US20100282026A1

US20100282026A1 - Method and system for automated earth boring drill bit manufacturing

Info

Publication number: US20100282026A1
Application number: US12/463,588
Authority: US
Inventors: David K. Luce; Sean W. Wirth; Alan J. Massey; Crystal A. Parrott; Glynn R. Bartlett
Original assignee: Baker Hughes Inc
Current assignee: Baker Hughes Holdings LLC
Priority date: 2009-05-11
Filing date: 2009-05-11
Publication date: 2010-11-11

Abstract

A method and system for manufacturing a earth boring tool, comprising placing a tool in a positioner of an system which then conforms the tool to a model through the performance of a plurality of processing steps thereon. The positioner may move the tool in two axis. The system may include a manipulator which performs each of the processing steps. Alternatively, the system may include a plurality of manipulators, each performing a different one of the processing steps. The processing steps may include various shaping, cleaning, painting, and packaging steps. The processing steps may be performed without removing the tool from the positioner. The tool may be repositioned in the positioner during or between processing steps. For example, performing the processing steps may comprise performing one or more of the process steps, repositioning the tool in the positioner, and re-performing the one or more of the process steps.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

None.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

REFERENCE TO APPENDIX

Not applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention
The inventions disclosed and taught herein relate generally to earth boring drill bits; and more specifically relate to manufacturing earth boring drill bits.
2. Description of the Related Art
U.S. Pat. No. 6,209,420 discloses a “method of fabricating rotary-type drill bits, drilling-related structures, and other articles of manufacture. The method includes fabricating a machinable matrix, machining the matrix, and dispersing a binder material throughout the matrix. The matrix of the rotary-type drill bit may be fabricated by layered-manufacturing techniques or by disposing a particulate or powdered material into a mold and binding the particles together with a resin or by sintering. The matrix may have the desired dimensions and features, the approximate dimensions and features, or lack desired dimensions or features of a drilling-related structure or other article of manufacture. The matrix is machined to correct any anisotropies or imperfections of the matrix, to refine features of the matrix, or to define the features in the matrix. The machined matrix may be infiltrated with a binder material to define a drill bit body.”
There are also several separate examples of automated processes, such as grinding, cleaning, shaping, masking, painting, curing, packaging, and labeling, in disparate industries and as applied to disparate products, such as U.S. Pat. Nos. 4,830,609, 5,175,018, 5,791,968, 6,270,394, 6,562,139, and 7,386,968.
The inventions disclosed and taught herein are directed to an improved method and system for manufacturing earth boring drill bits.

BRIEF SUMMARY OF THE INVENTION

The present invention is a method and system for manufacturing a earth boring tool, comprising providing at least a partial computer model of a finished earth boring tool to an automated manufacturing system and placing a tool in a positioner of the system which then conforms the tool to the model through the performance of a plurality of processing steps thereon. The positioner may move the tool in two axis. The system may include a manipulator which performs each of the processing steps. Alternatively, the system may include a plurality of manipulators, each performing a different one of the processing steps. The processing steps may include removing casting mold material from the tool, grinding cutter pockets of the tool, grinding junk slots of the tool, cleaning the tool, masking predetermined portions of the tool, preparing the tool for paint, painting the tool, curing the paint, preparing the tool for shipment, applying a protecting material to a portion of the tool, applying a label to the tool, and/or packaging the tool. In some embodiments, each of the plurality of processing steps may be performed without removing the tool from the positioner. However, in some embodiments, the tool may be repositioned in the positioner during or between processing steps. For example, performing the processing steps may comprise performing one or more of the process steps, repositioning the tool in the positioner, and re-performing the one or more of the process steps.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 illustrates a perspective view of a drill bit as might be designed using a computer aided design (CAD) system utilizing certain aspects of the present inventions;

FIG. 2 illustrates a flow chart of various processes that may be performed utilizing certain aspects of the present inventions;

FIG. 3 illustrates a block diagram of an initial cleaning process utilizing certain aspects of the present inventions;

FIG. 4 illustrates a block diagram of a shaping process utilizing certain aspects of the present inventions;

FIG. 5 illustrates a block diagram of a painting process utilizing certain aspects of the present inventions; and

FIG. 6 illustrates a block diagram of a packaging process utilizing certain aspects of the present inventions.

DETAILED DESCRIPTION

The Figures described above and the written description of specific structures and functions below are not presented to limit the scope of what Applicants have invented or the scope of the appended claims. Rather, the Figures and written description are provided to teach any person skilled in the art to make and use the inventions for which patent protection is sought. Those skilled in the art will appreciate that not all features of a commercial embodiment of the inventions are described or shown for the sake of clarity and understanding. Persons of skill in this art will also appreciate that the development of an actual commercial embodiment incorporating aspects of the present inventions will require numerous implementation-specific decisions to achieve the developer's ultimate goal for the commercial embodiment. Such implementation-specific decisions may include, and likely are not limited to, compliance with system-related, business-related, government-related and other constraints, which may vary by specific implementation, location and from time to time. While a developer's efforts might be complex and time-consuming in an absolute sense, such efforts would be, nevertheless, a routine undertaking for those of skill in this art having benefit of this disclosure. It must be understood that the inventions disclosed and taught herein are susceptible to numerous and various modifications and alternative forms. Lastly, the use of a singular term, such as, but not limited to, “a,” is not intended as limiting of the number of items. Also, the use of relational terms, such as, but not limited to, “top,” “bottom,” “left,” “right,” “upper,” “lower,” “down,” “up,” “side,” and the like are used in the written description for clarity in specific reference to the Figures and are not intended to limit the scope of the invention or the appended claims.
Particular embodiments of the invention may be described below with reference to block diagrams and/or operational illustrations of methods. It will be understood that each block of the block diagrams and/or operational illustrations, and combinations of blocks in the block diagrams and/or operational illustrations, can be implemented by analog and/or digital hardware, and/or computer program instructions. Such computer program instructions may be provided to a processor of a general-purpose computer, special purpose computer, ASIC, and/or other programmable data processing system. The executed instructions may create structures and functions for implementing the actions specified in the block diagrams and/or operational illustrations. In some alternate implementations, the functions/actions/structures noted in the figures may occur out of the order noted in the block diagrams and/or operational illustrations. For example, two operations shown as occurring in succession, in fact, may be executed substantially concurrently or the operations may be executed in the reverse order, depending upon the functionality/acts/structure involved.
Computer programs for use with or by the embodiments disclosed herein may be written in an object oriented programming language, conventional procedural programming language, or lower-level code, such as assembly language and/or microcode. The program may be executed entirely on a single processor and/or across multiple processors, as a stand-alone software package or as part of another software package.
Applicants have created a method and system for manufacturing a earth boring tool, comprising providing at least a partial computer model of a finished earth boring tool to an automated manufacturing system and placing a tool in a positioner of the system which then conforms the tool to the model through the performance of a plurality of processing steps thereon. The positioner may move the tool in two axis. The system may include a manipulator which performs each of the processing steps. Alternatively, the system may include a plurality of manipulators, each performing a different one or more of the processing steps. The processing steps may include removing casting mold material from the tool, grinding cutter pockets of the tool, grinding junk slots of the tool, cleaning the tool, masking predetermined portions of the tool, preparing the tool for paint, painting the tool, curing the paint, preparing the tool for shipment, applying a protecting material to a portion of the tool, applying a label to the tool, and/or packaging the tool. In some embodiments, each of the plurality of processing steps may be performed without removing the tool from the positioner. However, in some embodiments, the tool may be repositioned in the positioner during or between processing steps. For example, performing the processing steps may comprise performing one or more of the process steps, repositioning the tool in the positioner, and re-performing the one or more of the process steps.
In the manufacture of earth boring tools and components, such as the type having cutting elements fixed in recesses, accurate cutting element placement is critical. In an as cast or as initially machined form, there are minor defects that must be removed to allow accurate placement of the cutting elements, as well as other defects that may impact the performance of a finished tool.
For example, earth boring tools, such as drill bits, may be cast by infiltrating a binder material throughout a matrix of particulate material, such as powdered steel or tungsten carbide, as described in U.S. Pat. No. 6,209,420, which is incorporated herein by specific reference. While the matrix, or even a steel bit body blank, may be initially machined, additional imperfections often arise as or after the tool is cast or otherwise initially formed.
Referring now to FIG. 1, an exemplary drill bit 10 is depicted as modeled by a state-of-the-art computer aided design (CAD) system. Such systems are well-known and widely used, and a particularly suitable, commercially available CAD system for implementation of the present invention is the Pro/ENGINEER, offered by Parametric Technology Corporation. Drill bit 10, as shown, includes a variety of external and internal components, such as bit body 12 that may be secured to a blank (not shown), which is secured to a tubular bit shank 14 having a threaded pin connection 16 at the free end thereof and six blades or wings 18 carrying cutting elements 20 placed in cutter pockets 22 and supported from the rear by inclined buttresses 24. Gage trimmers 26 are set immediately adjacent and above (as depicted in the drawing figures) gage pads 28. Blades 18 are separated by generally radially extending fluid courses 30 leading to junk slots 32, fluid courses 30 and junk slots 32 being provided in operation with drilling fluid (“mud”) from the drill string through bit shank 14 communicating with internal fluid passages leading to nozzles 36 in cavities 38 opening onto fluid courses 30. Blades 18, fluid courses 30, and the topographical details thereof collectively define what may be termed the “bit face;” being the surface of the bit in contact with the undrilled formation at the bottom of the borehole. The exterior shape of a diametrical cross-section of the bit body 12 taken along the longitudinal bit axis 40 defines what may be termed the bit or “crown” profile.
The present invention comprises an automated, and/or semi-automated, method and system for conforming a rough, or initially formed, tool to a finished and ready-for-shipment earth boring tool, such as that discussed above and shown in FIG. 1. Referring also to FIG. 2, the method may include creating and providing a complete or partial computer model of the finished earth boring tool, or portion thereof, to an automated manufacturing system, as shown in step 2A; placing the tool in one or more positioners of the system, as shown in step 2B; and causing the system to conform the tool to a model through the performance of a plurality of processing steps thereon, as shown in steps 2C, 2D, 2E, 2F, 2G, and 2H.
More specifically, the drill bit 10 of the present invention may go through several processing steps, some or all of which may be automated, semi-automated, and/or manually performed. These processing steps include casting, mold removal, machining and/or grinding, shank attachment and/or welding, cutter attachment and/or brazing, cleaning, one or more quality inspections, marking, paint preparation, painting, and/or packaging. While most, if not all, of these processes may be automated according to certain aspects of the present invention, only a subset of these processing steps will be discussed below in an effort to aid in understanding the invention.
Furthermore, the system of the present invention will be described as a single system, with one or more sub-systems to accomplish various tasks. However, it should be understood that the system of the present invention may be implemented as one or more independent sub-systems. Finally, in one embodiment of the present invention, each of the processing steps may be automatically performed upon the tool, without manually removing the tool from the positioner. For example, the tool may be automatically repositioned within the positioner. Alternatively, the tool may be semi-automatically or manually repositioned within the positioner, as needed. In still other alternative embodiments, the tool is manually placed in the positioner for one or more of the processing steps, removed from the positioner for manual performance of one or more of the processing steps, and then replaced in the same or a different positioner for one or more of the processing steps. Thus, the present invention provides for automated and/or semi-automated performance of multiple, if not all, of the processing steps required to fabricate the bit 10.
In one embodiment, the positioner may secure the tool in a stationary position. For example, a stationary positioner may function similarly to a rigidly secured vise. Alternatively, the positioner may move the tool along, and/or rotate the tool about, one, two, or three dimensions, or axis. For example, the positioner may include a turn-table and/or a multi-dimensional robotic arm. The tool may be transferred from one positioner to another, with or without one or more processing steps being performed manually. Alternatively, one or more of the processing steps may be performed without removing the tool from a single positioner. In any case, the tool may be repositioned in the positioner(s) during or between processing steps, as shown in step 2I. For example, performing the processing steps may comprise performing one or more of the process steps, repositioning the tool in the positioner, and re-performing the one or more of the process steps. This would allow the process step(s) to be performed on an otherwise inaccessible portion of the tool that might otherwise be blocked by the positioner.
The system may include one or more manipulators which perform one, several, or each of the processing steps. For example, the manipulator may incorporate interchangeable attachments for each of the processing steps. The attachments may be automatically and/or manually exchanged. Alternatively, the system may include a plurality of manipulators, each performing a different one or more of the processing steps. For example, the positioner may move the tool to an appropriate one of the manipulators and/or the appropriate manipulator may come to the positioner and tool.
The system may be a single automated machine or multiple integrated automated machines and/or sub-systems, and may be integrated with other sub-systems. The system may include automated elements as well as manual elements. For example, the system may include an automated, semi-automated, and/or manual waste reclamation sub-system, running along-side various other processes and/or sub-systems.
As discussed above, the processing steps may include various casting, mold removal, machining and/or grinding, shank attachment and/or welding, cutter attachment and/or brazing, cleaning, one or more quality inspections, marking, paint preparation, painting, and/or packaging steps. More specifically, referring also the FIG. 3, initial cleaning processes 3A may include disassembly of a mold used to cast the tool 3B and/or removal of the mold material 3C. For example, after the tool is initially cast using a manual process and/or a mold assembly, the positioner may be used to capture the mold assembly containing the tool and move it to a station that grips and disassembles the mold components. More specifically, the system may capture a binder head and orient the tool to a position where there is access to remove a mold component assembly, which may include an outer mold shell, and then remove any remaining mold material.
These initial cleaning processes, as well as other processes, may be performed by one or more automated, semi-automated, or manual sub-systems. The system may also include an automated and/or manual mold component recovery sub-system. The system may further include an automated and/or manual mold component evaluation and disposition sub-system. These sub-systems may be integrated and operate in synchronization, or may be independently controlled to operate as needed.
In any case, the system may include sensors to assist with positioning and/or evaluation of the mold and/or tool. For example, evaluation sensors may be capable of evaluating dimensional measurements, oxidation levels, and the structural integrity of the tool. The sensors may operate by machine vision, structured light, laser scanning, and/or probe sensing. Evaluation information may be stored and utilized for ultimate disposition of the tool.
The manipulator may remove mold material and/or flashing from the mold assembly by crushing, blasting, wheel impact or a combination thereof. Blasting media may include any combination of water, abrasive water, shot, walnut shell, garnet, glass bead, metal oxides, and/or dry ice pellets. The manipulator may use any combination of rotating and/or impacting material removal tools such as wire wheels, wheel-type blasting, fiber wheels, hammer mills, and/or needle scaling.
As discussed above, the manipulator may be moved relative to the mold assembly, held in the positioner, and/or the mold assembly can be moved relative to the manipulator. The relative motion can be derived from CAD data and or sensor feedback. For example, a CAD model may be used to automatically or semi-automatically create algorithms consisting of positioner and manipulator relative motion paths and attachment control commands.
Referring also the FIG. 4, the shaping processes 4A may include machining 4B, grinding 4C, or otherwise shaping the blades 18, cutter pockets 22, fluid courses 30, and/or junk slots 32. Faces of blades 18 may be ground to remove matrix projections that would interfere with identification of cutter pocket locations. The cutter pockets 22 themselves may be ground to a final size and shape to accept the cutter elements 20. Thus, the cutter pockets 22 may be validated to insure proper fit, such as by using surface mapping, or sensory feedback. Corrections may be affected through further shaping through manual or automatic processes. Similarly, the fluid courses 30, and/or junk slots 32 may be ground to ensure proper flow of the drilling fluid and cuttings.
The shaping process may have portions that are automated and portions that are manual. More specifically, as discussed above, the shaping processes may be performed by one or more automated, semi-automated, or manual sub-systems. The system may also include an automated and/or manual waste recovery, evaluation, and/or recycling sub-system.
Grinding types that may be used include diamond, rock, garnet wheels, honing wheels, and/or cubic boron nitride (CBN). Grinding shapes that may be used include spherical, cylindrical, disk, and/or cone. Additionally, other grinding types and/or shapes may be used.
The system may utilize fixed patterns and/or adaptive patterns for shaping, as well as the other processes performed during manufacturing. For example, the system may use the CAD data and/or surface mapping to create grinding manipulator paths. Surface mapping techniques such as laser scanning, structured light and/or contact probing could be used to attain a surface map of the earth boring tool as well as cutting element pocket location, obstructions, graphite inclusions, matrix inclusions, and/or major casting deviations, etc. For example, linear displacement tools may be used to attain dimensional information of the earth boring tool. Additionally, or alternatively, force feedback may be used to adaptively control the shaping process. For example, the system may use torque, lateral side forces, and/or longitudinal end forces.
At this point, or virtually any other point in manufacturing, the tool may be marked. For example, tool marking may be done using an automated, semi-automated, or manual device. Marking can be accomplished with laser etch, impact, grinding, magnetic coding, RFID, flame spray, stencil, and/or chemical etch techniques.
Referring also the FIG. 5, the painting processes 5A may include various cleaning 5B, masking 5C, painting 5D, and/or curing 5E processes. As discussed above, the system may include single or multiple manipulators to systematically and consistently clean and/or apply surface treatments. Various degrees of manipulation and automation may be used. More specifically, as discussed above, the painting processes may be performed by one or more automated, semi-automated, or manual sub-systems. The system may also include an automated and/or manual waste recovery, evaluation, and/or recycling sub-system.
A single rotational axis positioner holding the earth boring tool or component coupled with a single linear axis manipulator with a paint and/or cleaning attachment could accomplish simple tool shapes. For complex shaped earth boring tools a two axis positioner holding the earth boring tool coupled with a multi-axis manipulator with the cleaning and/or painting attachment would allow for more complex manipulator, or attachment, to tool surface orientation. Thus, in one preferred embodiment, a two axis positioner holds the earth boring tool for a multi-axis manipulator with various paint preparation and paint application attachments.
As discussed above, the system may reposition the tool within the positioner during and/or between processes. For example, the system may clean, or otherwise process, the tool where accessible then reposition the tool within the positioner. The system may then clean, or otherwise process, the earth boring tool or component where access was constrained in the previous setup. The system may then apply masking if necessary, and to locations that are accessible. The earth boring tool would then be repositioned in the positioner in its original orientation. The system may then apply masking to areas inaccessible in the second earth boring tool orientation.
At this point, the basic surface prep, masking, and temperature can be inspected. The inspection may be conducted automatically, or semi-automatically, with sensors, or may be conducted manually. In either case, the tool may remain in the positioner, be removed from the positioner, and/or be moved to another positioner for inspection.
The results of this inspection, may be used in the decision to paint, re-prep, or alert for operator review. In the case where the decision is made to paint, the system may use a single paint gun with multiple paint feed stocks or multiple paint attachments each with one or more paint feed stocks. Masks can be applied and removed as necessary to attain selective multi-tone coatings. In each case, the tool may be repositioned in the positioner, such that the positioner allows access to portions of the tool to be painted. The earth boring tool may then be inserted into a curing oven or atmospheric control chamber where temperature and pressure may be used to increase the efficiency of or the resulting quality of the curing process.
More specifically, an automated or semi-automated cleaning process may include blasting, vapor degreasing, washing, steam washing, and/or solvent cleaning. Blasting media may include any combination of water, abrasive water, shot, walnut shell, garnet, glass bead, metal oxides, and dry ice pellets. As discussed above, the earth boring tool cleaning my include any combination of moving the earth boring tool and/or the cleaning attachment using an automated or semi-automated system. As also discussed above, earth boring tool cleaning can be enhanced in that systematic cleaning paths may be created automatically based on CAD data and utilized to reduce waste.
Automated or semi-automated masking of cutting elements 20 and/or cutter pockets 22 may include magnetic, adhesive stickers, tape, grease coating, and/or water soluble paste as masking agents. In some cases cutter faces of the cutting elements 20 are not masked prior to paint. Alternatively, the cutting elements 20 may be repainted for contrast with the rest of the earth boring tool.
Automated or semi-automated masking of nozzle orifices 38 may include screw in plugs, press in plugs and/or drop in plugs. Automated or semi-automated masking of the earth boring tool may be accomplished by inserting the tool 10 into a sleeve or installing a sleeve over the section or portion to be masked. An adjustable or multiple concentric sleeves could be used to adapt to varying diameters of earth boring tool sections that require masking. Shadow masks can be used where multiple paints are used on the earth boring tool.
As discussed above, and as with other manufacturing processes, automated or semi-automated masking of earth boring bit may include locating areas to be masked with vision sensing devices and/or CAD data. Similarly, automated or semi-automated cleaning, masking, painting, and/or curing may be accomplished with the movement of the earth boring tool under a stationary or moving attachment, and/or moving the attachment relative to the stationary or moving earth boring tool.
Painting, or coating, processes may be performed with an automated or semi-automated sub-system or technique, such as spray, dip, electrostatic powder coat, brush, roller, and/or flame spray. Automated or semi-automated painting of earth boring tools may be accomplished with one or more of the following coating types—epoxy, enamel, powder, latex, polyurethanes, and alkyd. Automated or semi-automated painting of earth boring tools may utilize one or more of the following coating delivery systems: dynamic mixing, pressure pots, canister, can, cartridge, bells, nozzles, reciprocators, automation. This painting process may be performed with a temperature controlled environment, an atmospherically controlled chamber, and/or a barometrically controlled chamber.
To decrease the curing time of an earth boring tool or component, heat may be applied to the earth boring tool, or portion thereof, prior to painting. Methods of preheating the earth boring tool may include convection oven, induction coil, radiant heat, flame, hot liquid tank, and/or hot liquid pressurized tank. These methods may be utilized with or without a color additive. The curing rate may be controlled in a barometric pressure chamber.
Referring also the FIG. 6, the packaging processes 6A may include applying protective materials to select portions of the tool 6B, labeling the tool 6C, and/or boxing or crating the tool 6D. Applying protective materials may comprise automated or semi-automated application of grease, wax, plastic, or other protective material to select portions of the tool, such as the shank. Such protective application may be accomplished through brushing, injecting, spraying, and/or dipping. Applying a more rigid shank protector, through automated or semi-automated installation, may be accomplished with vacuum, gripping, and/or magnetic techniques. Furthermore, a heat shrinkable material may be installed over the shank of the tool or component then heat activated to shrink down over the threads providing protection.
Labels may be applied to earth boring tools, components and their respective boxes using an automated or semi-automated sub-system. This sub-system may be the same sub-system that applies paint or separate therefrom. Labels may be printed based on CAD and/or other production control data and applied to the earth boring tool or component by the automated or semi-automated sub-system. The sub-system may use structured light, laser scanning, and/or CAD data to locate an appropriate position for the label on the earth boring tool or component.
Labels can be printed directly on the earth boring tool. Alternatively, or additionally, plain, or white, labels may be applied to the earth boring tool or component, identifying information being printed on the label, with the label on the tool. Alternatively, or additionally, Labels may be printed in batches and selected manually based on CAD or production control data and applied to the earth boring tool or component manually, by the automated system and/or by some semi-automated sub-system.
Similarly, an automated or semi-automated sub-system may be used to apply protective packaging materials and/or peripheral items to the tool as required by CAD or production control data and then place the tool in an appropriate shipping container. This sub-system may pick and place a lid onto the container and secure the container. This sub-system may also pick and secure an appropriate label on the container.
It can be seen that the system of the present invention may yield less cutting element recess geometric and dimensional variances and more accurate cutting element recess location relative to the design intent. The system of the present invention may also create more consistent higher quality surface treatments and more consistent surface finishes. The system of the present invention may also reduce labor cost and move operators away from potential safety hazards, as well as permit the use of materials that are potentially hazardous to human operators.
Other and further embodiments utilizing one or more aspects of the inventions described above can be devised without departing from the spirit of Applicant's invention. For example, an entire tool may be processed at once, or together, or individual components of a tool may be processed individually. Further, the various methods and embodiments of the present invention can be included in combination with each other to produce variations of the disclosed methods and embodiments. Discussion of singular elements can include plural elements and vice-versa.
The order of steps can occur in a variety of sequences unless otherwise specifically limited. The various steps described herein can be combined with other steps, interlineated with the stated steps, and/or split into multiple steps. Similarly, elements have been described functionally and can be embodied as separate components or can be combined into components having multiple functions.
The inventions have been described in the context of preferred and other embodiments and not every embodiment of the invention has been described. Obvious modifications and alterations to the described embodiments are available to those of ordinary skill in the art. The disclosed and undisclosed embodiments are not intended to limit or restrict the scope or applicability of the invention conceived of by the Applicants, but rather, in conformity with the patent laws, Applicants intend to fully protect all such modifications and improvements that come within the scope or range of equivalent of the following claims.

Claims

1. A method of manufacturing a earth boring tool, the method comprising the steps of:

providing at least a partial computer model of at least a portion of finished earth boring tool to an automated manufacturing system;

placing a tool in a positioner of the system;

causing the system to conform the tool to the model through the performance of a plurality of processing steps thereon.

2. The method of claim 1, wherein the positioner moves the tool in at least one axis.

3. The method of claim 1, wherein the system further includes a manipulator which performs the processing steps.

4. The method of claim 1, wherein the system further includes a plurality of manipulators, each performing a different one of the processing steps.

5. The method of claim 1, wherein the performance of the processing steps comprises:

performing one or more of the process steps;

repositioning the tool in the positioner; and

re-performing the one or more of the process steps.

6. The method of claim 1, the processing steps include:

removing an outer mold shell from the tool;

removing casting mold material from the tool; and

shaping the tool.

7. The method of claim 1, the processing steps include:

cleaning the tool;

masking predetermined portions of the tool; and

painting exposed portions of the tool.

8. The method of claim 1, the processing steps include:

preparing the tool for paint;

painting the tool; and

curing the paint.

9. The method of claim 1, the processing steps include:

painting the tool;

curing the paint; and

preparing the tool for shipment.

10. The method of claim 1, the processing steps include:

applying a shank protecting material to a shank of the tool;

applying a label to the tool; and

packaging the tool.

11. The method of claim 1, wherein each of the plurality of processing steps are performed without removing the tool from the positioner.

12. A method of manufacturing a earth boring tool, the method comprising the steps of:

providing at least a partial computer model of a finished earth boring tool to an automated manufacturing system;

placing a tool in a positioner of the system;

causing the system to conform the tool to the model through the performance of at least one of a plurality of first processing steps selected from the group consisting of—

removing casting mold material from the tool,

machining the tool, and

grinding the tool;

causing the system to conform the tool to the model through the performance of at least one of a plurality of second processing steps selected from the group consisting of—

preparing the tool for paint,

painting the tool, and

curing the paint;

causing the system to conform the tool to the model through the performance of at least one of a plurality of third processing steps selected from the group consisting of—

applying a shank protecting material to a shank of the tool,

applying a label to the tool, and

packaging the tool.

13. The method of claim 12, wherein the positioner moves the tool in two axis.

14. The method of claim 12, wherein the system further includes a first manipulator which performs the first processing steps, a second manipulator which performs the second processing steps, and a third manipulator which performs the third processing steps.

15. The method of claim 12, wherein the system further includes a plurality of manipulators, each performing a different one of the processing steps.

16. The method of claim 12, wherein the performance of the processing steps comprises:

performing one or more of the process steps;

repositioning the tool in the positioner; and

re-performing the one or more of the process steps.

17. The method of claim 12, wherein each of the processing steps of each of the plurality of processing steps are performed without removing the tool from the positioner.

18. A method of manufacturing a earth boring tool, the method comprising the steps of:

providing a computer model of a finished earth boring tool to an automated manufacturing system;

placing a tool in a two axis positioner of the system;

removing casting mold material from the tool,

machining the tool, and

grinding the tool;

wherein performing at least one of the first processing steps comprises—

performing one or more of the process steps,

repositioning the tool in the positioner, and

re-performing the one or more of the process steps;

preparing the tool for paint,

painting the tool, and

curing the paint;

wherein performing at least one of the second processing steps comprises—

performing one or more of the process steps,

repositioning the tool in the positioner, and

re-performing the one or more of the process steps;

applying a shank protecting material to a shank of the tool,

applying a label to the tool, and

packaging the tool.