Soil Material Removal System

Abstract

A plasma drilling system comprising: a movable support structure including a controller; a mounting mechanism removably coupled to the movable support structure; and a plasma torch head coupled to the mounting mechanism, the plasma torch head being movable along two axes.

Description

[Technical Field]

[0001] (Related Applications) This application claims priority to U.S. Provisional Patent Application No. 63 / 442,762, filed February 1, 2023, which application is incorporated by reference in its entirety.

[0002] FIELD OF THE INVENTION The present invention relates to material removal, and more particularly to removing earthen material using one or more plasma torches. [Background technology]

[0003] Trench excavation systems are used to dig trenches for laying utility pipes and for other purposes. Modern trench excavation systems typically use a skid loader with a trench digging attachment, or a trench excavator. These tools generally use cutter teeth on a rotating chain to break up the ground and excavate the trench. However, such trench excavation tools are slow and difficult to maintain. [Brief explanation of the drawings]

[0004] The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings, in which like reference numerals refer to similar elements and in which:

[0005] [Figure 1A] 1 is a simplified diagram of an embodiment of a geological material removal system. [Figure 1B] FIG. 1 illustrates one embodiment of a plasma torching head on an excavator. [Figure 1C] FIG. 1B shows the excavator of FIG. 1A with the plasma torching head in a vertical orientation. [Figure 1D] FIG. 1B illustrates an embodiment of the plasma torching head of FIG. 1A. [Figure 1E] 1 illustrates one embodiment of a range of motion for a plasma torching head. [Figure 1F]10 illustrates an alternative embodiment of a plasma torching head coupled to a mounting mechanism. [Figure 2A] FIG. 1 illustrates one embodiment of a baffle with a plasma torching head. [Figure 2B] FIG. 1 is a side view of one embodiment of a baffle with a plasma torching head, the baffle being transparent. [Figure 2C] FIG. 1 is a front view of one embodiment of a baffle with a plasma torching head, the baffle being transparent. [Figure 2D] FIG. 10 illustrates another embodiment of a baffle with a plasma torching head. [Figure 2E] FIG. 10 illustrates another embodiment of a baffle with a plasma torching head. [Figure 2F] FIG. 10 illustrates another embodiment of a baffle with a plasma torching head. [Figure 3A] FIG. 1 illustrates an embodiment of a system. [Figure 3B] FIG. 1 illustrates one embodiment of a plasma torching head. [Figure 3C] FIG. 1 is a front view showing one embodiment of a plasma torching head. [Figure 3D] FIG. 1 is a front view showing one embodiment of a three-torch plasma torching head. [Figure 3E] An alternative embodiment of a plasma torching head 380 is shown. [Figure 4A] FIG. 1 is a perspective view illustrating one embodiment of a plasma torching head and mounting mechanism. [Figure 4B] FIG. 1 is a side view illustrating one embodiment of a plasma torching head and attachment mechanism. [Figure 4C] FIG. 1 is a front view of one embodiment of a plasma torching head and mounting mechanism. [Figure 4D] FIG. 1 is a rear view of one embodiment of a plasma torching head and attachment mechanism. [Figure 5A] FIG. 1 illustrates one embodiment of a protective casing for a plasma torch. [Figure 5B] FIG. 5B shows the inside of the protective casing of FIG. 5A, with the casing being transparent. [Figure 5C] FIG. 10 illustrates one embodiment of a torch extension adjuster. [Figure 5D] FIG. 10 illustrates one embodiment of a torch extension adjuster. [Figure 6] 1 is a diagram of an embodiment of an air / water ejection device. [Figure 7] 10A-10C illustrate an embodiment of an attachment mechanism. [Figure 8A] FIG. 1 illustrates one embodiment of a vacuum head that may be used with the present system. [Figure 8B] FIG. 1 illustrates one embodiment of a kiln that may be used with the present system. [Figure 8C] FIG. 1 illustrates one embodiment of a kiln that may be used with the present system. [Figure 9A] 1 illustrates torch head embodiments showing various numbers of torches. [Figure 9B] 1 illustrates torch head embodiments showing various numbers of torches. [Figure 9C] 1 illustrates torch head embodiments showing various numbers of torches. [Figure 9D] FIG. 1 illustrates one embodiment of a vertical triple torch head torch arrangement. [Figure 9E] FIG. 9E is a side view of the view of FIG. 9D showing the movable outer torch. [Figure 9F] 1A-1C are diagrams of two exemplary configurations of a multi-torch arrangement having different torch sizes. [Figure 9G] 1A-1C are diagrams of two exemplary configurations of a multi-torch arrangement having different torch sizes. [Figure 10A] FIG. 1 illustrates one embodiment of system connections. [Figure 10B] FIG. 10 illustrates another embodiment of the system connections. [Figure 11] 1 is a flow chart of one embodiment of using the geological material removal system. [Figure 12]1 is a flow chart of one embodiment using a geological material removal system with a movable baffle. DETAILED DESCRIPTION OF THE INVENTION

[0006] An earth material removal system using one or more plasma torches is described. The earth material removal system includes a movable element having a plasma torch head coupled thereto. In one embodiment, the plasma torch head is designed to move and can be used at various angles between a horizontal and a vertical setting, and in one embodiment, can rotate up to 360 degrees. In one embodiment, the plasma torch head has six degrees of freedom. In one embodiment, the movable element is a mechanical arm coupled to an excavator or other heavy machinery. In another embodiment, the mechanical arm can be attached to a tractor or other equipment.

[0007] In one embodiment, the plasma torch head can be used with a baffle. A baffle is a partial or complete enclosure designed to control the dispersion of debris from material removal. The baffle can include rails along which the plasma torch head can move. The plasma torch head can also move up and down within the baffle to vary the offset distance between the plasma torch and the earthen material.

[0008] In one embodiment, the plasma torch head includes one or more plasma torches. In one embodiment, each plasma torch in the plasma torch head is surrounded by a protective casing. In one embodiment, a protective rod extends along part or all of the plasma torch. In one embodiment, the protective rod is designed to collapse if the torch is impacted and is designed to be field replaceable. In one embodiment, these protective rods are also used to direct air / water flow to the surface being removed.

[0009] The following detailed description of embodiments of the present invention refers to the accompanying drawings, in which like reference numerals indicate like elements and in which are shown, by way of illustration, specific embodiments in which the present invention is practiced. The description of these embodiments is in sufficient detail to enable those skilled in the art to practice the invention. Those skilled in the art will understand that other embodiments may be utilized and that logical, mechanical, electrical, functional, and other changes may be made without departing from the scope of the present invention. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims.

[0010] 1A is a simplified diagram of one embodiment of a geological material removal system. The geological material removal system 100 is designed to remove material using one or more plasma torches to excavate trenches, tunnels, or other structures. The term geological material refers to soil, earth, rock, metals, and other materials that make up the earth. In one embodiment, geological material may also include man-made materials, including cement. Removal of such materials is by breaking, crushing, fracturing, melting, and physical removal.

[0011] System 100 supports plasma torching head 101, which in this illustration is removing material to form a trench. Plasma torch head 101 may include one or more plasma torches. The plasma torches may be of various sizes / power levels. In one embodiment, the power of the plasma torches may range from 100 KW to 10 MW. However, other power levels may also be used.

[0012] The mechanical arm 102 provides multiple degrees of freedom, so the plasma plume can be positioned at various angles, depths, and positions. In one embodiment, the mechanical arm 102 combined with the plasma torching head 101 and vehicle 104 provides a full six degrees of freedom. The mechanical arm 102 is supported by a generator 103. The generator not only provides power to the plasma torching head 101 but also provides cold water / air to cool the plasma torch and, optionally, the soil material, thereby increasing the effectiveness of the plasma torch. In one embodiment, the nest 105 contains the remaining plant equipment. Such equipment may include one or more of a power supply, a transformer, a cooler, an air compressor, a pump, a motor, and / or a processor that provides control signals and analysis of sensor data. The vehicle portion 104 is designed to move the entire system 100, including the generator, nest, and mechanical arm. The illustrated configuration with a separate nest 105, generator 103, and vehicle 104 is merely an exemplary embodiment. Other configurations may integrate these elements into a single system, or may further separate the elements into additional elements that are not directly interconnected.

[0013] 1B illustrates one embodiment of a plasma torch head on an excavator. In this example, the plasma torch head 130 is coupled to a movable arm 115 of the excavator 110. In one embodiment, the mounting mechanism 120 provides movement about the Y axis, while the movable arm 115 provides movement along the X and Z axes. In one embodiment, the mounting mechanism 120 also provides some movement about the X axis, allowing the plasma torch head 130 to rotate downward.

[0014] Additionally, the excavator 110 provides locations for multiple sensors and / or cameras 150. In one embodiment, a sensor support bar 160 extends from the movable arm 115 to provide positioning for one or more sensors and / or cameras 150. Furthermore, in one embodiment, additional cameras / sensors 150 may be coupled to the movable arm 115 and / or the plasma torching head 130. The sensors / cameras 150 are positioned so that they can sense the area where material is being removed without being damaged by the hot plasma plume, debris, steam, or water. In one embodiment, some sensors may be hardening sensors located on or closer to the plasma torching head 130. Sensors may include, for example, cameras with and without fisheye lenses, infrared sensors, temperature sensors, ground-penetrating radar, LIDAR, SONAR, gas sensors to identify the presence of hazardous gases, gas sensors to determine the mineralogy of the rock or material being removed, molecular scanners for mineralogy analysis, moisture sensors, humidity sensors, and other sensors. In one embodiment, some or all of these sensors may be located within the excavator 110 or other parts of the system. In one embodiment, the sensors / cameras 1505 may be wirelessly coupled to an analysis system (not shown). In another embodiment, the sensors / cameras 150 may be coupled via cables or other connections. In one embodiment, there may be a receiving station that receives data from the sensors / cameras 150. In one embodiment, processing of the sensor / camera data may be performed by a processor within the excavator 110 and / or remotely at a server.

[0015] In one embodiment, the excavator 110 also provides various supplies to the plasma torching head 130, which may include power and cooling for the plasma torch and water and / or air for cooling the area where material is being removed. Additionally, the excavator 110, or a controller 155 located within the excavator, configures the plasma torch head, analyzes sensor data, and provides feedback to the user and the plasma torch head 130. In one embodiment, the controller 155 may include a local processor or computing system and / or a processor and computing system accessed over a network and remote from the site. Additionally, the excavator 110 may include a global positioning system (GPS), gyroscope, accelerometer, and / or other navigation sensors. In one embodiment, the controller 155 system may receive mapping data indicating the presence of existing underground structures. In one embodiment, some of the sensors may be used to identify such structures, which may be added to the map by the controller 155.

[0016] 1C illustrates the excavator of FIG. 1A with the plasma torching head 130 in a substantially vertical orientation. In one embodiment, the movable arm 115 can position the plasma torching head 130, with the mounting mechanism 120 providing additional positioning capabilities. In one embodiment, the movement of the plasma torching head 130 is limited so that the plasma plume cannot extend toward the excavator 110 or the support structure.

[0017] FIG. 1D is another view of one embodiment of the plasma torch head 130 of FIG. 1A. The mounting mechanism 120 includes an attachment to the movable arm 115 and a support element 160 to which the plasma torch head 130 is coupled. In one embodiment, the support element 160 includes an angle adjustment point 165 that allows the plasma torch head to rotate downward and upward. In one embodiment, the angle adjustment point 165 limits the movement of the plasma torch head 130 to ensure that the plasma plume cannot strike the movable arm 115 or the support structure. In one embodiment, the angle adjustment is controlled via a motor, actuator, or other mechanism (not shown). In one embodiment, a controller 155 controls the movable arm 115 and the mounting mechanism 120 to position the plasma torch head 130 at a selected angle. In one embodiment, the angle can range from horizontal (as shown) to vertical. In one embodiment, the mounting mechanism may also allow the plasma torch head 130 to move left and right. 1E shows one embodiment of the range of motion of the plasma torch head. In one embodiment, the movement of the plasma torch head 130 can be 360 ​​degrees around the Y axis and 90 to 270 degrees around the X axis.

[0018] FIG. 1E shows an alternative embodiment of a plasma torch head 170 coupled to a mounting mechanism 120. The mounting mechanism 120 is coupled to a mechanical arm. A plasma torch 175 is coupled to a carriage 180. In one embodiment, the coupling uses a quick clamp 190, which allows the plasma torch 175 to be removed and replaced as needed. The carriage 180 can move along rails 185 to change the offset of the plasma torch 175 from the material being removed. In one embodiment, the carriage 180 is moved by an actuator 187. In one embodiment, the plasma torch head 170 has a shield 177 in front of it, through which the plasma torch extends. In one embodiment, the shield protects the plasma torch head 170 and reflects heat from the plasma torch 175 to improve cutting efficiency and protect the plasma torch head.

[0019] FIG. 2A illustrates one embodiment of a baffle with a plasma torch head. The baffle 210 contains debris. In this configuration, a mounting mechanism 235, used to couple the system to the excavator, is coupled to the baffle 210. The baffle contains debris generated by the plasma torch. In one embodiment, dispersion slots 215 allow the debris to escape from the baffle 210. In one embodiment, the plasma torch head 225 is oriented downward and moves along a head support rail 230. In one embodiment, a drive mechanism 222 moves the plasma torch head 225 along the rail 230 and also up and down along the head support 220. The plasma torch head 225 can move up and down within the head support 220 to change the offset between the plasma torch and the ground.

[0020] This configuration of the system is designed to place the baffle 210 in a first position and then move the plasma torch head along the rail 230, possibly repeatedly, to remove material to the appropriate depth. The baffle 210 is then moved to the next position to continue removing material.

[0021] 2B is a side view of one embodiment of a baffle with a plasma torch head, with the baffle being transparent. In this configuration, as can be seen, the front of the plasma torch 240 extends below the bottom of the baffle. The plasma torch head support 220 allows for up and down movement of the plasma torch 240. In one embodiment, the plasma torch 225 is moved downward as more material is removed. As mentioned above, the controller sets the offset between the front of the plasma torch 240 and the ground. This distance can be set based on the depth of material to be removed and the composition of the soil material.

[0022] 2C is a front view of one embodiment of a baffle with a plasma torching head, with the baffle being transparent. One embodiment of dispersion slots 215 can be seen. As the plasma plume disrupts the ground, debris is thrown upward, where it can exit the baffle 210 through the dispersion slots 215. However, the majority of the debris is handled by a vacuum system, which will be described later.

[0023] 2D illustrates another embodiment of a baffle with a plasma torch head. In this configuration, a mounting mechanism 247 is coupled to a plasma torch head support 250. The plasma torch head can move up and down in this configuration, but it does not move along with the baffle 245. Thus, a mechanical arm moves the plasma torch head 252, and with it, the baffle 245. The baffle 245 moves along a rail or road using wheels 260 or another mechanism for movement. This configuration of the system is designed to position the baffle 245 in a first position and then move the baffle and plasma torch head along rails 265, possibly repeatedly, to remove material to the appropriate depth, with the horizontal movement of the plasma torch head 252 controlled directly by the mechanical arm via the mounting mechanism 247.

[0024] FIG. 2E illustrates another embodiment of a baffle with a plasma torch head. In this configuration, the baffle 280 is pulled by a tractor 270 or other motorized system using wheels or another mechanism to enable movement. In one embodiment, the plasma torch head 285 moves along rails on the baffle 280. In another embodiment, the plasma torch head 285 may be stationary within the baffle and move only up and down, with horizontal movement provided by the tractor 270 pulling the baffle 280. The attachment mechanism 275 in this embodiment is relative to the baffle 280. This configuration of the system is designed to place the baffle 280 in a first position and then move the plasma torch head along the rails, possibly repeatedly, to remove material to the appropriate depth. The baffle 280 is then moved to the next position to continue removing material.

[0025] 2F illustrates another embodiment of a baffle with a plasma torching head. In this configuration, the baffle 297 is part of a robotic self-mobility system 295. The system 295 can position the baffle 297 and move it using roads or rails, or other mechanisms. In one embodiment, power / water and other supplies for the system 295 can be provided by a separate supply system 290. In one embodiment, supplies are provided to the robotic self-mobility system 295 via an umbilical connection 292 between the supply system 290 and the robotic self-mobility system 295. In another embodiment, the robotic self-mobility system 295 can be a single integrated system. In one embodiment, such an integrated system can have connections to an external fixed supply system 290 for water / power / resource / control systems.

[0026] FIG. 3A is a block diagram illustrating one embodiment of the system. The movable support structure 310 in one embodiment can be any system that provides power and materials to the system. As noted above, the support structure 310 can be one or more combinations of an excavator, a tractor, or another type of vehicle, and / or a baffle in some embodiments. In one embodiment, the controller 305 can include a control system, such as a computer system, for analyzing data from the cameras and sensors and controlling system settings. The controller 305 can include memory and / or buffers for storing control software and status data, as well as sensor data. In one embodiment, the memory can include a local area map that provides information about existing underground piping and wiring, thereby ensuring that the system does not damage existing infrastructure. The supply controller controls the output from the power source and materials to the umbilical, including water and other materials delivered to the plasma torching head 330.

[0027] In one embodiment, the control system, supply controller, and memory may be remote from the movable support structure and coupled to the movable support structure 310 via a network connection. In one embodiment, the movable support structure 310 may include some of the elements of the control system, but the analysis may be performed on the remote system.

[0028] A power supply, in one embodiment, provides power to the plasma torch, as well as pumps and other electrically powered elements. Pumps and coolers are used to provide cool water and / or air to cool the plasma torch. In one embodiment, pumps and optional coolers are used to direct jets of water and / or air into the ground to assist in breaking up the rock. The temperature difference between the cooling jets and the heat of the plasma plume helps to break up the rock.

[0029] In one embodiment, the movable support structure 310 includes a mechanical arm 315 that moves the plasma torch head 330. In one embodiment, the mechanical arm 315 is the arm of an excavator. In another embodiment, the mechanical arm 315 can be any structure that provides multiple degrees of freedom to which the plasma torch head can be coupled. In another embodiment, the mechanical arm can be replaced by a head support rail and head support of a baffle.

[0030] An attachment mechanism 320 couples the plasma torching head 330 to the mechanical arm 315. An umbilical connection 325 provides supplies to the plasma torch, including water and / or other materials for cooling and power. In one embodiment, the umbilical 325 also provides data from sensors to the controller 305.

[0031] In one embodiment, camera / sensor bar 343 extends on either side of plasma torch head 330 and provides a location for one or more cameras and / or sensors 340. In one embodiment, the relative locations of cameras / sensors 340 are based on their ability to withstand the high temperatures generated by plasma torch 345. In one embodiment, camera / sensor 340 may be constrained to camera / sensor bar 343, movable support structure 310. In another embodiment, camera / sensor elements 340 may be outside baffle 337 or inside baffle 337. Baffle 337 in one embodiment is an enclosure for plasma torch 345, providing protection for the torch and providing protection from flying stones or other particulate matter.

[0032] In one embodiment, in addition to the baffle 337, the plasma torch 345 is further protected by a protective casing 335. In one embodiment, the protective casing 335 is a metal enclosure designed to protect the plasma torch. In other embodiments, the protective casing 335 may be made of other materials. In one embodiment, each plasma torch has a separate protective casing 335. In one embodiment, the protective casing 335 also maintains heat dissipation to reduce heat.

[0033] As shown in FIG. 3A , in one embodiment, the plasma plume 347 extends horizontally, and in a different embodiment, the plasma plume extends vertically from the plasma torching head 330. A configuration in which the plasma plume points forward may be more useful for some trenching or tunneling applications. The design of the present invention may be used for tunneling, trenching, drilling, etc. In one embodiment, the angle of the plasma plume 347 may be rotated to any angle between horizontal and vertical. In one embodiment, the angle may also point upward.

[0034] FIG. 3B illustrates one embodiment of a plasma torching head. This view shows the head 340 as transparent and does not show the plasma torch enclosed within the head. In one embodiment, a protective casing 335 includes a pair of field-replaceable tubes 350 that enclose some or all of the plasma torch. The tubes 350 are designed to protect the plasma torch from impact or damage. In one embodiment, the tubes 350 can also be used to provide mechanical force for material removal. In one embodiment, the tubes 350 can be used to scrape away material reduced by the plasma torch.

[0035] Additionally, in one embodiment, head 340 may include a side vacuum inlet 365 designed to vacuum debris from the plasma torch. In one embodiment, the debris includes small stones resulting from spalling, as well as molten rock and other materials. In one embodiment, vacuum inlet 365 includes a cooling mechanism to rapidly reduce the temperature of the material being vacuumed to prevent damage to the umbilical hose. In one embodiment, the end of the vacuum inlet is provided with a scraper 360, which may also be used to provide mechanical force to remove the material.

[0036] In one embodiment, head 340 also includes a discharge device 375 that provides cooling to the material being removed. In one embodiment, discharge device 375 intermittently sprays cooling water, mist, or air onto the material being removed by the plasma torch. In one embodiment, plasma torch offset adjuster 370 allows for movement of the plasma torch within head 340 to change the offset and position of the plasma torch for optimal cutting.

[0037] FIG. 3C is a front view of one embodiment of a plasma torching head. The front view shows a plasma torch 345 and several field-replaceable tubes 350. In one embodiment, the tubes are made of copper and are designed to be easily removed and replaced without special tools. In this embodiment, the field-replaceable tubes 350 extend only along a portion of the circumference of the plasma torch. In some embodiments, the tubes 350 can completely surround the plasma torch. In one embodiment, these tubes 350 are designed to protect the plasma torch from damage caused by soil debris. In one embodiment, the tubes can also be used to scrape away material that has been impacted by the plasma plume but has not completely crumbled. Rocks and earth become more friable after impact and, in one embodiment, can be scraped away using these tubes. Additionally, the tubes can be used to direct water and / or air to cool the ground. In one embodiment, water mixed with air is used in the form of a mist that is sprayed onto the earthen material being acted upon by the plasma torch. In some embodiments, the tube only surrounds the plasma torch closest to the ground, as shown in FIG. 3D.

[0038] FIG. 3E shows an alternative embodiment of a plasma torch head 380. The plasma torch head is coupled to a movable support structure using a mounting mechanism 382. This structure does not utilize a protective shell around the plasma torch, allowing for a smaller penetration area as the torch advances through the shield. The plasma torch 384, in one embodiment, is coupled to a carriage 386 using a quick clamp 390. In one embodiment, the quick clamp is a two-piece collar that allows for quick removal and replacement of the plasma torch. The carriage 386 can move back and forth along rails 388 to move the head of the plasma torch 384 and change the offset between the plasma torch and the material being removed.

[0039] In one embodiment, the plasma torch head 380 further includes dischargers 394, 396 that supply air and / or water to the area being worked on. In one embodiment, the head 380 includes one to four air lines using the air discharger 394 and one to four water lines using the water discharger 396. In one embodiment, the dischargers 394, 396 are flexible. In one embodiment, the dischargers 394, 396 can be positioned differently for different types of rock surfaces. In one embodiment, the output of the dischargers 394, 396 is computer controlled to provide pulsed water and / or air to the torch / material interface for cooling and fragmentation. In one embodiment, the output of the dischargers 394, 396 can be manually controlled.

[0040] In one embodiment, the length of the head 380 provides support for the hoses and umbilicals that power the plasma torch, the movement mechanism, the discharge devices, and other parts of the head.

[0041] FIG. 4A is a perspective view illustrating one embodiment of a plasma torch head and mounting mechanism. In this configuration, a plasma torch head 410 is supported by a hinged head frame 440 coupled to a mounting mechanism 415. The plasma torch includes a plasma torch head 420 and an umbilical mounting point 445 for power supply. In the illustrated embodiment, the plasma torch is protected by a protective casing 430. In one embodiment, an additional replaceable tube 435 surrounds the entire plasma torch head 420. As mentioned above, in some embodiments, the replaceable tube may extend only along a portion of the plasma torch head 420. In another embodiment, the tube may be omitted. In one embodiment, the hinged head frame 440 allows the plasma torch to tilt, providing additional movement about the X-axis.

[0042] Figure 4B is a side view of one embodiment of the plasma torch head and attachment mechanism of Figure 4A. The protective casing 430 is transparent to reveal the replaceable tube 435 within the casing. The umbilical attachment point 445 is shown in more detail, showing the separate connections for power, air, water, and control signals. Figure 4C is a front view of the plasma torch head and attachment mechanism of Figure 4A, and Figure 4D is a rear view of one embodiment of the plasma torch head and attachment mechanism of Figure 4A. The particular embodiment shown is not intended to be limiting, and the configuration of specific components may be varied without departing from the invention.

[0043] Figure 5A shows one embodiment of a protective casing for a plasma torch, with the casing being transparent, and Figure 5B shows the interior of the protective casing of Figure 5A, with the casing being transparent. The protective casing provides an enclosure, which in one embodiment is made from a heat-resistant metal. The protective casing also provides a structure for air / water control 530, which sprays cold water and / or air onto the torch / material interface to cool the material being removed and improve the effectiveness of the plasma torch in breaking down the material.

[0044] 5C-5D illustrate one embodiment of a torch extension adjuster. Protective casing 510 includes an adjustment mechanism that allows the plasma torch to move within the protective casing. In one embodiment, the adjustment mechanism is a torch extension adjuster 540 that includes two screws on each side of protective casing 610. In one embodiment, torch extension adjuster 540 is adjusted manually. In another embodiment, torch extension adjuster 540 can be adjusted automatically using an actuator (not shown).

[0045] FIG. 6 illustrates one embodiment of a dispensing device. Dispensing device 610 includes an input 620 and an output 630. In one embodiment, the input receives air and / or water from an umbilical coupled to the plasma torch head. The output is designed to output water / air onto the plasma plume / material interface. In one embodiment, the air / water supplied to the input is cooled. In one embodiment, output 630 includes a valve for pulsing the air / water. In another embodiment, an air / water control in the umbilical supplying the air / water is used to control the intermittent pulsing of material.

[0046] FIG. 7 illustrates one embodiment of a mounting mechanism. The mounting mechanism 710, in one embodiment, includes a power system mount 720 coupled to a mechanical arm. The mechanical arm mount, in one embodiment, has a rotatable base 730, allowing a hinged head frame 740 to rotate about the Y axis. The hinged head frame 740 supports a plasma torch head (not shown). Additionally, a mechanical travel limiter 750 allows the plasma torch head to rotate about the X axis while limiting travel to ensure the plasma plume does not intersect with the support structure.

[0047] 8A illustrates one embodiment of a vacuum head that may be used with the present system. In one embodiment, the vacuum head 810 is coupled to the front of the structure supporting the plasma torching head to remove debris. In one embodiment, the vacuum head is positioned directly below the torch to remove debris closest to the torch. In some embodiments, additional vacuum inlets and vacuum heads may be provided in the system.

[0048] The debris in one embodiment can be liquid (lava), pebbles, and sand-like material. Vacuum head 810 is powered through an umbilical and pulls in the debris. In one embodiment, the debris is cooled within vacuum head 810 and then directed to vacuum outlet 825 and through an umbilical connection. In one embodiment, the material within vacuum head 810 is rapidly agitated to form a continuous stream of debris. In one embodiment, the material swirls as it cools. In one embodiment, the cooling and agitation is accomplished using water. Water inlet 820 is where water is injected into a nozzle to cool the lava that is sucked into vacuum head 810.

[0049] In one embodiment, the by-products or waste of the process removed by the vacuum system can be used in trenching or tunneling applications, or other applications. In one embodiment, the waste is rapidly cooled while being agitated, forming sharp sand useful in construction.

[0050] 8B-8C illustrate one embodiment of a kiln that can be used with the present system. In one embodiment, kiln 840 is used to concentrate energy when the plasma torch is first turned on, before a hole in the rock face that will contain the plasma plume is created. In one embodiment, kiln 840 is made of insulating material with a refractive interior to concentrate energy from the plasma plume. In one embodiment, kiln 840 has a rock face attachment side 845 that attaches to the rock face. In one embodiment, attachment may be by pressure (e.g., the plasma torch head holds the kiln in place by pressure), adhesive, or other means. In one embodiment, the kiln includes a notch 850 through which debris, including lava (molten rock), can escape. In one embodiment, the kiln is used only until the initial hole is created in the rock. After the initial hole is created, the kiln can be removed.

[0051] 9A-9C show embodiments of plasma torch heads showing various numbers of torches. FIG. 9A shows a dual torch head 910 with two plasma torches side-by-side. In addition to horizontal dual torch heads, in some embodiments, systems may use vertical dual torch heads with two plasma torches arranged one above the other. FIG. 9B shows a triple torch head 920, and FIG. 9C shows a quad torch head 930. Other arrangements of two or more torch heads may also be used.

[0052] 9D illustrates one embodiment of a vertical triple torch head torch arrangement. The vertical triple torch head 940 includes three torch heads, a larger torch head in the middle and two smaller torch heads on either side. In this illustration, the size of the torch heads reflects the power output by the torch heads. Thus, in this configuration, the center torch is driven with more power than the two side torches. This configuration, in one embodiment, can be useful for drilling trenches that are deeper in the middle than on the sides.

[0053] 9E is a side view of the view of FIG. 9D showing the movable outer torch. In one embodiment, the movable outer torch 945 can be rotated about the X axis so that the output from the outer torch extends at an angle. This allows the vertical triple torch head 940 to cut trenches wider than the width of the torch head 940.

[0054] 9F-9G are diagrams of two exemplary configurations of a multi-torch arrangement with different torch sizes. The exemplary sizes can vary depending on the application. In one embodiment, the quick clamp configuration of the torch head allows for different sized plasma torches to be optimally positioned for the type of trench, tunnel, or other structure being created.

[0055] 10A is a diagram illustrating one embodiment of the system connections. In one embodiment, the system includes:

[0056] a power supply 1010, i. 1011 AC power supply; ii. 1012 DC power supply; and iii. 1013 Power System (PS) Heat Sink; a power supply 1010 having a

[0057] 1. A water supply system 1020, comprising: i. 1021 Cooling System (CS) Heatsink, ii. 1022 low pressure cooling loop; iii. 1023 Low Pressure (LP) Pump; iv. 1024 high pressure pump torch cooling water, v. 1025 Heat exchangers, and vi. 1026 High Pressure (HP) Pumps, a water supply system 1020 having a

[0058] 1. A torch system 1030 comprising: i. 1031 Visual camera and sensor systems (340); ii. 1032 Umbilical (325), iii. 1033 Mobile heavy machinery (310), iv. 1034 a movable baffle box (337) having a protective casing (335); v.1035 A plasma torch (345) having a head (330), vi. 1036 Torch mount having a controllable arm (315) with a rotating hinged mounting portion (320); vii. 1037 Air compressors, and viii. 1038 Combiner Junction Box (optionally provided to allow separation of water and power); and a torch system 1030 having a

[0059] 10B shows an alternative embodiment in which the combiner junction box 1038 is removed and the water and power are directed to the plasma torch 1035. In this configuration, the water and power interfaces are combined at the torch 1035, eliminating the need for a junction box.

[0060] 11 is a flow chart of one embodiment of using the plasma torch system. In one embodiment, the system may be used for tunnel boring, trenching, excavation, or other uses where the plasma torch moves through soil, rock, earth, or other material. The process begins at block 1110.

[0061] In block 1115, the number, size, offset, and angle of the plasma torches are determined. In one embodiment, the determination depends on the shape and location of the material to be removed and the earth material that the plasma torches will remove. In one embodiment, the torch size depends on the size and shape of the material to be removed, and in a multi-torch torch head, the relative sizes of the torches are also determined. The offset is the distance between the front of the plasma torch and the earth material. The angle determines the angle of the torch head and therefore the angle of the plasma torch. In one embodiment, for trench excavation, the initial angle may be a 90-degree angle with respect to the earth material to be removed for the trench, i.e., the plasma torch may be perpendicular.

[0062] In block 1120, various settings of the torch are set based on the determination.

[0063] The angle and speed of the movement are selected based on the material to be removed and the size of the intended area in block 1125. In one embodiment, the number of movements to dig the trench is also considered.

[0064] At block 1130, the process determines whether a kiln is required. The kiln is optionally used to concentrate energy during the initial stages of drilling into the rock before cavities are formed in the rock material. If a kiln is used, then at block 1135, the kiln is set up. In one embodiment, setting up the kiln includes positioning the kiln on the rock face where drilling will begin. The process then proceeds to block 1140. If a kiln is not used, then the process proceeds directly to block 1140.

[0065] At block 1140, material is removed using a plasma torch. In one embodiment, the plasma torch is moved back and forth. In one embodiment, the speed of movement depends on the composition of the earth material being removed and the power of the plasma torch. In one embodiment, the plasma torch remains in one location and is moved only after the material at the current location has been successfully removed.

[0066] At block 1150, the process optionally determines whether any of the sacrificial tubes are damaged. In one configuration, the plasma torch head is surrounded by a sacrificial tube that can be easily replaced if damaged. In one embodiment, this determination is made by manual inspection. In another embodiment, a camera is used to monitor the shape and configuration of the sacrificial tube, and the system automatically determines whether there is a deviation from the expected configuration that would indicate damage. If at block 1150, it is determined that any of the tubes are damaged, the process proceeds to block 1155. At block 1155, the system is turned off and the damaged tubes are replaced in the field.

[0067] At block 1160, the process determines whether removal of the current portion is complete. If not, the process proceeds to block 1140 to continue removing material. Conversely, if completed, the process proceeds to block 1170.

[0068] At block 1170, the process determines whether mechanical finishing is required. Mechanical finishing involves applying a mechanical force to remove remaining material in addition to or after the application of the plasma torch. If mechanical finishing is required, at block 1175, the prepared material made more friable by the plasma torch is removed using mechanical means. The mechanical means may include an excavator head, a scraper, a hammer, or another mechanism for removing material. The process then proceeds to block 1180.

[0069] At block 1180, the process determines whether there are more segments to remove. If so, the process proceeds to block 1190. At block 1190, the equipment supporting the plasma torching head is moved to the next location. The process then proceeds to block 1115 to evaluate the torch size. In one embodiment, if no change in the material being removed is detected, the process instead proceeds from block 1190 to block 1140 to begin removing material at the new location, since no other settings need to be changed. If there are no more portions to remove, the process ends at block 1195.

[0070] 12 is a flow chart of one embodiment of forming a trench using a plasma torch system with a movable baffle. The process begins at block 1210.

[0071] In block 1215, the location of the trench is determined.

[0072] At block 1220, the configuration of the plasma torch head is determined. In one embodiment, the configuration includes the size and position of the plasma torch, as well as an offset.

[0073] At block 1225, a baffle is positioned above a first zone of the trench to be excavated. In one embodiment, the baffle is positioned along the trench, such that the longest dimension of the baffle corresponds to the length of the segment of the trench that can be completed without moving the baffle.

[0074] At block 1230, a plasma torch is used to cut a trench in the baffle.

[0075] If the configuration includes tubes, the process determines if any tubes are damaged in block 1235. If so, then in block 1240, those tubes may be replaced in the field.

[0076] At block 1245, the process determines whether the portion of the trench covered by the baffle is complete. If not, the process returns to block 1230 to continue cutting the trench using the plasma torch. If complete, the process proceeds to block 1250.

[0077] At block 1250, the process determines whether there are more segments to cut. If there are not, the process ends at block 1260. If there are more segments, the process proceeds to block 1255, where the baffle is moved to the next segment. The process then proceeds to block 1215.

[0078] Although these processes are shown as flowcharts, it should be understood that in one embodiment, the order of operations is not constrained to the order shown, so long as the processes are not dependent on one another. Additionally, the system may be implemented using an interrupt-driven system, whereby the system does not check for occurrences, but rather sends notifications that trigger actions. Additionally, in some embodiments, some or all of the illustrated steps may be skipped.

[0079] The above examples of plasma torch system configurations are described in separate embodiments. However, those skilled in the art will understand that various embodiments can be combined. For example, various plasma torch head configurations can be used with various baffle configurations. A camera / sensor bar can be incorporated into a system that does not use an excavator, the number of plasma torches can be varied with different plasma torch heads, etc.

[0080] Thus far in the specification, the earth material removal system has been described with reference to specific exemplary embodiments thereof. It will, however, be apparent that various modifications and changes may be made therein without departing from the broader spirit and scope of the present disclosure as set forth in the appended claims. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense.

Claims

1. a movable support structure including a controller; A mechanical arm; an attachment mechanism removably coupled to the mechanical arm; a plasma torching head coupled to the mounting mechanism, the plasma torching head supporting a plasma torch for removing earth material, the plasma torching head being movable along two axes; 1. A soil material removal system comprising:

2. The earth material removal system of claim 1 , wherein the movable support structure is an excavator.

3. The geological material removal system of claim 1 , wherein the plasma torching head comprises a plurality of plasma torches.

4. The geological material removal system of claim 3 , wherein the plurality of plasma torches are of different sizes.

5. a plurality of sensors coupled to the earth material removal; a controller that determines the quality of the soil being removed and adjusts one or more settings of the plasma torch head; The geological material removal system of claim 1 further comprising:

6. The plasma torching head includes: a protective casing surrounding the plasma torch; a plurality of field-replaceable tubes configured to absorb shock to protect the plasma torch and disposed around a portion of the plasma torch; The geological material removal system of claim 1 , comprising:

7. The plasma torching head includes: a carriage movably coupled to the rail; a plasma torch coupled to the carriage; an actuator for moving the carriage to position the plasma torch for trench excavation; The geological material removal system of claim 1 , comprising:

8. The earth material removal system of claim 7 further comprising a shield disposed in front of the plasma torching head, the shield including an aperture through which the plasma torch extends.

9. The earth material removal system of claim 1 , further comprising a baffle surrounding the plasma torching head, the baffle configured to control the dispersion of debris during use of the earth material removal system.

10. the attachment mechanism coupled to the baffle; a head support configured to movably support the plasma torching head; a rail along which the head support moves to reposition the plasma torch head, so that the plasma torch moves while the baffle remains stationary; and The geological material removal system of claim 9 further comprising:

11. The earth material removal system of claim 9 , wherein the baffle includes distribution slots through which the soil can exit the baffle.

12. The earth material removal system of claim 9 , wherein the movable support structure comprises an excavator.

13. 10. The earth material removal system of claim 1, further comprising a discharge device for providing cooling to a surface being cut by the plasma torch, said cooling comprising one or more of air and water.

14. 10. The earth material removal system of claim 1, further comprising a vacuum head for vacuuming soil produced by the plasma torch, the vacuum head including a water inlet for cooling the soil before it enters a vacuum hose.

15. 10. The earth material removal system of claim 1, further comprising: a kiln comprising a tube of refractive material positioned in front of the plasma torch, said kiln configured to constrain the plasma plume as the initial perforation is formed.

16. a movable support structure including a trench excavation controller; a plasma torching head configured to cut the trench; a baffle surrounding the plasma torching head, the baffle providing protection from debris from the plasma torching head; 1. A soil material removal system comprising:

17. a mounting mechanism for movably coupling the plasma torching head to the movable support structure; a plasma torch within a protective casing; a replaceable tube disposed around at least a portion of the plasma torch and extending beyond an electrode of the plasma torch, the tube providing protection for the plasma torch, such that a plasma plume generated by the plasma torch extends beyond the tube; 1. A soil material removal system comprising:

18. 20. The earth material removal system of claim 17, further comprising a discharge device for directing a cooling flow to cool a surface being trenched.

19. 20. The earth material removal system of claim 17, further comprising a control system that adjusts the horizontal movement speed and depth of the plasma torch based on the size of the trench and the earth material being removed.

20. 20. The geological material removal system of claim 17, further comprising a baffle surrounding said plasma torching head, said baffle for controlling dispersion of soil debris from said removal.

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