PILEDRIVER MODULES, ADAPTIVE PILE DRIVER SYSTEM AND CORRESPONDING METHOD

An adaptive pile driver system for driving a pile at a worksite. The system comprises a pile driver comprising a motor, an electrical power unit, a drill rod with a first end and a second end. The system further comprises a vibrating module, a hammering module, a drilling module, and a rock drilling module. The pile driver is adaptable to the worksite where the pile is to be driven, by connecting one or more of pile driver modules to the drill rod.

FIELD

The present disclosure relates to pile driver modules, and an adaptive pile driver system for driving a pile at a worksite, wherein the pile driver system can be adapted to different situations by the piledriver modules.

BACKGROUND

Pile driving is used for a variety of applications, such as driving piles for foundations of buildings of varying sizes or smaller projects such as driving fence posts into the ground. These different applications impose different requirements on the pile driver used. Furthermore, the soil in which the pile is to be driven also gives rise to different requirements, e.g. if the pile is to be driven into sand it may be preferable to drive the pile by vibration, or if the pile is to be driven into clay it may be preferable to hammer or drill the pile.

Current pile drivers are normally configured to either drive a pile by vibration, hammering or drilling. The pile drivers are connected to a hydraulic system, which delivers the force needed for driving the pile. A draw back with current pile drivers is that they may be quite bulky, making it hard to gain access to some work sites. Furthermore, the terrain at some worksite does not allow the use of larger machinery as they risk tipping over or getting stuck. Even if it is possible to gain access with the pile driver, there is a risk that the pile driver is not suitable for the soil at the work site, as the pile driver may for example only be able to drill, where it would be more suitable to hammer or vibrate.

DE202015006358 U1 discloses a hand-held pneumatic pile driver with an exchangeable tool element. However, that disclosed hand-held pneumatic pile driver is reliant on an external source to deliver the air pressure. Furthermore, the hand-held pneumatic pile driver disclosed therein can only drive a pile by hammering.

Thus, it remains a problem to provide a simple, easy to handle, and easy to adapt pile driving system.

SUMMARY

It is therefore the object of the invention to provide an improved pile driver system which is simple to use, easy to handle, and easy to adapt to a worksite.

In a first aspect of the invention the above and other objects are achieved by a drilling module for driving a pile along a first axis, wherein the drilling module is connectable to a drill rod and comprises:

a drill bit configured to drive the pile along the first axis, wherein the drill bit is configured to rotate with the drill rod when the drilling module is connected to the drill rod, wherein the drill bit comprises a first cutter configured for drilling along the first axis, wherein the first cutter is rotatable between a drilling position and a collapsed position, wherein in the drilling position a width of the drill bit in a plane perpendicular to the first axis corresponds to or exceeds a width of the pile in the plane perpendicular to the first axis, and wherein in the collapsed position the width of the drill bit in a plane perpendicular to the first axis is less than the width of the pile in a plane perpendicular to the first axis.

Consequently, by being able to reduce a width of the drill bit to less than the width of a pile allows for the drill module to be retracted through the pile when driving of the pile is done, thus the drill module may be reused for other piles.

The drilling module may be connectable to the drill rod via a threaded connection, a bayonet connections, a male-female connection, or a combination of these.

In the context of this invention a cutter is to be understood as any tool suitable for drilling through soil.

The first cutter may be connected to a base part of the drilling module via a pivot connection to allow for the first cutter to rotate. Preferably, the drilling module is provided with means for delimiting rotation of the first cutter to the collapsed position, the drilling position and positions there in-between, e.g. the drilling module may be provided with stop plates which the first cutter abuts at the collapsed position and the drilling position.

The drill bit may further comprise a second cutter, a third cutter, and/or a fourth cutter all movable between a drilling position and a collapsed position. Preferably, if the drill bit comprises more than one cutter the cutters may be central symmetric around the first axis.

The drill bit may comprise one or more stationary cutters, i.e. cutter which are fixed in position on the drill bit.

The drilling position being a position where in the first cutter is configured for drilling through soil. The collapsed position being a position allowing for the drill bit to be retracted/moved through a pile.

In an embodiment the first cutter is rotatable around an axis parallel to the first axis.

In an embodiment the first cutter is rotatable from the collapsed position to the drilling position by rotating the drill bit around the first axis in a first direction, and wherein the first cutter is rotatable from the drilling position to the collapsed position by counter-rotating the drill bit around the first axis in a second direction.

Consequently, a convenient and easy way of changing the position of the first cutter is achieved which may be carried out after a pile has been driven down by the drilling module.

In an embodiment the first cutter is rotatable around an axis perpendicular to the first axis.

In an embodiment the first cutter is rotatable from the drilling position to the collapsed position by moving the drill bit towards a pile being driven by the drill bit.

Consequently, a convenient and easy way of changing the position of the first cutter is achieved which may be carried out after a pile has been driven down by the drilling module.

The movement of the drill bit towards the pile may be achieved in a plethora of ways. In embodiments wherein smaller piles are driven by the drilling module, the drill bit rod may simply be pulled up together with the drill rod, this may be achieved via a user pulling up the drill rod, alternatively the drill rod may be pulled up by a jack, a crane or other external means. In some embodiments the drill bit may be pulled towards the pile by counter-rotating the drill bit, i.e. rotating the drill bit in an opposite direction relative to when a pile was being driven down.

In an embodiment the drilling module comprises a pilot drill configured to guide driving of the pile along the first axis, wherein the pilot drill extends longitudinally along the first axis.

Consequently, it is facilitated that the pile is driven in a straight direction, which may further increase structural capabilities of such a pile.

The pilot drill preferably extends beyond the first cutter to engage with the ground before the first cutter when driving down a pile. The pilot drill may be provided with a pilot cutter to enable the pilot drill to drill through the ground.

In an embodiment the drilling module comprises a centering device configured for being at least partly inserted into the pile being driven by the drilling module to center the drill bit relative to the pile.

Consequently, it may assure the pile is driven in a straight direction along the first axis. Furthermore, it may assure an even distribution of forces acting on the drill bit.

The centering device may have a similar cross-section to the pile being driven in a plane perpendicular to the first axis, preferably the similar cross-section of the centering device is uniformly scaled by reduction relative to the cross-section of the pile.

In an embodiment the drill bit is connectable to the drill rod in a releasable connection.

Having a releasable connection between the drill rod and the drill bit allows for easy exchange of the drill bit. Furthermore, the releasable connection may give the possibility of using the drill bit as a sacrificial drill bit.

In an embodiment the drill bit is formed with a track configured for facilitating movement of soil away from the bottom of the pile.

Having a track in the drill bit provides a path for soil to take away from the bottom of the pile. Furthermore, the track may help facilitating an upwards movement of soil moved away from the bottom of the pile. The upwards movement of soil is desirable as soil moved up may press down on the drill bit, the pile and/or the drill rod, thereby assisting in driving in the pile. The track provided may be a spiral path, thereby facilitating the movement of soil into the track while the drill bit rotates. In some embodiments the tracks may cooperate with a track in the drill rock, e.g. if the drill rod is an auger the track in the drill bit may lead soil to the helical screw blade of the auger.

In an embodiment the drill bit is formed with a protrusion configured for disturbing and loosening soil underneath the drill bit.

When drilling it may happen that the drill bit is not able to get a hold of soil to be moved, this may especially be prevalent in rocky soil, in such cases disturbing/loosening soil may help the drill bit in getting a hold on soil to be moved.

One or more protrusions may preferably be formed on the first cutter. In embodiments, wherein the drilling module comprises a pilot drill then one or more protrusions may be formed on the pilot drill.

In an embodiment of the pile driver module the drill bit comprises one or more wings, which is configured to extend beyond the pile, the one or more wing being configured for facilitating movement of soil away from the bottom of the pile.

Having wings may help facilitating an upwards movement of soil moved away from the bottom of the pile. The one or more wing may be formed as blades, configured for radiating away from the pile, that are set at a pitch to form at least part of a helical spiral. The drill bit may comprise one, two, three, four or more wings. In some embodiment the first cutter in the drilling position may acts as a wing facilitating movement of soil away from the bottom of the pile.

In a second aspect of the invention the above and other objects are achieved by a rock drilling module for driving a pile along a first axis, wherein the rock drilling module comprises:

an outer rock drill bit configured to drill an outer annular hole through rock with a diameter corresponding to or exceeding the pile in a plane perpendicular to the first axis, wherein the outer rock drill bit is connectable to a drill rod, wherein the outer rock drill bit is configured to rotate with the drill rod when connected to the drill rod,

an inner rock drill bit configured to drill an inner cylindrical hole through rock within the outer annular hole, wherein the inner rock drill bit is connectable to a drill rod, wherein the inner rock drill bit is configured to rotate with the drill rod when connected to the drill rod,

a rock cracking wedge configured to be inserted into the inner cylindrical hole to crack the rock in-between the inner cylindrical hole and the outer annular hole.

In a third aspect of the invention the above and other objects are achieved by an adaptive pile driver system for driving a pile at a worksite comprising:

a pile driver comprising:

a motor for providing a rotational force,

an electrical power unit that provides power to said motor,

a drill rod with a first end and a second end, the drill rod being adapted for extending within the pile in parallel with the pile, wherein the motor is configured to rotate the drill rod,

the system further comprising:

a vibrating module configured to drive the pile by vibrating the pile, said vibrating module is connectable to the drill rod, wherein said vibrating module is drivable by rotation of the drill rod when mounted,

a hammering module configured to drive the pile by hammering the pile, said hammering module is connectable to the drill rod, wherein said hammering module is drivable by rotation of the drill rod when mounted, and

a drilling module configured to drive the pile by drilling, said drilling module is connectable to the drill rod, wherein said drilling module is drivable by rotation of the drill rod when mounted,

wherein the pile driver is adaptable to the worksite where the pile is to be driven, by connecting one or more of pile driver modules to the drill rod.

Thereby, an improved pile driver system for drive a pile at a worksite is provided. The different modules allow for the pile driver to be adapted to the conditions at different work sites. Furthermore, since each module is connected to the drill rod and driven by the rotation of the drill rod, no additional hydraulics or wiring is needed to be added for the pile driver to drive a pile by drilling, hammering, or vibration. If prior to arriving at a work site soil tests have been performed, a user of the adaptive pile driver may also choose to only bring the relevant modules from the system to the work site, thereby alleviating transport of the pile driver.

The adaptive pile driver system may comprise any combination of the modules, i.e. the vibrating module, the hammering module, the drilling module, and the rock drilling module. The adaptive pile driver system may comprise three different modules, e.g. the hammering module, the drilling module, and the rock drilling module. In some embodiments the adaptive pile driver system comprises all four modules, i.e. the vibrating module, the hammering module, the drilling module, and the rock drilling module.

By a worksite is meant a place where work is to be performed by the pile driver, the worksite may be defined by the terrain and/or the soil types present at the work site.

Being able to use a drilling module for adapting the pile driver system gives large degree of flexibility to the pile driver system. Furthermore, since the drilling module is driven by rotation of the drill rod no external external/added power means are needed to be provided together with the drill bit. Furthermore, drilling is widely used in different soil types, giving a wide range of soil type the pile driver may work in.

Being able to use a rock drilling module for adapting the pile driver system allows for the pile driver to drive piles through rock, concrete, boulders and/or stones.

In an embodiment of the pile driver system, the pile driver comprises a footrest, allowing a user of the adaptive pile driver system to deliver a pressure for driving the pile.

Providing a footrest to the pile driver adds an extra way of driving the pile. Alternatively, or additionally, the pile driver may be provided with handles on which a user can press down.

In an embodiment of the pile driver system, the pile driver is a hand-held and/or hand actuated pile driver.

For smaller piles larger machinery is not needed as everything can be handled by a person. In such cases it is advantageous to have a hand-held pile driver to avoid bulky, cumbersome, and costly machinery. Such a hand-held driver may be provided with handles. The handles may further be provided with actuators for starting and turning off the electric motor.

In an embodiment of the pile driver system, the motor of the pile driver is configured to provide a vibrational and/or a hammering force for driving the pile.

By having the motor providing a vibrational and/or a hammering force, the motor may then assist or fully replace some of the pile driver modules in driving the pile, as sometimes adding a pile driver module to achieve a vibrational and/or hammering force may be excessive.

In an embodiment of the pile driver system the motor is an electric motor.

By having an electric motor an easy to handle pile driver is achieved. The electric motor assures that wiring or hoses for generators or hydraulics is obsolete or at least kept to a minimum. This removes the risk of failures in externally exposed wiring and hosing, which in some cases can pose a severe safety risk. Furthermore, the electric motor adds extra mobility and freedom to the pile driver, as the pile driver is not limited by hosing or wiring but can be moved freely around.

In a third aspect of the invention the above and other objects are achieved by a vibrating module for driving a pile along a first axis, where the vibrating module comprises:

a vibration device comprising:

a drill rod part being connectable to a drill rod, the drill rod part being configured to rotate with the drill rod when connected to the drill rod,

an eccentric mass connected to the drill rod part,

a transfer member connected to the drill rod part,

where the eccentric mass is in-between the drill rod and the pile when the drill rod part is connected to the drill rod, wherein the eccentric mass is configured to generate vibration when the drill rod rotates, wherein the transfer member is configured to transfer the generated vibrations to the pile.

Thereby, a simple pile driving module capable of driving a pile by vibration is provided. By having the pile driving module connectable to the drill rod allows for easy addition and removal of the pile driver module. Having the pile driver module easy to add and remove allows for a pile driver to be adapted on-site at a work site.

Furthermore, the pile driver module may be installed at a desired position on a drill rod, thus allowing for the vibration module to deliver down the hole vibration. Having the vibration generated as a result of rotation generated by the drill rod also removes the need for extra hydraulic or wiring,

In a fourth aspect of the invention the above and other objects are achieved by a hammering module for driving a pile along a first axis, wherein the hammering module comprises:

a drill rod part being connectable to a drill rod, the drill rod part being configured to rotate with the drill rod,

a hammer element comprising a top surface and a bottom surface, wherein the bottom surface forms one or more bottom ledges,

a force device connected to the top surface of the hammer element, said force device being configured to store and release mechanical energy,

a stationary element with a top surface comprising one or more top ledges complementary to the bottom ledges of the hammer element, and wherein the top surface of the stationary element is engaged with the bottom surface of the hammer element, and

wherein the hammer element is configured to rotate relative to the stationary, wherein rotation of the hammer element relative to the stationary element moves the hammer element along a bottom ledge, wherein the movement of the hammer element along the bottom ledge stores mechanical energy in the force device, wherein the stored mechanical energy is released when the hammer element rotates past the bottom ledge, wherein the released mechanical energy, wherein the released mechanical energy is configured for being delivered to drive the pile.

In a fifth aspect of the invention the above and other objects are achieved by a method for adapting a pile drive at a work site, the method comprising the steps of:

assessing the work site;

providing a pile driver system as described above;

dependent on the assessment of the work site, adapting the pile driver by connecting either a vibrating module, a hammering module, a drilling module, a rock drilling module, or a combination of these to the pile driver.

The assessment of the work site may be carried out by prior soil sampling of the work site. Alternatively, the assessment of the work site may be carried out using the knowledge of the user of the pile driver. The adaptation of the pile driver is carried out by connecting one or more pile driver modules to the drill rod dependent on the assessment of the work site.

DETAILED DESCRIPTION

In the following description, reference is made to the accompanying figures, which show by way of illustration how the invention may be practiced.

Referring toFIG.1showing a schematic cross-sectional view of a pile driver1for driving a pile3at a worksite according to an embodiment of the invention. The pile driver1comprises a motor for providing a rotational force, the motor is not shown. The motor may be any kind of electrical motor, which is able to convert electric energy into mechanical energy. The electric motor may be an AC motor or a DC motor. Alternatively, the motor may be hydraulic motor or a combustion engine. The motor may additionally provide a vibrational force and/or a hammering force, which may assist in driving the pile3. This may for example be achieved by an impact mechanism as already known from hammer drills. Said motor is connected to an electrical power unit, the electrical power unit is not shown.

The electrical power unit may be a battery or any other unit capable of delivering energy to the motor. Preferably, the electrical power unit is a rechargeable battery.

The electric motor is configured for rotating a drill rod2. The drill rod2may be any standard drill rod used for drilling in soil. The drill rod2may have a small diameter such as 2 cm or 3 cm, or a larger diameter such as 14 cm or 15 cm. The drill rod2extends longitudinally between a first end and a second end. The drill rod2is configured to rotate around a longitudinal rotation axis R1. The drill rod2may be rotated clockwise or counter-clockwise around the longitudinal rotation axis R1. The drill rod2may be modular and comprise a plurality of drill rod parts21connected together. In some cases, the length of one drill rod part21may be enough to form the full drill rod2. The drill rod parts21may be inter-connected by threaded connections, bayonet connections, male and female connectors, or a combination of these. The drill rod parts21forming the drill rod2may also be of different lengths, allowing for a length of the drill rod2to be easily adaptable. The drill rod2may be a smooth drill rod2, alternatively the drill rod2may be provided as an auger. The auger2may facilitate transport of soil through the pile3.

The pile driver1is configured for driving the pile3. The pile3in the shown embodiment is a pipe pile3, though the invention is not limited to only pipe piles, but may be used for sheet piles, screw piles, secant piles, etc. The pile3chosen may depend on the needed function of the pile3, conditions at the work site, and how it is to be driven into the soil, e.g. if the pile is to be driven by vibration, drilling, hammering or a combination of these.

The pile driver1further comprises a footrest4. The footrest4allowing a user of the pile driver1to apply a pressure onto the pile3. The footrest4in the shown embodiment is formed as a plate, which allows the user to step onto the plate to deliver a pressure to the pile3. Alternatively, or additionally, pressure may be delivered to the pile3via hand-rests provided on the pile driver1.

The pile driver1may be a hand-held pile driver and/or a hand actuated pile driver. To facilitate it being a hand-held pile driver, the pile driver1may be provided with handles for holding the pile driver1during operation of the pile driver1. To facilitate it being a hand actuated pile driver the handles may be provided with an actuator for starting and stopping the electric motor of the pile driver1, e.g. push buttons or levers. Alternatively, the pile driver1may be controllable by a remote control unit. Furthermore, the pile driver1may be configured to be mounted on larger machinery, e.g. an excavator or a drill rig.

The pile driver1can be adapted to different work site conditions, e.g. soil type. Adaptation of the pile driver1is achieved by connecting a combination of different pile driver modules to the drill rod2of the pile driver system1. The pile driver modules may be connected to the pile driver1independently of each other, so the pile driver modules do not impose restrictions on each other. In the following text a more in-depth explanation of different modules for the pile driver system is given.

Drilling Module

In the embodiment shownFIG.1a drilling module5has been connected to the pile driver1. The drilling module5being configured for driving the pile3by drilling. The drilling module5is an example of a pile driver module for the pile driver1. The drilling module5comprises a drill bit51. The drill bit51may be made from steel or carbide; it may also be a steel bit with a tungsten carbide tip. The drill bit51may be formed with a track to facilitate the movement of soil to the sides of the pile3. The track may be formed in an exterior surface of the drill bit51. The track may be formed by milling of the exterior surface of the drill bit51. The drill bit51may be formed with one or more protrusions to disturb and loosen soil underneath the pile, thereby facilitating movement of the soil. The one or more protrusions extending from an exterior surface of the drill bit.

The drill bit51is connected to a drill rod part21of the drill rod2. The connection between the drill bit51and the drill rod part21may be achieved by a threaded connection, bayonet connection, or male and female connectors or any other suitable connection. Alternatively, the drill bit51may be provided as an integral part of a drill rod part21, wherein the drill rod part21may be connected to other drill rod part21of the drill rod2by a threaded connection, bayonet connection, or male and female connectors or any other suitable connection. When the drill bit51is connected to the drill rod part21it is able to rotate with the drill rod2, thereby facilitating drilling with the drill bit51. Furthermore, having a threaded connection or a male-female connection between the drill bit51and the drill rod part21allows for disconnecting the drill bit51from the drill rod part21, without needing to have access to the drill bit51. This is especially an advantage, if the drill bit51is a sacrificial drill bit51, which is to be left in the soil together with the pile. The disconnection between the drill bit51and the drill rod2when there is a threaded connection may happen by rotating the drill rod2counter-clockwise, e.g. if the threaded connection between the drill bit51and the drill rod2is achieved with a right-handed thread, the drill rod2may be rotated counter-clockwise to disconnect the drill bit51. In the case of a male-female connection between the drill bit51and the drill rod2the disconnection may happen by simply pulling up the drill rod2, e.g. if the drill bit51is provided with a female connector and the drill rod is provided with a male connector or vice versa.

In the embodiment shownFIG.1where the pipe pile3is used, the drill bit51acts as a barrier for the bottom of the pile3, thereby assuring soil does not enter the pile3from the bottom of the pile3when the pile3is driven into the soil. In some embodiments, the drill bit51may be a collapsible drill bit, thereby allowing for the drill bit51to be retracted subsequent to the pile3being driven into the soil. The drill bit51may also comprise wings, which extend beyond the pile3. The wings facilitating movement of soil away from the bottom of the pile3. Furthermore, as soil is pushed away from the bottom of the pile3, the moved soil will start pushing down on the wings, thereby pressuring the pile3in a downward direction.

If the pile driver1have not been provided with a drilling module5, the pile3may be closed off at the bottom to assure soil does not enter the pile3. The pile3may be closed off by a flat plate at the bottom of pile3. Alternatively, the pile3may be closed with a conical shaped plate at the bottom, to facilitate the pile3being pressured, vibrated, or hammered into the soil.

Referring now toFIG.3showing a schematic cross-sectional of an embodiment of a drilling module5connected to a drill rod2according to the invention. The drilling module5is configured for driving a pile3along a first axis. In the shown embodiment the first axis coincides with a longitudinal rotation axis R1of which the drill rod2is configured to rotate about. In the following description in relation toFIG.3the terms first axis and the longitudinal rotation axis R1are interchangeable with each other.

The drilling module comprises a drill bit51. The drill bit51is configured to rotate with the drill rod2when the drilling module5is connected to the drill rod2. The drill bit51comprises a first cutter511configured for drilling along the longitudinal rotation axis R1. The drill bit51further comprises a second cutter512configured for drilling along the longitudinal rotation axis R1. The first cutter511and the second cutter512are rotatable between a drilling position and a collapsed position. When the first cutter511and the second cutter512are in the drilling position a width of the drill bit51in a plane perpendicular to the longitudinal rotation axis R1corresponds to or exceeds a width of the pile3in the plane perpendicular to the longitudinal rotation axis R1. When the first cutter511and the second cutter512are in the collapsed position the width of the drill bit51in a plane perpendicular to the longitudinal rotation axis R1is less than the width of the pile3in a plane perpendicular to the longitudinal rotation axis R1.

In the shown embodiment the drilling module5further comprises a pilot drill52. The pilot drill52is configured to guide driving of the pile3along the longitudinal rotation axis R1. The pilot drill52extends longitudinally along the longitudinal rotation axis R1. The pilot drill52extends beyond the first cutter511and the second cutter512. The pilot drill52is configured to rotate with the drill rod2when the drilling module5is connected to the drill rod. The pilot drill52comprises a pilot cutter521at a longitudinal end of the pilot drill52. The pilot cutter521allows the pilot drill52to drill through soil.

In the shown embodiment the drilling module5comprises a centering device53. The centering device53is inserted into the pile3. The centering device centers the drilling module5relative to the pile3. The centering device53is provided as a ring extending along an inner circumference of the pile3. The centering device53restricts movement of the drilling module5in a plane perpendicular to the longitudinal rotation axis R1. The centering ring53also keeps the drill rod2centered relative to the pile3.

In the shown embodiment the drill rod2is provided as an auger2. The auger2comprises a helical screw blade21extending longitudinally along the longitudinal rotation axis R1. The auger2extends within the pile3. In the shown embodiment the helical screw blade21extends towards the inner circumference of the pile. In the shown embodiment, the helical screw blade21stops a distance from the inner circumference of the pile3. In other embodiments, the helical screw blade21extends so no to little distance separates the helical screw blade21and the inner circumference of the pile. Having no distance, or a small distance which does not allow soil to pass through in-between the inner circumference of the pile3and the helical screw blade21, may be useful for lifting soil up through the auger2.

Referring now toFIGS.4a-4dshowing a schematic top perspective view, a schematic bottom perspective view, a schematic bottom view, and a schematic top view of an embodiment of a drilling module5according to the invention.

The drilling module5comprises a first cutter511and a second cutter512. The first cutter511and the second cutter512each comprises a plurality of protrusions5111,5121. The plurality of protrusions may facilitate drilling by the first cutter511and the second cutter512by disturbing and loosening soil underneath the first cutter511and the second cutter512. The first cutter511and the second cutter512are pivotally connected to a base58of the drilling module5. The pivotal connections571,572between the base58and the first cutter511and the second cutter512allows the first cutter511and the second cutter512to rotate around an axis parallel to a first axis A1. Where the drilling module5is configured for driving a pile3along the first axis A1.

In the shown embodiment the first cutter511and the second cutter512are rotated to a drilling position. In the drilling position the first cutter and the second cutter abut a stop plate56. Furthermore, the first cutter511and the second cutter512extend beyond an outer circumference of a centering device53in the drilling position. The stop plate56prevents further rotation of the first cutter511and the second cutter512in a first direction. By rotating the first cutter511and the second cutter512in a second direction, opposite the first direction, the first cutter511and the second cutter512moves from the drilling position to the collapsed position. In the collapsed position the first cutter511and the second cutter512does not extend beyond an outer circumference of the centering device53.

The centering device53is provided as a ring. The centering device53being configured for being at least partly inserted into a pile3. Extending from an inner circumference of the centering device53are two ridges531. In some embodiments the centering device53comprise one ridge, three ridges, or four ridges. The ridges531are engaged with corresponding grooves581in the base58of the drilling module5. The engagement between the grooves581and the ridges531prevents the centering device53from rotating relative to the base58of the drilling module5. Furthermore, a bottom surface of the centering device53rests on a shelf582formed in the base58. Preferably, the base58is formed with a plurality of shelfs582on which the bottom surface of the centering device53can rest. The shelf582prevents movement of centering device53relative to the base58in one direction along the first axis A1.

The base58of the drilling module5is provided with a center hole55for receiving a drill rod2. When the drill rod2has been received in the center hole55it is rotatably locked relative to the drilling module by a suitable connection, e.g. by inserting a bolt or a clip through the base58and the drill rod2.

The drilling module further comprises a pilot drill52. The pilot drill52is configured to guide driving of a pile3. The pilot drill52extends beyond the first cutter511and the second cutter512. The pilot drill52is configured to rotate with the drill rod2when the drilling module5is connected to the drill rod. The pilot drill52comprises a pilot cutter521at a longitudinal end of the pilot drill52. The pilot cutter521allows the pilot drill52to drill through soil.

Referring brieflyFIG.5showing a different embodiment of a drilling module5according to the invention. In the shown embodiment a first cutter511and a second cutter are pivotally connected to a base58of the drilling module5. The pivotal connections571allows the first cutter and the second cutter to rotate around an axis perpendicular to the first axis A1.

Rock Drilling Module

Referring now toFIGS.6aand6bshowing perspective schematic cut-out views of a rock drilling module8according to an embodiment of the invention. The rock drilling module8being for drive a pile along a first axis A1. The rock drilling module8comprises an outer rock drill bit81. The outer rock drill bit81is in the shown embodiment configured to drill an outer annular hole841through rock84. The outer diameter of the annular hole841corresponding to or exceeding the pile3in a plane perpendicular to the first axis A1. The outer rock drill bit81is connectable to a drill rod2. The outer rock drill bit81is configured to rotate with the drill rod2when connected to the drill rod2. In the shown embodiment the outer rock drill bit81comprises four outer rock cutters811configured to drill through rock84, concrete, stone and/or boulders. The four outer rock cutters811are arranged center symmetric around the first axis A1. In other embodiments the outer rock drill bit81comprises one rock cutter, two rock cutters, three rock cutters, or more. The rock cutters811may be forces with a track or an inclination configured to create a force on the rock cutters forcing them away from the first axis A1in a plane perpendicular to the first axis A1.

The rock drilling module8further comprises an inner rock drill bit82configured to drill an inner cylindrical hole842through rock84within the outer annular hole841. The inner rock drill bit82is connectable to a drill rod2, and the inner rock drill bit82is configured to rotate with the drill rod2when connected to the drill rod2. In the shown embodiment the inner rock drill bit82comprises one inner rock cutter821configured to drill through rock84, concrete, stone and/or boulders. The inner rock cutter821is configured to drill an inner cylindrical hole842, where a center longitudinal axis of the inner cylindrical hole842coincides with the first axis A1. In other embodiments the inner rock drill bit82comprises two rock cutters, three rock cutters, four rock cutters, or more. Furthermore, in the shown embodiment the inner rock drill bit82extends beyond the outer rock drill bit81along the first axis A1, thus allowing the inner rock drill bit82to act as a pilot for the outer rock drill bit81. In an embodiment the inner rock drill bit82is configured to guide driving of the pile3along the first axis A1.

The rock drilling module8further comprises a rock cracking wedge83. The rock cracking wedge83is configured to be inserted into the inner cylindrical hole842to crack the rock84in-between the inner cylindrical hole842and the outer annular hole841. In the shown embodiment, the rock cracking wedge83is connected to the inner rock drill bit82and configured to follow the movement axial movement along the first axis A1of the inner rock drill bit82. The rock cracking wedge83comprises an outer wedge831. The outer wedge831is formed by two wedge parts8311. In the shown embodiment the two wedge parts8311are opposed each other. The two opposing wedge parts8311are movable relative to each other in a plane5perpendicular to the first axis A1. The outer wedge831is movably connected to the inner rock drill bit82to allow axial along the first axis A1relative to the inner rock drill bit82. The outer wedge831being formed with a hollow conical structure with a circular top opening at the top of the conical structure and a circular bottom opening at the bottom of the conical structure. Preferably, the inner rock drill bit821is configured to drill the inner cylindrical hole842with a diameter exceeding a diameter of the circular top opening and less than a diameter of the circular bottom opening. Arranged at least partly within the outer wedge831is an inner wedge832. The inner wedge832is fixedly connected to the inner rock drill bit82, i.e. the inner wedge832is connected to prevent relative movement in-between the inner wedge832and the inner rock drill bit82. The inner wedge832being formed as a conical structure, wherein a diameter of the base of the conical structure of the inner wedge832exceeds a diameter of the circular top opening of the outer wedge831. Consequently, the outer wedge831is prevented from sliding past the inner wedge832. In the shown embodiment, a conical shapes are used to achieve this effect, however the inner and outer wedges831,832may assume any shapes which prevent the outer wedge831from sliding past the inner wedge832.

During operation of the rock drilling module8the outer rock drill bit81forms the annular hole841in the rock84and the inner rock drill bit82forms the inner cylindrical hole842. As the rock drilling module8is further drilled into the rock84, the outer wedge831reaches and is partly inserted into the inner cylindrical hole842. Further, drilling of the rock drilling module8results in the outer wedge831being axially moved relative to the inner rock drill bit82along the first axis A1until it abuts the inner wedge832. Further, drilling of the rock drilling module8results in the two wedge parts8311outer wedge831being moved away from each other by the inner wedge, resulting in a horizontal force being delivered to the rock84, thus cracking the rock84in-between the inner cylindrical hole842and the outer annular hole841.

In other embodiments, the outer wedge831may be formed in one part of resilient material allowing for the outer wedge831to be expanded by the inner wedge832in order to deliver a force to material in-between the inner cylindrical hole842and the outer annular hole841. In yet other embodiments, the outer wedge831is formed with an outer protrusion on an interior side of the conical structure of the outer wedge831. The inner wedge832may then be formed with an inner protrusion on an outer side of the conical structure of the inner wedge832. During operation when the inner wedge832is rotating relative to the outer wedge831, the inner protrusion is also rotating relative to the outer protrusion. As the outer wedge831is moved towards the inner wedge832so are the inner protrusion and the outer protrusion. At some point the outer protrusion and the inner protrusion will collide with each other. The collision between the inner protrusion and outer protrusion deforms the outer wedge831and results in a force being delivered to the material in-between the inner cylindrical hole842and the outer annular hole841.

Vibrating Module

In the embodiment shownFIG.1a vibrating module6has been connected to the pile driver1. The vibrating module6being configured for driving the pile3by vibration. The vibrating module6is an example of a pile driver module for the pile driver1. The vibrating module6comprises a vibrating device. The vibrating device comprises a drill rod part21. The drill rod part21of the vibrating device is connectable to the drill rod parts21of the drill rod2. The drill rod part21of the vibrating device may be identical to other drill rod parts21of the drill rod2. When the drill rod part21of the vibrating device is connected to other drill rod parts21of the drill rod, the drill rod part21of the vibrating device is configured to rotate with the drill rod2.

In either direct or in-direct connection with the drill rod part21of the vibrating device is an eccentric mass61. The eccentric mass61being eccentric relative to the drill rod part21on which it is connected. The eccentric mass61is connected so as to rotate with the drill rod part21of the vibrating device. The eccentric mass61is placed in-between the drill rod2and the pile3. Rotation of the eccentric mass61around the drill rod2generates vibrations. The vibrations generated by the eccentric mass61are transferred to the pile3via a transfer member62. The transfer member62is configured for contacting the pile3and transferring vibrations generated by the eccentric mass61to the pile3. Alternatively, the eccentric mass61may contact the pile3directly, thereby also acting as the transfer member62. The transfer member62may be formed with an arm621extending from the drill rod2to the pile3. The transfer member62may also comprise a contacting element622for contacting the pile3. The contacting element622may be formed as an annular element, where the annular element has an outer diameter equal to an inner diameter of the pile3, thereby assuring a uniform contact to the pile3. If the transfer member62is formed with an arm621extending from the drill rod2to the pile3, the arm621may be bendable to allow the arm to deform in response to changes in the surface of the pile3, e.g. if a thread, bent or bump is present on the pile3. In the embodiment shown inFIG.1only one vibration module6is connected to the pile driver1, but it is also possible to connect a plurality of vibrating modules6to the pile driver1, e.g. two, three or more. Especially in cases, wherein it is required to connect several drill parts21together it may be advantageously to connect more than one vibrating module6to the pile driver1, to achieve a uniform down the hole vibration of the pile3.

ReferringFIG.8showing a perspective schematic view of a vibrating module6according to an embodiment of the invention. The vibrating module6being for driving a pile3along a first axis A1. The vibrating module6being configured for driving the pile3along the first axis A1by driving it down by vibration. In the shown embodiment, the vibrating module6is connectable to a drill rod2via a central through-going hole in a drill rod part21of the vibrating module. The central through-going hole being configured for receiving the drill rod2. When the drill rod2is received in the central through-going hole the drill rod part21is configured to rotate with the drill rod2. Arranged at a first longitudinal end of the vibrating module is an eccentric mass61. The eccentric mass61is provided as a bolt61extending perpendicularly to the first axis A1from the drill rod part21. When the drill rod part21starts to rotate the bolt61also rotates around the first axis A1, thus creating an eccentric force. The bolt61is configured to be in-between the drill rod2and the pile3. The vibrating module further comprises transfer members62. In the shown embodiment, the transfer members62are provided as three arms62extending from the drill rod part21. The three arms62are configured for transferring the eccentric force created by the bolt61to the pile3. The three arms62may be pivotably connectable to the drill rod part21, to allow the arms62to fold in when pulling up the vibration module6. The folding of the arms62may help in avoiding the arms62getting caught in the pile when pulling up the vibration module6.

Arranged at a second longitudinal end of the vibrating module6is a further eccentric mass63. The further eccentric mass63is arranged protruding form a further drill rod part211. When the further drill rod part211starts to rotate the further eccentric mass63also rotates around the first axis A1, thus creating an eccentric force. The further eccentric mass63is configured to be in-between the drill rod2and the pile3. In the shown embodiment, the further eccentric mass63directly contacts and transfers the eccentric force to the pile3.

Hammering Module

In the embodiment shownFIG.1a hammering module7has been connected to the pile driver1. The hammering module7being configured for driving the pile3by hammering. The hammering module7is an example of a pile driver module for the pile driver1.

A more detailed view of an embodiment of the hammering module7is shown onFIG.2. The hammering module7comprises a drill rod part21. The drill rod part21of the hammering module7is connectable to the drill rod parts21of the drill rod2. The drill rod part21of the hammering module7may be identical to other drill rod parts21of the drill rod2. When the drill rod part21of the hammering module7is connected to other drill rod parts21of the drill rod, the drill rod part21of the hammering module7is configured to rotate with the drill rod2. The hammering module7further comprises a hammer plate71, a force device72, a stationary element73, and a rotatable element74. In the shown embodiment onFIG.2the hammer module7further comprises a top plate75. The hammer plate71may be a steel plate. The hammer plate71is configured for imparting a hammering force to either the pile driver1or the pile3. In the shown embodiment the hammer plate71is placed directly on the pile3. Alternatively, the hammer plate may be place on top of a hammer cushion. The hammer plate71is connected to the force device72. The force device72may be a spring or a resilient material, which is capable of storing and releasing mechanical energy. Connected to the hammer plate71is also the stationary element73. The stationary element73may be welded on the hammer plate71. The stationary element73may be made from steel or other high durability metals. The stationary element73comprises a stationary inclined part731. Connected to the drill rod part21is the rotatable element74. The rotatable element74may be welded on the drill rod part21. The rotatable element74may be made from steel or other high durability metals. The rotatable element74comprises a rotatable inclined part741. The rotatable element74is configured to rotate with the drill rod part21. During rotation the rotatable element74is configured to slide onto and past the stationary element73. When the rotatable inclined part741slides onto the stationary inclined part731it causes the hammer plate71to rise. The rise of the hammer plate71stores mechanical energy in the force device72, e.g. by the compression of a spring. When the rotatable element74slides past the stationary element73it causes the hammer plate71to fall. The fall of the hammer plate71releases the stored energy from the force device72. In the embodiment shown onFIG.2the fall of the hammer plate71stops when it reaches the pile3, and thereby the released energy is transferred to the pile3as a hammering force. The hammering module7may be provided with a top plate75. The top plate75being connected to the drill rod part21and the force device72. The top plate72provides surface on which the force device72can be compressed against.

Referring toFIG.7showing an embodiment of a hammering module7according to the invention. The hammering module being for driving a pile along a first axis A1. The hammering module7comprises a drill rod part21being connectable to a drill rod2. The drill rod part21being configured to rotate with the drill rod2. In the shown embodiment the drill rod part is provided as a clamp21. The clamp21allows the hammering module7to be clamped onto the drill rod2. Connected to the drill rod part21is a force device72. The force device72is provided as spring72configured to store and release mechanical energy. The spring72is at one longitudinal end abutting the drill rod part21and at the other longitudinal end abutting a hammer element71.

The hammer element71comprises a top surface711connected to the spring72. Furthermore, extending from the top surface711is a hammer protrusion712. The hammer protrusion712extends from the surface711and into the spring72, thus restricting movement of the spring72relative to the hammer element71in a plane perpendicular to the first axis A1. The hammer element71further comprises a bottom surface, not shown. The bottom surface forms one or more bottom ledges713.

The hammering module7further comprises a stationary element73with a top surface, not shown, forming one or more top ledges731complementary to the bottom ledges713of the hammer element71. The top surface of the stationary element73is engaged with the bottom surface of the hammer element71. In some embodiments, the pile3is closed off at the bottom and the stationary element73is arranged resting on the bottom of the pile3.

The hammer element71is configured to rotate relative to the stationary element73. The rotation of the hammer element71relative to the stationary element73moves the hammer element71along the one or more top ledges731. The movement of the hammer element71along the bottom ledge731stores mechanical energy in the force device72. In the shown embodiment the hammer element71is moved towards the drill rod part21, thus resulting in a compression of the spring72. The stored mechanical energy is released when the hammer element71rotates past the one or more top ledges731. The released mechanical energy is configured for being delivered to drive the pile3.

Specific embodiments of the invention have now been described. However, several alternatives are possible, as would be apparent for someone skilled in the art. For example, the pile3do not need to be a pipe pile3, e.g. if only the hammering module7is connected to the pile driver1the pile3does not need to be hollow.

Furthermore, though not shown on the drawings any combination of the modules described herein may be used for adapting a pile driver according to the invention.

Such and other obvious modifications must be considered to be within the scope of the present invention, as it is defined by the appended claims.

In particular, it is to be understood that other embodiments may be utilized, and structural and functional modifications may be made without departing from the scope of the present invention.