Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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SUPPORT ASSEMBLY FOR A CORE DRILL
Cross Reference to Related Applications
This application is a continuation-in-part of US 12/799,615, filed April 27,
2010, published as US 2011/0262237, now US Patent No. 8,790,052, issued July
29, 2014; and a continuation-in-part of PCT/US11/00748, filed April 26, 2011,
and
US National Stage application 14/114,510, filed January 7, 2014, published as
US
2014/0112728, the entire content and disclosures of which are incorporated
herein
fully by reference.
Background
Field
The field of this invention relates generally toward cutting implements and
more particularly to the construction of a core drill.
Related Art
Core drills are commonly used for drilling holes in hard materials, such as
concrete and masonry. These holes are then used to support a structural
member,
such as a post, which is used on a support member for a building structure or
for
forming a large diameter borehole with the borehole being used for the passage
of
pipe lines or conduits. A typical core drill is constructed of hard metal,
such as steel,
and takes the shape of a tube with hardened cutting segments mounted at one
end
of the tube. The opposite end of the tube is closed generally by a solid steel
plate
with there being a drive connection mounted on this steel plate. The drive
connection
is to be connected to a rotating shaft of a drive machine which will cause the
tube to
be rotated and affect the cutting operation. The cutting segments at one end
normally comprise diamonds but also it has been known to use silicon carbide.
The
diamonds are held together by a suitable resin adhesive.
The plate at the closed end of the tube is of substantial thickness, generally
one half to one and a half inch thick. These core drills are frequently
designed to be
from six inches to thirty-six inches and more in diameter. The steel plate at
the
closed end is of substantial weight. It is important to have an extremely
strong
member at this closed end because all the force from the driving machine is
being
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transferred to this member to the tube. The force encountered by the tube in
cutting
the hole in masonry and concrete is substantial so it is important that the
plate at the
closed end of the tube establish an extremely strong connection. However, most
often these core drills are carried by a human from one location to another.
The plate
member at the closed end of a sixteen inch core drill is substantially heavier
than the
core drill constructed in accordance with this invention. That extra weight
can make
the difference as to whether a core drill can be carried by a single human
from one
location to another. It is readily apparent that the greater the diameter of
the core drill
the greater of the additional amount of weight. It would be desirable to
design some
type of closed end structure for a core drill which would be substantially
lighter in
weight than if a solid plate is used. Furthermore, there is a certain amount
of
deflection associated with the use of the core drill.
At times, when operating of a core drill, a plug of material, which would be
normally masonry or cement, gets caught within the hollow chamber of the core
drill
adjacent the closed end plate. At the present time, access into this area is
only
provided through the open end of a core drill which means some kind of an
elongated member has to be extended up through the hollow chamber of the core
drill and this member wedged against the caught material and somehow loosen it
to
dislodge it. It would be desirable to construct a core drill so that the
closed end
portion of the core drill could be removed from the tube which would provide
immediate local access to any wedged material that is caught within the hollow
chamber and located directly adjacent the closed end.
Summary
In one example, a bolt on drive assembly for a core drill includes a
cylindrical
tube having a cutting edge at one longitudinal end and an open end at an
opposite
longitudinal end; a mounting means mounted at said open end; a high strength
spoked reinforcer, said spoked reinforcer having a center hub from which
extends
radially a plurality of spoked members, said spoked members has a
strengthening
member extending perpendicularly therefrom in the direction of the Z-axis and
wherein said spoked members being attached to said mounting means; a disc
mounted onto said high strength spoked reinforcer and also onto said mounting
means; a drive connection centrally mounted on said disc, said drive
connection
adapted to connect to a drive shaft to cause rotation of said tube; and a
series of
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removable fasteners to secure said disc and said high strength spoked
reinforcer to
said mounting means.
The above example can be further modified by defining that the tube has a
hollow chamber, said mounting means comprising a mounting ring, said mounting
ring being located within said hollow chamber.
The above example can be further modified by defining that a water stop disc
is mounted to said high strength spoked reinforcer, said water stop disc to
function to
prevent the passage of water from within said hollow chamber through said open
end.
The above example can be further modified by defining that the drive
connection comprises a coupler adapted to be threadably secured to a drive
shaft.
The above example can be further modified by defining that the coupler is
removably mounted with bolt fasteners to said high strength spoked reinforcer.
The above example can be further modified by defining that the high strength
spoked reinforcer is integrally formed as one piece with said disc.
The above example can be further modified by defining that each of said
plurality of spoke members is offset from said center hub.
The above example can be further modified by defining that each of said
plurality of spoke members includes one or more supports along the length of
each
of said plurality of spoke members.
In another example of reinforcement, the reinforcement can be non-planar or
have a non-planar component. A non-planar structure can extend upward or
downward from a top plate, or from another structure or extension that extends
from
the center to the mounting ring. The non-planar structure can take a number of
configurations. In one example of a non-planar structure, the structure can be
nonlinear in the direction of the perimeter from the center area, but
substantially
straight or linear in the Z-axis direction. In another example, the non-planar
structure
can be linear in the direction toward the perimeter, but nonlinear in either
or both of
the Z-axis direction or in the X-Y direction or plane. One non-planar
structure can be
a triangular-cross-section tubular or channel structure extending from the
area of the
center toward the perimeter. In one example, the non-planar structure can have
a U-
channel configuration. In a further example, the tubular structure can be
extruded,
formed or machined. Any of the tubular or channel structures described herein
can
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be produced by forming, machining, or extrusion. Aluminum structures can be
easily
extruded, and steel structures can be easily roll-formed, for example.
In another example of a non-planar structure, the structure can be a square or
rectangular tubular structure, or have a square or rectangular cross section.
Such a
structure provides multiple reinforcement walls. Additionally, such a
structure allows
for the use of a thinner wall material relative to the planar reinforcement
element.
A further example of a reinforcement structure between a center of the tool
and a perimeter of the tool includes a non-planar extension, arm or strut
structure
extending from an area near the center of the tool to an area adjacent a
perimeter.
In one example, the extension can be a non-planar structure having a channel
along
a portion of the structure. In another example, the extension can be a non-
planar
structure having multiple walls spaced from each other. In one example, the
extension can be a triangular-shaped cross section or triangular-shaped
tubular or
channel structure. In another example, the extension is a triangular-shaped,
formed
structure, with or without welds closing or securing the structure. In a
further
example, a channel structure having a triangular cross-section configuration
can be
combined with other such structures to form a central mounting configuration
for a
drive assembly, for example one including a drive nut or drive hub. The number
of
such channel structures selected may be selected according to a diameter of
the
tool. For example, a smaller diameter tool may have 6 or 5 such channel
structures,
while a larger diameter tool may have seven or eight such extensions. With
multiple
channel-shaped structures, adjacent channel structures can be welded to each
other
in the area of the center of the tool. Each structure can also be secured to a
mounting ring or other structure for supporting the cylindrical core.
In any of the extensions described herein, a further structure can be mounted
on top of the extensions and/or below the extensions, and can be welded
thereto. In
one example, a top plate can be placed on the tops of the extensions and
welded
thereto. The outer perimeter dimensions of the top plate may be a function of
the
diameter tool, and may include an opening or other interface for receiving a
drive
hub, drive nut, or other driving structure, such as may be for a drill.
In another example of a non-planar structure for an extension, a rectangular,
square or other polygonal structure can be used, for example in conjunction
with
other such structures extending from a central portion of the tool to a
perimeter
portion of the tool. In one example, a square or rectangular channel is used
to form
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the extension, and in a further example, a U-channel forms the extension. In
one
example, the U-channel is an open channel, and in another configuration, the U-
channel is a closed configuration, for example partly or completely covered by
another structure, for example a planar structure. In one example, the
covering
structure can be a top plate, and in another example, the covering structure
can be a
linearly-extending cover for example, a combination that forms a spoke and a
reinforcement for the spoke.
In a further example of reinforcement, the reinforcement can include a water
or other fluid flow channel extending in the direction of the reinforcement
toward a
perimeter portion of the reinforcement, for example toward an area where the
reinforcement will be coupled to a mounting ring. In one configuration, the
fluid flow
channel substantially prevents fluid flow other than along the channel until
the fluid
reaches an outer perimeter portion of the channel, for example prevents more
than
10% of the fluid in the channel to exit before reaching the outer perimeter
portion of
the channel. In another configuration, the fluid flow channel extends at least
half
way from a center of the reinforcement to the perimeter of the reinforcement,
and in
another example at least three quarters of the distance, and in a further
example to a
location adjacent a mounting ring for the core drill. In one example, the
fluid flow
channel may be formed from a polygonal reinforcement structure extending from
a
center portion of the reinforcement to a perimeter portion thereof. In any of
the
examples described herein, a fluid flow channel may be formed as part of a
respective reinforcement arm or extension.
In one example, a support assembly for a core drill includes a support
element having a central opening and having at least one portion extending to
an
outer perimeter portion for being secured to and supporting a mounting element
for a
core drill. A coupling element couples the support assembly to a drill motor,
and the
coupling element includes openings to allow fluid to flow into and out of the
coupling
element. At least one channel has an opening adjacent the coupling element
configured to receive fluid from the coupling element, the at least one
channel
extending toward a point adjacent the outer perimeter portion and configured
so that
fluid can flow from the opening toward the outer perimeter portion. The
support
assembly may have the at least one channel extending at least half the
distance
from the coupling element to the outer perimeter portion. The channel may have
an
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end plate with an opening in the end plate for allowing fluid to flow from the
channel
outside, for example to a perimeter portion of the core drill.
In another example of reinforcement, the reinforcement can include a slanted
element. In the present configurations, "slanted element" will refer to a
structural
support element that has surfaces that are both nonparallel to the Z axis and
to the
X-Y plane. A slanted element improves structural support in the reinforcement
when
used with a device such as a core drill during operation of the core drill. In
one
example, a slanted element can be associated with a respective spoke, arm or
extension for improving the strength of the structure. In another example, a
slanted
element can be formed monolithic with a spoke, arm or extension, for example
in
one configuration by extrusion, and in another configuration by forming metal
into the
desired structure. In a further example, a slanted element can be combined
with an
extension in the X-Y plane to form a combined extension, arm or spoke, and in
another configuration a slanted element can be combined with an extension in
the Z-
axis direction to form a combined extension, arm or spoke. In another example,
multiple slanted elements can be used to form an extension, arm or spoke for
helping to form a support for a structure such as a core drill. In an
additional
example, at least one slanted element can be incorporated in an arm, extension
or
spoke in the form of a triangular-shaped channel or a triangular-shaped tube.
A
rectangular-shaped tube can also be configured in a reinforcement structure to
have
a slanted element. Additionally, a polygon structure having more than four
sides can
be configured to have a slanted element to assist in forming a support for a
structure
such as a core drill.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an external isometric view of one example of a core drill.
FIG. 2 is an exploded isometric view of a bolt on drive assembly for the core
drill of FIG. 1 where the connector of the drive assembly is welded onto an
outer
disc.
FIG. 3 is an inside bottom view of the high strength reinforcer looking up
from
the cutting edge of the drill.
FIG. 4 is a transverse cross-sectional view through the assembled drive
assembly of the core drill of one example of this invention.
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FIG. 5 is a transverse cross-sectional view through the assembled drive
assembly of the core drill of an alternate example wherein the vertical
portion of each
of the arms of the high strength spoked reinforcer is rectangular rather than
triangulated and is a stand alone piece.
FIG. 6 is a transverse cross-sectional view through the assembled drive
assembly of the core drill of a second alternate example wherein the spoked
reinforcer is welded directly the top plate and the vertical portion of each
of the arms
of the high strength spoked reinforcer is rectangular rather than triangular.
FIG. 7 is similar to FIG. 2, but wherein the high strength spoked reinforcer
is
welded directly to the top plate.
FIG. 8 is an isometric view of an underside of another example of a high
strength support for a drill, the support being shown with a mounting ring.
FIG. 9 is a bottom plan view of the assembly of FIG. 8.
FIG. 10 is a side elevation view of the assembly of FIG. 8.
FIG. 11 is a top plan view of the assembly of FIG. 8.
FIG. 12 is an isometric view of the assembly of FIG. 8 with a bottom plate or
water plate removed.
FIG. 13 is an upper isometric view of a reinforcement element used with a
spoke, arm or extension of the support of FIG. 8.
FIG. 14 is a plan view of the bottom plate or water plate of the support of
FIG.
8.
FIG. 15 is a side elevation view of the bottom plate or water plate shown in
FIG. 14.
FIG. 16 is a top plan view of the spoke, arm or extension assembly of FIG. 8.
FIG. 17 is a bottom plan view of the support and mounting ring of FIG. 8.
FIG. 18 is a partial transverse section of a portion of the support of FIG. 17
taken along the line 18-18.
FIG. 19 is an isometric view of an underside of another example of a high
strength support for a drill shown with a mounting ring.
FIG. 20 is a bottom plan view of the assembly of FIG. 19.
FIG. 20 is a side elevation view of the assembly of FIG. 19.
FIG. 22 is a top plan view of the assembly of FIG. 19.
FIG. 23 is an isometric view of the assembly of FIG. 19 with a mounting and
support hub removed.
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FIG. 24 is a lower isometric view of a spoke, arm or extension of the assembly
of FIG. 19.
FIG. 25 is a top plan view of a spoke, arm or extension of the assembly of
FIG. 19.
FIG. 26 is a first side elevation view of a spoke, arm or extension of the
assembly of FIG. 19.
FIG. 27 is a second side elevation view of a spoke, arm or extension of the
assembly of FIG. 19.
FIG. 28 is a first upper isometric view of a spoke, arm or extension of the
assembly of FIG. 19.
FIG. 29 is a further upper isometric view of a spoke, arm or extension of the
assembly of FIG. 19.
FIG. 30 is another upper isometric view of a spoke, arm or extension of the
assembly of FIG. 19.
FIG. 31 is still another upper isometric view of a spoke, arm or extension of
the assembly of FIG. 19.
FIG. 32 is a lower isometric view of a mounting and support hub in the
assembly of FIG. 19.
FIG. 33 is a side elevation view of the hub of FIG. 32.
FIG. 34 is a top plan view of the hub of FIG. 32.
FIG. 35 is an upper isometric view of the hub of FIG. 32.
FIG. 36 is a bottom plan view of the hub of FIG. 32.
FIG. 37 is a plan view of a top plate in the assembly of FIG. 19.
FIG. 38 is a bottom plan view of the assembly of FIG. 19.
FIG. 39 is a partial transverse section of the assembly of FIG. 38 taken along
line 39-39.
FIG. 40 is a top plan and detailed view of an arrangement of triangular arms
for a reinforced assembly configured to receive a hub such as that of FIG. 32.
FIG. 41 is a bottom plan and detailed view of the arrangement of FIG. 40.
Detailed Description
This specification taken in conjunction with the drawings sets forth examples
of apparatus and methods incorporating one or more aspects of the present
inventions in such a manner that any person skilled in the art can make and
use the
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inventions. The examples provide the best modes contemplated for carrying out
the
inventions, although it should be understood that various modifications can be
accomplished within the parameters of the present inventions.
Various benefits will become more apparent with consideration of the
description of the examples herein. However, it should be understood that not
all of
the benefits or features discussed with respect to a particular example must
be
incorporated into a tool, component or method in order to achieve one or more
benefits contemplated by these examples. Additionally, it should be understood
that
features of the examples can be incorporated into a tool, component or method
to
achieve some measure of a given benefit even though the benefit may not be
optimal compared to other possible configurations. For example, one or more
benefits may not be optimized for a given configuration in order to achieve
cost
reductions, efficiencies or for other reasons known to the person settling on
a
particular product configuration or method.
It should be understood that terminology used for orientation, such as front,
rear, side, left and right, upper and lower, and the like, are used herein
merely for
ease of understanding and reference, and are not used as exclusive terms for
the
structures being described and illustrated. In the drawings, reference
characters that
denote similar elements are used throughout the several views.
Referring in particular to FIG. 1, there is shown one example of a core drill
10.
The core drill 10 has a body that is in the shape of a tube 12. This tube 12
can have
a number of diameters as desired. The tube 12 has a through hollow chamber 14.
At one longitudinal end 16 of the core drill 10, there is adhesively or
otherwise
permanently affixed a series of cutting segments 18.
Generally, the cutting
segments 18 will comprise diamonds. The cutting segments 18 are what produce
the cut within the material, which is generally cement or masonry. This cut is
produced by rotation of the tube 12.
FIG. 2 shows an exploded view of FIG. 1. At the opposite longitudinal end of
the tube 12 from one longitudinal end 16 there is located a mounting ring 20.
The
mounting ring 20 has a series of spaced apart threaded holes 22. The mounting
ring
20 is generally no more than one-half to three-quarters of an inch wide and is
to be
fixedly mounted to the wall of the hollow chamber 14 a slight distance spaced
from
the outer edge 24 of the tube 12. Normally, this spacing of the mounting ring
20 will
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be no more than one-half inch. The mounting ring 20 is generally fixedly
secured to
the tube 12 by welding.
Mounted within the hollow chamber 14 is a disc 42. The disc 42 functions as a
cover. The disc 42 has a series of through holes 44 located directly adjacent
the
peripheral edge of the disc 42. In one example, there are through holes 44 to
align
with through holes 40 for each of the radial arms 38 of a high strength spoked
reinforcer 32. A bolt fastener 46 is to be placed through each of the aligned
holes
44, 40 and then be threadably tightened within the threaded hole 22. This will
secure in place the drive assembly which is composed minimally of the high
strength
spoked reinforcer 32 and the disc 42. The disc 26 provides for the prevention
of the
passage of water through the hollow chamber 14 and prevent such from being
discharged from the tube 12 past the mounting ring 20. Water is frequently
used
when drilling of cement and masonry in order to minimize the creation of heat.
Water control can also be achieved by an optional split 26 in the disc 42 as
well as
one or more apertures 30 found thereon. The drive assembly, which is composed
of
the high strength spoked reinforcer 32 and the disc 42 is exceedingly strong
but is
much lighter in weight than if it were a completely solid steel plate. This
has an
advantage in that the overall core drill is lessened in weight therefore
facilitating its
carryablity by a human.
Centrally mounted on the disc 42 is a drive connection 48. Drive connection
48 is shown to be in the shape of a hexagonal nut and has an internal threaded
opening 48. This internal threaded opening 48 is to connect to a drive shaft
of a
driving machinery, which is not shown. The driving machinery is to affect
rotation of
the drive connection 48 and the entire core drill 10. The drive connection is
to be
welded about center hole 52 formed within the outer disc 42.
The high strength spoked reinforcer 32 is situated either as a separate part
(See FIG. 1) or as an integral welded piece to the disc 42 (See FIG. 7). The
high
strength spoked reinforcer 32 has a centrally located hub 34 which also has a
center
hole 36 to facilitate handling. Extending radially outward from the hub 34 are
a
plurality of spaced apart radial arms 38. There are shown six in numbers of
the arms
38. Typically, there will only be used six in number of the arms 38 when the
diameter of the tube 12 is thirty inches and less. As the diameter increases,
the
number of arms 38 may be increased. Directly adjacent the outer end of each of
the
arms 38 is a through hole 40. A through hole 40 is to be in alignment with a
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hole 44. A water stop base 28 sandwiches the high strength spoked reinforce 32
and the disc 42.
As can be seen in FIG. 2, the high strength spoked reinforcer 32 extends
along the Z-axis 37 and is 3-dimensional. It is this 3-dimensional structure
that
provides for the increased performance at high weights with reduced deflection
vs.
weight ratios. The deflection vs. weight ratio mimics a solid plate's
performance
whereas a 2-dimensional spoked reinforcer sees significant deflection at
higher
weights. The high strength spoked reinforcer 38 serves the two fold purpose of
reduced weight for larger diameter cores and reduced deflection at said large
diameters.
FIG. 3 is an inside bottom view of the high strength spoked reinforce 32 when
looking up from the water stop base 28. Above the water stop base 26 is the
hub 34
of the high strength spoked reinforcer 32. This hub 34 includes the hole 36
that
receives the drive connection 48. It is important to note that each of the
radial arms
38 are off-set from the center 34. This offset distributes the load in an
advantageous
manner, reducing deflection during use. Also included on the arms 38 are
supports
52. When the diameter of the drilling exceeds 32 inches, a support is added
for
approximately every 9 inches distance from the hub 34.
Note that in the view shown in FIG. 3, the high strength spoked reinforcer 32
can either be bolted to the disc 42 or be formed as an integral piece with the
disc 42
and bolted only to the mounting ring 20. FIG. 7 shows the alternate example of
the
invention wherein the plate 42 is welded to the high strength spoked
reinforcer 32.
Note that there is no optional split 26 in this example.
FIGs. 4-6 show a cross-sectional side view of three different examples. In
FIG. 4 one example is shown. Drill fluid 60, usually water, enters through the
cavity
50 in the drive 48. The direction of the arrows 62 demonstrates how the water
enters the system and is flung to the outer edges as the drill is spinning. In
this
example, the high strength spoked reinforcer 32 is welded to the disc 42 and
bolted
down through bolts 46 to the mounting ring 20. In this example, the arms 38
have a
triangular profile in the direction of the Z-axis 37 relative to the water
stop base 28.
FIG. 5 shows an alternate example wherein the high strength spoked
reinforcer 32 is bolted to a top disc 42. Also in this example it is shown
that the
water base plate 28a extends to the outer perimeter of the drill. When the
water
base plate 28a extends all the way to the outer perimeter, the arms 38 of the
high
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strength spoked reinforcer 32 in the Z-axis 37 are rectangular in profile
rather than
triangular as seen in FIG. 4. FIG. 6 is the same example as shown in FIG. 5,
except
that the high strength spoked reinforcer 32 is welded directly to the disc 42
and not
bolted on as seen in FIG. 6.
When the instant invention is compared to the system described in U.S. Pat.
No. 6,890,132, the improvements in applied load vs. deflection and weight vs.
tube
diameter are substantial, with the greater benefit being found with increases
in the
diameter of the core drill 10.
In another example of a reinforcement assembly, reinforcement assembly 300
(FIGS. 8-18) may be mounted or otherwise secured to a mounting ring 302
through
holes 304 and fasteners (not shown) so as to enable driving a core drill or
other drill.
The mounting ring may already be in place on a suitable cylinder, or may be
installed
on a cylinder as desired. In the present configuration, a single opening and
fastener
combination is used to secure each arm of the reinforcement assembly to the
mounting ring.
Other configurations also may be used for combining the
reinforcement assembly with a cutting cylinder.
Reinforcement assembly 300 includes a top plate 310 (FIGS. 8-12, and 16-
18) helping to support the drill on a drill motor (not shown). In the
exemplary
configuration, the top plate is a substantially planar member, but can be
nonplanar in
either the upper surface (the surface visible in FIG. 11), the lower surface
(surface
visible in FIGS. 8-9, 12) or both. The top plate 310 is preferably formed from
a sheet
material, for example steel, and includes a central core area 312, which in
the
present discussion is illustrated as being a circular area 314 of material
from which
arms, extensions or spokes 316 extend. The central core area can also be
considered to transition to the arms 316 at an area defined by a hexagonal
shape
either interior or external to the imaginary circle 314, for example with the
points of
the hexagon coinciding with the dashed circle 314, or the dashed circle 314
coinciding with midpoints on a hexagon side between adjacent points. In a
further
example, the central core area can be considered to transition to the arms 316
where a side surface 318 on an arm (FIG. 11) begins to change direction, for
example at line 320.
A hex opening 322 (FIG. 16) or other polygon shape is formed in a center of
the top plate for receiving a hex drive nut 324 (FIGS. 10-12 and 18), or drive
nut of
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another geometric configuration suitable for the desired interface between the
nut
and the top plate.
The top plate (FIG. 11) includes at least one arm 316, and in the present
example a plurality of arms 316, formed monolithic with the central core area
312,
and extends outwardly to a perimeter area from the central core area. Each arm
extends in a respective direction to the perimeter area. In the present
example, the
perimeter area is the area of the mounting ring 302, and each arm terminates
at a
respective outer perimeter surface of the mounting ring. The illustrated
configuration
includes six arms, for example for a drill up to 30 inches in diameter, but
may include
fewer or more arms, as desired. For example, a drill diameter greater than 30
inches
can be supported in part by a reinforcement assembly having eight arms,
extensions
or spokes. Other elements of the assembly can be modified or adjusted to
accommodate the different number of arms.
The present example of the top plate 310 has each of the arms 316 identical
to the others. Therefore, the description of one arm 316 also applies to the
characteristics of the other arms in the top plate. Each arm 316 extends in a
direction off-center of a central axis through the opening 322 of the top
plate. It
should be understood that the arms and the non-planar components described
herein can be configured to extend radially from a center axis through the
opening
322 or radially from a central area concentric with the center axis, but an
off-center
configuration allows such arms and components to have more of the advantages
described herein. In the present examples, each arm extends from the center
core
area 312 to a perimeter area 326 (FIG. 11) adjacent the mounting ring 302. In
the
present configuration, the arm tapers or converges from the center core area
to the
perimeter end 328 of the arm. A substantial portion, namely the portion
between the
line 320 and the end 328, of the arm is substantially symmetrical about an arm
axis
330. In the present configuration, the arm axis 330 is the principal moment of
inertia
at the center of mass of the arm between the line 320 and the end 328. The arm
axis 330 does not intersect a center axis through the center of the top plate
310, but
is tangent to a circle having a non-zero radius centered on the center of the
drive nut
324. Therefore, in the present configuration, the arm axis 330 being the
principal
moment of inertia at the center of mass of the arm as described does not
intersect
the center, even if a side surface or another surface of an arm might
intersect the
center.
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The top plate can also include one or more slots or grooves 332 (FIG. 16).
The slots can be used to help reinforce or strengthen the reinforcement
assembly,
for example by receiving and securing on other structures of the assembly,
described more fully herein. In the present example, the slots are configured
to be
aligned with tabs in the other structures, and a plurality of the slots extend
along
each arm and into the core area. The geometric configuration of the slots can
be
selected to provide the desired strengthening of the assembly.
The reinforcement assembly 300 also includes a non-planar component 350
(FIGS. 8-10, 12-13 and 18). In the present example, the non-planar component
350
is an angled component having a rectangular cross-section. The angled
component
is configured to have a geometry complimentary to the geometry of a
corresponding
arm 316 of the top plate extending outward to the perimeter area. The angled
component 350 extends downward from a corresponding arm 316 and away from
the arm in the Z-axis direction. In this example, the angled component extends
perpendicular to the respective arm to which it is secured, so that a wall of
the
angled component forms a 90 angle with the arm. While the angled component
350
or any other non-planar component described herein can extend upward, or away
from the cutting edge of the drill, from the top plate, it is desirable to
keep the height
of the angled component in the upward direction below the plane of the
mounting
ring.
The angled component 350 includes a first wall 352 distal to the center of the
top plate, and a second wall 354 proximal to the center of the top plate, and
therefore the drive nut 324. In the present example, both the distal and
proximal
walls extend linearly toward the perimeter portion of the top plate, but
nonparallel to
each other, while it should be understood that the distal and proximal walls
could be
configured to be parallel to each other. Though they could be different, the
heights
of the distal and proximal walls are substantially identical, and they are
joined by a
transverse wall 356 extending the length of the angled component. In the
present
example, the transverse wall 356 extends substantially parallel to the arm 316
to
which the angled portion is attached. Additionally, the proximal and distal
walls and
an end wall (described below) extend linearly parallel to the Z-axis of the
drill, and
perpendicular to the X-Y direction or plane. Each of these walls are
substantially
planar, but the combination of the walls as a unit (formed monolithically in
the
present example) forms a non-planar component 350, as the component is non-
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planar even though each of the individual walls can be identified as a planar
part of
the component. The transverse wall 356 extends substantially parallel to the
arm
316 and perpendicular to the Z-axis direction.
In the illustrated configuration, each of the distal and proximal walls
include at
least one, and as illustrated, a plurality of tabs 358 extending parallel to
their
respective walls for engaging and being welded to corresponding slots 332 in
the top
plate. The heights of the respective tabs are typically the same as the depths
of the
respective slots. Additionally, each angled component 350 includes an end wall
360
extending between the distal and proximal side walls and a transverse wall at
a
perimeter end portion 362 of the angled component. The end wall 360 can be
welded to the adjacent sidewalls, but need not be. The angled component also
includes a support tab 364 configured to extend to a respective opening in the
mounting ring 302 and between the mounting ring and the corresponding arm 316.
The downward-facing (when the drill is facing downward) surface of the support
364
extends approximately co-planar with the exposed surfaces of the distal and
proximal side walls from which the tabs 358 extend.
The angled component 350 can be formed from a sheet of a selected metal,
such as steel, and formed into the shape illustrated, having the transverse
wall 356
and the sidewalls extending substantially perpendicular thereto, and the end
wall 360
also extending perpendicular to the transverse wall 356. In the illustrated
angled
portion 350, the distal and proximal sidewalls form two Z-axis extending
reinforcement portions for each arm 316. Therefore, this non-planar component
can
be formed from a thinner sheet of material than a single planar portion
extending in
the Z-axis direction.
The illustrated angled component 350 forms a channel 366 extending in the
direction of the respective arm. The channel 366 extends in one configuration
at
least half way from the drive nut 324 to the outer perimeter portion. The
combination
of the arm 316 and the channel allows relatively contained fluid flow from a
center
portion of the reinforcement assembly to a perimeter portion of the assembly.
In the
illustrated configuration, the end wall 360 includes one or more openings 368
for
allowing fluid to flow from the interior of the channel 366 to the outside in
the area of
the perimeter and the mounting ring 302. The channel has a rectangular or
square
cross-section at any given position along the axis, for example axis 330, and
in the
present example is closed off by the end wall 360.
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In the present example, the distal wall 354 includes one or more openings for
allowing fluid to pass into the channel 366. In the present example, a first
opening
370 is formed adjacent the end 372 of the proximal wall 354. A second opening
374
(FIGS. 13 and 18) is formed in the proximal wall adjacent the transverse wall
356. A
third opening 376 is formed in a top edge surface of the proximal wall. These
openings allow influx of fluid such as water from the drill motor assembly
into the
channel 366.
Each angled component 350 is secured to its respective arm 316 by inter-
engagement of the tabs 358 with respective slots 332, and preferably welded or
otherwise secured there. The reinforcement assembly is assembled with the
desired
number of angled components (six in the present example), and the top plate
with
the angled components and their respective arms are secured, for example by
welding. Adjacent angled components are also secured together in the present
example by welding or other means. Each angled component has welds along five
junctions with the adjacent surfaces. The proximal wall 354 is welded to the
adjacent arm at 378. It is also welded to the distal wall 352 of the adjacent
arm at
380. The edge between the proximal wall and the transverse wall is welded to
the
adjacent transverse wall edge at 382, and the transverse wall is welded to the
junction between the proximal wall 354 and transverse wall of the next
adjacent
angled component at 384. The distal wall 352 is welded to the adjacent arm and
386. The exemplary angled component is also secured to its respective arm by
way
of the fastener at the mounting ring.
With the assembly and securement of the angled components 350,
intersection of a given proximal wall with an adjacent proximal wall combines
with
the other intersections to form a hexagonal opening for receiving the drive
nut 324
(FIGS. 12 and 18). The hexagonal opening formed by the proximal wall portions
is
preferably flush with the hexagonal opening 322 in the top plate (FIG. 16).
The drive
nut 324 can then fit into the opening 322 and into the hexagonal cavity formed
by the
assembled angled components, and secured thereto, for example by welding or
other securement. The hex nut includes outer hexagonal flats and an internal
axial
bore 388, and outward-extending flow openings 390 extend through the wall of
the
drive nut at an axial position between the top and bottom of the channels 366
in the
adjacent angled components. During use, fluid flows into the bore 388 and out
the
openings 390 into the hexagonal chamber or manifold defined by adjacent
proximal
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walls. The fluid then flows into respective chambers through one or more of
the
openings 370, 374 and/or 376.
A bottom plate or water plate 392 (not shown in FIG. 12) is secured to
adjacent ones of the angled components 350 and closes part of the hexagonal
opening at the bottom of the reinforcement assembly. In the present
configuration,
the bottom plate has a hexagonal shape, and is welded to adjacent angled
portions
in the configuration shown in FIG. 8, thereby adding additional strength to
the
assembly. An opening 394 allows fluid to flow from the bottom of the
reinforcement
assembly, or it can be closed by a removable plug (not shown in FIG. 18).
On assembly, the reinforcement assembly can be mounted to the mounting
ring 302 and secured to a core drill in a conventional manner. A splash plate
can be
secured to the top of the assembly in a conventional manner to reduce the
amount of
water coming out the top of the core drill, for example when drilling
horizontally or
upwardly. A drill motor can be mounted to the drive nut 324 in the
conventional
manner and the assembly operated for drilling, with fluid being supplied
through the
drive nut 324.
In another example of a reinforcement assembly, reinforcement assembly 500
can be secured or otherwise mounted to a mounting ring 302 through holes in
the
mounting ring using fasteners 302A to allow driving a core drill or other
drill (FIGS.
19-41). In the illustrated configuration, a single opening and fastener
combination is
used to secure each arm of the reinforcement assembly to the mounting ring
302.
Other configurations may also be used to configure the reinforcement assembly
for a
cutting cylinder.
The reinforcement assembly 500 includes a top plate 510 (FIGS. 19-22, 37-
39) helping to support the drill on a drill motor (not shown). In the present
configuration, the top plate is a substantially planar member, but can be
nonplanar in
either the upper surface (the surface visible in FIG. 22), the lower surface
(the
surface visible in FIG. 19), or both. The top plate 510 is preferably formed
from a
sheet of material, for example steel, and includes a central core area 512
(FIG. 22),
which in the present illustration is shown as a circular area 514 of material
from
which arms, extensions or spokes 516 extend. The central core area can also be
considered to include the arms 516 so that the central core area would be
defined by
an imaginary circle including the outer tips of the arms 516.
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A hex opening 522 (FIG. 37) or other polygon shape is formed in a center of
the top plate for receiving a hex drive nut or other coupling for a drill
motor. Other
geometric configurations of the opening and drive nut may be suitable for the
desired
interface between the nut and the top plate.
The top plate is secured to a plurality of arms, extensions or spokes 540. The
arms 540 extend from a central area of the reinforcement assembly to a
perimeter
area. Each arm extends in a respective direction to the perimeter area. In the
present example, the perimeter area is the area of the mounting ring 302, and
each
arm terminates at a respective outer perimeter surface of the mounting ring.
In the
configuration illustrated, the reinforcement assembly includes six arms, for
example
for a drill up to 30 inches in diameter, but may include fewer or additional
arms, as
desired. For example, a drill diameter greater than 30 inches can be supported
in
part by a reinforcement assembly having eight arms, extensions or spokes.
Other
elements of the reinforcement assembly can be modified or adjusted to
accommodate the number of arms.
The present example of the arms 540 has each of the arms 540 identical to
the others. Therefore, the description of one arm 540 also applies to the
characteristics of the other arms in the reinforcement assembly. Each arm 540
extends in a direction off-center of a central axis through the opening 532 of
the top
plate. Each arm 540 extends from the central core area 542 to the perimeter
area
326 (FIG. 22) adjacent the mounting ring 302. In the present configuration,
each
arm extends outward to the perimeter area with the arm having a substantially
constant width over the length of the arm. A substantial portion, namely the
portion
between a proximal line 544 and a distal line 546, of the arm is substantially
symmetrical about an arm axis 548 (FIG. 22 and 25). In the present
configuration,
the arm axis 548 is the principal moment of inertia at the center of mass of
the arm
between the line 544 and 546, which is in the interior of the arm in the
present
example with three sides forming an equilateral triangle. The arm axis 548
does not
intersect a center axis through the center of the top plate 510, but is
tangent to a
circle having a non-zero radius centered on the center of the top plate 510.
Therefore, in the present configuration, the arm axis 548 being the principal
moment
of inertia at the center of mass of the arm as described does not intersect
the center,
even if a side surface or another surface of an arm might intersect the
center.
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The arms 540 are non-planar components and are configured to have a
triangular cross-section. The arm is configured to have a geometry that will
intersect
and reliably support a portion of the mounting ring 302 (FIGS. 19 and 22). The
arm
is also configured to have a geometry that will reliably intersect and join
adjacent
arms 540, and to more reliably support a drill cylinder. The arm includes
angular
portions, described more fully herein, and extends outward from a plane
defined by
the top plate 510, and away from the top plate in the Z-axis direction. In
this
example, none of the walls of the arm extends parallel to the Z-axis, but
instead
extend at an angle to the Z-axis. Additionally, two sides of each arm extend
at an
angle to the Z-axis, and also at an angle to the X-Y plane. All sides of each
arm
extends linearly parallel to the arm axis 548. While the arm 540 can extend
upward,
or away from the cutting edge of the drill, from the top plate, it is
desirable to keep
the height of the arm 540 in the upward direction below the plane of the
mounting
ring.
Considering an arm 540 in more detail, each arm of the present example
forms a triangle formed from three planar sides extending parallel to the arm
axis
548 (FIGS. 19-31 and 38-39). In the illustrated example, the sides form an
equilateral triangle. However, it is understood that one or more or all of the
arms can
be other types of triangles, namely isosceles, right triangle, or other
triangular
configurations where the sides are unequal. Additionally, the orientation of
sides of a
triangular arm can be selected as desired where a first surface is adjacent
the top
plate 510 and other surfaces extend away from the first surface.
In the present exemplary configuration, each arm includes a top side 560,
described herein as "top" side for ease of reference not because of a
positional
requirement, extending from a top proximal edge 562 to a top distal end
portion 564
having an end surface 566. The top distal end portion includes an opening 568
for
securing the distal end of the arm to the mounting ring 302. The proximal end
surface 562 is slanted or angled relative to a central axis of the top side
560 (an axis
parallel to and overlying the arm axis 548 in the view represented in FIG.
25). The
angle is selected so that all of the arms in the reinforcement assembly can
butt up
against each other, for example in the manner shown in FIGS. 40-41, for six
arms
having triangular cross-sections and identical geometries. The distal end
surface
566 is angled to approximately conform to the curvature of the mounting ring
302
where the arm joins the mounting ring.
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Each arm 540 includes a proximal end surface 570 that intersects an adjacent
arm. The end surface 570 is formed or cut to have a geometry that contacts as
closely as possible a side surface of an adjacent arm as illustrated in FIGS.
40-41.
The proximal edge 562 extends adjacent a top surface 560 of an adjacent arm
540.
Each arm includes a proximal side surface 572 joining the top surface 560
along a junction 574 (FIG. 25). The proximal side surface 572 is a planar
surface
and extends in a direction parallel to the arm axis 548 in the present
example. The
proximal side surface 572 includes a proximal edge surface 576 (FIG. 25) cut
or
formed so as to extend as closely as possible adjacent a proximal side 572 of
an
adjacent arm 540 (see FIG. 41). The proximal side surface also includes a
distal
end surface 578 adjacent the perimeter end portion 564. The distal end surface
is
configured to allow close-fitting of the distal end portion of the arm with
the mounting
ring 302.
Each arm 540 includes a distal side surface 580 joining the top surface 560
along a junction 582 (FIGS. 25-27 and 29-31). The distal side surface 580 is a
planar surface and extends in a direction parallel to the arm axis 548 in the
present
example. The distal side surface 580 includes a proximal edge surface 584 cut
or
formed so as to extend as closely as possible adjacent a distal side surface
580 of
an adjacent arm 540 (see FIG. 41). The distal side surface also includes a
distal end
surface 586 (FIG. 31) adjacent the perimeter end portion 564. The distal end
surface is configured to allow close-fitting of the distal end portion of the
arm with the
mounting ring 302.
In the present example, the top side surface 560, proximal side surface 572
and distal side surface 580 are substantially planar and extend in a direction
substantially parallel to the arm axis 548 in the present example. However, it
is
understood that the proximal and distal side surfaces could converge toward
each
other in the direction of the perimeter portion 564, and the width of the top
side 560
could decrease in the direction of the perimeter. Other configurations are
also
possible. In the present example, the top side wall 560 is positioned in the
reinforcement assembly to extend parallel to the X-Y direction or plane and
adjacent
and parallel to the top plate 510. At least one of, and in the present
example, both of
the proximal and distal side walls are configured to extend at an angle to the
Z-axis
and also at an angle to the X-Y direction or plane. Other orientations are
possible for
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the arms 540, for example by pivoting each arm about the axis 548 a selected
amount.
The proximal side surface 572 of each arm includes a fastening hole or
securing hole 590 at a proximal end portion of the arm. The fastening hole is
approximately centered in the width of the wall. The proximal side surface of
each
arm also includes an additional hole 592 also at a proximal end portion of the
arm.
In the present example, the hole 592 is positioned adjacent the top side 560,
for
example between the fastening hole 590 and the top side 560. The hole 592
allows
fluid such as cooling water from the drill motor assembly to pass into the
interior of
the arm. The interior of the arm 540 forms a channel 594 (FIG. 39) extending
along
the arm 540. The channel 594 allows fluid to flow from the central portion of
the
reinforcement assembly to the perimeter portion.
In the present configuration, the arms 540 are formed from planar sheets, for
example steel, and cut to the desired geometry for forming. Each of the
proximal
and distal side surfaces 572 and 580 are then bent or formed downward out of
the
plane of the top side 560 and inward toward each other to form a seam or joint
596
(FIGS. 27, 29-30 and 39). The seam 596 can then be welded if desired, for
example
stitch welded or otherwise joined together for greater strength.
The joinder of the arms 540 together, for example as illustrated in FIGS. 40-
41, forms a hexagonal opening (octagonal for eight arms, etc.), and an
arrangement
of arms where any one arm does not intersect a central axis of the assembly.
In the
present configuration, adjacent arms are welded to each other, and then the
top
plate 510 is placed on top of the arms and welded thereto around the perimeter
of
the top plate. In one example, the end of one arm is welded to the adjacent
proximal
side surface of the adjacent arm, for example around all three sides of the
end of the
one arm. In another example, the proximal end surface 576 and the proximal end
surface 584 are welded to the proximal side 572 of the adjacent arm (see FIG.
41).
They can be tack welded in a fixture and then the top plate 510 installed and
welded
to the arms, and then the proximal end surfaces 576 and the proximal end
surfaces
584 can then be completely welded to their respective adjacent arms. Other
ways of
securing the reinforcement assembly can be used.
The reinforcement assembly 500 is supported on a drill motor and driven by
way of a mounting and support hub 600 (FIGS. 32-36 and 39). In the present
example, the hub 600 is a monolithic construction, for example a cast or
otherwise
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generated metal structure, but the hex drive portion can be formed separate
from the
arm support portion and the arm support portion can be made part of the
reinforcement assembly. In the present example, the hub 600 includes a
hexagonal
drive nut 602 and a central bore 604 for receiving water from the drive motor
assembly. The end of the central bore is closed with a removable freeze plug
606.
Threads are formed in a counterbore 608 for securing the hub to the drive
motor
assembly.
The drive nut 602 terminates at a hexagonal collar surface 610. The collar
surface faces upwardly and extends radially outwardly in a plane substantially
transverse to a central axis of the hub 600. On assembly, the top plate 510
rests on
or contacts the collar surface 610.
The hub 600 includes an arm support hub 612 from the collar surface 610 to
an arm support shoulder 614. The arm support hub 612 is configured to support
the
proximal portions of the arms 540. The arm support hub includes a plurality of
angled or slanted flats 616 diverging downward and outward from the collar
surface
610 to the shoulder 614.
In the present configuration, the number of flats
corresponds to the number of arms in the reinforcement assembly. The flats
terminate at an upward-facing shoulder surface 618, which extends radially
outward
in a plane transverse to a center axis of the hub 600.
The arm support hub 612 includes fastening openings 624 receiving fasteners
622 (FIG. 39) to secure the flats 616 to respective arms to secure the hub in
the arm
assembly. Fasteners 622 can be bolts threaded into nuts 624 secured in
respective
channels of the adjacent arms 540. For example, the nuts 624 can be welded to
the
interior surfaces adjacent the fastening openings 590 or otherwise secured at
the
openings 590. The holes 620 pass through the sidewalls of the arm support hub
612
from a cavity 626 in the bottom of the support hub through the respective
flats 616.
The upper portion of the cavity 626 terminates at a transverse wall 628 (FIGS.
32, 36
and 39), where the bore 604 terminates and is closed by the freeze plug 606.
The support hub includes flow channels 630 formed through the walls of the
support hub. A flow channel 630 is formed for each arm 540. The flow channels
allow fluid from the drill motor assembly in the bore 604 to pass out to the
fluid
openings 592 in a respective arm. Fluid can flow from the drill motor assembly
into
the bore 604, out through the channels 630 and the openings 592 into
respective
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arms 540. The fluid can then travel along the channel 594 of the arms out to
the
perimeter adjacent the core cylinder.
Once the reinforcement assembly 500 is formed, and the arms 540 welded
with the top plate 510 in place, the central portion of the assembly will
appear as
illustrated in FIGS. 40-41. The hexagonal geometry of the proximal portions of
the
arms is then configured to receive the hub 600 by inserting hub from the lower
portion of the reinforcement assembly. It is noted that if the assembly is
configured
as reversed or flipped and incorporated into the drill system accordingly, the
hub
would be inserted from what would then be an upper portion of the
reinforcement
assembly. The proximal side surfaces 572 of each arm rests against the
respective
flats 616 of the hub, and extend outward toward the perimeter of the assembly.
The
lower edge of each arm rests on the upward-facing shoulder surface 618 of the
hub.
Each fluid opening 592 is confluent with a respective flow channel 630. A
respective
bolt 622 extends through the sidewall of the arm support hub 612, fastener
opening
590 and into the adjacent nut 624 for securing the support hub to the arms.
On assembly, the reinforcement assembly 500 can be mounted to the
mounting ring 302 and secured to a core drill in a conventional manner. A
splash
plate can be secured to the top of the assembly to reduce the amount of water
coming out the top of the core drill, for example when drilling horizontally
or
upwardly. A drill motor assembly can be mounted to the hub 600 in a
conventional
manner, and the assembly operated for drilling, with fluid being supplied
through the
hub 600 and out the channels in the arms 540.
Having thus described several exemplary implementations, it will be apparent
that various alterations and modifications can be made without departing from
the
concepts discussed herein. Such alterations and modifications, though not
expressly described above, are nonetheless intended and implied to be within
the
spirit and scope of the inventions. Accordingly, the foregoing description is
intended
to be illustrative only.
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