SOIL TRIMMING TOOL AND METHODS OF USING SAME

Abstract

Described herein are tools, systems, and methods for trimming a soil face.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/654,657 filed Jun. 1, 2012, the entire contents of which are hereby incorporated by reference.

The present application is a continuation in part patent application of U.S. patent application Ser. No. 13/487,010 filed Jun. 1, 2012 which claims the benefit of U.S. Provisional Patent Application No. 61/493,307 filed Jun. 3, 2011, the entire contents each of which are hereby incorporated by reference.

FIELD

Tools, systems, and methods for soil face trimming are described.

BACKGROUND

Generally, vertical precision soil shaping and removal require significant hand labor following large and heavy equipment excavation requiring high mobilization costs and incurring significant ground engaging tool wear and costs, further complicated by methods sensitive to very dense or stiff soils, organics, rock, and boulders. High productivity and accuracy can often be mutually exclusive. Current technologies waste energy, time and money.

SUMMARY

Soil trimming tools, systems and methods are described for cutting/trimming soil (e.g., a soil face). The tool can comprise: at least one drum including at least one first cutting tooth; at least one second cutting tooth associated with at least one chain; and a motor driven axle and/or sprocket assembly configured to move the at least one chain. In some embodiments, at least one attachment mechanism can be associated with the motor driven axle and sprocket assembly and configured to spin the at least one drum. In one embodiment, the attachment mechanism can be a rotor, splined hub, pinned shaft (M-M connection), polygonal shaped pin and socket (M-F connection), and/or a bolted flange connection.

Described are methods of preparing a flat cut wall comprising: engaging a trimming tool with a rough cut wall, wherein the trimming tool comprises at least one drum including at least one first cutting tooth; at least one second cutting tooth associated with at least one chain; a motor driven axle and sprocket assembly configured to move the at least one chain; and a axle driven rotor configured to spin the at least one drum.

In one embodiment, the tool can include a mount configured to attach the soil trimming tool to construction equipment and/or a carrier. The soil trimming tool can further include an upper drum and a lower drum bisected by the at least one chain.

Cutting teeth not associated with a drum can be attached to at least one flight associated with a chain link. In one embodiment, each flight includes more than one cutting tooth.

In some embodiments, (a) a first chain is driven by a first set of sprockets; and (b) a second is chain driven by a second set of sprockets. In one embodiment, a first drive axle is configured to provide power to a first driven axle and sprocket assembly and a second drive axle is configured to provide power to a second driven axle and sprocket assembly.

In one embodiment, the at least one drum and the cutting teeth associated with at least one chain can have a total height of about 6 ft and/or a weight at or less than about 8,000 lbs, about 10,000 lbs, about 12,000 lbs, about 14,000 lbs, about 16,000 lbs, about 18,000 lbs, about 22,000 lbs, about 24,000 lbs, or between about 8,000 lbs and about 20,000 lbs. In some embodiments, the trimming tool can be used to cut a 6 ft. tall wall under an existing concrete ring.

In one embodiment, the tools, systems and methods described can be guided by a global positioning satellite system, laser, or sonic tracer machine control system.

Methods are also described of preparing a flat cut wall comprising: engaging a trimming tool attached to a carrier with a rough cut wall under an existing concrete ring, wherein the trimming tool comprises an upper drum and a lower drum both having at least one circumferential cutting tooth, wherein the upper drum and the lower drum are bisected by the at least one chain; at least one second cutting tooth is associated with the at least one chain which in combination with the axle and sprockets are configured to spin the upper drum and the lower drum; and a motor driven axle and sprocket system configured to move the chain and drums.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a perspective view of a carrier including an example trimming tool as described herein.

FIG. 2 illustrates a perspective view including internal components of an example trimming tool described herein.

FIG. 3 illustrates a perspective view of two example chains driven by a sprocket and driven axle power transmission system.

FIG. 4 illustrates a perspective view of flight and teeth components of the trimming tool. FIG. 4A illustrates a perspective view of example flights and teeth that would be mounted onto the chains. FIG. 4B illustrates an alternate embodiment of a flight with removable teeth.

FIG. 5 illustrates a perspective view of an exemplary top and bottom drum attached to axle mounted rotors.

FIG. 6 illustrates a top view of an example trimming tool as described herein.

FIG. 7 illustrates a side view of an example trimming tool as described herein.

FIG. 8 illustrates a rear perspective view of an example trimming tool as described herein.

FIG. 9 illustrates a perspective view of a carrier including another example trimming tool as described herein

FIG. 10 illustrates a perspective view including internal components of another example trimming tool described herein.

FIG. 11 illustrates a perspective view of three example chains actuated by a driven axle and sprocket assembly system.

FIG. 12 illustrates a perspective view of flight and teeth components of the example trimming tool of FIG. 9.

FIG. 13 illustrates a perspective view of an exemplary top drum, bottom drum, second bottom drum, and diverting plate.

FIG. 14 illustrates a top view of the example trimming tool of FIG. 9.

FIG. 15 illustrates a side view of the example trimming tool of FIG. 9.

FIG. 16 illustrates a rear perspective view of the example trimming tool of FIG. 9.

FIG. 17 illustrates a rough cut wall.

FIG. 18A illustrates a side view of an example trimming tool from FIG. 1 attached to a carrier trimming the rough cut wall of FIG. 17. FIG. 18B is a top view of the example trimming tool in FIG. 1 attached to a carrier trimming the rough cut wall of FIG. 17. FIG. 18C is a side view of the another example trimming tool from FIG. 9 attached to a carrier trimming the rough cut wall of FIG. 17. FIG. 18D is a top view of the example trimming tool in FIG. 9 attached to a carrier trimming the rough cut wall of FIG. 17

FIG. 19 illustrates another top view of an example trimming tool attached to a carrier trimming a circular wall to build an underground structure.

FIG. 20 illustrates another top view of the example trimming tool attached to a carrier trimming a circular wall to build an underground structure.

DETAILED DESCRIPTION

Described herein generally are tools, systems and methods for cutting/trimming a soil/rock face. In one embodiment, tools, systems and methods can be used for cutting/trimming vertical soil/rock faces. The tools can comprise various components used to engage a soil face and provide power to those components. The tools, also referred to as trimming tools, can include at least one drum including circumferential cutting teeth (first tooth); cutting teeth associated with at least one chain (second teeth); powered axles (driven axle) and sprocket assemblies configured to spin the at least one chain and drum; and a motor driven sprocket and axle assembly (drive axle) powered by a motor.

An example trimming tool is illustrated in FIG. 1. Trimming tool 102 can be attached to any carrier 104 such as a tracked loader, land clearing carrier or bulldozing machine in place of a loading bucket or blade. Mount 190 can be used to attach trimming tool 102 in place of a blade. Carrier 104 or equivalent machinery can be any machine capable of supporting, powering, and driving the tools described herein. In another embodiment, power pack 106 can provide ample power to trimming tool 102. In such an embodiment, carrier 104 or equivalent machinery can be any machine capable of supporting and driving the tools described herein as trimmer tool can be powered by power pack 106.

A power pack can provide sufficient power to actuate the tools described herein without the aid of the machines actual drive motor. Sufficient power can be any amount of power needed to actuate a tool as described. Sufficient power can be about 50 hp, about 100 hp, about 150 hp, about 200 hp, about 250 hp, about 300 hp, about 350 hp, about 400 hp, about 450 hp, about 500 hp, about 550 hp, about 600 hp, about 700 hp, about 800 hp, about 900 hp, about 1,000 hp, at least about 50 hp, at least about 100 hp, at least about 200 hp, at least about 300 hp, less than about 2,000 hp, less than about 1,000 hp, less than about 700 hp, less than about 500 hp, between about 50 hp and about 2,000 hp, between about 100 hp and about 500 hp, between about 200 hp and about 1,000 hp, or any range of powers bound by any of the above values.

Power pack 106 can include one or more generators, one or more engines, one or more batteries, one or more solar panels, one or more compressors, one or more storage tanks or the like. In one embodiment, all power and accessory requirements for a trimmer tool can be encased in power pack 106. In some embodiments, a power pack may not be needed because the carrier can provide sufficient power to drive trimming tool 102. For example, power pack 106 may not be needed if the carrier has sufficient onboard power. In one embodiment, a carrier with sufficient power is a land clearing carrier. In another embodiment, a land clearing carrier has an accessory motor providing about 450 hp.

A trimming tool may be carried or self-supporting, driven from a carrier based power source (e.g. PTO, hydraulic QDs, etc.) or dedicated hydraulic power pack mounted to the carrier. Optionally, electrical drives may be used in conjunction with a trimming tool.

Different exemplary components of trimming tool 102 are illustrated in FIGS. 2-6. These illustrations are non-limiting and differences and variation in tool configuration, size, and arrangement are within the scope of the present description.

Trimming tool 102 can include chassis 108 which is equipped with front bearings 112, 112′ and rear bearings 116, 116′. Drive axle 122 and driven axle 128 fit into bearings 112, 112′ and 116, 116′ respectively. Front rotors 110, 110′ including front right sprocket 118 and front left sprocket 120 are fixed to front drive axle 122. Rear attachment mechanisms 114, 114′ including rear right sprocket 124 and rear left sprocket 126 are fixed to rear driven axle 128. Bearings 112, and 112′ allow front drive assembly including drive axle 122, front right sprocket 118 and front left sprocket 120, and front rotors 110, 110′ to rotate while securely fixed to chassis 108. Bearings 116, and 116′ can further allow rear driven assembly including driven axle 128, rear right sprocket 124 and rear left sprocket 126, and rear attachment mechanisms 114, 114′ to rotate while securely fixed to chassis 108. Drive axle 122 is rotated by means of a differential or gear box (not illustrated) and powered by motor 130.

Chassis 108 further includes hard points 132, 132′, 132″, 132′″ on both front face 134 and back face 136. Chassis 108 further includes first idler 138 and second idler 140. Each idler includes at least one roller 142 to help guide and provide tension to a chain when in motion.

Front right sprocket 118 and rear right sprocket 124 drive first chain 144. Front left sprocket 120 and rear left sprocket 126 drive second chain 146. Any number of sprockets and chains can be used. Each outer chain face 148 may be coupled to at least one flight 150. In one embodiment, one chain is used. In another embodiment, three chains are used with one chain spinning in an opposite direction compared to the other two chains.

As illustrated in FIG. 4A, each flight 150 can include at least one valley 152 and at least two mounting points 154. More valleys or high points can be included in a given flight. In one embodiment, flight 150 includes five valleys and six high points. In one embodiment, each high point can include at least one (second) blade, pick or tooth 156, giving a flight above six teeth per flight. In one embodiment, outer chain face 148 mounts to the middle of flight 150 at the middle of width 158. Width 158 can be about 6 in, about 8 in, about 10 in, about 12 in, about 18 in, about 24 in, about 30 in, about 36 in, about 42 in, about 48 in, about 54 in, about 60 in, about 66 in, or about 72 in, between 8 in to 24 in, 12 in to 30 in, 16 in to 36 in, 20 in to 42 in, 24 in to 48 in, 30 in to 54 in, 48 in to 60 in, 54 in to 66 in, or 60 in to 72 in, at most 12 in, at most about 18 in, at most about 24 in, at most about 30 in, at most about 36 in, at most about 42 in, at most about 48 in, at most about 54 in, at most about 60 in, at most about 66 in, or at most about 72 in.

An alternate flight 150′ is illustrated in FIG. 4B. Flight 150′ can have an otherwise flat surface with at least one mounting point 154′. Here, mounting point 154′ can optionally include a tooth 156′ which can also be removable. Tooth 156′ can be removable from the flight without having to remove the flight from a chain. This can reduce the amount of time required to replace teeth on a tool.

If flight 150 is mounted on first chain 144 and second chain 146, total width 160 can include 12 teeth. Again, more or fewer teeth can be used. Each chain can include one, two, three, four, five, six, seven, eight, nine, ten, eleven, twelve, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35 or more flights, and each flight can include one, two, three, four, five, six, seven, eight, nine, ten, eleven, twelve, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35 or more teeth.

Top drum 162 can be configured to attach to rear attachment mechanism 114. Attachment mechanism 114 can be a rotor, spine, or the like. Height 164 of top drum 162 can be larger than total width 160. Width 160 can be about 12 in, about 18 in, about 24 in, about 30 in, about 36 in, about 42 in, about 48 in, about 54 in, about 60 in, about 66 in, or about 72 in, between 12 in to 24 in, 18 in to 30 in, 24 in to 36 in, 30 in to 42 in, 36 in to 48 in, 42 in to 54 in, 48 in to 60 in, 54 in to 66 in, or 60 on to 72 in, at most 12 in, at most about 18 in, at most about 24 in, at most about 30 in, at most about 36 in, at most about 42 in, at most about 48 in, at most about 54 in, at most about 60 in, at most about 66 in, or at most about 72 in. In other embodiments, the two are the same. In still other embodiments height 164 of top drum 162 can be smaller than total width 160. Top drum 162 can include at least one (first) cutting tooth 166. Teeth 166 can be configured on drum face 168 in any manner that will aid in trimming of a soil face. Teeth 166 can be configured into a line 170. Line 170 can be spiraled as illustrated in FIG. 5. In other embodiments, a line of teeth can be straight and line up with teeth on flights 150. The radius 172 of drum 162 can provide teeth 166 that match radius 174 at each sprocket, chain, flight, and tooth combination.

Height 164 can be about 12 in, about 18 in, about 24 in, about 30 in, about 36 in, about 42 in, about 48 in, about 54 in, about 60 in, about 66 in, about 72 in, about 78 in, about 84 in, about 90 in, about 96 in, about 102 in, about 108 in, about 114 in, about 120 in, about 126 in, about 132 in, about 138 in, about 144 in, about 150 in, about 156 in, about 162 in, about 168 in, about 174 in, about 180 in, about 186 in, 192 in, 198 in, 204 in, about 210 in, about 216 in, between 12 in to 24 in, 18 in to 30 in, 24 in to 36 in, 30 in to 42 in, 36 in to 48 in, 42 in to 54 in, 48 in to 60 in, 54 in to 66 in, 60 on to 72 in, 66 in to 78 in, 72 in to 84 in, 78 in to 90 in, 84 in to 96 in, 90 in to 102 in, 96 in to 108 in, 102 in to 114 in, 108 in to 120 in, 114 in to 126 in, 120 in to 132 in, 126 in to 138 in, 132 in to 144 in, 138 in to 150 in, 144 in to 156 in, 150 in to 162 in, 156 in to 168 in, 162 in to 174 in, 168 in to 180 in, 174 in to 186 in, 180 in to 192 in, 186 in to 198 in, 192 in to 204, 198 to 210, 204 in to 216, at most 12 in, at most about 18 in, at most about 24 in, at most about 30 in, at most about 36 in, at most about 42 in, at most about 48 in, at most about 54 in, at most about 60 in, at most about 66 in, at most about 72 in, at most about 78 in, at most about 84 in, at most about 90 in, at most about 96 in, at most about 102 in, at most about 108 in, at most about 114 in, at most about 120 in, at most about 126 in, at most about 132 in, at most about 138 in, at most about 144 in, at most about 150 in, at most about 156 in, at most about 162 in, at most about 168 in, at most about 174 in, at most about 180 in, at most about 186 in, at most about 192 in, at most about 198 in, at most about 204 in, at most about 210 in, or at most about 216 in. Radius 174 can be in the range of 12 in to 24 in, 18 in to 30 in, 24 in to 36 in, 30 in to 42 in, 36 in to 48 in, 42 in to 54 in, 48 in to 60 in, 54 in to 66 in, or 60 on to 72 in.

Further still, line 170 can include eight teeth. In other embodiments, line 170 can have one, two, three, four, five, six, seven, eight, nine, ten, eleven, twelve, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35 or more teeth. Drum face 168 can have about 96 teeth. In other embodiments, drum face 168 can have 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100 or more teeth.

Teeth 166 can have a shape that is appropriate for a soil or rock type of interest. For example, teeth 166 can have a triangular shape. In other embodiments, teeth 166 can have an inner curved cutting edge 176 that can be sharpened and an outer curved non-cutting edge 178. Any other tooth shape known in the art can be used.

As previously described, chassis 108 may include first idler 138 and second idler 140. Idler 140 can be moved in and out providing proper tension to the chain. Idlers can help prevent flex of a chain as rollers 142 allow inner face 180 of a chain to glide across the roller.

Bottom drum 182 can be configured to attach to rear attachment mechanism 114′. Height 184 of bottom drum 182 can be smaller than total width 160. In other embodiments, the two are the same. In still other embodiments height 184 of bottom drum 182 can be larger than total width 160. Bottom drum 182 can include at least one cutting tooth 166. Teeth 166 can be configured on bottom drum face 186 in any manner that will aid in trimming of a soil face. Teeth 166 can be configured into a line 188. Line 188 can be spiraled as illustrated in FIG. 5. In other embodiments, a line of teeth can be straight and line up with teeth on flights 150. The radius of bottom drum 182 can provide teeth 166 that match the radius 174 at each sprocket, chain, flight, and tooth combination.

Height 184 can be about 6 in, about 12 in, about 18 in, about 24 in, about 30 in, about 36 in, about 42 in, about 48 in, about 54 in, about 60 in, about 66 in, or about 72 in, between 12 in to 24 in, 18 in to 30 in, 24 in to 36 in, 30 in to 42 in, 36 in to 48 in, 42 in to 54 in, 48 in to 60 in, 54 in to 66 in, or 60 on to 72 in, at most about 6 in, at most about 12 in, at most about 18 in, at most about 24 in, at most about 30 in, at most about 36 in, at most about 42 in, at most about 48 in, at most about 54 in, at most about 60 in, at most about 66 in, or at most about 72 in.

Further still, line 188 can include two teeth. In other embodiments, line 188 can have one, two, three, four, five, six, seven, eight, nine, ten, eleven, twelve, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35 or more teeth. Bottom drum face 186 can have about 24 teeth. In other embodiments, bottom drum face 186 can have 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31 or 32 teeth.

Chassis 108 can be attached to mount 190. Mount 190 can be affixed to chassis using at least one bolt 192 threaded into at least one hole 194 in hard points 132, 132′, 132″, 132′″. Mount 190 can further include equipment attachment points 196.

Trimming tool 102 attached to carrier 104 or other equipment sufficient to provide the needs of the tool can be used to trim soil faces. In one embodiment, a soil face is trimmed in order to provide a flat wall surface in order to install a ring of segments for an underground structure according to U.S. Pat. No. 7,722,293, which is hereby incorporated in its entirety. When used to trim a wall for an underground structure, total height 198 can be 6 ft. Trimming tool total height 198 can equal one segment height (5 ft) plus an overlap allowance of greater than about 12 in and less than about 18 in. However, this height can vary depending on the application. For example, total height 198 can be about 1 foot, about 2 ft, about 3 ft, about 4 ft, about 5 ft, about 6 ft, about 7 ft, about 8 ft, about 9 ft, about 10 ft, about 11 ft, about 12 ft, about 13 ft, about 14 ft, about 15 ft, about 16 ft, about 17 ft, about 18 ft, about 19 ft, about 20 ft, about 21 ft, about 22 ft, about 23 ft, about 24 ft, about 25 ft, about 26 ft, about 27 ft, about 28 ft, about 29 ft, or about 30 ft.

Another example trimming tool is illustrated in FIGS. 9-16. Trimming tool 902 can be attached to any carrier 104 in place of a loading bucket or blade. A mount can be used to attach trimming tool 902 in place of a blade. Carrier 104 or equivalent machinery can be any machine capable of supporting, powering, and driving the tools described herein. In another embodiment, power pack 106 can provide ample power to trimming tool 902.

Different exemplary components of trimming tool 902 are illustrated in FIGS. 10-16. These illustrations are non-limiting and differences and variation in tool configuration, size, and arrangement are within the scope of the present description.

Trimming tool 902 can include chassis 904 which is equipped with front bearings 906, 906′ and rear bearings 908, 908′. First driven axle 910 and second driven axle 912 fit into front bearings 906, 906′ and rear bearings 908, 908′ respectively. Chassis 904 further includes chain supports 914. Each chain support can be removable and can aid in guiding and tensioning a chain when in motion.

First motor 916 moves first drive chain (not illustrated) housed within first chain envelope 918. First drive chain moves first driven axel assembly 920 which supports first front sprocket 922, second front sprocket 924, and third front sprocket 926. Second motor 928 moves second drive chain (not illustrated) housed within second chain envelope 930. Second drive chain moves second driven axel assembly 932 which supports first rear sprocket 934, second rear sprocket 936, and third rear sprocket 938. First front sprocket 922 and first rear sprocket 934 can spin first driven chain 940. Second front sprocket 924 and second rear sprocket 936 can spin second driven chain 942. Third front sprocket 926 and third rear sprocket 938 can spin third driven chain 944. Any number of sprockets and chains can be used.

Each outer chain face 946 may be coupled to one or more flight 948. In one embodiment, one chain is used. In another embodiment, two chains are used. In another embodiment, three chains are used.

Each flight 948 can include at least one (second) blade, pick or tooth 950. Each flight 948 can have a height of about 6 in, about 8 in, about 10 in, about 12 in, about 18 in, about 24 in, about 30 in, about 36 in, about 42 in, about 48 in, about 54 in, about 60 in, about 66 in, or about 72 in, between 8 in to 24 in, 12 in to 30 in, 16 in to 36 in, 20 in to 42 in, 24 in to 48 in, 30 in to 54 in, 48 in to 60 in, 54 in to 66 in, or 60 in to 72 in, at most about 12 in, at most about 18 in, at most about 24 in, at most about 30 in, at most about 36 in, at most about 42 in, at most about 48 in, at most about 54 in, at most about 60 in, at most about 66 in, or at most about 72 in. Each flight 948 can have a width of about 6 in, about 8 in, about 10 in, about 12 in, about 18 in, about 24 in, about 30 in, about 36 in, about 42 in, about 48 in, about 54 in, about 60 in, about 66 in, or about 72 in, between 8 in to 24 in, 12 in to 30 in, 16 in to 36 in, 20 in to 42 in, 24 in to 48 in, 30 in to 54 in, 48 in to 60 in, 54 in to 66 in, or 60 in to 72 in, at most 12 in, about 18 in, about 24 in, about 30 in, about 36 in, about 42 in, about 48 in, about 54 in, about 60 in, about 66 in, or about 72 in.

In one embodiment, each flight 948 includes two teeth 950. Teeth 950 can be arranged in a configuration that each flight in the advancing direction has further spread teeth. For example a first flight in a linear sequence of flights can have two adjacent teeth in the center of the height of the flight. Then, each subsequent flight can have two teeth that are equally spread in the vertical direction. In one embodiment, such a sequence can occur on seven sequential flights. In other embodiments, the sequence can include, one, two, three, four, five, six, eight, nine, ten, eleven, twelve, 13, 14, 15, 16, 17, 18 19, or 20 flights.

Tooth 950 can be removable from a flight without having to remove the flight from a chain. This can reduce the amount of time required to replace teeth on a tool.

Flight 948 can include any number of teeth that can trim a desired surface. For example, each flight can include one, two, three, four, five, six, seven, eight, nine, ten, eleven, twelve, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35 or more teeth.

Top drum 162 can be configured to attach to second driven axle 912. In one embodiment, a splined axle is mated with a matching splined hub on top drum 162. The splined hub can slip onto the splined axle. The splined hub can be held in place by bolts which screw into the end of the axle. The hub is then fitted to the drum. Each drum described herein can attach to an axle in this manner or can be attached to an axle in any other manner known in the art.

Top drum 162 can include at least one (first) cutting tooth 166. Teeth 166 can be configured on drum face 168 in any manner that will aid in trimming of a soil face. The radius 172 of drum 162 can provide teeth 166 that match radius at each sprocket, chain, flight, and tooth combination.

Height 164 can be about 12 in, about 18 in, about 24 in, about 30 in, about 36 in, about 42 in, about 48 in, about 54 in, about 60 in, about 66 in, about 72 in, about 78 in, about 84 in, about 90 in, about 96 in, about 102 in, about 108 in, about 114 in, about 120 in, about 126 in, about 132 in, about 138 in, about 144 in, about 150 in, about 156 in, about 162 in, about 168 in, about 174 in, about 180 in, about 186 in, about 192 in, about 198 in, about 204 in, about 210 in, about 216 in, between 12 in to 24 in, 18 in to 30 in, 24 in to 36 in, 30 in to 42 in, 36 in to 48 in, 42 in to 54 in, 48 in to 60 in, 54 in to 66 in, 60 on to 72 in, 66 in to 78 in, 72 in to 84 in, 78 in to 90 in, 84 in to 96 in, 90 in to 102 in, 96 in to 108 in, 102 in to 114 in, 108 in to 120 in, 114 in to 126 in, 120 in to 132 in, 126 in to 138 in, 132 in to 144 in, 138 in to 150 in, 144 in to 156 in, 150 in to 162 in, 156 in to 168 in, 162 in to 174 in, 168 in to 180 in, 174 in to 186 in, 180 in to 192 in, 186 in to 198 in, 192 in to 204, 198 to 210, 204 in to 216, at most about 12 in, at most about 18 in, at most about 24 in, at most about 30 in, at most about 36 in, at most about 42 in, at most about 48 in, at most about 54 in, at most about 60 in, at most about 66 in, at most about 72 in, at most about 78 in, at most about 84 in, at most about 90 in, at most about 96 in, at most about 102 in, at most about 108 in, at most about 114 in, at most about 120 in, at most about 126 in, at most about 132 in, at most about 138 in, at most about 144 in, at most about 150 in, at most about 156 in, at most about 162 in, at most about 168 in, at most about 174 in, at most about 180 in, at most about 186 in, at most about 192 in, at most about 198 in, at most about 204 in, at most about 210 in, or at most about 216 in. Radius 174 can be in the range of 12 in to 24 in, 18 in to 30 in, 24 in to 36 in, 30 in to 42 in, 36 in to 48 in, 42 in to 54 in, 48 in to 60 in, 54 in to 66 in, or 60 on to 72 in.

Bottom drum 182 can be configured to attach to second driven axle 912. Bottom drum 182 can include at least one cutting tooth 166. Teeth 166 can be configured on bottom drum face 186 in any manner that will aid in trimming of a soil face. The radius of bottom drum 182 can provide teeth 166 that match the radius 174 at each sprocket, chain, flight, and tooth combination.

Height 184 can be about 6 in, about 12 in, about 18 in, about 24 in, about 30 in, about 36 in, about 42 in, about 48 in, about 54 in, about 60 in, about 66 in, or about 72 in, between 12 in to 24 in, 18 in to 30 in, 24 in to 36 in, 30 in to 42 in, 36 in to 48 in, 42 in to 54 in, 48 in to 60 in, 54 in to 66 in, or 60 on to 72 in, at most 6 in, at most about 12 in, at most about 18 in, at most about 24 in, at most about 30 in, at most about 36 in, at most about 42 in, at most about 48 in, at most about 54 in, at most about 60 in, at most about 66 in, or at most about 72 in.

Bottom drum face 186 can have about 24 teeth. In other embodiments, bottom drum face 186 can have 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31 or 32 teeth.

Chassis 904 can be attached to mount 952. Mount 952 can be affixed to chassis using at least one bolt. Mount 952 can further include equipment attachment points 954, 954′.

Trimming tool 902 can further include a second bottom drum 956 configured to attach to first driven axle 910. Second bottom drum 956 can be the same or different than bottom drum 182.

Trimming tool 902 can further include cutting edge assembly 958 comprised of a structural element that attaches to the bottom of the chassis 904. Cutting edge assembly 958 can include cutting edge 960 fitted with teeth holders and teeth 962 that cuts the soil and diverts it up the incline into the moving chain and flights. This cutting edge assembly can excavate the area between bottom drum 182 and second bottom drum 956. Cutting edge 960 can create angle 964 of attack of about 10 degrees, about 20 degrees, about 30 degrees, about 40 degrees, about 50 degrees, about 60 degrees, about 70 degrees, about 80 degrees, about 90 degrees, about 100 degrees, about 110 degrees, about 120 degrees, about 130 degrees, about 140 degrees, about 150 degrees, about 160 degrees, or about 170 degrees or any range encompassed by any of these values. In one embodiment, angle 964 is about 45 degrees. Further, cutting edge assembly 958 can include one, two, three, four, five, six, seven, eight, nine, ten, eleven, twelve, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35 or more teeth along cutting edge 960.

Trimming tool 902 can further include material diverting plate 966. Material diverting plate 966 can attach to chassis 904 and have a bottom edge 968 residing adjacent to the top of the sequence of flights. Right edge 970 terminates about at the outer edge of trimming tool 902 and can have a generally linear edge. Left edge 972 can terminate adjacent to top drum 162. Left edge 972 can have a generally concave shape that matches the side profile of top drum 162 to aid in preventing material from passing between them during use. Material diverting plate 966 can have a generally curved surface to aid in directing material in front of trimming tool 902 when in use.

Trimming tool 902 can further be accompanied by blade 974. Blade 974 can take the form of a scraping blade or mole board that scrapes the finished surface behind the trimming tool but before the carrier. Blade 974 can be attached to mount 952. Blade 974 can have a generally concave shape to direct material in a forward direction and angled transverse to the longitudinal direction of the carrier. Blade 974 can be situated at angle 976 to remove, plow, force, and/or scrape excess debris away from the trimmed surface. Angle 976 can be about 10 degrees, about 20 degrees, about 30 degrees, about 40 degrees, about 50 degrees, about 60 degrees, about 70 degrees, about 80 degrees, about 90 degrees, about 100 degrees, about 110 degrees, about 120 degrees, about 130 degrees, about 140 degrees, about 150 degrees, about 160 degrees, or about 170 degrees or any range encompassed by any of these values. Angle 976 can be adjusted during operation as needed to divert material. Blade 974 can remove and clean the bottom surface before the carrier runs on top of a possible irregular surface caused by incomplete muck removal.

Trimming tool 902 can be attached to carrier 104 or other equipment sufficient to provide the needs of the tool to be used to trim soil faces. In one embodiment, a soil face is trimmed in order to provide a flat wall surface in order to install a ring of segments for an underground structure according to U.S. Pat. No. 7,722,293, which is hereby incorporated in its entirety. When used to trim a wall for an underground structure, total height 198 can be 6 ft. Trimming tool total height 198 can equal one segment height (5 ft) plus an overlap allowance of greater than about 12 in and less than about 18 in. However, this height can vary depending on the application. For example, total height 198 can be about 1 ft, about 2 ft, about 3 ft, about 4 ft, about 5 ft, about 6 ft, about 7 ft, about 8 ft, about 9 ft, about 10 ft, about 11 ft, about 12 ft, about 13 ft, about 14 ft, about 15 ft, about 16 ft, about 17 ft, about 18 ft, about 19 ft, about 20 ft, about 21 ft, about 22 ft, about 23 ft, about 24 ft, about 25 ft, about 26 ft, about 27 ft, about 28 ft, about 29 ft, or about 30 ft.

As illustrated in FIG. 17, rough excavation 1702 is cut into a soil face using standard methods in the construction industry (e.g., hand dug, using a digger). In order to achieve accurate trimmed wall 1704, trimming tool 102 or 902 is attached to a carrier 104, engaged against the rough excavation 1702 in soil face, and the soil is trimmed (FIG. 18A-C). As trimming tool can be vertically straight, a straight wall can be cut. As such, in this example, angle 1706 is 90 degrees relative to surface 1708. However, as carrier 104 can control the angle of trimming tool 102 or 902, different acute and obtuse angles can be achieved. In some embodiments, angle 1706 can be about 60 degrees, about 70 degrees, about 80 degrees, about 90 degrees, about 100 degrees, about 110 degrees, about 120 degrees, or any range encompassed by any of these values.

As an underground structure according to U.S. Pat. No. 7,722,293 is cylindrical in shape, trimming tool 102 or 902 can be efficient in cutting a complete circle or circular shape (e.g., oval, ellipse) or any part thereof. As illustrated in FIGS. 18A-C and 19-20, trimming tool 102 or 902 can be engaged against rough cut wall 1702 and spun in a counter clockwise direction 1710. Carrier 104 can be manually navigated around the circle in direction 1712. In other embodiments, global positioning, laser, or sonic tracer machine control systems can be utilized in conjunction with carrier 104 to automatically navigate around the circle. After trimming tool has passed a portion of the circle, clean trimmed wall 1704 remains.

As further illustrated in FIG. 20, as trimming tool 102 or 902 is advanced around the circular cutting area, the chains can spin in counter clockwise direction 1710 thereby allowing the chains to direct debris 1714 to the center of the circle for collection and/or removal by appropriate equipment. In some embodiments, trimming tool 102 or 902 can direct debris onto a conveyor belt to remove it from the site.

The trimming tools described herein can be sufficiently rugged for the intended construction environment. The tools can withstand a 100% working hour availability. Further, lubrication, ground engaging tools i.e. flights, tooth replacement, and other maintenance can be accomplished at breaks/lunches/shift changes or planned hours of non-operation, thereby saving money in operation.

When constructing an underground structure, demobilization from the bottom of the shaft upon achievement of the design depths can be achieved. As such, the trimming tool 102 or 902 can be separated from the carrier 104 and separately lifted from the excavation. Equipment weights may not exceed 50,000 lbs, 40,000 lbs, 30,000 lbs, 20,000 lbs, or 12,000 lbs.

The trimming tool surface (the cut face) can be sufficiently accurate relative to the inner face of the final structure for proper function of grout seals, with suitable cut face roughness. Specification tolerances can be about +/−0.5 inch (12.5 mm) across 60″ vertical excavation face.

In some embodiments, muck lump size may not be important except as it affects roughness. A multi-pass cutter configuration can be possible. Design maximum rock size in face to be trimmed can be about 2 inches, about 3 inches, about 4 inches, about 5 inches, about 6 inches or more.

Generally, the systems described herein and their tools can include operator position and safety features which are in conformance with regulatory worker safety requirements such as OSHA. Remote controls may assist operator to view the excavation.

Again, if an underground structure is being constructed according to U.S. Pat. Nos. 7,722,293 and 8,322,949, shaft design contemplates construction of a 1 foot to 4 feet thick mat slab at the bottom of the shaft. Thus, the last ring in the structure can require a second pass and modification/adjustment of a guidance device to permit extension of the excavation depth (second pass) to accommodate the mat slab structural section and any subgrade aggregate requirements. Further, the trimming tool may not damage dampproofing or prior constructed ring's segments.

The trimming tool can achieve about 20 ft, about 30 ft, about 40 ft, about 50 ft, about 60 ft, about 70, ft, about 80 ft, about 90 ft, about 100 ft, about 120 ft, about 140 ft, about 160 ft, about 180 ft, or about 200 ft advance rates per hour.

The trimming tool can be more accurate when compared to current systems used in the construction industry. For example, when cutting a 4 ft, 5 ft, 6 ft, 7 ft, 8 ft, 9 ft, 10 ft, 11 ft, 12 ft, 13 ft, 14 ft, or 15 ft high face, the face can have a deviation of +/− about 0.5 in, +/− about 0.4 in, +/− about 0.3 in, +/− about 0.2 in, +/− about 0.1 in, +/− about 0.05 in. In other embodiments, less than about 5%, less than about 4%, less than about 3%, less than about 2%, less than about 1%, less than about 0.9%, less than about 0.8%, less than about 0.7%, less than about 0.6%, less than about 0.5%, less than about 0.4%, less than about 0.3%, less than about 0.2%, less than about 0.1% deviation can exist in a 4 ft, 5 ft, 6 ft, 7 ft, 8 ft, 9 ft, 10 ft, 11 ft, 12 ft, 13 ft, 14 ft, or 15 ft tall soil face. In one embodiment, the deviation is within the soil face of a ring.

In some embodiments, the trimming tool may not be required to remove toe of rough excavation. In other embodiments, the toe of rough excavation can be removed. In some embodiments, the equipment can independently let in to the rough excavation and establish machine designed alignment (circumferential) under a previously constructed ring in an underground structure.

The trimming tools described herein and accompanying machinery can be easy, cheap, and/or efficient to use. In some cases setup/operation by a crew of 2 can be achieved. In some embodiments, only a single person can setup/operate the tools. Periodic support for the tools can be required in some instances.

The trimming tools in some embodiments can clear muck from a trimmed face sufficiently to allow subsequent operations. Clearance distance can be about 1 ft, about 2 ft, about 3 ft, about 4 ft, about 5 ft, about 6 ft, about 7 ft, about 8 ft, about 9 ft, about 10 ft, about 12 ft, about 14 ft, about 16 ft, about 18 ft, about 20 ft, about 25 ft, about 30 ft, about 40 ft, or about 50 ft. Further, in other embodiments, the trimming tool can deliver muck to a main removal system (conveyors to grade, etc.).

In some embodiments, the bottom excavated surface may slope away from the vertical trimmed face at a minimum of 2%. This is to assure that the soil supporting eventual other machinery (e.g., jacks) does not become saturated during grouting when the dampproofing permits water to escape the grout mix or during rain events.

In one embodiment, the trimming tool and accompanying machinery may not allow excessive vibration to be transmitted to the surrounding environment. In some embodiments, excessive vibration would be vibration that disturbs previously constructed structures at a construction site (e.g., previously constructed underground structure ring).

In other embodiments, a trimming tool can be shipped to a construction site with only a power pack and the tool itself. Such an arrangement can reduce cost and the need for a specialized machine to be transported to the site. Here, a power pack and trimming tool can be attached to readily available machinery and all power requirements for trimming tool can be provided by the power pack. This further allows the trimming tool to be used with smaller machinery that would otherwise not be able to provide ample power to the tool. This can be beneficial in smaller construction sites because smaller equipment can be used.

Example 1

To excavate below a concrete ring in an underground structure according to U.S. Pat. No. 7,722,293, a trimming tool such as in FIG. 8 or FIG. 16 is attached to accompanying machinery such as on a bulldozer or other carrier (in place of a blade or bucket) as depicted in FIG. 9.

Before the trimming tool is utilized, standard heavy excavation equipment removes all but a small portion of the planed excavation. This phase is called the rough excavation. The intended trimming surface height can be a total of 6 ft (depending on the application and project requirements) which includes the 5 ft segment (or ring) height and an additional 1 ft clearance allowance. This phase, performed by the trimming tool, is called the finish grading phase. The soil remaining after the rough excavation phase may be shaped like a wedge or rectangle depending on soil type and rough excavation equipment used.

The soil requiring excavation may consist of undisturbed in situ soil ranging from silty clay, clayey silt and sandy silty clays or non-cohesive soils or gravels. The soil density can range from 90 to 130 pcf with a SPT blow count range between 1 and 40. The comminution forces and strength of the soil will dictate the teeth type, arrangement, and number used on the flights and drums.

Weak soils that cannot stand unsupported for the short period of time required to set and grout the ring, will be improved using the soil mixing technique outlined in U.S. provisional patent application No. 61/493,307, which is hereby incorporated in its entirety. The mixed soil can have a higher strength and density than the in situ soil and can consist of a mixture of soil, bentonite and/or cement, or other pulverulent.

The trimming tool and accompanying machinery is then positioned parallel to the intended alignment of the finished surface and true to the design vertical surface. Tool drive power is applied beginning rotation of the chains and drums. The chain and drum can rotate between 20 and 70 RPM depending on the soil strength, cutter tooth arrangement, and intended final soil face tolerance.

The carrier (bulldozer or loader) begins to advance into the remaining soil wedge moving toward the designed excavation alignment. The carrier operator may use the previously installed segments to gauge the intended depth of cut. Carrier machine control laser, sonic tracer, or GPS equipment is actuated and reference points acquired. The trimming tool and accompanying machinery is manually operated into proper position such that the width of the tool is perpendicular to the final soil wall surface and parallel to the shaft radius. Machinery maneuvering continues until the designed depth of cut and equipment alignment is achieved. The depth of cut is then manually checked. Positioning equipment is calibrated to produce the designed cut and machine control electronics and hydraulic carrier control circuits engaged.

The trimming tool, and accompanying machinery, now begins advancing parallel to the shaft circumference creating the intended machined soil face. Muck is continuously transported along the trimmer front face building a spoil pile or windrow on the inner side of the equipment's route of travel positioned outside of the carrier or bulldozer tracks. In one embodiment, a blade can remove and clean the bottom surface before the carrier runs on top of a possible irregular surface caused by incomplete muck removal. Once the excavation equipment has reached an appropriate operating speed, the operator continues to keep the carrier and tool face aligned parallel to the radius of the excavation as the equipment moves along the circumference of the shaft. Automated hydraulic machine controls assure accurate micro adjustments to the trimming tool position relative to the points of reference. The advance rate (depending on amount of soil to be excavated and the composition of the soil material) can range between 0.5 and 5 feet per minute. The finish grade trimming process continues uninterrupted around the entire circumference of the shaft or may be halted in place as rough excavation advances ahead of the finish grading operation.

Unless otherwise indicated, all numbers expressing quantities of ingredients, properties such as molecular weight, reaction conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements.

The terms “a,” “an,” “the” and similar referents used in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein is intended merely to better illuminate and does not pose a limitation on the scope otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.

Groupings of alternative elements or embodiments are not to be construed as limitations. Each group member may be referred to and claimed individually or in any combination with other members of the group or other elements found herein. It is anticipated that one or more members of a group may be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.

Certain embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Of course, variations on these described embodiments will become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventor expects skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than specifically described herein. Accordingly, the present description includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.

Furthermore, references have been made to patents in this specification. Each of the above-cited references and printed publications are individually incorporated herein by reference in their entirety.

In closing, it is to be understood that the embodiments disclosed herein are illustrative of principles. Other modifications that may be employed are within the scope of the present description. Thus, by way of example, but not of limitation, alternative configurations may be utilized in accordance with the teachings herein. Accordingly, the present description is not limited to that precisely as shown and described.

Claims

1. A soil trimming tool comprising:

at least one drum including at least one first cutting tooth;

at least one second cutting tooth associated with at least one chain;

a chain driven axle and sprocket assembly configured to move the at least one chain; and

a motor driven axle and sprocket assembly configured to transmit power via a chain to the driven axle.

at least one attachment mechanism associated with the driven axle and sprocket assembly configured to spin the at least one drum.

2. The soil face trimming tool of claim 1, which includes a mount configured to attach the soil trimming tool to a construction machine.

3. The soil trimming tool of claim 1, which includes an upper drum and a lower drum bisected by the at least one chain.

4. The soil trimming tool of claim 3, wherein the at least one second cutting tooth is associated with at least one chain link.

5. The soil trimming tool of claim 4, wherein a flight includes more than one cutting tooth.

6. The soil trimming tool of claim 1, which includes:

(a) a first and second chain driven by a first set of sprockets; and

(b) a third chain driven by a second set of sprockets.

7. The soil trimming tool of claim 6, wherein the first drive axle is configured to provide power to the first driven axle and sprocket assembly and the second drive axle is configured to provide power to the second driven axle and sprocket assembly.

8. The soil trimming tool of claim 1, wherein the at least one drum and at least one chain have a total height of about 6 ft.

9. The soil trimming tool of claim 1, wherein the soil trimming tool weighs less than about 20,000 lbs.

10. The soil trimming tool of claim 1, wherein the soil trimming tool and a carrier are guided by a laser, sonic tracer, or global positioning satellite machine control system.

11. A method of preparing a flat cut wall comprising:

engaging a trimming tool with a rough excavated soil or rock material,

at least one drum including at least one first cutting tooth; at least one second cutting tooth associated with at least one chain a motor driven axle and sprocket assembly configured to move the at least one chain; and at least one attachment mechanism associated with the motor driven axle and sprocket assembly configured to spin the at least one drum.

12. The method of claim 11, which includes a mount configured to attach the trimming tool to a construction machine.

13. The method of claim 11, which includes an upper drum and a lower drum bisected by the at least one chain.

14. The method of claim 13, wherein the at least one second cutting tooth is attached to a flight associated with at least one chain link.

15. The method of claim 14, wherein the flight includes more than one cutting tooth.

16. The method of claim 11, which includes:

(a) a first and second chain driven by a first set of sprockets; and

(b) a third chain driven by a second set of sprockets.

17. The method of claim 16, wherein a first drive axle is configured to provide power to the first driven axle and sprocket assembly and the second drive axle is configured to provide power to the second driven axle and sprocket assembly.

18. The method of claim 11, wherein the trimming tool is used to cut a 6 ft. tall wall under an existing concrete ring.

19. The method of claim 11, wherein the trimming tool and carrier are guided by a laser, sonic tracer, or global positioning satellite machine control system.

20. A method of preparing a flat cut wall comprising:

engaging a trimming tool attached to a carrier with a rough cut wall under an existing concrete ring,

wherein the trimming tool comprises an upper drum and a lower drum both having at least one cutting tooth, wherein the upper drum and the lower drum are bisected by the at least one chain; at least one second cutting tooth is associated with the at least one chain which in combination with the axle and sprockets are configured to spin the upper drum and the lower drum; and a motor driven axle and sprocket system configured to move the chain and drums.