Abstract
An air-operated hammer, comprising a hollow ram; a frame; an air cylinder and piston assembly disposed within the ram, wherein a top of the cylinder and piston assembly is attached to a top of the frame and wherein a piston rod of the cylinder and piston assembly is attached to a bottom of the ram; an air flow control valve mounted on and in fluid communication with a manifold disposed on a top of the frame; a first pressurized air reservoir comprising a first flexible hose of a first size attached to an outside surface of the frame, wherein lifting of the ram is caused by pressurized air from the pressurized air reservoir being supplied to and entering a bottom of the cylinder, wherein pressurized air entering a bottom portion of the cylinder causes the piston to raise the ram.
Claims
1. An air-operated hammer, comprising: a hollow ram; a frame; an air cylinder and piston assembly comprising an air cylinder and a piston disposed within the ram, wherein a top of the air cylinder and piston assembly is attached to a top of the frame and wherein a piston rod of the air cylinder and piston assembly is attached to a bottom of the ram; an air flow control valve mounted on and in fluid communication with a manifold disposed on a top of the frame; a pressurized air reservoir comprising a first flexible hose attached to an outside surface of the frame, wherein lifting of the ram is caused by pressurized air from the pressurized air reservoir being supplied to and entering a bottom of the air cylinder to lift the piston and the ram.
2. The air-operated hammer of claim 1, wherein the first flexible hose may comprise a flexible hose of various sizes as required for operation of the air-operated hammer.
3. The air-operated hammer of claim 1, further comprising an upper limit switch attached to an upper portion of the frame and lower limit switch attached to the frame below the upper limit switch.
4. The air-operated hammer of claim 1, further comprising a dwell-adjustment air tube connected in fluid communication between the lower limit switch and the air flow control valve for regulating dwell time of the ram at a bottom travel limit of the ram.
5. The air-operated hammer of claim 4, wherein the dwell-adjustment air tube is adjustable for adjusting the dwell time of the ram at the bottom travel limit of the ram.
6. The air-operated hammer of claim 1, further comprising one or more downstroke assist air tubes connected in fluid communication between the air flow control valve and respective one or more air inlets in a cylinder head of the air cylinder for supplying pressurized air into the air cylinder above the piston to assist in forcing the ram downward during a downstroke of the ram while pressurized air below the piston is allowed to flow through the air flow control valve and into the air cylinder above the piston.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) FIG. 1A shows a front view of a specific embodiment of a prior art air-operated hammer, with the hammer head in the up position, as disclosed in U.S. Pat. No. 6,619,407 issued Sep. 16, 2003 (the '407 Patent).
(2) FIG. 1B shows a front view of a specific embodiment of a prior art air-operated hammer of the '407 Patent, with the hammer head in the down position.
(3) FIGS. 2A and 2B show a top view of the prior art air-operated hammer of FIGS. 1A and 1B, respectively.
(4) FIGS. 3A and 3B show side views of the prior art air-operated hammer of FIGS. 1A and 1B, in the hammerhead up and down positions, respectively.
(5) FIGS. 4A and 4B show a bottom view of the anvil skirt and anvil of the prior art air-operated hammer of FIGS. 3A and 3B, respectively.
(6) FIGS. 5A and 5B show a specific embodiment of a prior art automatic control valve for an air-operated hammer, in the inlet air open position and inlet air closed position, respectively, in accordance with the '407 Patent.
(7) FIGS. 6A and 6B show a specific, embodiment of a prior art automatic control valve system for an air-operated hammer in accordance with the '407 Patent.
(8) FIG. 7 shows a perspective view of a specific embodiment of a prior art air-operated hammer of the '407 Patent.
(9) FIG. 8 shows a specific embodiment of a prior art automatic control valve system for an air-operated hammer in accordance with the '407 Patent.
(10) FIG. 9 shows a specific embodiment of a prior art air-operated hammer which incorporates a bounce chamber and shock bushings in accordance with the '407 Patent.
(11) FIG. 10 shows a specific embodiment of a prior art digital time delay module for an air-operated hammer which can be utilized in accordance with the '407 Patent.
(12) FIG. 11 shows a preferred embodiment of an air-operated hammer of the present disclosure.
(13) FIG. 12 shows a preferred embodiment of a lower frame component of the air-operated hammer of FIG. 11.
(14) FIG. 13 shows a preferred embodiment of a ram of the air-operated hammer of FIG. 11.
(15) FIG. 14 shows a preferred embodiment of an air cylinder of the air-operated hammer of FIG. 11.
(16) FIG. 15 shows a preferred embodiment of an upper frame component of the air-operated hammer of FIG. 11.
(17) FIG. 16 is a top plan view of a preferred upper frame component of the air-operated hammer of FIG. 11.
(18) FIG. 17A is a top plan view of the air-operated hammer of FIG. 11 configured for free-fall drops of the ram with the ram at the end of its downstroke.
(19) FIG. 17B is a cross-sectional view of the air-operated hammer of FIG. 17A along, Line A-A of FIG. 17A.
(20) FIG. 18A is a top plan view of the air-operated hammer of FIG. 11 configured for free-fall drops of the ram with the ram near the end of its downstroke.
(21) FIG. 18B is a cross-sectional view of the air-operated hammer of FIG. 18A along Line B-B of FIG. 18A.
(22) FIG. 19A is a top plan view of the air-operated hammer of FIG. 11 configured for free-fall drops of the ram with the ram at the top of its upstroke.
(23) FIG. 19B is a cross-sectional view of the air-operated hammer of FIG. 19A along Line C-C of FIG. 19A.
(24) FIG. 20A is a top plan view of the air-operated hammer of FIG. 11 configured for air-powered downstrokes of the ram with the ram at the end of its downstroke.
(25) FIG. 20B is a cross-sectional view of the air-operated hammer of FIG. 20A along Line A-A of FIG. 20A.
(26) FIG. 21A is a top plan view of the air-operated hammer of FIG. 11 configured for air-powered downstrokes of the ram with the ram near the end of its downstroke.
(27) FIG. 21B is a cross-sectional view of the air-operated hammer of FIG. 21A along Line B-B of FIG. 21A.
(28) FIG. 22A is a top plan view of the air-operated hammer of FIG. 11 configured for air-powered downstrokes of the ram with the ram at the top of its upstroke.
(29) FIG. 22B is a cross-sectional view of the air-operated hammer of FIG. 22A along Line C-C of FIG. 22A.
(30) FIG. 23 is a top plan view of a preferred manifold of the air-operated hammer of FIG. 11.
(31) FIG. 23A is a right-side view of the manifold of FIG. 23.
(32) FIG. 23B is a front elevational view of the manifold of FIG. 23.
(33) FIG. 23C is a left side view of the manifold of FIG. 23.
(34) FIG. 24 is a top perspective view of the manifold of FIG. 23.
(35) FIG. 25 is a top plan view of the manifold of FIG. 23 showing pressurized air flow in said manifold during ram raise in the air-operated hammer of FIG. 11 configured for free-fall drops of the ram.
(36) FIG. 26 is a top plan view of the manifold of FIG. 23 showing pressurized air and exhaust flows in said manifold during ram drop in the air-operated hammer of FIG. 11 configured for free-fall drops of the ram.
(37) FIG. 27 is a top plan view of the manifold of FIG. 23 showing pressurized air and exhaust flows in said manifold during ram raise in the air-operated hammer of FIG. 11 configured for air-powered downstrokes of the ram.
(38) FIG. 28 is a top plan view of the manifold of FIG. 23 showing pressurized air flows in said manifold during ram drop in the air-operated hammer of FIG. 11 configured for air-powered downstrokes of the ram.
DETAILED DESCRIPTION
(39) FIGS. 11-16 show a preferred embodiment of an air-operate hammer 100 of the present disclosure. Air-operate hammer 100 comprises an upper housing or frame 101 and a lower bell 160. Preferably, upper housing 101 and bell 160. Are attached with bolts 106, but such unit could also preferable made of one piece or multiple other pieces as needed. A hollow ram 130 fits within upper housing 101 and bell 160 for reciprocating linear motion therewithin. Preferably, ram 130 is designed to hit striker plate 108 at the end of its downstroke. Striker plate 108 has tabs 109 that are disposed in slots 107 in bell 160 as shown in FIG. 12. Tabs 109 act to maintain striker plate 108 at the proper orientation within bell 160. Air-cylinder 110 and piston 112 are preferably disposed within hollow ram 130 with a pin 131 connecting the piston rod 112 to the bottom of ram 130 which allows for a lower overall height of hammer 100. Cylinder base 117 preferably has a pressurized air inlet 119 for receiving pressurized air from hose 113 from manifold 120 and main valve 121 for lifting piston 111 and ram 130 within bell 160 and upper housing 101. Manifold 120 and valve 121 preferably receive pressurized air from flexible pressurized air reservoir 115 via connectors 116 and 122. Pressurized air reservoir 115 preferably comprises flexible and adjustable hose of a 1 inch to 3-inch diameter connected to a pressurized air source via a connector 116. Preferably, pressurized air reservoir 115 which is made from a flexible hose or tubing whose length can be changed by replacing the installed reservoir 115 with a flexible reservoir/hose of a different size and/or diameter, preferably using connectors 116. Preferably, universal or Chicago style connectors in 0.75 inches or 1-inch sizes are used for connectors 116.
(40) In the prior air-operated hammer discussed above, the air reservoir was fixed (bolted) onto the frame of the hammer, with the main valve sandwiched in between. The cylinder sat on top of the main valve and was incased in the air reservoir. The valve system was comprised of the main valve, master valve, and shuttle valve. The master and shuttle valve were bolted to a manifold, which was bolted to the air reservoir.
(41) Air-operated hammer 100 of the present disclosure features a flexible reservoir (hose) 115 which is preferably connected to the upper housing 101. Preferably, cylinder 110 is disposed inside of ram 130, with the flexible reservoir 115 supplying pressurized air to the cylinder 110 from manifold 120 and valve 121, which are preferably welded to upper housing 101. Main valve 121 is preferably modular, is disposed on manifold 120 and replaces the prior 3-valve system described above.
(42) Air-operated hammer 100 of the present disclosure comprises a main valve 121 with manifold 120 that can be converted to double acting (lifting and pushing down) of ram 130 using cylinder 110 and piston 111, resulting in a boost, or added energy transfer in addition to gravity causing 130 to fall in the downstroke of hammer 100. For this purpose, cylinder head 114 has one or more pressurized air inlets 118 for receiving pressurized air via hoses 124 from manifold 120 and valve 121 preferably disposed on top of upper housing 101.
(43) In the prior air-operated hammer described above, energy transfer dwell (timing) was timed via limit switch to shuttle valve to main valve. In air-operated hammer 100 of the present disclosure, dwell is accomplished via the connection of limit switch 141 to main valve 121 where dwell can be adjusted by changing the length of the hose/tubing 142.
(44) In the prior air-operated hammer described above, limit switches were mounted on a slide bar that was mounted to the frame of the air-operated hammer. Air-operated hammer 100 of the present disclosure uses limit switches 140 and 141 attached in fixed positions to upper frame 101 to control the reciprocating movement of ram 130.
(45) The components and design of air-operated hammer 100 of the present disclosure allow for greater adaptability in building smaller air-operated hammers as well as larger hammers with lower overall heights.
(46) The air-operated hammer 100 of the present disclosure can utilize a compressed-air source with a lower flow rate and/or lower pressure in comparison with a typical air-operated hammer, in order to achieve the same hammer performance. Alternatively, the air-operated hammer 100 of the present disclosure can utilize an equivalent compressed-air source in comparison with a typical air-operated hammer, in order to achieve superior hammer performance, for example shorter time periods to raise the hammer head, leading to more hammer cycles per time. In addition, other fluid sources can be utilized with air-operated hammer 100 of the present disclosure for example steam and various gases.
(47) The air-operated hammer 100 of the present disclosure also comprises an automatic control valve system 121 which can be utilized to cycle the hammer 101.
(48) As shown in FIGS. 11, 15 and 16, manifold 120 is preferably welded to upper frame 101 and has main valve 121 mounted to it. As shown in FIGS. 23, 23A, 23B, 23C and 24, manifold 120 preferably has external ports as follows: (1) IN has the Chicago fitting 122 connected to it and is the inlet for the pressurized Air Source; (2) B is ported directly to the IN port and has a constant supply of air available to it; (3) S is a small port also connected to the IN port and provides a constant supply of air for the limit switches 140, 141 as needed; (4) *A is the main on (pressure)/off (exhaust) port as controlled by the main valve 121; (5) EX is the exhaust port that vents pressure from cylinder 110 to atmosphere as controlled by the main valve 121. *ports A and B change function between single acting and double acting configurations, but IN, S, and EX remain unchanged.
(49) FIGS. 17A, 1713, 18A, 18B, 19A, 19B, 25 and 26 show air-operated hammer 100 of FIG. 11 configured for free-fall drops of ram 130. Single Acting Free Fall mode on the hammer 100 consists of cylinder hose 113 being connected to A port of manifold 120 and lower cylinder port 119. B port is plugged. At start up, hammer 100 rests on a pile (not shown) with ram 130 at the end of its downstroke and in contact with striker plate 108 as shown in FIG. 17B. Pressurized air from flexible reservoir 115 is directed to the hammer 100 via universal fitting 122 flowing into the IN port on manifold 120 and pressurizes the main valve 121 and limit switches 140, 141 (via the S port). The lower limit switch 141 is at that point activated by the lower ram ramp 105, and sends a pressurized air signal to the main valve 121 shifting it to direct the main flow of pressurized air out through the A port on manifold 120. The pressurized air 150 then flows through cylinder hose 113 and into the lower cylinder port 119. This build-up of pressurized-air 150 under piston 111 forces the ram 130 upward via the rod 112 and pin 131 as shown in FIG. 18B. Since the upper cylinder ports in manifold 120 are open to atmosphere, piston 111, rod 112 and ram 130 accelerate up unhindered.
(50) When the ram 130 nears the top of its stroke, ram ramp 104 triggers limit switch 140 which sends a pressurized air signal to the main valve 121. This pressurized air signal shifts the main valve 121, directing the pressurized air in the cylinder hose 113 to the exhaust port (EX), venting all pressurized air from cylinder 110 under piston 111 out to the atmosphere as shown at 151 in FIG. 19B. At this point both the upper 118 and lower 119 cylinder ports are open to atmosphere and the cylinder 110 breaths freely as ram 130 drops, impacting the striker/drive plate 108, transferring the energy into the pile (not shown) while ram ramp 105 activates the lower limit switch 141 to repeat the cycle. The cycle continues to repeat itself as long as pressurized air is supplied to the hammer 110.
(51) FIGS. 13-15, 20A, 20B, 21A, 21B, 22A, 22B, 27 and 28 show air-operated hammer 100 of FIG. 11 configured for pressurized air-powered downstrokes of the ram 130. Here, double-acting powered fall mode consists of the cylinder hose 113 being connected to B port on manifold 120 and to lower cylinder port 119. Hose assembly 124 is connected to A port on manifold 120 and to the two upper cylinder ports 118 on cylinder head 114.
(52) At start up, with hammer 100 resting on a pile, pressurized air from flexible reservoir 115 is directed to hammer 100 via universal fitting 122. The pressurized air flows into the IN port of manifold 120 and pressurizes S port, B port and the main valve 121. Lower limit switch 141 is at that time activated by ramp 105 on ram 130, and sends a pressurized-air signal to main valve 121 to shift it to its Exhaust position, venting all air from the cylinder 110 above piston 111 via hose assembly 124. With pressurized air 150 present in cylinder 110 below piston 111 via hose 113 connected to port B on manifold 120, the force acting on piston 111 accelerates the piston 111, rod 112, pin 131 and ram 130 upward as shown in FIG. 21B. Since the cylinder 110 above piston 111 is vented to atmosphere at 125 in FIG. 21A via ports 118 and hose assembly 124 through main valve 121, ram 130 accelerates upward unhindered.
(53) When ram 130 nears the top of its upstroke, ramp 104 triggers upper limit switch 140 causing it to send a pressurized-air signal to the main valve 121 shifting it to direct pressurized air out of the A port on manifold 120 while simultaneously closing off exhaust port EX, through hose assembly 124, to supply pressurized air 150 to cylinder 110 above piston 111 via ports 118. At this point both upper and lower cylinder ports 118 and 119, respectively, have pressurized air present and thus pressurized air is present above and below piston 111 as shown in FIG. 22B. The underside of piston 111 has less surface area on it than the upper side of piston 111 because of the cylinder rod 112, causing a force imbalance that arrests the upward motion of ram 130 and also causes piston 111 to start accelerating downward. The acceleration of the ram 130 downward is boosted (powered) by the force imbalance causing it to accelerate faster than it would in free fall mode. Since port A and port B are now connected via the hoses 113 and 124 through the main valve 121, the pressurized air in cylinder 110 under piston 111 is allowed to flow around to the upper side of cylinder 110 above piston 111 allowing rapid downward travel of ram 130.
(54) When ram 130 reaches the bottom of its downstroke, it impacts the striker/drive plate 108, transferring the kinetic energy into the pile to drive it into the ground. At the same time ramp 105 triggers the lower limit switch 141 which sends a pressurized-air signal to the main valve 121 via dwell-time adjustment tube 142. Such signal shifts main valve 121 to the exhaust position, blocking pressurized air from entering port A on manifold 120 while simultaneously connecting port A to exhaust port EX on manifold 120. Pressurized air is vented from the cylinder 110 above piston 111 which causes (i) ram 130 to rise on its upstroke and (ii) pressurized air to remain present in cylinder 110 below piston 111 throughout the upstroke/downstroke cycle of ram 130. At this point ram 130 is accelerated upwards and the upstroke/downstroke cycle of ram 130 continues to repeat itself as long as pressurized air is supplied to the hammer 100. Adjusting the length of dwell-time adjustment tube 142 by replacing it on hammer 100 with a longer or shorter tube lengthens or shortens, respectively, the dwell-time during which ram 130 remains at the bottom of its downstroke in contact with striker plate 108 during each downstroke of ram 130.
(55) All patents, patent applications, provisional applications, and publications referred to or cited herein are incorporated by reference in their entirety for all purposes.
(56) It should be understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application and the scope of the appended claims.
