PILE EXTRACTOR FOR REMOVING DRIVEN METAL PILES

Description

RELATED APPLICATIONS

This application claims priority from Australian provisional patent application no. 2023901390 filed 8 May 2023, and also Australian standard patent application no. application no. 2023203648 filed on 10 Jun. 2023, the contents of which are incorporated by reference.

TECHNICAL FIELD

The invention relates a pile extractor and a related method for removing or extracting piles from the ground. Such piles may be, but not limited to, metal piles that have been driven into the ground such as for fencing, structural foundations and road barricades.

BACKGROUND

Piles and related elongate structures that are driven into the ground may need to be removed. For example, in solar farm construction, solar panels are installed on a tracking system which is built upon thousands of large steel piles of various types, including universal beams, universal columns, C channels, American W-beams etc.

The steel piles are driven into the ground using a pile driving machine. Driven metal piles are also used in other industries like fencing, structural foundations and road guardrails. It is sometimes required to remove these piles from the ground, for example due to errors in construction, accidental damage or during decommissioning.

Due to the skin friction of the soil on driven piles it can take many hundreds of kilo-Newtons of force to remove them. Prior methods of extracting piles utilised cranes and heavy-duty lifting equipment to pull the piles out and/or physical excavation of piles from the ground or used steel wedges as a means of gripping the pile. The piles may be relatively long making it especially awkward and difficult to remove the piles. In addition, the shape of the pile that may be an I-beam can be difficult to grip and apply sufficient lifting force.

All of these existing methods may be time consuming and expensive, and dangerous as they involve large amounts of uncontrolled force and require workers to be in close proximity to the process.

This invention seeks to provide a safer, cheaper and quicker method to extract piles from the ground, or at least provide a useful alternative.

SUMMARY

In accordance with a first broad aspect there is provided, a pile extractor for removing a pile from a ground surface, the pile extractor including a frame arranged to seat upon the ground surface and a pile engaging arrangement operably coupled to and supported by the frame. The pile engaging arrangement includes rams which actuate associated clamps arranged to releasably engage with the pile in a reciprocal motion, the reciprocal motion including a lifting condition in which the rams extend to engage the clamps with the pile and exert a lifting force on the pile, and a release condition, in which the rams are relatively and simultaneously lowered which likewise simultaneously releases the clamps and allows the clamps to be lowered relative to the pile and reset to the lifting condition.

In an aspect, in the lifting condition, the rams are arranged to extend a first amount in which clamps are moved to engage with the pile, and then once engaged, a second amount in which the clamps and pile are lifted together.

In another aspect, in the release condition, the rams are arranged to retract a third amount in which clamps are moved to disengage with the pile, and then once disengaged, a fourth amount in which the clamps are lowered together reset to the lifting condition.

In yet another aspect, the pile engaging arrangement includes a clamping support movable relative to the frame, and wherein each of the clamps includes a clamp body having a first end arrange to engage the pile, a second end coupled to the associated one of the rams and an intermediate section pivotally coupled to the clamping support.

In yet another aspect, the first ends include jaws with engagement surfaces, the engagement surfaces of the jaws being splayed relative to one another in the released condition and movable toward being substantially parallel in the lifting condition.

In yet another aspect, the jaws are replaceable.

In yet another aspect, the each of the clamps is arranged such that an increased lifting force of the rams provides a corresponding increased gripping force between the engagement surfaces if the clamps.

In yet another aspect, the intermediate section of each clamp is pivotally coupled to the clamping support with a pin, the pin being located closer toward the first end relative the second end such that the clamp is over-centre.

In yet another aspect, the rams are spaced apart and generally vertically oriented.

In yet another aspect, each of the rams is directly pivotally coupled to the second end of its associated one of the clamps.

In yet another aspect, each of the rams includes of head end and a base end, the head end being directly pivotally coupled to the second end of its associated one of the clamps and the base end being pivotally coupled to the frame.

In yet another aspect, the rams are at least one hydraulic and electric rams.

In yet another aspect, the frame includes a guide arranged to vertically locate the pile between the clamps.

In yet another aspect, the guide is a vertically orientated frame tunnel.

In yet another aspect, the clamps are initially located above the frame tunnel.

In yet another aspect, the pile is an I-beam.

In yet another aspect, the pile engaging arrangement includes a clamping frame which pivotally supports each of the clamps.

In yet another aspect, the frame includes a further guide arranged to locate the clamping support relative to the frame.

In yet another aspect, in the lifting condition, the clamping support is elevated relative to the frame.

In accordance with a second broad aspect there is provided, a method for extracting a pile using a pile remover, the method including: inserting the pile between clamps of a pile engaging arrangement of the pile remover and placing a frame which supports the pile engaging arrangement on a ground surface; and actuating rams of the pile engaging arrangement to move the clamps between a lifting condition in which the rams extend to engage the clamps with the pile and exert a lifting force on the pile, and a release condition, in which the rams are relatively lowered which simultaneously releases the clamps and allows the clamps to be lowered relative to the pile and reset to the lifting condition.

In accordance with a third broad aspect there is provided, a method for extracting a pile using a pile remover, the method including: inserting the pile into a guide of the pile remover so as to locate between clamps of a pile engaging arrangement of the pile remover and placing a frame which supports the pile engaging arrangement on a ground surface; and actuating rams of the pile engaging arrangement in a reciprocal motion move the clamps between a lifting condition in which the rams extend to simultaneously engage the clamps with the pile and exert a lifting force on the pile, and a release condition, in which the rams are relatively lowered which simultaneously releases the clamps and allows the clamps to be lowered relative to the pile and reset to the lifting condition.

More generally, there is provided an extractor utilise hydraulic rams to actuate clamps that automatically grip the pile and push the pile out of the ground. The extractor may be lowered over the pile that is to be extracted, the two rams are extended upwards forcing the clamps to rotate inwards and grip the pile. Once the pile is gripped the clamps can no longer rotate and the upwards force from the rams is translated into vertical movement in the clamps and the pile they are gripping. Thus, pushing the pile out of the ground.

The self-actuating clamps may automatically grip the pile removing the need for workers to be near the pile at any point of the process. The extractor requires no excavations and no lifting gear, and all forces are safely contained within the frame.

The extractor may the process of removing piles many times quicker and cheaper and exponentially safer.

The extractor may be scaled to meet the force requirements for specific pile applications. The components can be designed in such a way as to exert varying maximum force amounts e.g., 50 T, 100 T, 200 T. The Clamps can also be adjusted/modified to suit different pile sections.

BRIEF DESCRIPTION OF THE FIGURES

The invention is described, by way of non-limiting example only, by reference to the accompanying figures, in which;

FIG. 1 is an isometric view illustrating a pile extractor for removing a pile from a ground surface in a lowered position;

FIG. 2 is a top view illustrating the pile extractor;

FIG. 3 is a side view illustrating the pile extractor;

FIG. 4 is an opposing side view illustrating the pile extractor;

FIG. 5 is an end view illustrating the pile extractor;

FIG. 6 is an isometric view illustrating the pile extractor for removing a pile from a ground surface in a raised position;

FIG. 7 is a side view illustrating the pile extractor,

FIG. 8 is an end view illustrating the pile extractor;

FIG. 9 is an opposing side view illustrating the pile extractor;

FIG. 10 is an isometric view illustrating the pile extractor with the pile removed;

FIG. 11 is an isometric view illustrating clamps and rams of the pile extractor in a lowered position;

FIG. 12 is a side view illustrating the clamps and rams;

FIG. 13 is an isometric view illustrating clamps and rams of the pile extractor in a raised position; and,

FIG. 14 is a side view illustrating the clamps and rams.

DETAILED DESCRIPTION

Referring to FIGS. 1 to 10 there is shown an apparatus 10 in the form of a pile extractor 12 for removing or extracting a pile 14 from a surface (not shown). The pile 14 may be an elongate metal pile have a H-section. However, the pile 14 may also take other forms and shapes such as being round, square or otherwise shaped. The surface may be the surface surrounding the pile 14 which may a ground surface such a dirt or grass, or may be any other suitable surface such as a roadway, planform or the like on which the pile extractor 12 is placed, in use.

The pile extractor 12 includes a main frame 15 arranged to seat and stand upon the ground surface and a pile engaging arrangement 16 operably coupled to and supported by the frame 15. The pile engaging arrangement 16 generally moves vertically relative to the frame 15, and the frame 15 provides support to stabilise the pile extractor 12 during the extraction of the pile 14.

The pile engaging arrangement 16 includes actuators 17 in the form of rams 18 which actuate associated clamps 20 arranged to releasably engage with the pile 14 in a reciprocal motion, the reciprocal motion including a lifting condition, best shown in FIGS. 6 and 13, in which the rams 18 extend to engage the clamps 20 with the pile and exert a lifting force on the pile 14, and a release condition, best shown FIGS. 1 and 11, in which the rams 18 are relatively and simultaneously lowered which likewise simultaneously releases the clamps 20 and allows the clamps 20 to be lowered relative to the pile 14 and reset to the lifting condition.

In more detail, the main frame 15 includes a base 22, a top 23 and frame members 24 which are arranged to support a clamping support body 26 of the pile engaging arrangement 16 which movable relative to the frame 15 at or toward the top 23 of the frame 15. The base 22 of the frame 15 includes apertures 30 to receive the tines of the forklift (not shown) and couplings 32 that may be used to lift and connect the pile extractor 12 to a vehicle (not shown) that may also provide power such as electric or hydraulic power to the pile extractor 12. A hydraulic motor (not shown) may also be used. It is noted the frame 15 may also carry a control unit or system which is hydraulic and/or electrical (not shown) with operator controls to operate the pile extractor 12.

The frame 15 includes a guide 34 which is generally centrally arranged to receive and guide the pile 12 relative to the clamps 20. In this example, the guide 34 is provided in the form of a short vertically arranged passage or chute 36 at or extending from the base 22. The frame 15 also includes a further clamp body guide 38 which is arranged to assist to align the clamping support body 26 to align it with the frame 15 as it raised and lowers during use. The further guides 38 are provided in the form of two upstanding angled sections 40 which are shaped to capture and direct the clamping support body 26 into alignment when it is lowered relative to the frame 15.

Turning to the clamping support body 26 in more detail, as best shown in FIG. 6, in this example, the clamping support body 26 includes rectangular clamping frame 42 with an open top and bottom 44, 46 through which the pile 14 extends in use. Each of the clamps 20 is pivotally coupled opposing sides 48 of the clamping support body 26 with pins 28. Ends 51 of the rectangular frame 42 fit with and are guided by the two upstanding angled sections 40. The bottom 46 of the clamping support body 26 may include a further guide 49 through which the pile 14 extends which aligned with the guide 34 of the frame 15 which assist to maintain the alignment with the pile 14 in use.

As best shown in FIGS. 10 to 14, each of the clamps 20 includes a clamp body 50 having a first end 52 arranged to engage the pile 14, a second end 56 coupled to the associated one of the rams 18, and an intermediate section 54 pivotally coupled by the pin 28 to the clamping support body 26.

The location of the pin 28 being located closer toward the first end 52 relative the second end such that the clamp is over-centre such that the clamps 20 are over-centre and an increased lifting force of the rams 18 provides a corresponding increased gripping force between clamps 20 and the pile 14 being lifted. In this regard, the clamps 20 may be considered self-actuating or self-tightening and the gripping force applied increases based on how much force is required to lift the pile 14.

The first ends 52 of the clamps 20 include jaws 58 with engagement surfaces 60. The engagement surfaces 60 of the jaws 58 are splayed relative to one another in the released condition and movable toward being substantially parallel in the lifting condition. The jaws 58 may be replaceable and formed of a different material in comparison of the clamp body 50.

The rams 18 are spaced apart and generally vertically oriented so as to be located on each side of the pile 14 in use. Each of the rams 18 is directly pivotally coupled to the second end 56 of its associated one of the clamps 20. The rams 18 each include a head end 62 and a base end 64.

The head end 62 is coupled by a pin 66 to the second end 56 its associated one of the clamps 20 and the base end 64 of each ram 18 is pivotally couped by a further pin 68 to the frame 15 at or toward the base 22 of the frame 15. The pivotal coupling of the rams 18 provide some play or movement to allow for some misalignment between the pile extractor 12, pile 14 and the ground surface which may be uneven. It is noted that when lifted, only the rams 18 support the clamping support body 26 above the main frame 15.

In use, the pile extractor 12 may be lifted over the pile 14 which results the pile 14 being located between clamps 20 of the pile engaging arrangement 16 of the pile extractor 12. The main frame 15 which supports the pile engaging arrangement may be placed or seated on the ground surface. The pile extractor 16 may remain connected to a machine to provide electric or hydraulic power or could be a standalone apparatus with its own associated power source. The pile 14 is located by the guides 34 and 49.

The pile extractor 12 may then be operated to initiate its lifting motion which includes generally includes a reciprocal motion to lift, release and lift the pile 14 from the ground. The pile extractor 12 initiates its motion being in a lowered position as shown in FIG. 1 and extends at the top of its stroke to a raised position as shown in FIG. 6.

Because the stroke of the rams 18 is limited and the embedded section of the pile 14 may be long, several lifting iterations may be required to extract the pile 14. The stoke defines the maximum height of the lift and the lift height reached by the clamping support 26 which carried the clamps 20.

The rams 18 are then actuated a reciprocal motion move the clamps 20 between the lifting condition in which the rams 18 extend to simultaneously engage the clamps 20 with the pile and exert a lifting force on the pile 14, and a release condition, in which the rams 18 are relatively lowered which simultaneously releases the clamps 20 and allows the clamps 20 to be lowered relative to the pile 14 and reset to the lifting condition.

In the lifting condition, the rams 18 are arranged to extend a first amount in which clamps 20 are moved to engage with the pile 12 and then once engaged, a second amount in which the clamps 20 and pile 14 are lifted together. This may be performed in a single action in which the pile 14 is engaged and lifted to the raised position as shown in FIG. 6.

In the release condition, the rams 18 are arranged to retract a third amount in which clamps 20 are moved to disengage with the pile, and then once disengaged, a fourth amount in which the clamps 20 are lowered together reset to the lifting condition and arrive in the lowered position as shown in FIG. 1.

The reciprocal motion may be continued until the pile 14 is sufficiently extracted. In some cases, the final lifting action may maintain the clamps 20 in a gripped condition, which allows the removed pile 14 to be held by the pile extractor 12 and even moved therewith in situation where the pile extractor 12 is lifted by or coupled to a machine. The guides 34, 39 are also helpful during the final stages of removal to maintain the vertical alignment of the pile 14.

Advantageously, there has been described a pile remover or extraction apparatus which is useful to remove elongate metal piles from a ground surface. The pile extractor includes features such as guides to align with the pile and pivotally couplings such as between the rams and the frame to allow for some misalignment. The pile extractor functions in reciprocal motion to extract the pile in short repeating motions in which the pile is grips and released by simultaneous actions of the rams and the associated clamps. Such a pile remover and extraction motion are particularly useful for machine driven metal piles with smooth surfaces such as a H-beam due to the high force required to remove such piles and the difficult to grip the surface of the pile.

Throughout this specification and the claims which follow, unless the context requires otherwise, the word “comprise”, and variations such as “comprises” and “comprising”, will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

The reference in this specification to any known matter or any prior publication is not, and should not be taken to be, an acknowledgment or admission or suggestion that the known matter or prior art publication forms part of the common general knowledge in the field to which this specification relates.

While specific examples of the invention have been described, it will be understood that the invention extends to alternative combinations of the features disclosed or evident from the disclosure provided herein.

Many and various modifications will be apparent to those skilled in the art without departing from the scope of the invention disclosed or evident from the disclosure provided herein.