Tunneling device including expandable section

Abstract

A tunneling device (102) includes an expander (136) extending along a longitudinal axis. The expander is expandable in a direction perpendicular to the longitudinal axis between a first configuration having a first width and a second configuration having a second width. The tunneling device also includes a tip (138) coupled to the expander. The tip includes a tunneling tool (142) configured to displace material and form a tunnel. The expander is configured to fit into and move through the tunnel formed by the tip when the expander is in the first configuration. The expander is configured to engage a sidewall of the tunnel and expand the tunnel when the expander is in the second configuration. The first width of the expander is less than or equal to the width of the tunneling tool. The second width of the expander is greater than the width of the tunneling tool.

Description

TUNNELING DEVICE INCLUDING EXPANDABLESECTIONSTATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT

[0001] This invention was made with Government support under contract number N00014-22-C-2009 awarded by the Department of Defense (DOD). The Government has certain rights in this invention.BACKGROUND

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

[0003] Tunneling devices are used to travel through underground locations and displace material to form and shape tunnels through the underground locations. At least some tunneling devices include a drive system to propel the tunneling devices through underground locations. In addition, a tool may be positioned at the front of the tunneling devices to displace material and form an interior cavity of the tunnel as the tunneling devices travel through the underground locations. However, the underground locations may have varying conditions and obstacles that make travel and access difficult. In addition, the size, shape, and power requirements of the tunneling device are at least partly dictated by the configuration of the tool used to displace material, the drive system, and environmental characteristics. Also, at least some known tools are not able to efficiently use the power provided by on an onboard power system to displace material and do not precisely remove material to shape the tunnel. Further, the tools’ ability to displace material, and thus the resulting size of the tunnel, may be limited by the size of the tool. Moreover, a separate apparatus is typically required to remove the displaced material from the tunnel.

[0004] Accordingly, it is desirable to provide a system including a tunneling device configured to travel through difficult to access locations and efficiently displace material.BRIEF DESCRIPTION

[0005] In one aspect, a tunneling device includes an expander extending along a longitudinal axis. The expander is expandable in a direction perpendicular to the longitudinal axis between a first configuration having a first width measured perpendicular to the longitudinal axis and a second configuration having a second width measured perpendicular to the longitudinal axis. The tunneling device also includes a tip coupled to the expander. The tip includes a tunneling tool configured to displace material and form a tunnel as the tip moves. The expander is configured to fit into and move through the tunnel formed by the tip when the expander is in the first configuration. The expander is configured to engage a sidewall of the tunnel and expand the tunnel when the expander is in the second configuration. The tunneling tool has a width measured perpendicular to the longitudinal axis. The first width of the expander is less than or equal to the width of the tunneling tool. The second width of the expander is greater than the width of the tunneling tool.

[0006] In another aspect, a system for use in maintaining a tunnel is provided. The system includes a tunneling device and a controller communicatively coupled to the tunneling device. The tunneling device includes an expander extending along a longitudinal axis. The expander is expandable in a direction perpendicular to the longitudinal axis between a first configuration having a first width measured perpendicular to the longitudinal axis and a second configuration having a second width measured perpendicular to the longitudinal axis. The tunneling device also includes a tip coupled to the expander and including a tunneling tool configured to displace material and form a tunnel as the tip moves. The tip has a width measured perpendicular to the longitudinal axis. The first width of the expander is less than or equal to the width of the tip. The second width of the expander is greater than the width of the tip. The controller is configured to operate the tunneling device to move the tip when the expander is in the first configuration, and is configured to stop movement of the tip when the expander is switched between the first configuration and the second configuration.

[0007] In yet another aspect, a method for maintaining a tunnel having a sidewall defining an interior cavity is provided. The method includes moving a tunneling device through an underground location. The tunneling device includes an expander extending along a longitudinal axis, a tip coupled to the expander and including a tunneling tool, and displacing material with the tip to form the tunnel as the tunneling device movesthrough the underground location. The expander is configured to fit into and move through the tunnel formed by the tip when the expander is in the first configuration. The expander is expandable in a direction perpendicular to the longitudinal axis between a first configuration having a first width measured perpendicular to the longitudinal axis and a second configuration having a second width measured perpendicular to the longitudinal axis. The tunneling tool has a width measured perpendicular to the longitudinal axis. The first width of the expander is less than or equal to the width of the tunneling tool. The second width of the expander is greater than the width of the tunneling tool. The method also includes switching the expander from the first configuration to the second configuration, wherein the expander is configured to engage a sidewall of the tunnel and expand the tunnel when the expander is in the second configuration.BRIEF DESCRIPTION OF THE DRAWINGS

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

[0009] FIG. 1 is a schematic diagram of a system including one embodiment of a tunneling device traveling underground, the tunneling device including an expander illustrated in a first configuration;

[0010] FIG. 2 is a schematic diagram of the system shown in FIG. 1, illustrating the expander of the tunneling device in a second configuration;

[0011] FIG. 3 is a flow chart of an example method of performing a maintenance operation using the tunneling device shown in FIG. 1;

[0012] FIG. 4 is a side view of an alternative embodiment of a tunneling device for use with the system shown in FIG. 1 , the tunneling device having a tip including a force transmitter; and

[0013] FIG. 5 is a side view of an alternative embodiment of a tunneling device for use with the system shown in FIG. 1, the tunneling device including a plurality of expanders.

[0014] Unless otherwise indicated, the drawings provided herein are meant to illustrate features of embodiments of this disclosure. These features are believed to be applicable in a wide variety of systems including one or more embodiments of this disclosure. As such, the drawings are not meant to include all conventional features known by those of ordinary skill in the art to be required for the practice of the embodiments disclosed herein.DETAILED DESCRIPTION

[0015] In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings.

[0016] The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.

[0017] “Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not.

[0018] Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about”, “approximately”, and “substantially”, are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and / or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.

[0019] As used herein, the terms “processor” and “computer,” and related terms, e.g., “processing device,” “computing device,” and “controller” are not limited to just those integrated circuits referred to in the art as a computer, but broadly refers to a microcontroller, a microcomputer, an analog computer, a programmable logic controller (PLC), and application specific integrated circuit (ASIC), and other programmable circuits, and these terms are used interchangeably herein. In the embodiments described herein, “memory” may include, but is not limited to, a computer-readable medium, such as a random access memory (RAM), a computer-readable non-volatile medium, such as a flash memory. Alternatively, a floppy disk, a compact disc - read only memory (CD-ROM), a magneto-optical disk (MOD), and / or a digital versatile disc (DVD) may also be used. Also, in the embodiments described herein, additional input channels may be, but are not limited to, computer peripherals associated with an operator interface such as a touchscreen, a mouse, and a keyboard. Alternatively, other computer peripherals may also be used that may include, for example, but not be limited to, a seamier. Furthermore, in the example embodiment, additional output channels may include, but not be limited to, an operator interface monitor or heads-up display. Some embodiments involve the use of one or more electronic or computing devices. Such devices typically include a processor, processing device, or controller, such as a general purpose central processing unit (CPU), a graphics processing unit (GPU), a microcontroller, a reduced instruction set computer (RISC) processor, an ASIC, a PLC, a field programmable gate array (FPGA), a digital signal processing (DSP) device, and / or any other circuit or processing device capable of executing the functions described herein. The methods described herein may be encoded as executable instructions embodied in a computer readable medium, including, without limitation, a storage device and / or a memory device. Such instructions, when executed by a processing device, cause the processing device to perform at least a portion of the methods described herein. The above examples are exemplary only, and thus are not intended to limit in any way the definition and / or meaning of the term processor and processing device.

[0020] Embodiments described herein relate to a system including a tunneling device. The tunneling device includes an expander extending along a longitudinal axis and a tip coupled to the expander. The expander is expandable in a direction perpendicular to the longitudinal axis between a first configuration having a first width measured perpendicular to the longitudinal axis, and a second configuration having a second width measured perpendicular to the longitudinal axis. The first width of the expander is equal to or less than a width of the tip, and the second width of the expander is greater than the width of the tip. The tunneling device is configured to travel through an underground location and perform a tunneling operation or a maintenance operation for a tunnel. For example, the tip may include a tunnelling tool configured to displace material and form a tunnel. The expander is configured to fit into the tunnel fomied by the tip when the expander is in the first configuration, and the expander is configured to engage a sidewall of the tunnel and expand the tunnel when the expander is in the second configuration. For example, the expander is configured to expand the interior cavity of the tunnel to a width that is greaterthan the maximum width of the tip. As a result, the tunneling device may form tunnels with dimensions that are not limited by the size of the tip, and the power requirements of the tunneling device may be reduced. Moreover, the tunneling device may be relatively easily removed from the interior cavity because the tip does not engage the sidewalls of the tunnel after the tunnel has been expanded by the expander.

[0021] FIG. 1 is a schematic diagram of a system 100 including a tunneling device 102 traveling underground. For example, tunneling device 102 is configured to travel through a tunnel 104 and / or displace material to form tunnel 104. Tunnel 104 includes a sidewall 106 having an interior surface 108 extending around a central axis 110 and defining an interior cavity 1 12. Tunneling device 102 is configured to fit within interior cavity 1 12 and travel along the length of tunnel 104. Accordingly, tunneling device 102 facilitates construction of tunnel 104 and / or inspection and repair of tunnel 104. Moreover, tunneling device 102 is self-propelled, meaning that tunneling device 102 moves within interior cavity 112 without an external force acting on tunneling device 102.

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

[0023] System 100 includes tunneling device 102, a controller 116 communicatively coupled to tunneling device 102, and a fluid supply system 118. Fluid supply system 118 includes a pressurized fluid source 120 that is coupled to tunneling device 102 via a fluid line 122. Fluid supply system 1 18 is configured to regulate pressurized fluid that is delivered to / removed from tunneling device 102 for operation of tunneling device 102, as described further herein.

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

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

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

[0027] Also, in the example embodiment, an operator interface 130 is configured to display information relating to the characteristics detected by tunneling device 102 for interpretation by the operator. Operator interface 130 may be included on a remote computing device (not shown) and / or may be incorporated with controller 1 16. Operator interface 130 may include, among other possibilities, a web browser and / or a client application. For example, in some embodiments, operator interface 130 displays images of interior surface 108 based on received signals. In some embodiments, operator interface 130 allows an operator to input and / or view information relating to control of tunneling device 102. In the example embodiment, operator interface 130 is configured to display informationrelating to the state of one or more of a maintenance device and a power source for interpretation by the operator. For example, state information may include a position of tunneling device 102 along a length of tunnel 104. State information may also include a charge status of a power source and / or a current draw for the various drive and positioning motors. In various embodiments, processor 126 translates operator inputs into steering, tool motion, camera control, sensor control, sensor motion, and / or any other commands and sends information via transceiver 124 to tunneling device 102 via a transceiver of tunneling device 102. In some embodiments, operator control of tunneling device 102 is in real time, such as through a joystick, a keyboard, a touchscreen, a remote motion capture system, and / or a wearable motion capture system or other interface having similar function. In other embodiments, tunneling device 102 is controlled partially or wholly according to a preprogrammed routine. In further embodiments, tunneling device 102 is at least partially automated. In some embodiments, an operator inputs information such as operation goals or conditional directions. In further embodiments, information, such as information received by controller 116 from tunneling device 102, control data sent to tunneling device 102, and additional operator inputs or state information (e.g., location, time, orientation, datalink quality, battery levels, repair material levels, failure mode indicators), is logged into memory 128.

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

[0029] Tunneling device 102 includes an expander 136 and a tip 138 coupled to expander 136. Expander 136 and tip 138 of tunneling device 102 extend along a longitudinal axis 140. Expander 136 and tip 138 are modular and are detachably coupled together. Tip 138 is configured to move tunneling device 102 through underground locations. For example, tip 138 includes a tunneling tool 142 and a force transmitter 148 coupled to andextending between expander 136 and tunneling tool 142. Force transmitter 148 is configured to deliver a force to move tip 138 in a direction parallel to longitudinal axis 140. For example, force transmitter 148 may include a reciprocating impact device having an actuator that is operated using pneumatics, hydraulics, and / or any suitable system. Force transmitter 148 is configured to induce movement of tip 138 based on instructions from controller 116 and / or when force transmitter 148 receives power from a power source. For example, force transmitter 148 is configured to move tip 138 in a direction parallel to longitudinal axis 140 and / or rotate tip 138 about longitudinal axis 140. In alternative embodiments, tunneling device 102 includes any force transmitter 148 that enables tunneling device 102 to operate as described herein. For example, in some embodiments, force transmitter 148 includes a motor, a percussion hammer or reciprocating impact device, a linear actuator, a rotary actuator, and / or a pneumatic actuator.

[0030] Tip 138 includes tunneling tool 142 that is shaped to engage material and displace material when force transmitter 148 causes tip 138 to move along longitudinal axis 140. In the example embodiment, tunneling tool 142 is a cone having a width 164 and tapering to a point that is configured to engage the material. In alternative embodiments, tunneling tool 142 is any shape that enables tunneling device 102 to operate as described herein. For example, in some embodiments, tunneling tool 142 includes a blade, a helix, a sphere, and / or any other suitable shape.

[0031] In some embodiments, tunneling device 102 includes at least one of a sensor and / or a repair tool, and tunneling device 102 is configured to perform a maintenance operation within tunnel 104. For example, in some embodiments, tunneling device 102 includes, without limitation, any of the following: an applicator, a drill, a grinder, a heater, a welding electrode, a sprayer, an optical sensor (e.g., visible, infrared, and / or multi- spectral sensor), a mechanical sensor (e.g., stylus profilometer, coordinate measurement probe, load transducer, linear variable differential transformer), a thermal sensor (e.g., pyrometer, thermocouple, resistance temperature detector), a magnetic sensor, an acoustic sensor (e.g., piezoelectric, microphone, ultrasound), and an electromagnetic sensor (e.g., eddy current, potential drop, x-ray). In some embodiments, a maintenance device on tip 138 is used to provide information for steering tunneling device 102 and / or to perform a maintenance operation. In alternative embodiments, tunneling device 102 includes any component that enables tunneling device 102 to operate as described herein.

[0032] In addition, in some embodiments, tunneling device 102 includes a light source (not shown) configured to irradiate at least a portion of interior cavity 112 to facilitate visual or non-visual steering of tunneling device 102 and / or to allow a maintenance device to capture images, for example. The light source may be coupled to tunneling device 102 and, in some embodiments, may be positionable relative to tunneling device 102. In alternative embodiments, tunneling device 102 includes any light source that enables tunneling device 102 to operate as described herein.

[0033] Expander 136 is coupled to tip 138 and extends along longitudinal axis 140. In the example embodiment, expander 136 is coupled behind tip 138 and is arranged to follow tip 138 as tunneling device 102 moves through the underground location in a forward direction. In particular, expander 136 is not positioned in front of tip 138 or force transmitter 148 and does not require force transmitter 148 or a separate locomotion force to act directly on or through expander 136 to move tunneling device 102. Rather, expander 136 follows tip 138 and expander 136 is pulled forward when tip 138 moves. Accordingly, expander 136 facilitates movement of tunneling device 102, and operation of tunneling device is simpler than other systems.

[0034] In the example embodiment, expander 136 is configured to switch between a first configuration and a second configuration. For example, expander 136 is expandable in a direction perpendicular to longitudinal axis 140 between a first configuration having a first width 154 (shown in FIG. 1) measured perpendicular to longitudinal axis 140 and a second configuration having a second width 156 (shown in FIG. 2) measured perpendicular to longitudinal axis 140. Expander 136 is configured to fit into and move through tunnel 104 formed by tip 138 when expander 136 is in the first configuration. For example, first width 154 of expander 136 in the first configuration is equal to or less than width 164 of tip 138. In the second configuration, expander 136 is configured to engage a sidewall 106 of tunnel 104 and expand tunnel 104. For example, second width 156 of expander 136 in the second configuration is greater than width 164 of tip 138. Accordingly, expander 136 facilitates tunneling device 102 forming tunnels 104 that have a width greater than width 164 of tip 138. As a result, tunneling device 102 increases the size of tunnels 104 that can be formed by tip 138 and reduces the amount of force needed to form tunnels 104.For example, the smaller size of tip 138 reduces the amount of force that is needed to move tip 138 and displace material.

[0035] Also, in the example embodiment, expander 136 includes a bladder 158 having an elastomeric material that is configured to expand / collapse when pressurized fluid is delivered / removed from bladder 158. In addition in the example embodiment, reinforcement muscles (e.g.. fibers) extend around bladder 158 and are connected to radial and axial actuators. In the example embodiment, the muscles are reinforced with a fiber mesh pattern that constrains the direction and amount of expansion of bladder 158 based on a fiber reinforcement angle determined by the design of the muscle. For example, the fiber reinforcement may form a first arrangement (e.g., a tight mesh grid around the circumference of bladder) that allows bladder 158 to expand in an axial direction but not in a radial direction when bladder 158 is pressurized. Conversely, the fiber reinforcement may form a second arrangement (e.g., a looser mesh grid around the circumference of bladder 158 allowing radial expansion or stretching of the mesh) that allows bladder 158 to expand in the radial direction but not the axial direction when bladder 158 is pressurized. In addition, the fiber reinforcement angle is designed to arrest the deformation of bladder 158 at a pre-defined setpoint in the radial and / or axial direction when bladder 158 is pressurized. In the example embodiment, the fiber reinforcement angle of the muscles is between 10 degrees and 50 degrees with respect to the circumferential axis of the bladder. In alternative embodiments, tunneling device 102 includes any expander 136 that enables tunneling device 102 to operate as described herein.

[0036] In addition, in the example embodiment, pressurized fluid source 120 is coupled to one or more components of tunneling device 102 via fluid line 122. For example, pressurized fluid source 120 is coupled to bladder 158 of expander 136 via fluid line 122. In the example, embodiment, fluid line 122 is coupled to an end of bladder 158 adjacent tip 138 such that fluid line 122 extends along the length of bladder 158 and delivers pressurized fluid to the end of bladder 158 that is positioned distally from pressurized fluid source 120. The location of fluid line 122 may reduce force on and risk of failure of bladder 158 when pressurized fluid is delivered to bladder 158. Bladder 158 is configured to transition expander 136 from the first configuration to the second configuration when pressurized fluid is delivered to bladder 158 via fluid line 122, and to transition expander136 from the second configuration to the first configuration when the pressurized fluid is removed from bladder 158 via fluid line 122. In alternative embodiments, system 100 includes any pressurized fluid source 120 that enables system 100 to operate as described herein. For example, in some embodiments, pressurized fluid source 120 includes separate fluid tanks and / or pumps that are coupled to and configured to regulate pressurized fluid in bladder 158 and / or other sections of tunneling device 102. In addition, in some embodiments, system 100 includes a plurality of fluid lines 122 coupled to expander 136.

[0037] FIG. 1 illustrates expander 136 of tunneling device 102 in the first configuration. FIG. 2 illustrates expander 136 of tunneling device 102 in the second configuration. Expander 136 extends along longitudinal axis 140 and has first width 154 measured perpendicular to longitudinal axis 140 in the first configuration and second width 156 measured perpendicular to longitudinal axis 140 in the second configuration. Tip 138 has width 164 measured perpendicular to longitudinal axis 140. First width 154 of expander 136 is equal to or less than width 164 of tip 138. Second width 156 of expander 136 is greater than width 164 of tip 138. Accordingly, in the first configuration, expander 136 is within the radial extents of tip 138 and fits in a first section of tunnel 104 (show n in FIG. 1) formed by tip 138 without engaging sidewalls 106 (shown in FIG. 1) of the first section of tunnel 104. In the second configuration, expander 136 extends beyond the radial extents of tip 138 and is configured to engage sidewalls 106 of the first section of tunnel 104. As a result, expander 136 in the second configuration can engage sidewalls 106 of the first section of tunnel 104 and compact and displace material in sidewalls 106 radially outward from longitudinal axis 140 to expand tunnel 104. For example, expander 136 enlarges tunnel 104 (shown in FIG. 1) by displacing the material because the pressure provided by expander 136 exceeds a cavity expansion pressure of the medium surrounding tunneling device 102. In alternative embodiments, expander 136 has any configuration that enables tunneling device 102 to operate as described herein. For example, in some embodiments, expander 136 has a third configuration different from the first and second configurations. In further embodiments, expander 136 includes a graduated adjustment between the first and second configurations. In further embodiments, expander 136 changes its length when expander 136 transitions between the first and second configurations.

[0038] Referring to FIGs. 1-3, during operation, tunneling device 102 is positioned proximate surface 114 such that distal tip 138 engages material of the surface 114. Controller 1 16 provides instructions that cause tunneling device 102 to tunnel into surface 114 and through underground locations. For example, controller 116 causes power to be supplied to force transmitter 148, and force transmitter 148 induces movement of tip 138. Tip 138 displaces material to form interior cavity 112 when tip 138 is moved by force transmitter 148. For example, tip 138 displaces the material in directions parallel and / or perpendicular to longitudinal axis 140. In the example embodiment, the cone shape of tip 138 causes material in front of tunneling device 102 to be compacted and directed at least partly in a direction perpendicular to longitudinal axis 140. Width 164 of tip 138 defines an initial width of interior cavity 112 oftunnel 104 as tip 138 displaces material. In the example embodiment, system 100 does not require an apparatus to remove at least some of the displaced material because tunneling device 102 compacts the displaced material around tunnel 104.

[0039] Also, in the example embodiment, expander 136 is configured to fit into tunnel 104 and follow tip 138 as tip 138 displaces material. For example, during movement of tunneling device 102, expander 136 stays in the first configuration or transitions from the second configuration to the first configuration to facilitate tunneling device 102 traveling through tunnel 104 (shown in FIG. 1). In the first configuration, first width 154 of expander 136 is less than or equal to width 164 of tip 138 and expander 136 is sized and shaped to follow behind tip 138 and fit within tunnel 104 that accommodates tip 138.

[0040] After tip 138 has displaced material, expander 136 is transitioned from the first configuration to the second configuration. For example, pressurized fluid is supplied to expander 136 to transition expander 136 to the second configuration. As expander 136 transitions to the second configuration, expander 136 engages sidewalls 106 of tunnel 104 and compacts material around tunnel 104. For example, expander 136 engages sidewall 106 and compresses material previously displaced by tip 138 and expands interior cavity 112 of tunnel 104. As a result, expander 136 increases a width of tunnel 104 from a width equal to width 164 of tip 138 to a width that is at least equal to second width 156 of expander 136.

[0041] In the example embodiment, when expander 136 switches to the second configuration, controller stops movement of tip 138, e.g., tunneling device 102 is parked, and tip 138 remains stationary as expander 136 displaces material to expand tunnel104. As result, forces on expander 136 may be reduced as expander 136 transitions between configurations. In addition, expander 136 is able to completely expand a section of tunnel 104. Tunneling device 102 is parked as expander 136 switches from the first configuration to the second configuration, and as expander 136 switches from the second configuration back to the first configuration. In alternative embodiments, tip 138 may move when expander 136 switches from the first configuration to the second configuration and / or when expander 136 is in the second configuration.

[0042] After expander 136 has compressed material and expanded interior cavity 112 of tunnel 104 to a desired width, pressurized fluid is removed from expander 136 to transition expander 136 back to the first configuration. When expander 136 is in the first configuration, tip 138 resumes movement and tunneling device 102 is propelled through tunnel 104 with expander 136 in the first configuration. Tip 138 engages new material to be displaced as tunneling device 102 is propelled forward.

[0043] Controller 116 provides instructions to direct tunneling device 102 through underground locations. For example, controller 116 may generate instructions to cause tunneling device 102 to travel in a straight direction and / or to turn as tunneling device 102 propels tunneling device 102. For example, controller 116 may send instructions that cause muscles in sections of tunneling device 102 to adjust and bend as sections are selectively switched between configurations.

[0044] In addition, controller 116 may provide instructions that determine the amount of force that force transmitter 148 delivers to tip 138. In addition, controller 116 may provide instructions that determine the amount and timing of pressurized fluid that is delivered to or removed from expander 136 when expander 136 switches configurations. For example, controller 116 may determine the amount of force to deliver to tip 138 and / or the amount of pressurized fluid that is delivered to expander 136 based on the type of material around tip 138 and / or expander 136, the characteristics of tip 138 and / or expander 136, the direction and magnitude of travel desired, a desired size and shape of tunnel 104, and / or any other operative parameters of system 100.

[0045] In some embodiments, system 100 includes a synchronization system 160 including a timer, odometer, or other synchronization device. Synchronization system 160 may be incorporated at least in part into controller 116, tunneling device 102, and / or an external system. Synchronization system 160 coordinates the movement of tip 138and transitions of expander 136. For example, synchronization system 160 records when tip 138 is moving using, for example, an odometer, and provides a signal when tip 138 is no longer moving. In addition, synchronization system 160 causes one or more valves of fluid supply system 118 to actuate and change flow of pressurized fluid into expander 136 when tip 138 is no longer moving. In some embodiments, synchronization system 160 causes tip 138 to move or stop and expander 136 to switch configurations based at least in part on synchronized timing information relating to operation of tunneling device 102. For example, synchronization system 160 causes tip 138 to move for a time required to displace a predetermined amount of material and, then, causes tip 138 to stop and expander 136 to expand for a time required to expand tunnel 104 a predetermined amount. Synchronization system 160 cycles through a tip 138 and expander 136 operations a number of times required to form tunnel 104.

[0046] FIG. 3 is a flow chart of an example method 200 of maintaining tunnel 104 (shown in FIG. 1) using tunneling device 102 (shown in FIG. 1). In reference to FIGS. 1-3, method 200 includes moving 202 tunneling device 102 through underground location. Also, method 200 includes displacing 204 material with tip 138 to form tunnel 104 as tunneling device 102 moves through the underground location. For example, tip 138 receives force from force transmitter 148, and tip 138 moves to displace material and form tunnel 104. Expander 136 is configured to fit into and move through tunnel 104 formed by tip 138 when expander 136 is in the first configuration.

[0047] In addition, method 200 includes switching 206 expander 136 from the first configuration to the second configuration. For example, pressurized fluid source 120 delivers pressurized fluid to expander 136 to switch expander 136 from the first configuration to the second configuration. As expander 136 transitions to the second configuration, expander 136 is configured to engage sidewall 106 of tunnel 104 and compress material to expand tunnel 104. In some embodiments, tip 138 does not move and tunneling device 102 is fixed against movement in the direction of longitudinal axis 140 as expander 136 switches between the first configuration and the second configuration.

[0048] When tunnel 104 has reached a desired width, expander 136 is switched from the second configuration back to the first configuration. For example, pressurized fluid source 120 removes pressurized fluid from expander 136 to switchexpander 136 from the second configuration to the first configuration. Tip 138 may resume movement during and / or after expander 136 transitions to the first configuration.

[0049] In the example embodiment, any steps of method 200 are repeated any number of times required for tunneling device 102 to travel a desired distance through tunnel 104 and / or to displace material and form a desired length of tunnel 104.

[0050] FIG. 4 is a side view of a tunneling device 400 suitable for use with system 100 (shown in FIG. 1). Tunneling device 400 includes an expander 402 and a tip 404 coupled to expander 402. Expander 402 and tip 404 of tunneling device 400 extend along a longitudinal axis 406. In alternative embodiments, tunneling device 400 includes any components that enable tunneling device 400 to operate as described herein. For example, in some embodiments, tunneling device 400 includes a body assembly with a plurality of sections that propel tunneling device 400 through underground locations.

[0051] Expander 402 is coupled to an end of tip 404 and positioned behind force transmitter 410. Expander 402 includes a bladder 412 and is configured to switch between a first configuration and a second configuration as described herein. In the first configuration, expander 402 is configured to fit into a tunnel formed by tip 404 and be pulled behind tip 404. In the second configuration, expander 402 is configured to engage sidewalls of a tunnel formed by tip 404 and displace material in the sidewalls radially outward to expand the tunnel.

[0052] In the example embodiment, tip 404 is configured to move tunneling device 400 through underground locations. For example, tip 404 includes a tunneling tool 408 and a force transmitter 410 coupled to tunneling tool 408. In the example embodiment, force transmitter 410 is a reciprocating impact device having an actuator that is operated using pneumatics, hydraulics, and / or any suitable system. Force transmitter 410 is configured to induce movement of tip 404 based on instructions from a controller and / or when force transmitter 410 receives power from a power source.

[0053] FIG. 5 is a side view of a tunneling device 500 suitable for use w ith system 100 (shown in FIG. 1). Tunneling device 500 includes a first expander 502, a second expander 504, a third expander 506, a fourth expander 508, and a tip 510. Expanders 502, 504, 506, 508 and tip 510 of tunneling device 500 extend along a longitudinal axis 512. In the example embodiment, tip 510 is configured to move tunneling device 500 throughunderground locations and displace material as tunneling device 500 moves. Tip 510 has a tip vxidth 514 that is configured to define an initial width of the tunnel. In alternative embodiments, tunneling device 500 includes any tip 510 that enables tunneling device 500 to operate as described herein.

[0054] First expander 502 is coupled to an end of tip 510 and is positioned behind tip 510 when tip 510 moves forward in a direction parallel to longitudinal axis 512. Second expander 504, third expander 506, and fourth expander 508 are coupled sequentially behind first expander 502. In the example, embodiment, first expander 502, second expander 504. third expander 506. and fourth expander 508 are coupled end-to-end and arranged sequentially by size along longitudinal axis 512. For example, first expander 502 has a first width 516 in a first configuration that is less than tip width 514 of tip 510. Second expander 504 has a second width 518 in a first configuration that is larger than first width 516. Third expander 506 has a third width 520 in a first configuration that is larger than second width 518. Fourth expander 508 has a fourth width 522 in a first configuration that is larger than third width 520. In alternative embodiments, tunneling device 500 includes any expander(s) that enable tunneling device 500 to operate as described herein. For example, in some embodiments, tunneling device 500 includes more or less than four expanders.

[0055] In the example embodiment, each of first expander 502, second expander 504, third expander 506, and fourth expander 508 includes a bladder and is configured to switch between a first configuration and a second configuration. In the first configuration, first expander 502, second expander 504, third expander 506, and fourth expander 508 are configured to be pulled forward into a respective section of a tunnel. Also, first expander 502, second expander 504, third expander 506, and fourth expander 508 are configured to expand the tunnel when switched to the second configuration. For example, first expander 502 is configured to fit into a tunnel formed by tip 510 and expand the tunnel when switched to the second configuration. Second expander 504 is configured to fit into the tunnel expanded by first expander 502 and expand the tunnel when switched to the second configuration. Third expander 506 is configured to fit into the tunnel expanded by second expander 504 and expand the tunnel when switched to the second configuration. Fourth expander 508 is configured to fit into the tunnel expanded by third expander 506 and expand the tunnel when switched to the second configuration. Accordingly, first expander 502, second expander 504, third expander 506. and fourth expander 508 facilitate forming a tunnelwith a width that is larger than a width of tip 510. In addition, tunneling device 500 may decrease power requirements and facilitate quicker formation of tunnels by separating the formation and expansion of the tunnel into a senes of stages.

[0056] An example technical effect of the methods, systems, and apparatus described herein includes at least one of: (a) reducing the time to construct tunnels through underground locations; (b) enabling tunneling operations and / or inspection and repair of an interior cavity of a tunnel at greater distances from an access opening; (c) increasing the tunnel dimensions that can be formed using a tip; (d) reducing the power requirements for tunneling devices during tunneling operations; (e) increasing the strength and robustness of tunnel constructions; and (f) reducing apparatus required to remove displaced material from tunnels during construction.

[0057] Example embodiments of systems and methods for use in tunneling operations are described above in detail. The methods and systems are not limited to the specific embodiments described herein, but rather, components of systems and / or steps of the methods may be utilized independently and separately from other components and / or steps described herein. For example, the method may also be used in combination with other components, and are not limited to practice only with tunnels as described herein. Rather, the example embodiment can be implemented and utilized in connection with many other applications.

[0058] Although specific features of various embodiments of the disclosure may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the disclosure, any feature of a drawing may be referenced and / or claimed in combination w ith any feature of any other drawing.

[0059] This w ritten description uses examples to disclose the embodiments, including the best mode, and also to enable any person skilled in the art to practice the embodiments, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements w ith insubstantial differences from the literal language of the claims.

Claims

WHAT IS CLAIMED IS:

1. A tunneling device comprising: an expander extending along a longitudinal axis, wherein said expander is expandable in a direction perpendicular to the longitudinal axis between a first configuration having a first width measured perpendicular to the longitudinal axis and a second configuration having a second width measured perpendicular to the longitudinal axis; and a tip coupled to said expander, wherein said tip includes comprises a tunneling tool configured to displace material and form a tunnel as said tip moves, wherein said expander is configured to fit into and move through the tunnel formed by said tip when said expander is in the first configuration, wherein said expander is configured to engage a sidewall of the tunnel and expand the tunnel when said expander is in the second configuration, wherein said tunneling tool has a width measured perpendicular to the longitudinal axis, wherein the first width of said expander is less than or equal to the width of said tunneling tool, and wherein the second width of said expander is greater than the width of said tunneling tool.

2. The tunneling device in accordance with Claim 1 , wherein said tip further comprises a force transmitter coupled to said tunneling tool, and wherein said force transmitter is configured to deliver a force to move said tip in a direction parallel to the longitudinal axis.

3. The tunneling device in accordance with Claim 2, wherein said tunneling device is configured to stop movement of said tip when said expander is sw itched between the first configuration and the second configuration, and is configured to move said tip when said expander is in the first configuration.

4. The tunneling device in accordance with Claim 1, further comprising a plurality of expanders coupled end to end, wherein the respective second widths of said plurality of expanders increase from the tip towards a back of said tunneling device.

5. The tunneling device in accordance with Claim 1, further comprising a synchronization system configured to synchronize movement of said tip and expansion of said expander.

6. The tunneling device in accordance with Claim 1, further comprising a pressurized fluid source and a fluid line coupled between said expander and said pressurized fluid source, wherein said expander comprises a bladder configured to transition said expander from the first configuration to the second configuration when pressurized fluid is delivered to said bladder via said fluid line, and transition said expander from the second configuration to the first configuration when the pressurized fluid is removed from said bladder.

7. The tunneling device in accordance with Claim 6, wherein said bladder is constrained by reinforcement fibers having a reinforcement angle that is selected to arrest deformation of said bladder at a pre-defined setpoint.

8. A system for use in maintaining a tunnel, said system comprising: a tunneling device comprising: an expander extending along a longitudinal axis, wherein said expander is expandable in a direction perpendicular to the longitudinal axis between a first configuration having a first width measured perpendicular to the longitudinal axis and a second configuration having a second width measured perpendicular to the longitudinal axis; and a tip coupled to said expander and comprising a tunneling tool configured to displace material and form a tunnel as said tip moves, wherein said tip has a width measured perpendicular to the longitudinal axis, wherein the first width of said expander is less than or equal to the width of said tip, and wherein the second width of said expander is greater than the width of said tip; and a controller communicatively coupled to said tunneling device, wherein said controller is configured to operate said tunneling device to move said tip when said expander is in the first configuration, and is configured to stop movement of said tip when said expander is switched between the first configuration and the second configuration.

9. The system in accordance with Claim 8, wherein said tip comprises a force transmitter coupled to said tunneling device, and wherein said force transmitter is configured to deliver a force to move said tip in a direction parallel to the longitudinal axis.

10. The system in accordance with Claim 8, wherein said controller further comprises a synchronization system configured to synchronize movement of said tip and expansion of said expander.

11. The system in accordance with Claim 8, further comprising a pressurized fluid source located remotely from said tunneling device and a fluid line coupled to said pressurized fluid source and to said expander.

12. The system in accordance with Claim 11, wherein said expander comprises a bladder configured to transition said expander from the first configuration to the second configuration when pressurized fluid is delivered to the bladder via the fluid line, and transition said expander from the second configuration to the first configuration when the pressurized fluid is removed from said bladder via the fluid line.

13. The system in accordance with Claim 12, wherein said bladder is constrained by reinforcement fibers having a reinforcement angle that is selected to arrest deformation of said bladder at a pre-defined setpoint.

14. The system in accordance with Claim 8. wherein said tunneling device comprises a plurality of expanders coupled end to end, and wherein the respective second widths of said plurality of expanders increases from the tip towards a back of said tunneling device.

15. The system in accordance with Claim 8, wherein said controller is located on board said tunneling device.

16. A method for maintaining a tunnel having a sidewall defining an interior cavity, said method comprising: moving a tunneling device through an underground location, the tunneling device including:an expander extending along a longitudinal axis, wherein the expander is expandable in a direction perpendicular to the longitudinal axis between a first configuration having a first width measured perpendicular to the longitudinal axis and a second configuration having a second width measured perpendicular to the longitudinal axis; and a tip coupled to the expander and including a tunneling tool, wherein the tunneling tool has a width measured perpendicular to the longitudinal axis, wherein the first w idth of the expander is less than or equal to the width of the tunneling tool, and wherein the second width of the expander is greater than the width of the tunneling tool; displacing material with the tip to form the tunnel as the tunneling device moves through the underground location, wherein the expander is configured to fit into and move through the tunnel formed by the tip when the expander is in the first configuration; and switching the expander from the first configuration to the second configuration, wherein the expander is configured to engage a sidewall of the tunnel and expand the tunnel when the expander is in the second configuration.

17. The method in accordance with Claim 16, further comprising delivering, using a force transmitter coupled to the tunneling tool, a force to move the tip in a direction parallel to the longitudinal axis.

18. The method in accordance with Claim 16, wherein switching the expander between the first configuration and the second configuration comprises delivering pressurized fluid to the expander to switch the expander from the first configuration to the second configuration or removing pressurized fluid from the expander to sw itch the expander from the second configuration to the first configuration.

19. The method in accordance with Claim 16, further comprising stopping movement of the tip w hen the expander is sw itched betw een the first configuration and the second configuration.

20. The method in accordance with Claim 19, further comprising sending signals from a controller to the tip to stop movement of the tip and to the expander to switch the expander between the first configuration and the second configuration.

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