Guided boring machine and method

• US 8,210,774 B1
• Filed: 05/20/2010
• Issued: 07/03/2012
• Est. Priority Date: 05/20/2010
• Status: Active Grant

• Current Assignee: Charles Machine Works Incorporated The
• Original Assignee: Astec Industries Incorporated (Johnson Crushers International)
• Inventors: Vidovic, David A., Thomas, Michael W.
• Primary Examiner(s): Singh, Sunil
• Assistant Examiner(s): Armstrong, Kyle
• Application Number:
  US12/800,669
• Time in Patent Office: 775 Days
• Field of Search: 405/138, 405/143, 405/141, 405/184, 299/55, 299/56, 299/68, 299/18, 175/61, 175/62
• US Class Current: 405/143
• CPC Class Codes: E21D 9/005 by forcing prefabricated elements through the ground, e.g. by pushing lining from an access pit driving shields E21D9/06
• CPC Class Codes: E21D 9/1093 Devices for supporting, advancing or orientating the machine or the tool-carrier measuring devices for guiding machines E21D9/003; anchoring in the borehole E21B4/18
• CPC Class Codes: E21D 9/124 Helical conveying means therefor E21D9/13 takes precedence

Abstract

A guided boring machine includes a cutter head, a steering head and an internal casing with an auger therein for conveying material cut by the cutter head towards the rear end of the auger. The boring machine bores a tunnel from a launch pit to a target pit along a desired boring direction and simultaneously installing a selected one of a plurality of differently-sized product casings in the tunnel. When the internal casing is placed within a selected product casing with its internal casing longitudinal axis coincident with the longitudinal axis of the selected product casing, an annular space is formed with respect to the selected product casing. The guidance assembly includes a laser that is mounted behind the boring machine and oriented so as to direct its beam in a desired boring direction within the annular space. A target mount is mounted to the steering head inside surface. The target mount includes a roll correction slot which is parallel to the adjacent steering head inside surface. A target is mounted to the target mount and adapted to move with respect thereto. The target has a target point which is intersected by the laser beam when the cutter head is properly oriented with respect to the desired boring direction. A gradiometer is mounted to the target to indicate the roll orientation of the steering head, and a roll correction assembly is provided to roll the steering head, if desired, to adjust its roll orientation.

Claims

1. A boring machine for boring a tunnel from a launch pit to a target pit along a desired boring direction and simultaneously installing a selected one of a plurality of differently-sized product casings in the tunnel, in which each product casing of a selected size has a product casing longitudinal axis, a product casing inside surface, a product casing outside diameter and a product casing inside diameter, wherein the boring machine comprises:

(a) an internal casing;

(i) having an internal casing longitudinal axis;

(ii) having an internal casing outside surface;

(iii) having an internal casing outside diameter which is less than all of the product casing inside diameters of the differently-sized product casings that may be installed using the boring machine;

(iv) which is adapted to be placed within a selected one of the product casings with its internal casing longitudinal axis coincident with the longitudinal axis of the selected product casing, thereby forming an annular space with respect to the selected product casing;

(b) an adjustable support assembly that is adapted to be located between the outside surface of the internal casing and the inside surface of the selected one of the differently-sized product casings for maintaining the coincidence of the internal casing longitudinal axis with the product casing longitudinal axis;

(c) an auger which;

(i) has a front end;

(ii) has a rear end;

(iii) is located within the internal casing and adapted to rotate with respect thereto;

(iv) is adapted to convey material towards its rear end as it is rotated;

(d) a rotational mechanism which is operationally connected to the auger;

(e) a pusher mechanism which is adapted to advance the selected product casing, the internal casing and the auger;

(f) a plurality of cutter heads, each of which;

(i) has a plurality of cutter blades which are attached to the front end of the auger;

(ii) has a cutter head diameter which corresponds to the product casing outside diameter of the selected product casing;

(g) which includes means for directing material cut by the cutter blades into the internal casing so that rotation of the auger will convey such material towards the rear end of the auger within the internal casing;

(h) a front bulkhead that is located behind the cutter head;

(i) a steering head that is operated to change the direction of the cutter head, said steering head having an inside surface;

(j) a guidance assembly comprising;

(i) a laser that is mounted behind the boring machine and oriented so as to direct its beam in a direction that is parallel to a desired boring direction within the annular space;

(ii) a target mount which is mounted to the steering head inside surface behind the front bulkhead, said target mount including a roll correction slot comprising an arc of correction which is parallel to the adjacent steering head inside surface;

(iii) a target which is mounted to the target mount and adapted to move with respect thereto along the arc of correction, said target having a target point which is intersected by the laser beam when the cutter head is properly oriented with respect to the desired boring direction;

(iv) a gradiometer which is mounted to the target so as to indicate the roll orientation of the steering head;

(v) a roll correction assembly that is adapted to roll the steering head in order to move the gradiometer to a desired roll orientation.

2. The boring machine of claim 1 wherein the gradiometer is adapted to indicate the pitch of the steering head.

3. The boring machine of claim 1 wherein:

(a) the target is mounted to the target mount by means of a plurality of roller guides that pass through the roll correction slot;

(b) the roll correction assembly comprises;

(i) a rack that is mounted on the target so as to be generally parallel with the steering head inside surface;

(ii) a pinion that is mounted through the target mount and in engagement with the rack;

(iii) a motor that is mounted to the pinion and adapted to rotate it;

wherein operation of the motor will cause the pinion to rotate, thereby moving the target along the arc of correction.

4. The boring machine of claim 1 which includes:

(a) a track;

(b) a carriage that is mounted on the track, said carriage including the pusher mechanism and being adapted to be moved thereby along with the product casing with respect to the track.

5. The boring machine of claim 1 wherein the steering head comprises:

(a) a plurality of steering openings near its front end;

(b) a plurality of steering assemblies, each of which is adapted to apply a steering force through a steering opening.

6. The boring machine of claim 1:

(a) wherein the cutter head includes a front hopper;

(b) wherein the auger extends into the front hopper.

7. The boring machine of claim 6 wherein:

(a) each of the cutter blades has a front side and a rear side;

(b) the means for directing material cut by the cutter blades into the internal casing comprises a plurality of collecting buckets, each of which is mounted on the rear side of a cutter blade, which collecting buckets sweep material cut by the cutter blades into the auger in the front hopper as the cutter head rotates.

8. The boring machine of claim 1 wherein the adjustable support assembly comprises a plurality of internal casing support legs spaced around the periphery of the internal casing.

9. The boring machine of claim 8 which includes an internal support band:

(a) that is disposed around the periphery of the internal casing;

(b) to which the internal casing support legs are attached;

(c) that includes a plurality of leg supports, each of which is adapted to cooperate with a internal casing support leg.

10. The boring machine of claim 9 wherein each internal casing support leg is in adjustable telescoping relationship with an associated leg support so that the length of the corresponding support assembly may be varied.

11. The boring machine of claim 10 wherein for each support assembly:

(a) an attachment pin is provided;

(a) one oldie internal casing support leg and associated leg support is provided with a plurality of adjustment holes, each of which is adapted to receive the attachment pin;

(b) the other of the internal casing support leg and associated leg support is provided with an adjustment hole that is adapted to receive the attachment pin;

wherein the internal casing support leg and associated leg support are arranged and configured so that the adjustment holes on each such component may be aligned in a plurality of configurations, each of which corresponds to a support assembly length, and so that the attachment pin may be placed therethrough to secure the internal casing support leg and associated leg support.

12. The boring machine of claim 1 wherein the internal casing comprises a plurality of internal casing components that are joined together end to end at a plurality of internal casing joints, wherein each such internal casing joint comprises:

(a) an end flange mounted to adjacent ends of adjacent internal casing components;

(b) a clamp that is adapted to engage the end flanges of adjacent internal casing components.

13. The boring machine of claim 12 wherein each clamp comprises:

(a) a band that is adapted to encircle and engage the end flanges of adjacent internal casing components, said band including;

(i) a pair of flange engagement sides;

(ii) a first end having a pair of spaced eyes, each of which includes a hole;

(iii) a second end having an engagement bracket which includes an engagement slot;

(b) a bolt comprising;

(i) a T-shaped head that is adapted to be received in the holes in the spaced eyes at the first end of the band;

(ii) a threaded end that extends into the engagement slot of the engagement bracket;

(c) a nut that is adapted to engage the threaded end of the bolt and be retained within the engagement bracket.

14. A boring machine comprising:

(a) a track;

(b) a carriage that is mounted on the track, said carriage comprising;

(i) a pusher mechanism that is adapted to move the carriage along the track;

(ii) a rotational mechanism;

(c) an internal casing that is located in front of the carriage and adapted to be moved by the carriage as the pusher mechanism moves the carriage along the track;

(d) an auger which;

(i) has a front end;

(ii) has a rear end;

(iii) has an auger longitudinal axis;

(iv) is located within the internal casing;

(v) is adapted to rotate with respect to the internal casing;

(vi) is operationally connected to the rotational mechanism of the carriage;

(v) is adapted to convey material towards its rear end as it is rotated;

(e) a cutter head having a plurality of cutter blades which are attached to the front end of the auger so as to rotate therewith;

(f) a steering head which;

(i) is adapted to be located behind the cutter head and in front of the internal casing;

(ii) has a steering head longitudinal axis that is coincident with the auger longitudinal axis;

(iii) has a steering head inside surface;

(g) a guidance assembly comprising;

(i) a laser that is mounted behind the carriage and oriented so as to direct its beam in a direction that is parallel to a desired boring direction;

(ii) a target mount which is mounted to the steering head inside surface behind the front bulkhead, said target mount including a roll correction slot comprising an arc of correction which is parallel to the adjacent steering head inside surface;

(iii) a target which is mounted to the target mount and adapted to move with respect thereto along the arc of correction, said target having a target point which is intersected by the laser beam when the cutter head is properly oriented with respect to the desired boring direction;

(iv) a gradiometer which is mounted to the target so as to indicate the roll orientation of the steering head;

(v) a roll correction assembly that is adapted to roll the steering head in order to move the gradiometer to a desired roll orientation.

15. The boring machine of claim 14 wherein:

(a) the target is mounted to the target mount by means of a plurality of roller guides that pass through the roll collection slot;

(b) the roll correction assembly comprises;

(i) a rack that is mounted on the target so as to be generally parallel with the steering head inside surface;

(ii) a pinion that is mounted through the target mount and in engagement with the rack;

(iii) a motor that is mounted to the pinion and adapted to rotate it;

wherein operation of the motor will cause the pinion to rotate, thereby moving the target along the arc of correction.

16. A method for boring a tunnel from a launch pit to a target pit along a desired boring direction and simultaneously installing a selected one of a plurality of differently-sized product casings in the tunnel, in which each product casing of a selected size has a product casing longitudinal axis, a product casing outside diameter, a product casing inside diameter and a product casing inside surface, wherein the method comprises:

(a) providing a boring machine comprising;

(i) an internal casing;

(1) having an internal casing longitudinal axis;

(2) having an internal casing outside surface;

(3) having an internal casing outside diameter which is less than all of the product casing inside diameters of the differently-sized product casings that may be installed using the boring machine;

(4) which is adapted to be placed within a selected one of the product casings with its internal casing longitudinal axis coincident with the longitudinal axis of the selected product casing, thereby forming an annular space with respect to the selected product casing;

(ii) an adjustable support assembly that is adapted to be located between the outside surface of the internal casing and the inside surface of the selected product casing for maintaining the coincidence of the internal casing longitudinal axis with the product casing longitudinal axis;

(iii) an auger which;

(1) has a front end;

(2) has a rear end;

(3) is located within the internal casing and adapted to rotate with respect thereto;

(4) is adapted to convey material towards its rear end as it is rotated;

(iv) a track having;

(1) an initial end;

(2) a terminal end;

(v) a carriage that is adapted to be mounted on the track and moved therealong, which carriage includes;

(1) a rotational mechanism which is operationally connected to the auger;

(2) a pusher mechanism which is adapted to move the carriage along the track to advance the selected product casing, the internal casing and the auger in the boring direction;

(vi) a plurality of cutter heads, each of which;

(1) has a plurality of cutter blades which are adapted to be attached to the front end of the auger;

(2) has a cutter head diameter which corresponds to the product casing outside diameter of one of the differently-sized product casings;

(vii) which includes means for directing material cut by the cutter blades into the internal casing so that rotation of the auger will convey such material towards the rear end of the auger within the internal casing;

(viii) a front bulkhead that is located behind the cutter head;

(ix) a steering head that is operated to change the direction of the cutter head, said steering head having an inside surface;

(x) a guidance assembly comprising;

(1) a laser that is mounted behind the carriage and oriented so as to direct its beam in a direction that is parallel to a desired boring direction within the annular space;

(2) a target mount which is mounted to the steering head inside surface behind the front bulkhead, said target mount including a roll correction slot comprising an arc of correction which is parallel to the adjacent steering head inside surface;

(3) a target which is mounted to the target mount and adapted to move with respect thereto along the arc of correction, said target having a target point which is intersected by the laser beam when the cutter head is properly oriented with respect to the desired boring direction;

(4) a gradiometer which is mounted to the target so as to indicate the roll orientation of the steering head;

(5) a roll correction assembly that is adapted to roll the steering head in order to move the gradiometer to a desired roll orientation;

(b) excavating a launch pit;

(c) excavating a target pit;

(d) placing the track in the launch pit and orienting it in the desired boring direction towards the target pit;

(e) mounting the carriage on the track in the launch pit;

(f) selecting a product casing from the differently-sized product casings that may be installed using the boring machine;

(g) selecting a cutter head having a cutter head diameter which corresponds to the product casing outside diameter of the selected product casing;

(h) installing the selected product casing over the internal casing;

(i) adjusting the adjustable support assembly to maintain the coincidence of the internal casing longitudinal axis with the product casing longitudinal axis of the selected product casing;

(j) attaching the selected cutter head to the front end of the auger;

(k) operating the rotational mechanism to rotate the auger and the cutter blades while operating the pusher mechanism to advance the selected cutter head, the selected product casing, the auger and the internal casing.

17. The method of claim 16 which includes:

(a) operating the pusher mechanism to move the carriage from the initial end of the track to the terminal end of the track, thereby advancing the selected cutter head, the selected product casing, the auger and the internal casing in the desired boring direction, while operating the rotational mechanism to rotate the auger and the cutter blades;

(b) stopping the operation of the rotational mechanism and the pusher mechanism;

(c) disengaging the selected product casing, the auger and the internal casing from the carriage;

(d) retracting the carriage from the terminal end of the track to the initial end of the track;

(e) providing an additional section of internal casing having a front end and a rear end;

(f) mounting an additional adjustable support assembly to the additional section of internal casing;

(g) providing an additional section of auger having a front end and a rear end;

(h) placing the additional section of auger within the additional section of internal casing with the front end of the additional section of auger adjacent to the front end of the additional section of internal casing;

(i) providing an additional section of the selected product casing having a front end and a rear end;

(j) placing the additional section of the selected product casing over the internal casing and auger with the front end of the additional section of the selected product casing adjacent to the front ends of the internal casing and auger, so that the additional adjustable support assembly maintains the coincidence of the internal casing longitudinal axis with the product casing longitudinal axis;

(k) placing the additional sections of product casing, internal casing and auger onto the track in front of the carriage;

(l) attaching the front ends of the additional section of the selected product casing, the additional section of the internal casing and the additional section of the auger to the casing and conveyor sections that were disengaged from the carriage;

(m) attaching the rear end of the additional section of the auger to the rotational mechanism;

(n) engaging the rear ends of the additional section of the selected product casing, the additional section of the internal casing and the additional section of the auger with the pusher mechanism;

(o) moving the carriage from the initial end of the track to the terminal end of the track while operating the rotational mechanism to rotate the auger and the cutter head, and while operating the pusher mechanism to advance the selected cutter head, the selected product casing, the auger and the internal casing;

(p) repeating steps (b) through (o) until the selected product casing reaches the target pit.