Tunneling device including flexible control section

Abstract

A tunneling device includes a body assembly extending along a longitudinal axis, a tether, and a control section coupled between the body assembly and the tether. The control section includes a flexible shell defining a cavity, at least one control component in the cavity, and at least one tension member extending along the longitudinal axis and between the body assembly and the tether. The at least one tension member is arranged to transfer forces between the body assembly and the tether.

Description

TUNNELING DEVICE INCLUDING FLEXIBLECONTROL SECTIONSTATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT

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

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

[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, one or more tools, sensors, and / or control systems. In addition, the tunneling devices may include valves, actuators, and / or power distribution components connected to the drive system, the one or more tools, the sensors, and / or the control systems. The size and shape of the valves, the actuators, the pumps, and / or the power distribution components may dictate a minimum size and shape of the tunneling device. In addition, the valves, the actuators, and / or the power distribution components may be rigid and require rigid connections and housings which restrict movement of the tunneling device. For example, the tunneling device may not be able to bend at the valves, the actuators, and / or the power distribution components or the components may be damaged. As a result, the maneuverability of the tunneling device may be restricted and the tunneling device may not be capable of traveling through tunnels or underground locations with obstacles or complex tunnel shapes.

[0004] Accordingly, it is desirable to provide a tunneling device having a flexible control section to facilitate improved movement of the tunneling device.BRIEF DESCRIPTION

[0005] In one aspect, a tunneling device includes a body assembly extending along a longitudinal axis, a tether, and a control section coupled between the body assembly and the tether. The control section includes a flexible shell defining a cavity, at least one control component in the cavity, and at least one tension member extending along the longitudinal axis and between the body assembly and the tether. The at least one tension member is arranged to transfer forces between the body assembly and the tether.

[0006] In another aspect, a system for use in maintaining a tunnel includes a base station and a tunneling device. The tunneling device includes a body assembly extending along a longitudinal axis, a tether extending to the base station, and a control section coupled between the body assembly and the tether. The control section includes a flexible shell defining a cavity and at least one tension member extending along the longitudinal axis and between the body assembly and the tether. The at least one tension member is arranged to transfer forces between the body assembly and the tether.

[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 body assembly of a tunneling device through an underground location. The tunneling device includes the body assembly extending along a longitudinal axis, a tether, and a control section coupled between the body assembly and the tether. The control section includes a flexible shell defining a cavity, at least one control component in the cavity, and at least one tension member extending along the longitudinal axis and between the body assembly and the tether. The method also includes transferring a force through the at least one tension member and between the body assembly and the tether when the body assembly or the tether move, and regulating at least one operating parameter of the tunneling device using the at least one control component in the cavity.BRIEF DESCRIPTION OF THE DRAWINGS

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

[0009] FIG. 1 is a schematic diagram of a system including one embodiment of a tunneling device traveling underground, the tunneling device including a control section having a flexible shell;

[0010] FIG. 2 is a perspective view of a portion of the tunneling device shown in FIG. 1, and illustrating the control section of the tunneling device;

[0011] FIG. 3 is a perspective view of the control section shown in FIG. 2, with a seam of the control section opened to illustrate control components within the control section;

[0012] FIG. 4 is a schematic diagram of the tunneling device shown in FIG. 1;

[0013] FIG. 5 is a perspective view of a control valve of the control section shown in FIGs. 2 and 3;

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

[0015] FIG. 7 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 control section and a distributed valve system; and

[0016] FIG. 8 is a schematic view of the tunneling device shown in FIG. 7.

[0017] 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

[0018] 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.

[0019] The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.

[0020] “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.

[0021] 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.

[0022] 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 magnetooptical 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 scanner. Furthermore, in the example embodiment, additional output channels may include, but not be limited to, an operator interface monitor or heads-up display. Some embodiments involve the use of one or more electronic or computing devices. Such devices typically include a processor, processing device, or controller, such as a general purpose central processing unit (CPU), a graphics processing unit (GPU), a microcontroller, a reduced instruction set computer (RISC) processor, an ASIC, a PLC, a field programmable gate array (FPGA), a digital signalprocessing (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.

[0023] Embodiments described herein relate to a system including a tunneling device. The tunneling device includes a body assembly, a tether, and a control section coupled between the tether and the body assembly. The control section includes a flexible shell defining a cavity, at least one control component in the cavity, and at least one tension member arranged to transfer forces between the body assembly and the tether. For example, the at least one tension member is coupled to a first support coupling coupled to the body assembly and a second support coupling coupled to the tether. The at least one tension member transfers forces between second support coupling on the tether and the first support coupling on the body assembly when the tether or the body assembly moves. In addition, the flexible shell of the control section facilitates the control section bending or changing shape as the tunneling device travels through an underground location and the at least one tension member protects the control section from damage due to forces caused by the tether or the body assembly moving relative to the other. As a result, the tunneling device has improved turning abilities to travel along complex tunnel paths with curves and changes in direction and may avoid obstacles in underground locations. In addition, the tunneling device may have a more compact shape.

[0024] FIG. l 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 112. Tunneling device 102 is configured to fit within interior cavity 112 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.

[0025] 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.

[0026] In the example embodiment, tunneling device 102 includes a body assembly 116, a control section 118. and a tether 120. Control section 118 is coupled between body assembly 116 and tether 120. Control section 118 is flexible to facilitate tunneling device 102 traveling through underground locations and changing direction. In addition, control section 118 is configured to receive and accommodate forces between body assembly 116 and tether 120 when body assembly 116 or tether 120 moves.

[0027] In addition, in the example embodiment, system 100 includes a base station 103 including a controller 122 communicatively coupled to tunneling device 102 and a fluid supply system 124. Base station 103 is connected to tunneling device 102 by one or more supply lines 128, 130 extending through tether 120 and / or tunneling device 102 and coupled to and extending between base station 103 and body assembly 116. For example, fluid supply system 124 includes a pressurized fluid source 126 that is coupled to tunneling device 102 via a supply line 128. Fluid supply system 124 is configured to regulate pressurized fluid that is delivered to / removed from tunneling device 102 for operation of tunneling device 102.

[0028] In addition, in the example embodiment, controller 122 is configured to provide instructions to move tunneling device 102 through tunnel 104 and / or to perform inspection or repair operations. Controller 122 includes a transceiver 132, a processor 134, and a memoiy 136. In the example embodiment, controller 122 is positioned remotely from tunneling device 102, e.g., controller 122 is located at base station 103, and enables an operator on an exterior of tunnel 104 (shown in FIG. 1) to interact with tunneling device 102. For example, controller 122 is communicatively coupled to control section 118 of tunneling device 102 and is configured to send signals for operating one or more control components of control section 118. In some embodiments, transceiver 132 and a transceiveron tunneling device 102 communicate wirelessly. In alternative embodiments, tunneling device 102 and controller 122 communicate in any manner that enables system 100 to operate as described herein. For example, in some embodiments, controller 122 and tunneling device 102 exchange information through a wired link extending between tunneling device 102 and controller 122 through tether 120.

[0029] In addition, in some embodiments, controller 122 is at least partly incorporated into and 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 122 executes instructions that cause tunneling device 102 to move in a selected direction. Controller 122 may be at located at least partly within control section 118. In alternative embodiments, tunneling device 102 includes any controller that enables system 100 to operate as described herein. In some embodiments, controller 122 is not located on board tunneling device 102.

[0030] 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.

[0031] Also, in the example embodiment, an operator interface 138 is configured to display information relating to the characteristics detected by tunneling device 102 for interpretation by the operator. Operator interface 138 may be included on a remote computing device (not shown) and / or may be incorporated with controller 122. Operator interface 138 may include, among other possibilities, a web browser and / or a client application. For example, in some embodiments, operator interface 138 displays images of interior surface 108 based on received signals. In some embodiments, operator interface 138 allows an operator to input and / or view information relating to control of tunneling device 102. In the example embodiment, operator interface 138 is configured to display information relating to the state of one or more of a maintenance device and a power source for interpretation by the operator. For example, state information may include a position of tunneling device 102 along a length of tunnel 104. 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 134 translates operator inputs into steering, toolmotion, camera control, sensor control, sensor motion, and / or any other commands and sends information via transceiver 132 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 122 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 136.

[0032] Moreover, in the example embodiment, controller 122 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 122 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 tether 120 while tunneling device 102 is moving within interior cavity 112 of tunnel 104. In alternative embodiments, controller 122 and tunneling device 102 are configured in any manner that enables system 100 to operate as described herein.

[0033] 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 cunent, potential drop, x-ray). In some embodiments, a maintenance device on tip 146is 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 descnbed herein.

[0034] In addition, in some embodiments, tunneling device 102 includes a light source (not shown) configured to irradiate at least a portion of interior cavity 112 to facilitate visual or non-visual steering 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.

[0035] Body assembly 116 of tunneling device 102 includes at least one expander 144 and a tip 146 coupled to expander 144. In the example embodiment, bodyassembly 116 includes a plurality of expanders 144 coupled behind tip 146. Expanders 144 and tip 146 of tunneling device 102 extend along a longitudinal axis 148. Expander 144 and tip 146 are modular and are detachably coupled together. Tip 146 is configured to move tunneling device 102 through underground locations. For example, tip 146 includes a tunneling tool 150 that is shaped to engage material and displace material tip 146 moves along longitudinal axis 148. For example, in some embodiments, tunneling tool 150 includes a cone, a blade, a helix, a sphere, and / or any- other suitable shape. In some embodiments, tunneling device 102 includes a force transmitter 152 configured to move tip 146 such as a motor, a percussion hammer or reciprocating impact device, a linear actuator, a rotary actuator, and / or a pneumatic actuator.

[0036] In the example embodiment, expanders 144 are configured to switch between a first configuration and a second configuration. For example, each expander 144 is expandable in a direction perpendicular to longitudinal axis 148 between a first configuration having a first width measured perpendicular to longitudinal axis 148 and a second configuration having a second width measured perpendicular to longitudinal axis 148. Expanders 144 are configured to fit into and move through tunnel 104 formed by tip 146 when expanders 144 are in the first configuration. In the second configuration, expanders 144 are configured to engage a sidewall 106 of tunnel 104. Accordingly, expanders 144facilitate tunneling device 102 traveling through underground locations and / or forming tunnels 104.

[0037] Also, in the example embodiment, each expander 144 includes a bladder 154 having an elastomeric material that is configured to expand / collapse when pressurized fluid is delivered / removed from bladder 154. In addition, in the example embodiment, reinforcement muscles (e.g.. fibers) extend around bladder 154 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 154 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 154 to expand in an axial direction but not in a radial direction when bladder 154 is pressurized. Conversely, the fiber reinforcement may form a second arrangement (e.g., a looser mesh grid around the circumference of bladder 154 allowing radial expansion or stretching of the mesh) that allows bladder 154 to expand in the radial direction but not the axial direction when bladder 154 is pressurized. In addition, the fiber reinforcement angle is designed to arrest the deformation of bladder 154 at a pre-defined setpoint in the radial and / or axial direction when bladder 154 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 144 that enables tunneling device 102 to operate as described herein.

[0038] FIG. 2 is a perspective view of a portion of tunneling device 102 including control section 118. FIG. 3 is a perspective view of control section 118. Control section 118 includes a flexible shell 156, at least one control component 160, and at least one tension member 162. Flexible shell 156 defines a cavity 158 sized to receive control components 160. In the example embodiment, flexible shell 156 is a hollow cylinder or sleeve. Flexible shell 156 is arranged to bend or rotate relative to longitudinal axis 148. Accordingly, flexible shell 156 improves the maneuverability of tunneling device 102 and facilitates tunneling device 102 traveling underground.

[0039] Also, in the example embodiment, flexible shell 156 includes a silicone impregnated fiber, a neoprene, a water-resistant fabric, rubber, and / or a plastic. In addition, in the example embodiment, flexible shell 156 is water resistant and inhibits moisture from an exterior contacting control components 160 when flexible shell 156 is closed. Accordingly, flexible shell 156 protects control components 160 from the environment around tunneling device 102. In addition, flexible shell 156 includes a seam 174 that is selectively openable to provide access to control component 160 within cavity 158. In alternative embodiments, control section 118 includes any flexible shell 156 that enables tunneling device 102 to operate as described herein.

[0040] FIG. 4 is a schematic view of tunneling device 102. Moreover, in the example embodiment, control section 118 includes a plurality of tension members 162. tension members 162 extend longitudinally along flexible shell 156. For example, tension members 162 extend along longitudinal axis 148 and between body assembly 116 and tether 120. In the example embodiment, tension members 162 are in cavity 158. In some embodiments, at least some of tension members 162 are positioned on an exterior of flexible shell 156.

[0041] In addition, in the example embodiment, tension members 162 are constructed to provide rigidity and transfer a tension force through control section 118 and facilitate bending of control section 118. For example, each tension member 162 is a metal wire having a rigidity7sufficient to transfer forces through control section 118 and facilitate bending of control section 118. In alternative embodiments, tension members 162 are constructed of any material that enables tunneling device 102 to operate as described herein. For example, in some embodiments, tension members 162 include a metal wire, metal rope, and / or natural or synthetic rope.

[0042] Tension members 162 are arranged to transfer forces between body assembly 1 1 and tether 120. For example, at a first end of control section 1 18, tension members 162 are coupled to a first support coupling 164 coupled to body assembly 116. At a second end of control section 118. tension members 162 are coupled to a second support coupling 166 coupled to tether 120. Tension members 162 are configured to transfer a force from first support coupling 164 to second support coupling 166. In alternative embodiments.tension members 162 are arranged in any manner that enables tunneling device 102 to operate as described herein.

[0043] In some embodiments, control section 118 includes control components 160 such as valves, pumps, power distributers, sensors, and / or controllers. In the example embodiment, control section 118 includes valves 168, regulator 170, and sensors 172. Valves 168. regulator 170. and sensors 172 are positioned within cavity 158 and connected to lines 130, 128. For example, valves 168 and regulator 170 are arranged in a row along longitudinal axis 148 and connected to fluid supply line 128. Sensors 172 are positioned alongside valves 168. Tension members 162 extend along control components 160 and prevent control components 160 experiences stress or forces when tether 120 or body assembly 116 moves. For example, tension members 162 direct forces from tether 120 and body assembly 116 around control components 160 and through control section 118.

[0044] Also, in the example embodiments, control components 160 are arranged to facilitate control section 118 having a compact shape. For example, valves 168 and regulator 170 are arranged next to each other along longitudinal axis 148. Valves 168 may be shaped like valve 176 shown in FIG. 5 to provide a more compact form factor. In addition, sensors 172 and other control components are aligned with valves 168 along longitudinal axis 148 and located radially outward from valves 168. Accordingly, control components 160 provide a stacked arrangement. Control components 160 may be coupled together by flexible couplings because tension members 162 accommodate forces on control section 118.

[0045] In some embodiments, control section 118 includes a rigid subhousing or mount (not shown) supporting at least one of control components 160. For example, a controller in cavity 158 may be mounted to a rigid subhousing. Because tension members 162 span the entire extension of flexible shell 156 and tension members reduce forces on control components 160, the rigid subhousing may be smaller and is not required to span the entire extension of flexible shell 156 or tension members 162.

[0046] In addition, in the example embodiment, pressurized fluid source 126 (shown in FIG. 1) is coupled to valves 168 via supply line 128. Valves 168 are coupled to one or more components of tunneling device 102 via supply lines 130 and configured toregulate pressurized fluid delivered from fluid source 126 to components of tunneling device 102 through supply lines 128, 130. For example, valves 168 are coupled to and configured to regulate fluid flow to bladders 154 of expanders 144 via supply lines 130. Bladders 154 are configured to transition expanders 144 from the first configuration to the second configuration when pressurized fluid is delivered to bladder 154 via supply line 130, and to transition expander 144 from the second configuration to the first configuration when the pressurized fluid is removed from bladder 154 via supply line 130. In alternative embodiments, system 100 includes any pressurized fluid source 126 that enables system 100 to operate as described herein. For example, in some embodiments, pressurized fluid source 126 includes separate fluid tanks and / or pumps that are coupled to and configured to regulate pressurized fluid in bladder 154 and / or other sections of tunneling device 102.

[0047] Referring to FIGs. 1-4, during operation, tunneling device 102 is positioned proximate surface 114 such that distal tip 146 engages material of the surface 114. Controller 122 provides instructions that cause tunneling device 102 to tunnel into surface 114 and through underground locations. For example, controller 122 causes power to be supplied to force transmitter 152, and force transmitter 152 induces movement of tip 146. Tip 146 displaces material to form interior cavity 112 when tip 146 is moved by force transmitter 152.

[0048] Also, in the example embodiment, expander 144 is configured to fit into tunnel 104 and follow^ tip 146 as tip 146 displaces material. For example, during movement of tunneling device 102, expander 144 stays in the first configuration or transitions from the second configuration to the first configuration to facilitate tunneling device 102 traveling through tunnel 1 4 (shown in FIG. 1). After tip 146 has displaced material, expander 144 may be transitioned from the first configuration to the second configuration. For example, pressurized fluid is supplied to expander 144 to transition expander 144 to the second configuration.

[0049] Control components 160 within control section 118 regulate operation of tunneling device 102. For example, control components 160 of control section 118 receive power, fluid, or other materials through supply lines 130 and regulate distribution and use of the materials to operate tunneling device 102. For example, valves 168 regulate pressurized fluid that is delivered to expanders 144. In addition, regulator 170 regulatespressurized fluid that is delivered to force transmitter 152 to induce movement to tip 146. Sensors 172 receive and transmit information about operating states of tunneling device 102. In addition, in the example embodiment, control section 118 is arranged to move through tunnel 104 and follow body assembly 116. For example, flexible shell 156 is flexible and bends when tunneling device 102 experiences turns. In addition, tension members 162 reduce the stresses and forces on the control components and accommodates forces on control section 118 when tunneling device 102 travels. As a result, control section 118 facilitates tunneling device 102 traveling through tunnel 104 (shown in FIG. 1).

[0050] Controller 122 provides instructions to direct tunneling device 102 through underground locations. For example, controller 122 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 122 may send instructions that cause muscles in sections of tunneling device 102 to adjust and bend as sections are selectively switched between configurations. In addition, controller 122 may provide instructions that determine the amount of force that force transmitter 152 delivers to tip 146. In addition, controller 122 may provide instructions that determine the amount and timing of pressurized fluid that is delivered to or removed from expander 144 when expander 144 switches configurations. For example, controller 122 may determine the amount of force to deliver to tip 146 and / or the amount of pressurized fluid that is delivered to expander 144 based on the type of material around tip 146 and / or expander 144, the characteristics of tip 146 and / or expander 144, the direction and magnitude of travel desired, a desired size and shape of tunnel 104, and / or any other operative parameters of system 100. Control components within cavity- 158 may regulate operation of tunneling device 102 based on instructions from controller 122.

[0051] FIG. 5 is a perspective view of a control valve 176 of the control section 118 (shown in FIGs. 2 and 3). Control valve 176 includes a first inlet 178. a first outlet 180, a second inlet 182, a second outlet 184, and an actuator 186. During operation, fluid enters a first cavity- 188 of control valve 176 through first outlet 180 and exits first cavity 188 through first outlet 180. Fluid enters a second cavity 190 of control valve 176 through second inlet 182 and exits second cavity 190 through second outlet 184. In alternative embodiments, control valve 176 includes any inlet(s), outlet(s), and cavity(ies) that enable control valve 176 to function as described herein.

[0052] Actuator 186 is configured to regulate fluid flow through cavities 188, 190. In the example embodiment, control valve 176 is an electrically actuated valve and includes a power coupling 192. Control valve 176 operates to regulate fluid flow when control valve 176 receives electrical power. For example, actuator 186 moves between opened and closed positions based on electrical signals. In alternative embodiments, control valve 176 includes any actuator 186 that enables control valve 176 to operate as described herein. For example, in some embodiments, actuator 186 is mechanically actuated.

[0053] Control valve 176 is configured to couple to supply lines 130, 128. For example, power coupling 192 of control valve 176 couples to an electrical line 131 (shown in FIG. 4) for receiving electrical signals. Inlets 178, 182 couple to supply lines 128, and outlets 180, 184 couple to supply lines 130. In alternative embodiments, control valve 176 couples to any suitable lines.

[0054] In addition, control valve 176 is configured to have a more compact form factor and occupy less space within control section 118 (shown in FIGs. 2 and 3) than other valves. For example, first inlet 178 and first outlet 180 are truncated and extend at an angle relative to first cavity 188. In addition, first inlet 178 and first outlet 180 include coupling mechanisms that facilitate connecting to lines 128, 130 (show n in FIG. 4) at different angles and with a more compact connection.

[0055] In the embodiment illustrated in FIG. 5, second inlet 182 includes a port for connecting a line with second cavity 190. In some embodiments, instead of connecting a line to second inlet 182, second inlet 182 may be closed from second cavity 190 and second cavity 190 arranged to receive flow from first cavity 188 via actuator 186. In further embodiments, second inlet 182, second outlet 184, and second cavity 190 may be arranged like first inlet 178, first outlet 180, and first cavity 188.

[0056] FIG. 6 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. 1-6, method 200 includes moving 202 tunneling device 102 through underground location. Also, method 200 includes transferring 204 a force through tension members 162 and between body assembly 116 and tether 120 when body assembly 1 16 or tether 120 move. For example, tension members 162 transfer force from first support coupling 164 coupled to body assembly 116 at a first end of control section 118 to second support coupling 166 coupled to tether 120 at a second end of control section 118.

[0057] In addition, method 200 includes regulating 206 at least one operating parameter of tunneling device 102 using at least one control component in cavity 158 of control section 118. Control section 118 facilitates delivering power, a communication signal, and / or a fluid through supply lines 128, 130, 131 coupled to and extending between body assembly 116 and the at least one control component 160. For example, valves 168 and / or regulator 170 regulate pressurized fluid that is delivered to body assembly 116. In some embodiments, controller 122 sends signals to at least one control component in cavity 1 12 of flexible shell 156, and the at least one control component of control section 1 18 operates in accordance with the signal from controller 122.

[0058] 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.

[0059] FIG. 7 is a side view of a tunneling device 700 for use with system 100 (shown in FIG. 1). FIG. 8 is a schematic view of tunneling device 700. Tunneling device 700 includes a body assembly 702 and a control section 704. In the example embodiment, body assembly 702 includes expanders 706, a distributed valve system 708, and a tip 710.

[0060] Also, in the example embodiment, tip 710 is configured to move tunneling device 700 through underground locations. For example, tip 710 may include a tunneling tool and a force transmitter 714 coupled to the tunneling tool. In the example embodiment, force transmitter 714 is a reciprocating impact device having an actuator that is operated using pneumatics, hydraulics, and / or any suitable system. Force transmitter 714 is configured to induce movement of tip 710 based on instructions from a controller 722 and / or when force transmitter 714 receives power from a power source.

[0061] Control section 704 includes valves 716, a power distribution assembly 718, a sensor assembly 720. a controller 722. and lines 724 arranged to regulate operation of tunneling device 700. For example, valves 716 regulate pressurized fluid that is delivered to body assembly 702. Controller 722 controls operation of force transmitter 714. In alternative embodiments, control section 704 includes any components that enable tunneling device 700 to operate as described herein.

[0062] Control section 704 also includes a flexible shell 726 defining a cavity 728. Valves 716, power distribution assembly 718, sensor assembly 720, controller 722. and lines 724 are positioned at least partly within cavity 728. Flexible shell 726 protects valves 716, power distribution assembly 718, sensor assembly 720, controller 722, and lines 724 from an environment around tunneling device 700 and facilitates tunneling device 700 traveling through an underground location.

[0063] Distributed valve system 708 includes a plurality of exhaust valves 730 for pressurized fluid to exit expanders 706 of body assembly 702. For example, exhaust valves 730 are selectively actuated to switch between an open position and a closed position. Exhaust valves 730 are operated in coordination with valves 716 within cavity 728 of control section 704 to regulate pressurized fluid delivered to and removed from expanders 706. For example, exhaust valves 730 receive instructions from a controller and are selectively actuated based on the instructions to release pressurized fluid from expanders 706 of body assembly 702. In the example embodiment, exhaust valves 730 are coupled between expanders 706 and between expanders 706 and force transmitter 714. As a result, exhaust valves 730 may facilitate tunneling device 700 having a more compact shape and requiring fewer fluid lines extending through tunneling device 700. For example, tunneling device 700 does not require return lines extending from each expander 706 and / or through control section 704 because exhaust valves 730 are configured to release pressurize fluid from expanders 706 next to each expander 706.

[0064] 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) improving maneuverability of tunneling devices: (d) providing a tunneling device that can be for complex tunnel formations; and (e) reducing the size of tunneling devices.

[0065] 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.

[0066] Although specific features of various embodiments of the disclosure may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the disclosure, any feature of a drawing may be referenced and / or claimed in combination with any feature of any other drawing.

[0067] 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: a body assembly extending along a longitudinal axis; a tether; and a control section coupled between said body assembly and said tether, said control section comprising: a flexible shell defining a cavity; at least one control component in the cavity; and at least one tension member extending along the longitudinal axis and between said body assembly and said tether, said at least one tension member arranged to transfer forces between said body assembly and said tether.

2. The tunneling device in accordance with Claim 1 , wherein said at least one control component includes a valve, a pump, a power distributer, a sensor, and / or a controller.

3. The tunneling device in accordance with Claim 1, wherein said flexible shell comprises a silicone impregnated fiber, a neoprene, a water-resistant fabric, rubber, or a plastic.

4. The tunneling device in accordance with Claim 1 , wherein said at least one tension member comprises a metal wire, metal rope, or natural or synthetic rope.

5. The tunneling device in accordance with Claim 1, wherein said flexible shell comprises a seam that is selectively openable to provide access to said at least one control component within the cavity.

6. The tunneling device in accordance with Claim 1 , wherein said at least one control component comprises a first control component and a second control component, wherein said first control component and said second control component are arranged in a row along the longitudinal axis, and wherein said at least one tension member extends alongsaid first control component and said second control component.

7. The tunneling device in accordance with Claim 1, further comprising a rigid housing enclosing said at least one control component, wherein said rigid housing does not span the entire extension of said flexible shell and said at least one tension member between said body assembly and said tether.

8. The tunneling device in accordance with Claim 1 , further comprising: a first support coupling coupled to said body assembly and said at least one tension member at a first end of said control section; and a second support coupling coupled to said tether and said at least one tension member at a second end of said control section, wherein said at least one tension member is configured to transfer a force from said first support coupling to said second support coupling.

9. The tunneling device in accordance with Claim 1. wherein said tunneling device comprises at least one supply line coupled to and extending between said body assembly and said at least one control component.

10. A system for use in maintaining a tunnel, said system comprising: a base station; and a tunneling device comprising: a body assembly extending along a longitudinal axis; a tether extending to said base station; and a control section coupled between said body assembly and said tether, said control section comprising: a flexible shell defining a cavity; and at least one tension member extending along the longitudinal axis and between said body assembly and said tether, said at least one tensionmember arranged to transfer forces between said body assembly and said tether.

11. The system in accordance with Claim 10, wherein said control section comprises at least one control component in the cavity of said flexible shell, and wherein said at least one control component comprises a valve, a pump, a power distributer, a sensor, and / or a controller.

12. The system in accordance with Claim 11 , further comprising a remote controller communicatively coupled to at least one control component in the cavity of said flexible shell.

13. The system in accordance with Claim 12, wherein said remote controller is located at said base station.

14. The system in accordance with Claim 11, further comprising at least one supply line coupled to and extending between said base station and said at least one control component and between said body assembly and said at least one control component.

15. The system in accordance with Claim 10, further comprising a first control component and a second control component in the cavity of said flexible shell, wherein said first control component and said second control component are arranged in a row along the longitudinal axis, and wherein said at least one tension member extends along said first control component and said second control component.

16. The system in accordance with Claim 10, further comprising a first support coupling coupled to said at least one tension member at a first end of said control section and a second support coupling coupled to said at least one tension member at a second end of said control section, wherein said first support coupling is coupled to said body assembly and said second support coupling is coupled to said tether, and wherein said at least one tension member is configured to transfer a force from said first support coupling to said second support coupling.

17. A method for maintaining a tunnel, said method comprising: moving a body assembly of a tunneling device through an undergroundlocation, the tunneling device including: the body assembly extending along a longitudinal axis; a tether; and a control section coupled between the body assembly and the tether, the control section including: a flexible shell defining a cavity; at least one control component in the cavity; and at least one tension member extending along the longitudinal axis and between the body assembly and the tether; transferring a force through the at least one tension member and between the body assembly and the tether when the body assembly or the tether move; and regulating at least one operating parameter of the tunneling device using the at least one control component in the cavity.

18. The method in accordance with Claim 17, further comprising: sending a signal from a remote controller to the at least one control component in the cavity of the flexible shell; and operating the at least one control component in accordance with the signal from the remote controller.

19. The method in accordance with Claim 17, further comprising delivering power, a communication signal, or a fluid through at least one supply line coupled to and extending between the body assembly and the at least one control component.

20. The method in accordance with Claim 17, further comprising transferring the force from a first support coupling coupled to the body assembly and the at least one tension member at a first end of the control section to a second support coupling coupled to the tether and the at least one tension member at a second end of the control section.

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