Patent Grant
10683634
The present disclosure relates to a microtrencher in the form of a radial saw for cutting a vertical channel or narrow slot trench into surfaces such as asphalt or concrete. The microtrencher includes a debris diverter allowing spoil from the cutting operation to be diverted and removed. It is described in the context of a representative system that is added to prime movers, such as skid-steer loaders.
In normal use, a skid-steer loader has a loader bucket pivotally attached to two front lift arms. Optionally, the loader bucket of a skid-steer loader may be removed and alternate or auxiliary implements such as a microtrencher may be attached to cut a trench in hard surfaces such as pavement surfaces of concrete or asphalt such as in roads, bridges or parking lots. A microtrench slot may be cut for instance with a radial saw, and may commonly have a depth in a range between approximately four to twelve inches. Microtrenches are often created and then wires or cables such as fiber optic cables are placed in the bottom of the trench. The trench is then filled with a sealant over the installed wires or cables.
The sealant may match or may be a different material from the prior surface material. For example, the sealant media may be a cold asphalt material or alternately may be formed using hot polymer, elasto-polymer or grout. Further, the sealant material has to be flexible enough to cope with corners on the route, crush resistant and sufficiently tough to cope with the pressure of the roadway above, which can reach 2900 psi. In certain situations, the microtrench must be dry and debris and dust free before the sealant can be installed in a manner which will properly bond with the inner microtrench sides and the surrounding surface material.
A currently common apparatus for cutting a microtrench uses a radial cutting saw mounted to the rear of a trenching machine. A substantial majority of the spoil from the cutting process remains in and immediately adjacent the cut. The spoil is a combination of debris and dust. Compressed air can be used to move the spoil, but that merely spreads the debris and dust over a larger area. To remove the debris and dust, in some arrangements a vacuum system is used consisting of a long hose with a nozzle wider than the trench placed above the trench and a large dedicated vacuum truck which immediately follows the trenching machine during use. In practice this is expensive and requires a large amount of space due to the presence of two different primary mover trucks/machines. This work is often done on roadways, which can cause traffic control problems. In practice, this arrangement often does not work well to remove the spoil because of the long distance that the heavy asphalt material must travel and the height to which the debris must be lifted in order to reach the vacuum truck collector.
Example embodiments include a microtrencher which includes arrangements for diverting and removing spoil created when a microtrench is being cut. The spoil includes a combination of typically larger debris and dust particles. In certain aspects, the disclosed arrangement diverts the debris and dust away from the microtrench during the cutting process, depositing the debris through an exit gap. In certain optional embodiments, a vacuum system is used to remove the dust particles during the debris diversion process. In further optional embodiments, a microtrench slot cleaning tool may be used. The microtrencher can be mounted on a skid steer loader or a similar support vehicle.
An illustrative embodiment is an arrangement with a housing configured to move at a height along an asphalt or concrete cutting surface in a forward direction of travel. A radial planar blade with grinding teeth is rotatably mounted within the housing and arranged to cut a slot in the cutting surface as the housing is moved. The housing defines an exit opening aligned with the plane of the blade and arranged so that spoil created by the blade exits the housing through the exit opening. A plenum defining an entrance opening is mounted in communication with the housing exit opening. The plenum defines an enclosed plenum passage extending between plenum sides, a roof and a floor. The plenum passage extends forward from the entrance opening and then turns and extends laterally relative to the entrance opening and then terminates in an exit end. An end plate extends across the exit end of the plenum passage. A downward facing exit gap is defined adjacent to the exit end between a terminus of the plenum floor and the end plate, wherein the gap is laterally spaced away from the slot cut by the blade so that spoil travelling through the plenum passage is deposited through the exit gap laterally away from the slot.
In certain optional embodiments, the plenum floor is angled downward along at least portions of its length to assist in urging spoil toward the exit gap. Optionally, the arrangement may include a spoil vacuum system with a spoil vacuum intake arranged over one or more openings defined in the end plate and operable to capture lighter-than-air particles within the spoil while allowing debris such as heavier-than-air particles within the spoil to be deposited through the exit gap.
An alternate embodiment comprises an arrangement with a housing carried by a host machine vehicle along an asphalt or concrete cutting surface in a forward direction of travel. A radial planar blade with grinding teeth is rotatably mounted within the housing and arranged to cut a slot in the cutting surface as the housing is moved. The housing defines an exit opening on a forward side of the housing, wherein the exit opening is substantially aligned with the plane of the blade and arranged so that spoil created by the blade exits the housing through the exit opening. A plenum defining an entrance opening is mounted in communication with the housing exit opening. The plenum defines an enclosed plenum passage extending between plenum sides, a roof and a floor. The plenum passage extends forward from the entrance opening, extends laterally relative to the entrance opening and terminates in an exit end. An end plate extends across the exit end of the plenum passage. A downward facing exit gap is defined between a terminus of the plenum floor and the end plate, wherein the gap is laterally spaced away from the blade so that spoil travelling through the plenum passage is deposited through the exit gap laterally away from the slot.
Optionally, the arrangement may include a slot cleaning tool carried by the host machine vehicle and connected to a slot tool vacuum intake of a slot vacuum system. The slot cleaning tool may be formed of a series of longitudinal hollow chambers arranged in parallel along a plane configured to be lowered into a vertical slot cut by the blade. The series of chambers define a series of openings staggered along the height of the chambers. Some may be side openings while other openings are downward facing.
Further forms, objects, features, aspects, benefits, advantages, and examples of the present disclosure will become apparent from a detailed description and drawings provided herewith.
For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the examples illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Any alterations and further modifications in the described examples, and any further applications of the principles of the disclosure as described herein are contemplated as would normally occur to one skilled in the art to which the disclosure relates. Certain examples of the disclosure are shown in detail; although it will be apparent to those skilled in the relevant art that some features which are not relevant to the present disclosure may not be shown for the sake of clarity.
An example embodiment includes a microtrencher arrangement which include a system for diverting and removing spoil created when a microtrench slot is being cut. The spoil includes a combination of typically larger heavier-than-air pieces generally referred to herein as debris and lighter particles which may be temporarily suspended to travel or floating through the air, generally referred to herein as dust. In certain aspects, the disclosed arrangements divert the debris and dust away from the microtrench during the cutting process. In certain optional embodiments, a vacuum system is used to remove the dust particles during the spoil diversion process. In further optional embodiments, a microtrench slot cleaning tool may be used. The microtrencher can be mounted on a skid steer loader or a similar support vehicle.
Referring generally to
As illustrated, an implement frame 30 is generally configured to be mounted to the left and right arms 20 of the skid steer loader and optionally the left and right hydraulic cylinders 22. In a preferred embodiment, brackets are provided at the rear of the frame allowing the frame and microtrencher 28 to be attached to the lift arms 20 and/or cylinders 22. Left and right arms 20 and the left and right hydraulic cylinders 22 may function in concert to pivot the orientation of frame 30 and the microtrencher. In a preferred embodiment, frame 30 is configured as a lateral piece, which may function as a debris shield and which may allow the microtrencher to be mounted or moved to the left or right of the centerline of the skid-steer loader in the direction of travel D if desired. Optionally ground engaging elements such as rollers 32 are mounted adjacent the foot of the frame 30 to allow the frame to rest upon and roll over a support surface.
The skid-steer loader 10 may have a hydraulic power system, which may be selectively coupled directly or through an interface to certain work implements to provide hydraulic power to the implements. Example supply and return lines 24, 26 to microtrencher 28 are shown. Generally the skid steer loader and any work implements are controlled by an operator through controls 19 located adjacent the operator position. In some skid steer loaders, the operator enters the operator position from the front of the vehicle.
Certain embodiments include a rotating cutting tool such as a microtrencher. Other embodiments may be used in conjunction with other types of tools which involve dust and debris, such as cold planers, slot cutters, milling machines or power brooms for asphalt or concrete. Microtrencher 28 in
As the microtrencher 28 is moved, the blade 46 cuts a narrow trench or slot in the asphalt or concrete cutting surface. A microtrench commonly has a slot depth of less than one foot, for instance in a range between approximately four and twelve inches and a width in a range of approximately 0.5 to 1.5 inches. In certain embodiments, microtrenchers may be made to cut a maximum depth of six or twelve inches. The microtrenchers may incorporate a depth gauge to measure and control the applied cut depth during use. These dimensions are representative and not intended to be limiting. Different municipalities have different microtrench requirements.
The microtrencher 28 may be mounted on a host machine vehicle or primary mover, such as via frame 30 to skid-steer loader 10, or it may operate independently, for example when mounted to an independent frame or trolley. The primary mover or host machine vehicle and frame are used independently or in cooperation to control the cutting depth of the microtrencher. In certain embodiments, the microtrencher housing 40 is mounted to a support frame 30 which supports housing 40 at a desired height to control the cutting depth of the blade and which is movable to move the housing and blade along the surface to be cut in the direction of travel D. Housing 40 may include a base piece with skids that straddle the path of blade 46, with blade 46 passing closely between the skids. The skids or skid shoes press against the cutting surface, and may be adjusted or changed with each blade width. Skids are used in controlling the cut depth and also support the asphalt directly adjacent to the cut by holding it down and in place. Since the blade is cutting in an upward direction, the skids keep the material edges from chunking out. This helps provide a clean edge at the sides of the cut.
In the illustrated embodiment, microtrencher 28 has a spoil chute mounted to and extending from the housing. The spoil chute includes plenum 60. Plenum 60 defines an entrance opening 63 which is mounted in communication with an exit opening 42 defined in housing 40. Preferably there are no gaps for spoil to escape between housing 40 and plenum 60. The housing exit opening 42 is aligned with the plane of blade 46. In some embodiments, exit opening 42 is a vertical slot through the housing. In the illustrated embodiment, exit opening 42 is defined in the forward portion of housing 40. Plenum 60 has portion 62 extending forward from the entrance opening and which then turns to the side. Portion 62 may define an approximate right angle or a curve or may be slanted or angled. In the illustrated embodiment a front side portion 62 is angled forward and laterally, forming a ramp which helps divert and deflect forward momentum of the spoil converting it to lateral momentum.
Portion 64 of plenum 60 extends laterally to an exit end which may be closed, for instance with an exit plate 66. Exit plate 66 may be integral with other portions of plenum 60 or may be a separate piece which is assembled across the exit end. The exit plate and/or exit end is optionally openable for cleaning and maintenance. Exit plate 66 is not shown in
In operation, spoil created by blade 46 exits housing 40 through opening 42 and enters the spoil chute through entrance opening 63. As illustrated in the interior view in
The spoil is then urged forwardly and laterally along the length of plenum 60, so that the spoil eventually exits through exit gap 70 and is deposited away from the blade. The spoil may be urged through plenum 60 in part by the pressure of an air stream created by the rotation of blade 46.
In certain embodiments, an optional spoil vacuum system 80 is connected to and works in cooperation with the plenum. When used, vacuum system 80 helps pull spoil toward the exit end and helps remove dust from plenum 60. Vacuum system 80 includes a vacuum pump for drawing air through hose 84. The dust is then captured and stored in vacuum machine 86, for instance in a storage tank, until it is disposed of. Vacuum system 80 may be carried by the same host machine vehicle as microtrencher 28.
In these embodiments, the exit end defines one or more openings or a series of openings in communication between the interior volume of the plenum and the exterior of the plenum. For instance, the openings may be defined in exit plate 66. A spoil vacuum intake 82 is arranged and sealed over the openings. Spoil vacuum intake 82 is connected to a hose 84 which extends to vacuum machine 86. In this embodiment, spoil vacuum system 80 may capture a significant portion of the lighter-than-air dust particles of the spoil which float or travel in the air. The heavier-than-air debris in the spoil remains and exits downward through exit gap 70. The deposited debris is laterally spaced from the slot cut by the blade. The deposited heavier-than-air debris may be later removed, for example with a street sweeping machine or broom.
In alternate embodiments, a misting system is connected to and works in cooperation with the spoil chute. In these embodiments, one or more openings are defined in the plenum walls, roof and/or exit plate and misting nozzles are mounted through the openings. In operation, the nozzles dispense water mist into plenum 60 to capture and remove dust particles from the air, causing the particles to exit downward through gap 70. Other embodiments may use a liquid such as oil for dust remission.
Selected embodiments of the disclosure include a slot cleaning tool 110. The slot cleaning tool 110 may operate in combination with the microtrencher and spoil chute, or optionally may be operated separately after a microtrench has been cut. In some arrangements, slot cleaning tool 110 is mounted to the host machine/primary mover and arranged to travel forward within the slot with movement of the primary mover to automatically clean a slot as the slot is cut. In other embodiments, slot cleaning tool 110 may be used manually.
Slot cleaning tool 110 is formed of a series of longitudinal hollow chambers 120. The chambers 120 are arranged in parallel along a plane. Chambers 120 are illustrated as rectangular, but other cross-sectional shapes may be used as desired. Tool 110 defines a height H at least tall enough to extend into the depth of the microtrench slot to be cleaned. The heights of the chambers may not all be equal. In use, the chambers are arranged in a plane which can be oriented and lowered into a vertical slot to the depth of the slot. The chambers 120 have a pair of outward facing opposing sides 122 that face the inward walls of the slot.
A series of openings 126 is defined from the exterior into the hollow chamber interiors. The series of openings corresponds to the series of chambers. The openings are staggered along the height of the series of chambers, preferably with at least one opening corresponding to each height within the microtrench slot. Certain openings may partially overlap in height. For at least one and optionally most chambers, one or more side openings 128 face the slot walls, with the center axis of each side opening substantially perpendicular to the plane of the chambers, and thus perpendicular to the slot walls during use. In some embodiments, a chamber may have a pair of side openings 128 defined through a pair of outward facing opposing sides 122. The chambers 120 with side openings 128 may have closed lower ends. One or more chambers 120 may define end openings 129 which face downward within the slot thus facing the floor of the slot.
In certain embodiments, tool 110 includes a pair of forward and rearward guides 130 bracketing forward and rearward ends of the series of chambers. The forward and rearward guides 130 form forward and rearward edges of tool 110. The forward and rearward guides 130 may have a width sized to substantially span the width of the microtrench slot, while allowing tool 110 to slidably move along the length of the slot. The guides 130 are preferably formed of a low-friction yet durable material which does not easily bind with the slot sides or wear. In certain embodiments, the width of the hollow chambers 120 is less than the width of the slot and less than the width of guides 130, creating a slight space or gap between the chambers and the slot walls on one or both sides. For chambers 120 which define end openings 129, the chamber height may be slightly spaced above the slot floor. The spacing may assist in allowing clearance space for air and dust removal.
The upper portion of tool 110 is connected to a slot tool vacuum intake 92 of slot vacuum system 90. Vacuum system 90 includes vacuum machine 96 with a vacuum pump for drawing air through hose 94. The dust is then captured and stored, for instance in a storage tank, until it is disposed of. Vacuum intake 92 feeds hose 94 which extends to vacuum machine 96. In selected alternate embodiments, vacuum system 90 can be configured as blower with hose 94 supplying compressed air to tool 110 or a nozzle accessory which can be used to blow spoil out of and away from the microtrench. In certain embodiments slot vacuum machine 96 may be separate from spoil vacuum machine 86. In other embodiments, vacuum systems 80 and 90 may share a vacuum machine and/or storage tank, with different ports for hoses 84 and 94.
In use, tool 110 is arranged and inserted into a slot so that the series of chambers 120 are vertically arranged along a plane along the length of the slot. When vacuum is applied to the upper ends of the chambers 120, air, dust and debris are drawn into the chambers through the side openings 128 to clean the slot walls. Air, dust and debris are also drawn into certain chambers through bottom openings 129 to clean the slot floor. The openings 126 are preferably staggered yet create a continuous pattern corresponding to the height of the slot. Tool 110 is then slid forward or rearward within the slot. As tool 110 slides within the slot, the pattern of openings 126 removes remaining spoil from the slot floor as well as along the height of the slot walls. The spoil is transported to vacuum machine 96 for later removal.
Vacuum systems 80 and 90 may be carried by the prime mover, or alternately can be on separate movable carts or vehicles. The vacuum systems 80 and 90 may be powered by the primary mover power supply, or by alternate power supplies such as generator 100.
While the disclosure has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred example has been shown and described and that all changes, equivalents, and modifications that come within the spirit of the disclosures defined by following claims are desired to be protected.
The present application claims priority to provisional application Ser. No. 62/561,933 filed on Sep. 22, 2017, which is incorporated by reference.
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