Drive Head for Foundation Support System

Abstract

A foundation support driving apparatus is provided. The apparatus includes a drive head which may be coupled to a hydraulic ram assembly for driving a foundation support. The drive head has sleeve plates that form a sleeve through which the foundation support may travel. The sleeve plates also form a pair of opposed yokes. The drive had has a pair of opposed rotating plates that rotate about respective pins positioned in opposed yokes. Gripping portions disposed at the inward ends of the rotating plates are adapted to engage the exterior surface of a foundation support extending through the sleeve. The hydraulic ram assembly rotates the rotating plates back and forth to move the gripping portions into and out of engagement with the foundation support in order to move the foundation support.

Description

TECHNICAL FIELD

The disclosure relates generally to foundation construction and repair and, more particularly, to a drive head for driving pipe in connection with an apparatus that is adapted to raise and support foundation structures.

BACKGROUND

Buildings, including houses, office buildings, strip malls and the like, are often constructed such that a building frame rests on a foundation. Foundation types are generally known and can include concrete slabs, reinforced concrete slabs, pier-and-beam, footings, and other types. Sometimes foundations include structures that are deep enough to contact, or tie into, solid strata such as bedrock. Other foundations are made shallow and rest on soil above the bedrock. These foundations may include structures, such as concrete slabs for example, that distribute the weight of the building across a relatively large area of the soil.

Changing soil conditions and/or improper building construction can result in portions of the building sagging or drooping. This can be caused by parts of the foundation sinking where the soil conditions are insufficient to support the structure. The sagging and drooping can, in turn, cause damage to the frame, drywall, flooring, plumbing, and other components of the building.

When a foundation structure such as a slab sinks, it becomes necessary to raise the sinking portion and support it such that it does not re-settle or sink further. Prior techniques have involved jacking up the slab and positioning pilings below the foundation for support. However, the pilings are not in contact with the solid strata, so additional foundation sinking can still occur. Additionally, these techniques can be very expensive and can be visually unpleasing as the repair components such as the pilings are typically visible after the repair work is completed.

SUMMARY

Certain embodiments of the invention provide an apparatus for driving a support structure, such as a piling, pipe or other structure, into the ground. The support structure may be a component of a foundation repair or support system. In some embodiments, the system may include a drive head that is adapted to grip the support structure such that it may be driven into the ground. In at least one embodiment, the drive head includes a pair of rotatable plates, each of which rotates in a vertical plane about a transverse rod. The end of each plate that is distal to the support structure when engaged by the drive head is adapted to receive a clevis for connection to a hydraulic arm. The proximal end of each plate is formed as a gripping portion. As the distal end of the plate is pulled downward, the plate is rotated about the transverse rod and the gripping portion engages the support structure. Thus, as the drive head is pulled in a downward motion, the opposed gripping portions engage the pipe or support structure and pull it downwardly.

In one example, an apparatus is provided for installing a foundation support. The apparatus includes a sleeve assembly having a sleeve adapted to receive and guide the foundation support. The apparatus also includes a first rotating plate rotatably coupled to the sleeve assembly about a pivot point. The first rotating plate has a first end and a second end, and the pivot point is located between the first and second ends of the first plate. The first end of the first rotating plate is proximal the sleeve and is adapted to engage an outer surface of the foundation support. The first rotating plate is operable to be rotated about the pivot point in a first rotation direction to engage the first end of the first rotating plate with the surface of the foundation support. The first end of the first rotating plate is adapted to impart movement of the foundation support in response to movement of the apparatus when the first end of the first rotating plate is engaged with the surface of the foundation support.

In another example, an apparatus is provided for installing a foundation support. The apparatus includes a sleeve assembly having a sleeve adapted to receive and guide the foundation support. The apparatus includes a first rotating plate rotatably coupled to the sleeve assembly and having a first end adapted to engage an outer surface of the foundation support when the first rotating plate is rotated in a first direction.

In another example, a method is provided for driving a foundation support. One step is disposing the foundation support within a sleeve of a drive head which is positioned at a first point relative to the foundation support, and which has at least one rotating plate adapted to be rotated in a first direction to force an end of the at least one rotating plate against a surface of the foundation support to grip the foundation support. Another step is rotating the at least one rotating plate in a first direction to impart engagement of the rotating plate with the foundation support. Another step is moving the drive head in a first direction to drive the foundation support into strata. Another step is rotating the at least one rotating plate in a second direction to disengage the rotating plate from the surface of the foundation support.

One or more of the embodiments may provide some, none, or all of certain of the following advantages. One advantage is that an apparatus is provided, which may be easily coupled with a foundation support and may easily drive the foundation support into strata. Among other things, simplicity is provided in that movement of a driving apparatus in a first direction may cause the drive head to engage and grip the foundations support, and additional movement of the driving apparatus in the same direction moves the gripped foundation support in the same first direction. This can be followed by movement of the driving apparatus in a second direction to disengage the drive head from the foundation support.

Additional simplicity is realized in that repeated vertical up-and-down motion of a driving apparatus imparts back-and-forth rotation of opposed rotating plates of a drive head to alternatively engage and disengage from a foundation support. During engagement, movement of the driving apparatus in a first direction automatically engages the drive head with the foundation support to move the foundation support in the first direction. Movement of the driving apparatus in a second direction automatically disengages the drive head from the foundation support to allow free movement of the drive head relative to the foundation support.

Additional simplicity is realized in that a support plate may be coupled to the foundation support and, once the foundation support is driven into a desired position, the support plate may be coupled to a foundation structure and the drive head and driving apparatus may be easily removed from foundation support.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of this disclosure and its features, reference is now made to the following description, taken in conjunction with the accompanying drawings, in which:

FIG. 1 is a perspective view of an apparatus for driving a foundation support structure in accordance with an embodiment of the invention;

FIG. 2 is a perspective view of another embodiment of an apparatus for driving a foundation support structure;

FIG. 3A is an illustration showing a foundation support driving apparatus in use in accordance with an embodiment of the invention;

FIG. 3B is an illustration showing a foundation support driving apparatus in use in accordance with an embodiment of the invention;

FIG. 4 is a schematic of a hydraulic system for actuating a foundation support drive apparatus in accordance with an embodiment of the invention.

FIG. 5A is a side view of a drive head for a foundation support driving apparatus in an engaged position in accordance with an embodiment of the invention;

FIG. 5B is a side view of a drive head for a foundation support driving apparatus in a disengaged position in accordance with an embodiment of the invention;

FIG. 6 is a top view of a drive head for a foundation support driving apparatus in accordance with an embodiment of the invention;

FIG. 7A is a perspective view of a drive head for a foundation support driving apparatus in accordance with an embodiment of the invention; and

FIG. 7B is a side view of a drive head for a foundation support driving apparatus in in accordance with an embodiment of the invention.

DETAILED DESCRIPTION

Various embodiments are illustrated in FIGS. 1-7. In summary, the various embodiments provide an apparatus for driving a foundation support into the ground. The apparatus may have a pair of opposed rotatable plates. Each plate may have an end proximal a sleeve through which the foundation support is guided. Rotation of a given plate about a pivot point in a first direction of rotation causes the proximal end of that plate to move toward an outer surface of the foundation support. Rotation of the opposed plate in the appropriate direction of rotation about its pivot point similarly causes its proximal end to move toward the outer surface of the foundation support. Structures on the proximal ends of the opposed plates may thereby engage the outer surface of the foundation support. When the foundation support is so engaged, the entire apparatus may be moved downwardly. The proximal end structures of the rotating plates grip the foundation support and pull the foundation support in the same downward direction of movement as the apparatus. The movement of the apparatus may be accomplished by a pair of hydraulically-operated arms, each attached to a respective one of the rotating plates. The arms may be actuated to pull a second, distal end of each plate to rotate the plates about their respective pivot points. When the arms are hydraulically moved in the opposite direction, the movement imparts an opposite rotation of the plates to disengage the proximal end structures from the foundation support. Then, the apparatus is free to move relative to the foundation support, in an upward direction for example, without imparting movement to the foundation support.

As shown in FIG. 1, a foundation lifting and support system 100 is provided. System 100 includes a lifting arm assembly 10. Assembly 10 includes a sleeve 12 having a lifting arm 14 connected (e.g., via weld) to an outer surface thereof. A bracket 16 is connected (e.g., via weld) to an outer surface of sleeve 12 and an upper surface of arm 14. Bracket 16 may be, for example, an L-shaped bracket. However, other shapes for bracket 16 are contemplated as being within the scope of the invention and any suitable shape may be employed depending, for instance, on the desired interaction between bracket 16 and a foundation. Assembly 10 also includes a pair of plates 17a and 17b, which are connected to, and extend perpendicular to, an outer surface of the vertical portion of bracket 16. Assembly 10 further includes a pair of mounting plates 18a and 18b, which are connected to and extend perpendicular to the respective plates 17a and 17b. Each mounting plate 18a and 18b has an opening extending therethrough.

System 100 is shown with a foundation support 40 (partial view). In the illustrated example, foundation support 40 is a pipe or series of pipes. Foundation support 40 may be a pier, column, pile, piling, or other similar foundation support structure. As described in further detail herein, foundation support 40 is driven downwardly to interact, abut, rest on, etc. the solid strata underneath the foundation of the building. Foundation support 40 also provides a structure to which lifting arm assembly 10 may be coupled in order to lift and support a foundation once the foundation support 40 has been driven to its desired depth. It should be noted that various embodiments may or may not include foundation support 40.

As shown in FIG. 2, a drive head 20 is provided for interaction with foundation support 40. As further illustrated in FIGS. 5A, 5B, and 6, drive head 20 includes a sleeve assembly, which includes a pair of first sleeve plates 21a and 21b. First sleeve plates 21a and 21b are connected (e.g., via a weld) to a pair of second sleeve plates 22a and 22b to form a sleeve through which foundation support 40 may move. It should be noted that the particular configuration of the sleeve is not critical and drive head 20 may have numerous configurations as long as a sleeve is provided through a body structure, or sleeve assembly, of drive head 20. Although not required, the sleeve is preferably large enough to allow movement of foundation support 40 in a relatively vertical direction, but small enough to provide reasonable transverse support of foundation support 40.

Drive head 20 further includes first and second rotating plates 26a and 26b. Together, first and second rotating plates 26a and 26b form a pair of opposed rotating plates. Preferably, one rotating plate is substantially identical to the other rotating plate but in a reverse, or “mirror,” orientation. For example, first rotating plate 26a has a first, or inward, end proximal foundation support 40 and a second, or outward, end distal foundation support 40. Second rotating plate 26b similarly has a first, or inward, end proximal foundation support 40 and a second, or outward, end distal foundation support 40.

The distal, or outward, end of each rotating plate is adapted for coupling to an arm (32a or 32b, respectively) of a hydraulic ram unit as described in further detail below. The proximal, or inward, end is formed as a grip portion for engagement with an outer surface of pipe assembly 40. Thus, the proximal end of first rotating plate 26a is formed as first grip portion 27a and the proximal end of second rotating plate 26b is formed as second grip portion 27b. In the illustrated embodiment, each grip portion has a partial cylindrical, and concave, shape such that a surface of the respective grip portion is adapted to fit to a corresponding outer surface of pipe assembly 40 when drive head 20 is in an engaged position as described herein. The surface of the grip portions may be formed with one or more protrusions (not expressly shown). The protrusions may comprise a series of ridges and valleys that extend either horizontally (i.e., in the direction generally planar to the ground and between the pair of first sleeve plates 21a and 21b). Alternatively, the ridges and valleys may extend vertically. In another configuration, the protrusions may comprise teeth, which may be formed as bumps or spikes extending outwardly from the respective surfaces of the first and second gripping portions 27a and 27b. It should be understood that any suitable type, shape, size and/or number of protrusions may be formed in the surface of a gripping portion. The protrusions preferably act to increase the gripping strength of the gripping portions and create additional friction and/or slip preventions when the gripping portion is engaged with the pipe assembly surface and pulled downwardly as described elsewhere herein. It should be noted that while the illustrated embodiment shows the proximal ends of the rotating plates to be formed as grip portions, other configurations are contemplated. For example, grip structures may be independently formed and coupled to the proximal ends of the rotating plates. The coupling may be accomplished by any suitable technique including, for example, welds or connectors (e.g., pins, rods, bolts, etc.).

Drive head 20 further includes a pair of pin assemblies 25a and 25b. Pin assemblies 25a and 25b may have any suitable configuration to allow a plate, through which a portion of a pin assembly extends, to rotate about the pin assembly in a relatively vertical plane. In the example illustrated in FIG. 1, each pin assembly 25a and 25b includes at least a pin 71a and 71b, respectively, extending between the pair of first sleeve plates 21a and 21b. Each pin extends through the respective plate 21a and 21b and is anchored in position by a hex nut. Each pin assembly 25a and 25b may have a pair of spacers 73a and 73b, respectively, through which the pins 71a and 71b extend. For example, a pin 71a, about which rotating plate 26a rotates, may have a first spacer 73a positioned between first sleeve plate 21a and rotating plate 26a, and a second spacer 73b between first second sleeve plate 21b and rotating plate 26a. The spacers 73a and 73b keep the respective rotating plates 26a and 26b roughly centered between the pair of first sleeve plates 21a and 21b.

The pair of first sleeve plates 21a and 21b cooperate to form yokes at both ends of drive head 20. First and second rotating plates 26a and 26b fit into the respective yokes and are held in place by the respective pin assemblies 25a and 25b, by virtue of the respective pins 71a and 71b extending through respective holes in rotating plates 26a and 26b. Plates 26a and 26b are rotatable within the respective yokes, and preferably in a relatively vertical plane (i.e., in a plane substantially parallel to a plane defined by either of first sleeve plates 21a and 21b).

Arms 32a and 32b each have, respectively, a clevis 34a or 34b coupled or attached to an end thereof. Each clevis has a yoke into which fits the distal end of the respective rotating plate. The rotating plates 26a and 26b are held in their respective clevis yokes by a respective clevis pin 70a or 70b. Generally, each clevis pin extends between the first pair of sleeve plates and through a hole in the respective rotating plate. The rotating plates are rotatable about their respective clevis pins in the relatively vertical plane.

As a given arm 32a or 32b extends, it pushes the distal end of the respective rotating plate in an upward direction. The distal end of the respective rotating plate rotates about its respective clevis pin. The respective rotating plate similarly rotates about the respective pin 71a or 71b, thereby forcing a proximal end of the rotating plate downwardly. This causes the respective gripping portions to rotate away from the pipe assembly surface to a position of disengagement (i.e., a position which allows relative movement of the pipe assembly upwardly or downwardly without being impeded by a gripping portion of a rotating plate of the drive head).

Retraction of a given arm 32a or 32b causes rotation of the respective rotating plate in an opposite direction. Thus the distal end of the rotating plate is pulled downwardly and the rotating plate rotates about both the clevis pin and the pin extending between the first sleeve plates. This, in turn causes the proximal end of the rotating plate to be forced upwardly and the gripping portion to be rotated into contact, or engagement, with the surface of the pipe assembly. The compression of the gripping portions against the pipe assembly creates a lateral force to grip the pipe assembly and hold it in position relative to the gripping portions. As the arms 32a and 32b retract further, the entire drive head 20 is pulled downwardly and the gripping portions pull the pipe foundation support 40 downwardly through the sleeve formed in the center of the drive head 20. This forces the pipe assembly further into the ground. Repeated up and down motion of the arms 32a and 32b repeats the release, gripping, and downward pulling of the pipe assembly to drive the pipe assembly further and further into the ground. Preferably the pipe assembly is driven to a point that an end thereof contacts solid strata (e.g., bedrock).

Once the pipe assembly is in contact with solid strata, it will no longer move in a downward position. Thus, when the arms 32a and 32b retract, the retraction causes the lifting arm assembly 10 to be raised upwardly along the pipe assembly. This, in turn, lifts the foundation upwardly. The foundation is thereby raised to a desired height. Once the foundation is at the desired height, the lifting arm assembly may be affixed (e.g., via a weld) to the pipe assembly to hold the lifting arm assembly (and the foundation) in its desired vertical position.

It should be noted that for rotating plates 26a and 26b to move into an engaged position, it is necessary for the gripping portions 27a and 27b to be able to avoid contact with second sleeve plates 22a and 22b. This may be achieved by forming the gripping portions below a certain predetermined point relative to the rotating plates such that when the gripping portions are moved into engagement, they travel below the second sleeve plates. Alternatively, slots or partial slots (not expressly shown) may be formed in the second sleeve plates through which the gripping portions may travel. Another alternative configuration involves a combination of slots in the second sleeve plates and proper positioning of the gripping portions.

The operation of the hydraulic lifting unit will now be described. Referring again to FIGS. 1 and 2, a pair of hydraulic ram units 30a and 30b are provided, which are installed between the respective plates 18a and 18b of the lifting arm assembly 10 and rotating plates 26a and 26b of drive head 20. A pair of arms 32a and 32b extend from the ram units 30a and 30b, it being understood that they are connected to pistons which reciprocate in the ram units in response to actuation of the units. This reciprocal movement of the pistons causes corresponding movement of the arms 32a and 32b between the extended position shown in FIG. 2 and a retracted position (not expressly shown).

As previously described, a pair of clevises 34a and 34b are connected to the end of the arms 32a and 32b, extend over rotating plates 26a and 26b, and are connected to the latter plates by a pair of pin assemblies. In a similar manner, a pair of clevises 36a and 36b are connected to the respective ends of the ram units 30a and 30b, extend over the plates 18a and 18b, and are connected to the latter plates by a pair of bolts.

A foundation support, shown in general by the reference numeral 40, and comprising a pipe or plurality of pipe segments, extends through the sleeve 12 of the lifting arm assembly 10 and through the sleeve in drive head 20 as shown in FIGS. 1 and 2. As previously described, drive head 20 can be manually lifted upwardly on the pipe assembly 40 without encountering substantial resistance. After connection to the hydraulic ram units 30a and 30b and the actuation of same to move drive head 20 downward, the gripping portions 27a and 27b grip the outer surface of the foundation support 40 and force it downwardly.

The operation of the lift-and-support apparatus will now be described in additional detail with reference to FIGS. 3A and 3B in connection with a house 44 having a corner that has a foundation failure causing a corresponding sinking of this portion of the house and thus requiring it to be raised, leveled and supported. The area around the corner of the foundation is initially evacuated and the lifting arm assembly 10 is placed in the evacuated area. Although only one assembly 10 is shown in the drawing it is understood that, in actual practice, several may be used, depending on the extent of the damage. The lifting arm 14 of each lifting arm assembly 10 is inserted underneath the house and against the lower surface of the foundation, as shown in FIG. 3A. A section of the foundation support 40 is then placed in the sleeve 12 of the lifting arm assembly 10, and the drive head 20 is placed over the upper portion of the pipe assembly. The hydraulic ram units 30a and 30b, in their extended positions, are then installed between the respective plates 18a and 18b of the lifting arm assembly 10 and the rotating plates 26a and 26b of the drive head 20. The ram units 30a and 30b are actuated simultaneously to cause a retracting motion of their corresponding pistons, and therefore the arms 32a and 32b, to rotate the rotating plates in a direction which rotates the respective gripping portions into engagement with the surface of foundation support 40. Drive head 20 is then pulled downwardly. As a result, the drive head 20 grips the foundation support 40 and forces it downwardly into the ground for a predetermined distance. The ram units 30a and 30b are then simultaneously actuated back to their expanded condition. This causes the reverse rotation of rotating plates 26a and 26b, thereby rotating the gripping portions 27a and 27b away from foundation support 40 and into a position of disengagement. The drive head 20 is then moved upwardly along foundation support 40 to an upper portion of foundation support 40, and the sequence is repeated. During this sequential driving of the foundation support 40 into the ground, additional pipe segments may be added to the foundation support assembly as needed.

The above procedure is repeated until the lower end portion of foundation support assembly encounters resistance in the ground, which is usually in the form of bedrock or the like, in which case the aforementioned driving movement is terminated.

After all of the foundation supports 40 have been driven into the ground in the foregoing manner until they encounter resistance, all of the ram units 30a and 30b associated with the pipe assemblies are simultaneously actuated again to raise the foundation, and therefore the house, a predetermined distance which can be, as an example, approximately two to five inches as shown is FIG. 3B. The raising of the respective lifting arm assemblies 10 occurs because the pipe assemblies cannot travel further downwardly. Thus, instead of the drive head pulling the pipe assembly downwardly, the drive head remains in position and the opposite end of the hydraulic unit pulls the lifting arm assembly, together with the foundation, upwardly.

After the foundation raising is completed to a point where the foundation is at the desired height, that portion of each foundation support 40 extending within the upper end of its corresponding sleeve 12 is affixed (e.g., via welding) to the sleeve. The ram units 30a and 30b, along with the clamping assemblies 20, are removed from the lifting arm assemblies 10. The foundation supports 40 are then cut at a point immediately above the weld between the respective foundation support 40 and the sleeve 12. The excavated area around each piling is then filled in and the procedure is complete.

FIG. 4 shows a flow diagram for the ram units 30a and 30b described above. Three pairs of the ram units 30a and 30b are shown schematically in the drawing, with fluid lines 50 and 52 connecting the upper portions and the lower portions, respectively, of the units. It should be understood that the fluid lines 50 and 52 feed fluid into the cylinder of their respective ram units 30a and 30b to cause corresponding movement of their pistons, in a conventional manner. The fluid lines 50 are connected, via lines 54, to a manifold 56, and the fluid lines 52 are connected, via lines 58, to a manifold 60.

The manifolds 56 and 60 are connected, via lines 62 and 64, respectively, to a pump, or compressor 66 which operates to selectively pump fluid into the manifold 56 and from the manifold 60 and, alternately, into the manifold 60 and from the manifold 56 depending on the particular stroke of the ram units 30a and 30b. Of course, when the pump flow is reversed, the fluid flow is reversed to cause movement of the piston portions of the hydraulic jack assemblies in the opposite direction.

Two additional lines 68 extend from the pump 66 which can feed a pair of manifolds (not shown), connected parallel to the manifold 66. As a result, a total of nine pairs of ram units identical to the units 30a and 30b can be actuated at one time in the event that the foundation damage is extensive and/or extends over a large area.

The various embodiments may result in some, all, or none of various technical advantages. For example, the foundation supports formed according to the present invention are supported directly on bedrock, which adds stability to the supporting system. Also, the foundation supports are relatively strong and invisible after the method is completed even though only minimum excavation of the ground surrounding the foundation is required.

Further, the system of the present invention eliminates the need for high pressure ram devices, yet permits all of the foundation support assemblies associated with the particular foundation to be raised at once.

It is understood that, although the above example was described in connection with the foundation of a building, the system of the present invention can also be used in an identical manner to raise a concrete slab extending underneath the entire area of a building or a house. In the case of a concrete slab, the lifting arm assembly 10 is engaged adjacent an outer edge of the slab in a manner similar to shown in FIG. 3A. In the case of damage to, or sinking of, an internal portion of the slab, a hole can be formed through the damaged portion of the slab, the lifting arm assembly 10 can be inserted through the hole, and the arm 14 and bracket 16 rotated to extend underneath the slab. Then, the lifting arm assembly 10 can be raised and the portion of the slab supported in the manner discussed above. Also, the lifting arm assembly 10 can be modified to provide a pair of diametrically opposed arms 14 and brackets 16 extending from the sleeve 12 to facilitate the lifting action of the arm assembly 10.

Referring to FIGS. 7A and 7B, an alternative drive head assembly 170 is illustrated. Operation of drive head 170 is similar to that already described in connection with drive head 20 shown, for example, in FIG. 2. Drive head 170 is provided for interaction with foundation support 40. Drive head 170 includes a sleeve assembly, which includes a pair of first sleeve plates 171a and 171b. First sleeve plates 171a and 171b are connected (e.g., via a weld) to a pair of second sleeve plates 172a and 172b to form a sleeve through which foundation support 40 may move. It should be noted that the particular configuration of the sleeve is not critical and drive head 170 may have numerous configurations as long as a sleeve is provided through a body structure, or sleeve assembly, of drive head 170. Although not required, the sleeve is preferably large enough to allow movement of foundation support 40 in a relatively vertical direction, but small enough to provide reasonable transverse support of foundation support 40.

Drive head 170 further includes first and second rotating plates 176a and 176b. Together, first and second rotating plates 176a and 176b form a pair of opposed rotating plates. Preferably, one rotating plate is substantially identical to the other rotating plate but in a reverse, or “mirror,” orientation. For example, first rotating plate 176a has a first, or inward, end proximal foundation support 40 and a second, or outward, end distal foundation support 40. Second rotating plate 176b similarly has a first, or inward, end proximal foundation support 40 and a second, or outward, end distal foundation support 40.

The distal, or outward, end of each rotating plate is adapted for coupling to an arm of a hydraulic ram unit as previously described in connection with the embodiment illustrated in FIG. 2. The proximal, or inward, end is formed as a grip portion for engagement with an outer surface of pipe assembly 40. Thus, the proximal end of first rotating plate 176a is formed as first grip portion 177a and the proximal end of second rotating plate 176b is formed as second grip portion 177b. In the illustrated embodiment, each grip portion has a partial cylindrical, and concave, shape such that a surface of the respective grip portion is adapted to fit to a corresponding outer surface of pipe assembly 40 when drive head 170 is in an engaged position as described herein. The surface of the grip portions may be formed with one or more protrusions (not expressly shown). The protrusions may comprise a series of ridges and valleys that extend either horizontally (i.e., in the direction generally planar to the ground and between the pair of first sleeve plates 171a and 171b). Alternatively, the ridges and valleys may extend vertically. In another configuration, the protrusions may comprise teeth, which may be formed as bumps or spikes extending outwardly from the respective surfaces of the first and second grip portions 177a and 177b. It should be understood that any suitable type, shape, size and/or number of protrusions may be formed in the surface of a gripping portion. The protrusions preferably act to increase the gripping strength of the gripping portions and create additional friction and/or slip preventions when the gripping portion is engaged with the pipe assembly surface and pulled downwardly as described elsewhere herein. It should be noted that while the illustrated embodiment shows the proximal ends of the rotating plates to be formed as grip portions, other configurations are contemplated. For example, grip structures may be independently formed and coupled to the proximal ends of the rotating plates. The coupling may be accomplished by any suitable technique including, for example, welds or connectors (e.g., pins, rods, bolts, etc.).

Drive head 170 further includes a pair of pin assemblies 175a and 175b. Pin assemblies 175a and 175b may have any suitable configuration to allow a plate, through which a portion of a pin assembly extends, to rotate about the pin assembly in a relatively vertical plane. In the illustrated example, each pin assembly 175a and 175b includes at least a pin 71a and 71b, respectively, extending between the pair of first sleeve plates 171a and 171b. Each pin extends through the respective plate 171a and 171b and is anchored in position by a hex nut. Each pin assembly 175a and 175b may have a pair of spacers 173a and 173b, respectively, through which the pins 71a and 71b extend. For example, a pin 71a, about which rotating plate 176a rotates, may have a first spacer 173a positioned between first sleeve plate 171a and rotating plate 176a, and a second spacer 173b between first second sleeve plate 171b and rotating plate 176a. The spacers 173a and 173b keep the respective rotating plates 176a and 176b roughly centered between the pair of first sleeve plates 171a and 171b.

The pair of first sleeve plates 171a and 171b cooperate to form yokes at both ends of drive head 170. First and second rotating plates 176a and 176b fit into the respective yokes and are held in place by the respective pin assemblies 175a and 175b, by virtue of the respective pins 71a and 71b extending through respective holes in rotating plates 176a and 176b. Plates 176a and 176b are rotatable within the respective yokes, and preferably in a relatively vertical plane (i.e., in a plane substantially parallel to a plane defined by either of first sleeve plates 171a and 171b).

It should be noted that drive head 170 is similar to drive head 20 illustrated in FIG. 2. However, there are some variations. For example, second sleeve plates 172a and 172b extend only partially, in the vertical direction, between the upper and lower edges of first sleeve plates 171a and 171b. As shown, second sleeve plates 172a and 172b are even with first sleeve plates 171a and 171b at the upper edge. Second sleeve plates 172a and 172b then extend downwardly to a position short of (or above as illustrated) the lower edges of first sleeve plates 171a and 171b. Among other things, this forms a passage or void below the second sleeve plates through which the first and second gripping portions 177a and 177b may freely travel.

Also, it should be noted that first and second gripping portions 177a and 177b have a somewhat different shape than the gripping portions illustrated in FIG. 2. The gripping portions still have the partial cylindrical feature. However, both upper and lower edges of the gripping portions are substantially horizontal with respect to the ground in the normal orientation. Said another way, the upper and lower edges of the gripping portions are substantially parallel with the upper and lower edges of all of the sleeve plates. Also, each respective gripping portion preferably has an upper limit at about the vertical midpoint of a body portion of the respective rotating plate. And, each respective gripping portion preferably has a lower limit slightly below the lower limit of the body portion of the respective rotating plate. The configuration of the gripping portions illustrated in FIGS. 7a and 7b provides for relative ease in forming the gripping portions separately from the body portions of the rotating plates and then attaching the gripping portions to the rotating plates. However, it should be noted that the gripping portions and the rotating plates (or body portions thereof) may be formed as integral units. Also, as illustrated, and as with the gripping portions shown in FIG. 2, the gripping portions extend laterally beyond the thickness of the body portions of the respective rotating plates.

The rotating plates of both drive head 20 and drive head 170 have distal holes (e.g., holes 178a and 178b in FIGS. 7A and 7B). These holes may be elongated. This provides for some lateral movement of the respective actuating arms during operation.

Each of the rotating plates shown in FIGS. 7B and 7B also has a recess, 179a and 179b respectively. Recesses 179a and 179b are preferably formed in the upper vertical half of the respective rotating plate body portion so that they are located in the region of the second sleeve plates. Recesses 179a and 179b serve to accommodate portions of sleeve plates 172a and 172b during rotation of the rotating plates. In other words, as the plates are rotated, a portion of each respective sleeve plate 172a and 172b (for example, near a lower outward edge, may fit into the respective recess 179a or 179b.

In another embodiment, as illustrated in FIGS. 8A and 8B, for example, the drive head device may be operated in a reverse manner. That is, the drive head device may be used to extract, or lift, a foundation support structure. It can be seen in FIGS. 8A and 8B that drive head 220 is similar in many respects to the assembly illustrated in FIGS. 5A and 5B. However, in this embodiment, drive head 220 includes first and second rotating plates 226a and 226b. Together, first and second rotating plates 226a and 226b form a pair of opposed rotating plates. In this embodiment, the distal, or outward, end of each rotating plate is adapted for coupling to an arm (32a or 32b, respectively) of a hydraulic ram unit. The proximal, or inward, end is formed as a grip portion for engagement with an outer surface of pipe assembly 40. Thus, the proximal end of first rotating plate 226a is formed as first grip portion 227a and the proximal end of second rotating plate 226b is formed as second grip portion 227b. In comparison to the device illustrated in FIGS. 5A and 5B, the grip portions 227a and 227b are formed substantially above the rotation points (i.e., at pins 71a and 71b)) of each rotating plate. Thus, rather than being urged into engagement with pipe assembly 40 as the hydraulic arms are retracted, the gripping portions 227a and 227b are urged against a surface of pipe assembly 40 when the hydraulic arms 32a and 32b are extended. Thus, as the hydraulic arms are extended, the rotating plates rotate to engage the gripping portions with the pipe assembly. As the hydraulic arms are further extended, the pipe assembly is extracted, or lifted, from the strata. After the hydraulic arms are fully extended, they may be retracted. The rotating plates are each rotated in an opposite respective direction causing the gripping portions to be rotated away from, and disengaged from, the pipe assembly. The hydraulic arms may continue to be retracted to a fully retracted position. Then, the hydraulic arms may be extended again to repeat the process of lifting the pipe assembly.

It should be understood that FIGS. 1-7 illustrate example embodiments of the apparatus and various aspects of the apparatus may be added, eliminated, and/or substituted for those shown. Such modifications may be made as is desired, suitable, and/or advantageous for performing the functionality described herein. Such modifications are within the scope of the invention.

Numerous other changes, substitutions, variations, alterations, and modifications may be ascertained by those skilled in the art and it is intended that the present invention encompass all such changes, substitutions, variations, alterations and modifications as falling within the spirit and scope of this description.

While this disclosure has described certain embodiments and generally associated methods, alterations and permutations of these embodiments and methods will be apparent to those skilled in the art. Accordingly, the above description of example embodiments does not define or constrain this disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this disclosure, as defined by the following claims.

Claims

1. An apparatus for installing a foundation support, the apparatus comprising:

a sleeve assembly having a sleeve adapted to receive and guide the foundation support,

a first rotating plate rotatably coupled to the sleeve assembly about a pivot point, the first rotating plate having a first end and a second end, the pivot point located between the first and second ends of the first plate, the first end of the first rotating plate being proximal the sleeve,

the first end adapted to engage an outer surface of the foundation support,

wherein the first rotating plate is operable to be rotated about the pivot point in a first rotation direction to engage the first end of the first rotating plate with the surface of the foundation support,

wherein the first end of the first rotating plate is adapted to impart movement of the foundation support in response to movement of the apparatus when the first end of the first rotating plate is engaged with the surface of the foundation support.

2. The apparatus of claim 1, wherein the first end comprises a gripping portion adapted to engage a surface of the foundation support.

3. The apparatus of claim 2, wherein the gripping portion is coupled to the first end.

4. The apparatus of claim 2, wherein the gripping portion is integrally formed with the first end.

5. The apparatus of claim 2, wherein the gripping portion has a concave surface to interact with a convex surface of the foundation support.

6. The apparatus of claim 2, wherein the gripping portion has a distal surface that matches an outer surface of the foundation support.

7. The apparatus of claim 2, wherein an engagement surface of the gripping portion has a plurality of protrusions adapted to engage a surface of the foundation support when the gripping portion is forced against the foundation support.

8. The apparatus of claim 1, further comprising a second rotating plate rotatably coupled to the sleeve assembly and operable to be rotated about a pivot point in a first rotation direction to engage a first end of the second rotating plate with the surface of the foundation support.

9. The apparatus of claim 8, wherein the first and second rotating plates are adapted to cooperate to impart opposed pressure against the surface of the foundation support.

10. The apparatus of claim 1, further comprising an arm coupled to the first rotating plate, wherein movement of the arm imparts rotation to the first rotating plate.

11. The apparatus of claim 10, wherein the arm is hydraulically actuated.

12. The apparatus of claim 10, wherein the arm moves in a substantially linear direction corresponding to the direction of driving the support.

13. The apparatus of claim 10, wherein the arm is adapted to be moved in a first direction to rotate the first rotating plate to engage the first end with the surface of foundation support, and where additional movement of the arm in the first direction moves the entire rotating plate in the first direction thereby imparting movement of the foundation support in the first direction.

14. The apparatus of claim 10, wherein movement of the arm in a first direction rotates the first rotating plate into an engagement position and movement of the arm in a second direction rotates the first rotating plate into a disengagement position.

15. An apparatus for installing a foundation support, the apparatus comprising:

a sleeve assembly having a sleeve adapted to receive and guide the foundation support,

a first rotating plate rotatably coupled to the sleeve assembly and having a first end adapted to engage an outer surface of the foundation support when the first rotating plate is rotated in a first direction.

16. The apparatus of claim 15, wherein the first rotating plate is adapted to be rotated in a first direction into an engagement position and in a second direction into a disengagement position.

17. The apparatus of claim 15, further comprising a second rotating plate rotatably coupled to the sleeve assembly and having a first end adapted to engage the outer surface of the foundation support.

18. The apparatus of claim 17, wherein the first and second rotating plates are adapted to be rotated in opposed directions to engage the first ends of the respective first and second rotating plates with a surface of the foundation support.

19. A method of driving a foundation support comprising:

disposing the foundation support within a sleeve of a drive head wherein the drive head is positioned at a first point relative to the foundation support, the drive head having at least one rotating plate adapted to be rotated in a first direction to force an end of the at least one rotating plate against a surface of the foundation support to grip the foundation support;

rotating the at least one rotating plate in a first direction to impart engagement of the rotating plate with the foundation support;

moving the drive head in a first direction to drive the foundation support into strata; and

rotating the at least one rotating plate in a second direction to disengage the rotating plate from the surface of the foundation support.

20. The method of claim 19, further comprising the step of moving the drive head in a second direction to position the drive head at a second relative to the foundation support.