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CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit under Title 35, U.S.C. §119(e) of U.S. Provisional Application Ser. No. 60/943,979, entitled MODULAR VIBRATORY PILE DRIVER, filed on Jun. 14, 2007. 
     
    
     BACKGROUND 
       [0002]    1. Field of the Disclosure 
         [0003]    The present disclosure relates to pile driving equipment. More particularly, the present disclosure relates to a modular vibratory side grip pile driver system and method for assembly. 
         [0004]    2. Description of the Related Art 
         [0005]    Vibratory pile drivers are used in a plurality of applications to drive pile, such as sheet pile, pipes, I-beams, H-beams, and poles, for example, into the ground. The pile driver may be mounted on an excavator and include articulating arms and side-gripping jaws to facilitate the pile driving process. 
         [0006]    Current side grip vibratory pile drivers have the disadvantage that they are designed for driving only one type of pile. Therefore, if it is desired to switch from driving sheet pile to H-pile, for example, a separate unit must be employed. This leads to significant increased cost at a job site and requires that the construction company inventory more than type of pile driver for use at its various job sites. 
       SUMMARY 
       [0007]    The modular vibratory pile driving system of the present invention comprises a base unit having a housing, a vibratory gear case and a mounting base rigidly connected to the housing. It also includes two jaws that are spaced apart longitudinally wherein the jaws include jaw halves that are movable relative to each other to enable a pile to be gripped. In a preferred embodiment, each of the jaws includes a stationary jaw half rigidly connected to the mounting base and a pivotable jaw rotatably connected to the mounting base and caused to open and close through the action of one or more hydraulic cylinders. The pile driver system also includes a set of gripping assemblies having different gripping profiles adapted for gripping a variety of different pile profiles. These gripping assemblies are interchangeable so that the same base unit can be utilized to drive a variety of pile profiles. In one embodiment, the gripping assemblies include elements that are removably attached to the stationary jaw halves as well as removable pivot arms including gripping profiles that match the profiles of the gripping assemblies mounted to the stationary jaws. 
         [0008]    Advantageously, the modular vibratory pile driver system eliminates the need to obtain a plurality of pile drivers matching the types of pile to be driven. Instead, the modular vibratory pile driver uses the same housing and gear case for all types of pile and utilizes modular sets of gripping assemblies to facilitate driving different types of pile, thereby reducing costs and saving time. Further, the modular vibratory pile drivers of the present disclosure facilitate centering of the pile with the pile driver, thereby enhancing the efficiency of energy transfer to the pile and reducing the stress on the gear case of the pile driver. Moreover, the modular vibratory pile driver facilitates straight driving of the pile because the centerline of the pile matches the centerline provided by the selected modular gripping assembly set. 
         [0009]    In one form thereof, the present invention is a modular side grip vibratory pile driver system comprising a housing that includes a mounting base comprising first jaw halves. A vibratory gear case is mounted to the housing and a pivotable arm assembly forming two second jaw halves is pivotally connected to the housing. The respective first and second jaw halves form a pair of spaced apart jaws adapted for gripping a pile at two longitudinally spaced apart locations. An attachment assembly connects the housing to a construction machine. The housing is rotatably connected to the attachment assembly and rotatable between a first position wherein the jaws are oriented vertically and spaced apart horizontally and a second position wherein the jaws are oriented horizontally and spaced apart vertically. The jaws are open thereby forming a gap so that a pile can enter the jaws laterally. A plurality of sets of gripping assemblies having different gripping profiles adapted for gripping a variety of different pile profiles are interchangeably connected to and form the pile gripping elements of the jaws. The jaws include a single set of the interchangeable gripping assemblies detachably and interchangeably connected thereto. 
         [0010]    In another form thereof, the invention constitutes a method of changing a modular side grip vibratory pile driver from a first configuration to a second configuration. One of the sets of gripping assemblies is selected from the plurality of sets wherein the selected gripping assembly accommodates the profile of a pile to be driven and this gripping assembly is substituted for the current set of gripping assemblies forming the gripping surfaces on each of the jaws. In one embodiment each of the jaws comprises a stationary jaw half and a removably rotatable jaw half and the step of substituting comprises replacing the current rotatable jaw halves with rotatable jaw halves from the plurality of sets having a gripping profile that accommodates the profile of the pile to be driven. The gripping assembly on the stationary jaw is replaced with a gripping assembly from the plurality of sets that accommodates the pile profile. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    The above-mentioned and other features of the disclosure, and the manner of attaining them, will become more apparent and will be better understood by reference to the following description of embodiments of the disclosure taken in conjunction with the accompanying drawings, wherein: 
           [0012]      FIG. 1  is a perspective view of a first embodiment modular side grip vibratory pile driver of the present disclosure, further illustrating a sheet pile clamped in the jaw assembly of the pile driver; 
           [0013]      FIG. 2  is another perspective view of the modular vibratory pile driver of  FIG. 1 ; 
           [0014]      FIG. 3  is a side view of the modular vibratory pile driver of  FIG. 1 ; 
           [0015]      FIG. 4  is a top view of the modular vibratory pile driver of  FIG. 1 ; 
           [0016]      FIG. 5  is another perspective view of the modular vibratory pile driver of  FIG. 1 , further illustrating the hydraulic cylinders used to power the jaw assembly of the pile driver; 
           [0017]      FIG. 6  is an exploded view of a portion of the modular vibratory pile driver of  FIG. 1 ; 
           [0018]      FIG. 7  is another exploded view of a portion of the modular vibratory pile driver of  FIG. 1 ; 
           [0019]      FIG. 8  is a perspective view of a second embodiment modular side grip vibratory pile driver of the present disclosure, further illustrating a large diameter pipe clamped in the jaw assembly of the pile driver; 
           [0020]      FIG. 9  is another perspective view of the modular vibratory pile driver of  FIG. 8 ; 
           [0021]      FIG. 10  is a side view of the modular vibratory pile driver of  FIG. 8 ; 
           [0022]      FIG. 11  is a top view of the modular vibratory pile driver of  FIG. 8 ; 
           [0023]      FIG. 12  is a perspective view of a third embodiment modular side grip vibratory pile driver of the present disclosure, further illustrating a small diameter pipe clamped in the jaw assembly of the pile driver; 
           [0024]      FIG. 13  is another perspective view of the modular vibratory pile driver of  FIG. 12 ; 
           [0025]      FIG. 14  is another perspective view of the modular vibratory pile driver of  FIG. 12 ; 
           [0026]      FIG. 15  is a side view of the modular vibratory pile driver of  FIG. 12 ; 
           [0027]      FIG. 16  is a top view of the modular vibratory pile driver of  FIG. 12 ; 
           [0028]      FIG. 17  is an exploded view of a portion of the modular vibratory pile driver of either  FIG. 8  or  FIG. 12 ; and 
           [0029]      FIG. 18  is another exploded view of a portion of the modular vibratory pile driver of either  FIG. 8  or  FIG. 12 . 
       
    
    
       [0030]    Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate embodiments of the disclosure and such exemplifications are not to be construed as limiting the scope of the invention in any manner. 
       DETAILED DESCRIPTION 
       [0031]    Referring now to  FIGS. 1-5 , modular vibratory side grip pile driver  30  is shown and generally includes housing  31 , first assembly  35 , and jaw assembly  50 . Pile driver  30  may be used to grasp and drive sheet or beam, e.g., I-beam and H-beam, pile  33  into the ground. Housing  31  includes vibratory gear case  36  and mounting base  37 . Bracket  41  connects housing  31  to attachment assembly  32  which is used to attach pile driver  30  to an excavator or other suitable construction machine for mounting pile driver  30  thereon. Rotational connector  38  is provided along with attachment plate  32  to permit rotation of housing  31  relative to the excavator. Rubber insulators  34  are included on the inner portions of housing  31  to reduce vibration caused by gear case  36  during use of pile driver  30  and to prevent such vibration from vibrating a portion of the excavator. Pile driver  30  is a modification of the Model SPM 15 vibratory pile driver manufactured by Hercules Machinery Corporation of Fort Wayne, Indiana, and incorporates most of the mechanism of such pile driver except for the structure that adds the modularity feature. In other words, the base unit remains the same for the various configurations adapted to grip certain types of sheet, pipe, H or other pile. 
         [0032]    A further example of a side grip vibratory pile driver is disclosed in U.S. Reissue Pat. No. RE37,661. The disclosure of this patent is specifically incorporated herein by reference. 
         [0033]    Mounting assembly  35  includes a mounting base  37  rigidly connected to the housing  31  and forming a first pair of jaw halves  37   a  and first gripping assembly  39 . In an exemplary embodiment, mounting base  37  having jaws  37   a  is stationary relative to gear case  36 . In an alternative embodiment, mounting base  37  is movable relative to gear case  36 . Referring to  FIGS. 6 and 7 , first gripping assembly  39  includes first gripping mount  53  which may include a plurality of slots  54  for mating engagement with a plurality of fasteners  55  for securing first gripping mount  53  to mounting base  37 . Slots  54  are provided instead of holes or apertures sized to accept fasteners  55  because slots  54  allow first gripping mount  53  to move and slightly adjust front-to-back and side-to-side relative to mounting base  37 , thereby allowing first gripping mount  53  to align with arm gripping assembly  52  in a complementary engagement to securely hold sheet pile  33 . First gripping assembly  39  also includes two contact plates  47  for providing direct contact with sheet pile  33 . In an exemplary embodiment, contact plates  47  have a knurled or otherwise roughened surface to enhance and facilitate gripping of sheet pile  33 . Each contact plate  47  is assembled to first gripping mount  53  with rubber washer  46 , bolt  43 , spring  45 , and nut  44 . Spring  45  advantageously allows contact plate  47  to adjust during engagement of sheet pile  33 . 
         [0034]    Referring now to  FIGS. 2 ,  3 ,  5 ,  6 , and  7 , jaw assembly  50  comprises a pair of jaws including first gripping assembly  39 , arms  40 , and arm gripping assemblies  52 . Each arm  40  is pivotally and detachably affixed to housing  31  and preferably to an extension of mounting base  37  via pin  48  which creates a pivot joint of arm  40  relative to base  37 . Each arm  40  is connected via pin  49  to hydraulic cylinder  42  which is connected to a hydraulic system (not shown) of the excavator to which pile driver  30  is attached to provide pivot control of arms  40 . Each arm  40  includes an arm gripping assembly  52  detachably affixed thereto. Each arm gripping assembly  52  includes contact plate  47  which is connected to arm  40  via rubber washer  46 , bolt  43 , spring  45 , and nut  44 . 
         [0035]    Referring now to  FIGS. 3 ,  5 ,  6 , and  7 , pile driver  30  preferably includes lower jaws  51  which provide mating contact plates  47  for gripping a top portion of sheet pile  33  to facilitate final driving of pile  33  into the ground. 
         [0036]    In operation and referring to  FIGS. 1-7 , jaw assembly  50  provides side-gripping force on pile  33  in which arms  40  are hydraulically actuated to grasp and move sheet pile  33  into a desired location for driving pile  33  into the ground. The upper and lower sets of jaw halves forming the jaws of jaw assembly  50  are open so that a pile  33  can enter the jaws laterally and then be gripped when the jaws  50  are closed. Arms  40  secure pile  33  while gear case  36  provides vibration while the excavator guides modular vibratory pile driver  30  towards the ground and sheet pile  33  into the ground. Modular vibratory pile driver  30  defines centerline  60  ( FIG. 4 ) along which the most focused and concentrated power is developed in pile driver  30 . Advantageously, centerline  60  matches centerline  61  of sheet pile  33 , thereby enhancing the efficiency of energy transfer to pile  33  and reducing stress on gear case  36 . Moreover, modular vibratory pile driver  30  facilitates substantially straight driving of pile  33  because centerline  60  matches centerline  61 . 
         [0037]    Referring now to  FIGS. 8-11 , modular vibratory pile driver configuration  130  is shown and is substantially identical to modular vibratory pile driver  30 , described above with reference to  FIGS. 1-7 , except for arms  140 , arm gripping assembly  152 , and first gripping assembly  139 , as described below that have been installed in place of arms  40  and gripping assemblies  52  and  39 , respectively. In other words, housing  31  remains the same in the configuration shown in  FIGS. 8-11  as compared with the configuration shown in  FIGS. 1-7 . 
         [0038]    Referring still to  FIGS. 8-11 , modular vibratory side grip pile driver  130  configured as a cylindrical pile driver is shown and generally includes housing  31 , assembly  135 , and jaws  150 . Pile driver  130  may be used to grasp and drive large pipe pile  133  into the ground or other desirable location. 
         [0039]    Mounting assembly  135  includes mounting base  37  and first gripping assembly  139 . First gripping assembly  139  includes first gripping mount  153  detachably mounted to base  37 . First gripping assembly  139  also includes two contact surfaces  147  for providing direct contact with pile  133 . In an exemplary embodiment, contact surfaces  147  are arcuate to match the outer diameter of pile  133  and are knurled to enhance and facilitate gripping of pile  133 . 
         [0040]    Jaw assembly  150  includes mounting base  37 , first gripping assembly  139 , arms  140 , and arm gripping assemblies  152 . Each arm  140  is pivotally and detachably affixed to base  37  via pin  48  which creates a pivot joint of arm  140  relative to mounting base  37 . Each arm  140  is connected via pin  49  to hydraulic cylinder  42  which is connected to a hydraulic system (not shown) of the excavator to which pile driver  130  is attached to provide pivot control of arms  140 . Each arm  140  includes an arm gripping assembly  152  detachably affixed thereto. Arm gripping assembly  152  includes arm gripping mount  156  with contact surfaces  147  for providing direct contact with pile  133 . In an exemplary embodiment, contact surfaces  147  are arcuate to match an outer diameter of pile  133  and are knurled to enhance and facilitate gripping of pile  133 . 
         [0041]    Arm gripping assembly  152  and first gripping assembly  139  encircle pile  133  and form pipe grip engagement  157  therebetween, as shown in  FIG. 11 . Pipe grip engagement  157  between arm gripping assembly  152  and first gripping assembly  139  prevents deformation of pile  133  when jaw assembly  150  is clamped shut and also enhances the hold of pile  133  in pile driver  130 . Referring now to  FIG. 10 , pile driver configuration  130  may optionally include lower jaws  151  which provide mating contact surfaces  147  for gripping a top portion of pile  133  for final driving of pile  133  into the ground. When pile  133  is engaged by only lower jaws  151  ( FIG. 10 ) to finally drive pile  133  into the ground, the interlocking engagement provided by pipe grip engagement  157  prevents arms  140  from flopping around due to the vibration. 
         [0042]    In operation and referring again to  FIGS. 8-11 , jaw assembly  150  provides side gripping force on pile  133  in a substantially similar manner as jaw assembly  50 , described above with respect to  FIGS. 1-7 . Advantageously, modular vibratory pile driver configuration  130  defines centerline  160  ( FIG. 11 ) which substantially matches centerline  161  of pile  133 . 
         [0043]    To switch from the configuration shown in  FIGS. 1-7  to the configuration shown in  FIGS. 8-11 , a user of pile driver  30  removes pins  48 ,  49  associated with arms  40 . Arms  40  are then removed from mounting base  37 . Arms  140  may then be attached to mounting base  37  with pins  48 ,  49  to form configuration  130  which is now equipped to grip pile  133 . 
         [0044]    Referring now to  FIGS. 12-16 , modular vibratory pile driver configuration  230  is shown and is substantially identical to configurations  30 ,  130 , described above with reference to  FIGS. 1-7  and  8 - 11 , except for arm gripping assembly  252  and first gripping assembly  239 , as described below, i.e., all of the structure, including housing  31 , remains the same in the configuration shown in  FIGS. 12-16  as compared with the configurations shown in  FIGS. 1-7  and  8 - 11 , and arms  140  remain the same in the configuration shown in  FIGS. 12-16  as compared with the configuration shown in  FIGS. 8-11 . Replacement gripping assemblies  235 ,  239 ,  250  and  252 , gripping mounts  253  and  256  and contact services  247  are sized to match the smaller diameter cylindrical pipe pile  233 . 
         [0045]    In operation, jaw assembly  250  provides side gripping force on pile  233  in a substantially similar manner as jaws  50 ,  150 , described above with respect to  FIGS. 1-7  and  8 - 11 . Advantageously, modular vibratory pile driver  230  defines centerline  260  ( FIG. 16 ) which substantially matches centerline  261  of pile  233 . 
         [0046]    To switch from the embodiment shown in  FIGS. 8-11  to the embodiment shown in  FIGS. 12-16 , the user removes fasteners  155  from first gripping assembly  139  and arm gripping assemblies  152  to detach first gripping assembly  139  and arm gripping assemblies  152 . First gripping assembly  239  and arm gripping assemblies  252  may then be respectively attached to mounting base  37  and arms  140  with fasteners  255 , thereby forming configuration  230  which is equipped to grip smaller diameter pile  233 . 
         [0047]    Referring to  FIGS. 17 and 18 , first gripping assembly  139  includes first gripping mount  153  which includes a plurality of slots  154  for mating engagement with a plurality of fasteners  155  for detachably affixing first gripping mount  153  to mounting base  37 . Slots  154  are provided instead of holes or apertures sized to accept fasteners  155  because slots  154  allow first gripping mount  153  to move and slightly adjust front-to-back and side-to-side relative to base  37 , thereby allowing first gripping mount  153  to align with arm gripping assembly  152  to securely hold pile  133 . First gripping assembly  139  also may include two contact surfaces  147  for providing direct contact with pile  133 . 
         [0048]    Piles  133 ,  233  may be formed as Schedule  40  piping having an outer diameter as small as approximately ½″, 1″, 1½″, 2″, 3″, 4″, or 4½″, or as large as 40″, 30″, 20″, 15″, 10″, 9″, 8″, 7″, 6⅝″, 6″, 5½″, or 5″. 
         [0049]    In operation, modular vibratory pile driver configurations  30 ,  130 ,  230  provide flexibility and options depending on the type of pile to be driven into the ground. For example, pile driver configuration  30  may be used to drive a sheet pile, e.g., sheet pile  33 , into the ground. Subsequently, a user of pile driver  30  may want to drive a pipe pile. Advantageously, the user simply removes arms  40  from pile driver  30  and replaces them with arms  140  using the same attachments, i.e., pins  48 ,  49 , to attach arms  140  to mounting base  37  and hydraulic cylinders  42  to form configuration  130 . In one embodiment, arms  140  have arm gripping assembly  152  detachably affixed thereto and mounting base  37  has complementary first gripping assembly  153  detachably affixed thereto to accommodate large pipe pile  133 . Alternatively, arms  140  have arm gripping assemblies  252  detachably affixed thereto and base  37  has complementary first gripping assembly  253  detachably affixed thereto to accommodate small pipe pile  233 . Therefore, arms  40 ,  140 , arm gripping assemblies  152 ,  252 , and first gripping assemblies  153 ,  253  are modular attachments that may be interchanged depending on the size and type of pile to be driven into the ground. 
         [0050]    Advantageously, the modular vibratory pile driver configuration described in the present application provide various degrees of modularity to provide variability and flexibility in selecting components to provide the optimum outcome for a desired pile driving procedure. For example, the pivotable arms are replaced with a different set of pivotable arms. In another example, the arms remain attached to the first portion but the gripping assemblies are replaced with a different set of gripping assemblies. Advantageously, the modular vibratory pile driver configurations of the present application all utilize the same housing  31  including gear case  36  and mounting base  37 . Thus, a user of the pile driver only needs to purchase a single base unit, instead of purchasing three or more separate pile drivers. The modular attachments of the present application are advantageously used interchangeably with the base unit to provide a modular side grip vibratory pile driver. Therefore, the overall cost of the pile driving system is substantially reduced. Moreover, the efficiency of the pile driving system is maintained. 
         [0051]    While this disclosure has been described as having exemplary designs, the present disclosure can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the disclosure using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this disclosure pertains and which fall within the limits of the appended claims.

Summary:
A modular side grip vibratory pile driver system having a housing, a vibratory gear case and a pair of jaws adapted to grip a variety of pile profiles. The housing is rotatably connected to a construction machine such that the jaws can be moved from a position wherein the jaws are oriented vertically and spaced apart horizontally to a position wherein the jaws are oriented horizontally and spaced apart vertically. A plurality of sets of gripping assemblies having different gripping profiles are interchangeably connected to the jaws.