Drop hammer systems and methods for driving elongate members into the earth

1 . A drop hammer pile driving system for driving a pile defining a pile upper end, the drop hammer pile driving system comprising:

a housing assembly comprising

a housing member defining a housing chamber, a pile opening, at least one plate slot, at least one first drive slot, and at least one second drive slot, where the at least one first drive slot and the at least one second drive slot define an engaging location relative to the housing assembly, and

a drop plate assembly, where

at least a portion of the drop plate assembly is arranged within the housing chamber, and

at least a portion of the drop plate assembly is arranged within the at least one plate slot to limit movement of the drop plate assembly relative to the housing member;

a hammer member arranged within the housing chamber for movement relative to the housing member and the drop plate assembly; and

a drive system comprising

a first drive wheel assembly comprising at least one first drive wheel and a first drive motor, where the at least one first drive wheel is arranged to extend into the at least one first drive slot, and

a second drive wheel assembly at least one second drive wheel and an actuator assembly, where the actuator assembly is arranged and configured to displace the at least one second drive wheel between

a first position in which the at least one second drive wheel does not extend through the at least one second drive slot, and

a second position in which in which at least a portion of the at least one second drive wheel extends through the at least one second drive slot into the housing chamber; wherein

with the pile upper end within the housing chamber, the drop plate assembly is arranged between the pile upper end and the hammer member; and

the engaging location is arranged relative to the drop plate assembly such that

when the pile upper end a first distance within the housing chamber and the drive wheel is in the second position, the pile upper end is below the engaging location, and

when the pile upper end a second distance within the housing chamber, the pile upper end is at the engaging location; and

when the pile upper end is at the engaging location and the drive wheel is in the second position, operation of the first drive motor rotates the first drive wheel such that the first and second drive wheels engage the hammer member such that the hammer member is lifted relative to the housing member.

2 . The drop hammer assembly as recited in claim 1 , in which the second drive wheel assembly further comprises a second drive motor, where operation of the second drive motor rotates the second drive wheel such that the first and second drive wheels engage the hammer member to lift the hammer member relative to the housing member.

3 . The drop hammer assembly as recited in claim 1 , in which the first drive wheel assembly further comprises a first axle member for supporting the first drive wheel for rotation relative to the housing assembly.

4 . The drop hammer assembly as recited in claim 2 , in which the second drive wheel assembly further comprises a second axle member for supporting the second drive wheel for rotation relative to the housing assembly.

5 . The drop hammer assembly as recited in claim 1 , in which the drop plate assembly comprises a drop plate defining:

an impact portion at least partly arranged within the housing chamber; and

at least one guide portion at least partly arranged within one of the at least one plate slots formed in the housing chamber.

6 . The drop hammer assembly as recited in claim 1 , in which the drop plate assembly comprises:

a drop plate; and

at least one hammer bumper configured to engage the hammer.

7 . The drop hammer assembly as recited in claim 1 , in which the drop plate assembly comprises:

a drop plate; and

at least one housing bumper configured to engage the housing.

8 . The drop hammer assembly as recited in claim 1 , in which the drop plate assembly comprises:

a drop plate;

at least one hammer bumper configured to engage the hammer; and

at least one housing bumper configured to engage the housing.

9 . A method of driving a pile defining a pile upper end, the method comprising the steps of:

providing a housing assembly comprising

a housing member defining a housing chamber, a pile opening, at least one plate slot, at least one first drive slot, and at least one second drive slot, where the at least one first drive slot and the at least one second drive slot define an engaging location relative to the housing assembly, and

a drop plate assembly, where

at least a portion of the drop plate assembly is arranged within the housing chamber, and

at least a portion of the drop plate assembly is arranged within the at least one plate slot to limit movement of the drop plate assembly relative to the housing member;

arranging a hammer member within the housing chamber for movement relative to the housing member and the drop plate assembly; and

providing a drive system comprising

a first drive wheel assembly comprising at least one first drive wheel and a first drive motor, where the at least one first drive wheel is arranged to extend into the at least one first drive slot, and

a second drive wheel assembly at least one second drive wheel and an actuator assembly, where the actuator assembly is arranged and configured to displace the at least one second drive wheel between

a first position in which the at least one second drive wheel does not extend through the at least one second drive slot, and

a second position in which in which at least a portion of the at least one second drive wheel extends through the at least one second drive slot into the housing chamber; wherein

with the pile upper end within the housing chamber, arranging the drop plate assembly between the pile upper end and the hammer member;

arranging the engaging location relative to the drop plate assembly such that

when the pile upper end a first distance within the housing chamber and the drive wheel is in the second position, the pile upper end is below the engaging location, and

when the pile upper end a second distance within the housing chamber, the pile upper end is at the engaging location; and

when the pile upper end is at the engaging location and the drive wheel is in the second position, operating of the first drive motor to rotate the first drive wheel such that the first and second drive wheels engage the hammer member such that the hammer member is lifted relative to the housing member.

10 . The method as recited in claim 9 , in which:

the step of providing the drive system further comprises the step of providing a second drive motor; and

the second drive motor is operated to rotate the second drive wheel such that the first and second drive wheels engage the hammer member to lift the hammer member relative to the housing member.

11 . The method as recited in claim 9 , in which the step of providing the drop plate assembly comprises the step of providing a drop plate defining:

an impact portion at least partly arranged within the housing chamber; and

at least one guide portion at least partly arranged within one of the at least one plate slots formed in the housing chamber.

12 . A drop hammer pile driving system for driving a pile defining a pile upper end, the drop hammer pile driving system comprising:

a housing assembly comprising

a housing member defining a housing chamber, a pile opening, at least one plate slot, at least one first drive slot, and at least one second drive slot, where the at least one first drive slot and the at least one second drive slot define an engaging location relative to the housing assembly, and

a drop plate assembly comprising a drop plate defining an impact portion and at least one guide portion, where

the impact portion of the drop plate assembly is arranged within the housing chamber, and

the at least one guide portion of the drop plate assembly is arranged within the at least one plate slot to limit movement of the drop plate assembly relative to the housing member;

a hammer member arranged within the housing chamber for movement relative to the housing member and the drop plate assembly; and

a drive system comprising

a first drive wheel assembly comprising at least one first drive wheel and a first drive motor, where the at least one first drive wheel is arranged to extend into the at least one first drive slot, and

a second drive wheel assembly at least one second drive wheel and an actuator assembly, where the actuator assembly is arranged and configured to displace the at least one second drive wheel between

a first position in which the at least one second drive wheel does not extend through the at least one second drive slot, and

a second position in which in which at least a portion of the at least one second drive wheel extends through the at least one second drive slot into the housing chamber; wherein

with the pile upper end within the housing chamber, the drop plate assembly is arranged between the pile upper end and the hammer member; and

the engaging location is arranged relative to the drop plate assembly such that

when the pile upper end a first distance within the housing chamber and the drive wheel is in the second position, the pile upper end is below the engaging location, and

when the pile upper end a second distance within the housing chamber, the pile upper end is at the engaging location; and

when the pile upper end is at the engaging location and the drive wheel is in the second position, operation of the first drive motor rotates the first drive wheel such that the first and second drive wheels engage the hammer member such that the hammer member is lifted relative to the housing member.

13 . The drop hammer pile driving system as recited in claim 12 , in which the second drive wheel assembly further comprises a second drive motor, where operation of the second drive motor rotates the second drive wheel such that the first and second drive wheels engage the hammer member to lift the hammer member relative to the housing member.

14 . The drop hammer pile driving system as recited in claim 12 , in which the first drive wheel assembly further comprises a first axle member for supporting the first drive wheel for rotation relative to the housing assembly.

15 . The drop hammer pile driving system as recited in claim 13 , in which the second drive wheel assembly further comprises a second axle member for supporting the second drive wheel for rotation relative to the housing assembly.

16 . The drop hammer pile driving system as recited in claim 12 , in which the drop plate assembly further comprises at least one hammer bumper configured to engage the hammer.

17 . The drop hammer pile driving system as recited in claim 12 , in which the drop plate assembly further comprises at least one housing bumper configured to engage the housing.

18 . The drop hammer pile driving system as recited in claim 12 , in which the drop plate assembly further comprises:

at least one hammer bumper configured to engage the hammer; and

at least one housing bumper configured to engage the housing.