This application relates generally to pile driving systems and methods. More specifically, this application describes mechanisms and methods for adapting a sonic drill head to a member that is to be driven in a pile driving application.
Pile drivers are mechanical devices used to drive piles, poles, I-beams, or other members into the ground or other surfaces to provide foundation support for buildings or other structures. Although pile drivers are well-established, it is always desirable to improve the speed and reliability of the equipment used. Thus, a recent innovation finding more use in the field is vibration-enhanced pile driving equipment. One example is a sonic pile driver.
Vibratory or sonic pile drivers include a sonic drill head which may be lifted and positioned over the member by a drill rig mast, excavator or crane, and then fastened to the member using threading or flanging, for example. Such pile drivers may be designed to generate mechanical oscillating forces wherein horizontal vibrations cancel out, while vertical vibrations (e.g., those most effective at improving pile driving speed and reliability) are transmitted into the member. These vibrations may be used to either drive in or extract the member, and the vibration rates may range from about 0 Hz to about 150 Hz (vibration cycles per second). To effectively and efficiently transmit the vibrations from the sonic drill head to the member, the coupling between the sonic drill head and member should be tight and secure. However, existing sonic drill heads are not optimally designed to form such a tight and secure coupling. As a result, the fastening of a sonic drill head to a member may result in poor transfer of oscillating force, or even slippage between the sonic drill head and the member.
Thus, it would be desirable to provide systems and methods to provide improved coupling of a sonic drill head to a member to transfer oscillating force thereto in a more efficient manner, thereby to improve effectiveness of all sonic pile driving applications.
In one embodiment, a pile driving adapter includes an upper attachment portion for selectively attaching the adapter to a drill head (using threaded engagement, flange connections, or other similar attachment means) and a lower housing portion including a first outer wall. The pile driving adapter further includes at least one actuator including a first portion slidably mounted to the lower housing portion and a second portion configured to expand from the first portion in a direction perpendicular to the first outer wall. The first portion may be slidably mounted to the lower housing portion via a sliding mount, and the lower housing portion may include at least one elongate slot for receiving at least a portion of the sliding mount. The first and second portions may include a cylinder and a piston, respectively. The adapter is configured to transfer sonic energy between the drill head and the member to be driven.
In another embodiment, a method of coupling a drill head to a member is provided, with the member including a first wall. The method includes selectively attaching the drill head to an upper attachment portion of an adapter using threaded engagement, flange connections, or another similar attachment mechanism. The adapter includes a lower housing portion having a first outer wall and further includes at least one actuator having a first portion slidably mounted to the lower housing portion and further having a second portion configured to expand from the first portion in a direction perpendicular to the first outer wall. The method also includes positioning the adapter over the member such that the first wall is received between the second portion and the first outer wall. The method further includes activating the at least one actuator such that the second portion expands away from the first portion toward the first wall and clamps the first wall against the first outer wall.
In another embodiment, a method of pile driving a member is provided, with the member including a first wall. The method includes selectively attaching the drill head to an upper attachment portion of an adapter using threaded engagement, flange connections, or another similar attachment mechanism. The adapter includes a lower housing portion having a first outer wall and further includes at least one actuator having a first portion slidably mounted to the lower housing portion and further having a second portion configured to expand from the first portion in a direction perpendicular to the first outer wall. The method also includes positioning the adapter over the member such that the first wall is received between the second portion and the first outer wall. The method further includes activating the at least one actuator such that the second portion expands away from the first portion toward the first wall and clamps the first wall against the first outer wall. The method also includes transferring energy such as sonic energy from the drill head to the member via the adapter.
Various additional features and advantages of the invention will become more apparent to those of ordinary skill in the art upon review of the following detailed description of one or more illustrative embodiments taken in conjunction with the accompanying drawings. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more embodiments of the invention and, together with the general description given above and the detailed description given below, serve to explain the one or more embodiments of the invention.
With reference to
As shown in
The housing portion 22 is made to fit the dimensions of the member to be pile driven whether said member is a pile, pole, I-beam, column or another member. Therefore, in the illustrated example embodiment, the housing portion 22 includes first, second, third, and fourth outer walls 50, 52, 54, 56 extending downwardly from the periphery of the upper wall 32, to match the generally rectangular shape of the member 14 to be driven shown in
First and second hydraulic actuators 90, 92 are slidably mounted to the lower housing portion 22 in the interior space 72 via first and second sliding mounts 100, 102, respectively, and thus are at least partially surrounded by the outer walls 50, 52, 54, 56, while providing clearance between the actuators 90, 92 and the outer walls 50, 52, 54, 56 to receive the upper portion of a member 14. The sliding mounts 100, 102 advantageously enable the reliable clamp action of the adapter 10 on the member 14, and these elements are described in further detail below.
Each actuator 90, 92 includes a cylinder 110 and a piston 112 configured to expand from the cylinder 110 in a direction substantially perpendicular to at least one of the first and second outer walls 50, 52 when the actuator 90, 92 is activated. For example, each piston 112 expands from the respective cylinder 110 when a chamber 114 of the actuator 90, 92 is pressurized, such as by supplying a hydraulic fluid to the chamber 114 via an input nozzle 116 and/or input port 118, as is known. To that end, hoses may fluidly couple the input nozzles 116 to a hydraulic fluid reservoir (not shown), and may extend through the passageway 42. Likewise, the pistons 112 are each retracted into the respective cylinder 110 when the chamber 114 is depressurized, such as by at least partially removing the hydraulic fluid from the chamber 114. Each piston 112 includes an abutment surface 120 opposite the respective cylinder 110, and each cylinder 110 includes an abutment surface 122 opposite the respective piston 112. A rod stop 130 provided on the piston 112 abuts a corresponding rod stop 132 provided on the housing portion 22 to limit the retraction of the piston 112 into the respective cylinder 110 to a predetermined/desired position. One or more O-rings 134 are provided between each piston 112 and the respective cylinder 110 to provide a fluid tight seal therebetween. In the embodiment shown, the first and second actuators 90, 92 are oriented in opposite directions, such that the pistons 112 expand in opposite directions. Alternatively, the first and second actuators 90, 92 may be oriented in the same general direction, such that the pistons 112 may expand in the same general direction.
Each cylinder 110 is slidably mounted to the upper wall 32 of the housing portion 22 by the respective sliding mount 100, 102. As best shown in
As shown, the first and second flanged bushings 160, 162, and thus the first and second threaded studs 164, 166, pass through the upper wall 32 via first and second elongate slots 180, 182, respectively. The elongate slots 180, 182 are sized and shaped to receive the first and second threaded studs 164, 166 to shift laterally therein between a first position (
With specific reference now to
With the member 14 fully inserted into the housing portion 22, hydraulic fluid is supplied to the chamber 114 of each actuator 90, 92, thereby pressurizing the chamber 114 and exerting a force on the piston 112 in the direction of the arrows A1, as shown in
While the piston 112 has been described in the embodiment above as expanding toward the first wall 190 prior to the cylinder 110 expanding toward the second wall 192, it will be appreciated that the piston 112 and cylinder 110 may expand away from each other and toward the respective walls 190, 192 simultaneously, or the cylinder 110 may expand toward the second wall 192 prior to the piston 112 expanding toward the first wall 190, without departing from the scope of this invention. For example, frictional forces between the sliding mount 102 and the upper wall 32 may impact the order of expansion. In any event, the first and second walls 190, 192 are ultimately clamped by the piston 112 and cylinder 110, respectively, and the corresponding outer wall 50, 52, to thereby reliably couple the sonic drill head 12 and the member 14 with the adapter 10, and in such a manner that sonic energy can be transferred from the sonic drill head 12 into the member 14.
It will be appreciated that hydraulic fluid may be provided to the chamber 114 of each actuator 90, 92 via a valve and/or control system (not shown) located at or near ground level, such that the actuators 90, 92 may be activated by personnel at or near ground level. Thus, the clamping of the member 14 by the adapter 10 may be performed without requiring personnel to manually adjust the adapter 10 at a position high above the ground, as members 14 such as piles are typically of significant height.
As shown in
In the embodiment shown, the stop plates 80, 82, 84 limit the insertion of the member 14 to a predetermined position, whereat the uppermost portions of the first and second walls 190, 192 are above the corresponding abutment surface 120, 122, such that substantially all the surface area of the abutment surface 120, 122 may contact the respective wall 190, 192. In addition, or alternatively, the abutment of the walls 190, 192 of the member 14 against corresponding stop plates 80, 82, 84 may contribute to the tight and secure clamping by preventing the uppermost portions of the member 14 from moving freely during operation of the sonic drill head 12. In the embodiment shown, the peripheral flange 60 provides increased rigidity to the first and second outer walls 50, 52 to prevent the outer walls 50, 52 and/or walls 190, 192 from substantially flexing outwardly under the force(s) exerted by the piston 112 and/or cylinder 110.
By providing a tight and secure clamping of the member 14 by the adapter 10, the connection between the sonic drill head 12 and the member 14 via the adapter 10 is substantially rigid. This may prevent slippage of the member 14 relative to the adapter 10 and/or sonic drill head 12 during operation of the sonic drill head 12, and provide an effective and efficient transfer of oscillating forces—from the drill head 12 to the member 14. In one embodiment, various components of the adapter 10 such as, for example, the attachment portion 20, upper wall 32, first and second outer walls 50, 52, cylinders 110, and pistons 112, are constructed of a material having a strength and/or durability capable of transferring oscillating forces typical in sonic drilling applications from the drill head 12 to the member 14. For example, various components of the adapter 10 may be constructed of steel.
To remove the adapter 10 from the member 14, such as after operation of the sonic drill head 12 to drive in or extract the member 14, at least a portion of the hydraulic fluid may be removed from the chamber 114 to thereby depressurize the chamber 114 and allow the piston 112 and cylinder 110 to be retracted from the respective walls 190, 192 and unclamp the member 14. In the embodiment shown, the piston 112 may be retracted until the rod stop 130 of the piston 112 abuts the rod stop 132 of the housing portion 22. In one embodiment, the abutment of the rod stops 130, 132 may assist in retracting the cylinder 110 from the second wall 192. In any event, when the piston 112 and cylinder 110 have been sufficiently retracted from the respective walls 190, 192, the adapter 10 may be lifted away from the member 14, such as via the sonic drill head 12, and stored or mounted to another member for continued operation, for example.
While first and second actuators 90, 92 slidably mounted to the housing portion 22 via first and second sliding mounts 100, 102 are shown in the illustrated embodiment, any number of actuators and corresponding sliding mounts may be used depending on the application. For example, one, three, or four actuators and a corresponding number of sliding mounts may be used in other embodiments. It will be understood that actuators other than hydraulic actuators 90, 92 may also be used in other embodiments consistent with the invention. For example, linear actuators such as pneumatic actuators or screw-type actuators may replace the hydraulic actuators 90, 92 shown in the illustrated embodiment. In one embodiment using a screw-type actuator, a lead tube may be coupled to a sliding mount 100, 102 in a manner similar to the cylinder 110, and a lead screw may expand therefrom and retract therein, in place of the piston 112, to provide the advantageous functionality in the pile driving context as set forth above.
Various sonic pile driving adapters 10 may be configured to accommodate members 14 of different sizes and shapes, such that a single sonic drill head 12 may be coupled to a variety of members 14 to effectively and efficiently transfer oscillating forces thereto. Thus, it will be appreciated that various features of the illustrated adapter 10 may be modified to accommodate a particular member 14. In particular, the spacing of the first outer wall 50 relative to the second outer wall 52 may be increased or decreased depending on the spacing of the first and second walls 190, 192 of a member. Likewise, the shapes and configurations of the stop plates 80, 82, 84 may be modified depending on the particular features of a member 14, such as a profile of the upper portion of the member 14.
With reference now to
While the present invention has been illustrated by the description of various embodiments thereof, and while the embodiments have been described in considerable detail, it is not intended to restrict or in any way limit the scope of the appended claims to such detail. Thus, the various features discussed herein may be used alone or in any combination. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the scope of the general inventive concept.
This application is a national phase application of, and claims priority to, International Application No. PCT/US2018/012523, filed Jan. 5, 2018, the disclosure of which is incorporated by reference herein in its entirety. This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/442,589, filed Jan. 5, 2017, the disclosure of which is incorporated by reference herein in its entirety.
Filing Document | Filing Date | Country | Kind |
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PCT/US2018/012523 | 1/5/2018 | WO | 00 |
Publishing Document | Publishing Date | Country | Kind |
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WO2018/129278 | 7/12/2018 | WO | A |
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International Searching Authority, Search Report and Written Opinion issued in International Application No. PCT/US18/12523 dated Mar. 9, 2018 (10 pages). |
Number | Date | Country | |
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20190323194 A1 | Oct 2019 | US |
Number | Date | Country | |
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62442589 | Jan 2017 | US |