Systems and methods for drilling while driving foundation components

Abstract

Automated systems and methods for drilling while driving foundation components are provided. In some cases, based on detected conditions, it may be desirable for an automated controller to change the bore diameter of a drill bit during a drilling and driving operation. The need for this may be determined based on monitoring the output of one or more sensors related to one or more corresponding performance metrics of the drilling and driving operation.

1 . An automated system for driving a foundation component with drill assist comprising:
 a rotary driver operable to travel along a machine mast and to impart rotational torque and downforce to the head of the foundation component to drive it into underlying ground;   a drilling tool positioned on the mast above the rotary driver and extending a drill rod through the rotary driver and the foundation component;   a drill bit attached to the end of the drill rod, the drilling tool operable to actuate the drill bit through the foundation component during driving; and   an automated controller controlling operation of the rotary driver and drilling tool, wherein the controller is programmed to cause the drilling tool to partially extend the drill bit out of an open lower end of the foundation component while it is being driven, to monitor at least one performance metric of either the rotary driver or drilling tool while actuating the drill rod through the rotary driver, and to cause the drilling tool, to extend the drill bit further out of the foundation component in response to a change in the at least one performance metric.   
     
     
         2 . The system according to  claim 1 , wherein the at least one performance metric is selected from the group consisting of hydraulic pressure supplied to the drilling tool, a rate of penetration of the foundation component, a torque at an output of the drill tooling, and a torque at an output of the rotary driver. 
     
     
         3 . An automated method of performing a drilling while driving operation to drive a foundation component into underlying ground, the method comprising:
 applying torque and downforce to a first end of the structural member to drive it into underlying ground with a rotary driver;   applying torque and downforce to a drill bit extending partially through the foundation component via a drill shaft connected to a drilling tool to enable a first cutting surface at a leading end of the drill bit to drill ahead of a leading end of the structural member, the first cutting surface having a first drilling diameter;   monitoring at least one performance metric of the operation with an automated controller; and   in response to a detected change in the at least one performance metric, causing the drilling tool to extend the drill bit further through the foundation component to enable a second cutting surface along a length of the drill bit to exit the foundation component, the second cutting surface having a second drilling diameter larger than the first drilling diameter.   
     
     
         4 . The method according to  claim 3 , wherein the at least one performance metric is selected from the group consisting of hydraulic pressure supplied to the drilling tool, a rate of penetration of the foundation component, torque at an output of the rotary driver, and torque at an output of the drilling tool.