WO2022094191A1

WO2022094191A1 - Systems and methods for boring and cutting

Info

Publication number: WO2022094191A1
Application number: PCT/US2021/057221
Authority: WO
Inventors: Miroslav Pavlovic; Karl H. Moller
Original assignee: Diamond Products Limited
Priority date: 2020-10-30
Filing date: 2021-10-29
Publication date: 2022-05-05

Abstract

Boring and cutting systems and methods are provided. In one embodiment, systems and methods for boring and cutting are provided using an electrical power source such as a battery or fuel cell. This reduces noise levels, gaseous emissions and the requirement of refueling with a combustible fuel. This further allows for the use of clean and economical fuel sources such as, for example, electricity. In another embodiment, systems and methods for boring and cutting are provided that recirculate cooling water. This allows multiple reuse of the cooling water during cutting operations. This reduces the need to carry spare water and/or obtain water replenishment and the frequency of water replenishment. In other embodiments, the water recirculation is further improved by the use of filters to remove any slurry components therein. In yet another embodiment, a totally self-contained system is provided that does not require outside water, electricity, and/or vacuum.

Description

Systems and Methods for Boring and Cutting

Cross-References to Related Applications

[0001] This application claims priority to U.S. Provisional Patent Application Ser. No. 63/107,646, filed Oct. 30, 2020 and titled “Systems and Methods for Boring and Cutting,” and which is hereby fully incorporated by reference.

Background

[0002] Boring and cutting holes in hard surfaces such as, for example, concrete is an important part of building and construction. Many buildings have concrete floors and/or walls for structural strength and stability. Some also include concrete or sinter block and/or stone construction. The floors and walls are formed at the very early stages of construction well before building mechanical, electrical and plumbing systems are put in place. When it is time to install these systems, bores, cuts and/or holes need to be made in these hard surfaces.

[0003] One example of a concrete boring machine is provided in U.S. Pat. No. 7,721,825, which is hereby incorporated by reference. The ‘825 Patent describes a portable boring machine powered by an internal combustion engine. While such a machine has been a valuable advance in the art and improved the ability to bore holes in concrete and other hard surfaces, improvements thereto are desirable. For example, combustion engines are loud, create emissions and require combustible fuel sources. Cutting in concrete and other hard surfaces is improved by use of a cooling fluid such as water. However, once the water is depleted, it must be replenished from another source. This may require extra water or cooling fluid to be carried to the job site. Further yet, many other tools are required at the job site such as, for example, wrenches, hammers, chisels, hand drills, drill/saw bits, etc. that may be needed for the boring process or assistance in the boring process and/or system installation.

[0004] What is desired is a system that addresses these and other aspects of boring and cutting systems and methods.

Summary

[0005] Boring and cutting systems and methods are provided. In one embodiment, systems and methods for boring and cutting are provided that use an electrical power source such as a battery or fuel cell. This reduces noise levels, gaseous emissions and the requirement of refueling with a combustible fuel. This further allows for the use of clean and economical fuel sources such as, for example, electricity. In another embodiment, systems and methods for boring and cutting are provided that recirculate the cooling water. This allows for multiple reuse of the circulating/cooling water during cutting operations. This also reduces the need to carry spare water and/or obtain water replenishment and the frequency of water replenishment. In other embodiments, the water recirculation is further improved by the use of filters to remove any slurry components therein. In yet another embodiment, a totally self-contained system is provided that does not require outside water, electricity, and/or vacuum.

Brief Description of the Drawings

[0006] In the accompanying drawings which are incorporated in and constitute a part of the specification, embodiments of the inventions are illustrated, which, together with a general description of the inventions given above, and the detailed description given below, serve to example the principles of the inventions.

[0007] Figure 1 shows of one embodiment of a system and method for boring or cutting holes.

[0008] Figures 2 illustrates one embodiment of an all-electric system and method for boring or cutting holes.

[0009] Figure 3 illustrates one embodiment of a recirculating cooling fluid system and method.

Description

[0010] As described herein, when one or more components are described or shown as being connected, joined, affixed, coupled, attached, or otherwise interconnected, such interconnection may be direct as between the components or may be indirect such as through the use of one or more intermediary components. Also, as described herein, reference to a member, component, or portion shall not be limited to a single structural member, component, element, or portion but can include an assembly of components, members, elements, or portions.

[0011] Embodiments of the present inventions provide, for example, a totally self-contained system for boring or cutting that does not require outside water, electricity, and/or vacuum. This provides a convenient and efficient system and method for the construction worker, jobsite and/or equipment owner. By being all-electric, noise levels and gaseous emissions are significantly reduced. Also, the requirement of refueling with a combustible fuel is eliminated. This also eliminates the need to stop at gasoline stations and the need to carry and store extra container(s) of gasoline or other combustible fuel. This further allows for the use of clean and economical fuel sources such as, for example, electricity. Electrical recharging of batteries can be done in hours or overnight and at the job site or elsewhere. Also, one or more electrical outlets can be provided provide power to hand tools like drills and saws, which may be needed.

[0012] Further, embodiments provide for the reuse or recirculation of cooling fluid or water. Normally, the cooling water is provided to the cutting area and allowed to run off and is not reclaimed. This requires the cooling water to be replenished frequently and sometimes required that a source of extra or spare water be provided at the jobsite. Embodiments of the present inventions capture the cooling water to recirculate it to the cutting area. This allows for multiple reuses of the circulating water during cutting operations. This also reduces the need to carry spare water and/or obtain water replenishment and reduces the frequency of water replenishment. In yet other embodiments, the water recirculation is further improved by the use of filters to remove any slurry components therein.

[0013] Further embodiments provide tool storage on the chassis or frame of the boring or cutting system. Tools such as wrenches, hammers, chisels, hand drills, drill/saw bits, etc. that may be needed for the boring process or assistance in the boring process and/or system installation can be maintained in a single convenient location with the boring machine, whereas these tools are typically scattered elsewhere. In one embodiment, the tool storage can be a tool drawer or tray that is extendable from the frame chassis and lockable for security. Other advantages and benefits will be apparent from the following descriptions.

[0014] Illustrated in Figure 1 is one embodiment of a boring and cutting system and method 100. In this embodiment, a self-contained system 100 for boring or cutting that does not require outside water, electricity, and/or vacuum is provided. The system 100 can be embodied in a self-propelled vehicle, cart, ride-along, or similar movable device. One example of such a self-propelled device shown and described in US Pat. No. 7,721,825 which is incorporated by reference herein. The system includes a frame or chassis 102 to which a plurality of wheels 104, 106 are connected. In one embodiment, chassis 102 generally has four sides and a top and a bottom. In one embodiment, four wheels are provided wherein two are in the front portion of the chassis and two are in the rear portion. One or more of wheels 104, 106 can be a driven wheel by use of one or more motors 126. Motor(s) 126 can be electric wheel hub motors, brushless motors, gearless motors, motors with gearbox/transmission, etc. In other embodiments, wheels 104, 106 do not need to be motor driven but can manual or push driven.

[0015] Connected to chassis 102 is a movable support frame assembly that includes, for example, support frame 110, linear actuator 108, and movable support plate 112. Support frame 110 connects linear actuator 108 to the chassis 102 in order to raise and lower movable support plate 112. Movable support plate 112 is in its raised position when chassis 102 is not in its boring or cutting position or when chassis 102 is being moved or driven. Movable support plate 112 is lowered by actuator 108 to contact the ground or supporting surface when chassis 102 is in its boring or cutting position. In the lowered position, support plate 112 provides additional stability to chassis 102 during the boring or cutting process. US Pat. No. 7,721,825 discloses one example of such a movable support frame assembly, which is hereby incorporated by reference. In the present embodiment, linear actuator 108 is electrically driven via a motor actuator or can be hydraulically driven via an electric motor pump.

[0016] In one embodiment, support plate 112 is provided with a vacuum pad, chamber or holes to better secure the front end of chassis 102 to the ground to prevent movement during operation. A vacuum pump 136 is provided and connected to support plate 112 via one or more hoses 150. Vacuum pump 136 is operated by an electric motor.

[0017] Further connected to chassis 102 is a boring or cutting assembly that includes, for example, one or more support brackets 120, support frame 114, linear actuator 118, boring motor or head 116, and boring or cutting bit/saw 122. Linear actuator 118 raises and lowers boring motor/head 116 and bit/saw 122 to perform the boring or cutting operation. US Pat. No. 7,721,825 discloses one example of such a boring or cutting assembly, which is hereby incorporated by reference. In the present embodiment, linear actuator 118 is electrically driven via a motor actuator or can be hydraulically driven via an electric motor pump.

[0018] During boring or cutting operations, cooling water can be provided to the cutting bit/saw 122 or the cutting area. Chassis 102 includes a cooling water recirculation system having a tank 138, a wet vac 140, water pump 142, water feed lines 146, 148, and water suction or recirculation line 152. Water pump 142 draws water from tank 138 via line 146 and directs it to the cutting bit/saw 122 or cutting area via line 148. An optional nozzle 154 and a return line 152 suck up or draw the cooling water and/or slurry mix back for return and reuse or recirculation to tank 138. In one embodiment, wet vac 140 and water pump 142 or powered by electrical motors.

[0019] Chassis 102 can further include the control panel 128 for controlling the various functions and operations of the boring and cutting process. In one embodiment, pushbutton controls (or equivalent) are provided, for example, for raising and lowering the actuators, starting and stopping vacuums and prompts, turning the system on and off, turning external lights on and off, and propelling the chassis from location to location through the motorized wheels, and starting and stopping the bit/saw. The chassis can further include one or more handlebars with throttle and brake controls to also assist in moving the chassis from location to location.

[0020] One or more inverters 130 can be provided to allow for one or more electrical voltage levels (12 V, 24 V, 120 V, 240 V, etc.) and types (e.g., AC and/or DC) to be used for powering various motors, pumps, vacuums, and actuators of the system. Chassis 102 can further include at least one charging port 132 for connecting external power to either charge/recharge power source 124 and/or provide power to one or more components of the system. Further yet, one or more electrical ports or outlets 134 can be provided and used for powering hand tools (e.g., drills, saws, etc.) at the job site.

[0021] In one embodiment, power source 124 provides the electrical energy required to power the various electrical components. Power source 124 can be one or more batteries or battery cells. For example, power source 124 can be one or more rechargeable 12 V lithium-based batteries providing approximately 300 Amp -Hours or power. In one embodiment, two such rechargeable batteries provided. One example such batteries includes the SB300 Smart Battery manufactured by Smart Battery, Tampa, Florida, United States. In other embodiments, more or less such batteries (or their equivalent) can be used.

[0022] Power source 124 can be located anywhere on chassis 102. In one embodiment, power source 124 is located in an accessible compartment in a lower portion of chassis 102. The compartment can be accessed via a door that allows inspection and/or replacement of power source 124. The compartment can also be optionally waterproofed or water-resistant to protect power source 124 from water/moisture and/or other undesirable substances. [0023] Chassis 102 can further include a tool storage 144. The boring and/or cutting process may require accessory tools such as, for example, hand drills, hammers, chisels, wrenches, pliers, screwdrivers, brushes, etc. Typically, these tools must be stored separately (e.g., toolboxes, tool buckets, etc.) or end up scattered throughout the jobsite. Tool storage 144 is provided to allow storage of such tools that are used in the boring and/or cutting process (or even generally of the jobsite) so that they are not scattered about or located in other areas. This increases performance efficiency by having all the tools stored and ready for use where they are needed.

[0024] In one embodiment, tool storage 144 is provided in an accessible location on chassis 102 such as, for example, the upper portion of the chassis. Tool storage 144 can be one or more tool drawers that can be extended from and retracted within chassis 102. Tool storage 144 can also be one or more bins having open and closable covers. Tool storage 144 can also be one or more canvas type tool packets located at various accessible positions of the worker on chassis 102. Tool storage 144 can also be lockable via a key lock, padlock, combination lock, etc. to protect the tools from theft.

[0025] Thus, a totally self-contained system for boring or cutting that does not require outside water, electricity, and/or vacuum is provided. This provides a convenient and efficient system and method for the worker, jobsite and/or equipment owner. By being all-electric, the use of clean, economical and renewable fuel sources such as, for example, electricity can be used. Electrical recharging of batteries can be done in hours or overnight and at the job site or elsewhere. Also, the reuse or recirculation of cooling fluid or water allows for multiple reuses of the circulating water during cutting operations. This reduces the need to carry spare water and/or obtain water replenishment and reduces the frequency of water replenishment. Further yet, a tool storage is provided on the rig or chassis to conveniently store all the accessory or hand tools required for the job.

[0026] Illustrated in Figure 2 is one embodiment of an all-electric boring and cutting system and method 200 showing, for example, the electrical components therefore. As previously described, power source 124 provides the electrical energy or power for the all-electric system and method. A charging port 202 is provided that allows for external power to be connected to the system. In one embodiment, charging port 202 includes a receptacle 202a for receiving an external power cable capable for providing 12 V, 24 V, 120 V, 240 V, etc. (AC or DC) power into the system for charging/recharging power source 124. Also, a solar cell panel 202b can be provided for solar based recharging/trickle charging of power cell 124. One or both of these sources can be provided.

[0027] Power source 124 delivers electrical power to one or more components of the boring and cutting system during operations. For example, power can be delivered in AC or DC format and at various voltage levels through the use of one or more inverters (e.g., 220). In one embodiment, power source 124 delivers power to drive wheel motor(s) 206 via a drive controller module 204. Drive controller module 204 allows a user to drive the wheels (and motors) forward (and backwards) and at a variety of speeds. Power source 124 also provides the chassis 102 with power for lighting functionality 210 via a control pushbutton 208 or similar. Lighting functionality 210 can include one or more energy efficient lights (LED’s, Fluorescent, etc.) including, for example, spot lighting for the cutting area and general lighting for the job area.

[0028] Power source 124 also powers the cooling water system. This includes powering the motor for cooling pump 214 via one or more pushbutton or other controls 212. The stability system 208 with raiseable and lowerable support plate and linear actuator is also powered by power source 124. Power source provides power the linear actuator (e.g., 108) to raise and lower support plate 112 (see Fig. 1) into position with the ground through one or more pushbutton or other controls 216.

[0029] The system vacuum pumps can also be electrically powered by power source 124. An inverter 220 can be used but that is not a requirement depending on the types of motors used. Power source 124 provides electrical power via inverter 220, or not, to the motor for vacuum pump 224 and control button(s) 222 that provide a vacuum to support plate 112. Electrical power can further be provided to the motor of wet vac 228 and control buttons 226 to vacuum up the cooling water/slurry from the cutting bit/saw and/or cutting location. This water is used advantageously in the water recirculation system. Inverter 220 can also be used to provide 120 VAC or 240 VAC (or other voltage(s)) via one or more electrical outlets 230 for powering hand tools such as drills, saws, grinders, etc.

[0030] Power source 124 also provides the electrical power for the boring and/or cutting process. An optional inverter and speed control 240 are provided to control the speed of boring motor head 244 and linear actuator motor 242 (of, for example, linear actuator 118 of Fig. 1). Linear actuator motor 242 may include an auto-feed control at automatically lowers the boring/cutting head at a predetermined rate during the boring and/or cutting process. This provides for a smooth, consistent, and controlled boring and cutting operation. Power source 124 also provides electrical power to linear actuator motor 248 for raising and lowering the boring/cutting head through pushbutton or similar controls 246 to provide gross position adjustment (e.g., up and down) of the boring/cutting head.

[0031] In another embodiment, system 200 can include a processor-based controller 250 having inputs, outputs and memory 252. Controller 250 can include various control software or computer readable instructions for receiving inputs from buttons (or other inputs devices like joysticks, touch displays, touch pads, etc.) and outputting control signals to actuate power to the various system components described herein. Controller 252 can also include logic for managing power operations including, for example, monitoring and displaying battery power, remaining battery power, remaining usage time, elapsed usage time, etc. Displays for any one or more of these can be provided including battery meter displays, time displays, etc.

[0032] In one embodiment, controller 250 can estimate the remaining usage time by determining the average power required per boring and/or cutting operation and comparing that to the amount of power remaining in power source 124. The result can be displayed on a display in any form including, for example, a numerical value representing the number of remaining boring/cutting operations possible. Other displays are possible including graphical displays depicting needles and gauges, pie charts, etc. to represent the same information. This provides the worker with information regarding whether the number of planned boring/cutting operations can be accomplished before a recharge is necessary. Other maintenance, diagnostic and troubleshooting features such as, for example, component (e.g., pump, vacuum, or motor failure, low cooling water level, lower power source level, etc.) can also be performed by controller 250 and messages and indications can be provided through various audio and visual displays to the user. Sensors for such functions can be provided that input values to the controller 250, which then are compared to threshold values representing safe operating conditions and/or out of value thresholds indicating maintenance or trouble.

[0033] In other embodiments, electrical system 200 can include more or less of these components. For example, controller 250 may not be provided in all embodiments. In yet another example, the cooling water recirculation system may also be omitted. In yet other embodiments, power may be provided by one or more power busses with each power bus having a different voltage and type (as described). Hence, the system can be design with flexibility taking into account needs, costs, and affordability of the users.

[0034] Illustrated in Figure 3 is one embodiment of a water-cooling system and method for boring and cutting that can be included in or on chassis 102 of Fig. 1. Cooling water is collected and advantageously recirculated within the system. This provides a better all-in-one system and reduces the amount and frequency that cooling water needs to be refilled in the system. This also advantageously reduces the amount of extra cooling water needed to be carried to and/or maintained at the job site. Furthermore, by including such a cooling water recirculation system on chassis 102, an all-in-one boring and cutting system that requires very little to no set up time is provided.

[0035] Cooling water or fluid is stored in tank 138. The cooling water is fed to the boring bit/saw or cutting area 302 by pump 142. A feed line 146 provides pump 142 with the cooling water. An optional filter 306 can be included to filter out particulates that may be present in the cooling water or fluid. A second feed line 148 provides the cooling water from pump 142 to the cutting area 302 to cool the boring bit/saw.

[0036] A wet vacuum pump 140 is provided to draw up or vacuum the cooling water at the cutting area 302. A vacuum nozzle can be provided at the cutting area 302 that connects to vacuum line 152, which is connected to wet vacuum 140. Wet vacuum 140 provides the drawn or sucked up water/slurry to the tank 138 through a filter 304 via lines 308 and 310. Filter 304 is a particulate filter that removes the slurry and allows water to pass. In this manner, the cooling water collected from cutting area 302 is filtered before being provided for re-use or recirculation. Filter 304 can be external or internal to tank 138. If internal to tank 138, then filter 304 is removable and replaceable via a securable door, cap or cover part of tank 138. Any of the filters described may be disposable and/or cleanable and reusable. An optional water level sensor 314 may be provided to indicate via audio or visual signal/display that the water level is too low thereby indicating action is required to correct the water level. While this embodiment illustrates use of particular water lines, it should be appreciated one or more water lines could be eliminated by incorporation. For example, the output of wet vacuum pump 140 could be directly to filter 304 and/or tank 138 thereby incorporating the pathways representing lines 308 and 310 without use of physical lines or hoses.

[0037] Thus, embodiments of the present inventions provide, for example, a totally self-contained system for boring or cutting that does not require outside water, electricity, and/or vacuum. A convenient and efficient system and method for the construction worker, jobsite and/or equipment owner is provided by the novel all-in-one arrangement. Advantageously, by being all-electric, noise levels and gaseous emissions are significantly reduced. Also, use of combustible fuel is eliminated thereby removing the need to stop at gasoline stations and to carry and store extra container(s) of gasoline or other combustible fuel. The use of battery power allows for a clean and economical fuel source and recharging of batteries can be done in hours or overnight and at the job site or elsewhere. Also, providing electrical power and storage for hand tools like drills, saws and grinders, and hammers, wrenches, chisels, pliers, etc. further adds to job site efficiency, organization, cleanliness and safety.

[0038] Further, the use and reuse or recirculation of cooling fluid or water from the boring and cutting rig’s chassis additionally promotes efficiency, safety, cleanliness, and job site organization. This allows for multiple reuses of the cooling water during cutting operations. This also reduces the need to carry spare water and/or obtain water replenishment and reduces the frequency of water replenishment. Lengthy hoses to water sources, which require set up time and can be a hazard to job site workers, can be eliminated.

[0039] While the present inventions have been illustrated by the description of embodiments thereof, and while the embodiments have been described in considerable detail, it is not the intention of the descriptions to restrict or in any way limit the scope of the disclosure to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the inventions, in broader aspects, are not limited to the specific details, the representative apparatus, and illustrative examples shown and described. Accordingly, departures can be made from such details without departing from the spirit or scope of the general inventive concept.

Claims

What is claimed:

1. A system for cutting hard surfaces comprising: a frame having a plurality of wheels and one or more drive motors connected to the wheels; a cutting assembly supported on the frame and having a linear actuator and a boring motor; a cooling system supported on the frame and having a retaining tank, motor-driven pump, and slurry filter; a power source supported on the frame and comprising at least one battery or fuel cell; at least one power inverter supported on the frame and converting energy from the power source into at least first and second voltage levels; at least one power outlet supported on the frame providing the first voltage level for powering one or more motor-driven hand tools; and a controller for controlling power delivered to one or more of the drive motors, boring motor, and motor-driven pump.

2. The system of claim 1 wherein the power source is rechargeable.

3. The system of claim 1 wherein the controller comprises logic for managing power operations.

4. The system of claim 1 wherein the controller comprises logic for monitoring and displaying a power level of the power source.

5. The system of claim 1 wherein the controller comprises logic for determining an average power required for a cutting operation.

6. The system of claim 1 wherein the controller comprises logic for determining an average power required for a cutting operation and comparing the average to a remaining power level in the power source.

7. The system of claim 1 wherein the controller comprises logic for determining a number of remaining cutting operations based on an average power requirement for a cutting operation and a remaining power level in the power source.

8. The system of claim 1 further comprising a power bus for distributing power at the first and second voltage levels.

9. The system of claim 1 further comprising a power bus supported on the frame for distributing power at a first voltage level to the at least one power outlet.

10. The system of claim 1 further comprising one or more tool storage compartments supported on the frame.

11. A system for cutting hard surfaces comprising: a frame having a plurality of motor driven wheels; a cutting assembly supported on the frame and having a linear actuator and a boring motor; a recirculation cooling system supported on the frame and having a retaining tank, motor-driven pump, and slurry filter; a power source supported on the frame and comprising at least one battery or fuel cell and at least one power inverter; a power distribution bus supported on the frame having a plurality of voltage levels; 17 at least one power outlet supported on the frame and connected to the power distribution bus and providing power at a first voltage level for powering one or more motor-driven hand tools; and a controller for controlling power delivered to one or more of the drive motors, boring motor, and motor-driven pump.

12. The system of claim 11 wherein the power source is housed in a water- resistant compartment.

13. The system of claim 11 wherein the power source is housed in a water- resistant compartment having an access door allowing for replacement of the power source.

14. The system of claim 11 further comprising a port for recharging the power source.

15. The system of claim 11 further comprising a port for recharging the power source and providing power to system electrical components.

16. A system for cutting hard surfaces comprising: a frame means and a means for electrically propelling the frame means; a cutting means supported on the frame means and having means for adjusting the position of a cutting bit and an electrical means for rotating the cutting bit; a cooling means supported on the frame means and for cooling the cutting bit; a power means supported on the frame means; a means for converting power from the power means into a plurality of power levels; 18 a power distribution means supported on the frame means; at least one power outlet means supported on the frame means and connected to the power distribution means and for providing power at a first power level for powering one or more motor-driven hand tools; and a control means for controlling power delivered to one or more of the means for electrically propelling the frame means, cutting means, and cooling means.

17. The system of claim 16 wherein the frame means comprises a means for housing the power means and resisting moisture.

18. The system of claim 16 wherein the frame means comprises a means for housing the power means, resisting moisture, and allowing access to the power means for replacement.

19. The system of claim 16 further comprising a means for recharging the power means.

20. The system of claim 16 further comprising a means for recharging the power means and providing power to system electrical components.