Patents by Inventor Max A. Metcalf
Max A. Metcalf has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Publication number: 20230332487Abstract: A brake system for maintaining an angular position of a spindle assembly. A pump-powered motor drives rotation of a spindle on the machine. When no rotation is desired, the spindle will slow, then stop at a desired angular orientation. A rotational sensor will determine the clock position, and a controller compares that to a desired angular orientation. If an error tolerance is exceeded, the motor will rotate the spindle back to the desired orientation.Type: ApplicationFiled: June 26, 2023Publication date: October 19, 2023Inventors: Joseph G. Greenlee, Aleksander S. Wolfe, Jarred R. Callaway, Max A. Metcalf
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Publication number: 20230332469Abstract: A spindle with a mechanism for transferring axial force from an inner drive assembly to an outer drive assembly. The spindle's inner drive shaft is connected to an inner member of a dual-rod pipe by a drive rod having a sliding sleeve. The sleeve is fixed rotationally with the drive shaft, but not axially. When axial force drives the drive rod toward the drive member of the spindle, the sleeve contacts a stop member which is paired to the outer drive assembly. The stop member may be a pair of dowel pins. Axial force is thereby transferred from the inner member to the outer member, allowing such forces to be absorbed by the outer member's larger drive components.Type: ApplicationFiled: June 26, 2023Publication date: October 19, 2023Inventor: Max A. Metcalf
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Patent number: 11708725Abstract: A rotation brake for stopping rotation of a spindle assembly on a horizontal directional drill. The rotation brake comprises a brake lock that is actuated by a cylinder and spring to interact with a non-rotating brake cap and a rotating pinion, thereby stopping rotation of the pinion. The brake lock is removed from the pinion by applying pressurized fluid to a cylinder such that a cylinder rod moves the brake lock out of a cavity between the brake cap and the pinion. Upon removing fluid pressure from the cylinder, a compressed spring moves the brake lock back to into the cavity, preventing rotation.Type: GrantFiled: June 21, 2021Date of Patent: July 25, 2023Assignee: The Charles Machine Works, Inc.Inventors: Max A. Metcalf, Philip J. Wosmek, Harry Bendure, Rick E. Barrett
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Patent number: 11708724Abstract: A spindle with a mechanism for transferring axial force from an inner drive assembly to an outer drive assembly. The spindle's inner drive shaft is connected to an inner member of a dual-rod pipe by a drive rod having a sliding sleeve. The sleeve is fixed rotationally with the drive shaft, but not axially. When axial force drives the drive rod toward the drive member of the spindle, the sleeve contacts a stop member which is paired to the outer drive assembly. The stop member may be a pair of dowel pins. Axial force is thereby transferred from the inner member to the outer member, allowing such forces to be absorbed by the outer member's larger drive components.Type: GrantFiled: December 3, 2021Date of Patent: July 25, 2023Assignee: The Charles Machine Works, Inc.Inventor: Max A. Metcalf
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Patent number: 11686180Abstract: A brake system for maintaining an angular position of a spindle assembly. A pump-powered motor drives rotation of a spindle on the machine. When no rotation is desired, the spindle will slow, then stop at a desired angular orientation. A rotational sensor will determine the clock position, and a controller compares that to a desired angular orientation. If an error tolerance is exceeded, the motor will rotate the spindle back to the desired orientation.Type: GrantFiled: September 13, 2021Date of Patent: June 27, 2023Assignee: The Charles Machine Works, Inc.Inventors: Joseph G. Greenlee, Aleksander S. Wolfe, Jarred R. Callaway, Max A. Metcalf
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Patent number: 11391100Abstract: A sensor assembly supported on a horizontal directional drilling machine adjacent a magazine. The magazine includes a plurality of vertical columns configured to store a plurality of pipe sections. The sensor assembly comprises an elongate tower that suspends a rigid support structure above the plurality of columns. The rigid support structure includes a sensor housing that carries a plurality of proximity sensors. The proximity sensors correspond with the columns in one-to-one relationship. The proximity sensors measure values indicative of the number of pipe sections contained within each column and transmit the measured values to a processor included in the drilling machine.Type: GrantFiled: August 19, 2020Date of Patent: July 19, 2022Assignee: The Charles Machine Works, Inc.Inventors: Max A. Metcalf, Taylor C. Culpepper
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Publication number: 20220178205Abstract: A spindle with a mechanism for transferring axial force from an inner drive assembly to an outer drive assembly. The spindle's inner drive shaft is connected to an inner member of a dual-rod pipe by a drive rod having a sliding sleeve. The sleeve is fixed rotationally with the drive shaft, but not axially. When axial force drives the drive rod toward the drive member of the spindle, the sleeve contacts a stop member which is paired to the outer drive assembly. The stop member may be a pair of dowel pins. Axial force is thereby transferred from the inner member to the outer member, allowing such forces to be absorbed by the outer member's larger drive components.Type: ApplicationFiled: December 3, 2021Publication date: June 9, 2022Inventor: Max A. Metcalf
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Publication number: 20210404293Abstract: A brake system for maintaining an angular position of a spindle assembly. A pump-powered motor drives rotation of a spindle on the machine. When no rotation is desired, the spindle will slow, then stop at a desired angular orientation. A rotational sensor will determine the clock position, and a controller compares that to a desired angular orientation. If an error tolerance is exceeded, the motor will rotate the spindle back to the desired orientation.Type: ApplicationFiled: September 13, 2021Publication date: December 30, 2021Inventors: Joseph G. Greenlee, Aleksander S. Wolfe, Jarred R. Callaway, Max A. Metcalf
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Publication number: 20210310308Abstract: A rotation brake for stopping rotation of a spindle assembly on a horizontal directional drill. The rotation brake comprises a brake lock that is actuated by a cylinder and spring to interact with a non-rotating brake cap and a rotating pinion, thereby stopping rotation of the pinion. The brake lock is removed from the pinion by applying pressurized fluid to a cylinder such that a cylinder rod moves the brake lock out of a cavity between the brake cap and the pinion. Upon removing fluid pressure from the cylinder, a compressed spring moves the brake lock back to into the cavity, preventing rotation.Type: ApplicationFiled: June 21, 2021Publication date: October 7, 2021Inventors: Max A. Metcalf, Philip J. Wosmek, Harry Bendure, Rick E. Barrett
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Patent number: 11118430Abstract: A brake system for maintaining an angular position of a spindle assembly. A pump-powered motor drives rotation of a spindle on the machine. When no rotation is desired, the spindle will slow, then stop at a desired angular orientation. A rotational sensor will determine the clock position, and a controller compares that to a desired angular orientation. If an error tolerance is exceeded, the motor will rotate the spindle back to the desired orientation.Type: GrantFiled: July 21, 2020Date of Patent: September 14, 2021Assignee: The Charles Machine Works, Inc.Inventors: Joseph G. Greenlee, Aleksander S. Wolfe, Jarred R. Callaway, Max A. Metcalf
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Patent number: 11041342Abstract: A rotation brake for stopping rotation of a spindle assembly on a horizontal directional drill. The rotation brake comprises a brake lock that is actuated by a cylinder and spring to interact with a non-rotating brake cap and a rotating pinion, thereby stopping rotation of the pinion. The brake lock is removed from the pinion by applying pressurized fluid to a cylinder such that a cylinder rod moves the brake lock out of a cavity between the brake cap and the pinion. Upon removing fluid pressure from the cylinder, a compressed spring moves the brake lock back to into the cavity, preventing rotation.Type: GrantFiled: August 12, 2019Date of Patent: June 22, 2021Assignee: The Charles Machine Works, Inc.Inventors: Max A. Metcalf, Philip J. Wosmek, Harry Bendure, Rick E. Barrett
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Publication number: 20200386064Abstract: A sensor assembly supported on a horizontal directional drilling machine adjacent a magazine. The magazine includes a plurality of vertical columns configured to store a plurality of pipe sections. The sensor assembly comprises an elongate tower that suspends a rigid support structure above the plurality of columns. The rigid support structure includes a sensor housing that carries a plurality of proximity sensors. The proximity sensors correspond with the columns in one-to-one relationship. The proximity sensors measure values indicative of the number of pipe sections contained within each column and transmit the measured values to a processor included in the drilling machine.Type: ApplicationFiled: August 19, 2020Publication date: December 10, 2020Inventors: Max A. Metcalf, Taylor C. Culpepper
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Patent number: 10851599Abstract: A spindle assembly for connecting a drill string to a rotational drive for use in a horizontal directional drilling operation. The assembly comprises a saver sub attached to the rotational drive, and a drive chuck for connection to the drill string. The drive chuck and saver sub form a torque-transmitting connection by engaging through a seat in the saver sub and an engagement point on the drive chuck. Dowel pins may be used to rotationally lock and provide the engagement between the saver sub and the drive chuck. A collar may thread to the saver sub and cause an interference fit by engaging the drive chuck at a shoulder.Type: GrantFiled: November 30, 2017Date of Patent: December 1, 2020Assignee: The Charles Machine Works, Inc.Inventors: Greg L. Slaughter, Jr., Floyd R. Gunsaulis, Max A. Metcalf
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Publication number: 20200347701Abstract: A brake system for maintaining an angular position of a spindle assembly. A pump-powered motor drives rotation of a spindle on the machine. When no rotation is desired, the spindle will slow, then stop at a desired angular orientation. A rotational sensor will determine the clock position, and a controller compares that to a desired angular orientation. If an error tolerance is exceeded, the motor will rotate the spindle back to the desired orientation.Type: ApplicationFiled: July 21, 2020Publication date: November 5, 2020Inventors: Joseph G. Greenlee, Aleksander S. Wolfe, Jarred R. Callaway, Max A. Metcalf
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Patent number: 10808466Abstract: A pipe handling assembly carried by a horizontal boring machine includes a pipe box having a plurality of columns. One or more pipe sections may be received and stored in any of the columns. A pair of shuttle arms are used to move the pipe sections from the pipe box to a carriage included in the machine. The pipe column selection assembly includes an elongate rotatable shaft that carries a series of stop elements. A shaft-mounted pinion gear drives movement of the shuttle arms. A longitudinally positionable bolt element can block the rotational path of any selected one of the stop elements. Such blockage stops movement of the shuttle arms beneath a corresponding one of the columns. The pipe column selection assembly allows an operator to select which column to load or unload a pipe section into and from within a pipe box.Type: GrantFiled: January 24, 2019Date of Patent: October 20, 2020Assignee: The Charles Machine Works, Inc.Inventors: Rick G. Porter, Max A. Metcalf
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Patent number: 10724347Abstract: A brake system for maintaining an angular position of a spindle assembly. A pump-powered motor drives rotation of a spindle on the machine. When no rotation is desired, the spindle will slow, then stop at a desired angular orientation. A rotational sensor will determine the clock position, and a controller compares that to a desired angular orientation. If an error tolerance is exceeded, the motor will rotate the spindle back to the desired orientation.Type: GrantFiled: December 4, 2017Date of Patent: July 28, 2020Assignee: The Charles Machine Works, Inc.Inventors: Joseph G. Greenlee, Aleksander S. Wolfe, Jarred R. Callaway, Max A. Metcalf
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Patent number: 10557332Abstract: A system for assuring that a rotation brake has engaged on a directional drilling machine. A pump-powered motor drives rotation of a spindle on the machine. The spindle is in turn attached to the above-ground end of a drill string. After the rotation brake is actuated, a controller causes the motor to transmit oppositely-directed rotational pulses to the spindle. If the brake is properly engaged, the pulses will produce spikes in pressure within the hydraulic circuit that powers the pump. When a pressure sensor detects such spikes, it signals the controller and confirms that the brake is engaged.Type: GrantFiled: December 4, 2017Date of Patent: February 11, 2020Assignee: The Charles Machine Works, Inc.Inventors: Aleksander S. Wolfe, Max A. Metcalf, Pete Ramos
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Publication number: 20190360272Abstract: A rotation brake for stopping rotation of a spindle assembly on a horizontal directional drill. The rotation brake comprises a brake lock that is actuated by a cylinder and spring to interact with a non-rotating brake cap and a rotating pinion, thereby stopping rotation of the pinion. The brake lock is removed from the pinion by applying pressurized fluid to a cylinder such that a cylinder rod moves the brake lock out of a cavity between the brake cap and the pinion. Upon removing fluid pressure from the cylinder, a compressed spring moves the brake lock back to into the cavity, preventing rotation.Type: ApplicationFiled: August 12, 2019Publication date: November 28, 2019Inventors: Max A. Metcalf, Philip J. Wosmek, Harry Bendure, Rick E. Barrett
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Patent number: 10407991Abstract: A rotation brake for stopping rotation of a spindle assembly on a horizontal directional drill. The rotation brake comprises a brake lock that is actuated by a cylinder and spring to interact with a non-rotating brake cap and a rotating pinion, thereby stopping rotation of the pinion. The brake lock is removed from the pinion by applying pressurized fluid to a cylinder such that a cylinder rod moves the brake lock out of a cavity between the brake cap and the pinion. Upon removing fluid pressure from the cylinder, a compressed spring moves the brake lock back to into the cavity, preventing rotation.Type: GrantFiled: September 4, 2015Date of Patent: September 10, 2019Assignee: The Charles Machine Works, Inc.Inventors: Max A. Metcalf, Philip J. Wosmek, Harry Bendure, Rick E. Barrett
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Publication number: 20190234158Abstract: A pipe handling assembly carried by a horizontal boring machine includes a pipe box having a plurality of columns. One or more pipe sections may be received and stored in any of the columns. A pair of shuttle arms are used to move the pipe sections from the pipe box to a carriage included in the machine. The pipe column selection assembly includes an elongate rotatable shaft that carries a series of stop elements. A shaft-mounted pinion gear drives movement of the shuttle arms. A longitudinally positionable bolt element can block the rotational path of any selected one of the stop elements. Such blockage stops movement of the shuttle arms beneath a corresponding one of the columns. The pipe column selection assembly allows an operator to select which column to load or unload a pipe section into and from within a pipe box.Type: ApplicationFiled: January 24, 2019Publication date: August 1, 2019Inventors: Rick G. Porter, Max A. Metcalf