TRENCH FILLING METHODS, MACHINES, AND SYSTEMS FOR FILLING TRENCHES

CROSS REFERENCE TO RELATED APPLICATION

[0001]This application is a Continuation of PCT Application Ser. No. PCT/US2024/045851 which was filed Sep. 9, 2024, entitled “Trench Filling Methods, Machines, and Systems for Filling Trenches”, which claims priority to and the benefit of U.S. Provisional Patent Application Ser. No. 63/537,412 filed Sep. 8, 2023, entitled “Trench Filling Machines and Systems for Filling Trenches”, and U.S. Provisional Patent Application Ser. No. 63/671,925 filed Jul. 16, 2024, entitled “Trench Filling Machines and Systems for Filling Trenches”, and U.S. Provisional Patent Application Ser. No. 63/678,262 filed Aug. 1, 2024, entitled “Trench Filling Machines and Systems for Filling Trenches”, the entirety of each of which is incorporated by reference herein.

TECHNICAL FIELD

[0002]The present disclosure relates to construction equipment, particularly construction machines and systems. In particular embodiments, the present disclosure provides trench filling machines and/or trench filling systems that and/or methods that can be used for filling trenches.

BACKGROUND

[0003]Currently, miles and miles of trenches are being dug every day and filled to particular specifications. Typically, the trenches must be filled with a bedding first, and then the trench is configured to receive some kind of construction material such as a pipe, for example, and then upon that pipe is additional material that is provided to reach the surface level. In the past, this has been a labor intensive process wherein an excavator or backhoe is provided to remove material from a material truck and put it alongside, or in the trench; then a construction worker, or workers, may need to go into the trench, spread the material upon the base of the trench, compact the material, provide the piece of construction equipment such as the pipe, and then provide additional material. This can cost numerous man hours and put construction workers at risk during the process. The present disclosure provides construction machines and/or systems and methods that can be used to fill trenches.

SUMMARY

[0004]Methods for filling a trench are provided. The methods can include: straddling the trench with a vehicle comprising opposing rotational assemblies, wherein each of the rotational assemblies reside along lateral surfaces of the trench; matriculating the vehicle along the length of the trench, while matriculating the vehicle, one or more of: depositing fill material from the vehicle; grading deposited fill material using a grader of the vehicle; and/or compacting graded fill material using a compactor of the vehicle.

[0005]Trench filling machines are also provided. The machines can include: a wheel base supporting a frame; and the frame supporting a drive train, at least one operator station, a fill material hopper assembly, a grading assembly, and a compacting assembly, all controlled from the at least one operator station, wherein one or more of the hopper assembly discharge, the grader of the grading assembly; and/or the compactor of the compacting assembly are operatively aligned at about midpoint between lateral ends of the wheel base.

BRIEF DESCRIPTION OF DRAWINGS

[0006]Embodiments of the disclosure are described below with reference to the following accompanying drawings.

[0007]FIGS. 1A, 1B, and 1C depict a top view of a trench, a side view of a trench, and a front view of a trench.

[0008]FIGS. 2A, 2B, and 2C depict a top view of a trench, a side view of a trench, and a front view of a trench when operatively engaged with a machine distributing substrate according to an embodiment of the disclosure.

[0009]FIG. 3 is a machine configured to bed a trench according to an embodiment of the disclosure.

[0010]FIG. 4 is a machine configured to provide sand as backfill and compact sand in a trench according to an embodiment of the disclosure.

[0011]FIG. 5 is another example of the machine of FIG. 4 according to an embodiment of the disclosure.

[0012]FIG. 6 is machine configured to provide slurry above a fixed piece of construction equipment, including a pipe, according to an embodiment of the disclosure.

[0013]FIG. 7 is a more detailed view of an example machine of FIG. 6 according to an embodiment of the disclosure.

[0014]FIG. 8 is another example of a configuration of the machine of FIG. 6 according to an embodiment of the disclosure.

[0015]FIG. 9 is a top view of the machine of FIG. 8 according to an embodiment of the disclosure.

[0016]FIG. 10 is another example configuration of the machine of FIG. 6 according to an embodiment of the disclosure.

[0017]FIG. 11 is another example configuration of the machine of FIG. 10 according to an embodiment of the disclosure.

[0018]FIG. 12 is an example configuration of a machine configured to bed backfill and slurry a trench according to an embodiment of the disclosure.

[0019]FIG. 13 is another view of a configuration of the machine of FIG. 12 according to an embodiment of the disclosure.

[0020]FIG. 14 is an elevational view of another machine according to an embodiment of the disclosure.

[0021]FIG. 15 is a view of wheel/track base of a machine according to an embodiment of the disclosure.

[0022]FIG. 16 is a view of yet another machine according to an embodiment of the disclosure.

[0023]FIG. 17 is a view of another configuration of the machine of FIG. 16 according to an embodiment of the disclosure.

[0024]FIG. 18 is a cross sectional view of the machine of FIG. 12 according to an embodiment of the disclosure.

[0025]FIG. 19 is another cross sectional view of the machine of FIG. 12 according to an embodiment of the disclosure.

[0026]FIG. 20 is another view of the configuration of the machine of FIG. 12 according to an embodiment of the disclosure.

[0027]FIGS. 21A, 21B, 21C are configurations of a discharge portion of the machine of FIG. 12 according to an embodiment of the disclosure.

[0028]FIG. 22 is another view of the discharge portion of the machine of FIG. 12 according to an embodiment of the disclosure.

[0029]FIGS. 23-26 are elevations of a trench filling machine according to an embodiment of the disclosure.

[0030]FIG. 27 is a detailed view of a hopper of the trench filling machine of FIGS. 23-26.

[0031]FIGS. 28-30 are views of a screed assembly of the trench filling machine of FIGS. 23-26.

[0032]FIG. 31 is a detailed view of a compactor assembly of the trench filling machine of FIGS. 23-26.

[0033]FIG. 32 is a view of a CPU control assembly of the trench filling machine of FIGS. 23-26.

DESCRIPTION

[0034]This disclosure is submitted in furtherance of the constitutional purposes of the U.S. Patent Laws “to promote the progress of science and useful arts” (Article 1, Section 8).

[0035]The present disclosure will be described with reference to FIGS. 1A-32. Referring first to FIGS. 1A-1C. 1, as described above, FIGS. 1A, 1B, and 1C, are a top view, side view, and front view of a trench according to an embodiment of the disclosure. As can be seen, trench 10 is surrounded by substrate 12 on either side and extends lengthwise between at least two points and in at least one direction. In this particular embodiment, the trench is linear, but the trench can be non-linear as well. About the trench 10 can be a surface 14 that defines an opening 18 of the trench. The trench can have a base 16 below opening 18, as well as sidewalls 20.

[0036]As shown in FIGS. 2A, 2B, and 2C, a machine 22 can be provided that is configured to be mobile in the direction of the linear extension of the trench 10. As can be seen, the mobility of the machine can be provided via wheels and/or tracks 24, that can be provided upon surface 14 about the trench, providing a center portion or midway portion over trench 10, particularly over opening 18 of trench 10. Machine 22 can be configured to provide material 30 to within trench 10 to a specific depth. Machine 22 can be configured to operate in a trench bedding configuration wherein a certain thickness of bedding of substrate 30 is provided to base 16 of trench 10. This thickness can be provided using either mechanical and/or electronic sensing equipment 26. The mechanical equipment can be screeds and/or compactors, as well as sensors 26 that can dictate the amount of material provided from machine 22. In accordance with example implementations, material can be provided to machine 22, and provided via gateways or flaps 28 through opening 18 to trench 10. In accordance with example implementations, configurations of sensors or apparatus 26 can be used to facilitate the providing of substrate of various compositions and in certain configurations along the trench base.

[0037]For example, in a typical series, trench bedding is provided to a certain depth to receive a trench pipe, for example, then sand, as backfill, is provided upon the pipe to a certain depth, and compacted. Then, a slurry that is provided over the compacted sandfill. According to example implementations, substrate 30 can be bedding, sand backfill and/or slurry, for example.

[0038]Referring to FIG. 3, a trench bedder machine 32 is provided that is configured to be pulled behind and/or pushed using other machines or equipment. Trench bedder 32 is designed to bed the trench to ensure the proper bedding depths. The trench bedder has a hopper to be loaded with sand or gravel by a loader type of equipment. The material then flows down a tube into the bottom of the trench. The flow tube is adjustable for proper depth placement of material. Bedder 32 can have two wheels that ride along the bottom of the trench. Sand or bedding material can flow out behind the wheels to stay consistent. Bedder 32 can have a manual or battery-operated slide gate on the flow tube to regulate and/or stop flow at any time. Bedder 32 can be pushed with a loader type machine, for example. Bedder 32 can be lowered into a trench with a loader as well. Bedder 32 can be flush with the loader type machine while material will be placed using gravity while traveling the trench. Bedder 32 can have adjustable wheels (training) to keep the bedder from leaning while traveling down the ditch. Once bedder 32 has completed bedding finished it can be lifted out with a quick coupler of choice.

[0039]Accordingly, machine 32 can include a hopper 34 that is approximately 8½ feet long, for example, and can be coupled in fluid communication with a material feed to conduit 36, and then operatively adjusted to provide material via a slide gate 38. This machine can include a push point assembly 40 that can be configured to engage a bucket 42 of a loader, for example. The material feed tube can be approximately 60″ long and be about 6″ in diameter. The length of the feed tube can be extended to approximately 10 feet, if need be. A training wheel assembly may be provided in addition to the wheels of machine 32, and a guide 44 to guide the machine within trench 10 can also be operatively engaged.

[0040]Referring next to FIGS. 4-6, a backfill machine 50 configured to provide sand backfill and compact same is provided. This machine can be configured to be lowered into the trench with a skid steer or loader. The machine will be pushed with any loader type of machine. The machine can include a paver type hopper configured to be filled by a 10-wheel dump truck and pushed by a loader type equipment. The machine can be guided by a rudder design in the trench. The machine depth will be adjustable to ensure proper depth of sand.

[0041]Once the sand is placed in the trench, a compaction wheel will run over the top of the trench with a vibrator to ensure compaction. In accordance with example implementations, machine 50 can include; a material hopper 34 and a screed configured to level the material received from the hopper into the trench to a specific level. Accordingly, the screed can be raised or lowered and/or adjusted side to side. In accordance with example implementations, machine 50 can also include a compactor assembly that can be configured to compact material received post-screed 52. The compact assembly can be raised or lowered and/or adjusted side to side as need be.

[0042]Accordingly, and with reference FIG. 5, sandfill compacting machine 50 can include a hopper 34 that is operatively engaged with a conduit 36. Conduit 36 can have the flow of substrate 30 provided through same and extend past guide 44 that can be operatively engaged to move from side to side between the sidewalls of the trench. In accordance with example implementations, a pipe is first laid on the trench bed and upon this trench bed, sand backfill is provided to a certain depth via dump truck 51 to hopper 34 wherein a compacting free floating vibration compactor 54 including free floating vibrator 53 is provided. Machine 50 can be pushed via a loader 42 to a push point 40 and provide compacted sand 31 upon pipe 52.

[0043]Referring next to FIG. 6, in accordance with another example implementation, machine 50 can be operatively mechanically configured to engage with sensor assembly 26. Sensor assembly 26 can be used to sense the level of sand backfill that is provided to the trench and mitigate the speed with which the backfill is delivered and/or the amount that is delivered as well as the height of the compactor assembly 54. In accordance with example implementations that will be described in the context of other autonomous or semi-autonomous configurations, the machine can be used with this sensor assembly to provide a bed height that is specific to the desired construction final product.

[0044]Referring next to FIGS. 7-11, various configurations for providing slurry on the compacted sand are provided. Slurry machine 60 can be configured to catch and place popcorn slurry in a trench. In accordance with example implementations, the belly dump truck pulls over the top of the hopper and hooks the chain to machine 60 once the truck is in position. Personnel will then open the belly dump gate and dump the material in the hopper. Once the hopper is full, the truck will move forward while leaving the gate open, pulling the device while the truck straddles the trench. The device will stay in the trench guided by the rudder that will hang down in the trench approximately 7″ wide by 6′ long with a rounded point to ensure the trench integrity. Machine 60 will trim the slurry flush to the top of the asphalt with an angled replaceable cutting edge located in the back of the machine. The device is approximately 16′ in length from edge to edge. Once the trench is filled, the chain will be detached and the truck will pull away from the machine.

[0045]Pull behind slurry attachment 60 can include a hopper as well as a guide. As with all guides, the guide can be configured to reside within trench 10. Machine 60 can include wheels 24 and can be configured to provide substrate 30 in the form of slurry to within trench 10. In accordance with example configurations, this substrate can be provided from a belly dump truck as shown in FIGS. 8 and 10. In accordance with example configurations, the wheels may reside across the trench top to provide a flat surface of slurry as the machine transitions the trench. As shown in FIG. 9, a top down view of the belly dump truck is shown having an opening 62 extending to hopper 34. As shown in FIGS. 10 and 11, a guide as well as the opening 62 is shown extending from the belly dump truck. The belly dump truck and/or the hopper can include an auger 64 configured to convey material to the hopper or to the trench.

[0046]Referring next to FIG. 12, machine 70 is provided. As shown, machine 70 can be autonomous or semi-autonomous and/or operable by an operator. For example, machine 70 can include a power plant for providing mobility or transition upon or across a trench. Machine 70 can include tracks as shown and/or wheels that extend on either side of a trench. Machine 70 also provides a hopper 34 as well as a discharge portion 36 into trench 10.

[0047]As can be seen, machine 70 can be configured with processing circuitry. In accordance with example implementations, these processes may be utilized in connection with the processing circuitry described. The processes may use software and/or hardware of the following combinations or types. For example, with respect to server-side languages, the circuitry may use Java, Python, PHP, .NET, Ruby, JavaScript, or Dart, for example. Some other types of servers that the systems may use include Apache/PHP, .NET, Ruby, NodeJS, Java, and/or Python. Databases that may be utilized are Oracle, MySQL, SQL, NoSQL, or SQLite (for Mobile). Client-side languages that may be used, this would be the user side languages, for example, are ASM, C, C++, C#, Java, Objective-C, Swift, ActionScript/Adobe AIR, or JavaScript/HTML5. Communications between the server and client may be utilized using TCP/UDP Socket based connections, for example, as Third-Party data network services that may be used include GSM, LTE, HSPA, UMTS, CDMA, WiMAX, WIFI, Cable, and DSL. The hardware platforms that may be utilized within processing circuitry include embedded systems such as (Raspberry PI/Arduino), (Android, iOS, Windows Mobile)—phones and/or tablets, or any embedded system using these operating systems, i.e., cars, watches, glasses, headphones, augmented reality wear etc., or desktops/laptops/hybrids (Mac, Windows, Linux). The architectures that may be utilized for software and hardware interfaces include x86 (including x86-64), or ARM.

[0048]Specific configurations of the processing circuitry can provide trench data logs; use Lidar, light detection and ranging as part of the sensors 26 to determine trench depth, width, machine movement, and or substrate depth.

[0049]Accordingly, utilizing the processing circuitry, machine 70 can be configured to run autonomously, or via using an operator. Sensors 26 can be used to dictate the path and/or rate of discharge and/or rate of speed of machine 70 as well as the direction of machine 70. Additionally, sensors 26 in combination with mechanical assemblies described later can be used to adjust the height, side to side, or trench wall to wall alignment for the screed and/or compaction of material from hopper 34.

[0050]FIG. 13 provides a top down view of machine 70 according to an embodiment of the disclosure. As can be seen, machine 70 can include a gate assembly 72 that can be configured with an auger as will be described later that is configured to receive material from hopper 34 and provide same to conduit 36 for eventual depositing in trench 10. Additionally, machine 70 can include a screed or gating assembly 74. Screed 74 can be aligned side to side or up and down, as directed by the operator and/or the processing circuitry. Also, machine 70 can include compactor assembly 76 that can be arranged side to side or up and down as configured by the operator and/or the processing circuitry. In accordance with example implementations, and with reference to FIG. 18, machine 70, as shown in at least one cross section, can include wheels 24 as well as hopper 34. Hopper 34 can extend to an auger 86 which is aligned in the direction of transition of the machine over trench 10. The auger can be set and controlled by the operator and/or by the processing circuitry and be operatively coupled to the machine. The amount of material 30 that is provided to trench 10 can be regulated using gates 80 and 82, which can be configured to overlap and adjust using rams 84 on opposite sides of the conduit extending from hopper 34.

[0051]Referring to FIG. 14, an elevational view of a machine is provided that depicts the machine wheel/track base 140 operably engaged with a machine chassis 142. Chassis 142 and base 140 are operably engaged via mount 144. Chassis 142 can be equipped with hopper 34, screed assembly 74, and/or compactor assembly 76.

[0052]Referring to FIG. 15, in accordance with at least one implementation, wheel/track base 140 can be configured with extendable/retractable members 146. Members 146 can be utilized to adjust to different widths and thus accommodate different trench widths.

[0053]Referring to FIG. 16, chassis 142 can be pivotably mounted to wheel/track base 140 via mount 144. Accordingly, using members 160, chassis 142 can be at a different angle in relation to base 140. This configuration can be used when the surface bed is other than horizontal and the trench is vertical as shown. In use, materials can be deposited and/or handled from hopper 34 for example while hopper 34 is aligned substantially normal to the trench and base 140 is other than normal to the vertical walls of the trench. Members 160 can be a working combination of hydraulic pistons for example. Referring to FIG. 17, another example of the configuration of the machine of FIG. 16 is shown having wheels as well as boom-mount.

[0054]Referring next to FIG. 19, machine 70 can include a screed assembly 74 that may be configured to vibrate up and/or down and/or may be able to be configured to extend using telly bars if desired. The screed platform 75 can be constructed of at least a pair of plates that can be changeable, 78 and 80, as well as rubber belting 82 on opposing sides of the changeable plates. In this configuration, screed assembly 74 is shown providing a bed depth for sand backfill 30 above pipe 52. In accordance with example implementations, the trench can be from 8 to 18 inches wide. The plate height can be as tall as 24 inches and the screed can extend from 0 to 60 inches of depth. In accordance with another example implementation, machine 70 can include a compactor assembly 76 that is configured as a weighted vibrating compactor. Assembly 76 can be configured to utilize a sleeve 90 configured to receive the weighted vibrating compactor assembly 76 which can be configured to be adjusted right to left and/or up or down by the operator and/or by the processing circuitry. The height of adjustment can be as much as 40 inches up and/or down. The assembly can include a compaction wheel that can be as high as 12 inches and be 8 to 18 inches wide and be replaceable. As shown in FIGS. 21A-C, various configurations of the flap design for the hopper are shown with the overlap shown in FIGS. 21A and 21B. Additionally, as the machine transverses along a trench, at the rear of the flaps can be a rubber or mini screed 100 that can prevent material from flowing too quickly out of the flaps. As can be seen in FIG. 22, auger 86 is shown above the exit flaps.

[0055]Referring next to FIGS. 23-26, multiple elevations of machine 70 are shown that can include hopper 34, screed assembly 74 and compactor assembly 76. All of which can be monitored and/or controlled using CPU/controls 190 from an operator position. Machine 70 can be operated and/or controlled by an operator at operator position 220 and/or operator position 222 using controls 190 and/or 192. Machine 70 can be powered by power source 224, in this particular configuration, a hydraulic compressor operably engaged with hydraulics configured to operate tracks shown as well as material gate 62, screed assembly 74, and/or compactor assembly 76.

[0056]Referring next to FIG. 27 hopper 34 is shown with a focus on material gate 62. Accordingly, material can be provided to hopper 34 and measured release of same through gate 62 can be accomplished by an operator from positions 220 or 224 which can allow the operator to view the trench passing below the operator.

[0057]Referring next to FIGS. 28-30, detailed views of screed assembly 74 are shown in relation to hopper 34 and compactor assembly 76. In this configuration screed assembly 74 can include a slidably engaged, but positionally fixable member 242 about a post member 240. Hopper 34 can be notched to accommodate assembly 74. Assembly 74 can include a screed plate 244 configured to engage material provided through gate 62 and level the material within the trench being filled to a specific depth as dictated by the one or more operators to provide a flat surface of material, for example. The relation of members 242 and 240 can be controlled hydraulically.

[0058]Referring next to FIG. 31 as well as FIG. 26, more detailed views of compactor assembly 76 are provided. Compactor assembly 74 can include a fixed and traveling frame assembly 270/272 configured to allow the compactor to both raise and lower as well as travel between walls of the trench or side to side, and can be adjusted for sweeping/turning trenches. This can be automated and/or controlled using trench sensors (LIDAR).

[0059]Referring to FIG. 32, CPU/controls 190 are shown in more detail. Accordingly, the trench can be monitored via video.

[0060]In accordance with the previous description, methods for filling a trench 10 are provided. The methods can include straddling the trench with a vehicle 22 comprising opposing rotational assemblies 24, wherein each of the rotational assemblies reside along lateral surfaces 12 of the trench. The method can continue with matriculating the vehicle along the length of the trench, and while matriculating the vehicle, one or more of: depositing fill material from the vehicle; grading deposited fill material using a grader of the vehicle; and/or compacting graded fill material using a compactor of the vehicle.

[0061]In accordance with example implementations, the fill material can be deposited from a hopper assembly 34 of the vehicle. The hopper assembly can include one or both of an auger 86 and/or a discharge gate assembly 80/82. The auger and/or discharge gate can be aligned about a midpoint between the rotational assemblies to provide fill material to within the trench while the vehicle is straddling the trench.

[0062]The methods can also include, while straddling the trench and/or matriculating the vehicle, the depth of the base of the trench can be determined and the level of deposited fill material above the base of the trench can be determined. The methods can also include one or both of grading the deposited fill material and/or compacting the graded and/or deposited fill material to the level.

[0063]The methods can also include depositing the fill material within an empty trench to a level to support a pipe, which may include depositing fill material about and/or above the pipe. The deposited fill material can be graded and/or compacted about and/or above the pipe. Along the direction of matriculation, fill material can be first deposited, then graded, then compacted.

[0064]In accordance with example implementations, the vehicle can be guided with a member 44 extending from the vehicle to within the trench. The member may also be configured direct fill material being deposited away from the forward direction of matriculation. In at least one configuration, the member can be aligned with an auger or discharge gate of a hopper assembly of the vehicle.

[0065]Trench filling or bedder machines 70 are provided that can include a wheel base 140 supporting a frame 142. The frame supporting a drive train 160, at least one operator station 220/222, a fill material hopper assembly 34, a grading assembly 74, and a compacting assembly 76, all controlled from the at least one operator station, wherein one or more of the hopper assembly discharge 30, the grader or screed 80 of the grading assembly; and/or the compactor 92 of the compacting assembly are operatively aligned at about midpoint between lateral ends of the wheel base.

[0066]The wheel base can be laterally expandable or contractable, and/or articulate in relation to the frame. The articulation can be along the longitudinal axis of the vehicle which can be aligned with the direction of matriculation.

[0067]The trench filling machine can include processing circuitry (CPU) configured to guide the machine along a trench while maintaining one or more of the fill material hopper assembly, the grading assembly, and/or the compacting assembly in operable alignment with the trench opening. The processing circuitry can also be configured to determine trench base depth and/or deposited fill material depth. The trench filling machine can also include sensors 26/36 operably coupled to the processing circuitry. At least one of the sensors 26 can be proximate a leading end of the vehicle and configured to determine the base of the trench. At least one of the sensors 36 can be proximate a trailing end of the vehicle and configured to determine the top of the fill material.

[0068]The hopper assembly of the machine can include an auger and/or door assembly operably coupled to processing circuitry and/or operator controls. The grading assembly of the machine can include a retractable and/or extendable grader blade or screed operably coupled to processing circuitry and/or operator controls to control depth within the trench. The compactor assembly of the machine can include an extendable and/or retractable compactor operably coupled to processing circuitry and/or operator controls. The compactor can include a compacting wheel and/or can be laterally movable within the trench.

[0069]The wheel base can be configured as tracks and/or the operator station can be located about the trailing end of the machine. Another operator station can be located laterally aligned with the operator station.

[0070]In compliance with the statute, embodiments of the invention have been described in language more or less specific as to structural and methodical features. It is to be understood, however, that the entire invention is not limited to the specific features and/or embodiments shown and/or described, since the disclosed embodiments comprise forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted in accordance with the doctrine of equivalents.