Note: Descriptions are shown in the official language in which they were submitted.
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A METHOD FOR HIGH CAPACITY STONE DELIVERY
WITH CONCENTRIC FLOW
AND ENHANCED NOSECONE FOR SOIL IMPROVEMENT
FIELD OF THE INVENTION
[0002] The present invention relates to a method and apparatus for
constructing stone
columns to improve soil stability that is more economical and with a higher
quality than has been
achieved with previous equipment by increasing production rates, reducing
cost, and improving
quality. More particularly, the present invention is directed to methods and
apparatus for a high
capacity stone column bottom feeding apparatus having multiple chutes for
increased stone
delivery that includes a control system, which can be hand operated or fully
automated
electronically for controlling the flow of air and pressure of air in the
system during the ground
improvement process as well as display the results on a screen in the
operator's cab in real time.
BACKGROUND OF THE INVENTION
[0003] Stone columns are simply vertical columns of compacted crushed stone,
gravel or
sand which extend through a deposit of soft material or soil to be
strengthened. In general, a
number of these densely compacted granular material columns are produced
beneath the site for
the intended construction project. These columns serve to stabilize the soil,
resulting in
considerable vertical load capacity and improved shear resistance in the soil
mass. The stone
columns improve drainage in fine grained soil deposits and increase load
bearing capacity to a
point where considerably larger bearing stresses may be sustained without
causing detrimental or
excessive settlement or bearing capacity failure in the ground.
[0004] The following applications have used stone columns for soil
stabilization to limit
loose dirt settlement under reinforced earth walls, tank farms, dam and
highway embankments,
bridge abutments, and buildings. Another application is the stabilization and
prevention of
landslides. Stone columns also function as efficient gravel drains in
providing a path for relief of
excess pore water pressures, thus preventing liquefaction during an
earthquake.
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[0005] Although there are a number of well-known methods for the formation of
stone
columns in the ground. A common method is the use of a special vibrator,
sometimes known as a
Vibroflot, which expels water from its body as it sinks into the ground, thus
forming a hole
which is held open by water pressure and then filled with stone and the stone
is compacted into
the ground in stages using the vibrator. An example of this method is
described in U.S. Pat. No.
4,397,588 for method of constructing a compacted granular or stone column in
soil masses and
apparatus. This method is more commonly know as the Wet Top Feed Method.
[0006] Utilization of this method produces very large quantities of soil laden
water by-
product which must be disposed of. Disposal of this by-product is difficult
and expensive under
the best of conditions, and virtually prohibitive at environmentally sensitive
locations.
Consequently, most column installations with vibrators now make use of
ancillary bottom-
feed equipment which provides a feed pipe to the tip of the vibrator. Stone is
fed through this
pipe to the tip of the vibrator using compressed air, thus eliminating the
need for water. Although
production by this method is somewhat slower, and thus slightly more
expensive, savings in the
disposal of the by-product usually more than offsets the additional cost. This
method is more
commonly know as the Dry Bottom Feed Method
[0007] Dry Bottom Feed stone columns are a soil improvement technique for such
applications where the Wet Top Feed Method is not feasible due to problems
related to the by
product of flushing water that is produced with the Wet Top Feed Method
[0008] Both the Wet Top Feed technique and the Dry Bottom Feed technique are
both
suitable for installing stone columns which can be used to reduce the effects
of differential soil
settlements and accelerates the time which cohesive soils require to
consolidate.
[0009] Since soil with a fines content of less than 12 % will compact easier
with the
vibrations associated with column installation, the stone column method (dry
or wet) is ideal for
the prevention of soil liquefaction in the event of an earthquake by
compacting granular layers of
soil. Stone columns also reinforce and drain cohesive soils at the same time.
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[0010] The dry bottom feed method occurs when a stone column is installed in a
way that
the gravel is transported without the use of water in the special duct
alongside the vibratory
mechanism.
[0011] The Dry Top Feed Method is the same as the Dry Bottom Feed Method;
however,
in the dry top feed method the gravel is dumped into the open hole while the
vibratory
mechanism is fully retracted. This method works only if the hole does not
collapse, i.e. instable
soil above ground water table.
[0012] The wet top feed method installation occurs when the gravel is added
from the top
of the hole using flushing water to keep open an annular space around the
vibratory mechanism.
[0013] The wet bottom feed method installation occurs when a stone column is
installed
in a way that the gravel is transported to the tip of the vibratory mechanism
with the aid of water
in the special duct alongside the vibratory mechanism.
[0014] Re-penetration occurs during the installation of stone columns, when
the vibratory
mechanism is lowered back into the gravel to enlarge the column diameter to
the desired value.
[0015] The vibratory mechanism is typically utilized to construct a sand or
stone
column, wherein the probe itself generally consists of a 12 to 16 inch
diameter hollow cylindrical
body. In general, the vibrator is powered by a motor (electric or hydraulic)
rated at a minimum of
130 kW and a minimum centrifugal force of 210 kN gyrating about a longitudinal
axis to create
lateral vibrations in the probe, i.e., vibrations in the horizontal plane. The
minimum double
amplitude (peak to peak measurement) of the probe tip is not less than 18 mm
in a horizontal
direction when the probe is in a free suspended position. The probe is
constructed with follower
tubes, electric cables, and/or hydraulic hoses. Water hoses can also be
connected to the
uppermost extension tube. The complete assembly of the vibrator probe (the
vibratory
mechanism) is usually supported from a commercial crane.
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[0016] In an effort to construct a stone column utilizing this type of probe,
wherein the
probe is penetrated into the soil to a predetermined depth under its own
weight and with
vibration and assistance of a jetting fluid, the jetting fluid, which is under
pressure, may be
compressed air or water. At the required depth, the probe is slowly retrieved
in small increments
to allow backfill material to be placed under the space left by the withdrawn
tip of the probe.
Granular backfill material is transported to the probe tip through a transfer
pipe that runs parallel
to the probe down to the tip of the nosecone. The transfer pipe is fed by a
hopper, typically
mounted at the top of the probe assembly. As the probe is withdrawn, the
granular material is fed
into the void by the probe tip. As the probe is partially lowered again with
the vibrating force, the
freshly deposited granular material in the surrounding soil becomes compacted.
By repetition of
these steps, the stone column is gradually constructed.
[0017] It is universally recognized that a multi chute stone feeding system
would increase
production rates, reduce cost, and improve quality. But, unfortunately the
industry has not been
able to achieve any success in operating any twin feeding system because of
constant blockages
and break downs of such apparatus. As a result, the industry has move away
from that system
and has adopted the single pipe feed system. As such, there is a need in the
art for a multi feeding
system that has two or more feeding chutes, which can increase production
rates, reduce cost,
and improve quality of the stone columns, and which does not have blockage
problems.
[0018] The twin chute feed system has been attempted in the past but was not
successful
largely because if one chute became slightly blocked, air flow was reduced by
the blockage at a
point in time when it was necessary to have it increased in order to remove
the blockage. This
had a cascading effect where the flow through the blocked chute became smaller
and smaller and
the flow through the clear chute became correspondingly larger. Eventually one
chute blocked
completely. Thus, there is a need in the art for a new method & apparatus that
can overcome the
above problems by constantly monitoring and adjusting the flow of air and
pressure of the air in:
(1) stone chamber, (2) stone feed pipe (3) transition splitter chute, and (4)
multiple feed chutes
attached to vibratory mechanism through either a hand operated or fully
automated control
system.
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[0019] In previous systems, if debris became stuck to the stone valve the
usual way to
clean the valve was to open and close it several times in the hopes that it
would dislodge the
debris and clear itself. As such, there is a need in the art for a new device
that can overcome the
above problems.
[0020] Stone capacity of the hopper is one of the factors which directly
limits the stone
delivery system. The size of the hopper is limited by the need to keep the
equipment within legal
load limits for road transportation.
[0021] The industry has chosen to limit the width of the stone skip to the
same width or
smaller than the stone hopper which in turn limits the width of the loader
which is used to fill the
skip to the same or smaller width as the skip. The industry average capacity
is about 2cycles per
charge of stone. Thus, there is a need in the art for a new method & apparatus
that can overcome
the above problems and limitations to increase the stone storage capacity of
the skip.
SUMMARY OF THE INVENTION
[0022] It is the object of the present invention to construct an apparatus to
use stone
columns to improve soil stability and firmness.
[0023] It is the object of the present invention to construct an apparatus
that creates stone
columns more economically and higher quality than has been achieved with
previous equipment.
[0024] It is an object of the present invention to construct a control system
that can be
designed to be either hand operated or fully automated programmable controller
system.
[0025] It is also the object of the present invention to construct a control
system that is
designed to improve the efficiency of the operation and to improve the quality
of constructed
stone column.
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[0026] It is also the object of the present invention to construct a control
system that can
be designed to monitor and control for the flow of air and stone during the
ground improvement
process as well as simultaneously display the results on a monitor in the
operator's cab in real
time.
[0027] It is the object of the present invention in the preferred embodiment
to construct
an apparatus comprising: a crane, a skip, a hopper, a stone chamber, a stone
feed pipe, a
transition splitter chute, a vibratory probe mechanism, a nosecone, and a
control system.
Said control system whether hand operated or fully automated controller
constantly monitors the
flow of air and the pressure of the air in the chutes to ensure that each
chute remain unblocked
thus allowing a continuous and uniform discharge of material from each chute.
[0028] In the simplest version of the control system, it is comprised of. a
stone valve, an
air inlet valve, an air vent valve, and an air pressure sensor (Here - no air
sensor, no compressor,
and no air hose is needed), wherein said valves are interlocked together to
pressurize the flow of
material traveling from the stone chamber to feed pipe to the splitter chute
to vibratory probe
mechanism and then out the nosecone.
[0029] Alternatively, we could we just use a compressor and multiple air hoses
(and not
pressurize the system or use a stone valve, an air inlet valve, an air vent
valve) to still get
material to flow properly.
[0030] In another version of the control system, it is comprised of. a stone
valve, an air
inlet valve, an air vent valve, air pressure sensor, air flow sensor, a
compressor, and at least one
air hose for each chute, wherein an operator or a fully automated controller,
constantly monitors
and adjusts the flow of air and pressure of the air in the system to ensure
for a continuous and
uniform discharge of material from each chute.
[0031] It is the object of the present invention that the control system is
comprised of: a
stone valve, an air inlet valve, an air vent valve, air pressure sensor, a
volume measuring device
(e.g. air flow sensor), air modulating valves, a compressor, an air hose for
each chute and an
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automated electronic controller that automatically adjusts air flow in the
hoses and air pressure in
said valves to ensure that the material continuously and uniformly travels
without encountering
any blockage.
[0032] It is the object of the present invention to construct an apparatus
comprising: a
hopper, a stone chamber, a feed pipe, a two way splitter, a vibratory probe
mechanism, a
nosecone, and a control system. Wherein, all of the aforementioned components
(with the
exception of the skip) are connected together and suspended from the main line
of a crane. The
skip is filled with stone using a conventional front end loader and raised to
fill the hopper using
the auxiliary line of the crane. A special valve (the stone valve) located
between the hopper and
the stone chamber is opened to allow stone to fall from the hopper into the
stone chamber. The
valve is closed when the hopper is empty and the stone chamber is pressurized
with air. The air
pressure in the stone chamber, combined with the balanced flow of flushing air
which is fed
through the stone chutes allows stone to be continuously and uniformly
discharged from each
chute. A level measuring device (interlocked with the control system)
continuously monitors the
rate of flow of stone leaving the stone chamber. By constantly measuring the
volume of stone
discharged and the depth over which the stone is discharged, it is possible to
determine the
diameter of the stone column constructed in the ground.
[0033] It is also the object of the present invention to construct a method of
operation for
this apparatus: Wherein the operator approaches the system, air pressure is at
zero, all valves are
open, and no stone is in the system. The hopper, stone chamber, follower tube
and vibratory
probe mechanism are suspended from the main winch of a crane. The skip is
suspended from the
auxiliary winch of the same crane. The first operation is to close the stone
valve located between
the hopper and the stone chamber, and fill the skip with stone using the front
end loader. The
auxiliary winch on the crane is used to raise the skip to full height and
empty the stone from the
skip into the hopper. The stone valve opens to allow stone to drop from the
hopper into the stone
chamber. When the hopper is emptied, the stone valve is closed and the stone
chamber is
pressurized. A combination of the pressure in the stone chamber, gravity, and
the action of the
vibratory mechanism causes the stone to travel through the stone pipe, through
the transition
splitter chute and out through the twin stone chutes at the tip of the
vibratory probe mechanisms.
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Raising the vibratory probe mechanism to the predetermined height allows stone
to fall into the
previously created cavity. A sensor on the stone pipe measures the quantity of
stone released into
the cavity. Lowering the vibratory probe mechanism into the previously placed
stone displaces
the stone laterally into the surrounding soil. The amount of re-penetration
into the previously
placed soil is determined either by reaching a pre-determined diameter of
stone column or by
reaching a predetermined density as measured by the amount of energy applied
to the vibratory
probe mechanism. Depending on whether diameter or energy is controlling the
process, the
controlling parameter is calculated in real time and displayed on the
operator's screen in the cab
of the crane. The cycle of raising the vibratory probe mechanism to allow
stone to discharge, and
re-penetrating the stone to increase the diameter of the column is repeated
until all the stone has
been discharged from the stone hopper. When the sensor in the stone chamber
detects that all of
the stone has been discharged, the stone chamber is ventilated, the pressure
is reduced to
atmospheric, and the stone valve is opened. Concurrently the skip (full of
stone) is raised to the
stone hopper and emptied into the stone hopper. The stone valve is opened to
allow stone to
move from the stone hopper into the stone chamber. When the hopper has emptied
all the stone
into the stone chamber, the stone valve is closed, the stone chamber is
pressurized. The cycle is
repeated until the stone column has been constructed to the required diameter
or density for the
entire depth of the column.
[0034] It is a further object of the present invention to construct a method
of operation
for this apparatus wherein a control system monitors and controls the air
pressure inside the
stone chamber and the feed pipe. In addition, two separate air hoses discharge
air into the stone
outlet chutes close to the tip of the vibratory probe mechanism. This air flow
is monitored and
adjusted continuously to ensure that both chutes remain unblocked thus
allowing a continuous
and uniform discharge of stone from each chute. The condition of all valves
(open or closed) is
displayed on the operator's screen. The diameter of the stone column at each
lift of stone is
calculated and displayed in real time.
[0035] It is an object of the present invention to construct an apparatus that
has means for
opening the stone valve to allow stone to drop from the hopper into the stone
chamber.
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[0036] It is also an object of the present invention to construct an apparatus
that has
means for closing the stone valve and pressurizing the stone hopper.
[0037] It is a further object of the present invention to have an electronic
control system
which constantly monitors the flow of air and the pressure of the air in both
stone chutes. If air
flow in one chute drops below the pre-determined level, this is an indication
of a potential
blockage. The controller senses this change and reduces air flow to the other
chute (the clear
chute), and diverts more air to the potentially blocking chute which causes an
increase in flow
and pressure in the potentially blocking chute. As soon as the blockage is
cleared the sensor
detects a drop in pressure which is a signal for the controller to reverse the
previous operation
and balance the flow of air to both chutes. The controller constantly monitors
the flow and
pressure of air in both chutes and constantly makes adjustments. The
monitoring and adjustment
of air flow and pressure of the air in the chutes ensures that both chutes
remain unblocked thus
allowing a continuous and uniform discharge of stone from each chute. The
electronically
monitored air supply [called out as Y1 and Y2 in Figure 11] is introduced to
the system just
above the transition splitter chute which connects the stone supply pipe to
the vibratory probe
mechanism. In addition to the air supply described above, a secondary air
supply is introduced
through the center of the vibratory probe mechanism. This air supply
bifurcates within the
vibratory probe mechanism and exits midway along the length of the vibratory
probe
mechanism. The air [labeled X in Figure 11 ] is directed downward through the
stone chutes and
prevents debris from entering the stone chutes when the remainder of the
system is de-
pressurized. This air supply is also used when the vibratory mechanism is
being lowered to the
pre-determined design depth at the start of the stone column construction
cycle.
[0038] It is an object of the present invention to utilize two or more air
supplies in each
chute to help prevent any potential blockage.
[0039] It is also an object of the present invention in alternative
embodiments to utilize
two or more air supplies in each chute to help prevent any debris from
entering the stone chutes
in an up draft when the remainder of the system is de-pressurized.
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[0040] It is also an object of the present invention to pressurize air; in
order to get the
stone to flow [even with a single tube system] the stone chamber needs to be
pressurized, and the
stone chamber must be de-pressurized at the end of the cycle in order to open
the stone valve and
add stone to begin the next cycle. The quantity of stone added during each
cycle is called a
"charge of stone". The time taken to pressurize the chamber after stone has
been loaded and the
time needed to vent the air in preparation for the next charge of stone is non-
productive time and
should be kept to a minimum. The normal sequence of operation from the
beginning of a cycle is
as follows: the air vent valve is in the open position, the air fill valve is
in the closed position,
and the stone valve is in the closed position. With no pressure in the stone
chamber, a charge
(skip) of stone is placed in the stone hopper, the stone valve is opened,
stone falls from the stone
hopper into the stone chamber, the stone valve is closed, the air vent valve
is closed and the air
fill valve is opened. This sequence of operations causes the stone chamber to
be pressurized
which is necessary in order to assist the stone to travel down the stone pipe
and into the two side
chutes and out at the tip of the vibratory probe mechanism. It is important to
know when to
instigate the correct valve sequencing both from a safety and an efficiency
viewpoint.
[0041] This system uses a pressure sensor mounted on top of the stone chamber
and
sends the information to the controller described earlier [the same controller
that controls the
modulated air supply to both side tubes]. In this instance the valves (air
inlet valve, air vent
valve, and stone valve) are interlocked together so that it is not possible to
open the stone valve
while the stone chamber is pressurized [could be a dangerous event]. In
previous systems the
decision as to when it was safe to open the stone valve was left to the
operator. If the operator
opened the stone valve too early while the chamber was pressurized air would
rush out through
the stone valve and might eject stone from the stone hopper. If the operator
delayed too long in
opening the stone valve it was inefficient (wasted time). With this system, if
the operator wants
to add stone to the stone chamber, he activates the stone valve as usual [i.e.
he presses the button
"Open Stone Valve"] but the stone valve will not operate until the air inlet
valve has been turned
off, the air vent valve has been opened and the air pressure within the system
has dropped to a
level where it is safe to open the stone valve. This sequence of valve changes
is done
automatically by the electronic controller and was all triggered by the
operator indicating to the
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system that he wanted to fill stone (ie activate the stone valve). This is
faster and safer than
manual operation.
'[0042] It is an object of the present invention to construct an apparatus
with wear / slide
plates fitted to the stone chamber outlet to assist with the stone feed.
[0043] It is a further object of the present invention to construct an
apparatus that can
split the quantity of stone evenly and allow the same quantity of stone to
exit from both outlet
chutes at the tip of the vibratory probe mechanisms.
[0044] It is an object of the present invention to construct an apparatus that
has a sensor
that detects the level of stone in the stone chamber, detects when all of the
stone has been
discharged, when the stone chamber is ventilated, when the pressure is reduced
to atmospheric,
and when the stone valve is opened.
[0045] It is an object of the present invention to construct an apparatus that
has a control
system that monitors and controls the air pressure inside the stone chamber
and the stone feed
pipe.
[0046] It is an object of the present invention in one embodiment to construct
an
apparatus that has at least one separate air hoses for discharging air into
each outlet chute around
the splitter to prevent blockage.
[0047] It is an object of the present invention in another embodiment to
construct an
apparatus that has at least one air hose positioned in each chute near the
splitter and at least one
air hose positioned in the middle of each chute of the vibratory probe
mechanism.
[0048] It is an object of the present invention to construct an apparatus that
monitors and
adjusts the air flow continuously to ensure that both chutes remain unblocked
thus allowing a
continuous and uniform discharge of stone from each chute.
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[0049] It is an object of the present invention to construct an apparatus
wherein the
condition of all valves (open or closed) is displayed on the operator's
screen, to allow the
diameter of the stone column to be calculated at each lift, and to display
this information in the
operator's cab in real time.
[0050] It is a further object of the present invention to construct a stone
column apparatus
that utilizes a twin stone feed chute which will replace the single stone tube
feed system.
[0051] It is a further object of the present invention to construct an
apparatus that feeds
the stones to the tip of the vibratory probe mechanism using twin chutes.
[0052] It is also an object of the present invention to construct a stone
column apparatus
that utilizes two or more stone feed chutes.
[0053] It is an object of the present invention to construct a control system
that measures
and continuously monitors the flow rate of stone leaving the stone chamber.
[0054] It is also an object of the present invention to construct an apparatus
that uses a
control system which balances the purging air to each stone chute thus
allowing each chute to
flow full under all various conditions.
[0055] It is also an object of the present invention to construct an apparatus
that uses an
air control system that contains a device to balance air flow to each stone
chute which keeps each
chute flowing full under all conditions.
[0056] It is also an object of the present invention to construct an apparatus
that uses a
control system to continuously measure in real time the amount of stone placed
into the ground
which will increases the accuracy of stone column diameter calculation which
will increase the
quality of the final product.
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[0057] It is an object of the present invention to construct a control system
which
constantly measuring the volume of stone discharged and the depth over which
the stone is
discharged, thereby allowing the user to determine the diameter of the stone
column constructed
in the ground over much shorter vertical intervals than could be determined
with previous
systems.
[0058] It is an object of the present invention to construct a faster and more
efficient
stone feeder than traditional systems because the twin feed chutes work
without blocking.
[0059] It is also an object of the present invention to construct an apparatus
with two or
more chutes for feeding stone to the vibratory probe mechanism to create a
more circular and
concentric column than traditional systems that only feeds stone from one
tube.
[0060] It is also an object of the present invention to construct an apparatus
with a special
tip at the nosecone where the stone is discharged which cuts the ground to
allow easier
penetration of the vibratory mechanism and to assist with pushing stone
laterally during stone
column construction.
[0061] It is also an object of the present invention to construct an apparatus
that uses a
nosecone which contains a device to allow faster penetration of the vibratory
probe mechanism
which reduces wear and tear on the external parts and further reduces
potential damage to the
motor of the vibratory probe mechanism.
[0062] It is a further object of the present invention in an alternative
embodiment to
construct an apparatus having a nosecone with air jets to assist with ground
penetration.
[0063] It is an object of the present invention to construct an apparatus
which allows a
user to raise the vibratory probe mechanism to a predetermined height and
allow stone to fall into
the previously created cavity. It is also an object of this invention to
utilize a sensor in the stone
chamber to measure the quantity of stone released into the cavity. It is a
further object of this
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invention to lower the vibratory probe mechanism into the previously placed
stone and displace
the stone laterally into the surrounding soil.
[0064] In alternative embodiments, a loader (also known as a bucket loader,
front
loader, front end loader, payloader, scoop loader, shovel, skip loader, and/or
wheel loader) could
be used instead of the skip as identified in the preferred embodiment of this
invention to load
material into the hopper.
[0065] It is an object of the present invention to minimize the number of
times that a user
has to pressurize the chamber after stone has been loaded since the time
needed to pressurize the
stone chamber is non-productive time. As such, there is a need in the art for
a way to increase the
stone capacity of the system.
[0066] It is an object of the present invention to minimize the number of
times that a user
has to de-pressurize the chamber after stone has been used since the time
needed to vent the air
in preparation for the next charge of stone is non-productive time.
[0067] It is an object of the present invention to increase the stone capacity
of the system
[the charge size] by double the industry average. One of the factors which has
limited the
capacity of previous systems as well as the industry is the need to keep the
equipment within
legal load limits for road transportation. In previous systems this has
limited the width of the
stone skip to the same width or smaller than the stone hopper which in turn
limits the width of
the loader which is used to fill the skip to the same or smaller width as the
skip. The industry
average capacity is about 2cy per charge of stone. This system still uses a
stone hopper which is
within legal road transportation dimensions but the skip is over 20% wider
than the hopper
which means a 4cy loader can be used to load the skip. Now, the skip is
instead transported
lengthwise on a truck, so it is still within legal transport dimensions. A
series of baffles within
the skip channel the stone from the large width of the skip to the smaller
width of the road legal
width of hopper. Additionally, the hopper utilizes two hooks for making a
centered connection to
a latch on the skip and thereby centering the larger skip about the smaller
hopper and creating a
pivot point for the larger skip to properly and completely dump the stone into
the smaller hopper.
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[0068] It is an object of the present invention to increase the stone capacity
by
developing a set of baffles in the skip which allows a l Oft wide skip to
discharge into an 8ft wide
hopper without spilling any appreciable amount of stone.
[0069] It is an object of the present invention to construct a skip having
lifting arms that
are a curved shape which causes the ann to always fall toward the back of the
skip and out of the
way when the loader is filling the skip with stone. This feature, along with
the concealed design
of the sheaves [protected by the bail arm] help protect the sheave bearings
from excessive wear
and/or damage.
[0070] It is an object of the present invention to construct a skip having
bearings
supporting the sheaves on the skip arm that are concealed to reduce the
potential for accidental
damage which can be caused during the dumping of stone from the loader into
the skip.
[0071] It is an object of the present invention to construct a skip having two
arms which
are attached to an crossbar having sheaves positioned on each side for raising
said skip to fill the
hopper using the auxiliary line from the crane. Wherein said sheaves are
positioned under the
crossbar to prevent damage to the sheaves.
[0072] It is an object of the present invention to construct a skip having two
curved anus
which is weighted to increase the probability that the skip will always fall
away from the loader.
[0073] It is an object of the present invention to construct a hopper having
one or more
hooks for centering the skip about the hopper allowing the skip to properly
and completely
dump the stone into the hopper.
[0074] It is an object of the present invention to construct a hopper having
one or more
hooks for connecting to a latch on the skip and thereby creating a pivot point
for the skip to
properly and completely dump the stone into the hopper.
CA 02766447 2012-01-31
16
[0075] It is also an object of the present invention to have a valve between
the hopper
and the stone chamber, which has a self-cleaning seal to ensure a complete
seal without re-tries.
[0076] It is also an object of the present invention to have two picking
points on each
side of the center of the hopper which are directly in line with the
centerline of the vibratory
probe mechanism. This causes the unit to hang truly vertical which creates
vertical columns and
reduces stress on the apparatus.
[0076] It is also an object of the present invention to construct stone
columns more
economically and of better quality by increasing production rates, reducing
cost, and improving
quality.
[0077] It is also an object of the present invention to construct a large
capacity hopper, a
stone chamber, and a skip box.
[0078] It is also an object of the present invention to construct a large
valve between the
hopper and the stone chamber to allow faster filling.
[0079] It is also an object of the present invention to construct two large
valves, an air
inlet valve and an air vent valve for pressurizing and de-pressurizing the
stone chamber faster
that previous systems.
[0080] It is also an object of the present invention to construct the largest
stone tube to
allow for faster feeding of stone.
[0081] It is also an object of the present invention to provide an apparatus
that is easy to
manufacture, simple to assemble, reliable in operation, and relatively
inexpensive to produce.
[0082] It is an object of the present invention to provide a method of using
the apparatus
wherein it is simple to install and use in various applications.
CA 02766447 2012-01-31
17
[0083] Instead of a skip, a loader (a bucket loader, front loader, front end
loader, payloader, scoop loader, shovel, skip loader, and/or wheel loader)
could be used in this
invention to load the stone into the hopper.
[0084] In addition to the above objects, various other objects of this
invention will be
apparent from careful reading of this specification including the detailed
description contained
herein below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0085] These as well as other features of the present invention will become
more
apparent upon reference to the accompanying drawings wherein like numerals
designate
corresponding parts in the several figures summarized as follows:
Figures 1 - 3 show a disassembled view of this apparatus, wherein:
Figure 1 shows a side view of a feed pipe, a two way splitter, a vibratory
probe
mechanism, and a nosecone;
Figure 2a shows an overhead view of the inside of the skip showing the baffles
that are used to funnel the stones from a larger skip into a smaller hopper;
and
Figure 2b shows a bottom perspective view of the skip;
Figure 3 shows a front perspective view of the hopper and a stone chamber.
Figure 4 is a side view of the preferred embodiment of this invention showing
a skip, a
hopper, a stone chamber, a feed pipe, a two way splitter, a vibratory probe
mechanism, a
nosecone, and a control system of this invention having air supply, all
suspended from a
standard crane, wherein a loader is used to load the stones into the skip or
hopper.
CA 02766447 2012-01-31
18
Figure 5 is a side view of the preferred embodiment of this invention showing
a skip, a
hopper, a stone chamber, a feed pipe, a two way splitter, a vibratory probe
mechanism, a
nosecone, and a control system of this invention having air, all suspended
from a standard
crane.
Figure 6 is the internal structure of the stone chamber showing the stone
valve located
between the hopper and stone chamber, which is opened to allow the stone to
fall from
the hopper to the stone chamber. Also shown are a series of air jets that are
located in a
valve seating ring to direct air against the valve to clean said valve and
remove any debris
which might otherwise impact the ability of the valve to achieve an air tight
seal.
Figure 7 is the internal structure of a skip, a hopper, stone chamber and a
stone valve
located between the hopper and stone chamber.
Figure 8 is the internal structure of a skip, a hopper, stone chamber and a
stone valve
located between the hopper and stone chamber.
Figure 9 is the internal structure of a skip, a hopper, stone chamber and a
stone valve
located between the hopper and stone chamber.
Figure 10 shows an inside view of the inner workings of this apparatus,
wherein the stone
valve is closed and the system is pressurized, the pressurized stone travels
from the stone
chamber through the feed pipe, towards the transition splitter and ultimately
down each
chute of the vibratory probe mechanism and out the nosecone.
Figure 11 shows an electronic controller and a compressor that provides the
main air
supply, which shows where the air is supplied to said system.
[0086] Other features and advantages of the invention will be become apparent
from the
following detailed description, taken in conjunction with the accompany
drawings, which
illustrate, by way of example, various features of the invention.
CA 02766447 2012-01-31
19
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0087] The following detailed description and accompanying drawings are
provided for
purposes of illustrating and describing presently preferred embodiments of the
present invention
and are not intended to limit the scope of the invention in anyway. It will be
understood that
various changes in the details, materials, arrangements of parts or
operational conditions which
have been herein described and illustrated in order to explain the nature of
the invention may be
made by those skilled in the art within the principles and the scope of the
invention.
[0088] Referring to the drawings more particularly by reference numbers, FIGS.
1
through 11 shows the apparatus and method of the present invention for forming
a column of
compacted material in soil to increase load bearing capabilities and provide
improved drainage
capabilities. Thereby enhancing ground improvement namely foundation support
and
liquefaction mitigation.
[0089] A method of operation for this apparatus occurs wherein the operator
approaches
the system, air pressure is at zero, all valves are open, and no stone is in
the system. The hopper
20, stone chamber 30, feeder pipe 70, splitter pipe 80 and vibratory probe
mechanism 100 are
suspended from the main winch 210 of a crane 200. The skip 140 is suspended
from the auxiliary
winch 220 of the same crane 200. The first operation is to close the stone
valve 40 located
between the hopper 20 and the stone chamber 30, and fill the skip 140 with
stone using the front
end loader. The auxiliary winch 220 on the crane 200 is used to raise the skip
140 to full height
and empty the stone from the skip 140 into the hopper 20. The stone valve 40
opens to allow
stone to drop from the hopper 20 into the stone chamber 30. When the hopper 20
is emptied, the
stone valve 40 is closed and the stone chamber 30 is pressurized. A
combination of the pressure
in the stone chamber 30, gravity, and the action of the vibratory mechanism
100 causes the stone
to travel through the feeder pipe 70, through the transition splitter pipe 80
and into the splitter
chute 90 and out through the chutes 110 of the vibratory probe mechanisms 100.
Raising the
vibratory probe mechanism 100 to the predetermined height allows stone to fall
into the
previously created cavity. A sensor 45 on the stone chamber measures the
quantity of stone
CA 02766447 2012-01-31
released into the cavity. Lowering the vibratory probe mechanism 100 into the
previously placed
stone displaces the stone laterally into the surrounding soil. The amount of
re-penetration into the
previously placed soil is determined either by reaching a pre-determined
diameter of stone
column or by reaching a predetermined density as measured by the amount of
energy applied to
the vibratory probe mechanism 100. Depending on whether diameter or energy is
controlling the
process, the controlling parameter is calculated in real time and displayed on
the operator's
screen in the cab of the crane. The cycle of raising the vibratory probe
mechanism 100 to allow
stone to discharge, and re-penetrating the stone to increase the diameter of
the column is repeated
until all the stone has been discharged from the stone hopper 20. When the
sensor 45 in the stone
chamber 30 detects that all of the stone has been discharged, the stone
chamber 30 is ventilated,
the pressure is reduced to atmospheric, and the stone valve 40 is opened.
Concurrently the skip
140 (full of stone) is raised to the hopper 20 and emptied into the hopper 20.
The stone valve 40
is opened to allow stone to move from the hopper 20 into the stone chamber 30.
When the
hopper 20 has emptied all the stone into the stone chamber 30, the stone valve
40 is closed, the
stone chamber 30 is pressurized. The cycle is repeated until the stone column
has been
constructed to the required diameter or density for the entire depth of the
column.
[0090] It is a further method of operation for this apparatus wherein a
control system 130
monitors and controls the air pressure inside the stone chamber 30 and in the
system, when it is
closed. In addition, two separate air hoses discharge air into the chutes.
This air flow is
monitored and adjusted continuously to ensure that both chutes remain
unblocked thus allowing
a continuous and uniform discharge of stone from each chute. The condition of
all valves (open
or closed) is displayed on the operator's screen. The diameter of the stone
column at each lift of
stone is calculated and displayed in real time.
[0091] This apparatus in one embodiment is comprised of a system 10 having: a
hopper
20, a stone chamber 30, a transition splitter pipe 80 having at least two
outlet chutes 90, a
vibratory probe mechanism 100 having a tip 105, a nosecone 120, and a control
system 130; said
vibratory probe mechanism 100 has same number of chutes 110 as said transition
splitter pipe
80; said additional chutes 110 are positioned along the side of said vibratory
probe mechanism
100 to increasing the flow rate of a material being discharged into a soil;
said hopper 20 is
CA 02766447 2012-01-31
21
connected to said stone chamber 30 which in turn is connected to said
transition splitter pipe 80,
said transition splitter pipe 80 has chutes 90 that are connected to said
chutes 110 of said
vibratory probe mechanism 100, wherein said vibratory probe mechanism 100 is
connected to
said nosecone 120; said control system 130 constantly monitors the pressure of
the air in said
system to ensure that said chutes continuously and uniformly discharge said
material; wherein
said control system 130 has one or more valves (Stone Valve 40), and one or
more sensors 45,
which are interlocked together to create a pressurized air system which is
necessary in order to
assist said material to travel down said pipes and into said chutes and out at
the tip 105 of the
vibratory probe mechanism 100.
[0092] In an effort to provide soil improvement, this apparatus can use
material that is
selected from group consisting of sand, gravel, pebbles, stone, crushed stone,
or concrete.
[0093] In another embodiment of this apparatus, a stone feed pipe 70 is used
to expand
stone capacity, wherein said feed pipe 70 is positioned as well as connected
to said stone
chamber 30 and said transition splitter chute 80.
[0094] In one embodiment of this apparatus, the control system 130 has a stone
valve 40
which is located between said hopper 20 and said stone chamber 30; when said
stone valve 40 is
opened said material will fall from said hopper 20 into said stone chamber 30;
when said stone
valve 40 is closed after said hopper 20 is emptied, said stone chamber 30 is
then pressurized with
air; wherein said air pressure in said stone chamber 30 is combined with said
air delivered by
said control system used to flush said chutes (90 & 110), said material is
then continuously and
uniformly discharge from each chute (90 & 110).
[0095] A hanging bracket is used to position the stone valve 40 between the
hopper 20
and the stone chamber 30. The apparatus that has means for opening the stone
valve 40 to allow
material to drop from the hopper 20 into the stone chamber 30. After the
material has dropped
from the hopper 20 into the stone chamber 30, the apparatus has means for
closing the stone
valve 40 and pressurizing the stone chamber 30.
CA 02766447 2012-01-31
22
[0096] In the preferred embodiment of this apparatus, the control system 130
further
comprises an air inlet valve 60 and air vent valve 65 to more accurately
control the air pressure
in said system as well as control the pressurizing and de-pressurizing of said
stone chamber 30
faster.
[0097] In one embodiment of this apparatus, the control system 130 further
comprises a
compressor 50 which is connected to said control system to supply the air to
each chute (90 &
110) through an air hose 54; and wherein said control system 130 now
constantly monitors the
flow of air as well as the pressure of the air in said system 10 to ensure
that said chutes (90 &
110) continuously and uniformly discharge said material.
[0098] It is an object of the present invention to construct a control system
that can be
designed to be either hand operated or fully automated programmable controller
system. In one
embodiment, the control system 130 has a live operator for constantly
monitoring the flow of air
and the pressure of the air in the chutes (90 & 110) using sensors 45 to
ensure that each chute (90
& 110) remain unblocked thus allowing a continuous and uniform discharge of
material from
each chute (90 & 110). In another embodiment, the control system 130 has a
fully automated
controller, which constantly monitors the flow of air and the pressure of the
air in the chutes (90
& 110) to ensure that each chute (90 & 110) remain unblocked thus allowing a
continuous and
uniform discharge of material from each chute (90 & 110).
[0099] Wherein the flow of air and pressure of air in said control system 130
is used to
clear chutes (90 & 110) by reducing air flow from a clear chute(s) and diverts
more air to the
potentially blocked chute (90 & 110) which causes an increase in flow and
pressure in the
potentially blocked chute (90 & 110), when the blockage is cleared, the
previous operation is
reversed and the flow and pressure of air to each chute (90 & 110) is balanced
once again.
[0100] Wherein said control system 130 electronically monitors the flow of air
and
pressure of air in said system through the use of two or more sensors 45 to
detect changes in air
flow or pressure which may be an indication of a potential blockage.
CA 02766447 2012-01-31
23
[0101] In one embodiment, said control system 130 has an air inlet valve 60
and an air
vent valve 65 which are used to accurately control the air pressure in said
system, when said
system is closed by said stone valve.
[0102] It is also an object of the present invention to have a valve between
the hopper
and the stone chamber, which has a self-cleaning seal to ensure a complete
seal without re-tries.
Wherein, said stone valve 40 has a series of air jets 44 that are located in
the valve sealing ring
42 to direct air against the stone valve to clean said stone valve and remove
any debris which
might otherwise impact the ability of the stone valve to achieve an air tight
seal.
[0103] In one embodiment of this apparatus it is comprised of. a skipl40; a
system 10
comprised of: a hopper 20; a stone chamber 30; a transition splitter pipe 80
having at least two
outlet chutes 90; a vibratory probe mechanism 100 having a tip 105; a nosecone
120; and a
control system 130; said vibratory probe mechanism 100 has same number of
chutes 110 as said
transition splitter pipe 80; said additional chutes 110 are positioned along
the side of said
vibratory probe mechanism 100 to increasing the flow rate of a material being
discharged into a
soil; said hopper 20 is connected to said stone chamber 30 which in turn is
connected to
transition splitter pipe 80, said transition splitter pipe 80 has chutes 90
that are connected to said
chutes 110 of said vibratory probe mechanism 100, wherein said vibratory probe
mechanism 100
is connected to said nosecone120; a compressor 50 is connected to said control
system 130 to
supply the air; said control system 130 has a stone valve 40, an air inlet
valve 60 and an air vent
valve 65, air pressure and air flow sensors 45 which are interlocked together
to create a
pressurized air system which is necessary in order to assist said material in
traveling down said
pipe and into said chutes and out at the tip of the vibratory probe mechanism;
said control system
130 further comprises positioning at least one air hoses 54 directed
downwardly in each chute to
prevent any blockage of said material and also prevent any debris from
entering the stone chutes
in an up draft when the remainder of the system is de-pressurized; wherein
said air inlet valve
and said air vent valve are used to accurately control the air pressure in
said system, when said
stone valve is closed; and wherein the flow of air and pressure of air in said
control system is
used to clear chutes by reducing air flow from a clear chute(s) and diverts
more air to the
potentially blocked chute which causes an increase in flow and pressure in the
potentially
CA 02766447 2012-01-31
24
blocked tube, when the blockage is cleared, the previous operation is reversed
and the flow and
pressure of air to each chute is balanced once again.
[0104] In another embodiment of this apparatus, said control system 130 has an
operator
for monitoring the flow of air and pressure of air in said system and
constantly makes
adjustments by reducing air flow from said clear chute, and diverts more air
to the potentially
blocked chute air, which causes an increase in air flow and pressure in the
potentially blocked
chute, thereby causing either said pressure sensor or said air flow sensor to
go off, when the
blockage is cleared said operator reverses the previous operation and balances
the flow and
pressure of air to each chute.
[0105] In yet another embodiment of this apparatus, said control system 130
has a fully
automated controller, which electronically monitors the flow of air and
pressure of air in said
system and constantly makes adjustments by reducing air flow from said clear
chute, and diverts
more air to the potentially blocked chute air, which causes an increase in air
flow and pressure in
the potentially blocked chute, when the blockage is cleared the previous
operation is reversed by
said fully automated controller and the flow of air and pressure of air to
each chute is balanced.
[0106] In an embodiment of this apparatus, a stone feed pipe 70 is used to
expand stone
capacity, wherein said feed pipe 70 is positioned as well as connected between
said stone
chamber 30 and said transition splitter chute 80.
[0107] In one embodiment of this apparatus, said system 10 is suspended from a
main
line 210 of a crane 200 and said skip 140 is connected to an auxiliary line
220 of said crane 200;
wherein a stone column construction parameters are calculated in real time and
displayed on a
screen in a cab of said crane for said operator to view.
[0108] In the embodiment of this apparatus, said hopper 20 utilizes two hooks
190 for
making a centered connection to a latch 180 on said skip 140 and thereby
centering the larger
skip 140 about the smaller hopper 20 and creating a pivot point for the larger
skip 140 to
properly and completely dump the stone into the smaller hopper 20.
CA 02766447 2012-01-31
[0109] In the embodiment of this apparatus, said skip 140 has a series of
baffles / diverter
plates 150 within said skip 140 to channel said material from the large width
of the skip 140 to
the smaller width of hopper 20.
[0110] An object of the present invention is to have an electronic control
system which
constantly monitors the flow of air and the pressure of the air in both stone
chutes. If air flow in
one chute drops below the pre-determined level, this is an indication of a
potential blockage. The
controller senses this change and reduces air flow to the other chute (the
clear chute), and diverts
more air to the potentially blocking chute which causes an increase in flow
and pressure in the
potentially blocking chute. As soon as the blockage is cleared the sensor
detects a drop in
pressure which is a signal for the controller to reverse the previous
operation and balance the
flow of air to both chutes. The controller constantly monitors the flow and
pressure of air in both
chutes and constantly makes adjustments. The monitoring and adjustment of air
flow and
pressure of the air in the chutes ensures that both chutes remain unblocked
thus allowing a
continuous and uniform discharge of stone from each chute. The electronically
monitored air
supply [called out as Y1 and Y2 in Figure 11] is introduced to the system just
above the
transition splitter chute which connects the stone supply pipe to the
vibratory probe mechanism.
In addition to the air supply described above, a secondary air supply is
introduced through the
center of the vibratory probe mechanism. This air supply bifurcates within the
vibratory probe
mechanism and exits midway along the length of the vibratory probe mechanism.
The air
[labeled X in Figure 11 ] is directed downward through the stone chutes and
prevents debris from
entering the stone chutes when the remainder of the system is de-pressurized.
This air supply is
also used when the vibratory mechanism is being lowered to the pre-determined
design depth at
the start of the stone column construction cycle.
[0111] It is also an object of the present invention to pressurize air; in
order to get the
stone to flow [even with a single tube system] the stone chamber needs to be
pressurized, and the
stone chamber must be de-pressurized at the end of the cycle in order to open
the stone valve and
add stone to begin the next cycle. The quantity of stone added during each
cycle is called a
"charge of stone". The time taken to pressurize the chamber after stone has
been loaded and the
CA 02766447 2012-01-31
26
time needed to vent the air in preparation for the next charge of stone is non-
productive time and
should be kept to a minimum. The normal sequence of operation from the
beginning of a cycle is
as follows: the air vent valve is in the open position, the air fill valve is
in the closed position,
and the stone valve is in the closed position. With no pressure in the stone
chamber, a charge
(skip) of stone is placed in the stone hopper, the stone valve is opened,
stone falls from the stone
hopper into the stone chamber, the stone valve is closed, the air vent valve
is closed and the air
fill valve is opened. This sequence of operations causes the stone chamber to
be pressurized
which is necessary in order to assist the stone to travel down the stone pipe
and into the two side
chutes and out at the tip of the vibratory probe mechanism. It is important to
know when to
instigate the correct valve sequencing both from a safety and an efficiency
viewpoint.
[0112] This system uses a pressure sensor mounted on top of the stone chamber
and
sends the information to the controller described earlier [the same controller
that controls the
modulated air supply to both side tubes]. In this instance the valves (air
inlet valve, air vent
valve, and stone valve) are interlocked together so that it is not possible to
open the stone valve
while the stone chamber is pressurized [could be a dangerous event]. In
previous systems the
decision as to when it was safe to open the stone valve was left to the
operator. If the operator
opened the stone valve too early while the chamber was pressurized air would
rush out through
the stone valve and might eject stone from the stone hopper. If the operator
delayed too long in
opening the stone valve it was inefficient (wasted time). With this system, if
the operator wants
to add stone to the stone chamber, he activates the stone valve as usual [i.e.
he presses the button
"Open Stone Valve"] but the stone valve will not operate until the air inlet
valve has been turned
off, the air vent valve has been opened and the air pressure within the system
has dropped to a
level where it is safe to open the stone valve. This sequence of valve changes
is done
automatically by the electronic controller and was all triggered by the
operator indicating to the
system that he wanted to fill stone (ie activate the stone valve). This is
faster and safer than
manual operation.
[0113] It is an object of the present invention to construct an apparatus that
can split the
quantity of stone evenly and allow the same quantity of stone to exit from the
outlet chutes at the
tip of the vibratory probe mechanisms.
CA 02766447 2012-01-31
27
[0114] A sensor to detect the level of stone in the stone chamber, detects
when all of the
stone has been discharged, when the stone chamber is ventilated, when the
pressure is reduced to
atmospheric, and when the stone valve is opened.
[0115] It is an object of the present invention in one embodiment to construct
an
apparatus that monitors and adjusts the air flow continuously to ensure that
both chutes remain
unblocked thus allowing a continuous and uniform discharge of stone from each
chute.
[0116] It is also an object of the present invention to construct an apparatus
that uses an
air control system that contains a device to balance air flow to each stone
chute which keeps each
chute flowing full under all conditions.
[0117] The apparatus in alternative embodiments uses a control system to
continuously
measure in real time the amount of stone placed into the ground which will
increases the
accuracy of stone column diameter calculation which will increase the quality
of the final
product.
[0118] The control system constantly measuring the volume of stone discharged
and the
depth over which the stone is discharged, thereby allowing the user to
determine the diameter of
the stone column constructed in the ground over much shorter vertical
intervals than could be
determined with previous systems.
[0119] The control system that can be designed to monitor and control for the
flow of air
and stone during the ground improvement process as well as simultaneously
display the results
on a monitor in the operator's cab in real time.
[0120] It is an object of the present invention to construct a faster and more
efficient
stone feeder than traditional systems because the twin feed chutes work
without blocking.
CA 02766447 2012-01-31
28
[0121] It is also an object of the present invention to construct an apparatus
with two or
more chutes for feeding stone to the vibratory probe mechanism to create a
more circular and
concentric column than traditional systems that only feeds stone from one
tube.
[0122] The nosecone where the stone is discharged cuts the ground to allow
easier
penetration of the vibratory mechanism and to assist with pushing stone
laterally during stone
column construction.
[0123] The nosecone allows for faster penetration of the vibratory probe
mechanism
which reduces wear and tear on the external parts and further reduces
potential damage to the
motor of the vibratory probe mechanism.
[0124] A user will typically raise the vibratory probe mechanism to a
predetermined
height and allow stone to fall into the previously created cavity. It is also
an object of this
invention to utilize a sensor in the stone chamber to measure the quantity of
stone released into
the cavity. It is a further object of this invention to lower the vibratory
probe mechanism into the
previously placed stone and displace the stone laterally into the surrounding
soil.
[0125] It is an object of the present invention to minimize the number of
times that a user
has to pressurize the chamber after stone has been loaded since the time
needed to pressurize the
stone chamber is non-productive time. As such, there is a need in the art for
a way to increase the
stone capacity of the system.
[0126] It is an object of the present invention to increase the stone capacity
of the system
[the charge size] by double the industry average. One of the factors which has
limited the
capacity of previous systems as well as the industry is the need to keep the
equipment within
legal load limits for road transportation. In previous systems this has
limited the width of the
stone skip to the same width or smaller than the stone hopper which in turn
limits the width of
the loader which is used to fill the skip to the same or smaller width as the
skip. The industry
average capacity is about 2cy per charge of stone. This system still uses a
stone hopper which is
within legal road transportation dimensions but the skip is over 20% wider
than the hopper
CA 02766447 2012-01-31
29
which means a 4cy loader can be used to load the skip. Now, the skip is
instead transported
lengthwise on a truck, so it is still within legal transport dimensions. A
series of baffles within
the skip channel the stone from the large width of the skip to the smaller
width of the road legal
width of hopper. Additionally, the hopper utilizes two hooks for making a
centered connection to
a latch on the skip and thereby centering the larger skip about the smaller
hopper and creating a
pivot point for the larger skip to properly and completely dump the stone into
the smaller hopper.
[0127] It is an object of the present invention to increase the stone capacity
by
developing a set of baffles / diverts in the skip which allows a l Oft wide
skip to discharge into an
8ft wide hopper without spilling any appreciable amount of stone.
[0128] A skip having lifting arms that are a curved shape which causes the arm
to always
fall toward the back of the skip and out of the way when the loader is filling
the skip with stone.
This feature, along with the concealed design of the sheaves [protected by the
bail arm] help
protect the sheave bearings from excessive wear and/or damage. The skip has
bearings
supporting the sheaves on the skip arm that are concealed to reduce the
potential for accidental
damage which can be caused during the dumping of stone from the loader into
the skip. The skip
has two arms which are attached to an crossbar having sheaves positioned on
each side for
raising said skip to fill the hopper using the auxiliary line from the crane.
Wherein said sheaves
are positioned under the crossbar to prevent damage to the sheaves. The skip
has two curved
arms which is weighted to increase the probability that the skip will always
fall away from the
loader.
[0129] It is an object of the present invention to construct a hopper having
one or more
hooks for centering the skip about the hopper allowing the skip to properly
and completely dump
the stone into the hopper.
[0130] It is an object of the present invention to construct a hopper having
one or more
hooks for connecting to a latch on the skip and thereby creating a pivot point
for the skip to
properly and completely dump the stone into the hopper.
CA 02766447 2012-01-31
[0131] It is also an object of the present invention to have two picking
points on each
side of the center of the hopper which are directly in line with the
centerline of the vibratory
probe mechanism. This causes the unit to hang truly vertical which creates
vertical columns and
reduces stress on the apparatus.
[0132] In the preferred embodiment of this invention, the method for
calculating a
diameter or a density of a column which is constructed of a material in real
time so information
is displayed on an operators screen: providing a system having a hopper, a
stone chamber, a
transition splitter pipe having at least two outlet chutes, a vibratory probe
mechanism having a
tip, a nosecone, and a control system, said vibratory probe mechanism has same
number of
chutes as said transition splitter pipe, said additional chutes are positioned
along the side of said
vibratory probe mechanism to increasing the flow rate of a material being
discharged into a soil,
said hopper is connected to said stone chamber which in turn is connected to
said transition
splitter pipe, said splitter pipe has outlets that are connected to said
chutes of said vibratory probe
mechanism, wherein said vibratory probe mechanism is connected to said
nosecone, a
compressor is connected to said control system to supply the air, said control
system has a stone
valve, an air inlet valve, an air vent valve, an air pressure sensor and an
air flow sensor which are
interlocked together to create a pressurized air system which is necessary in
order to assist said
material to travel down said pipes and into said chutes and out at the tip of
the vibratory probe
mechanism; said control system further comprises at least one air hose
directed downwardly in
each chute(s) at splitter to prevent any blockage of said material; and
wherein an operator
approaches said system, air pressure is at zero, all valves are open, and no
stone is in said
system; wherein the first operation is to close the stone valve, fill said
hopper with said material;
wherein said hopper has been filled with said material, said stone valve is
opened to allow said
material to drop from the hopper into the stone chamber; wherein after all of
said material has
been transferred from the hopper into the stone chamber, the stone valve is
closed and the stone
chamber is pressurized; wherein said stone chamber is pressurized, said
operator begins lowering
said vibratory probe mechanism into the soil to the design depth to create a
cavity; wherein the
pressurized stone is transported to the outlet chutes at the tip of the
vibratory probe mechanisms;
wherein the vibratory probe mechanism is raised to a predetermined height to
allow said material
to fall into said previously created cavity; wherein a sensor in the stone
chamber measures the
CA 02766447 2012-01-31
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quantity of material released into the cavity; wherein the vibratory probe
mechanism is lowered
into the previously placed material, said material is laterally displaced into
the surrounding soil;
wherein the cycle of raising the vibratory probe mechanism to allow said
material to discharge
and re-penetrating said material to increase the diameter of a column is
repeated until all said
material has been discharged from said stone hopper; wherein the amount of re-
penetration into
the previously placed soil is determined either by reaching a pre-determined
diameter of said
column or by reaching a predetermined density as measured by the amount of
energy applied to
the vibratory probe mechanism; whether the diameter or energy is controlling
the process, the
controlling parameter is calculated in real time and displayed on said
operators screen; and
wherein the cycle is repeated until said column has been constructed of said
material to the
required diameter or density for the entire depth of said column.
[0133] While the description above refers to particular embodiments of the
present
invention, it will be understood that many subsequent modifications can be
made while
maintaining the spirit of the subject invention intact. As such, the presently
disclosed
embodiments are to be considered in all respects as illustrative and not
restrictive.
