Apparatus and Method for Steering a Pipe Jacking Head

This invention relates to a steerable pipe jacking head for laying small diameter pipes such as gas, water, and the like conduits, precisely in position underground. In particular, the invention relates to an apparatus and method for steering a pipe jacking head in two degrees of freedom, i.e. vertical and horizontal directions.

Heretofore, apparatus have been provided for laying pipes in the ground such as drainage, gas, water pipes, and the like, of relatively small diameter. Typically, pipe casings are pushed through the ground by the use of a hydraulic jack which advances a link of pipe casing underground and then is retracted. A new link of pipe casing is then threaded onto the advanced pipe casing and is itself advanced. The procedure is repeated until a desired length of pipe casing has been pushed underground. The problem arises of steering the string of pipe casings as they are pushed through the ground. Often, it is necessary to go underneath a conduit, creek bed, and the like, so that the desired path for the pipe casing is usually not straight. In any event, it is difficult to maintain a straight advance of the laid in pipe casings. It has been proposed to provide a detector pipe extending along the axis of the laid in pipes which may be detected so as to measure a vertical position of the forward end of the laid in pipe casings. Typically, a transmitter is located at the forward end of pipe casings and a receiver is utilized above ground to locate the forward end of the pipe casings. However, this is not entirely reliable since there are numerous factors underground which can interfere with the transmission and accuracy of the signal. Even if the vertical position of the front end of the pipe is known, it is often difficult to steer the string of laid in pipe casings when deviations occur in the detected vertical position. While the problems of detecting and steering in regards to vertical positions are difficult, the measuring and steering in a horizontal plane are even more difficult. The directional control of small diameter pipes which are pushed through the ground requires not only skilled operators, but reliable means of measuring the position and then steering the forward end of the pipe casings. Suitable measuring and steering devices have not been provided by the prior art. U.S. Pat. No. 4,026,371 discloses a pilot head for laying small diameter pipes which comprises an expandable and contractible pilot jack disposed within a pilot casing, a pivoting cylinder adapted for pivoting the pilot jack in a selected direction in a plane normal to the central axis of the pilot head, and an electromagnetic valve for operating the cylinder. A clinometer is used for detecting the vertical position angle and direction of the pilot head. However, the mechanism for pivoting the pilot jack involves ball joints which easily become worn, particularly when considering the pressure exerted on such a pipe jack due to the compression of the soil as the pipe head is advanced by a hydraulic or other jack through the ground. While the patent discloses both measuring the vertical position with a clinometer and/or transit, there is no means provided for measuring the horizontal position or for steering the pipe head according to a desired heading. Even if a cased bore is formed with pipe casings along a desired vertical direction, many times the cased bore will be off several feet to the left or right. When this occurs, it is often necessary to relay the pipe casings to form another cased bore, hopefully more accurately in line. This involves considerable additional expense and effort. It is not guaranteed that the second cased bore will be any more accurate in its horizontal position than the first.

Accordingly, the problem of measuring the vertical and horizontal positions of a pipe casing which is jacked or pushed through the ground, and of steering a forward end of the pipe casing in both a horizontal and vertical direction, is a problem to which considerable attention need be given.

Accordingly, an object of the invention is to provide an apparatus and method for guiding and steering a pipe jacking head in two degrees of freedom.

Another object of the invention is to provide a simple, yet reliable, means for guiding and measuring a steerable pipe jacking head in two degrees of freedom, that is both the horizontal and vertical directions.

Another object of the invention is to provide an apparatus and method which is simple in construction and yet is effective for steering a pipe jacking head in both a horizontal and vertical direction as pipe casing is pushed underground from a pit station.

Another object of the invention is to provide an effective steering device for a steerable pipe jacking head which may be extended to steer the pipe jacking head and change direction and then retract it so that the pipe jacking head may be pushed in that direction until a further direction change is needed.

Another object of the invention is to provide a simple and reliable guidance system for measuring the horizontal and vertical positions of a steerable pipe jacking head having such an effective steering device.

The above objectives are accomplished according to the present invention by providing a pipe jacking head which can be steered for laying pipe casings underground to form a cased bore. The steerable pipe jacking head is carried by the forward pipe casing. A steering device, preferably a wedge, is carried by the pipe jacking head for creating a directional steering force to steer the head in a prescribed direction. The steering wedge has a desired rotational position in which the steering wedge creates the directional steering force to steer the pipe jacking head, and an advanced position in which the steering wedge is extended forward of the pipe jacking head to steer the pipe jacking head, and a retracted position in which the steering wedge is retracted within the pipe jacking head so that the directional force is not created. An actuator is provided for rotating the steering wedge to a desired rotational position and for moving the steering wedge between the advanced and retracted positions. The actuator includes a first actuator for rotating the steering wedge to the desired rotational position corresponding to the prescribed direction, and a second actuator for reciprocating the steering wedge in and out of the pipe jacking head between advanced and retracted positions. The second actuator includes a fluid cylinder which has a piston rod attached to the steering wedge. The wedge has a slanted surface which creates the directional force. The first actuator includes a drive motor for rotating the steering wedge to the desired rotational position, and a coupling which connects the steering wedge and drive motor for rotating the steering wedge and permitting the steering wedge to be extended along a longitudinal axis of the pipe jacking head. A guidance system measures an inclination and a heading of the pipe jacking head and generates corresponding first and second position signals. A control controls the first and second actuators in response to the first and second position signals to control the steering wedge to steer the pipe jacking head according to a prescribed path. The guidance system includes a first sensor for measuring the inclination of the pipe jacking head and generating the first position signal. A second sensor measures the heading of the pipe jacking head and generates the second position signal. A rotary sensor is provided for detecting the rotational position of the steering wedge and for generating a rotational position signal. A computer processes the first and second position signals and calculates vertical and horizontal deviations of the pipe jacking head with respect to the prescribed path, and processes the rotational position signal. A visual display graphically displays the deviations of the pipe jacking head, and the rotational position of the steering wedge. The control device comprises manually operated controller for controlling the first and second actuators in response to the display of deviations and rotational position to move the steering wedge and steer the pipe jacking head to nullify the deviations. Preferably, the second sensor includes a magnetometer sensor, and compensation circuit for compensating for magnetic field anomalies to eliminate errors in the second position signal caused by field anomalies.

The method of the invention for steering and guiding a steerable pipe jacking head which lays pipe casings underground includes providing a steerable pipe jacking head having a steering device which is rotated within the pipe jacking head to a desired rotated position corresponding to a desired steering direction. The steering device is extended from the pipe jacking head to steer the pipe jacking head, and then retracted so as not to steer the pipe jacking head. The position of the pipe jacking head is measured as it is pushed through the ground to lay pipe casings and position signals are generated. Next, the method includes rotating and then extending the steering device in response to position signals to steer the pipe jacking head as it is pushed through the ground in a prescribed direction along a desired path, and then retracting the steering device after the pipe jacking head has been steered to a prescribed direction. Preferably, the steering device is provided in the form of a steering wedge having a slanted surface which creates a directional force to steer the pipe jacking head. Measuring the position of the pipe jacking head is accomplished by measuring the inclination of heading of the pipe jacking head, and generating inclination and heading signals. The rotational position of the steering wedge is detected and a rotation position signal is generated. The rotational position of the steering wedge is controlled in response to inclination and heading signals and rotational position signal to steer the pipe jacking head along the prescribed path.

The construction designed to carry out the invention will hereinafter be described, together with other features thereof. The invention will be more readily understood from a reading of the following specification and by reference to the accompanying drawings forming a part thereof, wherein an example of the invention is shown and wherein:

FIG. 1 is a side elevation illustrating an apparatus and method for pushing small diameter pipe casings underground using a steerable pipe jacking head according to the apparatus and method of the invention;

FIG. 2 is a sectional view taken along line 2--2 of FIG. 1;

FIG. 3 is a sectional view of a steerable pipe jacking head constructed in accordance with the invention;

FIG. 4 is a schematic diagram illustrating a guidance system for a steerable pipe jacking head according to the invention; and

FIG. 5 is a perspective view illustrating a computer processor and display, and manual control for controlling a steerable pipe jacking head according to the invention.

Referring now in more detail to the drawings, an apparatus and method laying small diameter pipe casings underground is illustrated which includes a boring pit 10 having a hydraulic jack, designated generally as 12, which pushes pipe casings 14 underground in a conventional manner. While the pit is illustrated underground, the apparatus and method of the present invention may be utilized and carried out from above ground as well. In that case, the pipe casing may be pushed through the ground with a desired entry angle and the vertical position of the pipe casing is controlled accordingly. As can best be seen in FIGS. 1 and 2, pipe jacking apparatus includes a pair of hydraulic cylinders 16 and 18 which have piston rods 16a and 18a connected to a push bar 20. A push bar slides along a track which includes a pair of rails 22. Push bar 20 includes a recess 24 which receives a butt end of a pipe casing for pushing the pipe casing through the ground. Typically, pipe casings 14 have an outside diameter of 5 inches and a length of 52 inches. There is an alignment collar 26 which has a central aperture 26a through which pipe casings 14 are received and aligned for being pushed through the ground, as can best be seen in FIG. 1. Hydraulic cylinders 16, 18 are controlled by suitable controls 28 and 30. Control 28 extends hydraulic piston 16a, 18a to push pipe casings 14 through the ground via push bar 20, and control 30 admits pressurized fluid to the opposite end of the hydraulic cylinders for retracting the push bar so that a new pipe casing may be threaded into the prior pipe casing for pushing further casings through the ground. For this purpose, threaded couplings are provided at 32 for coupling pipe casing sections together in a conventional manner. There is a forward pipe casing 14a which is threaded into a steerable pipe jacking head A which is constructed in accordance with the apparatus and method of the present invention. Steerable pipe jacking head A includes a steering means B which creates a directional force to steer the pipe jacking head in a desired direction, as will be more fully explained.

As can best be seen in FIG. 3, pipe jacking head A includes a main housing 40. There is a rear plug 42 into which forward pipe casing 14a is threaded. There is a fluid motor 44 which may be any suitable hydraulic motor carried by a motor mount 46 within housing 40. There is a coupling means in the form of a splined coupling 46 which connects an output shaft 44a of motor 44 to a splined end 48 of a piston rod 50. This allows piston rod to slide axially within the coupling means while it is rotated by hydraulic motor 44 for purposes that will be more fully explained later. There is a rotation stop 51 carried by mounting plate 46 and a rotation stop 51a carried by splined coupling 46. The rotation stops allow for rotation of piston rod 50 in 359 degrees of rotation, but not continuous rotation. Means for rotating hydraulic motor 44 include a fluid line 44a which is connected to a manual control valve 44b at the pit station (FIG. 2). Control 44b is controlled manually by the operator. There is a piston cylinder 52 carried within main housing 40 which includes a first cylinder end cap 54 and second cylinder end cap 56. There is a slidable piston 58 carried within fluid cylinder 52. Preferably, fluid cylinder 52 utilizes a hydraulic fluid. There is an advance port 60 which admits hydraulic fluid through a hydraulic line 60a to a space 62 between cylinder end cap 54 and slidable piston 58 for advancing piston 58 and piston rod 50. Hydraulic line 60a is connected to a manual control valve 60b at the pit station for admitting fluid for advancing piston rod 50. There is a retraction port 64 formed in piston rod 50 which communicates with a space 66 between second cylinder end cap 56 and slidable piston 58 for retracting the slidable piston and piston rod 50. For this purpose, there is a hydraulic line 64a communicating with retraction port 64 which includes a bore 65 formed in the interior of piston rod 50 and a flexible hydraulic line 64b which is routed through the interior of main housing 40 and pipe casings 14a and 14 to the pit station and is controlled by a manual control 64c. In this manner, piston rod 50 is rotated by manual control 44b and piston rod 50 is reciprocated in extended and retracted positions by controls 60b and 64c , respectively. Steering means B is carried at the end of piston rod 50 and affixed thereto in the form of a piston wedge 69 having a slanted face 69a which creates a directional steering force when extended forward of a plug opening 74 carried at a front end of pipe jacking head A.

In accordance with the apparatus and method of the present invention, steering wedge B is rotated by hydraulic motor 44 and control 44b to a desired position so that when slanted face 42 is extended into the soil and pipe casing is pushed, directional steering force is created which steers the pipe jacking head, and attached pipe casings 14, in the desired direction to correct for deviations in the position of the pipe jacking head with respect to horizontal and vertical position angles. As it is understood, of course, in operation, that pipe jacking head A and pipe casings 14 do not rotate, but are pushed through the underground without rotation. Once the desired direction change has occurred by way of steering wedge 60, the steering wedge is retracted to the position shown in FIG. 3 and the pipe casing head is thereafter pushed in that direction in a straight manner. Steering means B has a retracted position as shown in FIG. 3 and an extended position, as can best be seen in FIG. 1. Steering wedge B must be rotated before it is extended and is retracted after the pipe jacking head has been brought back to a desired path position.

A rotary sensor means (FIG. 3) is shown which includes a rotary sensor 71 attached to a tail shaft 44c of hydraulic motor 44 for measuring the rotation of shaft 44a of motor 44 as it rotates 359 degrees between rotation stops 51 and 51a, in counter-clockwise turns. The rotational position of steering wedge 69 can be detected by detecting this rotational position of hydraulic motor shaft 44a since there is a 1:1 correspondence. Rotary sensor means 71 generates a rotation position signal 71a representing the rotational position of steering wedge B. Rotary sensor means 71 may be any suitable rotary sensor such as a high resolution laser rotary encoder manufactured by Cannon USA, Inc. of Lake Success, N.Y. There is an encoder disk 71b, having one degree increments read by sensor 71, freely carried on tail shaft 44c. Encoder disk 71b is gravity referenced by a pendulum mass 71c. Encoder disk 71b is maintained in a vertical position by the pendulous mass while rotary sensor 71 rotates with the wedge B and shaft of hydraulic motor 44. In the illustrated embodiment, the rotational position of steering wedge B is referenced to the vertical.

Guidance means are provided for measuring the position of the pipe jacking head. It is desirable to measure the position of the pipe jacking head in both the vertical plane and horizontal plane. For this purpose, an inclinometer 70 is provided which measures the position angle of the pipe jacking head about a horizontal axis and generates a first position signal 72 corresponding to the vertical position angle in terms of up and down position in tenths of degrees. A second sensor means for measuring the position of pipe jacking head A in a horizontal plane includes a directional heading sensor 74 carried centrally within the interior diameter of forward pipe casing 14a for generating a second position signal 76 corresponding to the horizontal position angle or heading of the pipe casing and pipe jacking head. Inclinometer 70 may be any suitable inclinometer such as a digital angle star protractor manufactured by Lucas Sensing Systems, Inc. Preferably, heading sensor 74 is a KVH directional heading sensor, model C-100, manufactured by KVH Industries of Middletown, R.I. That heading sensor is a miniature device which may easily fit within the pipe casing and measure the direction in which the pipe jacking head points or heads at any instant. The heading is expressed in angular units from a reference direction, usually from zero degrees at the reference direction clockwise 360 degrees. In accordance with the present invention, the directional heading sensor manufactured by KVH using a toroidial fluxgate magnetometer having a free floating ring core in the center, is particularly advantageous because it does not require the gimballed structure of a conventional magnetometer. The free floating ring core floats like a bobbin and has been found to be accurate within plus or minus 16 degrees of roll or pitch variation when used to measure heading in a pipe jacking head according to the invention. In contrast to the use of magnetometer systems, the guidance system of the invention can be used in steel pipe which is much cheaper than stainless steel or monel metal pipes, which are non-magnetic. The guidance system can be used in steel pipe without affecting accuracy because of its auto-calibration circuitry of the KVH sensor 74, as identified above, which compensates very precisely for hard and soft iron errors introduced by steel pipe around the sensor.

To calibrate sensor 74, the sensor is installed in pipe casing 14a, placed in the calibration mode, and the pipe is slowly moved left and right 20.degree. to 30.degree., at 2.degree. to 3.degree. intervals, with a pause for several seconds at each point. A window average is then taken. Compensation means is provided by sensor 74 which includes a microprocessor that decides which of the reading groups to sample by looking at the stability of the readings within the groups. The unit then calibrates a series of auto-compensation factors which are entered into EEPROM memory. These constants define a compensation equation which automatically corrects the output heading. The compensating means or microprocessor also includes an auto-compensation algorithm which also compensates for magnetic field anomalies caused by a magnetic signature of steel utilities that the pipe jacking head might be going over or under. In this case, computer 90 holds the last reading and displays an invalid data message until the pipe jacking head was past this unknown magnetic signature. This feature is valuable because without it, an unknown magnetic signature would introduce errors indicating a deviation of left or right which would not be true. The data is integrated and may be averaged for 5 seconds to remove jitter caused by the vibration. The combination of these features make sensor 74 unique compared to magnetometer guided systems.

A conventional microprocessor 80 may be utilized to receive sensor signal 76 and convert the signals into serial data which may be transmitted by an RS-232 line at 76a through a suitable cable shielding 82. Likewise, a microprocessor 80 can be utilized to convert the position signal 72 from inclinometer 70 into serial data which can be transmitted over an RS-232 line at 72a through cable shield 82 for processing by a computer 90 and displayed on a display 92. Rotation position signal 71a from rotary sensor 71 may be done likewise. The position signals 76 from heading sensor 74 may be displayed as left and right position angle signals in terms of tenth of degrees. The position signal 72 from inclinometer 70 may be displayed as up and down positions displayed in tenths of degrees. Rotation position signal 71a is processed and displayed in graphic form about a compass rose 92a on display 92. Microprocessor 80 may be any conventional microprocessor such as a ADC 1001 manufactured by National Semiconductor which receives the position signals and a Max-232 circuit manufactured by Max & Company which buffers and drives the signal along the RS-232 line for display at computer 90. Computer 90 and display 92, of course, will be utilized at the boring station 10 along with controls 44b for rotating steering wedge B and controls 60b and 64b for extending and retracting steering wedge B, respectively. A plot of a desired path for a cased bore formed by pushing pipe casings 14 through the ground may be drawn before the pipe laying operation begins. The distance of front end 74 of pipe jacking head A may be determined by measuring the length of pipe casings which has been pushed through the ground by measuring the pipe casing links at the boring station 10. Thus, by knowing the horizontal and vertical positions of pipe jacking head A on display 92, and the distance by measuring pipe casing links, or by any other suitable distance measuring means, the exact position of the pipe jacking head may be determined at all times. By comparing this position to the desired path of the pipe jacking head and pipe casings, deviations in the position of the pipe jacking head and pipe casings from the desired path may be determined on the display. The operator of the steerable pipe jacking head may control the position of the steering wedge B accordingly and extend that steering wedge to steer pipe jacking head A in a desired direction and bring the pipe jacking head back to its nominal position along the desired path. When the pipe jacking head has reached its nominal position, steering wedge B may be retracted and the pipe steering head may continue to be pushed through the ground in that direction until it again deviates or until a direction change is required from the plot as read by the operator.

While a preferred embodiment of the invention has been described using specific terms, such description is for illustrative purposes only, and it is to be understood that changes and variations may be made without departing from the spirit or scope of the following claims.