Drill rod guard and systems and methods of using same

Abstract

A drill rod guard having a feed shaft assembly that supports a feed shell for receiving a drill rod. First and second shafts are respectively pivotally coupled to opposed sides of the feed shaft assembly. A plurality of guard elements are operatively coupled to the first and second shafts, and opposed guard elements are selectively engageable with one another. Upon engagement between the opposed guard elements, the guard elements cooperate with the feed shell and/or the feed shaft assembly to substantially enclose the portion of the drill rod within the feed shell to thereby prevent contact with the drill rod.

1 . A drill rod guard for use with a drilling system, the drill rod guard having a longitudinal axis, the drilling system comprising a feed shell having first and second side portions positioned on opposing sides of the longitudinal axis of the drill rod guard, the feed shell being configured to receive at least a portion of a drill rod, the drill rod guard comprising:
 a feed shaft assembly configured to support the feed shell, the feed shaft assembly comprising at least one support element, wherein each support element comprises a first side portion and a second side portion, the first side portion being positioned on an opposing side of the longitudinal axis of the drill rod guard from the second side portion, wherein the first side portion of each support element is configured to be positioned proximate the first side portion of the feed shell, and wherein the second side portion of each support element is configured to be positioned proximate the second side portion of the feed shell;   opposed first and second shafts, the first shaft being pivotally coupled to the first side portions of each support element of the feed shaft assembly, the second shaft being pivotally coupled to the second side portions of each support element of the feed shaft assembly, wherein the first shaft is configured for selective rotation relative to a first rotational axis and the second shaft is configured for selective rotation relative to a second rotational axis, and wherein the first rotational axis and the second rotational axis are substantially parallel to the longitudinal axis of the drill rod guard; and   a plurality of guard elements, the plurality of guard elements comprising a first set of guard elements operatively coupled to the first shaft and a second set of guard elements operatively coupled to the second shaft, each guard element of the first set of guard elements being substantially opposed from and configured for selective engagement with a corresponding guard element of the second set of guard elements,   wherein, upon engagement between the first set of guard elements and the second set of guard elements, the plurality of guard elements are configured to cooperate with the first and second side portions of the feed shell to substantially enclose the portion of the drill rod within the feed shell.   
     
     
         2 . The drill rod guard of  claim 1 , wherein the at least one support element of the feed shaft assembly comprises a plurality of support elements spaced relative to the longitudinal axis of the drill rod guard. 
     
     
         3 . The drill rod guard of  claim 1 , wherein the first side portion of each support element of the feed shaft assembly comprises a bore configured to receive a portion of the first shaft, and wherein the second side portion of each support element of the feed shaft assembly comprises a bore configured to receive a portion of the second shaft. 
     
     
         4 . The drill rod guard of  claim 1 , further comprising a plurality of bushings positioned between adjacent guard elements of the plurality of guard elements. 
     
     
         5 . The drill rod guard of  claim 1 , wherein the first and second shafts are configured for rotation about and between a first rotational position and a second rotational position, wherein when the first and second shafts are positioned in the first rotational position, each respective guard element is configured for movement about and between a closed position and a partially open position, wherein in the closed position, the guard element is positioned for engagement with a corresponding opposed guard element. 
     
     
         6 . The drill rod guard of  claim 5 , wherein when the first and second shafts are positioned in the second rotational position, each respective guard element is positioned in a fully open position. 
     
     
         7 . The drill rod guard of  claim 5 , wherein each guard element of the plurality of guard elements is biased toward the closed position. 
     
     
         8 . The drill rod guard of  claim 7 , wherein the first set of guard elements is rigidly mounted to the first shaft, and wherein the second set of guard elements is rigidly mounted to the second shaft, and wherein each guard element comprises an outer portion that defines a hinge configured to bias the guard element toward the closed position. 
     
     
         9 . The drill rod guard of  claim 8 , wherein at least a portion of each guard element comprises an elastic material. 
     
     
         10 . The drill rod guard of  claim 9 , wherein when the first and second shafts are positioned in the first rotational position, each respective guard element is configured for movement to the partially open position upon application of an outward radial force to the guard element relative to the longitudinal axis of the drill rod guard and each respective guard element is configured to return to the closed position upon removal of the outward radial force. 
     
     
         11 . The drill rod guard of  claim 8 , wherein each respective guard element defines an inner shoulder surface, wherein the inner shoulder surface of each guard element of the first set of guard elements is configured to engage a portion of the first shaft to limit bending of the guard element toward the longitudinal axis of the drill rod guard, and wherein the inner shoulder surface of each guard element of the second set of guard elements is configured to engage a portion of the second shaft to limit bending of the guard element toward the longitudinal axis of the drill rod guard. 
     
     
         12 . The drill rod guard of  claim 1 , wherein each guard element has a proximal end operatively coupled to one of the first and second shafts and an opposed distal end, wherein the distal end of each guard element comprises at least one engagement member, and wherein the at least one engagement member of each respective guard element of the first set of guard elements is configured for complementary engagement with the at least one engagement member of a corresponding guard element of the second set of guard elements. 
     
     
         13 . A drilling system configured for drilling relative to a drilling axis,
 comprising:   a drill head assembly;   a drill rod operatively coupled to the drill head assembly;   a feed shell having first and second side portions positioned on opposing sides of the drilling axis, the feed shell being configured to receive at least a portion of a drill rod; and   a drill rod guard comprising:
 a feed shaft assembly configured to support the feed shell, the feed shaft assembly comprising at least one support element, wherein each support element comprises opposed first and second side portions, the first side portion being positioned proximate the first side portion of the feed shell and the second side portion of each support element being positioned proximate the second side portion of the feed shell; 
 opposed first and second shafts, the first shaft being pivotally coupled to the first side portions of each support element of the feed shaft assembly, the second shaft being pivotally coupled to the second side portions of each support element of the feed shaft assembly, wherein the first shaft is configured for selective rotation relative to a first rotational axis and the second shaft is configured for selective rotation relative to a second rotational axis, and wherein the first rotational axis and the second rotational axis are substantially parallel to the drilling axis; and 
 a plurality of guard elements, the plurality of guard elements comprising a first set of guard elements operatively coupled to the first shaft and a second set of guard elements operatively coupled to the second shaft, each guard element of the first set of guard elements being substantially opposed from and configured for selective engagement with a corresponding guard element of the second set of guard elements, 
   wherein, upon engagement between the first set of guard elements and the second set of guard elements, the plurality of guard elements are configured to cooperate with the first and second side portions of the feed shell to substantially enclose the portion of the drill rod within the feed shell.   
     
     
         14 . The drilling system of  claim 13 , wherein the at least one support element of the feed shaft assembly comprises a plurality of support elements spaced relative to the drilling axis. 
     
     
         15 . The drilling system of  claim 13 , wherein the first side portion of each support element of the feed shaft assembly comprises a bore configured to receive a portion of the first shaft, and wherein the second side portion of each support element of the feed shaft assembly comprises a bore configured to receive a portion of the second shaft. 
     
     
         16 . The drilling system of  claim 13 , further comprising a plurality of bushings positioned between adjacent guard elements of the plurality of guard elements. 
     
     
         17 . The drilling system of  claim 13 , wherein the first and second shafts are configured for rotation about and between a first rotational position and a second rotational position, wherein when the first and second shafts are positioned in the first rotational position, each respective guard element is configured for movement about and between a closed position and a partially open position, wherein in the closed position, the guard element is positioned for engagement with a corresponding opposed guard element. 
     
     
         18 . The drilling system of  claim 17 , wherein when the first and second shafts are positioned in the second rotational position, each respective guard element is positioned in a fully open position to permit access to the drill rod. 
     
     
         19 . The drilling system of  claim 17 , wherein each guard element of the plurality of guard elements is biased toward the closed position. 
     
     
         20 . The drilling system of  claim 19 , wherein the first set of guard elements is rigidly mounted to the first shaft, wherein the second set of guard elements is rigidly mounted to the second shaft, and wherein each guard element comprises an outer portion that defines a hinge configured to bias the guard element toward the closed position. 
     
     
         21 . The drilling system of  claim 20 , wherein at least a portion of each guard element comprises an elastic material. 
     
     
         22 . The drilling system of  claim 19 , wherein the drill head assembly is configured for selective axial movement along a length of the feed shell relative to the drilling axis, wherein the drill head assembly comprises plurality of drill head components and a deflecting frame that generally defines an outer periphery of the drill head assembly and is spaced from the plurality of drill head components, wherein upon axial movement of the drill head assembly through the drill rod guard, the deflecting frame is configured to contact inner surfaces of the plurality of guard elements. 
     
     
         23 . The drilling system of  claim 22 , wherein when the first and second shafts are positioned in the first rotational position and the drill head assembly moves through the drill rod guard relative to the drilling axis, each respective guard element is configured for movement to the partially open position upon application of an outward radial force to the guard element by the deflecting frame of the drill head assembly and each respective guard element is configured to return to the closed position when the outward radial force is removed upon disengagement between the deflecting frame and the guard element. 
     
     
         24 . The drilling system of  claim 20 , wherein each respective guard element defines an inner shoulder surface, wherein the inner shoulder surface of each guard element of the first set of guard elements is configured to engage a portion of the first shaft to limit bending of the guard element toward the drilling axis, and wherein the inner shoulder surface of each guard element of the second set of guard elements is configured to engage a portion of the second shaft to limit bending of the guard element toward the drilling axis. 
     
     
         25 . The drilling system of  claim 13 , wherein each guard element has a proximal end operatively coupled to one of the first and second shafts and an opposed distal end, wherein the distal end of each guard element comprises at least one engagement member, and wherein the at least one engagement member of each respective guard element of the first set of guard elements is configured for complementary engagement with the at least one engagement member of a corresponding guard element of the second set of guard elements. 
     
     
         26 . A method of drilling relative to a drilling axis, comprising:
 operatively coupling a drill rod to a drill head assembly;   positioning at least a portion of the drill rod within a feed shell, the feed shell having first and second side portions positioned on opposing sides of the drilling axis; and   using a drill rod guard to substantially enclose the portion of the drill rod within the feed shell, the drill rod guard comprising:
 a feed shaft assembly configured to support the feed shell, the feed shaft assembly comprising at least one support element, wherein each support element comprises opposed first and second side portions, the first side portion being positioned proximate the first side portion of the feed shell and the second side portion of each support element being positioned proximate the second side portion of the feed shell; 
 opposed first and second shafts, the first shaft being pivotally coupled to the first side portions of each support element of the feed shaft assembly, the second shaft being pivotally coupled to the second side portions of each support element of the feed shaft assembly, wherein the first shaft is configured for selective rotation relative to a first rotational axis and the second shaft is configured for selective rotation relative to a second rotational axis, and wherein the first rotational axis and the second rotational axis are substantially parallel to the drilling axis; and 
 a plurality of guard elements, the plurality of guard elements comprising a first set of guard elements operatively coupled to the first shaft and a second set of guard elements operatively coupled to the second shaft, each guard element of the first set of guard elements being substantially opposed from and configured for selective engagement with a corresponding guard element of the second set of guard elements, 
   wherein, upon engagement between the first set of guard elements and the second set of guard elements, the plurality of guard elements cooperate with the first and second side portions of the feed shell to substantially enclose the portion of the drill rod within the feed shell.   
     
     
         27 . (canceled) 
     
     
         28 . The method of  claim 26 , further comprising:
 selectively positioning the plurality of guard elements in an open position when the drill head assembly is not in use, wherein in the open position the first set of guard elements is disengaged from the second set of guard elements.   
     
     
         29 . The drilling method of  claim 26 , wherein the at least one support element of the feed shaft assembly of the drill rod guard comprises a plurality of support elements spaced relative to the drilling axis.