Patent Application
20220090451
The disclosed technology regards a modular drilling apparatus and ground treatment methods useful in a multitude of applications concerning prepared ground surfaces and natural ground conditions.
Traditionally, drilling through asphalt, concrete, or rock is an expensive, slow and laborious process, which significantly degrades machinery. Specifically, present drilling systems use a single drill rod and bit, drilling one hole at a time. Often these systems use air as a drilling propellant, thereby generating significant dust at the worksite and causing the machinery to become exceedingly hot, damaging the drilling rod and bit. Known drilling systems of the prior art are large, heavy, and expensive, and in operation require an inefficient use of human resources.
Present soil conditioning systems drive hollow rods into the ground, injecting water and additives to condition the soil. These rods do not rotate or drill into the surface; rather they use force to drive the rods into the surface. Further, these systems are permanently affixed to bulldozers, and due to the weight of this vehicular machinery and the design of the injection systems, the injection systems themselves must provide a heavy counterweight to the bulldozer to drive the rods into the ground.
Therefore, there is a need to provide a drilling apparatus that can drill multiple holes into the ground surface at the same time and also efficiently use and inject water and additives into the strata. Such a drilling apparatus should minimize the generation of dust at the worksite, the operational heat of the machinery, and necessary human resources.
The disclosed technology overcomes the deficiencies in the prior art and addresses these and other needs by providing a modular apparatus having four hollow drill rods which quickly and efficiently drill into the earth and present pressurized water and additives to ground strata. The apparatus is lightweight, and may be coupled with and decoupled from a skid steer or other machinery (e.g., excavators, dozers and trucks) and transported by a pickup truck to another work site. By its novel design, operation of the apparatus requires limited personnel, maximizing safety and decreasing operational costs. Further, with the use of fluid as a propellant, dust at the worksite is minimized, the apparatus operates with lower heat and less wear on drill rods and bits, and generates smoother holes in the earth.
The disclosed technology is useful in innumerable applications, including for example for: excavation; installing drainage controls, irrigation canals and levee securements; slip repairs and the installation of soil nails to hold hill sides; breaking up overburden, permafrost, frozen ground, coal, and rock; injecting soil treatments into contaminated or unstable soil; injecting grout for sealing or raising building foundations; injecting gel or epoxy for securing steel to rock beds; applying pest control agents in difficult to reach places; applying gel for sealing fishers or leaks in ponds and levees; and breaking through fragipans. In one particular application, the additive may be a soil stabilizing fluid which reduces the overall swell potential of clay based soils, sufficiently increasing the ground compression strength to support buildings, roadways and other construction.
The disclosed technology provides a novel drilling apparatus for drilling into prepared ground surfaces and natural ground conditions. Generally, the apparatus includes a mast assembly, a support structure assembly flexibly coupled with the mast assembly, a plurality of drill assemblies affixed to the support structure assembly, and a frame.
The mast assembly includes a top mast beam and a pair of hydraulic cylinders, with the hydraulic cylinders being affixed at a first end to the top mast beam and at a second end to the frame such that the mast assembly is raised and lowered relative to the frame through the extension and retraction of the hydraulic cylinders. The support structure assembly flexibly coupled to the mast assembly includes a top support beam and a mid support beam; the flexible coupling allows the support structure assembly to move vertically with the mast assembly. The frame supports the mast assembly and includes a top horizontal frame beam, a pair of vertical frame beams, and a base beam. Each of the top horizontal frame beam and the base beam are affixed to the vertical frame beams, and a universal skid steer coupler is secured to the rear of the frame.
The plurality of drill assemblies affixed to the support structure assembly of the disclosed technology each include a gearbox secured to a first facing side of the top support beam, a hydraulic power take off (PTO) coupled with and secured to the corresponding gearbox such that an output gear of the PTO supplies torque to the gearbox with the gearbox amplifying the torque, and a hollow drill rod with a drill bit at one end and secured at the other end to the corresponding gearbox to receive the amplified torque and pressurized fluid from the gearbox. Each drill rod is vertically supported by aligned apertures in the mid support beam and the base beam, and the drill bit includes exterior cutting elements and interior fluid diverters.
Several separate hosing systems are provided, including a first hosing system for supplying pressurized hydraulic fluid to the hydraulic cylinders; a second hosing system to provide pressurized hydraulic fluid to each PTO of the drill assemblies; and a third hosing system for supplying pressurized water with or without additives to each of the drill assemblies.
In some embodiments the apparatus includes one or more flow dividers provided with one or more of the hosing systems to divert fluid flow to each of the drill assemblies or the hydraulic cylinders, as applicable. In one such flow divider providing pressurized hydraulic fluid to each PTO, the divider allocates differing volumes of pressurized hydraulic fluid among the drill assemblies as each corresponding drill rod encounters different soil compaction or conditions, thereby directly affecting the torque supplied to each of the drill rods, resulting in equalized shaft bore rates among the drill rods.
As herein described, the top beam of the support structure assembly is flexibly coupled with the mast assembly, intending that the beam is not rigidly affixed to the mast assembly or the frame, but rather being capable of angling away from its natural position of horizontal to a ground surface to accommodate varying bore rates among the drill rods in operation. In an embodiment, this flexible coupling is accomplished through a pair of chains affixed at opposing ends to the top support beam and the frame, respectively, being supported about a top sprocket gear affixed to the mast assembly. Offering the same flexibility, the mid support beam may likewise be coupled with the top support beam by chains, affixed at one end to the top support beam, at another end to the frame, and being supported about a mid sprocket gear affixed to the mid support beam.
The disclosed technology further provides a method of drilling into a ground surface, by providing a drilling apparatus having a mast assembly, a support structure assembly flexibly coupled with the mast assembly, a plurality of drill assemblies affixed to the support structure assembly, and a frame. Each of the drill assemblies include a hollow drill rod with a drill bit at one end, the bit having exterior cutting elements and interior fluid diverters. Pressurized fluid and torque is supplied to the drill rods, and by means of the mast assembly and support structure assembly the drill rods are moved downward so that using the downward force and rotation of the bits as well as the pressurized fluid, the drill rods drill into the ground surface.
The pressurized fluid supplied to the drill rods includes water and from time to time an additive. The flexible coupling of the top and mid support beams as herein disclosed greatly enhances this drilling method.
The apparatus of the disclosed technology is intended to be removably coupled with a skid steer or similar vehicle, and the method of drilling is similarly well suited to the use of such vehicles. These and other novel attributes of the apparatus and methods of the disclosed technology are provided through embodiments shown and described below.
As shown in
The support structure assembly 10 comprises in parallel configuration a top support beam 101 and a mid support beam 102. The top support beam is flexibly coupled with the mast assembly by means of a pair of chains 101a (or similar strong, durable and flexible material), wherein each chain is affixed at one end to the top support beam (e.g., on the rear of the beam), is supported about a top sprocket gear 101b affixed to the mast assembly, and is affixed at a second end to the frame. By this configuration and as the top support beam is not rigidly affixed to the mast assembly or the frame (except through the chain coupling described), the top support beam moves vertically with the mast assembly, positioned with its length generally horizontal to the ground although capable of angling away from such horizontal position to accommodate varying bore rates among the drill rods. Such varying bore rates may be experienced as a result of different soil compaction, rock or other conditions as may be independently encountered by each of the drill rods.
Similarly, the mid support beam 102 is flexibly coupled with the top support beam 101 by means of a pair of chains 102a (or similar strong, durable and flexible material), wherein each chain is affixed at one end to the top support beam 101 (e.g., on the rear of the beam), is supported about a mid sprocket gear 102b affixed to the mid support beam, and is affixed at a second end to the frame 30. By this configuration, the mid support beam moves vertically with the mast assembly and the top support beam (except when the mid support beam is resting atop a base beam, as hereinafter described), with flexibility similar to the top support beam hereinabove described as relates to its position relative to horizontal, thereby accommodating varying bore rates among the drill rods.
As shown in
Pressurized hydraulic fluid is supplied through flexible hosing 114 to each PTO 113 of the drill assemblies 110 and the hydraulic cylinders 202, originating from a hydraulic pump provided on the skid steer or otherwise at the site, wherein the hydraulic fluid supplied to the hydraulic cylinders is supplied to the cylinders by means of a hydraulic distribution block 115a. As shown in
While the flow of hydraulic fluid is primarily controlled through operation of the pump and the hydraulic flow divider, one or more knobs, buttons or switches 117 may be affixed to one or both sides of the top support beam 101 (or elsewhere on the assemblies of the disclosed technology), the knobs or buttons being in communication with the hydraulic flow divider to cause the divider to reroute the flow of hydraulic fluid to the pump when the knob/button/switch is engaged. Hydraulic fluid used in the system may be filtered by means of a filtering system 123 provided on the mast or elsewhere.
A pressure regulator 118 may be coupled between the pressurized fluid source and the hydraulic flow divider to allocate the pressure of the hydraulic fluid delivered to the divider and that delivered to the hydraulic cylinders, thereby controlling the maximum torque applied to the drill rods 111 (and the hydraulic cylinders). As shown in
Pressurized water is supplied by means of another pump to each drill assembly 110 at the gearbox 120, by means of hosing 121, and then sprayed into the earth by means of the rotating drill rods 111 and the interior fluid dividers of the drill bits 111a. In embodiments of the disclosed technology, an input port and another hydraulic flow divider 122b may be affixed to the top support beam 101 or otherwise on the apparatus of the disclosed technology to receive the pressurized water (and added additives, from time to time) from the pump, and divert it to each of the drill assemblies, providing pressurized water through each of the drill rods at an operating pressure of about 300 psi, handling about 100 gpm flow rate of water.
Soil stabilizing fluid or other specialized formulations for soil conditioning as may be necessary or desirable at the treated earth may likewise be mixed with the water and delivered to each gearbox 120. Likewise, other additives may be supplied to the drill assemblies such as grout for sealing or raising building foundations, gel or epoxy for securing steel to rock beds or for sealing fishers or leaks in ponds and levees, and pest control agents. Soil stabilizers and other additives can be corrosive, and therefore the components of the drill assemblies 110 and the flow divider 122B may be constructed out of chromium-molybdenum steel or other materials resistant to acidic corrosion.
By the afore-described configuration, the supplied amplified torque cause the hollow drill rods 111 to bore or drill into the earth and deliver pressurized water (and additives when desired) at and below the earth surface. The fluids may be delivered consistently or intermittently, as controlled for example at the source pumps.
As herein described, the drill rod is hollow to facilitate the delivery of fluids into the earth. As shown in
In the embodiment shown, the drill assemblies 110 are affixed to the top support beam 101 such that the drill rods 111 are positioned about 40-50″, or 44″ apart. When operating with ideal water pressure (300 psi), in this configuration the circumference of the resulting spray overlaps between each of the drill rods, thereby fully saturating and achieving full stabilization of the earth at multiple bore depths.
Referring to
In the embodiment shown, one end of the hydraulic cylinders are affixed respectively to the top mast beam by means of a rotating bushing 202a, while the other end of the hydraulic cylinders are affixed respectively to the frame. Pressurized hydraulic fluid is supplied to the hydraulic cylinders through flexible hosing from a hydraulic pump provided on the skid steer or otherwise at the site, and may be the same hydraulic pump (with a diverter) as the pump for the PTOs hereinabove described. Thereby, the vertical position of the mast assembly relative to the frame is controlled through extension and retraction of the hydraulic cylinders. As hereinabove described, top sprocket gears 101b are supported on each side of the mast assembly to couple the assembly with the support structure assembly, and by this configuration the mast assembly and the support structure assembly move vertically together in relation to the frame, and force downward movement of the mast assembly causing the torqued drill rods to rotationally bore or drill into the earth.
In the embodiment shown, one or more guide wheels 205 are provided on the vertical frame beams to prevent the mast from torqueing from side to side.
The mast assembly is supported by the frame 30. As shown in
Supply of hydraulic fluid to each of the PTOs and the hydraulic cylinders, can be controlled at a remote location, such as on the skid steer, by coupling the elements thereof to the control system on the skid steer by mean of a seven pin connector, for example, thereby allowing control of the apparatus at the skid steer.
An apparatus of the disclosed technology may be 12′ wide×8′ tall×3′ deep, and weighs less than 4,000 lbs.
In an embodiment of the operation of the disclosed technology, the apparatus is coupled with the skid steer, which lifts the apparatus (at the coupling with the frame) off of the ground and moves it to the ground area of interest. With the mast assembly raised (by means of the hydraulic cylinders), hydraulic power is then supplied to the drilling assemblies. As the mast assembly and the coupled support structure assembly move vertically down relative to the frame, the drill rods of the drilling assemblies approach and bore into the ground surface. Pressurized water is provided through the drill rods and bits to facilitate drilling; consistently or intermittently additive can be supplied with the pressurized water to achieve saturation. In many applications the drill rods bore a certain distance into the ground, e.g. 1′, and continue to rotate without further vertical movement to ensure full saturation at a certain bore depth; then continue deeper, halt for saturation, and the process is repeated. Once the intended drilling depth is achieved, the rods are withdrawn from the soil and the apparatus is moved a distance further, e.g. 4′, into the treatment site area.
By means of the present apparatus, soil can be treated 4′, 8′ or even 12′ or even 16′ under the ground surface. The apparatus is capable of drilling through soil, rock, gravel, asphalt, concrete, and stone, and injecting high pressurized fluids into the subsurface of the ground. As an exemplary application, when used on concrete or other solid surfaces the drill grid pattern may be 1′/2″ holes 4′ apart, which efficiently and economically provides ideal conditions for an excavator to rip out the solid surface.
Further provided by the disclosed technology are methods of treating ground surfaces. The ground surface may be asphalt, concrete, or rock, other natural or man-made conditions, and soil, including contaminated or unstable soil. In these methods, an apparatus is provided such as but not limited to the embodiments of the apparatus hereinabove described. The apparatus performs the method by (a) simultaneously rotating and applying vertical pressure to a plurality of drill rods, each rod including a drill bit, so that the rods bore into the ground surface; (b) while the drill rods bore into the ground surface, supplying pressurized water through the drill rods and at an angle from the drill bits, the water being supplied alone, with an additive, or intermittently with an additive.
In view of the embodiments described above, it should be apparent to those skilled in the art that the present invention may, be embodied in forms other than those specifically described herein without departing from the spirit or central characteristics of the invention. Thus, the specific embodiments described herein are to be considered as illustrative and by no means restrictive.
The above description is that of a preferred embodiment of the invention. Multiple modifications and variations are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. Any reference to claim elements in the singular, e.g. using the articles “a,” “an,” “the,” or “said” is not construed as limiting the element to the singular.
Further, it is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the preceding claims. None of the above inventions and patents, taken either singly or in combination, is seen to describe the instant invention as claimed.
| Number | Date | Country | |
|---|---|---|---|
| 63081931 | Sep 2020 | US |
