Automatic drill pipe add and remove system

Abstract

A drilling rig carousel assembly includes a drilling rig carousel comprising a plurality of slots for holding drill components, a first actuator coupled to the drilling rig carousel and configured to axially rotate the drilling rig carousel, a second actuator coupled to the drilling rig carousel and configured to move the drilling rig carousel between a first position and a second position, and a sensor assembly. The sensor assembly includes a rotation sensor configured to monitor an axial rotation of the drilling rig carousel, and a position sensor configured to provide a signal representative of whether the drilling rig carousel is in the first position or the second position.

What is claimed is: 
     
         1 . A drilling rig carousel assembly, comprising:
 a drilling rig carousel comprising a plurality of slots for holding drill components;   a first actuator coupled to the drilling rig carousel and configured to axially rotate the drilling rig carousel;   a second actuator coupled to the drilling rig carousel and configured to move the drilling rig carousel between a first position and a second position; and   a sensor assembly, comprising:
 a rotation sensor configured to monitor an axial rotation of the drilling rig carousel; and 
 a position sensor configured to provide a signal representative of whether the drilling rig carousel is in the first position or the second position. 
   
     
     
         2 . The assembly of  claim 1 , further comprising:
 a lock coupled to the drilling rig carousel and configured to removably couple the first actuator to the drilling rig carousel.   
     
     
         3 . The assembly of  claim 2 , wherein the sensor assembly further comprises a lock sensor configured to monitor whether the lock is in a locked position or an unlocked position. 
     
     
         4 . The assembly of  claim 1 , further comprising:
 a control module configured to receive signals from the sensor assembly, and to control a movement of the drilling rig carousel.   
     
     
         5 . The assembly of  claim 4 , wherein the control module is configured to cause the drilling rig carousel to axially rotate such that one of the plurality of slots is indexed to a loading position. 
     
     
         6 . The assembly of  claim 5 , wherein the sensor assembly further comprises a slot sensor configured to detect the presence of the drill components within one or more of the plurality of slots. 
     
     
         7 . The assembly of  claim 6 , wherein the control module is configured to cause the drilling rig carousel to axially rotate based on the presence of the drill components within one or more of the plurality of slots. 
     
     
         8 . The assembly of  claim 6 , wherein the slot sensor comprises proximity sensors coupled to the drilling rig carousel and configured to detect the presence of a drill component with a slot of the drilling rig carousel. 
     
     
         9 . The assembly of  claim 1 , wherein the assembly is part of a drilling rig, the drilling rig further comprising:
 a drill string comprising one or more drill components; and   a control module configured to:
 receive signals from the sensor assembly; and 
 control a movement of the drill string and the drilling rig carousel in order to add one or more of the drill components to the drill string from the drilling rig carousel, or to remove one or more of the drill components from the drill string and store within the drilling rig carousel. 
   
     
     
         10 . The assembly of  claim 9 , wherein the sensor assembly further comprises a drill sensor configured to monitor a rotation of the drill string. 
     
     
         11 . The assembly of  claim 9 , wherein the drilling rig carousel is positioned in axial alignment with the drill string in the first position, and the drilling rig carousel is positioned adjacent to the drill string in the second position. 
     
     
         12 . A drilling rig for drilling at a desired drill depth, the drilling rig comprising:
 a drill string having a drill tool and comprising one or more drill pipe segments;   a drill pipe storage rack configured to store the one or more drill pipe segments;   a sensor assembly configured to monitor a position of the drill string and a position of the drill pipe storage rack;   an operator interface configured to receive one or more operator inputs; and   a control module configured to:
 receive signals from the sensor assembly and the operator interface; and 
 control a movement of the drill pipe storage rack and the drill string in order to add the one or more drill pipe segments from the drill pipe storage rack to the drill string, extending the drill string to reach the desired drill depth. 
   
     
     
         13 . The drilling rig of  claim 12 , wherein the sensor assembly comprises:
 a rotation sensor configured to monitor an axial rotation of the drill pipe storage rack; and   a position sensor configured to provide a signal representative of whether the drill pipe storage rack is in a first position or a second position.   
     
     
         14 . The drilling rig of  claim 13 , further comprising:
 a first actuator coupled to the drill pipe storage rack and configured to axially rotate the drill pipe storage rack about a center axis of the drill pipe storage rack.   
     
     
         15 . The drilling rig of  claim 13 , further comprising:
 a second actuator coupled to the drill pipe storage rack and configured to move the drill pipe storage rack between the first position and the second position.   
     
     
         16 . The drilling rig of  claim 12 , wherein the sensor assembly further comprises a drill sensor configured to monitor a rotation of the drill string. 
     
     
         17 . The drilling rig of  claim 12 , wherein the drill pipe storage rack comprises a plurality of slots for holding the one or more drill pipe segments. 
     
     
         18 . The drilling rig of  claim 17 , wherein the sensor assembly comprises a slot sensor configured to monitor one or more slots of the drill pipe storage rack to determine whether a drill pipe segment is present within one of the plurality of slots. 
     
     
         19 . An automatic drill pipe add and remove system for a drilling rig having a drill string, the system comprising:
 a sensor assembly configured to monitor a position of the drill string and a position of a drill pipe storage rack;   an operator interface configured to receive one or more operator inputs; and   a control module configured to:
 receive signals from the sensor assembly; 
 receive a desired drill depth from the operator interface; 
 determine a desired drill string length for reaching the desired drill depth; and 
 automatically add drill pipe segments to the drill string until the drill string reaches the desired drill string length. 
   
     
     
         20 . The system of  claim 19 , wherein the control module is configured to automatically remove one or more of the drill pipe segments once the desired drill depth is reached such that the drill string comprises a single drill pipe segment.