US20200048030A1

US20200048030A1 - Coil whipline dispensing and recovery trailer

Info

Publication number: US20200048030A1
Application number: US16/533,606
Authority: US
Inventors: Rick D. Arzola; Christopher A. Brady
Original assignee: Santa Fe Springs Winwater Works Inc
Current assignee: Santa Fe Springs Winwater Works Inc
Priority date: 2018-08-07
Filing date: 2019-08-06
Publication date: 2020-02-13

Abstract

In one example, an apparatus is provided that includes a trailer, one or more rotatable reels mounted to the trailer and configured to hold a length of flexible pipe, a motor configured and arranged to rotate any of the reels, an assembly/disassembly station arranged to slide along the trailer to selectively align with one of the reels, and a line regulator configured to move in unison with the assembly/disassembly station so as to be selectively alignable with any of the reels.

Description

RELATED APPLICATIONS

This application hereby claims priority to U.S. Provisional patent application, Ser. 62/715,765, entitled COIL WHIPLINE DISPENSING AND RECOVERY TRAILER, filed Aug. 7, 2018. All of the aforementioned applications are incorporated herein in their respective entireties by this reference.

FIELD OF THE INVENTION

Embodiments of the present invention generally concern portable fluid dispensing systems. Some particular embodiments are directed to a trailer having one or more powered reels that carry, and are able to dispense and retract, one or more lengths of coiled pipe that are connected to one or more fluid dispensing elements such as sprinkler risers.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to describe the manner in which at least some aspects of this disclosure can be obtained, a more particular description will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only example embodiments of the invention and are not therefore to be considered to be limiting of its scope, embodiments of the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings.

FIG. 1 discloses an example embodiment of a coil whipline dispensing and recovery trailer.

FIG. 2 discloses aspects of the configuration and arrangement of an example hydraulic power unit.

FIG. 3 discloses aspects of an example trailer and reel assembly.

FIG. 4 discloses aspects of an example roller support assembly.

FIG. 5 discloses further aspects of an example roller support assembly.

FIG. 6 discloses aspects of a spring arrangement of an example roller support assembly.

FIG. 7 discloses an example roller configuration for a rear of a reel.

FIG. 8 discloses aspects of an example movable work station.

FIG. 9 discloses aspects of an example storage rack.

FIG. 10 discloses further aspects of an example storage rack.

FIG. 11 discloses aspects of an example arrangement of reels and bearing assemblies.

FIG. 12 discloses further aspects of an example arrangement of reels and bearing assemblies.

FIG. 13 discloses aspects of an example speedloader.

FIG. 14 discloses aspects of an example arrangement of reels and speedloaders.

FIG. 15 discloses aspects of a locking mechanism for a reel.

FIG. 16 discloses aspects of an example level-wind assembly.

FIG. 17 discloses further aspects of an example level-wind assembly, and shuttle.

FIG. 18 discloses aspects of an example shuttle and line regulator.

FIG. 19 discloses an example hydraulic control configuration.

FIGS. 20-24 disclose aspects of an example riser and sled assembly.

DETAILED DESCRIPTION OF SOME EXAMPLE EMBODIMENTS

Embodiments of the present invention generally concern portable systems for providing a fluid, such as freshwater for example, at one or more desired locations. One particular embodiment is directed to a portable irrigation system that can be deployed wherever needed.
In some example embodiments, a trailer is provided that is configured to be pulled by a motor vehicle and includes one or more reels that are mounted to the trailer and are each configured to dispense and retract one or more lengths of coiled flexible pipe of various sizes. The coiled flexible pipe may include, at intervals along its length, reinforced openings in the sidewall. The reels can be sized and configured to hold coils of any length, and two or more coils of different respective lengths can be disposed on a single reel. Rotation of the reels, whether to dispense or retract the coil(s), is effected by a motor, such as a hydraulic motor for example, that is connected to a drive shaft which, in turn, is coupled to one or more of the reels. The drive shaft and/or reels are configured so that one or more of the reels can be selectively coupled to, and uncoupled from, the drive shaft input. In this way, any of the reels may be rotated independently of the other reels, or any two or more reels may be rotated in unison with each other. In some embodiments, the reels are only powered during a coil retraction process and are not powered by the motor during coil deployment. Embodiments of the invention also provide a level wind mechanism to help ensure that the coils are evenly distributed on the reel during recovery.
In operation, a hose grip is temporarily attached to the free end of the coil so that a line attached to the hose grip can be used to unspool the coil from the reel. The free end of the coil may be capped. The line may be temporarily attached to a vehicle so that by simply driving away from the reel, the vehicle pulls the coiled pipe off the reel in the desired direction. A regulator or other device may be used to help ensure that the coiled pipe is not unspooled too quickly and/or to ensure that the coiled pipe is deployed without being twisted or otherwise distorted. As each reinforced opening portion comes off the reel, an installer can attach a sprinkler riser and a support base for the sprinkler riser to the reinforced opening portion. Each sprinkler riser is in fluid communication with the interior of the pipe so that when the entire coil length has been deployed, an area can be irrigated with the sprinkler risers by connecting a source of pressurized fluid to the deployed coil.
In general, the coil can be wound up in the reverse manner in which it was deployed. One exception is that the motor and drive shaft may be used to rotate the reel in a direction that causes the coil to be wound up on the reel. The system can include a control device, such as a control panel for example, operable by the person disassembling the coil, sprinkler riser, and base, so that person can stop and start the coil windup process when necessary. When the coil is deployed, the assembler communicates with the driver of the vehicle that is guiding the coil direction & layout from the reel so that the driver will start and stop the coil deployment when necessary to enable assembly of the sprinkler risers and bases to the coil.
Advantageously then, at least some embodiments of the invention provide for a portable irrigation system that can be quickly stored, loaded, transported, deployed, and wound up. For example, in some circumstances, a 3 man crew can dispense coil whiplines at a rate of about 3000 feet/hour, and can also recover coil whiplines at a rate of about 2000 feet/hour. As well, the coils can be dispensed and recovered with little or no twisting, candy striping, or other distortion.

A. Example Operating Environments

Embodiments of the invention may be particularly useful in irrigation applications but the scope of the invention is not limited to irrigation applications and environments. More generally, embodiments of the invention may be implemented in any environment where there is a need for a portable system to disperse a large volume of fluid, and/or to quickly deploy and retract one or more lengths of flexible materials, such as a fluid conduit. For example, other embodiments of the invention may be used for cleanup, wash-down operations, Dewatering, or in firefighting operations.

B. Aspects of an Example System and Components

Components of embodiments of the invention can be constructed from any of a variety of materials including metal, plastic, and rubber. Example metals include, but are not limited to, steel including stainless steels, aluminum, brass, copper, and alloys of any of the foregoing. Metal components can include, for example, the speedloaders and their components, reels and their components, the ramp, level wind mechanism and its components, structural supports, bearing supports, bearings, reel support assemblies, and roller support assemblies. Rollers disclosed herein can be made of metal, plastic such as polyurethanes, or rubber. Fluid conduit can be made of plastics, including HDPE. The foregoing materials are provided only by way of example and are not intended to limit the scope of the invention.
In general, a primary function of an example embodiment is to implement the deployment and recovery of a flexible fluid conduit. As used herein, ‘fluid’ includes any one or more, in any combination, of: solids; liquids; or gases including vapor. One example of a flexible fluid conduit is a high-density polyethylene (HDPE) fluid/water conveyance pipe, also referred to herein as a ‘whipline,’ which can have a wide range of nominal diameters, such as in a range of about 1″ to about 6.″ To this end, some embodiments of a Coil Deployment And Recovery Trailer (CDART) comprise a trailer with hydraulically controlled components capable of deploying, and retracting, water pipe at a relatively high rate. As well, the CDART system includes an irrigation riser sled, which may be referred to herein simply as a ‘sled,’ which attaches to the line so that, upon deployment of the line and sleds, a reliable, vertical, and consistent water dispersion is provided across the coverage area. Among other things, the CDART system allows for uniform, unkinked, and safe irrigation piping deployment and recovery by way of one or more irrigation reels, which may be referred to herein simply as ‘reels.’ An embodiment of the CDART system includes an integral storage system, which can include a storage rack connected to the trailer for example, for one or more irrigation riser sleds. Depending upon the embodiment, the CDART system can be safely and efficiently operated by a team of as few as three operators, with minimal startup and training assistance. In some example embodiments, the CDART system may only require a 60 psi source of water pressure to convey adequate flow rates through the deployed piping and irrigation riser sleds. Following is a brief discussion of some components of an example implementation of a CDART system.
One or more embodiments of a CDART system may include, but are not limited to, a hydraulic gear drive unit, reel speed loader system, hydraulic control unit, pipe constraint system, HDPE coil reel management, pipe hole location ID, Line Integrated Modulating Regulator for Irrigation Coils (LIMRIC), sled storage unit with riser dispensing system, onboard sled loading ramp, and control panel for the CDART system. Various other components may additionally, or alternatively, be included in one or more embodiments, and the foregoing is not intended to be an exhaustive or exclusive list of components that may be included in an embodiment. Following is a brief discussion of the function/operation of some of the aforementioned components of an example implementation of a CDART system.
A primary function of the hydraulic pump and gear drive is to provide a self-contained power to the drive shaft that will facilitate recovery of the HDPE fluid conduits, or whiplines, back onto the reels connected to the drive shaft. This may include a “creep mode” to allow a slower speed to be engaged, at the control panel, as a sled enters the work station platform prior to stopping the advancement of sled and coil. This functionality could also be utilized during the distribution, that is, deployment, of the coiled pipe as well.
Another function that can be implemented by the hydraulic pump and gear drive is the ability to control the rate of speed of the rotation of the reels during the unwinding and deployment of the whiplines when placing the lines in designated locations. This feature can help to prevent unraveling and free spinning, or freewheeling, of the coil and reel during whipline deployment.
Embodiments of a hydraulic pump can provide a variety of additional functions, such as to provide hydraulic power to the motor on the level wind self reversing screw assembly, which may be utilized to ensure the correct fleet angle of the pipe on the reels. The hydraulic pump and gear drive may also enable adjustments to the rate at which the level wind travels. This functionality is useful because the diameter of the reel effectively increases as more pipe is wound back onto the reel, and a relatively larger diameter of the reel corresponds to a relatively higher pickup rate of the pipe. Thus, the rotational speed of the reel may be reduced, possibly continuously or nearly so, while pipe is being wound back on the reel, to ensure that the pick up rate of the pipe remains relatively constant. Correspondingly, the rate of travel of the level wind may decrease as well with increased diameter of the reel. Some other example functions of the hydraulic pump may include raising and lowering the loading slide/work platform into place prior to coil deployment or recovery.
The coil reel management system and components can implement various functions. Such functions can include providing a sturdy and high torque system for the pipe as it is stored, deployed, and recovered.
Embodiments of a LIMRIC system generally serve to provide a Bending & Straightening mechanism operable for facilitating and controlling the pipe while it is deployed from, and recovered back into, the reel. The LIMRIC system also removes debris from the exterior of the piping as the piping is deployed and/or recovered. As well, the LIMRIC system includes a line check system that prevents the piping from unraveling once spooled on the reel. As a further example, the LIMRIC system oscillates the pipe, by way of the level wind mechanism, back and forth across the width of the reel to provide uniform dispensing of the lines from, and recovery to, the reel.
As noted herein, embodiments of the invention include one or more reel speed loader systems. In general, the speed loaders provide a simple, strong, and secure method of selectively engaging a specific operating reel to the center shaft while the balance of the reels are not engaged during hydraulic center shaft rotation.
A pipe constraint system may also be provided in some embodiments at least. Among other things, the pipe constraint system generally operates to maintain the pipe in a tight and unraveled manner on the reel during deployment and take-up.
As well, a pipe hole location ID can be provided in some embodiments. The pipe hole location ID serves to provide a mechanism of clear visual hole identification for the operators of the system, and can take the form of colored text, colored markings, and any other visible indicia that indicate to the operator where a sled and irrigation riser should be installed on a pipe.
Embodiments of the invention can include a sled storage unit with riser dispensing system that serves to provide efficient storage of sleds and irrigation risers in sufficient quantity equal to the coils loaded onboard. This unit thus helps to ensure that a fully loaded trailer can dispense piping in an efficient manner without interrupting operation in order to reload appurtenances.
Finally, embodiments of the invention can include a control panel for the entire system. This control panel serves to provide operating and speed adjustment controls for the hydraulic and LIMRIC systems. As well, the control panel allows an operator to control the operation from a convenient location with access to the loading and unloading platform. Finally, the control panel allows for safety control stops if required.
Further examples of system and operational features of example embodiments are disclosed in Appendix A hereto, entitled ‘CDART Coil Deployment & Recovery Trailer.’ Appendix A contains 3 parts and forms part of this disclosure and is incorporated herein in its entirety by this reference.

C. General Operational Aspects of an Example System

With the foregoing example embodiments in view, attention is directed now to some operation aspects of example embodiments disclosed herein. For ease of reference, an embodiment of the overall process may be referred to as the ‘CDART System Process’ although it should be noted that this name is not intended to limit the scope of the invention in any way. In one implementation of the process, the following equipment and personnel are employed: 1 ea CDART trailer (4 reel capacity); 1 ea CDART reel loading trailer (support); 1 ea CDART sled & riser assembly trailer (support); 1 ea side×side or coil pulling equipment (support); personnel: 1 ea—hydraulic control operator, 1 ea—riser assembly loader, 1 ea—side×side driver; radio equipment sufficient for reliable communication between above personnel; and, twb2 color coded map indicating the required coil lengths per whipline.
Following is a brief description of an example preparation process that can be used to prepare the CDART system for use. the process can include the following actions: 1—Irrigation Area line color map indicates the required coil length for each whipline; 2—CDART trailer is loaded with the prescribed color coded reel lengths required for the coverage area; 3—all are transported to desired tillage area; 4—CDART trailer is maneuvered onto a berm road adjacent to whipline layout area; 5—both support trailers are maneuvered close to CDART trailer; and 6—side×side vehicle is backed into place on playa.
Once the equipment and personnel have been thus positioned, the whiplines can be deployed. The whipline deployment process can be performed as follows: 1—hydraulic control operator dispenses the whipline reel sufficiently to allow for strap connection to side×side vehicle; 2—whipline reel is dispensed to the initial color identified sled/riser location and stopped; 3—sled assembly #5 and riser assembly #4 are installed onto pipe; 4—control operator and side×side driver coordinate (thru radio) dispensing of whipline to the next sled/riser location; 5—optional assembly #2 is installed between the assembly #1 lateral connection point & assembly #3; and, 6—after all whiplines are installed, the lateral lines, that is, deployed whiplines, are loaded & operational.
After the area of interest has been irrigated, the whiplines can be recovered. the whipline recovery process can be performed as follows: 1—whipline is disengaged from Assy #1; 2—pulling head is attached and pulled through the regulator to the reel via a strap; 3—hydraulically controlled recovery process winds the whipline coils uniformly and level onto each reel; 4—each whipline is controlled and stopped at each sled/riser location for disassembly; 5—sleds and risers are re-loaded onto the sled and riser assembly trailer; 6—fully loaded reels are relocated to the reel loading trailer; and, 7—CDART is relocated to a new area.

D. Aspects of an Example Overall System

With reference now to FIGS. 1-10, details are provided concerning the configuration of various example embodiments of the invention. Elements that are common to two or more figures may be labeled in only one, or less than all, of those figures.
As indicated in FIGS. 1-10, an example CDART system 1000 is disclosed that includes a trailer 1002 to which one or more reels 1004 are mounted. In some embodiments, the trailer 1002 may be about 40 feet long and configured to be towed by a pickup truck. A hydraulic power unit (HPU) 1006, which may include a motor such as a hydraulic motor for example, may be provided that is operable to rotate the reels 1004. The trailer 1002 may include a shelter 1008 or other enclosure to cover and protect the hydraulic power unit 1006. A gasoline, diesel, or propane, powered engine 1010 can be used to power the hydraulic power unit 1006, including a hydraulic pump that can connect to a hydraulic gearbox 1003 which, in turn, is connected to a drive shaft 1005 of the first reel 1004.
As shown, the reels 1004 have rim-and-spoke configuration, however, any other configuration could alternatively be used. The reels 1004 may be configured to hold any length of whipline coiled pipe 1012 (or, more broadly, flexible pipe) including, but not limited to, any lengths up to 1000 feet. Some reels 1004 may hold more than 1000 feet of flexible pipe 1012. In the example embodiment of FIGS. 1-9, four (4) reels 1004 are provided on the trailer 1002, but more, or fewer, reels 1004 can be employed in other embodiments. In various embodiments of the invention, the pipe 1012 is rigid, or non-collapsible, that is, the pipe 1012 retains its shape and form whether or not it is charged with fluid. While not required, some embodiments can employ a collapsible fluid conduit, such as collapsible hose for example, that collapses when it is not charge with fluid.
The size of the flexible pipe 1012 can vary from one reel 1004 to another, or the flexible pipe 1012 on the reels 1004 may be the same size on two or more reels 1004. The flexible pipe 1012 can be made of any suitable material, examples of which include plastic, rubber, fabric, and any combination of these. The flexible pipe 1012 can be of a reinforced type that includes wire, fabric, and/or any other suitable reinforcement materials, although reinforcement is not required. Various coil assemblies of flexible pipe 1012 can be constructed and employed. In at least some embodiments, a coil assembly of flexible pipe 1012 is about 1000 feet long and can be configured in various ways such as with 10 lengths that are each 100 feet long, 4 lengths that are each 250 feet long, or 2 lengths that are each 500 feet long. The scope of the invention is not limited to any particular coil assembly length, or to any particular lengths or numbers of the constituent portions that make up a coil assembly.
The reels 1004 may be supported by frames 1014 that are mounted to the trailer 1002. In some embodiments, the frames 1014 may comprise square or rectangular metal tube, but that is not required and the frames 1014 can be constructed of any other suitable elements. Construction metals for the frames 1014 include, for example, steel, and aluminum. The frames 1014 may include one or more reel support assemblies 1016 that contact, support, and guide, the outer rim of the reel 1004 so that the reel 1004 rotates smoothly and without wobbling or other undesired motion. In the example of FIGS. 1-9, a total of four (4) reel support assemblies 1016 are provided for each reel 1004. In the example of FIG. 5, the reel support assemblies 1016 can take the form of flanged casters mounted on 6″×2″ rectangular tube, although other configurations of reel support assemblies are possible.
As shown in FIGS. 1-10, for example, each reel 1004 may also include one or more roller support assemblies 1018 that contact and support the flexible pipe 1012 as it is deployed from, and recovered to, the reel 1004, and also to support the flexible pipe 1012 as the CDART system 1000 is in transit. A roller support assembly 1018, which may be spring loaded so as to bias a roller against the flexible pipe 1012, may be employed at the front, and/or rear, of each reel 1004.
With particular attention to FIGS. 6 and 7, the roller support assembly 1018 may comprise one or more springs 1020 connected to, and supported by, a linear track bearing 1022 that is movable along a track 1024. In some embodiments, the springs 1020 may include a hook or loop (not shown) at each end that slips onto a vertical pin (not shown) or other structure of the linear track bearing 1022.
In operation, as the effective diameter of the reel 1004 increases/decreases due to take up or deployment, respectively, of the coil whipline 1012, the springs 1020 accommodate this change in diameter of the reel 1004 by moving along the track 1024. That is, when the reel 1004 is empty, the springs 1020 may be in a substantially neutral, or substantially undeformed, state. As used herein, ‘substantially undeformed’ means less than or equal to about 5% deformation, that is, in the substantially undeformed state, the springs 1020 may be only about 5% longer than they would be in a completely undeformed state.
As the reel 1004 diameter increases, the springs 1020 deform, that is, stretch, in response. Particularly, the spring 1020 at the rear of the reel 1004 and the spring (omitted for clarity) at the front of the reel 1004 are stretched in opposite directions with respect to each other, with the rear spring 1020 being lengthened in a direction toward the back (as viewed from the perspective of FIG. 6) of the reel 1004 and the front spring being lengthened in an opposite direction toward the front of the reel 1004.
As the springs 1020 are stretched due to the increasing diameter of the reel 1004, the springs 1020 react by exerting a spring force (F=kX, where F is the spring force, k is a constant specific to the spring, and X is the distance that the spring has been lengthened relative to its undeformed state) that tends to bias the front and rear roller support assemblies 1018 toward each other. This spring force, or bias, thus tends to retain the roller support assemblies 1018 in contact with the flexible pipe 1012 on the reel 1004. Among other things, the bias exerted by the roller support assemblies 1018 can help to ensure that the flexible pipe 1012 is tightly wound on the reel 1004, to retain the flexible pipe 1012 on the reel 1004, and to help prevent the flexible pipe 1012 from whipping or other undesired movements during take up and deployment. Finally, when the flexible pipe 1012 is deployed, the springs 1020 of the roller support assemblies 1018 tend to become less deformed, moving toward, and eventually assuming, their respective undeformed configurations.
As best shown in FIG. 7, the roller support assemblies 1018 can include a set of rollers 1019 configured and arranged to contact the flexible pipe 1012 on the reel 1004. The rollers 1019, which are biased into contact with the flexible pipe 1012 by the springs 1020, can help to ensure that the flexible pipe 1012 is smoothly picked up and deployed. As well, the rollers 1019 can help to ensure that the flexible pipe 1012 remains flat to the reel 1004 and does not cross over itself. Finally, because the rollers 1019 are connected, at least indirectly, to the springs 1020, the rollers 1019 are able to move toward, and away from, the reel 1004, while maintaining contact with the flexible pipe 1012 that is disposed on the reel 1004.
With continued reference to FIGS. 1-10, the example CDART system 1000 may include an assembly/disassembly (A/D) station 1026 that may be used by an operator when the flexible pipe 1012 is being deployed, and when the flexible pipe 1012 is being recovered. Among other things, the A/D station 1026 may include a folding ramp/guide assembly 1028 that serves to guide and support the flexible pipe 1012 and associated components off of, and onto, the trailer 1002. As well, the folding ramp/guide assembly 1028 helps to keep the flexible pipe 1012 elevated off of rough surfaces, so as to reduce wear and tear on the flexible pipe 1012. The A/D station 1026 may be slidable along a track, linear bearing, or other structure on the trailer 1002 so that it can be selectively aligned with one of the reels 1012. Further details concerning an A/D station, such as the example A/D station 1026, and some related systems and components are disclosed elsewhere herein.
With particular reference to FIGS. 9 and 10, one or more embodiments of the CDART system 1000 may include a storage rack 1030 that can be permanently, or removably such as by way of pins for example, connected to the trailer 1002, such as at the rear of the trailer 1002. In some embodiments, the storage rack 1030 can hold one or more risers 1030 a and sleds 1030 b, discussed elsewhere herein, in a stacked or other configuration. The storage rack 1030, which can be made of angle steel and/or other materials, can include a lockable door.

E. Aspects of an Example Speedloader System

With reference now to FIGS. 11-15, details are provided concerning an example speedloader and associated drive shaft bearing assemblies. In FIGS. 11-15, an example speedloader is denoted generally at 1100, and example drive shaft bearing assemblies are denoted generally at 1150. In general, a pair of drive shaft bearing assemblies 1150 are provided for each reel 1004. Each drive shaft bearing assembly 1150 may be supported at one end by a bracket 1152 that is mounted to a corresponding frame 1154, and each drive shaft bearing assembly 1150 may receive a respective end of a drive shaft 1005 of the associated reel 1004.
In general, the drive shaft bearing assemblies 1152 are configured so that they are all coupled together to form a drive train and rotate in unison in response to an input from the motor 1006. As explained in further detail below, the reels 1004 can be individually coupled and uncoupled to the drive train so that operation of the motor causes only one reel 1004 to rotate at a time.
In more detail, each reel 1004 is associated with one or more speedloaders 1100 that are movable back and forth in an axial direction with respect to the reel 1004. As shown in FIG. 12 for example, the speedloader 1100 is in a position where the pins 1102 of the speedloader 1100 are disengaged from the spokes 1007 of the reel 1004. Thus, when the speedloader 1100 moves in an axial direction away from the reel 1004, the pins 1102 are disengaged from the spokes 1007, and rotation of the speedloader 1100 has no effect with respect to the reel 1004. That is, the reel 1004 is in an idle mode when the speedloader 1100 is disengaged from the spokes 1007, and an input from the motor 1006 does not rotate the reel 1004. In contrast, when the speedloader 1100 is moved axially toward the reel 1004, the pins 1102 of the speedloader 1100 engage with the spokes 1007 of the reel 1004, so that operation of the motor 1006 causes rotation of the reel 1004. The speedloaders 1100 can be selectively locked in the engaged, and disengaged, positions. Thus configured and arranged, rotation of the speedloader 1100 causes a corresponding rotation of the reel 1004 with which the speedloader 1100 is engaged.
As noted, the speedloader 1100 includes pins 1102 that are selectively engageable with the spokes 1007 of a reel 1004. In order to positively engage, and disengage, the pins 1102 so that the speedloader 1100 is not inadvertently disengaged from, or engaged with, the reel 1004, the speedloader 1100 can also include a locking mechanism. One embodiment of a locking mechanism involves the use of the speedloader plate 1104 and shaft coupling 1009 of the shaft 1005.
For example, to engaged the speedloader plate 1104 with the reel 1004, the speedloader plate 1104 is moved axially over the shaft coupling 1009 and locks into the coupling 1009 via a keyway 1105 in the shaft coupling 1009, and leverlock pin 1106. As shown in FIGS. 13 and 15 for example, the leverlock pins 1106, connected to the speedloader plate 1104, are positioned to be received in either of keyway 1105 (engaged) or 1107 (disengaged) of the shaft coupling 1009. To move the speedloader plate 1104, the leverlock pins 1106 can be retracted from keyway 1105 or 1107, as applicable, and the speedloader plate 1104 moved to the desired axial position, either engaged with the reel 1004 (keyway 1105) or disengaged from the reel 1004 (keyway 1107). In some embodiments, spring-loaded pins, that bias into a keyway, can be used in place of the leverlock pins 1106.

F. Aspects of an Example Level Wind Mechanism

Turning now to FIGS. 16-19, details are provided concerning a level wind assembly, one example of which is denoted generally at 1200. The level wind assembly 1200 includes a base 1202 configured to move back and forth along a track 1011 situated on the trailer 1002 so that the level wind assembly 1200 can be positioned at any of the reels 1004. Once positioned at a reel 1004, or anywhere else along the track 1011, the level wind assembly 1200 can be locked into position, such as with one or more leverlock mechanisms (not shown), to the track 1011. In at least some embodiments, the level wind assembly 1200 is configured to be pushed along the track 1011 manually, that is, by hand.
In general, the level wind assembly 1200 serves to move the pipe 1012 back and forth across the reel 1004 as the pipe is taken up, or deployed. The level wind assembly 1200 thus helps to ensure, among other things, that the pipe 1012 is properly stacked and distributed on the reel 1004 and does not pinch or bind other portions of the pipe 1012 as the pipe 1012 is retracted or deployed.
As indicated in the Figures, the level wind assembly 1200 includes a self-reversing screw 1204 that is rotatable by a hydraulic motor 1206. A shuttle 1208 is engaged with the self-reversing screw 1204, which passes through the body of the shuttle 1208, so that as the self-reversing screw 1204 is rotated by the hydraulic motor 1206, the shuttle 1208 moves back and forth along the self-reversing screw 1204. A guide rail 1210 may be provided to stabilize and guide the shuttle 1208 as the shuttle 1208 moves along the self-reversing screw 1204. Due to the configuration and operational nature of the self-reversing screw 1204 with which it is engaged, when the shuttle 1208 reaches one end of the self-reversing screw 1204, the shuttle 1208 automatically stops, if only momentarily, and then begins to travel the opposite direction to the other end of the self-reversing screw 1204.
With continued reference to FIGS. 16-19, a line regulator 1212 can be mounted to the shuttle 1208 so that the line regulator moves in unison with the shuttle 1208. In general, the line regulator 1212 helps to ensure that the flexible pipe 1012 does not become twisted or kinked as the flexible pipe 1012 is deployed and recovered. As well, the line regulator 1212 serves to guide the flexible pipe 1012 onto, and off of, the reel 1004, and also controls movement of the flexible pipe 1012 to avoid whipping or other undesired movement of the flexible pipe 1012 during these operations. The line regulator 1212 operates in tandem with the level wind assembly 1200 to ensure that the flexible pipe 1012 is distributed evenly across the width of the reel 1004, instead of stacking up on one side of the reel 1004, as the flexible pipe 1012 is recovered. The level wind assembly 1200 is operable at variable speeds to evenly distribute the flexible pipe 1012 as it is deployed from, and recovered to, the reel 1004.
In more detail, the line regulator 1212 may include various rollers 1214, which can have a concave configuration as shown, and/or other rotatable devices that serve to guide and support the flexible pipe 1012. In the example embodiment of FIGS. 16-18, the line regulator 1212 may include a hydraulic ram 1216 connected directly, or indirectly, to one or more of the rollers 1214. In some embodiments, the rollers 1214 may be made of ultra high molecular weight (UHMW) polyurethane, although other materials could alternatively be used. As the flexible pipe 1012 passes between two or more of the rollers 1212, the hydraulic ram 1216 can compress the flexible pipe 1012 by pushing the rollers 1214 together, thereby compressing the flexible pipe 1012. In this way, the hydraulic ram 1216 helps remove, and/or avoid, kinks and bends in the flexible pipe 1012 as the flexible pipe 1012 is taken up, or deployed. The hydraulic ram 1216 can additionally, or alternatively, be used to raise and lower the pipe 1012, within the line regulator 1212, relative to an inlet/outlet guide 1218 of the line regulator 1212. As also indicated in the Figures, the inlet/outlet guide 1218 includes a cleaning brush assembly 1220 that cleans the flexible pipe 1012 as it is retrieved/deployed, and is rotatable to accommodate upward/downward movement of the flexible pipe 1012 as the flexible pipe 1012 is deployed from, and recovered to, the reel 1004.

G. Aspects of an Example Control Panel

As indicated in the Figures, and with particular reference to FIG. 19, embodiments of the invention include a control panel 1300. The control panel 1300 can be mounted to the base 1202, or another structure connected to the base 1202, so as to move along the track 1011 in tandem with the level wind assembly 1200. In some embodiments, the base 1202 and track 1011 collectively take the form of a linear track bearing in which the base includes a linear bearing portion having a generally U-shaped configuration within which the track 1011 is received. In another embodiment, the track 1011 may comprise two C-shaped portions, with the open sides facing toward each other, that confine therebetween corresponding structure of the base 1202. Such configurations can avoid the need to use ball bearings, which may not be well suited for use in the environments in which embodiments of the invention may be employed.
In general, the control panel 1300 enables an operator to control, at the control panel 1300: the speed of rotation of each of the reels 1004; starting/stopping rotation of each of the reels 1004; starting/stopping rotation of the self-reversing screw 1204; the speed of rotation of the self-reversing screw 1204, and thus, the speed of the back and forth movement of the shuttle 1208 along the self-reversing screw 1204; starting/stopping operation of the hydraulic ram 1216; and, the extent of compression exerted by the hydraulic ram 1216.
As such, the control panel 1300 includes start/stop controls, speed controls, and speed indicators, which can take the form of lights, sounds, and/or other indicators perceptible by the senses of the operator, for each of the respective hydraulic motors that rotate the reels 1004, the self-reversing screw 1204, and the hydraulic ram 1216. The control panel 1300 can also include a master ON/OFF switch to activate or shut down the control panel 1300. As well, the control panel 1300 includes an electrical power quick connect/disconnect connection (not shown) which enables the control panel 1300 to be easily disconnected from an electrical power supply when being moved from one reel 1004 to another, and to be easily reconnected to the electrical power supply when positioned at a new reel 1004. The electrical power supplied to the control panel 1300 also enables the control panel 1300 to control the operation of the HPU 1006, as shown in FIG. 19. As shown in FIG. 19, and discussed elsewhere herein, the HPU 1006, in turn, can provide hydraulic fluid to a manifold 1006 a that includes hydraulic connections to a hydraulic gearbox 1003 connected with the reels 1004, the hydraulic ram 1216, and the hydraulic motor 1206 that powers the self-reversing screw 1204.
As noted above, an electrical quick disconnect coupling can be provided near each of the reels 1004 to enable quick connection and disconnection of the control panel 1300 to/from a power source. Further, hydraulic quick disconnect couplings can likewise be located near each of the reels 1004 to enable quick connection and disconnection of a source of hydraulic pressure to/from the hydraulic ram 1216, and the hydraulic motor 1206 that powers the self-reversing screw 1204. While not specifically indicated in the Figures, the electrical cabling, hydraulic lines, and respective electrical and hydraulic quick disconnect couplings can be located on the trailer 1002, such as along the underside of the trailer 1002.
As is apparent from the discussion, the control panel 1300 provides all the necessary controls and functionality to enable a single operator to control all aspects of the operation of the CDART system 1000. The portability of the control panel 1300 also enables it to be positioned near the reel 1004 in use, or expected to be used, so that the operator can readily observe the associated operations.

H. Aspects of an Example Riser and Sled Assembly

With attention to FIGS. 20-24, details are provided concerning a riser and sled assembly, one example of which is denoted generally at 1400. The sled 1410 may be configured to provide lateral stability to the riser assembly 1450 so that the riser assembly 1450 does not tilt or move out of position when pressurized with fluid. In general, the riser assembly 1450 can include any element that is operable to dispense a pressurized fluid. In at least some embodiments, the riser assembly 1450 comprises a rotary sprinkler head that, in operation, has a rotational range of motion in the range of about zero degrees to about 360 degrees. The riser assembly 1450 may be made of any suitable material(s), or combinations thereof, including metal, plastic, and rubber. Example metals used in the riser assembly 1450 include aluminum, copper and brass.
The sled 1410 may be made of any suitable material(s). In some embodiments, the sled 1410 is molded, such as by rotomolding or blow molding for example, from a plastic, such as cross-linked polyethylene (PEX/XPE/XLPE), although the scope of the invention is not so limited. The sled 1410 material may be UV-resistant so as to provide for longer life when the sled 1410 is exposed to sunlight. The sled 1410 may be any color. Depending upon the application, and the manufacturing method used, the sled 1410 may be solid or hollow. Where the sled 1410 is hollow, it can be filled with water, sand, or other ballast, to provide stability.
As shown, the sled 1410 may define a recess 1412 in its upper surface that is sized and configured to receive part, or all, of the circumference of a length of flexible pipe 1012. The fit between the recess 1412 and the flexible pipe 1012 may be loose, or can be an interference fit or snap fit. A plate and clamp assembly may be used to releasably secure the riser assembly 1450 to the sled 1410. Any other component(s) of comparable functionality could be used however. The plate and clamp assembly may include one or more threaded knobs 1416 or other devices that can be used to releasably secure the clamping plate 1414 and, thus, the riser assembly 1450, to the sled 1410. That is, the threaded knobs 1416 can each engage a corresponding threaded fastener 1418 passing through a bracket 1420 at the underside of the sled 1410.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

Claims

What is claimed is:

1. An apparatus, comprising:

a trailer;

one or more rotatable reels mounted at least indirectly to the trailer and configured to hold a length of flexible pipe;

a motor operable and arranged to rotate any of the reels;

an assembly/disassembly station arranged to move along the trailer to selectively align with any of the reels; and

a line regulator operable to move in unison with the assembly/disassembly station so as to be selectively alignable with any of the reels.

2. The apparatus as recited in claim 1, wherein the line regulator comprises:

a level wind mechanism with a self-reversing screw; and

a shuttle engaged with the self-reversing screw and movable along the self-reversing screw in response to rotation of the self-reversing screw.

3. The apparatus as recited in claim 1, further comprising a track mounted to the trailer, and the line regulator is movable along the track.

4. The apparatus as recited in claim 1, wherein the line regulator comprises a pair of rollers, and one of the rollers is movable relative to the other of the rollers so that the size of a gap between the rollers is variable.

5. The apparatus as recited in claim 1, further comprising:

a hydraulic motor coupled to the line regulator; and

a hydraulic control panel connected to the hydraulic motor, and the hydraulic motor and hydraulic panel are movable along the trailer in unison with the line regulator.

6. The apparatus as recited in claim 1, further comprising one or more speedloader plates, each of which is configured to selectively engage a respective reel so that the respective reel can be switched between an idle state where input from the motor does not cause the reel to rotate, and an engaged state where input from the motor causes the reel to rotate.

7. The apparatus as recited in claim 6, further comprising a shaft connected to the motor and extending through the center of each reel, and the speedloader plates are mounted to the shaft.

8. The apparatus as recited in claim 7, wherein each speedloader plate is movable axially along the shaft independent of the other speedloader plates.

9. The apparatus as recited in claim 6, wherein one of the speedloader plates includes a plurality of pins configured and arranged so that, in the engaged state of the speedloader plate, each pin is interposed between two spokes of the engaged reel.

10. The apparatus as recited in claim 6, wherein in the disengaged state of the speedloader plate, the shaft is free to rotate relative to the reel associated with that speedloader plate.

11. An apparatus, comprising:

a wheeled trailer connectible to a motor vehicle;

a track disposed lengthwise along the trailer;

a shaft disposed lengthwise with respect to the trailer;

one or more reels mounted to the shaft;

a motor connected to the shaft and operable to rotate the shaft;

a speedloader plate mounted to the shaft and configured for selective engagement with one of the reels;

an assembly/disassembly station arranged to move along the track to selectively align with any of the reels; and

a line regulator operable to move along the track so as to be selectively alignable with any of the reels.

12. The apparatus as recited in claim 11, wherein the line regulator comprises:

a level wind mechanism with a self-reversing screw; and

13. The apparatus as recited in claim 12, further comprising:

a hydraulic motor coupled to the line regulator and operable to rotate the self-reversing screw; and

14. The apparatus as recited in claim 11, wherein the speedloader plate is configured and arranged for axial movement along the shaft.

15. The apparatus as recited in claim 11, wherein the apparatus comprises a respective pair of speedloader plates selectively engageable with each reel.

16. The apparatus as recited in claim 11, wherein the line regulator comprises a pair of rollers and a hydraulic ram configured and arranged to act on one or both of the rollers to vary the size of a gap between the rollers.

17. The apparatus as recited in claim 11, wherein the speedloader plate is configured to selectively engage a reel so that the reel can be switched between an idle state where input from the motor does not cause the reel to rotate, and an engaged state where input from the motor causes the reel to rotate.

18. The apparatus as recited in claim 17, wherein the speedloader plate includes a plurality of pins configured and arranged so that, in the engaged state of the speedloader plate, each pin is interposed between two spokes of the engaged reel.

19. The apparatus as recited in claim 17, wherein in the disengaged state of the speedloader plate, the shaft is free to rotate relative to the reel associated with that speedloader plate.

20. The apparatus as recited in claim 11, wherein the speedloader plate is configured to be selectively locked to the shaft so as to rotate in unison with the shaft.