Pile driving apparatus

Abstract

A pile driving apparatus is provided. The pile driving apparatus includes abase, a drive system connected to the base and operable to move the base in at least one direction of motion, and a housing supported by the base. The housing includes one or more components of a control system, wherein the control system is operable to control the drive system to selectively move the base in the at least one direction of motion. The pile driving apparatus also includes a mast system comprising a mast base assembly and a mast assembly. The mast assembly includes an outer mast tube and a mast base tube within the outer mast tube. The pile driving apparatus further includes a hammer system comprising a carriage assembly, a hammer frame removably coupled to the carriage assembly, and a hammer housed within the hammer frame.

Description

PILE DRIVING APPARATUSCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and benefit from U.S. Provisional Patent Application No. 63 / 519,516, filed August 14, 2023, which is hereby incorporated by reference in its entirety.DISCUSSION OF ART

[0002] The field of the disclosure relates generally to a pile driving apparatus, and, more particularly, to an apparatus to drive piles into the ground at distinct locations.

[0003] Piles are commonly used in the construction of building foundations and clean energy resources, such as to mount solar panels across a solar field. However, driving piles into the ground at distinct locations can be an inefficient process. Due to the size and weight of piles, large machinery is often used to drive piles into the ground, which may require more time to move between pile locations. Additionally, manual maintenance and repair of large machinery may be time and resource consuming.

[0004] Thus, there is a need for a pile driving apparatus that facilitates increasing the efficiency of driving piles into the ground at distinct locations.SUMMARY

[0005] In one embodiment, a pile driving apparatus is provided. The pile driving apparatus includes a base, a drive system connected to the base and operable to move the base in at least one direction of motion, and a housing supported by the base. The housing includes one or more components of a control system, wherein the control system is operable to control the drive system to selectively move the base in the at least one direction of motion. The pile driving apparatus also includes a mast system comprising a mast base assembly and a mast assembly. The mast assembly includes an outer mast tube and a mast base tube within the outer mast tube. The pile driving apparatus further includes a hammer system comprising a carriage assembly, a hammer frame removably coupled to the carriage assembly, and a hammer housed within the hammer frame, the carriage assembly being operably engaged with the outer mast tube of the mast assembly by one or more carriage chains. The outer mast tube is operable to move in relation to the mast base tube to raise and lower the carriage assembly via the one or more carriage chains to raise and lower the hammer.

[0006] In another embodiment, a track assembly is provided. The track assembly includes front and rear rollers, a track frame extending around the front and rear rollers and defining an interior of the track assembly, a track extending around the track frame, a track tensioning mechanism to set a tension of the track, and a removeable cover coupled to the track frame and encasing the interior of the track assembly.

[0007] In still another embodiment, a mounting system for use to mount a vibratory hammer on a pile driving apparatus is provided. The mounting system includes a mast and a carriage assembly slidably mounted on the mast, the carriage assembly having a mounting member comprising a pair of apertures and a clamping assembly. The clamping assembly comprises a top clamping member, a bottom clamping member, and a pivot clamping member, the top clamping member being pivotally coupled to the pivot clamping member to bring the top and bottom clamping members together to form a mounting channel. The mounting system also includes a vibratory hammer frame having a tubular mounting member and an aperture. Coupling the vibratory hammer frame to the carriage assembly includes the tubular mounting member of the vibratory hammer frame being received in the mounting channel of the carriage assembly, with the top and bottom clamping members secured together around the tubular mounting member, and a securing pin being inserted into and secured within the pair of apertures of the mounting member of the carriage assembly and the aperture of the vibratory hammer frame.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 is a perspective view of a pile driving apparatus.

[0009] FIG. 2 is another perspective view of the pile driving apparatus shown in FIG. 1.

[0010] FIG. 3 is a side view of the pile driving apparatus shown in FIG. 1.

[0011] FIG. 4 is a perspective view of a mast system for use with a pile driving apparatus, the mast system including a mast base assembly and a mast assembly.

[0012] FIG. 5 is a perspective view of the mast system shown in FIG. 4, including an outer mast tube of the mast assembly.

[0013] FIG. 6 is a perspective view of a hammer system for use with the mast system shown in FIG. 5.

[0014] FIG. 7A is a side view of a pile driving apparatus, including a mast system in a lowered configuration.

[0015] FIG. 7B is a side view of a pile driving apparatus, including a mast system in a raised configuration.

[0016] FIGS. 8 A and 8B are side views of a pile driving apparatus, including a mast system in an extended configuration.

[0017] FIGS. 9 A and 9B are schematics illustrating engagement within the mast system shown in FIG. 5.

[0018] FIG. 10 is a top cross-sectional view of the mast system shown in FIG. 5.

[0019] FIG. 11 is a perspective view of a carriage assembly for use with a pile driving apparatus.

[0020] FIG. 12 is a perspective view of a hammer frame coupled to the carriage assembly shown in FIG. 11.

[0021] FIG. 13A is a perspective view of a track assembly for use with a pile driving apparatus, including a track cover.

[0022] FIG. 13B is a perspective view of the track assembly shown in FIG. 13 A, with the track cover removed.

[0023] FIG. 14A is a perspective view of the track assembly shown in FIG. 13B.

[0024] FIGS. 14B and 14C are side views of the track assembly shown in FIG. 14 A.

[0025] FIG. 15 is a schematic of a control system for use with a pile driving apparatus.DETAILED DESCRIPTION

[0026] There is a need for a pile driving apparatus that facilitates increasing the efficiency of driving piles into the ground at distinct locations. Specifically, there is a need for a pile driving apparatus that facilitates increased efficiency of movement and maintenance.

[0027] When introducing elements of various embodiments disclosed herein, the articles “a”, “an”, “the”, and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including”, and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.

[0028] Unless otherwise indicated, approximating language, such as “generally”, “substantially”, and “about”, as used herein indicates that the term so modified may apply to only an approximate degree, as would be recognized by one of ordinary skill in the art, rather than to an absolute or perfect degree. Accordingly, a value modified by a term or terms such as “about”, “approximately”, and “substantially” is not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to theprecision of an instrument for measuring the value. Additionally, unless otherwise indicated, the terms “first”, “second”, etc. are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer. Moreover, reference to, for example, a “second” item does not require or preclude the existence of, for example, a “first” or lower-numbered item or a “third” or higher-numbered item.

[0029] FIGS. 1, 2, and 3 are views of a pile driving apparatus 100. The pile driving apparatus 100 includes a base 102, a drive system 104, a control system 106 (shown in FIG. 15), a mast system 108, and a hammer system 110. The base 102 may include one or more base components welded together to form a mainframe of the pile driving apparatus 100. The mast system 108 includes a mast base assembly 112 and a mast assembly 114. The mast base assembly 112 is coupled to the base 102 and supports the mast assembly 114. The base 102 is oriented along a first horizontal axis 111 and the mast assembly 114 is oriented along a vertical axis 115, with the mast assembly 114 extending vertically from a horizontal plane created by the first horizontal axis 111 and a second horizontal axis 117 perpendicular to the first horizontal axis 111.

[0030] The hammer system 110 includes a carriage assembly 116, a hammer frame 118 coupled to the carriage assembly 116, and a hammer 120 housed within the hammer frame 118. The carriage assembly 116 is engaged with the mast assembly 114 for movement of the carriage assembly 116, and thus the hammer frame 118 and the hammer 120, along a length of the mast assembly 114 oriented parallel to the vertical axis 115.

[0031] The base 102 is oriented along a base axis 122, with a first base side 124 and a second base side 126 opposite the first base side 124. The first base side 124 and the second base side 126 each extend parallel to the base axis 122, with the base axis 122 extending along the first horizontal axis 111. The mast system 108 is positioned proximate the second base side 126, with the mast assembly 114 positioned outside of the periphery of the base 102 proximate the second base side 126. A housing 128 is supported by the base 102 and may be oriented perpendicular to the base axis 122, parallel to the second horizontal axis 117. The housing 128 may include one or more components of the control system 106 (shown in FIG. 15), in addition to an engine (not shown), one or more hydraulic pumps (not shown), a cooling system (not shown), and / or a battery (not shown).

[0032] The drive system 104 is coupled to the base 102 and is operable to move the base 102 in at least one direction of motion. The drive system 104 may include one or more trackassemblies 130 to move the base 102 on a surface. Each track assembly 130 may include a track cover 132. The control system 106 (shown in FIG. 15) is communicatively coupled to the drive system 104 to control the drive system 104, in that the control system 106 may control the drive system 104 to selectively move the base 102 between pile placement locations to drive a pile into the ground at each distinct pile placement location.

[0033] Mast System and Hammer System

[0034] FIG. 4 is a perspective view of the mast base assembly 112 and the mast assembly 114 of the mast system 108. The mast base assembly 112 includes one or more tilt cylinders 140, one or more side tilt cylinders 142, a mast slide frame 144, a mast pivot frame 146, and a mast raise frame 147. The one or more tilt cylinders 140 extend between the mast slide frame 144 and the mast pivot frame 146 at an angle to support the orientation of the mast raise frame 147 along the vertical axis 115. The one or more tilt cylinders 140 operate as actuators to raise the mast pivot frame 146, and thereby the mast raise frame 147, into the orientation along the vertical axis 115, pivoting about a first pivot pin 145 oriented parallel to the first horizontal axis 111. The mast slide frame 144 is coupled to the base 102 of the pile driving apparatus 100. The mast pivot frame 146 facilitates improved efficiency of operation of the pile driving apparatus 100, as the drive system 104 may operate at faster speeds when the mast assembly 114 is lowered (e.g., towards the second horizontal axis 117 and away from the vertical axis 115) by the mast pivot frame 146. The pile driving apparatus 100 may also be stowed with the mast assembly 114 lowered.

[0035] The mast pivot frame 146 includes a frame face 148 and a pair of frame sides 150 extending perpendicular to the frame face 148 along opposing edges of the frame face 148. The one or more side tilt cylinders 142 are oriented substantially parallel to the frame face 148 and positioned exterior to the pair of frame sides 150 to support the mast raise frame 147. The one or more side tilt cylinders 142 operate as actuators to tilt the mast raise frame 147 in relation to the second horizontal axis 117.

[0036] The mast base assembly 112 also includes a mast slide 152, a mast slide cylinder 154, and a mast frame cylinder 156. The mast slide cylinder 154 is oriented parallel to the mast slide frame 144 and operates as an actuator to move the mast slide 152 along the second horizontal axis 117, relative to the mast slide frame 144 and the base 102 of the pile driving apparatus 100. The mast frame cylinder 156 is oriented perpendicular to the mast slide cylinder 154 andoperates as an actuator to move the mast pivot frame 146 along the first horizontal axis 111 at a first pivot pin 145 and / or a second pivot pin 157.

[0037] The mast base assembly 112 also includes a mast raise cylinder 160 coupled to the mast raise frame 147 and an inner mast tube 161. The mast raise cylinder 160 moves the mast assembly 114 vertically along the vertical axis 115. The mast raise frame 147 is engaged with the frame face 148. The mast raise cylinder 160 is oriented parallel to the mast raise frame 147, extending from a first cylinder end 162 coupled to the mast raise frame 147 past an open frame end 164 of the mast raise frame 147. The inner mast tube 161 extends through an inner cavity of the mast raise frame 147, the inner mast tube 161 being movable relative to the mast raise frame 147 such that the inner mast tube 161 may be extended past the open frame end 164 of the mast raise frame 147.

[0038] The mast raise cylinder 160 extends past the open frame end 164 of the mast raise frame 147 to a second cylinder end 166 coupled to the inner mast tube 161 via a mast tube connector 168. Thus, when the mast raise cylinder 160 is extended relative to the open frame end 164 of the mast raise frame 147, the inner mast tube 161 is likewise extended through the mast raise frame 147 due to the coupling between the second cylinder end 166 of the mast raise cylinder 160 and the inner mast tube 161 at the mast tube connector 168. The inner mast tube 161 is coupled to the mast tube connector 168 at a first tube end 170 and to a mast base plate 172 at a second tube end 174 opposite the first tube end 170.

[0039] The mast assembly 114 includes a mast base tube 176, a mast cylinder 178 mounted within the mast base tube 176, and an outer mast tube 177 (shown in FIG. 5). The mast base tube 176 and the mast cylinder 178 are both oriented parallel to the mast raise frame 147, each extending along the vertical axis 115. The mast base tube 176 extends from a closed base tube end 182, coupled to the mast base plate 172, to an open base tube end 184, and includes one or more wear plates 186 proximate the open base tube end 184.

[0040] FIG. 5 is a perspective view of the mast system 108, including the outer mast tube 177 of the mast assembly 114. The outer mast tube 177 fits over the mast base tube 176 (shown in FIG. 4), extending along the vertical axis 115. The outer mast tube 177 is coupled to the mast cylinder 178 (shown in FIG. 4) housed within the mast base tube 176 (shown in FIG. 4) at a connection 187 at a top mast assembly end 189. The mast cylinder 178 (shown in FIG. 4) operates as an actuator to move the outer mast tube 177 along the vertical axis 115, relative to the base 102 of the pile driving apparatus 100.

[0041] FIG. 6 is a perspective view of the mast system 108 engaged with the hammer system 110. The hammer system 110 includes an upper roller 188, a lower roller 190, one or more carriage lowering chains 191, and one or more carriage raising chains 192. Each carriage lowering chain 191 is attached to the mast tube connector 168 at a first mast attachment point 193 and extends down along the outer mast tube 177 (e.g., along the vertical axis 115 towards the mast base plate 172) and around the lower roller 190 to attach to the carriage assembly 116 at a first carriage attachment point 194. Each carriage raising chain 192 is attached to the mast tube connector 168 at a second mast attachment point 195, extends up along the outer mast tube 177 (e.g., along the vertical axis 115 away from the mast base plate 172) and around the upper roller 188, and then extends down along the outer mast tube 177 (e.g., along the vertical axis 115 towards the mast base plate 172) to attach to the carriage assembly 116 at a second carriage attachment point 196. The hammer system 110 may include more than one of the carriage lowering chain 191 and the carriage raising chain 192. For example, as illustrated in FIG. 6, the hammer system 110 may include two pairs of carriage chains, each pair including the carriage lowering chain 191 and the carriage raising chain 192. The two pairs of carriage chains may be positioned along unique sides of the outer mast tube 177.

[0042] The carriage raising chain 192 operates to lift the carriage assembly 116, and thus the hammer frame 118 and the hammer 120, along the mast assembly 114 (e.g., along the vertical axis 115 away from the mast base plate 172). The carriage lowering chain 191 operates to lower the carriage assembly 116, and thus the hammer frame 118 and the hammer 120, along the mast assembly 114 (e.g., along the vertical axis 115 towards the mast base plate 172). The carriage assembly 116 includes one or more retainer plates 197 to hold the carriage assembly 116 against the outer mast tube 177 for raising and lowering the carriage assembly 116 along the mast assembly 114. The movement of the carriage assembly 116 along the outer mast tube 177 facilitates improved stability of the pile driving apparatus 100, as the carriage assembly is moving over a single tube to move the hammer frame 118 and the hammer 120 for driving piles into the ground.

[0043] The carriage chains (e.g., the carriage lowering chain 191 and the carriage raising chain 192) move the carriage assembly 116 up and down along the outer mast tube 177 based on the extension and retraction of the mast cylinder 178 (shown in FIG. 4). Specifically, the extension of the mast cylinder 178 (shown in FIG. 4) raises the outer mast tube 177 along the vertical axis 115 via the carriage raising chain 192 attached to the carriage assembly 116 at thesecond carriage attachment point 196. Conversely, the retraction of the mast cylinder 178 (shown in FIG. 4), assisted by gravity, lowers the outer mast tube 177 along the vertical axis 115 via the carriage lowering chain 191 attached to the carriage assembly 116 at the first carriage attachment point 194. In some embodiments, the carriage lowering chain 191 may be used to create downward force on the hammer system 110 to help drive the hammer system 110 downward when driving a pile into the ground.

[0044] FIG. 7A is a side view of the pile driving apparatus 100, including the mast system 108 in a lowered configuration. In the lowered configuration, the mast raise cylinder 160 is not extended, with the second cylinder end 166 proximate the open frame end 164 of the mast raise frame 147. FIG. 7B is a side view of the pile driving apparatus 100, including the mast system 108 in a raised configuration. In the raised configuration, the mast raise cylinder 160 is extended, with the second cylinder end 166 extended away from (e.g., upwards along the vertical axis 115) the open frame end 164 of the mast raise frame 147. The movement of the outer mast cylinder 178 may be controlled independently of the mast raise cylinder 160. That is, in both the lowered configuration and the raised configuration of the mast system 108, the outer mast tube 177 may not be extended. Therefore, the length dimension (e.g., along the vertical axis 115) of the mast assembly 114 may not change between the lowered configuration and the raised configuration of the mast system 108.

[0045] FIGS. 8A and 8B are side views of the pile driving apparatus 100, including the mast system 108 in an extended configuration. In the extended configuration, the mast raise cylinder 160 is extended and the outer mast tube 177 is extended, with a machine height of the pile driving apparatus 100 defined vertically between the top mast assembly end 189 and a surface 198 on which the pile driving apparatus 100 is being operated. The mast assembly 114 facilitates improved efficiency of operation of the pile driving apparatus 100, as the drive system 104 may operate at faster speeds when the outer mast tube 177 is lowered (e.g., along the vertical axis 115) from the extended configuration. For example, the drive system 104 may need to operate at decreased speeds when the mast system 108 in is the extended configuration with the outer mast tube 177 extended to facilitate improved stability of the mast system 108. That is, the one or more sets of telescoping tubes of the pile driving apparatus 100, including the outer mast tube 177 over the mast base tube 176 and the inner mast tube 161 through the mast raise frame 147, allows the hammer system 110 to be raised to accommodate larger piles,with the telescoping tubes extended, while also allowing the pile driving apparatus 100 to operate at faster speeds, with the telescoping tubes withdrawn.

[0046] In some embodiments, the machine height in the lowered configuration (shown in FIG. 7A) may be approximately 19 feet. Additionally, in the extended configuration (shown in FIGS. 8A and 8B), the carriage assembly 116, and thus the hammer frame 118 and the hammer 120, may be raised to a pile clearance height defined vertically between a bottom hammer end 199 and the surface 198 on which the pile driving apparatus 100 is being operated. The pile clearance height may be less than the machine height. In some embodiments, the pile clearance height, and thus the maximum length of pile that may be used with the pile driving apparatus 100, may be approximately 25.5 feet.

[0047] FIGS. 9 A and 9B are schematics illustrating engagement between the mast base tube176 and the outer mast tube 177 of the mast system 108. The outer mast tube 177 includes a slot 202 extending along a length of the outer mast tube 177. The slot 202 is oriented for access to the mast base tube 176 through the outer mast tube 177. For example, as the outer mast tube177 moves in relation to the mast base tube 176, access to hydraulics components and / or controls may be provided by the slot 202. The movement of the outer mast tube 177 in relation to the mast base tube 176 may facilitate increased efficiency in welding and assembling the mast assembly 114.

[0048] FIG. 10 is a top cross-sectional view of the mast system 108 and the hammer system 110. The mast base assembly 112 may include one or more base spring assemblies 204 to keep the inner mast tube 161 and the mast raise frame 147 pressed together as the inner mast tube 161 moves in relation to the mast raise frame 147. Each base spring assembly 204 may include a spring-loaded plate 206 in contact with the inner mast tube 161.

[0049] The mast assembly 114 may include one or more mast spring assemblies 208 to keep the mast base tube 176 and the outer mast tube 177 pressed together as the outer mast tube 177 moves in relation to the mast base tube 176. The mast spring assembly 208 may press on a wear plate 210 between the mast base tube 176 and the outer mast tube 177. In some embodiments, the wear plate 210 may be between the mast base tube 176 and the outer mast tube 177 on all sides of the mast assembly 114, with the one or more mast spring assemblies 208 only pressing on a subset of the sides of the mast assembly 114. In other embodiments, the wear plate 210 may be present between the mast base tube 176 and the outer mast tube 177 only on the sides of the mast assembly having the mast spring assembly 208.

[0050] Carriage Assembly and Hammer Frame of Hammer System

[0051] FIG. 11 is a perspective view of the carriage assembly 116. The carriage assembly 116 includes a carriage frame 301, one or more mounting plates 302, an extension member 304, one or more mounting members 306, one or more clamping assemblies 308, and a mounting pin 310. The one or more mounting plates 302 are oriented along the vertical axis 115 to be flush with, and engaged with, the sides of the outer mast tube 177 (shown in FIG. 6) of the mast assembly 114. The one or more mounting members 306 are also oriented lengthwise along the vertical axis 115, with a width extending along the second horizontal axis 117. Each mounting member 306 includes an aperture 312 sized to receive the mounting pin 310, and the one or more mounting members 306 are positioned to slide the mounting pin 310 through two or more apertures 312 to couple the hammer frame 118 to the carriage assembly 116.

[0052] Each clamping assembly 308 includes a top clamping member 314, a bottom clamping member 316, and a pivot clamping member 318. The pivot clamping member 318 is attached to the mounting member 306, such as by welding. The top clamping member 314 is pivotally coupled to the pivot clamping member 318 to pivot the top clamping member 314 relative to the first horizontal axis 111. The top clamping member 314 and the bottom clamping member 316 are shaped to form a mounting channel 320 therethrough when the top clamping member 314 is pivoted around the first horizontal axis 111 to be flush against the bottom clamping member 316. The channel 320 is sized to receive a tubular mounting member 322 (shown in FIG. 12) of the hammer frame 118 to couple the hammer frame 118 (shown in FIG. 6) to the carriage assembly 116.

[0053] FIG. 12 is a perspective view of the hammer frame 118 coupled to the carriage assembly 116. The hammer frame 118 includes a frame structure 324, a pair of frame extending members 326, and an aperture 327. The frame extending members 326 extend outwards from the frame structure 324 along the second horizontal axis 117. The tubular mounting member 322 is oriented perpendicular to, and extends between, the pair of frame extending members 326. When the hammer frame 118 is engaged with the carriage assembly 116, the tubular mounting member 322 of the hammer frame 118 is received by the channel 320 of the carriage assembly 116 and the clamping assemblies 308 of the carriage assembly 116 are secured around the tubular mounting member 322 of the hammer frame 118 to couple the hammer frame 118 to the carriage assembly 116. That is, the tubular mounting member 322 of the hammer frame 118 is received by the channel 320 and the top clamping member 314 is pivoted relative to thefirst horizontal axis 111 to be flush against the bottom clamping member 316. When engaged, the top clamping member 314 and the bottom clamping member 316 are pulled together by a securing pin 328 oriented through both the top clamping member 314 and the bottom clamping member 316 along the vertical axis 115.

[0054] The coupling of the hammer frame 118 to the carriage assembly 116 by the mounting pin 310 of the carriage assembly 116, through the aperture 327 of the hammer frame 118 and the pair of apertures 312 of the carriage assembly 116, and the tubular mounting member 322 of the hammer frame 118 facilitates improved stability of the hammer system 110. During operation of the pile driving apparatus 100, the hammer frame 118 and / or the carriage assembly 116 may be subjected to vibration. A coupling system between the hammer frame 118 and the carriage assembly 116 such as the coupling disclosed, utilizing the tubular mounting member 322 of the hammer frame 118 and the mounting pin 310 of the carriage assembly 116, facilitates stronger weldments to secure the hammer frame 118 and the carriage assembly 116 together to withstand vibration.

[0055] Additionally, the coupling of the hammer frame 118 to the carriage assembly 116 by the mounting pin 310 of the carriage assembly 116 and the tubular mounting member 322 of the hammer frame 118 facilitates more efficient removal of the hammer frame 118 from the carriage assembly 116. That is, removing the hammer frame 118 from the carriage assembly 116 requires removal of the mounting pin 310 and the one or more securing pins 328 of the carriage assembly 116, which may be performed at an operation location of the pile driving apparatus 100, instead of requiring disassembly at a machine manufacturing and / or repair location for components that are welded together. Removal of the mounting pin 310 and the one or more securing pins 328 of the carriage assembly 116 also facilitates more efficient removal and replacement of the pile driving means attached to the carriage assembly 116, allowing hammer frames 118 for various pile driving means to be mounted to the carriage assembly 116 of just one pile driving apparatus 100, such as if the pile driving apparatus 100 needs to switch between a hammer and a rotary drive to install piles into the ground.

[0056] Track

[0057] FIG. 13A is a perspective view of the track assembly 130, including the track cover 132. FIG. 13B is a perspective view of the track assembly 130, with the track cover 132 removed. The track assembly 130 includes a track 131 and a track frame 133. The track 131 extends around the track frame 133 between a pair of rollers 414. The track cover 132 mayfacilitate improved efficiency of operation of the pile driving apparatus 100, as the track cover 132 may keep debris from getting stuck in the interior of the track assembly 130. Additionally, the track cover 132 is removable, allowing protection from debris during operation of the pile driving apparatus 100 while also allowing access to the interior of the track assembly 130 when needed, such as for inspection and / or repair. The track cover 132 includes one or more engagement mechanisms 402 to secure the track cover 132 onto the track frame 133, allowing the track cover 132 to be put onto, and taken off of, the track assembly 130 without using tools.

[0058] FIG. 14A is a side perspective view, and FIGS. 14B and 14C are side views, of the track assembly 130. The track 131 includes a track guide component 404 to facilitate measurement of track tension. The track guide component 404 may be positioned in, and moved between, a first track guide position 403, as shown in FIGS. 14A and 14B, and a second track guide position 405, as shown in FIG. 14C. During operation of the pile driving apparatus 100, the track guide component 404 is positioned in the first track guide position 403, raised to support the track 131, as shown in FIGS. 14A and 14B. For tension measurement and adjustment, the track guide component 404 is moved to the second track guide position 405, as shown in FIG. 14C.

[0059] During operation of the pile driving apparatus 100, a top surface 406 of the track 131 may sag from a flat orientation 408 parallel to the first horizontal axis 111, as shown in FIG. 14C, to maintain proper track tension of the track assembly 130 using catenary sag. The track guide component 404 may be positioned in the second track guide position 405 with a distance 409 between a top surface 410 of the track guide component 404 and a flat plane extending 411 between a top middle apex 412 of each roller 414 showing the proper amount of catenary sag to maintain the desired track tension of the track 131. Thus, the track guide component 404 may facilitate more efficient operation of the track assembly 130, and the pile driving apparatus 100, as measuring the catenary sag using the track guide component 404 in the second track guide position 405 does not require disassembly of the track assembly 130, nor the use of a separate tool (such as a pressure gauge or a straight edge).

[0060] The track guide component 404 may be moved between the first track guide position 403 and the second track guide position 405 using one or more removable pins 416. Specifically, the one or more removable pins 416 may be used to position the track guide component 404 in the first track guide position 403, raised to the track 131, and the second track guide position 405, lowered to measure track tension. In the first track guide position 403,a track guide subcomponent 418 may be raised away from a bottom track guide plate 420, as shown in FIGS. 14A and 14B. In the second track guide position 405, the track guide subcomponent 418 may be lowered into contact with the bottom track guide plate 420, as shown in FIG. 14C.

[0061] Control System

[0062] FIG. 15 is a schematic of the control system 106 for use with the pile driving apparatus 100. The control system 106 includes a controller 510 in communication with the mast system 108, the hammer system 110, the drive system 104, and a plurality of sensors. The controller 510 includes a memory 512 and a processor 514. The memory 512 may be any device allowing information such as executable instructions and / or data to be stored and retrieved. The processor 514 may include one or more processing units to retrieve and execute instructions and / or data stored by the memory 512.

[0063] The control system 106 may use signals received from the plurality of sensors to control the pile driving apparatus 100. The plurality of sensors may include, but is not limited to, one or more positioning sensors 516 and one or more orientation sensors 518. The control system 106 may also use signals received from a server 524. The server 524 may be in communication with a computing device 526, such as, but not limited to, a user computing device.

[0064] The controller 510 may receive positioning data as related to the pile driving apparatus 100 from the one or more positioning sensors 516. The one or more positioning sensors 916 may include one or more position sensors, one or more proximity sensors, one or more infrared sensors, one or more ultrasonic sensors, one or more laser sensors, one or more magnetic position sensors, one or more linear position sensors, and / or any other sensors known in the art that facilitate the collection of positioning data as related to the various elements of the pile driving apparatus 100. For example, the one or more positioning sensors 516 may be oriented on the mast assembly 114 to determine the position of the mast assembly 114 in space and / or relative to the base 102, along the vertical axis 115, the first horizontal axis 111, and / or the second horizontal axis 117. The position of the mast assembly 114 may be determined by the one or more positioning sensors 516 while the pile driving apparatus 100 is in the lowered configuration, the raised configuration, and / or the extended configuration. That is, the position of the mast assembly 114 may be determined by the one or more positioning sensors 516 with the mast at any height up to the machine height with the mast assembly 114 fully extended.

[0065] Additionally, for example, the one or more positioning sensors 516 may be oriented on the carriage assembly 116 to determine the position of the carriage assembly 116 in space and / or relative to the base 102, along the vertical axis 115. The position of the carriage assembly 116 may be determined by the one or more positioning sensors 516 while the pile driving apparatus 100 is in the lowered configuration, the raised configuration, and / or the extended configuration. That is, the position of the carriage assembly 116 may be determined by the one or more positioning sensors 516 with the carriage assembly 116, and thus the hammer frame 118 and the hammer 120, fully raised on the outer mast tube 177.

[0066] The controller 510 may receive orientation data as related to the pile driving apparatus 100 from the one or more orientation sensors 518. The one or more orientation sensors 518 may include one or more angular orientation sensors, one or more infrared sensors, one or more ultrasonic sensors, one or more laser sensors, one or more inclinometers, and / or any other sensors known in the art that facilitate the collection of orientation data as related to the various elements of the pile driving apparatus 100. For example, the one or more orientation sensors 518 may be oriented on the mast assembly 114 to determine the orientation of the mast assembly 114 in space and / or relative to the base 102, as angularly measured from the vertical axis 115, the first horizontal axis 111, and / or the second horizontal axis 117. Additionally, for example, the one or more orientation sensors 518 may be oriented on the base 102 to determine the orientation of the base 102 in space and / or relative to the surface 198, as angularly measured from the vertical axis 115, the first horizontal axis 111, and / or the second horizontal axis 117.

[0067] The controller 510 may control the pile driving apparatus 100 based on data received from the one or more positioning sensors 516 and / or the one or more orientation sensors 518. For example, the controller 510 may determine the mast height using the one or more positioning sensors 516 oriented on the mast assembly 114 and / or the base 102. Additionally, for example, the controller 510 may determine the angle of the mast assembly 114 when extended using the one or more positioning sensors 516 oriented on the mast assembly 114 and / or the base 102. Further, for example, the controller 510 may determine the hammer height using the one or more positioning sensors 516 oriented on the carriage assembly 116 and / or the base 102. The controller 510 may also use the determined mast height, mast angle, and / or hammer height in combination. For example, an angle between the mast assembly 114 and the base 102, and / or a center of gravity of the mast assembly 114 and / or the pile driving apparatus 100, may be determined using one or more of these determined measurements.

[0068] The pile driving apparatus 100 is configured for operation under active control by an operator (e.g., a user). Additionally, the pile driving apparatus 100 may be configured for autonomous operation via the control system 106. For example, the controller 510 is configured to receive operating instructions from a user with active control of the pile driving apparatus 100. Active control of the pile driving apparatus 100 may be executed via a control unit 540 positioned on the pile driving apparatus 100, such as on a surface of the housing 128 (shown in FIG. 1). Active control of the pile driving apparatus 100 may also be executed via the computing device 526 communicatively connected to the server 524.

[0069] Additionally, for example, the controller 510 may be configured to autonomously control one or more operations of the pile driving apparatus 100. Autonomous control of the pile driving apparatus 100 may be for automated operation, such that active control by the user is maintained throughout operation with limited control transferred to the controller 510 for a specific subset of operation functions. Additionally, autonomous control of the pile driving apparatus 100 may be for semi-autonomous operation, such that a subset of operation functions may be controlled by the controller 510 and another subset of operation functions may be actively controlled by the user. Furthermore, autonomous control of the pile driving apparatus 100 may be fully autonomous, such that the controller 910 controls all machine safety-critical and operational-critical functions related to its defined operations without operator interaction.

[0070] Automated operation of the pile driving apparatus 100 may include the controller 510 receiving a command, via the control unit 540 and / or the computing device 526 through the server 524, to control the mast system 108, the hammer system 110, and / or the drive system 104. For example, the drive system 104 may be paused or stopped based on signals received by the controller 510, such as the angle, height, and / or center of gravity of the mast assembly 114. Additionally, for example, the drive system 104 may be controlled to move the pile driving apparatus 100 to a more stable position on the surface 198 based on signals received by the controller 510, such as the angle, height, and / or center of gravity of the mast assembly 114 and / or the orientation of the base 102. Further, for example, the drive system 104 may be controlled based on data indicative of a site plan and / or as received from a positioning system (such as, but not limited to, a GPS) to move and position the pile handling apparatus 100 as needed.

[0071] This written description uses examples to disclose the invention, including the best mode and to enable a person of ordinary skill in the relevant art to make and practice theinvention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims. Such other examples are 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 languages of the claims. Aspects from the various embodiments described, as well as other known equivalents for each such aspects, can be mixed and matched by one of ordinary skill in the art to construct additional embodiments and techniques in accordance with principles of this application.

Claims

WHAT IS CLAIMED IS:

1. A pile driving apparatus comprising: a base; a drive system connected to the base and operable to move the base in at least one direction of motion; a housing supported by the base, the housing comprising one or more components of a control system, wherein the control system is operable to control the drive system to selectively move the base in the at least one direction of motion; a mast system comprising a mast base assembly and a mast assembly, the mast assembly comprising an outer mast tube and a mast base tube within the outer mast tube; and a hammer system comprising a carriage assembly, a hammer frame removably coupled to the carriage assembly, and a hammer housed within the hammer frame, the carriage assembly being operably engaged with the outer mast tube of the mast assembly by one or more carriage chains, wherein the outer mast tube is operable to move in relation to the mast base tube to raise and lower the carriage assembly via the one or more carriage chains to raise and lower the hammer.

2. The pile driving apparatus of claim 1, wherein the mast base assembly comprises a mast raise frame and an inner mast tube within the mast raise frame, wherein the inner mast tube moves in relation to the mast raise frame and is operable to raise and lower the mast assembly.

3. The pile driving apparatus of claim 1, wherein the outer mast tube comprises a slot through which the mast base tube is accessed.

4. The pile driving apparatus of claim 1, wherein the control system is communicatively coupled to one or more sensors positioned on one or more of the mast assembly and the base to operate the mast system and the drive system.

5. The pile driving apparatus of claim 1, wherein the hammer frame is removably coupled to the carriage assembly by one or more removable pins.

6. A track assembly comprising: front and rear rollers; a track frame extending around the front and rear rollers and defining an interior of the track assembly; a track extending around the track frame; a track tensioning mechanism to set a tension of the track; and a removeable cover coupled to the track frame and encasing the interior of the track assembly.

7. The track assembly of claim 6, wherein the removeable cover is sized to encase both the front and rear rollers.

8. The track assembly of claim 6, wherein the removeable cover is secured to the track frame by one or more engagement mechanisms to removably secure the removeable cover to the track frame.

9. The track assembly of claim 8, wherein removal of the removeable cover from the track frame and application of the removeable cover to the track frame using the one or more engagement mechanisms does not require tools.

10. The track assembly of claim 6, wherein removal of the removeable cover allows for access to the front and rear rollers, the track frame, and the track tensioning mechanism.

11. The track assembly of claim 6, wherein the track defines an outer periphery of the track assembly, the removeable cover being sized to be within the outer periphery.

12. The track assembly of claim 6, wherein the track tensioning mechanism comprises a track guide positionable in first and second positions, the track guide in the first position serving to guide the track during operation and the track guide in the second position serving to measure and set the tension of the track.

13. The track assembly of claim 12, wherein the track guide is secured in the first position by pins.

14. The track assembly of claim 12, wherein the track defines an outer periphery of the track assembly, the track guide being within the outer periphery.

15. The track assembly of claim 12, wherein adjusting positioning of the track guide between the first and second positions does not require tools.

16. The track assembly of claim 12, wherein a track-contacting portion of the track guide extends through the removeable cover.

17. The track assembly of claim 12, wherein the track guide is mounted to the track frame.

18. The track assembly of claim 17, wherein the track guide is between the track frame and the track.

19. The track assembly of claim 17, wherein the track guide is within the interior of the track assembly between the front and rear rollers.

20. The track assembly of claim 19, wherein the track guide is within an upper portion of the interior of the track assembly.

21. A mounting system for use to mount a vibratory hammer on a pile driving apparatus, the mounting system comprising: a mast; a carriage assembly slidably mounted on the mast, the carriage assembly having a mounting member comprising a pair of apertures and a clamping assembly, the clamping assembly comprising a top clamping member, a bottom clamping member, and a pivot clamping member, the top clamping member being pivotally coupled to the pivot clamping member to bring the top and bottom clamping members together to form a mounting channel; a vibratory hammer frame having a tubular mounting member and an aperture, wherein coupling the vibratory hammer frame to the carriage assembly comprises: the tubular mounting member of the vibratory hammer frame being received in the mounting channel of the carriage assembly, with the top and bottom clamping members secured together around the tubular mounting member; anda securing pin being inserted into and secured within the pair of apertures of the mounting member of the carriage assembly and the aperture of the vibratory hammer frame.

22. The mounting system of claim 21, wherein the top and bottom clamping members are secured together with a fastener to create a compressive force to secure the top and bottom clamping members around the tubular mounting member of the vibratory hammer frame.

23. The mounting system of claim 21, wherein the vibratory hammer frame is removeable from the carriage assembly while the carriage assembly is mounted to the mast.

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