Drill rod tallying system and method

1. An apparatus for automatic tallying drill rods of a drill string for use with a drilling machine, the machine comprising a rack and a rotary drive configured for longitudinal displacement relative to the rack between different longitudinal positions, the drill rod tallying apparatus comprising:

a sensor system configured to:

monitor the machine to detect a clamping force applied to rotationally immobilize the drill string and to detect a break-out torque generated by the rotary drive;

detect a first longitudinal position of the rotary drive whereat the break-out torque or a make-up torque is generated; and

detect a second longitudinal position of the rotary drive whereat the make-up torque or the break-out torque is generated by the rotary drive; and

a controller configured to:

prevent release of the clamping force until the make-up torque is detected; and

automatically enable release of the clamping force after the make-up torque is detected and, concordantly, to update a drill rod tally only when the first longitudinal position is different than the second longitudinal position.

2. The apparatus of claim 1 , wherein the controller is configured to update the drill rod tally only when the first longitudinal position is different than the second longitudinal position and in response to detecting that the clamping force is automatically allowed to release after the make-up torque is generated by the rotary drive.

3. The apparatus of claim 1 , wherein:

the first longitudinal position is a distal position proximate a location where the drill string enters the ground; and

the second longitudinal position is proximal of, and spaced apart from, the first longitudinal position by at least a distance equal to a length of a drill rod.

4. The apparatus of claim 3 , wherein the controller is configured to increment the drill rod tally by one count in response to the combined steps of the rotary drive generating the break-out torque at the first longitudinal position and the rotary drive generating the make-up torque at the second longitudinal position.

5. The apparatus of claim 3 , wherein the controller is configured to decrement the drill rod tally by one count in response to the combined steps of the rotary drive generating the break-out torque at the second longitudinal position and the rotary drive generating the make-up torque at the first longitudinal position.

6. The apparatus of claim 1 , wherein the controller is configured to:

prevent release of the clamping force until the make-up torque is generated by the rotary drive;

detect the second longitudinal position of the rotary drive at which the make-up torque generated by the rotary drive reaches a predetermined make-up torque; and

automatically allow release of the clamping force after the make-up torque is generated by the rotary drive and concordantly update the drill rod tally if the first longitudinal position is different than the second longitudinal position.

7. The apparatus of claim 1 , further comprising a user interface coupled to the controller, the user interface configured to generate a human-perceivable indication of a change to the drill rod tally.

8. The apparatus of claim 1 , further comprising a user interface coupled to the controller, the user interface configured to generate a rod tally display and a torque display or audible indicator of the make-up torque generated by the rotary drive in a rod-tightening direction.

9. The apparatus of claim 1 , wherein the controller is configured to release the clamping force subsequent to automatically enabling release of the clamping force in response to an operator action.

10. A method of automatically tallying drill rods for use with a drilling machine, the method comprising:

monitoring the machine to detect a clamping force applied to immobilize a drill string and to detect a break-out torque generated by a rotary drive;

detecting a first longitudinal position of the rotary drive at which the clamping force is applied and the break-out torque or a make-up torque is generated;

preventing release of the clamping force until the make-up torque is generated by the rotary drive;

detecting a second longitudinal position of the rotary drive at which the make-up torque or the break-out torque is generated by the rotary drive; and

automatically allowing release of the clamping force after the make-up torque is generated by the rotary drive and updating a drill rod tally when the first longitudinal position is different than the second longitudinal position.

11. The method of claim 10 , wherein automatically updating the drill rod tally comprises detecting that the break-out torque is generated by the rotary drive at one of the first and second longitudinal positions and that the make-up torque is generated by the rotary drive at the other of the first and second longitudinal positions.

12. The method of claim 10 , wherein automatically updating the drill rod tally comprises:

detecting that the break-out torque is generated by the rotary drive at one of the first and second longitudinal positions and detecting that the make-up torque is generated by the rotary drive at the other of the first and second longitudinal positions; and

detecting that the clamping force is automatically allowed to release after the make-up torque is generated by the rotary drive.

13. The method of claim 10 , wherein:

the first longitudinal position is a distal position proximate a location where the drill string enters the ground; and

the second longitudinal position is proximal of, and spaced apart from, the first longitudinal position by at least a distance equal to a length of a drill rod.

14. The method of claim 13 , wherein automatically updating the drill rod tally comprises:

incrementing the drill rod tally by one count in response to the combined steps of the rotary drive generating the break-out torque at the first longitudinal position and the rotary drive generating the make-up torque at the second longitudinal position.

15. The method of claim 13 , wherein automatically updating the drill rod tally comprises:

decrementing the drill rod tally by one count in response to the combined steps of the rotary drive generating the break-out torque at the second longitudinal position and the rotary drive generating the make-up torque at the first longitudinal position.

16. The method of claim 10 , further comprising generating a human-perceivable indication of a change to the drill rod tally.

17. A method of automatically tallying drill rods for use with a drilling machine, the method comprising:

detecting whether a rotary drive of the machine is at a first longitudinal position or at a second longitudinal position;

monitoring the machine to detect a break-out event and a make-up event; and

automatically updating a drill rod tally based on detecting a combination of the break-out and make-up events.

18. The method of claim 17 , wherein automatically updating the drill rod tally is based on detecting a combination of the break-out and make-up events and detecting positions where the break-out and make-up events occurred.

19. The method of claim 17 , wherein automatically updating the drill rod tally is based on detecting a combination of the break-out and make-up events, detecting positions where the break-out and make-up events occurred, and determining a chronological order of the break-out and make-up events.

20. The method of claim 17 , further comprising:

preventing release of a clamping force applied to a drill rod or a drill string until a make-up torque is generated by the rotary drive; and

automatically allowing or enabling release of the clamping force after the make-up event is detected.

21. The method of claim 17 , further comprising releasing the clamping force subsequent to automatically allowing or enabling release of the clamping force in response to an operator action.

22. The method of claim 17 , further comprising generating a human-perceivable indication of a change to the drill rod tally.