Progressive Dual-Shaft Drill Head and Systems and Methods Thereof

Abstract

Implementations of the present invention relate to system and apparatus for increasing and lowering speed and torque transferred to a drive shaft from a drive source. In particular, the present disclosure relates to a system that allows engagement and disengagement of low and high gears with a single shifter that can move in a single direction to shift between gears.

What is claimed is: 
     
         1 . A drill head, comprising:
 at least one drive source;   at least one drive shaft; and   a power transmission system configured to transmit power from the at least one drive source to the at least one drive shaft and having at least a gearbox and a gear shifting system operatively coupled to the gearbox, wherein the gearbox further comprises:
 a drive rod operatively coupled to the at least one drive source, a first hollow shaft, a second hollow shaft and an upper coupler, and wherein:
 the drive rod is configured to move laterally to selectively couple directly to the first hollow shaft and to the second hollow shaft, 
 the upper coupler is configured to move laterally to selectively couple the first and second hollow shafts, 
 the first hollow shaft is operatively coupled to the at least one drive shaft, and 
 the gear shifting system is operatively coupled to the gearbox to affect lateral movement of at least one of the drive rod and the upper coupler. 
 
   
     
     
         2 . The drill head of  claim 1 , wherein the power transmission system further comprises a reducer operable to couple the drive rod to the second hollow shaft. 
     
     
         3 . The drill head of  claim 1 , further comprising a housing, wherein at least a portion of one of the gearbox and drive shaft is enclosed in the housing. 
     
     
         4 . The drill head of  claim 1 , wherein the gearbox further comprises a drive source adapter operable to couple the drive source to the gearbox. 
     
     
         5 . The drill head of  claim 1 , wherein the gearbox further comprises an output gear operable to couple to the drive shaft. 
     
     
         6 . The drill head of  claim 1 , wherein the power transmission system has a high gear and a low gear, and wherein the high gear can transfer a higher rate of rotational speed to the at least drive shaft than the low gear. 
     
     
         7 . The drill head of  claim 1 , wherein the first and second hollow shafts are configured to rotate independently and freely if not coupled to the upper coupler. 
     
     
         8 . The drill head of  claim 7 , wherein the first and second hollow shafts are configured to rotate in unison when coupled to the upper coupler. 
     
     
         9 . The drill head of  claim 1 , wherein the drive rod is configured to engage the first hollow shaft and transfer rotation from the at least one drive source to the first hollow shaft. 
     
     
         10 . The drill head of  claim 9 , further comprising a planetary gear system configured to transmit power and rotation to the second hollow shaft, wherein the drive rod is configured to engage the planetary gear system. 
     
     
         11 . The drill head of  claim 10 , wherein the planetary gear system comprises a sun gear, one or more planet gears, an outer ring and a planet carrier, wherein the planet carrier is configured to connect the one or more planet gears within the planetary gear system. 
     
     
         12 . The drill head of  claim 11 , wherein the sun gear is configured to transmit motion to the planet gears. 
     
     
         13 . The drill head of  claim 10 , wherein the planetary gear system is configured to act as a reducer and reduce the number of RPM from the at least one drive source. 
     
     
         14 . A drill head comprising:
 a drive source;   a drive rod connected to the drive source and operable to transmit rotation to the drive rod;   a drive shaft; and   a gearbox, comprising:
 a first hollow shaft operatively connected to the drive shaft such that rotation of the first hollow shaft is transmitted to the drive shaft, 
 a second hollow shaft, 
 a planetary gear comprising a sun gear secured to the second hollow shaft and at least one planet gear, wherein at least a portion of the planetary gear moves in response to rotation of the sun gear, and 
 an upper coupler configured to engage the first and the second hollow shafts, such that rotation of the second hollow shaft is transmitted to the first hollow shaft; and 
   wherein the drive rod is configured to selectively engage at least one of the at least one planetary gear and the first hollow shaft.   
     
     
         15 . The drill head of  claim 14 , wherein the planetary gear system further comprises an outer ring and a planet carrier, wherein the planet carrier is configured to connect the one or more planet gears within the planetary gear system. 
     
     
         16 . The drill head of  claim 14 , wherein the planetary gear system is configured to act as a reducer and reduce the number of RPM from the drive source. 
     
     
         17 . The drill head of  claim 14 , wherein the upper coupler is configured to move laterally to selectively couple the first and second hollow shafts. 
     
     
         18 . A drill head, comprising:
 a drive shaft operatively coupled to a transmission system, the transmission system comprising:   a gearbox comprising:
 a first hollow shaft, 
 a second hollow shaft, 
 a planetary gear system having a sun gear and at least one planet gear, wherein a portion of the planetary gear system is configured to move in response to rotation of the sun gear is secured to the second hollow shaft, 
 a drive rod configured to selectively engage at least one of the planetary gear and the first hollow shaft when moved laterally; and 
 an upper coupler operable to couple the first and the second hollow shafts when moved laterally; and 
   a gear shifting system operatively coupled to the gearbox and operable to cause lateral movement of at least one of the drive rod and the upper coupler.   
     
     
         19 . The drill head of  claim 18 , wherein the planetary gear system further comprises an outer ring and a planet carrier, wherein the planet carrier is configured to connect the one or more planet gears within the planetary gear system. 
     
     
         20 . The drill head of  claim 18 , wherein the planetary gear system is configured to act as a reducer and reduce the number of RPM from the drive source.