Abstract:
A machine or apparatus for installing resilient or elastomeric strip seals of indefinite length in expansion joints in, for example, highways and bridges. The machine includes an open, upper frame connected to a lower frame supported at its four corners by four freely rotating wheels. A pair of clamping pistons on the lower frame includes rollers which are adjusted to engage one face of the expansion joint. A toothed wheel or blade rotates about an inclined axis and is powered by a motor through a speed reducing gearbox. The toothed wheel engages the seal and forces it into a channel on the side of the expansion joint opposite to the side engaged by the rollers.

Description:
FIELD 
     The present disclosure relates to apparatus for and method of installing elongate seals and more particularly to a machine for and method of installing elastomeric strip seals of indefinite length in expansion joints in highways and bridges. 
     BACKGROUND 
     The statements in this section merely provide background information related to the present disclosure and may or may not constitute prior art. 
     In many highway installations and virtually all modern concrete deck bridges, sections of the structure are separated by expansion joints. Such joints run transversely or obliquely to the length and traffic flow of the structure and allow for longitudinal expansion and contraction resulting from ambient temperature changes. Typically, the ends of the concrete section adjacent the expansion joint are trimmed out with a cast in place metal frame or rail member which defines a re-entrant or “C”-shaped slot or channel. Secured within the opposed channels and extending across the expansion joint is an resilient seal strip. The seal strip may define a “V”-shaped or other cross section as installed so that it can accommodate increase or reduction of the width of the expansion joint. The seal strip maintains the water-tightness of the bridge deck thereby preventing foreign material and water from falling and collecting on the superstructure. 
     As ubiquitous as such expansion joint rails and seals have become, the installation of the two edges of the seal strip into the opposed rail channels is not an easy task. First of all, it is highly labor intensive and essentially takes place at or slightly below surface level. Thus, it is difficult for workers to comfortably and carefully perform the tedious installation process. Unfortunately, even the smallest gaps resulting from incomplete installation can effectively negate the benefits of the strip seal. Second of all, for the same reasons installation is difficult, it is also difficult to carefully and fully inspect the installed seal strip. Finally, although a combination lubricant and adhesive is utilized to facilitate installation of the strip seal, unless the edges of the seal strip are fully seated in the channels, the strip may dislodge, thereby failing to achieve its intended purpose. The foregoing difficulties suggest that an improved manner of installing the strip seal in expansion joint rails would be desirable. 
     SUMMARY 
     The present invention provides an apparatus for and method of installing resilient, elastomeric strip seals of indefinite length in expansion joints in, for example, highways and bridge decks. The machine includes an open, upper frame connected to a lower frame supported at its four corners by four freely rotating wheels. A pair of clamping pistons on the lower frame includes rollers which are adjusted to engage one face of the expansion joint. A toothed wheel or blade rotates about an inclined axis and is powered by an air motor through a speed reducing gearbox. The toothed wheel engages the seal and forces it into a channel on the side of the expansion joint opposite to that engaged by the rollers. The machine includes components which facilitate adjustment of both height and angle of incline of the toothed wheel. Pneumatic pressure regulators and valves disposed on the open, upper frame control air flow to the pistons and the air motor. A pair of smaller, auxiliary wheels, also attached to the upper frame, facilitates transport of the machine in a horizontal position to reduce the possibility of accidental damage to the rollers and toothed wheel. 
     The installation method comprehends the steps of placing the strip seal adjacent the two parallel rails in the deck, spreading or spraying a lubricant/adhesive in the lower grooves of the rails, installing the lower lug of each edge of the seal in the lower grooves in the rails, spreading or spraying a lubricant/adhesive on the upper lugs at each edge of the seal, disposing a machine having a rotating installation wheel against an upper lug on one edge of the seal and rotating the wheel to continuously install the upper lug in the upper groove of the rail. The machine and wheel are then repositioned and the other, upper lug is installed in the adjacent rail in the same direction by the rotating wheel. 
     Thus it is an object of the present invention to provide a machine for installing resilient strip seals in expansion joints in, for example, highways and bridges. 
     It is a further object of the present invention to provide a machine for installing elastomeric strip seals of indefinite length in expansion joints in, for example, highways and bridges. 
     It is a still further object of the present invention to provide a machine for installing elastomeric strip seals having an open, upper and a lower frame. 
     It is a still further object of the present invention to provide a machine for installing elastomeric strip seals having a pair of air cylinders and pistons having rollers for engaging a face of an expansion joint. 
     It is a still further object of the present invention to provide a machine for installing elastomeric strip seals having a seal installing wheel powered by an air motor through a speed reducing gearbox. 
     It is a still further object of the present invention to provide a machine for installing elastomeric strip seals having an inclined, toothed wheel powered by an air motor through a speed reducing gearbox. 
     It is a still further object of the present invention to provide a method of installing elastomeric strip seals of indefinite length in expansion joints in, for example, highways and bridges. 
     It is a still further object of the present invention to provide a method of continuously installing elastomeric strip seals of indefinite length in expansion joints in, for example, highways and bridges. 
     It is a still further object of the present invention to provide a method of continuously installing elastomeric strip seals of indefinite length with a rotating, toothed wheel. 
     Further objects, advantages and areas of applicability will become apparent from the description provided herein. It should be understood that the description and any specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
    
    
     
       DRAWINGS 
       The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. 
         FIG. 1  is a perspective view of a strip seal installing machine according to the present invention; 
         FIG. 2  is an exploded perspective view of a base portion of a strip seal installing machine according to the present invention; 
         FIG. 3  is an exploded perspective view of a seal insertion assembly of a strip seal installing machine according to the present invention; 
         FIG. 4  is an exploded perspective view of an upper frame assembly of a strip seal installing machine according to the present invention; 
         FIG. 5  is an exploded perspective view of an air circuit portion of a strip seal installing machine according to the present invention; 
         FIG. 6  is a perspective view of the bottom of a strip seal installing machine according to the present invention showing the height adjustment mechanism for the toothed wheel; 
         FIG. 7  is a perspective view of the incline adjustment mechanism for the toothed wheel of a strip seal installing machine according to the present invention; 
         FIG. 8  is a perspective view of an exemplary flat surface such as a bridge deck and the equipment and steps relating to installation of a strip seal according to the present invention; and 
         FIG. 9  is an enlarged, side elevational view of the process of installation of an expansion joint strip seal in an expansion joint with the strip seal installing machine according to the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. 
     With reference to  FIG. 1 , a strip seal installing machine according to the present invention is illustrated and generally designated by the reference number  10 . The strip seal installing machine  10  includes several assemblies which will be described and illustrated separately in the following text and drawings including a lower frame assembly  20  illustrated in  FIG. 2 , a seal insertion assembly  70  illustrated in  FIG. 3 , an upper frame assembly and portion of the air circuit  120  illustrated in  FIG. 4  and controls and the remaining portion of the air circuit  150  illustrated in  FIG. 5 . 
     Referring now to  FIGS. 1 ,  2 ,  6  and  7 , the lower frame assembly  20  includes a pair of parallel, spaced-apart box beams  22 A and  22 B which are connected by a pair of transverse rails  24 A and  24 B. Preferably, the box beams  22 A and  22 B include notches or cut-outs  26  which receive the transverse rails  24 A and  24 B and are secured to the rails  24 A and  24 B by welding or other positive means. The transverse rails  24 A and  24 B also include notches or cutouts  28  located proximate the front box beam  22 A. Extending transversely from the outer corners of the box beams  22 A and  22 B are four shafts or axles  32  which each freely rotatably receive one of four rubber tired wheels  34 . The wheels  34  are retained on the axles  32  by four threaded fasteners  36 , snap-on retainers or similar removable retention devices. On the top and at each end of the box beams  22 A and  22 B are secured four circular, blind sockets  42 , the purpose of which will be described subsequently. Each of the blind sockets  42  includes a pair of through, aligned openings  44  in the walls of the sockets  42 . Finally, on the outer face of the rear box beam  22 B is disposed a quick-connect female air supply fitting or connector  46 . The air supply connector  46  receives a complementary male connector (not illustrated) which is connected to a hose and a source of pressurized air (also not illustrated). 
     Secured to the outer faces of each of the pair of transverse rails  24 A and  24 B by suitable fasteners  48  are a pair of pneumatic cylinder assemblies  50 A and  50 B. Each of the pneumatic cylinder assemblies  50 A and  50 B include a pair of vertically stacked, double acting piston and cylinder assemblies  52  which are coupled to and bi-directionally translate a common drive plate  54 A and  54 B. On each of the upper piston and cylinder assemblies  52  are a pair of air supply ports. Two first ports  56 A and  56 B communicate with one end of the cylinder assemblies  50 A and  50 B and, when supplied with air under pressure, the common drive plates  54 A and  54 B retract. Two second ports  58 A and  58 B communicate with the other end of the cylinder assemblies  50 A and  50 B and, when supplied with air under pressure, the common drive plates  54 A and  54 B extend. A shaft  62  is secured to each of the drive plates  54 A and  54 B, extends downwardly therefrom and freely rotatably receives a stiffly resilient idler or clamping or locating wheel  64 . The locating wheels  64  are preferably fabricated of rubber or a similar elastomer. 
     Referring now to  FIGS. 1 ,  3 ,  6  and  7 , the seal insertion assembly  70  includes a pair of spaced-apart locking stanchion blocks  72  which are secured within the notches or cutouts  28  of the transverse rails  24 A and  24 B by suitable fasteners or welding (not illustrated). A stanchion shaft  74  is received, selectively locked within and extends between the stanchion blocks  72 . A third stanchion block  76  is received on and tightly secured to the stanchion shaft  74  and is attached to a mounting plate  78  by suitable fasteners (not illustrated). The mounting plate  78  is, in turn, secured to an air motor assembly  80  by a plurality of, preferably four, threaded fasteners  79  extending through elongate slots in the mounting plate  78 . The pair of stanchion blocks  72  may be unlocked to allow the stanchion shaft  74 , the third stanchion block  76 , the mounting plate  78  and the air motor assembly  80  to rotate about the axis of the stanchion shaft  74  to adjust the angle of incline of the air motor assembly  80 . The vertical position of the air motor assembly  80  may be adjusted by loosening the threaded fasteners  79 , moving the air motor assembly  80  up or down as necessary relative to the mounting plate  78  and re-tightening the fasteners  79 . 
     The air motor assembly  80  includes an air motor  82  having air supply and exhaust ports  84  and an output shaft  86  that directly drives a gear or speed reduction unit  88 . The air motor  82  provides a nominal output speed of 700 to 800 r.p.m. at load. The gear reduction unit  88  preferably provides a speed reduction of approximately 14 to 16 to 1. The gear reduction unit  88  includes an output shaft  92  which is coupled to and directly drives a toothed insertion wheel or blade  94 . The output shaft  92  of the gear reduction unit  88  rotates at between 45 and 55 r.p.m. The insertion wheel  94  is between four and eight inches in diameter and is preferably about six inches in diameter and includes a plurality of teeth  96 , between sixty-five and seventy-five teeth  96  and preferably about seventy-two teeth  96 , about its periphery 
     An inclination adjustment assembly  100  cooperates with the pair of locking stanchions  72  and the stanchion shaft  74  to adjust and fix the angle of inclination of the air motor assembly  80  and thus of the insertion wheel  94  relative to the lower frame assembly  20  and the adjacent, supporting surface. The adjustment assembly  100  includes an angle bracket  102  which is secured to the air motor assembly  80  by suitable fasteners (not illustrated) and carries and supports a pair of bearings  104 . The pair of bearings  104  each freely rotatably receives and supports a pair of stub shafts  106 . Each of the stub shafts  106  is secured to and rotates an associated chain sprocket  108 . The pair of chain sprockets  108  are coupled for simultaneous rotation by a chain  110 . Each of the stub shafts  106  includes male threads  112  at its end opposite the chain sprocket  106 . The threaded end of each stub shaft  106  is received within female threaded openings  114  in a right angle spherical bushing or bearing  116 . Each of the spherical bearings  116  includes a pin or locating stub  118  oriented generally at a right angle to the axis of the threaded opening  114  which is received within an aperture or blind hole in the front box beam  22 A. As the chain  110  is moved, the threaded stub shafts  106  rotate in unison, effectively increasing or decreasing the distance between the angle bracket  102  (and the air motor  82 ) and the front box beam  22 A, thereby adjusting the angle of incline of the air motor assembly  80  and the toothed wheel  94 . The air motor assembly  80  is maintained in its desired center position on the stanchion shaft  74  by the inclination adjustment assembly  100 . 
     It should be understood that other, simpler inclination adjustment assemblies are deemed to be within the scope of this invention. For example, a single assembly such as a turnbuckle (not illustrated) or a single bearing  104 , single stub shaft  106  and single spherical bearing  116 , and many other linear adjustment mechanisms may be utilized. However, since the air motor assembly  80  provides the sole driving force to the strip seal installing machine  10  and thus generates reaction torque, it has been determined that a pair of co-acting, spaced-apart devices which stabilize the air motor assembly  80  is a preferred configuration. 
     Referring now to  FIGS. 1 and 4 , the upper frame assembly and portion of the air circuit  120  includes a pair of spaced-apart, inverted U-shaped frames  122 A and  122 B. The front upper frame  122 A is received within the sockets  42  on the front box beam  22 A and the rear upper frame  122 B is received within the sockets  42  on the rear box beam  22 B. The lower ends of the frames  122 A and  122 B include radially aligned openings  124  that align with the openings  44  in the sockets  42  and receive retaining pins  126  which, in turn may be retained in the sockets  42  by clips or cotter pins (both not illustrated). The upper frames  122 A and  122 B may be single pieces of formed tubing or multiple sections connected by corner components. The front upper frame  122 A includes a pair of front panel mounting brackets  132 . A second pair of side mounting brackets  134  are secured to each of the upper frames  122 A and  122 B and receive a side mounting plate  140 . The side mounting plate  140  extends between the front upper frame  122 A and the rear upper frame  122 B and is secured to the side mounting brackets  134  by suitable fasteners or welds (not illustrated). On the outside face of the side mounting plate  140  are disposed a pair of swivel casters  142  which may be secured to the side mounting plate  140  by suitable fasteners or welding (not illustrated). 
     It should be appreciated that components of the strip seal installing machine  10  such as the clamping or locating wheels  64  and the toothed insertion wheel or blade  94  normally extend below the surface upon which the seal installing machine  10  is disposed. It should also be appreciated that the wheels  34  extend beyond the ends of the box beams  22 A and  22 B. Accordingly, in order to ensure safe transport of the machine  10  from worksite to worksite, it may readily be tipped on its side, so that it rests on the pair of wheels  34  adjacent the transverse rail  24 A and the pair of swivel casters  142 . In this orientation, the strip seal installing machine  10  may readily and safely be moved from worksite to worksite or to various locations at one worksite. 
     On the inside face of the side mounting plate  140  is disposed a pneumatic filtration, lubrication and air pressure regulation assembly  144 . The filtration, lubrication and air pressure regulation assembly  144  is a conventional assembly that filters the air supplied to the strip seal installing machine  10 , regulates the air pressure delivered to the components of the machine  10  and provides a metered quantity of lubricant in the air delivered to the components of the machine  10  which is especially important to ensure the long service life of the air motor  82 . The pneumatic assembly  144  is supplied with pressurized air through an inlet hose or line  146  which communicates with the inlet fitting or connector  46 . An outlet hose or line  148  provides filtered, pressure regulated and lubricant containing air to control components of the machine described directly below. 
     Referring now to  FIGS. 1 and 5 , the controls and the remaining portion of the air circuit  150  include a front panel  152 . The front panel  152  extends between the two uprights of the front upper frame  122 A and is secured to the front panel mounting brackets  132  by suitable fasteners or welds (not illustrated). The outlet hose or line  148  is coupled to and communicates with an inlet of a first, air motor control valve  160 . The air motor control valve  150  is a bi-directional or reversing valve having two outlets or ports  162 A and  162 B and which is therefore capable of providing pressurized air to one of the two outlets  162 A and  162 B while the other outlet  162 B or  162 A functions as an air return or exhaust path and vice versa. Preferably, an exhaust muffler  164  is connected to the air motor control valve  160  and muffles the sound of the air exhausted by the control valve  160  to the atmosphere. 
     The air motor control valve  160  thus includes a three position control lever  166  having a center, neutral or off position wherein no air is supplied to the air motor  82 , a first, rotated or offset position in which pressurized air is provided through the outlet  162 A and returned and exhausted through the outlet  162 B and the muffler  164  causing the air motor  82  to rotate in a first direction and a second, oppositely rotated or offset position in which pressurized air is provided through the outlet  162 B and returned and exhausted through the outlet  162 A and the muffler  164  causing the air motor  82  to rotate in a second, opposite direction. A first air motor supply hose or line  168 A communicates between the outlet or port  162 A and one inlet or port  172 A of the air motor  82  and a second air motor supply hose or line  168 B communicates between the outlet or port  162 B and one inlet or port  172 B of the air motor  82 . 
     The outlet hose or line  148  also communicates with the input of a secondary or clamp air pressure regulator  178 . The secondary air pressure regulator  178  is in series with and downstream of the air pressure regulation assembly  144  and thus it can further reduce the air pressure at its outlet but can provide no higher pressure than that delivered by the air pressure regulation assembly  144 . The outlet of the secondary air pressure regulator  178  communicates with an inlet of a second, clamp control valve  180 . The clamp control valve  180  is also a bi-directional or reversing valve having two outlets or ports  182 A and  182 B and which is capable of proving pressurized air to one of the two outlets  182 A and  182 B while the other outlet  182 B or  182 A functions as a return or exhaust port and vice versa. Preferably, a second exhaust muffler  184  is connected to the second, clamp control valve  180  and muffles the sound of the air exhausted by the clamp control valve  180  to the atmosphere. 
     The second, clamp control valve  180  also includes a three position control lever  186  having a center, neutral or off position wherein no air is supplied to the pneumatic cylinder assemblies  50 A and  50 B, a first, rotated or offset position in which pressurized air is provided through the outlet  182 A and returned and exhausted through the outlet  182 B and the muffler  184  causing the pneumatic cylinder assemblies  50 A and  50 B to translate in a first direction and a second oppositely rotated or offset position in which pressurized air is provided through the outlet  182 B and returned and exhausted through the outlet  182 A and the muffler  184  causing the pneumatic cylinder assemblies  50 A and  50 B to translate in the opposite direction. A first pair of pneumatic cylinder supply hoses or lines  188 A communicate between the outlet or port  182 A and a pair of inlets or ports  192 A of the piston and cylinder assemblies  50 A and  50 B and a second pair of pneumatic cylinder supply hoses or lines  188 B communicate between the outlet or port  182 B and a pair of inlets or ports  192 B of the piston and cylinder assemblies  50 A and  50 B. 
     It will thus be appreciated, first of all, that adjustment of the secondary or clamp air pressure regulator  178  will control the force generated by the piston and cylinder assemblies  50 A and  50 B and applied by the clamping or locating wheels  64  and, second of all, that air pressure in the lines or hoses  188 A will advance (release) the pistons and clamping wheels  64  and air pressure in the lines or hoses  188 B will retract (engage) the pistons and clamping wheels  64 . 
     Referring now to  FIGS. 1 ,  6 ,  7 ,  8  and  9 , a description of set-up, adjustment and operation of the strip seal installing machine  10  will be presented. It will be appreciated that in order to locate the toothed insertion wheel or blade  94  at its optimum position as illustrated in  FIG. 9  of between 25° and 30° and preferably 28° to the bridge deck  200  or other horizontal surface and with the lower edge of the toothed blade  94  just below the upper edge of the upper channel  204  in a rail  202 , it may be necessary to raise or lower the air motor assembly  80  or adjust its angle of incline. To adjust the height of the air motor assembly  80  and the wheel or blade  94 , the threaded fasteners  79  are loosened, the air motor assembly  80  is moved up or down as necessary relative to the mounting plate  78  and the fasteners  79  are re-tightened. To adjust the angle of incline, either to the preferred angle of 28°, to accommodate the spacing of the rails  202  or for other reasons, the locking stanchion blocks  72  are unlocked and the chain  110  is translated clockwise or counter-clockwise to adjust the angle of incline of the air motor assembly  80 . Upon achieving a desired or satisfactory angle of the wheel or blade  94 , the stanchion blocks  72  are re-locked. 
     As illustrated particularly in  FIG. 8 , to install a resilient or elastomeric strip seal  220 , the strip seal  220  is placed into position generally parallel to and proximate the rails  202 . A source of compressed air  210 , such as a gas powered air compressor, provides compressed air in a line  212  to the strip seal installing machine  10  and, if desired, to a lubricant/adhesive container  214 . A suitable lubricant-adhesive compound from the container  214  is supplied through a hose  216  to one or more application wands  218 . Alternatively, the lubricant/adhesive may be applied with rollers or brushes. First, the lubricant/adhesive is liberally applied or sprayed on the sides and the lower grooves or channels  206  of each rail  202 . Then, the strip seal  220  is placed between the rails  202  and the lower lugs  226  are positioned in the lower grooves or channels  206 . Next, the lubricant/adhesive is applied liberally to the upper lugs  224  of the strip seal  220  and the wheel or blade  94  of the strip seal installing machine  10  is disposed as illustrated in  FIG. 8 . 
     The second, clamp control valve  180  is rotated so that the clamping piston and cylinder assemblies  50 A and  50 B extend, moving the wheel or blade  94  into the position and maintaining it in the position illustrated in  FIG. 9 . The first, air motor control valve  160  is then positioned so that the air motor  82  begins to rotate the wheel or blade  94 , translating the strip seal installing machine  10  slowly and continuously along the rails  202 , to the right in  FIG. 8 , and installing the strip seal  220  in the upper groove or channel  204 . Typical installation speed of the strip seal  220  will be approximately 25 feet per minute or less. The strip seal  220  is installed in the opposing upper channel  204  of the opposing rail  202  by the same method and preferably in the same direction. 
     It will be appreciated that on many bridge decks and similar transversely confined roads such as within tunnels, guardrails and similar structures along traffic lanes will obstruct the path of the strip seal installing machine  10  and prevent it from installing the ends of the strip seal  220 . In such situations, labor intensive, prior art installation techniques may be utilized to install end and obstruction adjacent portions of the strip seal  220 . 
     The description of the invention is merely exemplary in nature and variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention and the following claims.