Roller butter rock boring apparatus and method

Claim 2

An earth boring machine comprising: a rotary cutter carrier having an open center; a plurality of cutter assemblies on said carrier spaced radially and angularly apart, each said cutter assembly comprising a kerf forming disc cutter wheel and mounting means mounting said cutter wheel for free rotation about its axis and rolling travel along a circular path concentrically related to the paths of the other cutter wheels, with the innermost said cutter assembly placing its cutter wheel closely adjacent the outer boundary of said open center; a rotary shaft in said open center having tool joint means at its forward end; a relatively high speed center zone cutter having a mounting portion including tool joint means connected to the tool joint means of said shaft, and a cutting portion including abrasion type cutter means substantially filling the circular center zone inwardly of said innermost cutter wheel and axially forwardly of said shaft, said cutting portion sweeping a path during use which has a forward boundary that is substantially even with the forward boundary of the cutting path traveled by said innermost cutter assembly; means for rotating said cutter carrier at the angular velocity necessary for effective operation of said disc cutter wheels; means for rotating said shaft and said center zone cutter at a faster angular velocity necessary for effective operation of said abrasion type cutter means; and means for moving said boring machine axially forwardly, with the cutter wheels and the center zone cutter advancing axially together at substantially the same rate.

Claim 3

The earth boring machine of claim 1, wherein said cutter carrier has a central tubular hub portion, the interior of which forms said open center, and said shaft is journaled for rotation within said hub portion, and said boring machine further comprises seal means between said shaft and said hub portion near the forward end of said open center.

Claim 4

The earth boring machine of claim 2, wherein said seal means comprises a first hard material seal element carried by said hub and having a forwardly directed seal face, and a second hard material seal element carried by said shaft and having a rearwardly directed seal face in tight contact with the seal face of said first seal element, with both of said seal elements being annular and both surrounding said shaft.

Claim 5

The earth boring machine of claim 1, wherein at least the innermost cutter assembly includes a cutter wheel located closely adjacent the radially outer boundary of the center zone cutter.

Claim 6

An earth boring machine comprising: a rotary cutter carrier having an open center; a plurality of cutter assemblies on said carrier spaced radially and angularly apart, each said cutter assembly comprising a kerf forming disc cutter wheel and mounting means mounting said cutter wheel for free rotation about its axis and rolling travel along a circular path concentrically related to the paths of the other cutter wheels, with the innermost said cutter assembly placing its cutter wheel closely adjacent the outer boundary of said open center, said cutter carrier having a central tubular hub portion, the interior of which forms said open center; a rotary shaft in said open center having tool joint means at its forward end, said shaft being journaled for rotation within said hub portion; a relatively high speed center zone cutter having a mounting portion including tool joint means connected to the tool joint means of said shaft, and a cutting portion including abrasion type cutter means substantially filling the circular center zone inwardly of said innermost cutter wheel and axially forwardly of said shaft; means for rotating said cutter carrier at the angular velocity necessary for effective operation of said disc cutter wheels; a motor mount carried by and rotated with the cuttEr carrier; means for rotating said shaft and said center zone cutter at a faster angular velocity necessary for effective operation of said abrasion type cutter means, said means comprising a motor means drivingly connected to said rotary shaft, including a housing which is secured to and rotates with said motor mount; and means for moving said boring machine axially forwardly, with the cutter wheels and the center zone cutter advancing axially together at substantially the same rate.

Claim 7

An earth boring machine comprising: a rotary cutter carrier having an open center; a plurality of cutter assemblies on said carrier spaced radially and angularly apart, each said cutter assembly comprising a kerf forming disc cutter wheel and mounting means mounting said cutter wheel for free rotation about its axis and rolling travel along a circular path concentrically related to the paths of the other cutter wheels, with the innermost said cutter assembly placing its cutter wheel closely adjacent the outer boundary of said open center, said cutter carrier having a central tubular hub portion, the interior of which forms said open center; a rotary shaft in said open center having tool joint means at its forward end, said shaft being journaled for rotation within said hub portion; a relatively high speed center zone cutter having a mounting portion including tool joint means connected to the tool joint means of said shaft, and a cutting portion including abrasion type cutter means substantially filling the circular center zone inwardly of said innermost cutter wheel and axially forwardly of said shaft; means for rotating said cutter carrier at the angular velocity necessary for effective operation of said disc cutter wheels; a motor mount carried by and rotated with the cuttEr carrier; means for rotating said shaft and said center zone cutter at a faster angular velocity necessary for effective operation of said abrasion type cutter means, said means comprising a motor means drivingly connected to said rotary shaft, including a housing which is secured to and rotates with said motor mount; and means for moving said boring machine axially forwardly, with the cutter wheels and the center zone cutter advancing axially together at substantially the same rate.

Claim 8

The earth boring machine of claim 5, wherein said motor is a fluid motor having a supply port and said machine includes a stationary fluid supply conduit, and swivel coupler means interconnected between said stationary supply conduit and the supply and port of said motor.

Claim 9

The earth boring machine of claim 5, wherein said motor mount comprises an elongated tubular member at least the forward portion of which is located inside said tubular hub, said rotary shaft is housed within said tubular member and bearing means are located radially between said shaft and said tubular member, with said motor means being removably secured to a rear portion of said tubular member, and said motor means having an output shaft coaxially related to and coupled to said rotary shaft.

Claim 10

The earth boring machine of claim 7, wherein said boring machine further comprises seal means between said shaft and said hub portion, said seal means comprising a first seal element carried by said hub and having a seal face of hard material, and a second seal element carried by said shaft and having a seal face of a second hard in tight contact with the seal face of said first seal element, with both of said seal elements being annular and both surrounding said shaft.

Claim 11

An earth boring machine comprising: a rotary cutter carrier having an open center; a plurality of cutter assemblies on said carrier spaced radially and angularly apart, each said cutter assembly comprising a kerf forming disc cutter wheel and mounting means mounting said cutter wheel for free rotation about its axis and rolling travel along a circular path concentrically related to the paths of the other cutter wheels, with the innermost said cutter assembly placing its cutter wheel closely adjacent the outer boundary of said open center, said cutter carrier having a central tubular hub portion, the interior of which forms said open center; a rotary shaft in said open center having tool joint means at its forward end; a relatively high speed center zone cutter having a mounting portion including tool joint means connected to the tool joint means of said shaft, and a cutting portion including abrasion type cutter means substantially filling the circular center zone inwardly of said innermost cutter wheel and axially forwardly of said shaft; said machine also including a cutterhead support frame, a tubular support member having a rearward portion secured to said support frame and a forward portion which projects forwardly into said open center, with said rotary shaft being journaled for rotation within said tubular support member; means for rotating said cutter carrier at the angular velocity necessary for effective operation of said disc cutter wheels; means for rotating said shaft and said center zone cutter at a faster angular velocity necessary for effective operation of said abrasion type cutter means, said means comprising motor means secured to said support frame, and means drivingly interconnecting the motor means and said rotary shaft; and means for moving said boring machine axially forwardly, with the cutter wheels and the center zone cutter advancing axially together at substantially the same rate.

Claim 12

An earth boring machine comprising: a rotary cutter carrier having an open center; a plurality of cutter assemblies on said carrier spaced radially and angularly apart, each said cutter assembly comprising a kerf forming disc cutter wheel and mounting means mounting said cutter wheel for free rotation about its axis and rolling travel along a circular path concentrically related to the paths of the other cutter wheels, with the innermost said cutter assembly placing its cutter wheel closely adjacent the outer boundary of said open center, said cutter carrier having a central tubular hub portion, the interior of which forms said open center; a rotary shaft in said open center having tool joint means at its forward end; a relatively high speed center zone cutter having a mounting portion including tool joint means connected to the tool joint means of said shaft, and a cutting portion including abrasion type cutter means substantially filling the circular center zone inwardly of said innermost cutter wheel and axially forwardly of said shaft; said machine also including a cutterhead support frame, a tubular support member having a rearward portion secured to said support frame and a forward portion which projects forwardly into said open center, with said rotary shaft being journaled for rotation within said tubular support member; means for rotating said cutter carrier at the angular velocity necessary for effective operation of said disc cutter wheels; means for rotating said shaft and said center zone cutter at a faster angular velocity necessary for effective operation of said abrasion type cutter means, said means comprising motor means secured to said support frame, and means drivingly interconnecting the motor means and said rotary shaft; and means for moving said boring machine axially forwardly, with the cutter wheels and the center zone cutter advancing axially together at substantially the same rate.

Claim 13

The earth boring machine of claim 9, wherein an axially movable support sleeve is located inside of said tubular support member, said rotary shaft is rotatably supported in said support sleeve and is axially movable therewith, said motor means includes an output shaft and a spline connecTed to said rotary shaft, and said machine further includes transducer means interconnected between said movable sleeve and a portion of said support frame, for both limiting axial movement of said rotary shaft and measuring the thrust forces imposed on the center zone cutter by the material being bored.

Claim 14

An improved method of boring hard rock or earth formations comprising: providing a rotatable carrier with a plurality of kerf forming disc cutter wheels in sufficient numbers to result in contiguous radial and circumferential spacing of such cutter wheels over the full extent of the carrier; mounting the cutter wheels on said carrier, each with its forward cutting boundary substantially on a common radially continuous cutting face with the forward cutting boundary of each adjacent cutter wheel; mounting each cutter wheel for both free rotation about its axis and rolling travel along a circular path concentrically related to both the paths of the other cutter wheels and the axis of rotation of said carrier; locating an abrasion type cutter at the center of said carrier to rotate in a path having a forward boundary that is substantially even with the forward boundary of the path traveled by at least the innermost cutter wheel; and moving said carrier, the cutter wheels thereon, and said abrasion type cutter axially forwardly at substantially the same rate of travel while rotating said cutter carrier at an angular velocity necessary for effective operation of said disc cutter wheels, and rotating said abrasion type cutter at a faster angular velocity necessary for effective operation of said abrasion type cutter means.

Claim 15

An improved method of boring hard rock or earth formations comprising: providing a rotatable carrier with a plurality of kerf forming disc cutter wheels in sufficient numbers to result in contiguous radial and circumferential spacing of such cutter wheels over the full extent of the carrier; mounting the cutter wheels on said carrier, each with its forward cutting boundary substantially on a common radially continuous cutting face with the forward cutting boundary of each adjacent cutter wheel; mounting each cutter wheel for both free rotation about its axis and rolling travel along a circular path concentrically related to both the paths of the other cutter wheels and the axis of rotation of said carrier; locating an abrasion type cutter at the center of said carrier to rotate in a path having a forward boundary that is substantially even with the forward boundary of the path traveled by at least the innermost cutter wheel; and moving said carrier, the cutter wheels thereon, and said abrasion type cutter axially forwardly at substantially the same rate of travel while rotating said cutter carrier at an angular velocity necessary for effective operation of said disc cutter wheels, and rotating said abrasion type cutter at a faster angular velocity necessary for effective operation of said abrasion type cutter means.

Claim 16

The method of claim 11, further comprising sensing the axial thrust forces on said abrasion type cutter and changing the angular velocity of said cutter in response to a change in the thrust force, towards a more efficient operation of said cutter.

Claim 17

An earth boring machine comprising: an inner rotary cutter carrier; an annular outer rotary cutter carrier concentrically surrounding said inner carrier; a plurality of cutter assemblies on each carrier spaced both radially and angularly apart, each said cutter assembly comprising a cutter wheel and mounting means mounting the cutter wheel for free rotation about its axis and rolling travel along a circular path concentrically related to the paths of the other cutter wheels, with the distance between adjacent cutter wheel paths being less than the radial length of a cutter assembly, with the cutter assemblies on the outer carrier placing a plurality but equal number of cutter wheels on each outer carrier cutter wheel path, with the inner radial boundary of the outer cutter carrier and the outer radial boundary of the inner cutter carrier being substantially immediately radially inwardly of where the angular space between angularly adjacent cutter assemblies is less than the width of a cutter assembly, and wherein the cutter assemblies on the inner carrier place a single cutter on each inner carrier cutter wheel path; means for rotating the outer cutter carrier at a predetermined angular velocity; and means for rotating the inner cutter carrier at a substantially faster angular velocity.

Claim 18

An earth boring machine comprising: an inner rotary cutter carrier; an annular outer rotary cutter carrier concentrically surrounding said inner carrier; a plurality of cutter assemblies on each carrier spaced both radially and angularly apart, each said cutter assembly comprising a cutter wheel and mounting means mounting the cutter wheel for free rotation about its axis and rolling travel along a circular path concentrically related to the paths of the other cutter wheels, with the distance between adjacent cutter wheel paths being less than the radial length of a cutter assembly, with the cutter assemblies on the outer carrier placing a plurality but equal number of cutter wheels on each outer carrier cutter wheel path, with the inner radial boundary of the outer cutter carrier and the outer radial boundary of the inner cutter carrier being substantially immediately radially inwardly of where the angular space between angularly adjacent cutter assemblies is less than the width of a cutter assembly, and wherein the cutter assemblies on the inner carrier place a single cutter on each inner carrier cutter wheel path; means for rotating the outer cutter carrier at a predetermined angular velocity; and means for rotating the inner cutter carrier at a substantially faster angular velocity.

Claim 19

An earth boring machine according to claim 13, wherein at least the innermost cutter assembly on the outer carrier, and at least the outermost cutter assembly on the inner carrier, each comprises mounting means located wholly on the side of its cutter wheel directed away from the boundary between the two carriers.

Claim 20

An earth boring machine according to claim 13, wherein the innermost cutter assemblies on the outer carrier, and the outermost assembly on the inner carrier, each comprises an exposed full side face located closely adjacent the boundary between the inner and outer carriers.

Claim 21

An earth boring machine according to claim 13, further comprising a fixed support, bearing means mounting the outer cutter carrier on said support, for rotation theReabout, and bearing means between said inner and outer cutter carrier, whereby said inner carrier is supported by said outer carrier.

Claim 22

An earth boring machine according to claim 16, wherein said fixed support is tubular and a speed increasing planetary gear means is housed within the forward portion thereof, and said gearing drivenly connects the outer carrier to the inner carrier, and drive means for directly driving the outer carrier.

Claim 23

In an earth boring operation, a method of arranging and utilizing roller cutters, comprising: mounting a plurality of roller cutters on each of an inner rotary cutter carrier and an annular outer rotor cutter carrier concentrically surrounding said inner carrier; on each cutter carrier spacing the roller cutters both radially and angularly apart; on each cutter carrier mounting each roller cutter for both free rotation about its axis and rolling travel along a circular path concentrically related to the paths of the outer cutter wheels; on each cutter carrier radially spacing the roller cutters relatively close together so that the distance between adjacent cutter paths is less than the combined radial length of a cutter and its mounting means; on the outer cutter carrier placing a predetermined plurality but equal number of roller cutters on each cutter wheel path; locating the inner radial boundary of the outer cutter carrier, and the outer radial boundary of the inner cutter carrier, substantially immediately radially inwardly of the smallest circular path on to which space availability on the outer carrier will permit the placement of said predetermined plural number of roller cutters; on the inner carrier placing a single cutter wheel on each inner carrier cutter wheel path; rotating the outer cutter carrier at a predetermined angular velocity; and rotating the inner cutter carrier at a substantially faster angular velocity.

Claim 24

In an earth boring operation, a method of arranging and utilizing roller cutters, comprising: mounting a plurality of roller cutters on each of an inner rotary cutter carrier and an annular outer rotor cutter carrier concentrically surrounding said inner carrier; on each cutter carrier spacing the roller cutters both radially and angularly apart; on each cutter carrier mounting each roller cutter for both free rotation about its axis and rolling travel along a circular path concentrically related to the paths of the outer cutter wheels; on each cutter carrier radially spacing the roller cutters relatively close together so that the distance between adjacent cutter paths is less than the combined radial length of a cutter and its mounting means; on the outer cutter carrier placing a predetermined plurality but equal number of roller cutters on each cutter wheel path; locating the inner radial boundary of the outer cutter carrier, and the outer radial boundary of the inner cutter carrier, substantially immediately radially inwardly of the smallest circular path on to which space availability on the outer carrier will permit the placement of said predetermined plural number of roller cutters; on the inner carrier placing a single cutter wheel on each inner carrier cutter wheel path; rotating the outer cutter carrier at a predetermined angular velocity; and rotating the inner cutter carrier at a substantially faster angular velocity.

Claim 25

An earth boring machine comprising: a rotary cutter carrier including an inner zone and an annular outer zone concentrically surrounding said inner carrier; a plurality of cutter assemblies in each said zone spaced both radially and angularly apart, each said cutter assembly comprising a cutter wheel and mounting means mounting the cutter wheel for free rotation about its axis and rolling travel along a circular path concentrically related to the paths of the other cutter wheels, with the distance between adjacent cutter wheel paths being less than the radial length of a cutter assembly, with the cutter assemblies in the outer zone placing a plurality but equal number of cutter wheels on each outer carrier cutter wheel path, with the inner radial boundary of the outer zone and the outer radial boundary of the inner zone being substantially immediately radially inwardly of where the angular space between angularly adjacent cutter assemblies is less than the width of a cutter assembly, and with the cutter assemblies in the inner zone placing a single cutter on each cutter wheel path of the inner zone; a center zone cutter mounted for independent rotation at the center of said cutter carrier, said cutter being of a type which requires a relatively high rotational velocity for effective utilization and long life; means for advancing both the cutter carrier, and the cutter wheels carried thereby, and the center zone cutter, axially forwardly into the material being bored; means for rotating the cutter carrier at an angular velocity necessary for effective operation of the cutter wheels; and means for rotating the inner cutter carrier at a substantially faster angular velocity necessary for effective operation of said center zone cutter.

Claim 26

An earth boring machine comprising: a rotary cutter carrier including an inner zone and an annular outer zone concentrically surrounding said inner carrier; a plurality of cutter assemblies in each said zone spaced both radially and angularly apart, each said cutter assembly comprising a cutter wheel and mounting means mounting the cutter wheel for free rotation about its axis and rolling travel along a circular path concentrically related to the paths of the other cutter wheels, with the distance between adjacent cutter wheel paths being less than the radial length of a cutter assembly, with the cutter assemblies in the outer zone placing a plurality but equal number of cutter wheels on each outer carrier cutter wheel path, with the inner radial boundary of the outer zone and the outer radial boundary of the inner zone being substantially immediately radially inwardly of where the angular space between angularly adjacent cutter assemblies is less than the width of a cutter assembly, and with the cutter assemblies in the inner zone placing a single cutter on each cutter wheel path of the inner zone; a center zone cutter mounted for independent rotation at the center of said cutter carrier, said cutter being of a type which requires a relatively high rotational velocity for effective utilization and long life; means for advancing both the cutter carrier, and the cutter wheels carried thereby, and the center zone cutter, axially forwardly into the material being bored; means for rotating the cutter carrier at an angular velocity necessary for effective operation of the cutter wheels; and means for rotating the inner cutter carrier at a substantially faster angular velocity necessary for effective operation of said center zone cutter.

Claim 27

The earth boring machine of claim 19, wherein said cutter carrier has a central tubular hub portion, and said center zone cutter is at the forward end of a shaft journaled for rotation within said hub portion, and said boring machine further comprises seal means between said shaft and saiD hub portion comprising a first seal element carried by said hub having a hard material seal face, and a second seal element carried by said shaft and having a hard material seal face in tight contact with the seal face of said first seal element.

Claim 28

The earth boring machine of claim 19, wherein at least the innermost cutter assembly includes an overhung cutter wheel located radially inwardly of its mounting means, and closely adjacent the radially outer boundary of the center zone cutter.

Claim 29

The earth boring machine of claim 19, wherein said cutter carrier has a central tubular hub portion, and said center zone cutter is at the forward end of a shaft journaled for rotation within said hub portion, and said boring machine also comprises a motor mount carried by and rotated with the cutter carrier, and motor means drivenly connected to said rotary shaft, said motor means including a housing which is secured to and rotates with said motor mount.

Claim 30

The earth boring machine of claim 22, wherein said motor is a fluid motor having a supply port and said machine includes a stationary fluid supply conduit, and swivel coupler means interconnected between said stationary supply conduit and the supply and port of said motor.

Claim 31

The earth boring machine of claim 22, wherein said motor mount comprises an elongated tubular member at least the forward portion of which is located inside said tubular hub, said rotary shaft is housed within said tubular member and bearing means are located radially between said shaft and said tubular member, with said motor means being removably secured to a rear portion of said tubular member, and said motor means having an output shaft coaxially related to and coupled to said rotary shaft.

Claim 32

The earth boring machine of claim 19, wherein said cutter carrier has a central tubular hub portion, the center zone cutter is at the forward end of a short shaft, and said machine includes a cutterhead support frame, a tubular support member having a rearward portion secured to said support frame and a forward portion which projects forwardly into said open center, with said shaft being journaled for rotation within said tubular support member, motor means carried at the rear of said tubular support member, and means drivenly interconnecting the motor means and said shaft.

Claim 33

An earth boring machine comprising a frame having a forwardly directed tubular portion of relatively large diameter; a cutter carrier having an annular support portion positioned concentrically surrounding said tubular portion of the frame, and a generally radial forward cutter carrying part portion forwardly of, and extending both radially inwardly and radially outwardly from, the forward end of the tubular portion of said frame, and having an open center; a plurality of roller type cutters mounted on said cutter carrying part; bearing means located radially between said tubular frame portion and the annular support portion of the cutter carrier, and serving to rotatably mount the cutter carrier onto said tubular housing, for rotation thereabout; and an inner cutter assembly in the open center of said cutter carrier, said inner cutter assembly including a short drive shaft journaled in the tubular forward portion of the frame for rotation about an axis coincident with the axis of rotation of the cutter carrier, forwardly directed cutter means at its forward end, and drive means contained wholly within said tubular portion of the frame, for rotating the inner cutter carrier at a higher angular velocity than the outer cutter carrier.

Claim 34

An earth boring machine comprising a frame having a forwardly directed tubular portion of relatively large diameter; a cutter carrier having an annular support portion positioned concentrically surrounding said tubular portion of the frame, and a generally radial forward cutter carrying part portion forwardly of, and extending both radially inwardly and radially outwardly from, the forward end of the tubular portion of said frame, and having an open center; a plurality of roller type cutters mounted on said cutter carrying part; bearing means located radially between said tubular frame portion and the annular support portion of the cutter carrier, and serving to rotatably mount the cutter carrier onto said tubular housing, for rotation thereabout; and an inner cutter assembly in the open center of said cutter carrier, said inner cutter assembly including a short drive shaft journaled in the tubular forward portion of the frame for rotation about an axis coincident with the axis of rotation of the cutter carrier, forwardly directed cutter means at its forward end, and drive means contained wholly within said tubular portion of the frame, for rotating the inner cutter carrier at a higher angular velocity than the outer cutter carrier.

Claim 35

The earth boring machine of claim 26, wherein said drive means comprises a system of speed increasing gears interconnected between a radially inner portion of the cutter carrier and said drive shaft, and means for rotatively driving said cutter carrier with it in turn driving said drive shaft through the intermediacy of said system of gears.

Claim 36

The earth boring machine of claim 26, wherein the drive means for the drive shafT is a motor which is at least partially housed within the tubular housing portion of the frame and includes an output shaft which is drivenly connected to said drive shaft.