Robotic Excavation Platform

This application is a continuation of and claims priority to PCT Application No. PCT/US23/86399, filed on 2023 Dec. 29, which claims priority to U.S. Provisional Application No. 63/478,081, filed on 2022 Dec. 30. Each application is incorporated herein by reference in its entirety for all purposes.

This invention relates generally to the field of subterranean excavation and more specifically to new and useful methods for earthworks or excavation, such as boring, trenching, and other techniques, with new and useful non-contact boring systems.

Traditional boring techniques engage the ground through contact, and thus are limited by thrust and torque. By extension, conventional techniques are limited in face monitoring, steering, and localized control of the cutting action at the face. Thus, traditional boring techniques struggle with various boring conditions and requirements and, accordingly, are limited in their ability to conduct versatile boring operations.

Described herein are new methods and systems for a non-contact boring system. In a certain embodiment, the system may comprise a chassis, configured to perform excavation operations within a borehole, the chassis comprising a non-contact boring element, configured to perform thermal spallation within the borehole, a conical head, a first sensor, coupled to conical head, and a controller, communicatively coupled to the first sensor and configured to receive first data from the first sensor and determine, from the first data, that the conical head is contacting a portion of a borehole.

In the following description, numerous specific details are outlined to provide a thorough understanding of the presented concepts. The presented concepts may be practiced without some or all of these specific details. In other instances, well-known process operations have not been described in detail to not unnecessarily obscure the described concepts. While some concepts will be described in conjunction with the specific embodiments, it will be understood that these embodiments are not intended to be limiting.

In the following description, various techniques and mechanisms may have been described in singular form for clarity. However, it should be noted that some embodiments include multiple iterations of a technique or multiple instantiations of a mechanism unless otherwise noted. For example, an excavation system may be described with a cutterhead, but can include a plurality of cutterheads while remaining within the scope of the present disclosure unless otherwise noted. Similarly, various techniques and mechanisms may have been described as including a connection between two entities. However, a connection does not necessarily mean a direct, unimpeded connection, as a variety of other entities (e.g., fasteners, spacers, fittings etc.) may reside between the two entities.

It is appreciated that, for the purposes of this disclosure, when an element includes a plurality of similar elements distinguished by a letter following the ordinal indicator (e.g., “A” and “B”) and reference is made to only the ordinal indicator itself (e.g., “”), such a reference is applicable to all the similar elements.

This disclosure details certain earthwork or excavation systems and techniques. It is appreciate that, for the purposes of this disclosure, though reference may be made to “boring,” “drilling,” or other specific earthwork processes, such disclosure may be extended to any other earthwork or excavation system or technique.

Traditional boring techniques suffer from a variety of limitations. The non-contact boring systems and techniques described herein may allow for overcoming of these limitations. Non-contact boring techniques, such as the techniques described herein, may utilize thermal spallation through operation of a thermal cutterhead. The thermal cutterhead may be, for example, combusters such as turbine combusters, turbine-less combusters, afterburners, air-breathing rockets, and/or fuel combustion torches. The thermal cutterhead may also be, in certain other examples, plasma, water jet, and/or other such techniques that utilize heat, mass flow, and/or a combination thereof to perform boring. As the output (e.g., exhaust or afterburner) of the thermal cutterhead used for thermal spallation has a temperature gradient, precise positioning of the thermal cutterhead relative to the bore face is advantageous.

Precise positioning of the thermal cutterhead requires both accurate determination of the positioning of the non-contact boring system and and accurate positioning of the thermal cutterhead. The systems and techniques described herein allow for such determination and positioning, relative to the bore face of a borehole. Furthermore, the systems and techniques described herein allow for offsite utilization of the non-contact boring system and the data generated herein.

In various embodiments, non-contact boring may include boring techniques that utilize jet engines, plasma, acetylene, water jet, and/or other such techniques that utilize heat, mass flow, and/or a combination thereof to perform boring. Non-contact boring techniques may include, for example, utilizing a thermal cutterhead to effect thermal spallation of a bore face of a borehole.

In certain embodiments, the system may include one or more controllers for automated or semi-automated control of the systems described herein. Such a system may be of a hierarchical architecture where certain controllers may have the ability to override instructions of other controllers. Thus, for example, the system may include automated excavation systems, which may include automated or semi-automated contact and non-contact boring tools. Operation of such excavation systems may be override through remote operators and/or by operators local to the jobsite. The relationship between the jobsite and the control system may also be hierarchical. That is, in certain embodiments, the local operators may be able to override the instructions of remote operators, or vice versa. The operators may provide such instructions through user devices. The user devices may include graphical user interfaces or human machine interfaces (e.g., dials, levers, and/or other such interfaces).

For the purposes of this disclosure, references to various permutations of “boring” may refer 1) to “boring” for investigation, assessment, and/or installation of various installations, 2) to “drilling” for extraction of materials, 3) to “trenching,” 4) to “rehabilitation” of existing bores and/or structures, and/or 5) to any other technique that includes the excavation, removal of, or disturbance of subterranean materials.

illustrates a representation of an example boring situation, in accordance with certain embodiments.illustrates systemthat may be used for various boring scenarios. Systemmay include chassiswith drivetrainand non-contact boring element. Chassisand the elements thereof may be coupled to onsite facilityvia umbilical cord. Onsite facilitymay, in certain embodiments, be optionally communicatively coupled to offsite controllervia communications medium, which may be wired and/or wireless communications medium configured to provide and receive data, such as Internet, satellite communications, cable communications, and/or other types of communications techniques.

Chassismay be any type of chassis where elements of a boring system may be coupled to thereof (e.g., non-contact boring elementmay be coupled to chassis). Thus, chassismay, in certain embodiments, be a space frame, sled, and/or other such chassis. Drivetrainmay be coupled to chassisand may include a set of wheels or tracks driven by an electric, hydraulic, and/or pneumatic motor. Drivetrainmay be configured to move chassis, and the elements coupled thereof, downhole to position chassis.

Non-contact boring elementmay be coupled to chassisand may be configured to excavate portions of a geological formation through a non-contact technique, such as through the use of heat, mass flow, a combination of the two, and/or a similar non-contact technique. Non-contact boring elementmay include one or more of a cutterhead, a plasma torch, a jet engine exhaust, jet engine exhaust plus afterburner, a flame jet, a pneumatic drill, a water jet, a steam or gas jet, an abrasive material jet, a sonic wave generator, an electromagnetic or particle beam, and/or any similar non-contact technique.

Systemmay further include sensors (as described herein), a spoil evacuatorconfigured to draw or force waste (e.g., gas, spall, tailing, and/or other waste) from between the boring element(s) and bore face. Spoil evacuatormay be configured to remove such waste to a region out of boreholeand/or away from bore face. A filtration or collection elementmay, additionally or alternatively, be configured to collect spoil at bore face(e.g., debris or waste created by the excavation of boreholeor bore face). Removal of such waste or spoil may be via umbilical cord, which may be configured to receive such materials from spoil evacuatorand/or filtration or collection element. Filtration or collection elementmay collect spoil and filter out appropriate size spoil for analysis (e.g., mineralogy analysis at, for example, onsite facility. Spoil collected may include solid spoil as well as liquid and/or gaseous spoil (e.g., vapors).

In various embodiments, boreholemay be a tunnel, trench, or other feature created by system. Boreholemay, in various embodiments, be a lined or unlined borehole. In embodiments where boreholeis typically unlined, the sensors of systemmay generate a three-dimensional spatial and surface finish map of boreholevia data from sensors described herein. Such sensors may include, for example, one or more cameras, radar, lidar, and/or other such sensors. From such a map, one or more controllers of systemmay generate an image or model and determine whether boreholeis suitable for use without a liner or whether a liner is needed. For example, some types of geology may yield hard and smooth bored surfaces, for which an interior liner may not be necessary. Other types of geology may yield softer or more jagged bored surfaces, for which an interior liner may be desirable. Boreholemay include both types of example geologies, as well as other such geologies.

Umbilical cordmay be configured to allow for communication between onsite facilityand chassisand, thus, between onsite facility, as well as other facilities and controllers associated with boring, and the boring elements and/or other elements coupled to chassis. Such communications may include data communications (e.g., for communications of sensor data and/or for communications of instructions) as well as material communications (e.g., of waste from bore faceto the surface). Umbilical cordmay also be configured to provide electrical power, combustion material, and/or gas between chassisand onsite facility. Though the embodiment described herein may communicate data and/or signals via a physical connection through umbilical cord, it is appreciated that, in certain other embodiments, such data and/or signals may be communicated wirelessly.

Onsite facilityand/or offsite controllermay be configured to provide instructions for boring operations (e.g., to chassisand/or the boring elements thereof). In various embodiments, such instructions may be predetermined (e.g., based on recipes based on the geotechnical report for the jobsite), may be adjusted on the fly (e.g., based on differences in on-site conditions from expected conditions), and/or may be determined in response to sensor readings (e.g., via machine learning or through a global set of rules that provides instructions responsive to sensor readings).

Onsite facilitymay be located within the general geographical vicinity of the job site, while offsite controllermay be located offsite. In certain embodiments, onsite facilitymay include a controller and may communicate with offsite controllervia one or more data connections (e.g., Internet or other such connections). In various embodiments, one or both of onsite facilityand/or offsite controllermay not be present. In certain embodiments, chassismay include its own controller. Variously, the controller(s) may provide instructions such as instructions for operation of the boring elements, chassis, and/or other portions of system. The controllers described herein may include one or a mixture of computing devices (e.g., computers) that allow for the determination of data and/or instructions.

In certain embodiments, offsite controllermay, additionally or alternatively, include additional facilities. Thus, for example, such offsite facilities may be configured to receive spoil samples from boring and may be configured to perform analysis of such spoil. For example, the offsite facilities may include an x-ray diffraction (XRD) analyzer, a laser induced breakdown spectroscopy (LIBS) analyzer, a laser induced fluorescence (LIF) analyzer, a Raman spectrometer, a mass spectrometer, a scanning electron microscope, an energy-dispersive x-ray spectroscopy, and/or an x-ray fluorescence analyzer, and/or any similar analytical technique to perform analysis of the spoil or similar geological feature.

In certain embodiments, onsite facilitymay include various different auxiliary components of system. Thus, for example, onsite facilitymay include components such as support vehicles (e.g., vacuum truck, water truck, fuel truck), spoil handling facilities, and/or analysis labs (e.g., for analysis of spoil to determine mineral composition, according to the techniques described herein). In various embodiments, onsite facilitymay be located proximate to borehole, pit(as shown in), within pit, and/or within a distance away from the boring site.

The controllers may also be configured to receive data from various sensors of system. The controllers may utilize such data to determine conditions of borehole, such as conditions at bore face. For example, such data may allow for one or more controllers to generate a map (e.g., an optical map) of bore facebased upon an optical composition model determined from optical data from an optical sensor. The controllers may cause systemto adjust the operation of non-contact and/or contact boring elements currently in use (e.g., through adjustment of power output, stand-off distance, and/or other elements of non-contact boring elements and/or through adjustment of a boring speed of contact boring elements). The controllers may, additionally or alternatively, cause systemto transition between non-contact and contact boring elements, according to the techniques described herein, and may further control the targeting and/or aiming of non-contact boring elementand/or contact boring element, based upon the detected conditions.

The controllers may operate the boring elements during various phases of boring operations. Thus, one, some, or all of the controllers described herein may receive data, monitor sensors, measure parameters, determine states of the system, determine corrections, adapt to changes in the geology of the bore face, and/or transmit instructions and directions to one or more components (e.g., boring elements), subsystems, actuators, or sensors of systemin order to improve or optimize the performance of system(e.g., boring rate or energy consumption) in an autonomous or substantially autonomous manner.

Systemmay be operated in formations with varying geological conditions. For example, in the example of, systemmay be operated in a mixed geological environment that includes geological regionsA-F. Each such region may include different geological conditions, such as different types of rock, geological formations with varying hardness, abrasivity, intactness, soil types, different concentrations of ground water and/or void space, different geological types, and/or other such differences in conditions.

In certain embodiments, operation of systemmay be adjusted according to the techniques described herein.

In certain situations, bore facemay include a mix of geological regions, such as a mix of geological regionsA andB, as illustrated herein. The systems and techniques described herein allow for the optimization of boring operations in such mixed conditions. Additionally, systemmay bore through a plurality of different geological regions, such as geological regionsA,B,C,D, andE (though not geological regionF).

illustrates a representation of another example boring situation, in accordance with certain embodiments.illustrates systemthat may be another boring scenario. In, pitmay first be excavated (e.g., through conventional techniques). Thus, for example, pitmay be a shallow trench, a pit, a quarry, a shaft, and/or another such subterranean feature. For purposes of this disclosure, “pit” may be any type of subterranean feature that may allow for the housing of equipment and/or the launching of boring systems. Once pithas been excavated, tools for boring, such as onsite facilityA and various bore heads, may then be placed within pit. In certain embodiments, equipment, such as onsite facilityB, may also be placed on the surface. Systemmay be accordingly set up through the digging of a trench (a.k.a. a pit, for the placement of certain boring equipment, which may be distinct from “trenching” as a tunneling technique) at the start of the boreholeand systemmay then be placed within the trench (e.g., pit). Systems for operation of one or more boring elements (e.g., non-contact boring element) may then be accordingly coupled (e.g., fuel or air supplies may be coupled and provided via umbilical). Boreholemay then be bored with the various techniques described herein.

While illustrative reference is made herein to “borehole,” the systems and techniques described herein may be utilized within boreholes, in drilling techniques, in pipes (e.g., carrier pipes), and/or in any other such supported or unsupported subterranean environments, such as mass excavation operations, mining, etc. It is appreciated that, for the purposes of this disclosure, “borehole” is used as an all-encompassing term and may refer to any such supported or unsupported subterranean environment. Furthermore, such subterranean environments may include varying cross-sectional dimensions (e.g., varying hole diameters and/or varying non-circular shapes, such as D-shaped boreholes with a flat bottom). Thus, for example, for pipe environments, the pipe type and/or diameter may vary.

In, chassisA may include non-contact boring elementwhile chassisB may include contact boring element. In certain embodiments, a single chassis may house or support a single boring element. A non-contact or contact boring element may be selected and operated. Thus, in the example of, chassisA with non-contact boring elementA may be currently selected for boring operations (e.g., may be launched from pitand may bore through the geological formation and, thus, create borehole). In certain embodiments, a determination may be made during boring operations that another boring element may be better suited for conditions. While certain embodiments may include a plurality of switchable boring elements on a single chassis, the embodiment shown inmay switch boring elements by removing chassisA from boreholeand inserting a chassis with the more suitable boring element (e.g., contact boring elementof chassisB). The more suitable boring element may then be operated (e.g., by onsite facilityA/B and/or via umbilical, which it might be coupled to) until a further determination is made to switch boring elements.

Auxiliary systemsA andB may be present within systemof. Such auxiliary systems may include, for example, power generation, spoil removal, non-boring excavation, pipe positioning/pushing/jacking/laying/connecting/attaching/welding, dewatering, injection, communication, and other such systems. Auxiliary systemsA andB may be appropriate positioned either on the surface or within pitor borehole, as appropriate. In certain situations, one or more auxiliary systems may be centered around pitand/or borehole, to provide for quick support to boring activities.

illustrates a representation of a further example boring situation, in accordance with certain embodiments.illustrates systemwhere chassisA may be boring through boreholetowards pit. In various embodiments, chassisA may be communicatively coupled to onsite facilityA and/or onsite facilityB, disposed within pit. Thus, in certain such embodiments, chassisA may be boring towards onsite facilityB located within pit. In certain embodiments, one of onsite facilitiesA andB may be located elsewhere and/or may not be present.

Furthermore, in certain embodiments, onsite facilityB may include its own associated bore head (e.g., associated with chassisB) which may be, for example, boring from pittowards borehole. Such an operation may be a “meet in the middle” operation. In certain such operations, chassisA andB may approach each other and the final operations of completing the hole may be via a pipe welding/joining technique, such as from a pipe welding/joining robot.

In certain embodiments, the boring techniques described herein may include boring at an angle (e.g., at an angle different from horizontal). Thus, for the example of, one or both of the boring operations illustrated could be boring at an angle (e.g., between 0 to 90 degrees from horizontal). For boring operations that includes a change in depth, the change in depth may cause a change in pressure. Operation of systemmay be adjusted to adjust the mass flow needed to maintain positive conditions at the bore face(s). For example, in certain embodiments, the bore face may be maintained at approximately 1 atmosphere of pressure, with positive pressure flow out of the bore head and negative pressure at the evacuator of spoils, to minimize back pressure.

illustrates a representation of an excavation system, in accordance with certain embodiments.illustrates systemin operation. Systemdescribed inmay include chassisdisposed within borehole, as well as other components described in, but not shown in.

As described herein, boreholemay, in various embodiments, be an unlined borehole or include liner. Linermay be, for example, a metal, concrete, clay, composite, or other lining around at least a portion of borehole. Linermay, for example, protect bore payload, which may be disposed within liner. Bore payloadmay be, for example, a pipe, one or more wires, and/or another such item that is disposed within boreholethat may be the final product for the intended boring.

Chassisincludes various sensorsthat may be configured to sense certain parameters of boring and allow for adjustment of certain aspects of boring. For example, sensorsmay include radar, LIDAR, beacon emitter, theodolite, LED target system, optical, laser, and/or other sensors that are configured to generate data to allow a controller to generate a three-dimensional spatial map of the casing (e.g., the external pipe or liner which houses bore payload).

From such a map, one or more controllers of systemmay generate an image or model and determine whether boreholeis suitable for use without a liner or whether a liner is needed, whether lineris properly disposed within borehole(e.g., properly aligned), and/or whether bore payloadis properly disposed within boreholeand/or liner.

For example, some types of geology may yield hard and smooth bored surfaces, for which an interior liner may not be necessary. Other types of geology may yield softer or more jagged bored surfaces, for which an interior liner may be desirable. Boreholemay include both types of example geologies, as well as other such geologies.

In another example, the positions of linerand/or bore payloadmay be confirmed in three-dimensional space based on the spatial map generated. Such confirmation allows for the determination of whether boreholehas been properly bored (e.g., bored in accordance with engineering cutouts), and/or whether linerand/or bore payloadhas been properly positioned, allowing for detailed, accurate, and fast confirmation of quality of work. For example, the project specification documents may specifiy a particular profile and alignment for the casing pipe along a specific grade, as well as an alignment of the product pipe within the casing pipe as a function of spacers and filler materal. The three-dimensional spatial map may cross-reference the as-designed versus the as-built of the installation. The three-dimensional map may also provide data as to the relationship between bore payloadand liner(e.g., providing a three-dimensional CAD of the component used to maintain the distance between the linerand bore payload).

In a further embodiment, sensorsmay allow for the determination of geology, according to the techniques described herein. In the planning stages of a project, a geotechnical report is typically produced that describes the geological conditions the project is likely to meet. Sensorsmay allow for determination of geological conditions during excavation. The determined geological conditions may be cross-referenced with the geological report and, if there is a discrepancy, a user and/or customer may be informed and/or a change order may be prepare (and sent). For example, a jacking force of systemand the movement of shoring may be determined from sensorsto confirm that any limitations in systemperformance is due to geological discrepancies and, thus, would require a change order.

illustrates a side view of an example non-contact bore head, in accordance with certain embodiments.illustrates bore headA that includes chassis, non-contact boring positioning element, non-contact boring element, controller, spoil evacuator, filtration or collection element, and sensors. Bore headA may be a boring machine that may freely move within boreholes and may be easily removable for ease of maintenance, repair, tool swapping, method swapping, and/or other such maintenance activities.

In various embodiments, a reference numeral may apply to a plurality of similar elements (e.g., sensorsA-D), each denoted by different letters. Reference to just the number element itself may indicate that the description applies to elements that share the number reference.

Non-contact boring positioning elementof bore headA may be configured to locate non-contact boring elementrelative to chassis. That is, non-contact boring positioning elementmay advance and retract non-contact boring elementlongitudinally, laterally, and/or vertically relative to chassisas well as tilt non-contact boring elementin pitch and yaw on chassis(e.g., by up to +/−30° or another such angle).

In certain embodiments, non-contact boring elementmay be configured to provide boring through mass flow. Non-contact boring elementmay, for example, be a fully-contained cutterhead that includes a Brayton-cycle turbojet engine configured to compress fresh air from an above-ground air supply within a compressor of the engine and configured to mix this compressed air with fuel from an above-ground fuel source. This fuel-air mixture may be combusted to provide energy to drive the compressor and exhausted to provide high temperature and high mass flow rate exhaust gases toward a face of an underground bore (e.g., bore face). These high temperature and high mass flow rate exhaust gases may reach bore facewithin a jet impingement area, which may be an area of focus for non-contact boring. The exhaust gases may shock geologies at bore face, leading to spallation or other removal means of geologies and removal of rock spall from bore face.

Various sensorsmay be configured to sense certain parameters of boring and allow for adjustment of certain aspects of boring. Sensorsmay include, for example, a temperature sensor configured to output a signal representing the temperature of these exhaust gases. Controllermay be configured to receive such data signals and, in response, vary the fuel flow rate into the engine and/or adjust other boring parameters within the engine in order to maintain the temperature of these exhaust gases below the minimum melting temperature of all geologies present at the face (e.g., less than 1400° C. for certain geologies) or below the melting temperature of a particular geology detected at bore facein order to maintain a high volume of rock removal per unit time and per unit energy consumed by the system. Controllermay include, for example, a processor and a memory and may be configured to receive data (e.g., operating or sensor data) and provide data (e.g., instructions) to the various components of systemand/or bore headA via communications interfaces. Communications interfacesmay be, for example, any wired and/or wireless communications technique that allows for the communication of data between components.

Sensorsmay be, for example, a thermocouple, an air temperature sensor, a resistance temperature detector (RTD) sensor, a speed/torque sensor, a pressure transducer, a pressure sensor, an electrical output sensor, a flow rate sensor, a water pressure sensor, a water temperature sensor, a water electrical conductivity sensor, a spectropyrometer, a gas flow meter, a height sensor, a potentiometer, a clearance sensor, an accelerometer, a gyroscope, a tachometer or revolutions per minute (RPM) sensor, lidar, radar, a camera (e.g., a red-green-blue or RGB camera, hyperspectral camera, thermal camera, and/or another such camera), an acoustic sensor, a vibration sensor, a structured light sensor, and/or another such sensor. For certain embodiments, sensorA and/orB may be, for example, a camera, radar, lidar, and/or other such sensor and may be configured to determine stand-off distanceof non-contact boring mechanismfrom bore face. In another embodiment, sensorA and/orB may be configured to determine a power output of non-contact boring mechanism(e.g., to, for example, determine a temperature of exhaust and/or plasma outputted by non-contact boring mechanism). Stand-off distancemay be a distance of inches or feet and stand-off distancemay first be implemented as a nominal stand-off distance (e.g., 6 inches) and then adjusted during operation. Stand-off distanceand/or power output may, for example, affect how flame frontof non-contact boring mechanismmay perform during non-contact boring of bore face(e.g., may adjust the intensity and size of the jet impingement area of flame front). Other sensor types may allow for the determination of other aspects of operation.

Various sensorsmay also be configured to provide data for guiding movement of chassis. Such sensorsmay include, for example, LIDAR, radar, a laser, an accelerometer, a gyroscope, a wheel speed or wheel orientation (e.g., steering angle) sensor, and/or other such sensors. Such sensorsmay generate data that may allow for a determination of the positioning and/or movement of the chassis. In various embodiments, chassismay be configured to move automatically and may utilize data from such sensorsfor guiding such movement.

Stand-off distancemay be adjusted to control particle size distribution of spall resulting from non-contact boring. Particle size distribution of spall may be a function of stand-off distance, as well as other boring parameters described herein. Such other boring parameters may include, for example, the number and size of capillary tubes, the configuration of the flame holder of the afterburner, hole pattern of afterburner cooler, and/or air fuel mixture and may define the characteristic profile of the flame of the afterburner (e.g., in terms of temperature and/or mass flow). Adjustment of stand-off distanceand/or the other boring parameters may allow for tuning of the system in response to conditions at bore faceto optimize particle size distribution (e.g., for maximally efficient spoil evacuation).