Inventions
with revolutionary engineering design
Multi-Functional Pile-Breaker
Please
refer to the patent office for all diagrams mentioned in
these descriptive texts
www.patent.gov.uk
A pile
breaker that can be driven by hydraulic fluid or air
pressure to break down concrete, and reinforced concrete,
piles of any shape, size or proximity to each other, without
damaging the integrity of the remaining structure. It is
designed to work under a system of extremely rapid,
short-shock pressure and release sequences resulting in
resonance shock waves transmitted within the designated
section of the pile. This, combined with the action of the
specially designed elliptical teeth, increases the
destructive effect on the concrete while protecting the
internal reinforcing structure of the piles.
Maximum
effect is gained when the chassis-main cylinders are paired.
This allows each tooth’s action to be combined with that
exerted by the directly opposing tooth.
The pile
breaker is operated remotely, from the source, thereby
ensuring that the operators do not suffer from vibrations,
noise, or dust inhalation. This also reduces the risk from
flying debris.
Technical field:
This
invention relates to a pile breaking machine that may be
driven by either hydraulics or pressurised air that allows
the top of reinforced concrete piles, (used in the
construction industry), to be removed without giving rise to
the handlers suffering any effects from vibration and other
related problems.
Background:
Since the
health and safety ruling on the effects of using vibratory
tools (known as white finger) it has been difficult for
construction companies to easily remove the tops from all
types of reinforced concrete piling. There are some machines
and methods that can remove the tops from specific piles
that are individually set at some distance from each other.
Nevertheless, many companies are still forced to return to
hand held vibratory machinery such as heavy breakers when
dealing with secant walling and other similar types. The
health restrictions on hours of use are both costly and time
consuming while remaining necessary.
This
invention is designed to operate best in matched pairs
joined together by high strength interwoven straps that are
themselves hydraulically adjustable and undergo constant
resetting with the pressure changes as the machine is
operated. The pile breaker is designed to work under a
system of extremely rapid, short shock pressure and release
sequences that result in resonance shock waves transmitted
within the designated section of the pile. This, combined
with the actual action of the specially designed elliptical
teeth, increases the destructive effect on the concrete
without causing damage to the internal metal reinforcement
structure of the piles.
This
invention provides the solution to all types of piling as it
can be manufactured in various shapes and sizes. An added
advantage is its remote operation, which ensures that no
personnel on site suffer any harmful effects from vibration
or other related problems such as noise, dust inhalation and
flying debris. As it is hydraulically driven, it also
incorporates a safety strap that will be the subject of
another patent application.
Essential technical figures:
This
invention (pile breaker) comprises of two aluminium
chassis-main cylinders (shown as no. 1 in the figures 1-10)
that incorporate six wet chambers (shown as no. 2 in figures
1-10) mounted with six smaller elliptical cylinders (shown
as no. 5 in the figures 1-10). These contain elliptical
pistons (shown as no. 8 in the figures 1-10) driven by a
hydraulic system. Each chassis-main cylinder (shown as no. 1
in the figures 1-10) also contains two dry chambers at its
far ends. Within each of these sections are located the
smaller round cylinders operating two high density straps
(shown as no. 10 in the figures 1-10). The high density
interwoven straps (shown as no. 10 in the figures 1-10) exit
the body of the main cylinders (shown as no. 1 in the
figures 1-10) through size matched holes (shown as no. 11 in
the figures 1-10) on both sides from the side facia of the
dry sections. The high density interwoven straps (shown as
no. 10 in the figures 1-10) are guided by and forced to roll
over a set of pulleys (shown as no. 7 in the figures 1-10).
Each main cylinder (shown as no. 1 in the figures 1-10) is
fitted with an air release valve (shown as no. 14 in the
figures 1-10) on its top, centre far end. The main cylinders
(shown as no. 1 in the figures 1-10) can be used
individually or as multiples of two and the number of
elliptical teeth (shown as no. 9 in the figures 1-10) can
vary to suit requirements. Each piston in turn, drives
elliptical teeth (shown as no. 9 in the figures 1-10), which
are manufactured of hardened steel, capped with an alloy,
such as (ra 3-10 or incoloy ds), that are both hard and heat
resistant. The chassis-main cylinder (shown as no. 1 in the
figures 1-10) is sealed and provides a reservoir for the
hydraulic fluid acting at the same time as a main cylinder
operating all elliptical pistons (shown as no. 8 in the
figures 1-10) at equal pressure. The chassis-main cylinder
(shown as no. 1 in the figures 1-10) has sides, which are
covered with shock absorbent latex that can be replaced when
worn. This feature provides a damping effect when working in
contact with adjacent piles, as is the case with secant
walling.
The
structure of the chassis-main cylinder (shown as no. 1 in
the figures 1-10) is constructed with inner reinforcing
walls (shown as no. 3 in the figures 1-10). These are
perforated to allow the flow of hydraulic fluid between the
inner sections. The inner reinforcing walls (shown as no. 3
in the figures 1-10) provide a dual function of moving the
centre of maximum pressure away from any walling. This
limits (almost entirely) the risk of deformation of the
outer walling and thus prolongs the lifespan of the pile
breaker.
All the
components of the chassis-main cylinder (shown as no. 1 in
the figures 1-10) are manufactured from a special type of
aluminium alloy, which has been formed, into plates under
High
pressure to provide maximum density and strength. The
manufactured components are then joined together by welding
(using the same material as welding rod). Corner joints
between these components are further reinforced by a joint
lining with the profile of a right angled triangle where the
hypotenuse is replaced by an arc. The additional arc
profiles have a solid formation. They are welded into place
in the process of manufacture. This additional rounding
feature of the interior corners vastly improves the
equalisation of pressure flow within the chassis-main
cylinder (shown as no. 1 in the figures 1-10) as well as its
rigidity.
Each paired
section is joined to the other by a wide, high density strap
(shown as no. 10 in the figures 1-10) made of interwoven
textile fibres. The strap (shown as no. 10 in the figures
1-10) is approximately 5mm thick and 150 mm wide. The straps
(shown as no. 10 in the figures 1-10) are able to withstand
& absorb approximately 3 times the maximum total level of
resulting forces. The strap's (shown as no. 10 in the
figures 1-10) also enable use of this invention on secant
walling where the distances between the piles are minimal.
Each strap (shown as no. 10 in the figures 1-10) is
connected to its chassis-main cylinder (shown as no. 1 in
the figures 1-10) by a fixed pin (shown as no. 15 in the
figures 1-10) joint on both opposite sides of one
chassis-main cylinder (shown as no. 1 in the figures 1-10).
Each pin is fitted with a drilled horizontal hole (shown as
no. 16 in the figures 1-10) in its bottom section into which
a retention device is to be inserted to hold it in its
preset position. On each opposite side is a constantly
adjusted hydraulically operated, round cylinder (shown as
no. 6 in the figures 1-10). Both of these round cylinders
(shown as no. 6 in the figures 1-10) receive the same amount
of pressure as the chassis, main cylinder (shown as no. 1 in
the figures 1-10). The free end of the strap (shown as no.
10 in the figures 1-10) is inserted into this receptor link.
This mechanism allows an optional design where one main
cylinder (shown as no. 1 in the figures 1-10) holds within
one of its side dry sections the round cylinder (shown as
no. 6 in the figures 1-10) and within its other dry section
a pin joint (shown as no. 15 in the figures 1-10). This
design is to be used as a single unit, which can be operated
independently where access to the pile(s) is restricted to
one face. Such cases would prevent mounting of the second
unit on the opposite side. This is done in such a way that
the short strap (shown as no. 10 in the figures 1-10) is
exchanged for a longer strap (shown as no. 10 in the figures
1-10) that goes round the pile and is joined back to the
same unit.
Each single
unit has four lifting eyes (shown as no. 13 in the figures
1-10) mounted on its upper surface, two just behind and two
in front of the imaginary line, which both bisects the
centre of gravity and is parallel to the foremost points of
the unit.
The
pressure hose linkage (shown as no. 12 in the figures 1-10)
is on the upper face, centrally placed at the rear of each
unit. When the units are used normally, (i.e. Paired), then
the hydraulic hoses are fed through a (t) or a (y) joint to
allow even distribution of pressure between both
chassis-main cylinders (shown as no. 1 in the figures 1-10)
and all twelve secondary (guiding) ones.
Although
the system described within this application uses as an
illustration, hydraulic fluid to provide the pressure
required for breaking the pile, exactly the same effect can
be achieved with compressed air. This alternate means of
providing pressure can be used with this exact structure as
the units are sealed against leakage.
Inside each
main cylinder (shown as no. 1 in the figures 1-10) there are
six smaller elliptical cylinders (shown as no. 5 in the
figures 1-10) welded into the front facia (shown as no. 4 in
the figures 1-10). Each one then provides the setting for an
elliptical piston (shown as no. 8 in the figures 1-10). Each
piston (shown as no. 8 in the figures 1-10) comprises of an
elliptical shape which is 75% hollow. The solid front of the
piston (shown as no. 8 in the figures 1-10) provides a
mounting for the breaking tooth (shown as no. 9 in the
figures 1-10). The piston (shown as no. 8 in the figures
1-10) is constructed of high density, pressed aluminium
alloy of the same kind. The solid front portion of the
piston (shown as no. 8 in the figures 1-10) contains an
elliptical hole of identical proportions to the tooth (shown
as no. 9 in the figures 1-10) mounting to allow for
attachment. The insides of the elliptical pistons (shown as
no. 8 in the figures 1-10) and elliptical cylinders (shown
as no. 5 in the figures 1-10) are treated with a hardener to
ensure a long life span. Elliptical shape design of the
teeth, cylinders, & pistons ensures that the elliptical
teeth (shown as no. 9 in the figures 1-10) remain in a
preset horizontal cutting position as rotation is
eliminated.
Each tooth
(shown as no. 9 in the figures 1-10) comprises of an
elliptical solid shape tapered towards the front. The
breaking surface is formed by two concave indentations at
top of the tooth (shown as no. 9 in the figures 1-10) and a
highly sharpened triangular front edge and a flat horizontal
underside. This construction of the tooth (shown as no. 9 in
the figures 1-10) allows it to break the concrete structure
while avoiding causing damage to any part of the internal
metal reinforcements. The elliptical teeth (shown as no. 9
in the figures 1-10) are designed as exchangeable to achieve
lower cost of maintenance.
The pile
breaker construction design can also be made of smaller
singular sections connected to each other by means of
classical pin-hole joints or by any other suitable means.
The
elliptical design of the cylinders used can also be replaced
with classical round shaped ones while the avoidance of
teeth turning can be achieved by other means than mentioned
within this description.
Each
chassis-main cylinder (shown as no. 1 in the figures 1-10)
is fitted with six elliptical teeth (shown as no. 9 in the
figures 1-10); each mounted on it is own piston/cylinder
structure, and protruding from the front face part between
the two reinforced facia (shown as no. 4 in the figures
1-10) in a curve.
The pile
breaking action is executed by pairs of elliptical teeth
(shown as no. 9 in the figures 1-10) acting against each
other on opposite sides of the concrete pile. This occurs
when two units are used together. It is this formation which
results in maximum horizontal interior structural damage,
that is solely limited to the concrete part of the pile
between the elliptical teeth (shown as no. 9 in the figures
1-10) and its adjacent structural surroundings. This means
providing that the pile breaker is set at a small distance
from where the pile is required to be effective then no
damage occurs to the integrity of the remaining pile.
Accompanying figures:
Fig (1/10)
shows the full top view of paired pile breaker version, in
operation on 3 piles of secant concrete walling.
Fig (2/10)
shows the top detail view of a single pile breaker main
cylinder.
Fig (3/10)
shows the front view of the first main cylinder section
incorporating smaller round cylinders and four guiding strap
pulleys.
Fig (4/10)
shows the front view of the second main cylinder section
incorporating retention pins and two guiding strap pulleys.
Fig (5/10)
shows the main cylinder dry section top detail view
incorporating strap join mechanism created by pin and
pulley.
Fig (6/10)
shows the main cylinder dry section top detail view
incorporating strap guiding and extension mechanism created
by the use of round hydraulic cylinders and a set of guiding
pulleys.
Fig (7/10)
shows the top cut detail position view of elliptical
cylinders and pistons.
Fig (8/10)
shows the front view of elliptical cylinder/pulley position
in detail.
Fig (9/10)
shows the elliptical cylinder and tooth front view in
detail.
Fig (10/10)
shows the main cylinder dry section detail incorporating
pulley and pin it their positions.
Claims:
1- A
hydraulic pile breaker that is adjustable and can be
manufactured to cope with any size or shape of concrete pile
and its reinforcing bars.
2- A
pile breaker as claimed in claim 1, but driven by compressed
air.
3- A
hardened triangular breaker tooth (shown as no. 9 in the
figures 1-10) with two concaved top sides.
4- An
adjustable high density interwoven linking strap (shown as
no. 10 in the figures 1-10) controlled by hydraulics.
5- An
adjustable high density interwoven linking strap (shown as
no. 10 in the figures 1-10) as claimed in claim 4, but
controlled by compressed air.
6- A
pile breaker as claimed in claim 1 & 2 that can operate as a
single unit.
7- A
pile breaker as claimed in claim 1 & 2, that can operate
under fresh or salt water.
8- A
pile breaker as described in claims 1 & 2 which is
constructed of dense aluminium alloy or any other metallic
or metallic alloy material.
9- A
pile breaker as described in claims 1 & 2 that is
constructed of any suitable dense polymer.
10- A pile
breaker as claimed in claim 1 that is driven by hydraulic
fluid pressurised from a direct pump or other suitable
source such as a tele handler or an excavator.
11- A pile
breaker as claimed in claim 2 that is driven by pressurised
air from a stand alone compressor or other suitable source.
12- A main
cylinder (shown as no. 1 in figures 1-10) is claimed where
the body acts as a fluid/air reservoir and smaller
elliptical cylinders (shown as no. 5 in the figures 1-10)
are contained therein.
13- A pile
breaker as claimed in claim 12 where the main chassis (shown
as no. 1 in the figures 1-10) is full of air (not
pressurised) and small hydraulic hoses feed each elliptical
cylinder (shown as no. 5 in the figures 1-10) or round
cylinder (shown as no. 6 in the figures 1-10) individually
as in a standard cylinder operation.
14- A pile
breaker as claimed in claim 13 where the standard cylinders
are operated by compressed air fed individually.
15- An
exchangeable latex side padding functioning as a vibration
damper between and adjacent concrete piles is claimed.
16- A pile
breaker substantially as describer herein with reference to
figures 1 to 10 of the accompanying drawings.
Please
refer to the patent office for all diagrams mentioned in
these descriptive texts
www.patent.gov.uk
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