Patent Grant
10145193
This application relates to the field of equipment used in drilling large foundation holes for buildings and bridges and more specifically to a unique telescopic drilling bucket mechanism. The current invention provides a drilling bucket assembly along with a unique drill head apparatus that improves the operation by which a drilling operator can remove dirt from a drilling device. With the combination of a drilling head and bucket, the unit can be raised to the surface where the bucket portion is moved up or down from the drill head to empty the excavated material.
Foundation chilling has evolved over time and continues to be an essential operation for all construction of bridges, buildings and skyscrapers. Without proper holes for the drilled foundation piles, a budding or bridge could be destroyed in the event of an earthquake. In an effort to improve the production and quality of drilled foundations, there has been a sizable investment, and significant advancement, in the equipment and tools of the trade.
Some of the most common tools used by foundation drillers are the separate digging, and cleanout buckets. Digging buckets are used to dig through hard layers of dirt and rock and are known for their ability to keep holes true and straight as possible. Drilling buckets are often used to manage water in the hole when drilling fluid is necessary to keep the holes from caving in. Axially separating drill buckets keep the drill fluids clean by containing the loose soils and preventing them from mixing with or contaminating drill fluids. Augers are used for digging large holes but have no efficient means of moving the material to the surface. Cleanout buckets are used to clean the bottom of the holes during the digging process to remove any loose rocks and soil to ensure a clean solid bottom surface for a foundation.
In executing pile foundations in construction work, a unique method of drilling earth is proposed in this application. In this method a rotatable bucket is used for excavating a straight pile bore and also moving the excavated soil from the bore hole to the surface. The Axially separating drill bucket assembly is attached to the lowermost position of a Kelly bar, a conventional part of the drilling rig, and suspended to perform the drilling operation. When the bucket is rotated, the soil excavated by a unique drill head is moved into the drill bucket. The drill bucket filled with the excavated soil is then raised by the drilling rig and the soil in the bucket is removed when an actuator member comes in contact with the stationary sombrero, a conventional part of the drilling rig, and the drill bucket is either raised above the drill head or the drill head pushed down from the drill bucket. Several methods can be used to accomplish this similar process, some being a scissor action mechanical method, a hydraulic actuated method, a direct downward pressure method and a method where a latch is actuated by a rod coming against the sombrero to release the drill head to translate down a telescoping shaft to remove the material by the means of rapidly spinning the device.
Numerous innovations for drills used for drilling foundation piles have been provided in the prior art that are described as follows. Even though these innovations may be suitable for the specific individual purposes to which they address, they differ from the present design as hereinafter contrasted. The following is a summary of those prior art patents most relevant to this application at hand, as well as a description outlining the difference between the features of the Axially separating drill bucket and the prior art.
U.S. Pat. No. 5,234,062 of Hachiro Inoue describes an automatic evacuation drilling bucket comprising a follower formed with a working space for receiving a blade member which is capable of coming in contact with an osculating arm, the working space having upper, lower, transition and receiving compartments. If the blade member is located in the upper and lower compartments, the blade member is engaged with the follower when a drive shaft member is rotated in the normal and reverse directions. If the blade member is urged to move into the receiving compartment through the transition compartment, the blade member comes in contact with the osculating arm when the drive shaft member is rotated in the reverse direction.
This patent describes an automatic evacuation drilling bucket that operates with a fixed drill bucket that has a hinged member at the bottom for the removal of the excavated material. If the material sticks to the side of the drill bucket it must be jarred to remove it and that often damages the equipment involved. It does not have the capability of digging the hole, cleaning the hole out, moving the material to the surface, separating the drill bucket from the drill head and pushing the material out in one operation.
U.S. Pat. No. 4,971,163 of Akira Ohashi et al. describes a drilling bucket apparatus for expanding a bore-hole bottom for a cast-in-place pile. Drill bits are pivotally suspended from the upper portion of a drill pipe, which is a main frame of the apparatus, and are expanded and retracted radially by means of hydraulic cylinders. A bucket is attached to the lower end of the drill pipe and scrapers are installed on the side of the bucket. The scrapers are arranged to open and close sideward, following the movement of the drill bits. During drilling work, the apparatus is suspended from a Kelly bar of a drilling machine. When the apparatus is rotated and the drill bits are expanded, the whole expanded shape of a bore-hole bottom is drilled simultaneously and cuttings are scraped into the bucket by means of the drill bits and the scrapers. Further, a bottom lid of the bucket can be released by operating a hydraulically-actuated opening lever, whereby, cuttings are discharged automatically.
This patent describes a drilling bucket apparatus for expanding a bore-hole bottom for a cast-in-place pile. It does not have the capability of digging the hole, cleaning the hole out, moving the material to the surface, separating the drill bucket from the drill head and pushing, the material out in one operation.
U.S. Pat. No. 4,604,818 of Hachiro Inoue describes an under reaming pile bore excavating bucket and the method of excavating an under reamed part of a pile bore, and more particularly to an excavating bucket such that an under reamed part of a pile bore can be excavated and further the excavated soil can be moved into the bucket body for easy removal of soil. The bucket includes, in particular, a plurality of slidable wing bits housed within a bucket and moved downward and extended outward along guide rails at the bottom of an already excavated straight pile bore.
This patent describes an under reaming pile bore excavating bucket and the method of excavating an under reamed part of a pile bore. The bucket includes, in particular, a plurality of slidable wing hits housed within a bucket and moved downward and extended outward along guide rails at the bottom of an already excavated straight pile bore. It does not have the capability of digging the hole, cleaning the hole out, moving the material to the surface, separating the drill bucket from the drill head and pushing the material out in one operation.
U.S. Pat. No. 2,126,124 of Frank S. McCutcheon describes an excavating bucket that may be used for circular shafts and wells, and that may be completely operated and controlled with only one cable. A further object of my invention is to provide an excavating bucket to be used in confined quarters where the space of operation is limited. Still further objects of this invention are to provide an excavating bucket that is positive in its action, which conforms to the shape of the excavation, that allows water to run from the excavated material in the bucket and that has few moving parts. A still further object of my invention is to provide an excavating bucket that is economical in manufacture, durable and efficient in use.
This patent describes an excavating bucket that may be used for circular shafts and wells. It does not have the capability of digging the hole, cleaning the hole out, moving the material to the surface, separating the drill bucket from the drill head and pushing the material out in one operation.
Patent Application Publication No. US 2004/0168831 A1 of Satoshi Nozaki et al. describes locking elements that are provided at an inner member connected to a Kelly bar, and a locking element bearing plate provided at an outer member. The outer member includes a cylindrical bucket and a grab bucket housed inside the cylindrical bucket. When an excavating tool is in its most contracted state, the inner member is rotated forward to lock the locking elements at the locking element bearing plate, thereby disallowing relative vertical movement of the inner member and the outer member. As the excavating tool is rotated by applying a force to the Kelly bar along the lifting direction in this state, an excavating operation can be executed while applying a load smaller than the load of the excavating tool. As a result, it becomes possible to execute an excavating operation with a large excavating tool in conjunction with an earth drill having a small drive force. Projections provided at the outer circumference of the inner member are fitted at guide rails extending along the longitudinal direction and provided at the inner circumference of the second member so as to be allowed to move up/down freely. Thus, the grab bucket having an underground obstacle grabbed therein can be rotated to remove the underground obstacle.
This patent describes a device where the outer member includes a cylindrical bucket and a grab bucket housed inside the cylindrical bucket. When an excavating tool is in its most contracted state, the inner member is rotated forward to lock the locking elements at the locking element bearing plate, thereby disallowing relative vertical movement of the inner member and the outer member. It does not have the capability of digging the hole, cleaning the hole out, moving the material to the surface, separating the drill bucket from the drill head and pushing the material out in one operation.
None of these previous efforts, however, provides the benefits attendant with the Axially separating drill bucket. The present design achieves its intended purposes, objects and advantages over the prior art devices through a new, useful and unobvious combination of method steps and component elements, with the use of a minimum number of functioning parts, at a reasonable cost to manufacture, and by employing readily available materials.
In this respect, before explaining at least one embodiment of this application in detail it is to be understood that the design is not limited in its application to the details of construction and to the arrangement of the components set forth in the following description or illustrated in the drawings. The Axially separating drill bucket is capable of other embodiments and of being practiced and carried out in various ways. In addition, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
The principal advantage of the Axially separating drill bucket is that it eliminates the stress and shock loads incurred on the machinery's hydraulic equipment when attempting to remove material from existing drill buckets.
Another advantage of the Axially separating drill bucket is that it both drills the hole and removes the material in a single operation.
Another advantage of the Axially separating drill bucket is that in different designs the bucket can be raised above the drill head or the drill head can be lowered below the bucket to remove the excavated material.
Another advantage is Axially separating drill buckets keep the drill fluids clean by containing the loose soils and preventing them from mixing with or contaminating drill fluids.
Another advantage of the Axially separating drill bucket is that the unique drill head has the capability to be rotated in one direction to drill the hole with the material entering the drill bucket and rotating in the opposite direction to close off the opening to the internal cavity to retain the material to be lifted to the surface.
Another advantage of the Axially separating drill bucket is that several methods can be used to either raise the bucket or lower the drill head.
Another advantage of the Axially separating drill bucket is that when lifted above the surface an actuator member can come in contact with the sombrero of the drill rig to activate the release mechanism.
Another advantage of the Axially separating drill bucket is the material does not rely on gravity to fall out of the bucket.
Another advantage of the Axially separating drill bucket is the material can be pushed out and spread out evenly by the accelerated spinning motion.
Another advantage of the Axially separating drill bucket is the material cannot stick in the bucket.
Another advantage of the Axially separating drill bucket is if water is in the hole when drilling, there is an internal cavity to allow the water to pass through the Drill Bucket.
Another advantage is the time saved by only using a single operation rather than lowering a drill unit and an excavating unit separately.
Another advantage is to provide an Axially separating drill bucket assembly that reduces costly repairs.
Another advantage is to provide a simple device with few moving parts.
Another advantage is to provide spring loaded latching mechanism to release and re-latch the drill head from the drill bucket.
Another advantage is having the angled section on the spring loaded push rod to activate the spring loaded latching mechanism.
Another advantage is having the spring loaded push rod pressed down by the sombrero against the pusher plate to move the material within the drill bucket out.
Another advantage is having the telescoping capability between the outer tubular telescoping drill stem with a latching catch and the inner tubular drill stem.
Another advantage is using square heavy all tubing for the outer tubular telescoping dull stem and the inner tubular drill stem to minimize the torsional stresses on the drill stem when the Axially separating drill bucket is rotated.
Another advantage is using a sealed hydraulic or pneumatic cylinder with a limited bypass within the square drill stem to cushion lowering of the drill head.
Another advantage is the addition of the centering tip on the dill head.
Another advantage is the addition of digging teeth on the outer perimeter of the drill tip plate to create a cleaner clearance hole.
Another advantage is using a nylon strap or limiting device within the square drill stem to cushion abrupt stopping of the drill head when the material is released.
Another advantage is using a hydraulic cylinder with a manual fluid flow control valve to cushion lowering of the drill head.
Another advantage is using a hydraulic cylinder along with a second hydraulic cylinder and a pilot operated check valve to control and cushion the lowering and latching of the drill head.
Another advantage will be the addition of the bowtie configuration of the drill tip plate along with the two orifices in the drill head plate creating the ability to fill the drill bucket faster.
These together with other advantages of the Axially separating drill bucket along with the various features of novelty, which characterize the design, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. In this respect, before explaining at least one of the embodiments of the Axially separating drill bucket in detail it is to be understood that the design is not limited in its application to the details of construction and to the composition set forth in the following description or illustrated in the drawings
The Axially separating drill bucket is controlled by the means of heavy equipment, commonly called the drill rig, with a drill boom that rotatably activates a conventional Kelly bar attached to the device. A unit called the sombrero is a fixed pan of the drill boom that the Kelly bar passes through extending to a box section of the Axially separating drill bucket assembly. The Kelly bar attaches to the box section by a variety of connection means but most often by the means of a square section inserted in a square orifice with a locking retainer. The box section is permanently attached to the drill stem that can be either a round or square cross section and extends through the drill bucket to be connected to the drill head. The drill bucket consists of a heavy walled steel tubular member open at one end and closed at the other h the means of a heavy steel cap plate welded in place. In the center of the cap plate on the preferred embodiment is an orifice where the drill stem passes through and the drill bucket translates up and down.
A long vertical key section is part of the drill stem that engages in a key slot in the steel cap plate keeping the drill bucket from rotating when the Axially separating drill bucket assembly is turning A pusher plate can be permanently attached to the drill stem in order to push the material out of the drill bucket central cavity when drill bucket is raised.
In the preferred embodiment the drill bucket will be raised by a single external scissor action mechanism on the outside of the drill bucket above the steel cap plate. The actuator member translates through an elongated slot of the box section to pivotally attach to the first scissor section that rotates about a pivot attached to the drill stem. At the distal end of the first scissor section is a pivoting link attached to a pivot lug fixed to the upper surface of the steel cap plate. A second similar external scissor action mechanism can be added on the other side of the drill stem to equalize the forces required to raise the drill bucket. When the Axially separating drill bucket is raised above the surface the actuator member makes contact with the stationary sombrero exerting a downward force raising the drill bucket. The elongated slot in the box section keeps the mechanism from being clogged when in operation.
In the first alternate embodiment of the Axially separating drill bucket where the drill bucket will be raised by a single internal scissor action mechanism within the drill bucket. In this process the actuator member translates through an elongated slot of the box section and an elongated slot in the steel cap plate to pivotally attach to the first scissor section that rotates about a pivot point on the drill stem. At the distal end of the first scissor section the second scissor section is pivotally attached with its distal end pivotally attached to a pivot lug fixed to the under surface of the steel cap plate. When the Axially separating drill bucket is raised, the actuator member makes contact with the stationary sombrero exerting a downward force raising the drill bucket. The elongated slots in both the box section and the steel cap plate keep the mechanism from being clogged when in operation. A second similar scissor action mechanism within the drill bucket can be added on the other side of the drill stem to equalize the forces required to raise the drill bucket.
The drill head consists of a drill head plate that is permanently attached to the distal end of the drill stem. There may be several drill bucket alignment features with the first, being a beveled edge to the drill bucket mating with a beveled edge on the drill head plate. Another alignment feature will be a number of alignment tabs welded around the circumference of the drill head plate with anti-rotation stop blocks attached to the inner surface of the drill bucket to resist any twisting between the drill bucket and the drill head plate. Another alignment feature will be an extension of intermittent side segments of the lower surface of the drill bucket mating with cutouts in the drill head plate. The drill tip plate has polarity of digging teeth and a central rod extending into as mating hole in the drill stem. A circumferential groove on the central rod aligns with a slot in the drill stem where a drill tip plate retainer allows the drill tip plate to rotate and be easily removed if necessary.
In the digging operation the drill tip plate with cutting teeth pivots against a stop plate welded on the drill head plate so that when rotating the Axially separating drill bucket the opening in the drill head plate is exposed with the material going into the drill bucket cavity. By reversing the rotation, the drill tip plate is forced in the opposite direction against a second stop plate closing the opening in the drill head plate so that the device can be raised to the surface without releasing the excavated material. The limiting stops, on the bottom surface of the drill head plate, act to keep the drill tip plate from making a full rotation in either direction.
A steel angle bar can be welded to the length of the inner surface of the drill bucket with an orifice in the steel cap plate and the drill head plate creating a separate cavity where water that might accumulate at the bottom of the hole could travel up through the Axially separating drill bucket. This is an option that can be incorporated into any of the embodiments of this application.
In the second alternate embodiment of the Axially separating drill bucket assembly, the process is to raise the drill bucket by the means of using a large capacity hydraulic cylinder attached to the box section with an actuator member extending up to make contact with the sombrero when the Axially separating drill bucket is raised above the surface. This contact forces the hydraulic fluid into a smaller and longer hydraulic cylinder attached to a lug on the upper surface of the steel cap plate raising the drill bucket away from the drill head plate. Additionally, a second smaller and longer hydraulic cylinder connected to the same large capacity hydraulic cylinder, would be attached to a second lug on the other side of the drill stem on the upper surface of the steel cap plate to equalize the forces required to raise the drill bucket.
A third alternate embodiment of the Axially separating drill bucket assembly w use the large capacity hydraulic cylinder with actuator member extending up to make contact with the sombrero when the Axially separating drill bucket assembly is raised above the surface. This contact forces the hydraulic fluid into a second set of smaller and longer hydraulic cylinders attached to a lug on the under surface of the steel cap plate raising the drill bucket away from the drill head plate.
A forth alternate embodiment of the Axially separating drill bucket assembly will use the large capacity hydraulic cylinder attached to the box section that is permanently attached to the drill stem with the actuator member extending up to make contact with the sombrero when the Axially separating drill bucket assembly is raised above the surface. The drill bucket will be welded permanently to the drill stem and hydraulic fluid forced into one or more smaller and longer hydraulic cylinders attached to a lug on the under surface of the steel cap plate. This action lowers the drill bead plate by the means of a telescoping stem inner member that is an integral part of the drill head plate.
A fifth alternate embodiment of the Axially separating drill bucket assembly will have the actuating rod spring loaded against the top surface of the drill bucket. The drill bucket and drill stem are welded together with a telescoping stem inner member part of the drill head plate. The actuating rod is welded to the steel drill head plate so that when it comes in contact with the sombrero on the surface the spring is compressed and the drill head plate is lowered away from the drill bucket.
The sixth alternate embodiment of the Axially separating drill bucket assembly will have a spring loaded latching mechanism holding the drill head up against the drill bucket with an actuator member extending up through the steel cap plate. The box section is permanently attached to the steel cap plate with the Kelly bar held in place by the means of the locking retainer. When the Axially separating drill bucket assembly is raised the actuator member makes contact with the Sombrero releasing the telescoping drill stem extension to lower by the means of gravity until it hits the stop on the lower inner surface of the drill bucket.
Another embodiment of the Axially separating drill bucket assembly will have a spring loaded latching mechanism incorporating a spring loaded push rod and a central hydraulic cylinder. The spring loaded push rod translates downward through the tubular guide with the angled lower section that activates the spring loaded latching mechanism when pressure is applied by the sombrero as the Axially separating drill bucket assembly is raised. An enlarged tubular guide section of the tubular guide limits the downward travel when pushed downward by the sombrero. The spring loaded push rod translates further downward pressing the pusher plate down to assist in emptying the drill bucket A hydraulic cylinder is housed within the outer tubular square drill stem and the inner tubular square drill stem anchored at the top by the means of the cross pin in the inner tubular drill stem and at the bottom in the outer tubular drill stem by the means of the cross pin. The drill head is at the lower end of the drill bucket.
Another embodiment of the Axially separating drill bucket assembly will have the spring loaded latching mechanism with a nylon strap replacing the hydraulic cylinder to lower the drill head to a cushioned lower position. The strap will be held by the means of the cross pin in the inner tubular drill stem and at the bottom in the outer tubular drill stem by the means a second cross pin.
Another embodiment of the Axially separating drill bucket assembly with the spring loaded latching mechanism will have the hydraulic cylinder where the fluid flow is controlled through the hydraulic lines to the manual hydraulic fluid flow control valve attached to the exterior of the drill bucket or within the cab of the drill rig to control the descent of the drill head.
Another embodiment of the Axially separating drill bucket assembly having the drill head released by the means of the sombrero pressing down on the activation rod of a second hydraulic cylinder to open pilot operated check valve to release and control descent of the drill head through the hydraulic cylinder.
The Axially separating drill bucket assembly will have an interlocking system between the drill head plate and the drill bucket where the segments of the drill bucket interlock with the cavities in the drill head plate to create a rigid structure. In this embodiment the drill head plate has two orifices into the central cavity of the drill bucket constructed in a bow tie shape with the digging teeth on either side Digging teeth can additionally be added around the perimeter of the drill tip plate. Two stop blocks are welded on the drill head plate to limit the rotation of the drill tip plate to a point of opening or covering the two orifices and trapping the material within the drill bucket central cavity. A replaceable centering tip, with digging teeth, is located on the drill tip plate.
The foregoing has outlined rather broadly the more pertinent and important features of the present Axially Separating Drill Bucket in order that the detailed description of the application that follows may be better understood so that the present contribution to the art may be more fully appreciated. Additional features of the design will be described hereinafter which form the subject of the claims of this disclosure. It should be appreciated by those skilled in the art that the conception and the disclosed specific embodiment may be readily utilized as a basis for modifying or designing other structures and methods for carrying out the same purposes of the present design. It should also be realized by those skilled in the art that such equivalent constructions and methods do not depart from the spirit and scope of this application as set forth in the appended claims.
The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the Axially Separating Drill Bucket and together with the description, serve to explain the principles of this application.
For a fuller understanding of the nature and advantages of the Axially Separating Drill Bucket, reference should be had to the following detailed description taken in conjunction with the accompanying drawings which are incorporated in and form a part of this specification, illustrate embodiments of the design and together with the description, serve to explain the principles of this application.
Referring now to the drawings, wherein similar parts of the Axially Separating Drill Bucket 10 are identified by like reference numerals, there is seen in
At the lower distal end of the drill stem 36 is the drill head 60 consisting of a drill head plate 62 that is permanently attached to the distal end of the drill stem 36. A drill tip plate 64 located below the drill head plate 62 has polarity of digging teeth 66 and a central rod 68 extending into a mating hole 70 in the drill stem 36. A circumferential groove 72 in the central rod 48 aligns with a slot 74 in the drill stem 36 where a drill tip plate retainer 76 allows the drill tip plate 64 to rotate and be easily removed if necessary. An opening 78 ahead of the digging teeth 66 of the drill tip plate 64 allows the excavated material to enter the drill bucket central cavity 56.
The unique feature of this application is when the Axially Separating Drill Bucket assembly 200 is rotating in a clockwise direction in the digging operation, indicated by the arrow 284, the drill tip plate 64 is held against the two stop blocks 278 opening the two orifices 276 into the drill bucket central cavity 56. After the digging the Axially separating drill bucket assembly 200 is rotating in the counter clockwise direction moving the drill tip plate 64 to closes off the two openings 276 to the drill bucket central cavity 56. To remove the material, the Axially separating drill bucket assembly 200 is raised up till the pushrod presses against the sombrero releasing the latch mechanism and the drill head 60 is lowered and rotated spreading the material out to the sides. When the drill bucket 60 is emptied it is lowered down away from the sombrero and pushed against the ground to automatically latch the assembly closed again. This operation can be completed by one person in the drill rig 14 with just the Axially separating drill bucket assembly 200.
The Axially Separating Drill Bucket 10, and the Axially Separating Drill Bucket assembly 200, shown in the drawings and described in detail herein disclose arrangements of elements of particular construction and configuration for illustrating preferred and alternate embodiments of structure and method of operation of the present application. It is to be understood, however, that elements of different construction and configuration and other arrangements thereof, other than those illustrated and described may be employed for providing an Axially Separating Drill Bucket 10, and the Axially Separating Drill. Bucket assembly 200, in accordance with the spirit of this disclosure, and such changes, alternations and modifications as would occur to those skilled in the art are considered to be within the scope of this design as broadly defined in the appended claims of this application.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
| Number | Name | Date | Kind |
|---|---|---|---|
| 1442984 | Smith | Jan 1923 | A |
| 2873950 | Kandle | Feb 1959 | A |
| 2997797 | Frankum, III | Aug 1961 | A |
| 6533048 | Groce, Jr. | Mar 2003 | B2 |
| 6655476 | Groce, Jr. | Dec 2003 | B2 |
| 8615906 | Matthias | Dec 2013 | B2 |
| Number | Date | Country | |
|---|---|---|---|
| 20160251899 A1 | Sep 2016 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 13845556 | Mar 2013 | US |
| Child | 15095085 | US |
