AONE 0 ‘US 2016008401681 cu») United States cz) Patent Application Publication co) Pub. No.: US 2016/0084016 A1 Slaughter, JR. et al. (43) Pub. Dat Mar. 24, 2016 (54) HORIZONTAL DIRECTIONAL D ublication Clasifiation DRIVE CONNECTION WITH LOCKING FEATURE (50) In E2IB 17046 (2006.01) (71). Applicont: The Charles Machine Works, Ine. F168 X00 (2006.01) Perry. OK (US) 2B 17082 (2006.01) (2) US.CL (72) Inventors: Greg L. Staughter, JR. Per, OK (US); che E218 17/046 201301), £200 177042 Floyd R. Gunsauls, Pore. OK (US) (2013.01), F768 400 (201301) Max A. Metcalf, Stillwater, OK (US) oN ABSTRACT (21) Appl. Nos 149960,639 The present invention is directed to a spindle assembly for connecting a drill string to a rotational drive for vse in a Filed: Dee. 7.2018 horizontal directional drilling operation. The assembly com- prises saver sub attached tothe rotational drive, and a drive Related US. Application Data chuck for connection wo the dil siting. The drive ebuck and Saver sub form a torguc-transmitting connection by engaging ‘hrougha seatin the saversuband an. engagement point onthe drive chuck. Dowel pins may he used to eotationaly lock and (60) Provisional application No. 61/823,015, filed on May provide the engagement hesween the saver suh and the drive 14, 2013, provisional application No. 61/683,968, chick. A collar may thread to the saver sub and emuse an fled on Aug. 16, 2012, interference fit by engaging the dive chuek at a shoulder. (63) Continuation of application No, 13/965,961, filed on Aug. 13, 2013, sow Pat. No. 9.206851Patent Application Publication Mar. 24, 2016 Sheet 1 of 8 US 2016/0084016 AI 15 16 FIG. | 7Patent Application Publication Mar. 24, 2016 Sheet 2 of 8 US 2016/0084016 AI FIG. 2Patent Application Publication Mar. 24, 2016 Sheet 3 of 8 72 20 34 - 44 / i: TE 64 \ Le 30 46 70 32 al US 2016/0084016 AI FIG. 3Patent Application Publication Mar. 24, 2016 Sheet 4 of 8 t So iL US 2016/0084016 AIPatent Application Publication Mar. 24, 2016 Sheet 5 of 8 US 2016/0084016 AI A 48 o : 7 Y L 92 2i FIG. 5Patent Application Publication Mar. 24, 2016 Sheet 6 of 8 US 2016/0084016 AI FIG. 6Patent Application Publication Mar. 24, 2016 Sheet 7 of 8 ‘US 2016/0084016 AL 18 40 102 100 26 30 Le ea FIG. 7 22 20 m\Patent Application Publication Mar. 24, 2016 Sheet 8 of 8 US 2016/0084016 AI FIG. 8US 2016/0084016 AI HORIZONTAL DIRECTIONAL DRILL PIPE, DRIVE CONNECTION WITH LOCKING. FEATURE ‘CROSS REFERENCE TO RELATED "APPLICATION [0001] This application is a continuation of U.S. patent application Ser. No. 13/965,961, fled Aug. 13, 2013, now US. Pat, No, 9,206 851, which claims the henefit of provi- sional patent application Ser No, 61/823,015, filed May’ 14, 2013, and provisional patent application Ser No, 61/683,968, Sled Aug. 16, 2012, the enire contents of which are incorpo” rated herein by reference. FIELD 10002] The present invention relates generally to eonnee- tion mechanisms for tansferring torque to adil string in horizontal directional dling processes BACKGROUND [0003] Horizontal boring machines are used to install i= fay services oroher products underground. Horizontal dree- tional drilling eliminates surface disruption along the length ‘ofthe project, except atthe entry and exit points, and rauces, the likelihood of damaging previously buried products, 10004] The boring operation isa process of using a boring ‘machine to advance adel string through the ear along & desired path, The boring machine generally comprises a Jame, drive system mounted on the frame andl connected 10 ‘one end ofthe dil string, and a boring tool connect the ‘other end ofthe drill string. The drive system provides thrust, ‘and rotation needed to advance the dil sting andthe boring tool through the earth, The drill string is generally comprised ‘ofa plurality of dil pipe sections joined together at threaded. ‘connections. As the pilot bore operation proceeds, the dill, ‘rings lengthened by repeatedly adding pipe setions wo the dil string [0005] _ When he pilot bore operations completed, the dil ‘tring ispulled back through the borehole during a backream- ing operation, generally with the uy line or prodiet to be installed underground connected to the end ofthe drill tring. uring this backreaming operation, pipe sections are removed from the drill string asthe dil string gts shorter. ach imea pipe section istaken from the drill string Asis the ‘case with the alton of pipe sections tothe dri string, the process is repetity [0006] A “Uriver" or “saver sub is used asaconnection to transmit the tongue and thnistpallback forees generated by the relational drive of an FIDD machine toa dil string. The ‘connection comes in contact with every pipe involved with 3 boring operation during both boring and pull-back and thus ‘encounters high rates of wear on the connection surfaces of the component, Assueh, itis beneficial to make the part easily replaceable. Further, iis beneficial to limit the wear points oF the saver sub such that itis easy to replace, without requiring ‘excessive abort rebuild the saver sub SUMMARY, 10007] The present invention comprises torgue-transmit- ting assembly for use with a rotational drive used in a hori- ‘ontal directional drilling operation. The assembly comprises 8 siver sub and drive chick. The saver sub s rotationally ‘attached tothe rotational drive and comprises seat and 8 Mar. 24, 2016 ‘threaded portion, The drive chuck comprises an engagemes point to engage the sat and a connection member for atc ‘meat tothe cell string, The deve chuek and saver sub are ationally locked. [0008] In another embodiment of the invention, it is directed 10 4 torque-transmitting assembly for use with a ‘ational drive used ina horizontal directional drilling per- tion, Theassembly comprises saver sub, acive chuek, and ‘colar. The saver suis rotationally attached to the rotational rive. The saver sub comprises seat and a threaded portion. The drive chuck comprises a shoulder, an engagement pot to engage the sea, and a connection member for attachment to the dill string. The collar comprises threaded porioa and an nteral shoulder. The interal shoulder contacts the shoul- ‘er of the drive chuck such that threading the collar onto the saver sub roationally leks the saver sub to the drive chuck [0009] In another embodiment, the invention is directed to 4 spindle assembly for rotating a drill sting. The spindle assembly comprises a saver sub, a drive chuck, and a colar The drivechuek is engazed with the saver sub in non-threaded ‘orque-ransmitting engagement. Te collar is disposed abe both an outer surface of the saver sub and aa outer surface of the drive chuck to secure the saver sub tothe drive chuck. The colle is tread on the saver sub BRIEE DESCRIPTION OF THE DRAWINGS. [0010] FIG. 1is aside view of an HDD machine and drill string for use with the spindle assembly of the invention disclosed herein. [0011] FIG. 2 is an exploded perspective view of compo- ‘ent parts ofa spindle assembly [0012] FIG. 3 is a sectional side view of the assembled spindle assembly of FIG. 2 [0013] FIG. 4a sectional exploded perspective view of a cola drive chuck, anda wreach for use withthe spine assembly of FIG. 2 [0014] FIG. Sis an exploded perspective view of an alter- ative embodiment of a spindle assembly. [0015] FIG. 6 is a perspective view of the assembled spindle assembly of FIG. 5. [0016] FIG. 7 is a soctiona side view of an altemative ‘embodiment of a spindle assembly. [0017] FIG. 8 isan exploded perspective view of an alter- ‘ative embodiment of a spindle assembly. DESCRIPTION OF THE PREFERRED EMBODIMENT [0018] ‘Thedisclosed inventionisdectedto atonque-trans- :niting spindle assembly 10 for use in horizontal diretional Grilling operations for boring under a surface of the ground 11. With reference to FIG. 1, the spindle assembly 10 con- ‘ects rotational deve 12 ofa horizontal directional dilling (HDD) apparatus 14 to a dail ssing 16, The dell sting 16 comprises a plurality of segments which meet at pipe joints 18, The spindle assembly 10, when fully assembled scribed in’ more detail below, is replaceable when the repeated making up and breaking out sections of dell pipe ‘uses wear, Rotation of the rotational drive 12 eauses the spindle assembly 10 to rotate, which transits torgue to the Grill string 16 when the HDD apparatus 14 isin operation This torque can make up or break loose the dill string 16US 2016/0084016 AI ‘during sition oF removal of individual pipe sections, oF ‘eansiit thrust and rotation through the drill string to down- hole tool 17, 10019] With reference to FIG. 2, the spindle assembly 10 ‘comprises a saver sub 18, a dive chuck 20, a plurality of ‘dvsel pins 1, and 2 collar 22, The saver sub 18 comprises 9 fist end 24 and a second end 26. The frst end 24 is fixedly attaehed to the rotational drive 12 (FIG. 1). The connection may take place through a ange, a sliding spline connection, ‘4 Welded connection, frictional interference fit, or other suitable methods of joining the tational drive 12 (othe saver sub 18, As shown ia FIG. 2, the saver sub 18 comprises @ spline connection. The second end 26 comprises an opening 28,2 threaded portion 30 anda seat 32. The opening 28 may be formes such that the ceive chuck 20 comes in contact with the inner wall ofthe saver sub 18, oF may be clearance fit sch thatthe saver sub and drive ehuek do not contact one anether ‘within the opening. As shown, the set 32 comprises a plus rality of eastellaions 34 formed in the second end 26. The ‘astellations 34 are configured to engage a torque-camrying Teature to transmit toque from the HDD apparatus 14 (FIG. 1) to the dil string 16 (FIG. 1), As shown herein, the castcl- Jations 34 engage the plurality of dowel pins 21. As shown, there are six dowel pins 2, though other numbers are pos” sible. The eastellations 34 may be formed with a tapered ‘opening to ensure that the dowel pins 21 can slipeasiy inand, ‘out of position when the spindle assembly 10 is not assembled. As shown, the spindle assembly 10 comprises six ‘castellations 34 and dowel pins 21 10020] The drive chuck 20 comprises a first end 40, 9 sec- ‘ond end 42, an engagement point 44 «plurality of depres- sions 46, and a shoulder 48. The first end 40 extends within the opening 28 of the saver sub 18. The first end 40) may ‘operate to transmit thrust between the saver sub 18 and drive chuck 20, or may alternatively only seal the connection between the saver sub and drive ehuek. The second end 42 is 4 connection member for thrust and rotation-transmitting ‘connection toa dill sting (FIG. 1). This connestion atthe second end 42 may be a threaded connection. The threaded ‘connection of the second end 42 may be on the inside oF ‘outside of the drive ehuck 20, The engagement point 44 is ‘adapted t0 engage the seat 32 of the saver sub 18 for tans> mission of rotation forces between the saver sub andthe drive ‘chuck 20, The engagement between the seat 32 and engage ‘ment point 44 also may transmit thnist between the dive ‘chuck 20 and saver sub 18, {0021} The plurality of depressions 46 provide a foeation Torte dowel pins 21 to be placed. Thedepressions 46 may be formed with a tapered opening to allow the dowel pins 21 t0 ‘easily slip into and out ofthe depressions. Altematively, the ‘depressions 46 may ave parallel walls o provide a press-fit ‘connection when the spindle assembly 10 is assembled. The ‘engagement point 44 may be machined such thatthe engage ‘ment point only engayes the seat 32 through the dowel pins 21-Inthis embodiment, no direct connection between the seat 32 and engagement point 4 takes place, and all the trque- transmission and thrist-irnsmission occurs between the seat andthe dowel pins 21 and the dowel pins and the engagement Point. The depressions 46 may be evenly spaced or may be Uunevenly spaced o allow for “clocking” orientation herieen the saver sub 18 and the drive chuck 20, The shoulder 48 ‘comprises a section ofthe drive chuck 20 where the diameter Mar. 24, 2016 ofthe deve ehuek changes. Preferably the shoulder 8 con Pisce aslopedsurlae for interaction wth internal eae of the collar 1. {0022] "The collar 22 comprises fist end 60 ala second aid 62 The ist ed interact withthe thread portion 10 the sver sub 186 hold the elements othe spindle assembly 10 together. One shilled i the set will appreciate tht the spindle assembly could transmit tongue without theuse of the collar 22 (0023) With reference now to FIG. 3 the spindle assembly 10s showa formed together in eosssction. As shown, the dowel pins 21 are located within the depressions 46 ofthe dive chuck 20nd the castllatons M4 ofthe saver sub 18 The depressions 46 have tapered bottom to allow easy removal when te spindle assembly 10 is disassembled. The coll 22 or comprises an intemal shoulder 64 and 9 {hrcaded portion 66 fermen it interal Wal. The head portion 66 is located at the fist end 60 ofthe collar 22 and acts withthe threaded portion 30 ofthe saver sub 18 0 attach the collar to the saver sub. When fully foeme the Jnteral shoulder 64 coatsets the shoulder 48 ofthe deve chuck 20. Ths connection forees the engagement point 44 toward the seat 32. {0024} One sill inthe at will appreciate hat an aneleof contact between the intemal shoulder 6¢ and shoulder 48 ay besetat acute angles, or angles below 48 degrees. This canes a rail component in the preload three bet ees he collar 22 fn the deve chuck 200s the threaded setion 66 ofthe cllar is tighteaod onto the threaded portion 30 of the saver su ‘Thus, during the assembly ofthe spindle assembly 10, some ofthe rotational enemy used frees the diameter of the eallar 22 0 expand and the diameter of the ceive eck 201 con- trae. This reduces relative movement between the saver sb 18 and drive chuck 20 and thus decreases wear on intemal comportets othe spindle assembly 1 (0025) When fully formed, te spindle assembly 10 may oamprise a internal chansel 70 located within the ceater of the saver sub 8 and drive chuck 20. The intemal channel 70 allows ito be transite rom the HDD anachine 1G. 1) {© the dill suing (FIG. 1), seal 72 is located about a Perper ofthe drive eck 20 to prevent Mid rom escaping the connection of the deve chuck and saver sub 18. Aer ‘ately, he seal ould be placed within the opening 28 the Savers or mating wit the fist end 4 ofthe deve chuck 20-As shown, th sal 72 ian o-ring. Other elastomeric or face seal mechanisms may be used to provide a Teak free conncetin between the dive eck 20 ahd the saver sub 18 [0026] Withreteence now 1oF1G. 4 the collar 2 and dive inc 20 are shown in croserctin with erench $0, The ‘wrench comprises handle 8 and locking feature 84. The bande 82 allows an operstor to apply forge and tum the ‘wench 80. The locking feature is adap o mate withthe ‘cond ad 62th coll 22. The second end 62nd locking eature 4 havea complementary polygonal profile. Ths, the wrench 80 may bese Led nd tre the collar 20 to saver sub 18 FIG. 3), The operator may either rotate the swrench 0, othe collar 22 my be eld place by the wrench bravisewhiletherotational drive 12(F1G. 1) rotates the ver sb 1 [0027] With reference to FIG. §, the colle 22 may alten tively heattached tothe saver sob 18 tsi a plurality ofbots 90 though a Dange 92 inthe collar The plurality of bolts apply a clamping load to the drive chuck 20 throwgh is shoulder 48, The saver sub 18 comprises plurality of boltUS 2016/0084016 AI holes 94 adapted to receive the bolts 90, This embediaent transfers torque between the saver sub 18 and drive chuck 20 «through dove pins 21 as deseribed with reference FIGS.2 ‘and 3 10028] When fully connected to the rotational drive 12 of the HDD machine 14, this embodiment of the spindle assem- bly 10 appears as shown in FIG. 6, The spindle assembly 10 is attached tothe rotational drive 12 (FIG. Lat the sub saver 418 trough ange connection. The collar 22 is connected 10 the sub saver 18 through bolts 90. The drive chuck 20 is ‘engagestby the collar 2 at tsshoulder FIG. S)andis adapted or connection toa dil string (not shown) st its sccond end 2. 10029] _Altemative embodiments ofthe spindle assembly 10 without the use of dowel pins are disclosed herein, Wi reference 10 FIG. 7, the first end 40 of the drive chuck 20 ‘comprises an external threaded portion 100. The second end 26 ofthe saver sub 18 comprises an internal threaded portion 4102 within the opening 28. The pitch of the intenal threaded portion 102 may be slightly different than the pitch of the threaded portion 30 of the saver sub 18, Alternatively, the ‘etna threaded portion may allow fora “right-hand” nea While the dareaded portion 30 isa “left-hand” thread, o vice versa As such, the forees generated on the intemal threaded portion during make up and break out ofthe collar 22 on the Ever sub 18 would no snthread the drive chuck 20 [0030] With reference to FIG. 8, another altemative ‘embovliment of the spindle assembly 10 is shown, Tn this ‘embodiment, the seat 32 of the saver sub 18 comprises as tellaions 44. Those castelations 34 are adapted to dioetly ‘engage complementary castelatons 110 of the engagement Point 44 ofthe drive chuck 20. Toryue transmission occurs directly on the complementary eastellations 34, 119. The ‘eastllstions 34, 110 may be machined or casted. As shown, the shoulder 48 ofthe drive chuck 20 is perpendicular, rather than the angled surface of FIG. 3, but it will be appreciated that these may altematively be angled as discussed above. 0031] In operation, the spindle assembly 10 js assembled Joruse with HDD machine 14, The saver sub 18 is ixed tothe rotational drive 12 ofthe HDD machine. The dowel rods 21 are placed within the depressions 46 of te drive chuck 20, ‘The drive chuck 20 s then placed int the saver sub 18 such that the seat 32 is proximate the engagement point 44. As shown in FIG. 2, the saver sub 18 engages the drive chuck 20 Jn tonue-transmitting arrangement through the dowel rods 21, Thecollar22isthen placed around perimeterof thedrive ‘chuck 20 and secured wo the saver sub 18 such thatthespindle assembly is rationally locked. The cola 22 may be tight- ‘nex by sing weench 80, lteratively, the collar 22 may be ‘clamped by vice wrenches (901 shown) of the HDD machine 14, then tightened by rotating the rotational deve 12 of the HDD machine 14 to tightea the eollar oa the sver sub 18. Sections of drill sring 16 may then be threaded onto the drive ‘chuck 20. the spindle assembly is used o male upor break ‘out sections of dil string. and to transmit torque to a doven- hole tool 17 for use in HDD operations, 10032} | While the dowel rods 21 have boon disclosed herein 2 seated in depressions 46 of the drive chuck 20 for interae= tion withcastellationson the saver sub 1, itisanticipatod that this may be reversed. The depressions may altematively be placed onthe saver sub 18 forinteration withcastellaionson the drive chuck 20. In this alternative arrangement, the com- ponents wold sill be constrained by the tightening of the collar 22 Mar. 24, 2016 [0033] One skilled ia the at will appreciate that the ‘embodiments herein are not limiting on the scope of this invention. Altemative mechanisms for locking the spindle assembly 10 together suc that tongue is transmitted between the rotational deve 12 and del sting 16 aro possible with slight variation. For example, the dowel mods 21 may be ‘ntgrally formed with the drive chuck 20. The dowel rods ‘may be replaced with ring that interacts withthe drive chuck 20 and saver sub 18 to transmit torgue [0034] Further, dhe connection discussed herein could also ‘be used to connect the drill string 16 witha downhole tool or culing epparats (aot showa) ata terminal end ofthe dell string [0035] The spindle assembly 10 disclosed may be modified Tor use with a dal-membor dell string 16, for torgue tans- sssion to the inner member, ouler member, oF both (not shown) What is claimed is: 1. torque-transmitting assembly for use ia @ horizontal iretional operation, the assembly comprising: ‘saver sub having an end 8 drive chuck having an end; ‘an extemal collar that joins adjacent ends ofthe saver sub ‘and drive chuck at an interface where they are main- ‘ained in coaxial and non-costating relationship; and ‘an intemal key that locks the drive chuck and saver sub in ‘rotaionally-fied relationship, 2. The tongue-ransmiting assembly ofclaim I whereinthe ey comprises at least one dowel pin, 3. Tho tongus-transmittingassembly’of claim 2 whersin the drive chuck defines at least one depression for placement of the at least one dowel 4 The torque-trans key comprises six dowel pits. '. The tonque-ransmiting assembly ofelaim 2 whereinthe at feast one dowel pin is characterized by a circular cross- section ‘6. The torque-ransmitting assembly ofclaim I whereinthe ey is placed within atleast one recess formed adjacent the interlace ofthe saver sub and the drive chuck. 7.The torque-trans ly of elsim A wherein the rive chuck comprises al least one depression for placement ofthe key. 8. Thelonque-trnsmiting assembly ofclaima 7 whercinthe key i radially removable from the at leat one depression, 9. The torquestransmitting assembly of elim 1 further comprising: a shoulder disposed onthe drive eek; and fan internal shoulder disposed within the collar, ‘wherein te intemal shoulder contacts the shoulder ofthe deve chuck when the siver sub and the collar are attached. 10, The torque-transmiting assembly of claim 9 wherein thesaversub and collar ar attached ina threaded connection. 11, The torue-transmiting assembly of ela 9 wherein the saver sub ad collar are attached with bots 12, The torque-transmiting assembly of claim 9 wherein the drive chuck is attached to dal-member pipe string. 13. A spindle assembly for rotating # dill sting, the spindle assembly comprising saver sub: ‘drive chuck; and ‘akey disposed between thesaversub andthe drivechuck at ‘an engagement point wherein theUS 2016/0084016 AI ‘wherein the saver sub nd dive chuck ae in nonthreaded torjue-iransmilting engagement and are engaged a the engagement point only rough the key. 14, The spindle wssembly of claim 13 further comprising @ collar disposed about the swer sub and the drive chuck, wherein the colliis movable between a locked positon and an unlocked position 15, The spindle assembly of claim 14 wherein the drive ‘chuck is interference ft between the collar and the key when, the collars in the locked postion 16, The spindle assembly of claim 18 wherein the colar ‘comprises an inner shoulder and the deve chuck comprises ‘corresponding outer shoulder. 17. The spindle assembly of claim 13 wherein the drive ‘tuck comprises atleast one depression corresponding tothe key, 18, The spindle assembly of claim 17 wherein the key is radially removable Irom the at least one depression 19. The spindle sssembly of claim 13 wherein the key ‘comprises atleast one dowel pi 20. 4 kt comprising’ ‘collar configured to suround interfacing ends ofa saver ‘ub an a drive chuck to maintain them in coaxial and non-contacting relationship: and 1 plurality of dowel pins configured to lock the collard ‘ver sb and drive chuck in otationally-tixe rela ship. 21 The kit of claim 20 in which each dove pin is regis: trable with concavities formed in each ofthe saver suband the drive chuck Mar. 24, 2016