Patent Application
20180002886
The present invention relates to systems and methods for striking objects, such as piles, and, in particular, to systems and methods for allowing a diesel hammer to be used as a hydraulic impact hammer.
In construction, objects such as piles are often inserted into the earth. Such insertion may be by placement of a pile into an excavated hole, but it is typically quicker and more efficient to simply insert the pile into the earth without prior excavation. Such insertion may be by auguring the pile into the earth, crowding (forcing) the pile into the earth with constant pressure, applying a vibrational driving force to the pile, by striking the pile with repeated blows on an upper end of the pile, commonly referred to as hammering, or by combinations of those methods.
Another common construction task is to test the load bearing capacity of a pile that has been driven into the earth. In a particular, information obtained by striking a driven pile with a controlled striking force can be used to test and/or confirm the load bearing capacity of the driven pile.
The present invention relates to systems and methods for striking a pile for the purpose of driving the pile into the earth and/or testing a load capacity of a pile that has been driven into the earth. In the following discussion, the term “strike” will be used to refer to the act of impacting or applying a force to a pile for the purpose of driving the pile and/or for the purpose of testing the load bearing capacity of a driven pile.
Pile hammer systems typically employ a heavy ram member that is raised and allowed to fall such that the ram member repeatedly applies a short duration striking force directly or indirectly to the pile. A number of mechanisms are used to raise the ram member.
One type of pile hammer is commonly referred to as a diesel hammer. A diesel hammer injects diesel fuel below the falling ram such that the falling ram compresses and then ignites the diesel fuel as the ram applies the driving force to the pile. After the driving force has been applied to the pile, the ignited diesel fuel expands and forces the ram up to repeat the cycle.
Another type of pile hammer is commonly referred to as a hydraulic impact hammer. A hydraulic impact hammer uses a hydraulic actuator to raise the ram and force the ram down against the pile.
One type of pile hammer may be preferred over another depending on factors as the specifications of the pile to be struck, the purpose for applying the striking force to the pile (e.g., driving or load testing), and soil conditions. Often, it is desirable to change from one type of pile hammer to another type of pile hammer, sometimes for the same pile at the same location. For example, it may be desirable to use a diesel hammer to a certain soil depth and a hydraulic impact hammer beyond that depth, or vice versa. As another example, it may be desirable to use a diesel hammer to drive the pile to a predetermined depth and a hydraulic impact hammer to test the load bearing capacity of the pile at the predetermined depth.
The need exists for systems and methods that facilitate the change from one type of pile hammering to another type of pile hammering.
The present invention may be embodied as a hydraulic impact hammer for striking a pile comprising a main housing, a ram supported for movement within the main housing, a coupler rod detachably attached to the ram, a conversion housing detachably attached to the main housing, a hydraulic actuator supported by the conversion housing, the hydraulic actuator defining an actuator rod, a lifting head, a lift connector, and a ram connector. The lift connector is detachably attaches the actuator rod to the lifting head. The ram connector detachably attaches the coupler rod to the lifting head. Operation of the hydraulic actuator raises and lowers the ram to strike the pile.
The present invention may also be embodied as a pile striking system for striking at least one pile. The pile striking system comprises a main housing, a valve assembly supported by the main housing, an anvil supported by the main housing, a ram supported for movement within the main housing, a cap detachably attachable to the main housing, a coupler rod detachably attachable to the ram, a conversion housing detachably attachable to the main housing, a hydraulic actuator supported by the conversion housing, the hydraulic actuator defining an actuator rod, a lifting head, a lift connector, and a ram connector. The lift connector detachably attaches the actuator rod to the lifting head. The ram connector detachably attaches the coupler rod to the lifting head. The cap is attached to the main housing and the valve assembly is configured to operate in a diesel mode such that the pile striking system to operate as a diesel hammer to cause the ram to impact the anvil to strike at least one pile. The conversion housing is attached to the main housing, the coupler rod is attached to the ram and to the ram and to the lifting head by the ram connector, the actuator rod is detachably attached to the lifting head by the lift connector, the valve assembly is configured to operate in a hydraulic mode, and operation of the hydraulic actuator raises and lowers the ram such that the pile striking system operates as a hydraulic impact hammer to cause the ram to impact the anvil to strike at least one pile.
The present invention may also be embodied as a method of striking a pile comprising the following steps. A ram is supported for movement within a main housing. A coupler rod is detachably attached to the ram. A conversion housing is detachably attached to the main housing. A hydraulic actuator defining an actuator rod is supported from the conversion housing. The actuator rod is detachably attached to a lifting head. The coupler rod is detachably attached to the lifting head. The hydraulic actuator is operated to raise and lower the ram to strike the pile.
The present invention may also be embodied as a method of striking at least one pile comprising the following steps. A valve assembly is supported from a main housing. A ram is supported for movement within the main housing. A hydraulic actuator defining an actuator rod is provided. The pile striking system is operated as a diesel hammer by attaching a cap to the main housing and configuring a valve assembly to operate in a diesel mode to cause the ram to impact an anvil to strike at least one pile. The pile striking system is operated as a hydraulic impact hammer by attaching a conversion housing to the main housing, attaching a coupler rod to the ram, attaching the coupler rod to a lifting head, attaching the actuator rod to the lifting head, configuring the valve assembly to operate in a hydraulic mode, and operating the hydraulic actuator to raise and lower the ram to cause the ram to impact the anvil and strike at least one pile.
Referring initially to
The example diesel hammer 22 is or may be conventional and will be described herein only to that extent helpful to a complete understanding of the present invention. As perhaps best shown in
The ram 32 is configured to move between upper and impact positions within the diesel housing 30 as shown by a comparison of
When the example valve assembly 36 is configured in a diesel hammer mode, the ram 32 moves through a diesel impact cycle. At an initial point in the diesel impact cycle, the ram 32 is in the upper position as shown in
The example valve assembly 36 of the example diesel hammer 22 may further be configured to operate a hydraulic mode. As will be described in further detail below, in the hydraulic mode the ram 32 is allowed to move between the upper and lower positions without injection of diesel fuel and with minor controlled compression of fluids (e.g., air) within the diesel chamber 40 for the purpose of pre-compression as described, for example, in U.S. Pat. Nos. 7,694,747, 8,181,713, and 8,496,072. In particular, in the hydraulic mode the valve assembly 36 is configured to allow air within the diesel chamber 40 to flow out such that movement of the ram 32 from the upper position to the lower position is impeded only by resistance of compressed air sufficient to establish pre-compression of the anvil 34 against the pile 26 immediately prior to the striking of the anvil 34 by the ram 32. As described in the U.S. Pat. Nos. 7,694,747, 8,181,713, and 8,496,072 patents, this pre-compression inhibits transmission of potentially damaging shocks into the pile 26. However, the example hydraulic impact hammer 20 may be operated such that the ram 32 strikes the anvil 34 without pre-compression when operated in the hydraulic mode.
Given the foregoing understanding of the construction and operation of the example diesel hammer 22, the construction and operation of the first example hydraulic impact hammer 20 will now be generally described with reference to
Initially, the diesel hammer 22 is reconfigured to allow the diesel hammer to be combined with the conversion assembly 24 to form the first example hydraulic impact hammer 20. The diesel hammer 22 is reconfigured by removing the cap 52 of the diesel housing 30. As will be described below, all components of the diesel hammer 22 except for the cap 52 are combined with the conversion assembly 24 to form the first example hydraulic impact hammer 20.
The example conversion assembly 24 comprises a conversion housing 120, a hydraulic actuator 122, and a coupler assembly 124. The conversion housing 120 supports the hydraulic actuator 122 in a desired position relative to the ram 32 when at least a portion of the diesel hammer 22 is combined with the conversion assembly 24. With the hydraulic actuator 122 in a desired position relative to the ram 32, the example coupler assembly 124 detachably attaches the hydraulic actuator 122 to the ram 32 to complete assembly of the hydraulic impact hammer 20.
The example conversion housing 120 comprises an upper portion 130, a transition portion 132, and a top plate 134. The transition portion 132 is adapted to be detachably attached to the main housing 50 of the diesel housing 30 of the diesel hammer 22. The upper portion 130 is adapted to be attached to the transition portion 132. The top plate 134 is adapted to the attached to the upper portion 130.
As perhaps best shown in
The seal 148 is configured between the inner and outer cylinders 140 and 142 to define an inner chamber 154 and an outer chamber 156. The piston 146 is arranged within the inner chamber 154 to define a first inner chamber portion 154a and a second inner chamber portion 154b. One or more cylinder ports 158 (
One or more actuator ports 160 (
As best shown in
To assemble the first example hydraulic impact hammer 20, the transition portion 132 thereof is detachably attached to the main housing 50 of the diesel housing 30, the upper portion of the conversion housing 120 is attached to the transition portion 132 thereof, and the top plate 134 is detachably attached to the upper portion 130 to complete assembly of the conversion housing 120. In the example conversion housing 120, the second lower flange 184 of the transition portion 132 is detachably attached to the main flange 54 of the main portion of the diesel housing 30 by bolts, threads, or the like, the second upper flange 182 is detachably attached to the first lower flange 176 by bolts, threads, or the like, and the top plate 134 is detachably attached to the first upper flange 174 by bolts, threads, or the like.
Bolts (not shown) are typically used to assemble the conversion housing 120 and to detachably attach the conversion housing 120 to the main housing 50 of the diesel housing 30. In this case, a plurality of bolts are arranged to extend at least partly through holes (not shown) in the flanges 54, 184, 182, 176, and 174 and main plate portion 190 at evenly spaced locations about the perimeter of these components. The bolts may be threaded into such holes or may pass through the holes and secured by nuts. The bolts should be of sufficient size and number to securely and rigidly hold the various components 50, 130, 132, and 134 together during normal use of the first example hydraulic impact hammer 20. Permanent connections such as welds may be used to attach two or more of the components 130, 132, and 134 if convenient. But the attachment of the transition portion 132 of the conversion housing 120 to the main housing 50 of the diesel housing 30 should be by non-permanent connection such as bolts, threading, clamps, or the like to allow the transition portion 132 to be detachably attached to the main portion 50.
Turning now to
The example actuator rod 144 is configured to be detachably attached to the second example coupler assembly 124. In particular, the example actuator rod 144 defines a main portion 250 having a diameter D1, an intermediate portion 252 having a diameter D2, and a distal end portion 254 having a diameter D3. The diameter D1 is greater than the diameter D2, and the diameter D2 is greater than the diameter D3. The example intermediate portion 252 is threaded. A first shoulder surface 256 is formed at the juncture of the main portion 250 and the intermediate portion 252 of the actuator rod 144. A second shoulder surface 258 is formed at the juncture of the intermediate portion 252 and the distal end portion 254 of the actuator rod 144.
In the example coupler assembly 124, the example lift connector 222 comprises a rod nut 260, a rod jam nut 262, a rod end washer 264, one or more socket cap screws 266, and one or more lock washers 268. One or more impact cushions 270 are arranged between the rod end washer 264 and an upper surface of the top wall 230, and a lifting cushion 272 is arranged between the rod nut 260 and a lower surface of the top wall 230. A bushing 274 is arranged around the intermediate portion 252 of the actuator rod 144 within the actuator rod opening 240 in the upper wall 230.
The example ram connector 224 comprises a coupler rod 280, a torque nut 282, a plurality of torque nut studs 284, a torque nut washer 286, and a disc spring 288. The example coupler rod 280 defines a first threaded end 290 and a second threaded end 292. The example ram connector 224 is formed by what is commonly referred to as a Superbolt torque nut assembly, but any connector assembly capable of functioning in a manner similar to that of the example Superbolt torque nut assembly may be used.
To assemble the hydraulic impact hammer 20, the cap 52 of the diesel housing 30 is removed from the main housing 50 thereof to expose the top of the ram 32. The second threaded end 292 of the coupler rod 280 is threaded into the threaded bore 38 of the ram 32 to secure the coupler rod 280 to the ram 32.
The conversion assembly 24 is then assembled as follows. The actuator rod 144 is initially inserted through the rod end washer 264, through the impact cushion(s) 270, through the bushing 274, and through the actuator rod opening 240 in the lifting head 220 such that the first shoulder surface 256 is in contact with the rod end washer 264, the impact cushions 270 are in contact with the upper surface of the lifting head top wall 230, and the intermediate actuator rod portion 252 and bushing 274 are within the ram rod opening 242. The lifting cushion 272 is then arranged over the intermediate portion 252 of the actuator rod 144. The rod nut 260 is then threaded onto the actuator rod intermediate portion 252 such that the lifting cushion 272 is held against the lower surface of the lifting head top wall 230. The rod end jam nut 262 is next arranged over the distal end portion 254 of the actuator rod 144, and the socket cap screws 266 are extended through the lock washers 268 and the rod end jam nut 262 and into the rod nut 260 to secure the rod end jam nut 262 in place. The distal end portion 154 of the actuator rod 144 is thus secured to the lifting head 220. The transition portion 132 of the conversion housing 120 is also attached to the upper portion 130 of the conversion housing 120.
At this point, the conversion assembly 24 is assembled and is attached to the diesel hammer 22 from which the cap 52 has been removed to form the hydraulic impact hammer 20. In particular, the conversion housing 120 is arranged such that the first threaded end 290 of the coupler rod 280, which has been secured to the ram 32, extends through the ram rod opening 242 in the lifting head bottom wall 232. The disc spring 288 and torque nut washer 286 are then arranged over the first threaded end 290 of the coupler rod 280. The torque nut 282 is then threaded onto the first threaded end 290 of the coupler rod 280, and the torque nut washers 286 and studs 284 are used to secure the torque nut 282 to the coupler rod 280.
The conversion housing 120 is detachably attached to the main housing 50 of the diesel housing 30 using bolts, threads, or the like. In the example hydraulic impact hammer 20, bolts are passed at least partly through one or both of the main flange 54 defined by the main housing 50 and the second lower flange 184 defined by the conversion housing 30 to detachably attach the conversion housing 120 to the main housing 50.
The outer and inner access openings 186 and 244 allow the socket cap screws 266 and torque nut studs 284 to be tightened with the conversion housing 120 attached to or otherwise held in place relative to the main housing 50. The lifting head 220, the lift connector 222, and the ram connector 224 allow the actuator rod 144 to be quickly and securely attached to the ram 32 with simple tools available in the field.
Further, the hydraulic impact hammer 20 can be easily and quickly converted back into the diesel hammer 22 simply by reversing the steps described above.
In the forgoing discussion, a particular sequence for combining the conversion assembly 24 with the diesel hammer 22 has been described. The exact sequence described is not essential to a given implementation of the present invention as a method of forming a hydraulic impact hammer, a method of converting a diesel hammer into a hydraulic impact hammer, or a method of converting a hydraulic impact hammer into a diesel hammer.
To use the example hydraulic impact hammer 20, the valve assembly 36 is configured in the hydraulic mode to allow the ram 32 to move between the upper and lower positions. The hydraulic actuator 122 is then operated raise and lower the ram 32. In its lowest position, the ram impacts the anvil 34 and thus the pile 26 to strike the pile 26 along the strike axis A.
