Directional boring system with an asymmetric impact bit

Abstract

A tunneling device (102) includes a body assembly (136) configured to travel through an underground location. The body assembly extends along a longitudinal axis (140). A tip (142) is coupled to the body assembly. The tip includes a tunneling tool configured to displace material and form a tunnel as the tip moves. The tip is positionable relative to the body assembly. The tip is arranged to extend at an angle relative to the longitudinal axis. At least one actuator (148) is coupled to the tip and configured to change a position of the tip about the longitudinal axis and redirect the tunneling device through the underground location. The tip is capable of rotating circumferentially about the longitudinal axis.

Description

DIRECTIONAL BORING SYSTEM WITH AN ASYMMETRIC IMPACT BITSTATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT

[0001] This invention was made with Government support under contract number D19AC00018 awarded by the Defense Advanced Research Projects Agency (DARPA). The Government has certain rights in this invention.BACKGROUND

[0002] The field of the disclosure relates to tunneling devices, and more particularly to tunneling devices including a body assembly and tip.

[0003] Tunneling devices are used to travel through underground locations and displace material to form and shape tunnels through the underground locations. At least some tunneling devices include a drive system to propel the tunneling devices through underground locations. In addition, a tool may be positioned at the front of the tunneling devices to displace material and form an interior cavity of the tunnel as the tunneling devices travel through the underground locations. However, the underground locations may have vary ing conditions and obstacles that make travel and access difficult. In addition, the size, shape, and power requirements of the tunneling device are at least partly dictated by the configuration of the tool used to displace material, the drive system, and environmental characteristics. Moreover, at least some tunneling devices are difficult to steer and have limited maneuverability beyond moving in straight lines. Accordingly, the tunneling devices may have difficulty avoiding obstacles and may not be able to form complex tunnel systems.

[0004] Therefore, it is desirable to provide a system including a tunneling device that is simpler to steer and is configured to travel through difficult to access locations and form complex tunnel systems.BRIEF DESCRIPTION

[0005] In one aspect, a tunneling device includes a body assembly configured to travel through an underground location. The body assembly extends along a longitudinal axis. A tip is coupled to the body assembly. The tip includes a tunneling tool configured to displace material and form a tunnel as the tip moves. The tip is positionable relative to the body assembly. The tip is arranged to extend at an angle relative to the longitudinal axis. At least one actuator is coupled to the tip and configured to change a position of the tip about the longitudinal axis and redirect the tunneling device through the underground location. The tip is configured to rotate circumferentially about the longitudinal axis.

[0006] In another aspect, a system for use in maintaining a tunnel including a tunneling device. The tunneling device includes a body assembly configured to travel through an underground location. The body assembly extends along a longitudinal axis. A tip is coupled to the body assembly. The tip includes a tunneling tool configured to displace material and form a tunnel as the tip moves. The tip is positionable relative to the body assembly. The tip is arranged to extend at an angle relative to the longitudinal axis. At least one actuator is coupled to the tip and configured to change a position of the tip about the longitudinal axis to redirect the tunneling device through the underground location. The tip is capable of rotating circumferentially about the longitudinal axis. The system also includes a controller communicatively coupled to the tunneling device. The controller is configured to provide instructions to move the body assembly and to provide instructions to the actuator to adjust the position of the tip and direct the tunneling device through the underground location.

[0007] In yet another aspect, a method for redirecting a tunneling device through an underground location includes moving a tunneling device through an underground location. The tunneling device includes a body assembly extending along a longitudinal axis. A tip includes a tunneling tool configured to displace matenal and form a tunnel as the tip moves. The tip is arranged to extend at an angle relative to the longitudinal axis. The tip is positionable relative to the body assembly. An actuator coupled to the tip. The method also includes operating the actuator to change a position of the tip relative to the body assembly and redirect the tunneling device through the underground location.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

[0009] FIG. 1 is a schematic diagram of a system including one embodiment of a tunneling device traveling underground, the tunneling device including a tip;

[0010] FIG. 2 is a schematic diagram of a portion the tunneling device shown in FIG. 1 ;

[0011] FIG. 3 is an isometric view- of a portion of an alternative embodiment of a tunneling device for use with the system shown in FIG. 1, the tunneling device having an anchor;

[0012] FIG. 4 is an isometric view of a portion of the tunneling device shown in FIG. 3;

[0013] FIG. 5 is a side view of a portion of the tunneling device shown in FIG. 3; and

[0014] FIG. 6 is a flow chart of an example method of performing a maintenance operation using the tunneling device shown in FIG. 1.

[0015] Unless otherwise indicated, the drawings provided herein are meant to illustrate features of embodiments of this disclosure. These features are believed to be applicable in a wide variety of systems including one or more embodiments of this disclosure. As such, the drawings are not meant to include all conventional features known by those of ordinary skill in the art to be required for the practice of the embodiments disclosed herein.DETAILED DESCRIPTION

[0016] In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings.

[0017] The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.

[0018] “Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not.

[0019] Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about”, “approximately”, and “substantially”, are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and / or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.

[0020] As used herein, the terms “processor” and “computer,” and related terms, e.g., “processing device,” “computing device,” and “controller” are not limited to just those integrated circuits referred to in the art as a computer, but broadly refers to a microcontroller, a microcomputer, an analog computer, a programmable logic controller (PLC), and application specific integrated circuit (ASIC), and other programmable circuits, and these terms are used interchangeably herein. In the embodiments described herein, “memory” may include, but is not limited to, a computer-readable medium, such as a random-access memory (RAM), a computer-readable non-volatile medium, such as a flash memory. Alternatively, a floppy disk, a compact disc - read only memory (CD-ROM), a magneto-optical disk (MOD), and / or a digital versatile disc (DVD) may also be used. Also, in the embodiments described herein, additional input channels may be, but are not limited to, computer peripherals associated with an operator interface such as a touchscreen, amouse, and a keyboard. Alternatively, other computer peripherals may also be used that may include, for example, but not be limited to, a scanner. Furthermore, in the example embodiment, additional output channels may include, but not be limited to, an operator interface monitor or heads-up display. Some embodiments involve the use of one or more electronic or computing devices. Such devices typically include a processor, processing device, or controller, such as a general-purpose central processing unit (CPU), a graphics processing unit (GPU), a microcontroller, a reduced instruction set computer (RISC) processor, an ASIC, a PLC, a field programmable gate array (FPGA), a digital signal processing (DSP) device, and / or any other circuit or processing device capable of executing the functions described herein. The methods described herein may be encoded as executable instructions embodied in a computer readable medium, including, without limitation, a storage device and / or a memory device. Such instructions, when executed by a processing device, cause the processing device to perform at least a portion of the methods described herein. The above examples are exemplary only, and thus are not intended to limit in any way the definition and / or meaning of the term processor and processing device.

[0021] Embodiments described herein relate to a system including a tunneling device. The tunneling device includes a body assembly, a tip coupled to the body assembly, and an actuator coupled to the tip. The body assembly extends along a longitudinal axis and is configured to travel through an underground location. The tip includes a tunneling tool configured to displace material and form a tunnel as the tip moves. The tip extends at an angle relative to the longitudinal axis and is positionable relative to the body assembly. The actuator is configured to change the position of the tip about the longitudinal axis and redirect the tunneling device through the underground location. For example, the tip can rotate circumferentially about the longitudinal axis and define the angle relative to the longitudinal axis.

[0021] FIG. 1 is a schematic diagram of a system 100 including a tunneling device 102 traveling underground. For example, tunneling device 102 is configured to travel through a tunnel 104 and / or displace material to form tunnel 104. Tunnel 104 includes a sidewall 106 having an interior surface 108 extending around a central axis 1 10 and defining interior cavity 112. Tunneling device 102 is configured to fit within interior cavity 112 and travel along the length of tunnel 104. Accordingly, tunneling device 102 facilitatesconstruction of tunnel 104 and / or inspection and repair of tunnel 104. Moreover, tunneling device 102 is self-propelled, meaning that tunneling device 102 moves within interior cavity 112 without an external force acting on tunneling device 102.

[0022] During operation, for example, tunneling device 102 may be positioned at a surface 114 proximate an underground location and tunneling device 102 travels through surface 114 to form an opening into tunnel 104. In the illustrated embodiment, tunneling device 102 travels in a travel direction 115. In some embodiments, tunneling device 102 traverses transitions in tunnel 104 such as bends or size transitions. As tunneling device 102 travels through underground locations, tunneling device 102 is configured to form tunnel 104 and / or inspect and / or repair any portions of tunnel 104.

[0023] System 100 includes tunneling device 102, a controller 116 communicatively coupled to tunneling device 102, and a fluid supply system 118. Fluid supply system 118 includes a pressurized fluid source 120 that is coupled to tunneling device 102 via a fluid line 122. Fluid supply system 118 is configured to regulate pressurized fluid that is delivered to / removed from tunneling device 102 for operation of tunneling device 102, as described further herein.

[0024] In addition, in the example embodiment, controller 116 is configured to provide instructions to move tunneling device 102 through tunnel 104 and / or to perform inspection or repair operations. Controller 1 16 includes a transceiver 124, a processor 126, and a memory' 128. In some embodiments, controller 116 is positioned remotely from tunneling device 102, e.g., controller 116 is located at a base station that enables an operator on an exterior of tunnel 104 (show n in FIG. 1) to interact with tunneling device 102, and / or controller 116 can be at least partly incorporated into and located on board tunneling device 102. Transceiver 124 is communicatively coupled with tunneling device 102 and is configured to send information to and receive information from a transceiver of tunneling device 102. In some embodiments, transceiver 124 and a transceiver on tunneling device 102 communicate wirelessly. In alternative embodiments, tunneling device 102 and controller 116 communicate in any manner that enables system 100 to operate as described herein. For example, in some embodiments, controller 116 and tunneling device 102 exchange information through a wired link extending between tunneling device 102 and controller 116.

[0025] In addition, in some embodiments, controller 116 is at least partly located on board tunneling device 102 and is configured to execute instructions for controlling components of tunneling device 102, such as a maintenance device and drive systems. For example, controller 116 executes instructions that cause tunneling device 102 to move in a selected direction. In alternative embodiments, tunneling device 102 includes any controller that enables system 100 to operate as described herein. In some embodiments, controller 116 is not located on board tunneling device 102.

[0026] In some embodiments, tunneling device 102 includes one or more sensors and / or repair tools or pipe maintenance tools. For example, in some embodiments, tunneling device 102 includes a repair tool configured to repair interior surface 108, or an inspection tool configured to inspect a portion of interior cavity 112.

[0027] Also, in the example embodiment, an operator interface 130 is configured to display information relating to the characteristics detected by tunneling device 102 for interpretation by the operator. Operator interface 130 may be included on a remote computing device (not shown) and / or may be incorporated with controller 116. Operator interface 130 may include, among other possibilities, a web browser and / or a client application. For example, in some embodiments, operator interface 130 displays images of interior surface 108 based on received signals. In some embodiments, operator interface 130 allows an operator to input and / or view information relating to control of tunneling device 102. In the example embodiment, operator interface 130 is configured to display information relating to the state of one or more of a maintenance device and a power source for interpretation by the operator. For example, state information may include a position of tunneling device 102 along a length of tunnel 104 (shown in FIG. 1) and / or an orientation of tip 142. State information may also include a charge status of a power source and / or a current draw for the various drive and positioning motors. In various embodiments, processor 126 translates operator inputs into steering, tool motion, camera control, sensor control, sensor motion, and / or any other commands and sends information via transceiver 124 to tunneling device 102 via a transceiver of tunneling device 102. In some embodiments, operator control of tunneling device 102 is in real time, such as through ajoystick, a keyboard, atouchscreen, a remote motion capture system, and / or a wearable motion capture system or other interface having similar function. In other embodiments, tunneling device 102 is controlled partiallyor wholly according to a pre-programmed routine. Tn further embodiments, tunneling device 102 is at least partially automated. In some embodiments, an operator inputs information such as operation goals or conditional directions. In further embodiments, information, such as information received by controller 116 from tunneling device 102, control data sent to tunneling device 102, and additional operator inputs or state information (e.g., location, time, orientation, datalink quality, battery levels, repair material levels, failure mode indicators), is logged into memory 128.

[0028] Moreover, in the example embodiment, controller 116 is positioned on the exterior of tunnel 104 and communicates with tunneling device 102 positioned within interior cavity 112 of tunnel 104. For example, controller 116 is configured to send information to the tunneling device 102 relating to the propulsion and / or steering of tunneling device 102 while tunneling device 102 is moving within interior cavity 112 of tunnel 104 through a wireless connection and / or atether 132. In alternative embodiments, controller 11 and tunneling device 102 are configured in any manner that enables system 100 to operate as described herein.

[0029] Tunneling device 102, in the example embodiment, includes a body assembly 136, a tip 142 coupled to body assembly 136, and an actuator 148. Body assembly 136 of tunneling device 102 has a longitudinal axis 140. In the example embodiment, tip 142 has freedom of movement with at least two degrees of freedom relative to body assembly 136. For example, tip 142 can both traverse along a path parallel to longitudinal axis 140 and can also rotate in a direction about longitudinal axis 140 independently from body assembly 136.

[0030] Further, in the example embodiment, tunneling device 102 includes an actuator 148 coupled to and extending between body assembly 136 and tip 142. Actuator 148 is configured to rotate tip 142 in a direction about longitudinal axis 140. For example, a shaft 138 is coupled to and extends between actuator 148 and tip 142. Tip 142 is coupled to body assembly 136 by shaft 138. Shaft 138 extends through a bore defined in body assembly 136. Actuator 148 is configured to cause shaft 138 and tip 142 to move relative to body assembly 136. For example, actuator 148 is configured to cause shaft 138 and tip 142 to rotate in a direction about longitudinal axis 140, repositioning tip 142 relative to bodyassembly 136.

[0031] Also, in the example embodiment, tunneling device 102 includes a force transmitter 158 coupled to and extending between body assembly 136 and actuator 148. Force transmitter 158 is configured to deliver a force to tip 142 to move tip 142 in a direction parallel to longitudinal axis 140. For example, shaft 138 is coupled to and extends between force transmitter 158 and tip 142. Shaft 138 extends through a bore defined in actuator 148. Force transmitter 158 is configured to cause shaft 138 and tip 142 to move relative to body assembly 136 in the direction parallel to longitudinal axis 140.

[0032] Tip 142 is shaped to displace material when force transmitter 158 causes shaft 138 and tip 142 to move relative to body assembly 136 in the direction parallel to longitudinal axis 140. Tip 142 is additionally shaped in such a way to engage material and guide tunneling device 102 when actuator 148 causes shaft 138 and tip 142 to rotate relative to body assembly 136. For example, tip 142 includes a tunneling tool 182 configured to displace material as tip 142 moves. In the example embodiment, tip 142 is a cone having a width at one end and tapering to a point that is configured to engage the material. In alternative embodiments, tip 142 is any shape that enables tunneling device 102 to operate as described herein. For example, in some embodiments, tip 142 includes a blade, a helix, a sphere, and / or any other suitable shape. In some embodiments, force transmitter 158 and actuator 148 may both act on tip 142 and shaft 138 at the same time as to induce both translation and rotational motion concurrently. In further embodiments, force transmitter 158 and actuator 148 may act on tip 142 and shaft 138 independently from one another to induce translation or rotational motion of tip 142.

[0033] In some embodiments, tip 142 includes at least one of a sensor and / or a repair tool, and tip 142 is configured to perform a maintenance operation within tunnel 104. For example, in some embodiments, tip 142 includes, without limitation, any of the following: an applicator, a drill, a grinder, a heater, a welding electrode, a sprayer, an optical sensor (e.g., visible, infrared, and / or multi-spectral sensor), a mechanical sensor (e.g., stylus profilometer, coordinate measurement probe, load transducer, linear variable differential transformer), a thermal sensor (e.g.. pyrometer, thermocouple, resistance temperature detector), a magnetic sensor, an acoustic sensor (e.g., piezoelectric, microphone, ultrasound), and an electromagnetic sensor (e.g., eddy current, potential drop, x-ray). In some embodiments, a maintenance device on tip 142 is used to provide information for steeringtunneling device 102 and / orto perform amaintenance operation. In alternative embodiments, tunneling device 102 includes any tip 142 that enables tunneling device 102 to operate as described herein.

[0034] In addition, in some embodiments, tunneling device 102 includes a light source (not shown) configured to irradiate at least a portion of interior cavity 112 to facilitate visual or non-visual steering oftunneling device 102 and / orto allow amaintenance device to capture images, for example. The light source may be coupled to body assembly 136 and, in some embodiments, may be positionable relative to body assembly 136. In alternative embodiments, tunneling device 102 includes any light source that enables tunneling device 102 to operate as described herein.

[0035] FIG. 2 is a schematic diagram of a portion tunneling device 102. In the example embodiment, tip 142 is arranged to extend at an angle 180 relative to longitudinal axis 140. In the example embodiment, angle 180 is between 0° and 90° relative to longitudinal axis 140. For example, angle 180 determines the rate at which tunneling device 102 is redirected. In some embodiments, the position of tip 142 relative to body assembly 136 is fixed at a single predetermined state, and angle 180 does not change during operation of tunneling device 102. Also, in some embodiments, tip 142 is removably coupled to body assembly 136 and can be swapable with another tip 142 that has a different angle 180. In further embodiments, angle 180 is adjustable during operation of tunneling device 102. For example, controller 1 16 may provide instructions to an actuated joint in tip 142 to adjust angle 180, depending on a required rate of redirection to achieve the desired tunneling path while tunnelling device 102 is traveling through an underground location. In yet another alternative embodiment, angle 180 may be fixed prior to operating tunneling device 102. For example, tip 142 may include a lockable joint that is adjustable only when tunneling device 102 is not moving.

[0036] In the example embodiment, actuator 148 and force transmitter 158 are aligned along longitudinal axis 140. FIG. 2 shows actuator 148 coupled between tip 142 and force transmitter 158. In some embodiments illustrated in FIGS. 3-5, force transmitter 158 is positioned between tip 142 and actuator 148. Accordingly, in the embodiment shown in FIGS. 3-5, force transmitter 158 and tip 142 are rotated by actuator 148. In alternativeembodiments, actuator 148 and tip 142 are arranged in any manner that enables tunneling device 102 to operate as described herein.

[0037] In addition, in the example embodiment of FIG. 2, force transmitter 158 includes a housing 166 and a drive unit 168. In the example embodiment, housing 166 is cylindrical and extends along longitudinal axis 140. Drive unit 168 is disposed within housing 166 and is configured to induce movement of shaft 138 based on instructions from controller 116 and / or when force transmitter 158 receives power from a power source. For example, force transmitter 158 is configured to move shaft 138 and tip 142 in a direction parallel to longitudinal axis 140. Additionally, shaft 138 and tip 142 rotate about longitudinal axis 140 independently of force transmitter 158. In alternative embodiments, force transmitter 158 is configured to rotate about longitudinal axis 140 with shaft 138 and tip 142 as induced by actuator 148.

[0038] FIG. 3 is an isometric view of a portion of an embodiment of a tunneling device 200 for use with system 100 shown in FIG. 1. Tunneling device 200 includes an anchor 134. Anchor 134 is coupled to body assembly 136. Anchor 134 is configured to fix a position of at least a portion of body assembly 136 when tip 142 changes position. For example, anchor 134 is expandable in a direction perpendicular to longitudinal axis 140 between a first configuration and second configuration. Anchor 134 in the first configuration has a width facilitating free movement between anchor 134 and sidewall 106 of tunnel 104. Anchor 134 in the second configuration has a width resisting free movement between anchor 134 and sidewall 106 of tunnel 104, and anchor 134 engages sidewall 106 of tunnel 104 in the second configuration. Anchor 134 facilitates force transmitter 158 to induce movement of tip 142 when anchor 134 is in the second configuration. In addition, anchor 134 allows actuator 148 to induce rotation of tip 142 when anchor 134 is in the second configuration.

[0039] In the example embodiment, anchor 134 includes an elastomeric material that is configured to expand / collapse when pressurized fluid is delivered / removed from anchor 134. In addition, in the example embodiment, reinforcement muscles (e.g., fibers) extend around anchor 134 and are connected to radial and axial actuators. In the example embodiment, the muscles are reinforced with a fiber mesh pattern that constrains the direction and amount of expansion of anchor 134 based on a fiber reinforcement angledetermined by the design of the muscle. For example, the fiber reinforcement may form a first arrangement (e.g., a tight mesh grid around the circumference of anchor 134) that allows anchor 134 to expand in an axial direction but not in a radial direction when anchor 134 is pressurized. Conversely, the fiber reinforcement may form a second arrangement (e.g., a looser mesh grid around the circumference of anchor 134 allowing radial expansion or stretching of the mesh) that allows anchor 134 to expand in the radial direction but not the axial direction when anchor 134 is pressurized. In addition, the fiber reinforcement angle is designed to arrest the deformation of anchor 134 at a pre-defined setpoint in the radial and / or axial direction when anchor 134 is pressurized. In the example embodiment, the fiber reinforcement angle of the muscles is between 10 degrees and 50 degrees with respect to the circumferential axis of anchor 134. In alternative embodiments, tunneling device 102 includes any anchor 134 that enables tunneling device 102 to operate as described herein. For example, in some embodiments, anchor 134 includes at least one member that is movable relative to body assembly 136 and is arranged to selectively engage sidewall 106 of tunnel 104. In further embodiments, anchor 134 includes a brake that is configured to engage one or more drive members of tunneling device 102 and thereby prevent movement of bodyassembly 136.

[0040] Referring to FIGS. 1 and 3, in the example embodiment, pressurized fluid source 120 is coupled to one or more components of tunneling device 102, 200 via fluid line 122. For example, pressurized fluid source 120 is coupled to anchor 134 of tunneling device 200 via fluid line 122 and to body assembly 136 via fluid line 122. Anchor 134 is configured to transition from the first configuration to the second configuration when pressurized fluid is delivered to anchor 134 via fluid line 122, and to transition anchor 134 from the second configuration to the first configuration when the pressurized fluid is removed from anchor 134 via fluid line 122. In addition, in some embodiments, one or more sections of body assembly 136 are configured to selectively switch configurations and propel body assembly 136 when pressurized fluid is delivered to or removed from body assembly 136 via fluid line 122. Also, in some embodiments, anchor 134 and / or one or more sections of body assembly 136 are configured to propel tunneling device 200 through the underground location when anchor 134 and / or one or more sections of body assembly 136 switch configurations. In alternative embodiments, system 100 includes any pressurized fluid source 120 that enables system 100 to operate as described herein. For example, in someembodiments, pressurized fluid source 120 includes separate fluid tanks and / or pumps that are coupled to and configured to regulate pressurized fluid in anchor 134 and / or body assembly 136. In addition, in some embodiments, system 100 includes a plurality of fluid lines 122 coupled to body assembly 136 and / or anchor 134.

[0041] FIGS. 4 and 5 show views of a portion of tunneling device 200. In the example embodiment of FIG. 3, force transmitter 158 includes ahousing 166 and a drive unit 168. In the example embodiment, housing 166 is cylindrical and extends around and along longitudinal axis 140. Drive unit 168 is disposed within housing 166 and is configured to induce movement of shaft 138 based on instructions from controller 116 and / or when force transmitter 158 receives power from a power source. For example, force transmitter 158 is configured to move shaft 138 and tip 142 in a direction parallel to longitudinal axis 140. In alternative embodiments, tunneling device 200 includes any force transmitter 158 that enables tunneling device 102 to operate as described herein. For example, in some embodiments, force transmitter 158 includes a motor, a percussion hammer or reciprocating impact device, a linear actuator, and / or a pneumatic actuator.

[0042] In addition, in the example embodiment of FIG. 3, actuator 148 includes a housing 176 and a drive unit 178. In the example embodiment, housing 176 is cylindrical and extends along longitudinal axis 140. Drive unit 178 is disposed within housing 176 and is configured to induce movement of shaft 138 based on instructions from controller 116 and / or when actuator 148 receives power from a power source. For example, actuator 148 is configured to rotate shaft 138 and tip 142 about longitudinal axis 140. In alternative embodiments, tunneling device 102 includes any actuator 148 that enables tunneling device 102 to operate as described herein. For example, in some embodiments, actuator 148 includes a motor, an engine, a rotary actuator, and / or a pneumatic actuator.

[0043] Force transmitter 158 has a width measured perpendicular to longitudinal axis 140. First width of anchor 134 is less than or equal to width of force transmitter 158. Second width of anchor 134 is equal to or greater than width of force transmitter 158. During operation, anchor 134 transitions from the second configuration to the first configuration to facilitate body assembly 136 traveling through tunnel 104 (shown in FIG. 1). Anchor 134 is sized and shaped to fit within the tunnel that accommodates body assembly 136 because width of body assembly 136 is greater than or equal to the first widthof anchor 134. Body assembly 136 is sized and shaped to and fit within the tunnel that accommodates anchor 134 because width of body assembly 136 is less than or equal to second width of anchor 134.

[0044] Referring to FIGS. 1 -5, in addition, in the example embodiment, during operation, tunneling device 102, 200 is positioned proximate surface 114 such that distal tip 142 engages material of the surface 114. Controller 116 provides instructions that cause tunneling device 102, 200 to tunnel into surface 114 and through underground locations. For example, pressurized fluid is supplied to anchor 134 to transition anchor 134 to the second configuration. In the second configuration, anchor 134 engages sidewalls 106 of tunnel 104 to resist movement and facilitates force transmitter 158 to move tip 142. For example, anchor 134 engages sidewalls 106 of tunnel 104 and resists longitudinal movement. Power is delivered to force transmitter 158 and force transmitter 158 transfers force to tip 142 while anchor 134 is in the second configuration to cause tip 142 to move and, thereby, displace material.

[0045] Tip 142 displaces material to form interior cavity 112 when tip 142 is moved by force transmitter 158. For example, tip 142 displaces the material in directions parallel and / or perpendicular to longitudinal axis 140. In the example embodiment, the cone shape of tip 142 causes material in front of tunneling device 102, 200 to be compacted. Width of tip 142 defines an initial width of interior cavity 112 of tunnel 104 as tip 142 displaces material. In the example embodiment, system 100 does not require an apparatus to remove at least some of the displaced material because tunneling device 102, 200 compacts the displaced material around tunnel 104. Also, in the example embodiment, body assembly 136 is in a stationary position braced by anchor 134 as tip 142 displaces material or repositions relative to body assembly 136.

[0046] After tip 142 has displaced material, anchor 134 is transitioned back to the first configuration. For example, pressurized fluid is removed from anchor 134 to transition anchor 134 back to the first configuration. Body assembly 136 propels tunneling device 102 through tunnel 104 with anchor 134 in the first configuration. Tip 142 engages new material to be displaced as body assembly 136 is propelled forward.

[0047] As tip 142 engages new material, pressurized fluid is supplied to anchor 134 to transition anchor 134 to the second configuration. As anchor 134 transitions to the second configuration, anchor 134 engages sidewall 106 and compresses material previously displaced by tip 142 and. in some embodiments, expands interior cavity 112. In the second configuration, anchor 134 braces tunneling device 102 against longitudinal displacement and focuses the force from force transmitter 158 on tip 142. Power is delivered to force transmitter 158 and force transmitter 158 delivers force to tip 142 to cause tip 142 to move relative to the material and. thereby, displace material. After tip 142 displaces material, anchor 134 is transitioned back to the first configuration again and body assembly 136 propels tunneling device 102 through tunnel 104 with anchor 134 in the first configuration. Tunneling device 102 iteratively displaces material and propels through underground locations to provide a desired length of tunnel 104.

[0048] Controller 116 provides instructions that cause tunneling device 102 to alter travel direction 115 through underground locations. For example, pressurized fluid is supplied to anchor 134 to transition anchor 134 to the second configuration. In the second configuration, anchor 134 engages sidewalls 106 of tunnel 104 to resist movement and facilitates actuator 148 rotating tip 142. For example, anchor 134 engages sidewalls 106 of tunnel 104 and resists rotational movement. Power is delivered to actuator 148 and actuator 148 rotates tip 142 about longitudinal axis 140 while anchor 134 is in the second configuration to cause tip 142 to rotate and, thereby, changing travel direction 115.

[0049] In addition, controller 116 may provide instructions that determine the amount of force that force transmitter 158 delivers to tip 142. For example, controller 116 may determine the amount of force to deliver to tip 142 based on the type of material around tip 142, the characteristics of tip 142, the direction and magnitude of travel desired, and / or any other operative parameters of tunneling device 102. In addition, in the example embodiment of FIG. 2, actuator 148 includes a housing 176 and a drive unit 178. In the example embodiment, housing 176 is cylindrical and extends along longitudinal axis 140. Drive unit 178 is disposed within housing 176 and is configured to induce movement of shaft 138 based on instructions from controller 116 and / or when actuator 148 receives power from a power source. For example, actuator 148 is configured to rotate shaft 138 and tip 142 in a direction about longitudinal axis 140. For example, a protrusion or engagement member 184(shown in FIG. 2) on shaft 138 is configured to engage drive unit 178 and receive a rotational force from drive unit 178. Additionally, shaft 138 and tip 142 move parallel to longitudinal axis 140 independently of actuator 148. In alternative embodiments, actuator 148 is configured move parallel to longitudinal axis 140 with shaft 138 and tip 142 as induced by force transmitter 158. Also, in the example embodiment, rotation of tip 142 by actuator 148 changes an orientation of tip 142 relative to body assembly 136. For example, the orientation of tip 142 relative to body assembly 136 determines a direction of body assembly 136. Accordingly, actuator 148 changes an orientation of tip 142 to redirect or steer body assembly 136 through the underground location. As a result, tip 142 and actuator 148 facilitate tunneling device 102 reorienting and changing a tunnel direction at any underground position and independent of the prior path of tunneling device 102. Tunneling device 102 is configured to form complex tunnel shapes. Moreover, tunneling device 102 provides improved maneuverability and reduces the cost and time required for tunneling operations because tunneling device 102 is configured to turn simply and quickly without complex reorientation steps or removal from the underground location.

[0050] FIG. 6 is a flow chart of an example method 600 maintaining tunnel 104 (shown in FIG. 1). In reference to FIGS. 1 -6, method 600 includes moving 602 tunneling device 102, 200 through an underground location. In some embodiments, tunneling device 102, 200 is propelled through underground locations using a plurality of sections of body assembly 136. For example, pressurized fluid from pressurized fluid source 120 is delivered to or removed from sections of body assembly 136 to sequentially adjust a length and / or a width of sections and propel body assembly 136 through the underground locations.

[0051] Referring to FIGS. 3-5, in addition, in the example embodiment, during operation, tunneling device 200 includes a universal joint 185 to couple body assembly 136 to tip 142 for transmitting rotary power over a range of angles between body assembly 136 and tip 142. For example, universal joint 185 may be an articulated or flexible coupling that transmits longitudinal and / or rotational forces from one rigid segment to another rigid segment. For example, in some embodiments, universal joint 185 may include rotation constrained spherical joints, elastomeric couplings, and / or flexible shaft couplings. Additionally, tunneling device may further include a universal joint 185 to couple bodyassembly 136 to force transmitter 158 and transmit rotary power over a range of angles between body assembly 136 and force transmitter 158.

[0052] In addition, method 600 includes operating actuator 148 to change a position of tip 142 relative to body assembly 136. For example, actuator 148 is configured to rotate shaft 138 and tip 142 about longitudinal axis 140 when controller 116 sends instructions to actuator 148 and / or when actuator 148 receives power from a power source. Actuator 148 is configured to rotate tip 142 through 360 degrees around longitudinal axis 140 and around an entire circumference of shaft 138 to position tip 142 at any possible orientation. Tip 142 extends at angle 180 relative to longitudinal axis 140 such that rotation of tip 142 changes an orientation of tip 142 relative to longitudinal axis 140 and thus changes a path of tunneling device 102 provided by tip 142.

[0053] Further, method 600 includes redirecting said tunneling device 102, 200 through the underground location. For example, when tip 142 is positioned relative to body assembly 136 by actuator 148 in a desired orientation, tunneling device 102, 200 is moved through the underground location. Tunneling device 102. 200 follows a path provided by the orientation of tip 142. Accordingly, tunneling device 102, 200 is configured to travel along and / or form complex tunnel shapes and tunneling device 102, 200 is able to turn in any direction quickly and simply.

[0054] In the example embodiment, any steps of method 600 are repeated any number of times required for tunneling device 102, 200 to travel a desired distance through tunnel 104 and / or to displace material and form a desired length of tunnel 104.

[0055] An example technical effect of the methods, systems, and apparatus described herein includes at least one of: (a) reducing the time to construct tunnels through underground locations: (b) enabling tunneling operations and / or inspection and repair of an interior cavity of a tunnel at greater distances from an access opening; (c) increasing the information that is available during tunneling operations; (d) reducing the power requirements for tunneling devices during tunneling operations; (e) increasing the maneuverability of tunneling devices to avoid obstacles and traveling along complex paths; and (f) facilitating tunneling devices being able to turn quickly and simply when traveling through underground locations and without being removed from the underground locations.

[0056] Further aspects of the present disclosure are provided by the subject matter of the following clauses:

[0057] A tunneling device including: a body assembly configured to travel through an underground location, said body assembly extending along a longitudinal axis; a tip coupled to said body assembly, wherein said tip comprises a tunneling tool configured to displace material and form a tunnel as said tip moves, wherein said tip is positionable relative to said body assembly, wherein said tip is arranged to extend at an angle relative to said longitudinal axis; and at least one actuator coupled to said tip and configured to change a position of said tip about the longitudinal axis and redirect said tunneling device through the underground location; wherein said tip is capable of rotating circumferentially about the longitudinal axis.

[0058] The tunneling device in accordance with any applicable clause, further including a force transmitter coupled to said tip, wherein said force transmitter is configured to reciprocally translate said tip in a direction parallel to the longitudinal axis.

[0059] The tunneling device in accordance with any applicable clause, wherein said tip and said at least one actuator are translationally independent from one another, facilitating isolated movement parallel to the longitudinal axis of said tip.

[0060] The tunneling device in accordance with any applicable clause, wherein said tip and said force transmitter are rotationally independent from one another, facilitating isolated rotation about the longitudinal axis of said tip.

[0061] The tunneling device in accordance with any applicable clause, further including ajoint for facilitating the adjustment of the angle of said tip relative to said longitudinal axis, wherein the angle of said tip relative to said longitudinal axis affects the rate at which said tunneling device is redirected.

[0062] The system in accordance with any applicable clause, further including an anchor configured to fix a position of at least a portion of said body assembly when said tip changes position.

[0063] The tunneling device in accordance with any applicable clause, wherein said tip includes at least one of a sensor and / or a repair tool, and wherein said tip is configured to perform a maintenance operation within a tunnel.

[0064] The tunneling device in accordance with any applicable clause, further including a universal joint configured to couple said body assembly to said tip.

[0065] The tunneling device in accordance with any applicable clause, further including a universal joint configured to couple said body assembly to said force transmitter.

[0066] A system for use in maintaining a tunnel, said system including: a tunneling device including: a body assembly configured to travel through an underground location, said body assembly extending along a longitudinal axis; a tip coupled to said body assembly, wherein said tip comprises a tunneling tool configured to displace material and form a tunnel as said tip moves, wherein said tip is positionable relative to said body assembly, wherein said tip is arranged to extend at an angle relative to said longitudinal axis; and at least one actuator coupled to said tip and configured to change a position of said tip about the longitudinal axis to redirect said tunneling device through the underground location; wherein said tip is capable of rotating circumferentially about the longitudinal axis; and a controller communicatively coupled to said tunneling device, said controller configured to provide instructions to move said body assembly and to provide instructions to said actuator to adjust the position of said tip and direct said tunneling device through the underground location.

[0067] The system in accordance with any applicable clause, wherein said controller is configured to send instructions to said actuator to cause said actuator to change a position of said tip relative to said body assembly to redirect said tunneling device through the underground location.

[0068] The system in accordance with any applicable clause, further including a force transmitter coupled to said tip, wherein said force transmitter is configured to reciprocally translate said tip in a direction parallel to the longitudinal axis.

[0069] The system in accordance with any applicable clause, wherein said controller is configured to send instructions to said force transmitter to cause said force transmitter to reciprocally translate said tip in a direction parallel to the longitudinal axis.

[0070] The system in accordance with any applicable clause, further including an anchor configured to fix a position of at least a portion of said body assembly when said tip changes position.

[0071] The system in accordance with any applicable clause, wherein said controller is located on board said tunneling device.

[0072] A method for maintaining a tunnel, said method including: moving a tunneling device through an underground location, the tunneling device including: a body assembly extending along a longitudinal axis; a tip including a tunneling tool configured to displace material and form a tunnel as said tip moves, wherein said tip is arranged to extend at an angle relative to said longitudinal axis, wherein said tip is positionable relative to said body assembly; and an actuator coupled to said tip; operating the actuator to change a position of said tip relative to said body assembly and redirect said tunneling device through the underground location.

[0073] The method in accordance with any applicable clause, further including delivering, using a force transmitter coupled to said tip, reciprocally motion to said tip in a direction parallel to the longitudinal axis.

[0074] The method in accordance with any applicable clause, further including displacing material to form the tunnel as said tip moves, wherein the body assembly is configured to fit into the tunnel formed by the tip.

[0075] The method in accordance with any applicable clause, further including stopping the movement of the body assembly using an anchor, wherein said anchor is configured to fix a position of at least a portion of said body assembly when said tip changes position.

[0076] The method in accordance with any applicable clause, further including stopping the movement of the body assembly when operating the actuator to change the position of the tip.

[0077] Example embodiments of systems and methods for use in tunneling operations are described above in detail. The methods and systems are not limited to the specific embodiments described herein, but rather, components of systems and / or steps of the methods may be utilized independently and separately from other components and / or steps described herein. For example, the method may also be used in combination with other components, and are not limited to practice only with tunnels as described herein. Rather, the example embodiment can be implemented and utilized in connection with many other applications.

[0078] Although specific features of various embodiments of the disclosure may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the disclosure, any feature of a drawing may be referenced and / or claimed in combination with any feature of any other drawing.

[0079] This written description uses examples to disclose the embodiments, including the best mode, and also to enable any person skilled in the art to practice the embodiments, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

Claims

WHAT IS CALMED IS:

1. A tunneling device comprising: a body assembly configured to travel through an underground location, said body assembly extending along a longitudinal axis; a tip coupled to said body assembly, wherein said tip comprises a tunneling tool configured to displace material and form a tunnel as said tip moves, wherein said tip is positionable relative to said body assembly and is arranged to extend at an angle relative to the longitudinal axis; and at least one actuator coupled to said tip and configured to change a position of said tip about the longitudinal axis and redirect said tunneling device through the underground location; wherein said tip is configured to rotate circumferentially about the longitudinal axis.

2. The tunneling device in accordance with claim 1, further comprising a force transmitter coupled to said tip, wherein said force transmitter is configured to reciprocally translate said tip in a direction parallel to the longitudinal axis.

3. The tunneling device in accordance with claim 2. wherein said tip and said at least one actuator are translationally independent from one another, facilitating isolated movement parallel to the longitudinal axis of said tip.

4. The tunneling device in accordance with claim 2, wherein said tip and said force transmitter are rotationally independent from one another, facilitating isolated rotation about the longitudinal axis of said tip.

5. The tunneling device in accordance with claim 1, further comprising a joint for facilitating adjustment of the angle of said tip relative to said longitudinal axis, wherein the angle of said tip relative to said longitudinal axis affects the rate at which said tunneling device is redirected.

6. The tunneling device in accordance with claim 1, further comprising an anchor configured to fix a position of at least a portion of said body assembly when said tip changes position.

7. The tunneling device in accordance with claim 1, wherein said tip comprises at least one of a sensor and / or a repair tool, and wherein said tip is configured to perform a maintenance operation within a tunnel.

8. The tunneling device in accordance with claim 1 , further comprising a universal joint configured to couple said body assembly to said tip.

9. The tunneling device in accordance with claim 2, further comprising a universal j oint configured to couple said body assembly to said force transmitter.

10. A system for use in maintaining a tunnel, said system comprising: a tunneling device comprising: a body assembly configured to travel through an underground location, said body assembly extending along a longitudinal axis; a tip coupled to said body assembly, wherein said tip comprises a tunneling tool configured to displace material and form a tunnel as said tip moves, wherein said tip is positionable relative to said body assembly, wherein said tip is arranged to extend at an angle relative to the longitudinal axis; and at least one actuator coupled to said tip and configured to change a position of said tip about the longitudinal axis to redirect said tunneling device through the underground location; wherein said tip is capable of rotating circumferentially about the longitudinal axis; and a controller communicatively coupled to said tunneling device, said controller configured to provide instructions to move said body assembly and to provide instructions to said actuator to adjust the position of said tip and direct said tunneling device through the underground location.

11. The system in accordance with claim 10, wherein said controller is configured to send instructions to said actuator to cause said actuator to change a position of said tip relative to said body assembly to redirect said tunneling device through the underground location.

12. The system in accordance with claim 10, further comprising a force transmitter coupled to said tip, wherein said force transmitter is configured to reciprocally translate said tip in a direction parallel to the longitudinal axis.

13. The system in accordance with claim 12, wherein said controller is configured to send instructions to said force transmitter to cause said force transmitter to reciprocally translate said tip in a direction parallel to the longitudinal axis.

14. The system in accordance with claim 12, further comprising an anchor configured to fix a position of at least a portion of said body assembly when said tip changes position.

15. The system in accordance with claim 10, wherein said controller is located on board said tunneling device.

16. A method for maintaining a tunnel, said method comprising: moving a tunneling device through an underground location, the tunneling device including: a body assembly extending along a longitudinal axis; a tip including a tunneling tool configured to displace material and form a tunnel as the tip moves, wherein the tip is arranged to extend at an angle relative to the longitudinal axis, wherein the tip is positionable relative to the body assembly; and an actuator coupled to the tip; operating the actuator to change a position of the tip relative to the body assembly and redirect the tunneling device through the underground location.

17. The method in accordance with claim 16, further comprising delivering, using a force transmitter coupled to the tip, reciprocal motion to the tip in a direction parallel to the longitudinal axis.

18. The method in accordance with claim 16, further comprising displacing material to form the tunnel as the tip moves, wherein the body assembly is configured to fit into the tunnel formed by the tip.

19. The method in accordance with claim 16, further comprising stopping the movement of the body assembly using an anchor, wherein the anchor is configured to fix a position of at least a portion of the body assembly when the tip changes position.

20. The method in accordance with claim 19, further comprising stopping the movement of the body assembly when operating the actuator to change the position of the tip.

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