodiment. The breakout system 900 is similar to the breakout system 100, and one skilled in the art will understand that various aspects of other embodiments may be applicable to the embodiment in FIGS. 9-13. Some similarities and differences between the breakout system 900 and the breakout system 100 are described and shown herein.

Referring to FIG. 9, the breakout system 900 can include a first wrench 910 having a first wrench body 920 and a second wrench 912 having a second wrench body 940 (shown in FIG. 12). In one aspect, the first wrench 910 can be positioned beneath the second wrench 912, such that an opening (e.g., opening 104) provided within the first wrench 910 can be (e.g., axially) aligned, preferably along the axis 114, with an opening (e.g., opening 104) provided within the second wrench 912. Further, the first wrench 910 can be coupled to or supported on the mast 14 (e.g., the first wrench 910 can be substantially stationary), and the second wrench 912 can be supported for movement relative to the first wrench 910 (e.g., by one or more bearings). The second wrench 912 is driven to rotate relative to the first wrench 910 by actuation of a wrench actuator 1000. In one instance, the first wrench 910 is similar to the first wrench 110 and the second wrench 912 is similar to the second wrench 112. Each of the first wrench 910 and the second wrench 912 includes one or more clamp members. For example, the first wrench 910 includes clamp members 130 and the second wrench 912 includes clamp members 150.

Moreover, the breakout system 900 can include at least one hinge. In one embodiment, the first wrench body 920 can include a first hinge 986 and a second hinge 988 (e.g., positioned on the same side of the wrench body 920) designed to facilitate rotating the sides 124 and 126 outwardly (e.g., in opposite directions) from the wrench body 920. When the side 124 and/or the side 126 is rotated outwardly, the associated clamp member(s) 130 can be accessed for service. In other instances, the hinges 986 and/or 988 can be provided in a different configuration (e.g., on diagonally opposite corners of the wrench body 920).

Similarly, the second wrench body 940 can include a first hinge 990 and a second hinge 992 (e.g., positioned on the same side of the wrench body 940) designed to facilitate rotating the sides 146 and 148 outwardly (e.g., in opposite directions) from the wrench body 940. When the side 146 and/or the side 148 is rotated outwardly, the associated clamp member(s) 150 can be accessed for service. In other instances, the hinges 990 and/or 992 can be provided in a different configuration (e.g., on diagonally opposite corners of the wrench body 940).

Additionally, in one instance, as shown in FIGS. 9-12, the first wrench body 920 can include a first lug or protrusion 980 positioned on the wrench body 920 (for example, the first protrusion 980 may extend from and/or be integrally formed with an upper portion or surface 982 of the wrench body 920), and, the wrench body 940 can include a second lug or protrusion 984 (for example, the second protrusion 984 may extend from and/or be integrally formed with a lower portion or surface 989 of the wrench body 940). Further, in some embodiments, the upper surface 982 of the wrench body 920 and the lower surface 989 of the wrench body 940 are spaced apart by a distance to avoid contact between surfaces as the wrench bodies move relative to one another. In some embodiments, each of the protrusions 980, 984 includes an opening formed therein and can be provided in any suitable shape. Further, the protrusions 980 and 984 can be spaced apart from one another by a distance 994 (FIG. 10).

As shown in FIGS. 9-11, the breakout system 900 includes the wrench actuator 1000 for rotating at least one of the first wrench body 920 and/or the second wrench body 940 with respect to one another. In the illustrated embodiment, the wrench actuator 1000 includes a fluid cylinder 1002 extending between a first end 1004 and an (e.g., opposing) second end 1006, and a fluid manifold 1008 for facilitating flow of pressurized fluid to operate the cylinder 1002. In one aspect, the length of the cylinder 1002 is substantially the same as the distance 994. In other aspects, the cylinder 1002 can be any suitable length.

The first end 1004 of the wrench actuator 1000 can be coupled to or supported on the protrusion 984 (e.g., of the lower surface 989) of the second wrench body 940 and the second end 1006 can be coupled to or supported on the protrusion 980 (e.g., of the upper surface 982) of the first wrench body 920. Further, the fluid manifold 1008 is coupled to or supported by the cylinder 1002, and the fluid manifold 1008 is in fluid communication with a supply of pressurized fluid (e.g., hydraulic fluid) to facilitate operation of the wrench actuator 1000. During operation, the wrench actuator 1000 is designed to move between a first position (e.g., nominal, contracted) and a second position (e.g., activated, expanded) position 1010 (shown in FIGS. 9-11). In the first position, the wrench bodies 920 and 940 are substantially aligned with one another as viewed along an axis of the drill string. In the second position, the wrench body 940 is rotated with respect to the first wrench body 920 to apply torque to the drill string to facilitate breaking the drill string 22.

In the illustrated embodiment, the breakout system 900 includes a guide and track system to facilitate movement of the clamp member 130 and/or clamp member 150. For example, a guide or rail 1020 (FIG. 10) may be positioned on each side of the clamp member 130, and may engage a sidewall of the associated wrench body 920. For example, the rail 1020 may slide within a slot or track 1022 (FIGS. 10 and 12) positioned on the sidewall. The rail 1020 and track 1022 can be positioned on one or both sides of each clamp member, and each of the wrenches 910, 912 may include a rail 1020 and track 1022 between the wrench body and the associated clamp members. In the illustrated embodiment, the rail 1020 is positioned on the clamp member 130, 150 and the track 1022 is positioned on the sidewall. In other embodiments, the rail may be positioned on the sidewall and engage a track positioned on the clamp member. The engagement of the rails 1020 and tracks 1022 assist in guiding and stabilizing the clamp members 130, 150 during use, and supports the clamp members 130, 150 against reaction forces exerted on the clamp member.

In the illustrated embodiment, each clamp member 130 and/or 150 includes one or more protrusions 1030 (e.g., a spline surface-FIG. 13) to facilitate mounting a die thereon. The die engages the drill string 22 during operation. In the illustrated embodiment, a plurality (e.g., three) protrusions 1030 are positioned vertically and spaced a distance apart. In other embodiments, the dies may be coupled to the clamp member in a different manner.

It will be appreciated by those skilled in the art that while certain aspects have been described above in connection with particular embodiments and examples, the disclosure is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications and departures from the embodiments, examples and uses are intended to be encompassed by the claims attached hereto. Various features and advantages are set forth in the following claims.

Claims

1. A breakout system for an industrial drill including a mast, the industrial drill having a drill string with a drill pipe, the breakout system comprising: a first wrench designed to be coupled to the mast, the first wrench including, an opening configured to receive the drill string therethrough,a first clamp member designed to engage at least a portion of the drill string, andan open side;a second wrench coupled to the first wrench; andan actuator for applying a torque to rotate the second wrench relative to the first wrench, the first wrench permits viewing of the first clamp member from an operator cab through the open side.

2. The breakout system of claim 1, wherein the second wrench further includes a second open side, and the second wrench is supported on or coupled to the mast in an orientation to permit viewing a second clamp member of the second wrench from the operator cab.

3. The breakout system of claim 2, wherein the second wrench is configured to rotate relative to the first wrench between approximately 10 degrees and approximately 20 degrees about an axis that is substantially parallel to the drill string, and wherein the second open side of the second wrench is configured to move in a direction toward the operator cab as the second wrench is rotated.

4. The breakout system of claim 1, wherein the first clamp member includes a first tool and a second tool, wherein, during a clamping operation of the first wrench, the first tool is at a first orthogonal distance to a longitudinal plane of the mast and the second tool is at a second orthogonal distance to the longitudinal plane of the mast, and wherein the first orthogonal distance is greater than the second orthogonal distance.

5. The breakout system of claim 1, wherein the first clamp member includes a first tool and a second tool, wherein, during a clamping operation of the first wrench, a first tool location, a second tool location, and a view point in an operator window of the operator cab are arranged in a triangular configuration such that a first angle at the view point is between about 5 degrees and about 45 degrees.

6. The breakout system of claim 1, wherein the first clamp member includes a first tool and a second tool, wherein, during a clamping operation of the first wrench, a first tool location and a second tool location are located a third distance apart and in a first vertical plane, and a view point in an operator window is located in a second vertical plane transverse to a longitudinal axis of the industrial drill, wherein, during the clamping operation, a view area of the second vertical plane is defined by a fourth distance, wherein the fourth distance is defined between a first intersection of a first orthogonal line from the first tool location to the second vertical plane and a second intersection of a second orthogonal line from the second tool location to the second vertical plane, and wherein the fourth distance is at least 10 percent of the third distance.

7. The breakout system of claim 1, wherein the first clamp member includes a first tool with a first axis and a second tool with a second axis, wherein, during a clamping operation of the first wrench, the first axis is parallel to the second axis, and wherein, during the clamping operation of the first wrench, the first axis and the second axis both extend away from a longitudinal plane of the mast and a transverse plane within which an operator viewpoint of the operator cab is disposed.

8. A breakout system for an industrial drill including a mast and a drill string having a drill pipe, the breakout system comprising: a first wrench configured to be coupled to the mast, the first wrench including a wrench body having a first opening configured to receive the drill string therethrough, the wrench body having an upper portion and a first side wall, the first side wall is pivotably coupled to the upper portion;a second wrench including a second opening configured to receive the drill string therethrough;a wrench actuator for applying a torque to rotate one of the first wrench and the second wrench relative to the other of the first wrench and the second wrench;at least one clamp including a first clamp and a second clamp, wherein at least one of the first clamp and the second clamp is supported on the first side wall of the first wrench for movement relative to the wrench body; anda clamp actuator for driving the first clamp and the second clamp to engage at least a portion of the drill string passing through the first opening and the second opening.

9. The breakout system of claim 8, wherein the clamp actuator is supported on the first side wall of the first wrench, and wherein the first side wall is designed to pivot outward from the wrench body of the first wrench to provide access to an interior of the wrench body of the first wrench.

10. The breakout system of claim 9, wherein the at least one clamp is accessible for service when the first side wall is pivoted outward from the wrench body of the first wrench.

11. The breakout system of claim 8, wherein the second wrench has a second wrench body having a lower portion and a second side wall that is pivotably coupled to the lower portion, and the second side wall has a first surface designed to support the second clamp and the second side wall has an opposing second surface designed to support a second clamp actuator.

12. The breakout system of claim 11, wherein the first side wall is releasably securable to the upper portion and wherein the second side wall is releasably securable to the lower portion.

13. The breakout system of claim 11, wherein the first side wall is designed to pivot outward in a first direction away from the wrench body of the first wrench and towards the mast, and wherein the second side wall is designed to pivot outward in a second direction opposite the first direction such that the second side wall is designed to pivot away from the wrench body of the first wrench and away from the mast.

14. The breakout system of claim 11, wherein the first side wall is designed to pivot outward in a first direction away from the wrench body of the first wrench and towards the mast, and wherein the second side wall is designed to pivot outward in the first direction.

15. A surface-type drill comprising: a chassis supporting an operator cab;a mast supported on the chassis and configured to support a drill string having a plurality of drill pipe sections; anda breakout system configured to be positioned adjacent the drill string, the breakout system including, a first wrench supported on the mast in an orientation to permit viewing a first clamp member from the operator cab,a second wrench supported for movement relative to the first wrench, anda wrench actuator for applying a torque to move the second wrench relative to the first wrench.

16. The surface-type drill of claim 15, wherein the second wrench has a second clamp member, and the second wrench is supported in an orientation to permit viewing the second clamp member from the operator cab.

17. The surface-type drill of claim 16, wherein the first wrench is secured against movement relative to the mast, and the second wrench is configured to rotate relative to the first wrench by at least 10 degrees about an axis that is substantially parallel to the drill string, the first clamp member and the second clamp member remain in an orientation to permit viewing when the second wrench is in a rotated position.

18. The surface-type drill of claim 15, wherein the first clamp member includes a first tool with a first axis and a second tool with a second axis, wherein the first axis is parallel to the second axis during a clamping operation of the first wrench.

19. The surface-type drill of claim 15, wherein the breakout system further includes a clamp actuator designed to actuate the first clamp member to engage at least a portion of the drill string, wherein the clamp actuator is in an orientation to permit viewing from the operator cab.

20. The surface-type drill of claim 19, wherein the clamp actuator and the first clamp member are designed to pivot outward to provide access to an interior of at least one of the first wrench and the second wrench.