SELF-BORING ANCHORING DEVICE AND METHOD OF INSTALLING SUCH AN ANCHORING DEVICE
20170335537 · 2017-11-23
Inventors
Cpc classification
E21D21/00
FIXED CONSTRUCTIONS
International classification
Abstract
A fixation device is described comprising a shaft rotatable about a longitudinal axis with a first cutter at a first, distal end; a guide body on the shaft shaped to taper outwardly towards the first end of the shaft; an elongate sleeve disposed surroundingly about the shaft to be rotatable separately from the shaft and translatable in a longitudinal direction relative to the shaft; a flareable end formation at a first, distal end of the elongate sleeve comprising one or more second cutters; the guide body and flareable end formation being arranged so that urging the sleeve towards the first end over the guide body flares the end formation outward from the shaft; and a tensioning mechanism associated with a second end of the sleeve operable selectively to urge the shaft relative to the sleeve back towards the second end. A method of installing a fixation device into a substrate is also described, for example to serve as an anchor and pile, for example for a submerged or floating object.
Claims
1-43. (canceled)
44. A fixation device comprising: a shaft rotatable about a longitudinal axis with a first cutter at a first, distal end; a guide body on the shaft shaped to taper outwardly towards the first end of the shaft; an elongate sleeve disposed surroundingly about the shaft to be rotatable separately from the shaft and translatable in a longitudinal direction relative to the shaft; a flareable end formation at a first, distal end of the elongate sleeve comprising one or more second cutters; and a tensioning mechanism associated with a second end of the sleeve, wherein: the guide body and the flareable end formation are configured so that urging the sleeve towards the first end over the guide body flares the end formation outward from the shaft; and the tensioning mechanism is operable selectively to urge the shaft relative to the sleeve back towards the second end.
45. A fixation device in accordance with claim 44, wherein the tensioning mechanism is additionally configured to lock the shaft in a fixed mechanical relationship to the second end of the sleeve.
46. A fixation device in accordance with claim 44, wherein the tensioning mechanism further comprises a locking mechanism to lock the relative positions of the second end of the sleeve and the shaft at a selected relatively translated juxtaposition.
47. A fixation device in accordance with claim 44, wherein the tensioning mechanism is in either a direct mechanical association with or a fixed mechanical relationship to the second end of the sleeve.
48. A fixation device in accordance with claim 44, wherein: a projecting proximal end portion of the shaft is configured to project beyond a proximal end of the sleeve through an aperture in the said proximal end, and a shaft engagement system is configured to engage the projecting end portion and apply a tensioning force to the same by urging the end portion in a direction beyond the proximal end of the sleeve outwardly of the aperture.
49. A fixation device in accordance with claim 44, wherein: the tensioning mechanism includes a threaded formation; and a threaded portion on the shaft is provided and configured to engage with a complementary threaded formation provided in mechanical association with the second end of the sleeve.
50. A fixation device in accordance with claim 49, further comprising a tensioning nut disposed to engage in use upon a top bearing surface or cap of the second end of the sleeve whereby tightening of the tensioning nut tends to draw the shaft towards the second end of the fixation device.
51. A fixation device in accordance with claim 44, wherein: a portion of the sleeve at or about a second end is provided in association with a reaction formation having one or more reaction surfaces adapted in use with the fixation device in situ in a substrate to engage with the substrate; and the reaction formation comprises an anchoring structure associated with a portion of the sleeve towards the second end.
52. A fixation device in accordance with claim 51, wherein the anchoring structure is configured integrally as part of the portion of the sleeve towards the second end.
53. A fixation device in accordance with claim 52, wherein the anchoring structure comprises a tapered formation of the sleeve towards the second end configured to taper outwardly towards the second end.
54. A fixation device in accordance with claim 53, wherein the tapered formation comprises one or more third cutters disposed on an outer surface.
55. A fixation device in accordance with claim 54, wherein the one or more third cutters comprise one or more helical blades.
56. A fixation device in accordance with claim 51, further comprising a surface securing arrangement comprising: a formation in direct mechanical association with a portion of the sleeve at or about the second end and configured to be secured on or at the substrate surface; a reaction surface disposed to seat upon the substrate surface in use; and a “pile cap” or “top hat” attachment comprising a laterally extending plate-like member and a cylindrical member.
57. A fixation device in accordance with claim 44, wherein the sleeve is provided in two parts comprising a distal part and a proximal part, the two parts being axially spaced by a torque coupling by means of which they are co-rotatable as the sleeve is driven into the ground, but which torque coupling is adapted to allow relative translation of the two parts to reduce their axial spacing as an axial load is applied.
58. A fixation device in accordance with claim 57, wherein: the distal part and proximal part are axially spaced by a frangible torque coupling; the frangible torque coupling comprises mutually engageable projecting torque surfaces at a distal end of the proximal part and a proximal end of the distal part engaged together by one or more frangible connectors such as one or more shear pins; and the frangible torque coupling is configured to fail at a predetermined axial loading as a pre-tensioning force is applied to the shaft by the tensioning mechanism.
59. A fixation device in accordance with claim 58, wherein the torque surfaces comprise mutually engageable internally and externally splined formations.
60. A fixation device in accordance with claim 44, wherein: the shaft comprises a shaft drive coupling for applying torque to the shaft for driving the first cutter and the sleeve comprises a sleeve drive coupling for applying torque to the sleeve for driving the second cutters; and the drive couplings are bayonet drive couplings.
61. A fixation device in accordance with claim 44, wherein the guide body is a frustoconical body shaped to taper outwardly towards the first end of the shaft.
62. A fixation device in accordance with claim 44, wherein: the flareable end portion of the sleeve comprises a pivot configured to allow the flareable end portion to bend about the pivot and thereby be flared outward; and the flareable end portion of the sleeve comprises a plurality of pivotable fingers.
63. A method of installing a fixation device into a substrate, the fixation device comprising a shaft rotatable about a longitudinal axis having a first cutter at a first, distal end; a guide body on the shaft shaped to taper outwardly towards the first end of the shaft; and an elongate sleeve disposed surroundingly about the shaft to be rotatable separately from the shaft and translatable in a longitudinal direction relative to the shaft having a flareable end formation at a first, distal end of the elongate sleeve comprising one or more second cutters; the method comprising the steps of: rotating the shaft and thereby boring a hole into a substrate using the first cutter; translating the sleeve in a longitudinal direction distally relative to the shaft to urge the flareable end formation over the guide body and flare the end formation outward from the shaft; rotating the sleeve and thereby reaming out an undercut in the substrate; and urging the shaft relative to the sleeve back towards the second end to apply a tension to the shaft.
64. The method in accordance with claim 63, wherein: in a first phase of deployment the shaft is rotatably driven about its longitudinal axis to effect a cutting action via the first cutter and drive the first end of the shaft distally into the substrate; in a second phase of deployment the flareable end portion of the sleeve is caused to move over the guide body positioned towards the distal end of the shaft behind the first cutter, such that when the flareable end portion of the sleeve reaches and passes over the guide body it is urged outwardly, the sleeve is rotatably driven about the shaft, effecting a cutting action via the second cutters and causing the sleeve to be driven distally relative to the shaft to make an undercut in the substrate; and in a third phase of deployment a pre-tension is applied to the shaft by urging the shaft relative to the sleeve back towards a second end of the device, being the end proximal to the substrate surface, whereby a tensile load is applied the shaft in situ.
65. The method in accordance with claim 63, comprising the further step of locking the relative positions of the second end of the sleeve and the shaft when a desired tension has been introduced into the shaft.
66. The method in accordance with claim 63, wherein a projecting proximal end portion of the shaft is arranged to project beyond a proximal end of the sleeve, for example through an aperture in the said proximal end, and the step of urging the shaft relative to the sleeve back towards the second end to apply a tension to the shaft comprises applying an urging force to the projecting proximal end portion.
67. The method in accordance with claim 63, wherein a threaded portion is provided on the shaft configured to engage with a complementary threaded formation provided in mechanical association with the second end of the sleeve and the step of applying a tension to the shaft comprises tightening the thread.
68. The method in accordance with claim 63, wherein an upper portion of the sleeve towards the second end comprises a tapered formation whereby the sleeve is configured to taper outwardly towards the second end with one or more third cutters disposed on an outer surface and the step of translating the sleeve in a longitudinal direction distally relative to the shaft includes driving this tapered formation into the substrate surface to form a complementarily tapered hole.
69. The method in accordance with claim 63, wherein the sleeve is provided in two parts comprising a distal part and a proximal part axially spaced apart, the two parts are co-rotated as the sleeve is translated laterally, and the two parts are then caused to move axially closer together as the shaft is urged relative to the sleeve back towards the second end of the sleeve.
70. The method in accordance with claim 68, wherein the two parts are axially spaced by a frangible torque coupling and an axial load is applied to break this coupling.
Description
[0082] The invention will now be described by way of example only with reference to the accompanying drawings in which:
[0083]
[0084]
[0085]
[0086] Illustrated in the drawings are two embodiments of fixation device showing a number of improvements to embodiments of anchor described in GB2513942. In particular, certain improvements enable an anchor to be used also as a pile, that is to say, making it capable of withstanding a load in compression. These include at least the provision of a means to apply a tensile load to the shaft serving as the anchor stem in situ in the form of a suitable tensioning mechanism.
[0087] The first embodiment includes a sleeve or outer casing arrangement and tensioning nut for this purpose. The second embodiment includes additional refinements to facilitate this pre-tensioning including a more extensive upper tapered formation on the sleeve or outer casing arrangement that drives into the upper part of the hole to resist the tensile load in conjunction with the anchor at the bottom of the hole, and a modification whereby the sleeve is made collapsible as an axial load is applied to the shaft.
[0088] The drawings show the sequence of events involved in installing a fixation device with such an anchor and pile function into a substrate.
[0089] Referring to
[0090]
[0091] An elongate shaft 2 which will in due course serve as an anchor stem and pile tendon carries a first, pilot drill system including a drill head 6 mounted onto the distal end of the shaft with a first cutting tip at a most distal end in the form of a pilot drill bit 4. The drill head 6 comprises a body with a frustoconical surface. The drill bit 4 carries one or more first cutters to cut into the substrate, for example being a diamond impregnated cutter, a tungsten cutter, hardened steel cutter or a polycrystalline diamond cutter (PCD) or the like.
[0092] A suitable rotational drive is imparted to the shaft via a suitable torques linkage (not shown in
[0093] The anchor stem shaft 2 has a hollow central passage 10 communicating with channels 12 to provide a passage for a flushing solution to medium tom flush material away from the cutting surface of the drill bit 4.
[0094]
[0095] The sleeve casing in the illustrated embodiment has three principal components. At a distal end of the sleeve casing three outer casing articulating fingers 20 are provided, each carrying one or more second cutters 22 at a bottom end. Again, each cutter can be of any suitable material, for example being a diamond impregnated cutter, a tungsten cutter, a hardened steel cutter or a PCD cutter or the like. Each articulating finger is carried on an outer casing lower collar 24 by means of a pivot 26. The three articulating fingers 20 are distributed circumferentially about a bottom end of the outer casing lower collar on their respective pivots, and are thus enabled collectively to constitute a flareable end formation to the sleeve casing. An outer casing extension 28 extends upwardly out of the hole 8 and completes a sleeve casing structure embodying the principles of the invention.
[0096]
[0097] With reference to the drawings, in the second phase of deployment of the fixation mechanism when drilling a hole, the outer casing 28, 24, 20 is driven into the substrate so that the articulating fingers 20 project over the drill head 6 and ultimately beyond the drill bit 4. The drill head 6 on the shaft is tapered to flare outwardly towards the distal end of the shaft and thus acts as a guide body for the articulating fingers, which adopt a similar flare. The outer casing 28, 24, 20 is rotatably driven about the shaft, effecting a cutting action via the second cutters 22 at the tips of the articulating fingers 20 which cut “virgin” substrate (that is to say, substrate not cut into or disturbed by the first cutters of the drill bit 4) as the casing is driven distally relative to the shaft. This enables the second cutters 22 to make an undercut in the substrate 1 comprising a reverse taper cut into the substrate from the hole, wherein the angle of the taper corresponds generally to the angle of the flared surface of the drill head 6.
[0098] A surface securing arrangement comprising a top hat 36 with integrated collar is attached to the outer casing extension 28 at its proximal end. This has an inner collar which screws onto the outer casing extension 28. A bayonet drive 34 is attached to the collar using a bayonet fixing. The collar is tapered and fitted on its tapered surface with collar cutters which drill a tapered hole into the surface at the same time as the second, finger tip cutters 22 drill the undercut. The drill head taper and the collar taper in reverse directions co-operably resist the tensile load applied to the stem.
[0099] The central bore 10 of the shaft 2 and outer surface of the outer casing together define flushing channels 30, respectively for the pumping in and return to the surface of a flushing solution. A chevron seal 32 between the outer casing extension 28 and the collar prevents a flushing or washing medium, such as a liquid or air, which is pumped down into the hole through the anchor stem, from penetrating between the collar and the outer casing extension 28 on its way back to the surface.
[0100] The surface securing arrangement includes a “pile cap” or “top hat” attachment 36 comprising a laterally extending plate-like member and a cylindrical member. There are pile cap attachment cutters 40 on the open edge of the cylindrical member. Driving the collar also drives the pile cap or top hat attachment such that the pile cap attachment cutters 40 drill into the substrate at the same time as the collar cutters and finger tip cutters drill into the substrate. The cylindrical member extends distally into the annular groove that is cut. The pile cap attachment also takes compressive loads. In addition, the pile cap arrangement resists lateral loads imposed on the anchor. By extending distally into the substrate, the pile cap attachment assists in enabling the surface securing arrangement to withstand compressive loads. It also enables it to resist lateral loads. Moreover, the pile cap attachment may act as a platform or base on which a structure may stand.
[0101] By following a path underneath the top hat attachment via flushing channels 42, the chevron seal 32 preventing any escape, the flushing medium also washes cuttings away not only from around the drill bit, finger cutters and collar cutters, but also from around the pile cap attachment cutters.
[0102] The surface securing arrangement may dispense with the top hat arrangement.
[0103] A locking tensioning nut 44 is screwed onto a threaded upper portion of the anchor stem shaft 2.
[0104] In a third phase of deployment of the fixation device, once the fingers are fully engaged in the undercut, this is used to apply a pre-tension to the anchor stem shaft 10. The locking tensioning nut 44 is tightened tending to urge the anchor stem shaft 2 in a proximal direction back towards and out of the substrate surface. The fingers engaged in the undercut and the collar taper engaged at the top of the hole act in reverse directions co-operably to resist the tensile load applied to the anchor stem shaft 2. A tensile load can be generated in the anchor stem shaft in situ giving it functionality as a pile tendon and enabling the device as a whole better to resist the complex and variable load scenarios such as might be encountered when the device is used to fix a submerged structure to the sea bed for example.
[0105] Referring to
[0106]
[0107] The embodiment of
[0108] Surroundingly about the shaft 62 an outer casing or sleeve is provided. The casing or sleeve comprises a cylindrical lower casing part 73 provided at a distal end with cutting fingers 80 having second cutters 82 at a lower edge. The cutting fingers articulate about the lower part of the sleeve by means of pivots 86. The casing or sleeve further comprises an upper part 88, which is provided with a torque linkage to the lower part 73 by means of the breakable torque connection shown generally as 84 and in more detail in the middle of the three insets.
[0109] In a first phase of drilling a hole, a rotational drive is imparted to the shaft 62, either independently of the sleeve casing or in coupled manner in the sense that the entire arrangement is rotationally driven. This has the effect of rotatably driving the shaft about its longitudinal axis to effect a cutting action via the drill bit 64 and drive the device distally into the substrate through the hole thereby drilled in the substrate. An example drive for the shaft 62 is a hex drive.
[0110] In a second phase of deployment, the sleeve arrangement is rotatably decoupled from and driven separately from the shaft so that, in generally similar manner to the previous and prior art embodiments, the cutting fingers 80 effect the drilling of a reverse tapered undercut into the bottom of the hole and then serve integrally as an anchoring system engaging into the reverse taped undercut to fix the device therein.
[0111] This deployment is shown in particular by the illustration in
[0112] The fingers 80 have a graduated internal tapered profile so that when they are fully deployed over the tapered guide body the internal tapered profile exactly matches and engages a corresponding external graduated tapered profile of the guide body. This means that when the fingers are fully deployed the load is spaced evenly over the length of the fingers and guide body. This helps to prevent the fingers deforming under tensioning load. The feature therefore additionally facilitates the disengagement of the connection between the fingers and the guide body if removal of the anchor/pile device is required as described below.
[0113] The guide body 66 may be rigidly mounted on the shaft and for example form part of a drill head serving as a mounting for and rotating with the drill bit 64 as in the previous example.
[0114] In an alternative modified embodiment illustrate in
[0115] The guide body has a channel 67′ defining an inner bearing surface journalled onto a distal portion of the shaft ahead of the drill bit 64′. The guide body has a stepped engagement 63′ with the drill bit to prevent the drill bit from moving laterally back through channel in the guide body and a stepped engagement 65′ to prevent axial movement in the other direction. The centre stem comprising the shaft and drill bit thus rotates independently of the guide body, but the tensile load can still be applied to the centre stem and transferred via the guide body and fingers to the substrate. At the same time as the fingers 80 are driven down and over the frustoconical guide body 66, the upper part 88 of the sleeve casing drives into the top of the hole. The upper part 88 is given a taper, for example in that it comprises a frustoconical body, in the opposite direction to the reverse taper defined by the fingers 80 in the deployed configuration. In a preferred case, the outer surface of the upper part 88 is provided with helical bladed cutters to facilitate the driving of this part into the top portion of hole in the vicinity of the surface.
[0116] During this second phase of deployment, the entire casing is driven rotatably by a suitable drive, in the embodiment a bayonet drive, through the drive coupling 95 with torque transmitted to the lower part and to the cutting fingers by means of the torque coupling 84.
[0117] Generally, a non-threaded drive is preferred for each of the outer sleeve and inner shaft. In a preferred case in the present embodiment a bayonet drive is provided for the outer sleeve and a hex drive for the inner shaft. This allows easy disengagement of the respective drives from the anchor/pile device without having to prevent rotational movement of either the inner shaft or outer sleeve as would be the case if the connections were threaded for example. The bayonet connection to the outer sleeve also facilitates easy connection for withdrawal of the anchor/pile device from the substrate after use as described below.
[0118] Once the fingers 80 are deployed into position within the reverse tapered undercut as an anchor, a pre-tensioning is introduced into the shaft to enable it to function as a pile tendon. This is done by means of the tensioning nut 92.
[0119] In the embodiment, tensioning is effected by further operation of the bayonet drive in a manner best illustrated with reference to the left hand inset in
[0120] The collapsible torque connection 84 is shown in more detail in the middle inset. It comprises an internally splined compression sleeve 99, an externally splined compression sleeve 102, and two shear pins 100 holding them together, in addition to retaining split rings 101 and spacer rings 98.
[0121] In the initial configuration shown in particular in
[0122] The pre-tension in the shaft is then stabilised in admirably simple manner with the respective tapered and reversed tapered formations of the upper part 88 of the sleeve and of the deployed fingers 80 acting reactively in reverse directions co-operably to resist the tensile load in the anchor stem shaft 62, to stabilise the same, and to give functionality as a pile tendon. Optional disc springs 98 also play a role in maintaining the axial pre-tension.
[0123] A swivel cap 96 is provided in association with an upper end of the upper part 88 of the sleeve casing and/or shaft. When deployed in situ the tapered upper part 88 of the sleeve casing has been driven substantially into and seats stably within a correspondingly tapered top part of the hole in the vicinity of the surface of the substrate in which the device is retained. The swivel cap 96 sits above the surface and is mounted to be rotatable relative to the upper part 88 of the sleeve casing, for example having an internal bearing surface seated around an upper projection of the upper part of the shaft. Suitable connection formations such as the eyes 97 may be provided to provide a tethering site to secure chains, ropes, mooring lines etc for securing of structures to the anchored device, and for example in the preferred application submerged or floating structures. The swivel cap 96 allows movement of any such tether lines about the anchor.
[0124] It is a particular advantage of the illustrated embodiment that the device can readily arranged to be unloaded and removed. This may be effected by releasing the tensioning nut 92 and applying an axial load to the proximal end 91c of the inner shaft. This breaks the tape engagement at the distal end and releases the axial tension. The outer sleeve can then be withdrawn over the inner shaft allowing the fingers to collapse inwards. The preferred feature described above whereby the fingers have a graduated internal tapered profile that matches and engages a corresponding external graduated tapered profile of the guide body facilitates the ready disengagement of the fit between the fingers and the guide body.
[0125] As the outer sleeve is further withdrawn from the hole in the substrate it picks up the inner stem and the complete anchor/pile device is removed from the substrate.