The First Industrial Rocket Engine. Hammer for plastic deformation and Pile Driving Hammer

Engines are the artificial muscles of the civilization. Since the beginning of XIX century Industry has developed on the basis of 4 industrial engines: the steam, the electric, the internal combustion and the turbine engines. Furthermore, there are 2 another types of transport engines – rocket and explosion engines (the last one is the basis of all fire-arms). Our invention consists in the following: we used as a basis the transport engine and created the 5-th type of industrial engine – Industrial Rocket Engine (IRE), which is an alternative to implement Hydrogen technologies in the metal industry. This engine is created with the help of conventional machines but now only rockets fly on Hydrogen with no problem! The IRE can be used by the civil industry with big success. Fig. 1. The First Industrial

Rocket Engine (IRE)

Historically being the first engine, invented by humans, about 2000 years ago, it is still used only for transportation of explosives, equipment and people.

Rocket experts know that rocket engine has no competitors in 2 domains: 1. Flights in space, 2. Where and when one needs big effort for short time delivered by a small – sized engine.

Strangely enough for 2000 years nobody has noticed that the rocket engine could be also an industrial engine.

Use and application areas: Up to now we have developed 2 areas of application for the Industrial Rocket Engine

(IRE): 1. Industrial Rocket Engine for propelling of hammers for plastic deformation and

metalworking. 2. Industrial Rocket Engine for propelling of pile hammers. Technical data of Industrial Rocket Engine for propelling of hammers for

plastic deformation and metalworking. The majority of the metalworking machines use electricity to operate. This electricity

is transformed into motion of the parts of the machine using different type of rods, belts, gear-wheels, pistons and other gears (mediators). This is the fundamental reason for the low Energy-conversion efficiency (ECE) of the contemporary metalworking machines. The advantage of the IRE is that it can put in motion the machine parts without the above mentioned gears. The IRE is mounted directly on the working part and doesn’t need another gear (mediator). It can work in the atmosphere, out of the atmosphere, under water and in other type of mediums. It is a civil machine and it is safe to work with. As well it is safe to use it in a workshop. This is the only kind of rocket engine which doesn’t depend of the surrounding medium and doesn’t need a point of support to propel an impact! It can create a superior thrust, practically unlimited!

This is the only engine, which doesn’t depend on other working parts of the machine because he creates the energy and he transmits this energy to the working parts. Industrial forging and hammering machines perform short-time, big-effort impact / pressure. They also need to be safe, to withstand great dynamic load factors, etc.

Fig. 2. The First hammer propelled by Industrial Rocket Machine

We have sold all these problems using the new technology of the Industrial Rocket Engine (IRE), which has been designed, manufactured and tested to work for long period of time. It can propel a hammer and can endure the dynamic impact pressure!

Fig. 3. Scheme of feeding the IRE-2 with fuel and oxidant: 1 – compressor, 3 – oxidant (air) line, 5 - crane, 8 - receiver, 14 - safety relief valve, 16 – reductor, 17 – main electromagnetic valve, 19 – flexible hose for oxidant, 20 - rocket engine, 21- tube for air, 22, 28, 36 - electromagnetic valves, 24 –fuel dose, 25 – fuel (kerosene) line, 29 – filter, 30, 32 – throttles, 33 – fuel tank, 35 – pump, 38 – flexible hose for fuel.

Fig 4. Scheme of the rocket-powered hammer for plastic deformation:1. IRE (with liquid fuel), 2. Ram (impact body), 3. Upper stamp, 4. Guiding elements, 5. Bottom stamp, 6. Anvil, 7. Amortization pad, 8. Foundation

Use and application areas of IRE propelled hammers for plastic deformation and metalworking:

Compared with a conventional hammer the indisputable advantages of IRE propelled hammer are:

1. A forging/press machine with practically unlimited effort/thrust! 2. The absolutely unique in the world capability to perform the “Combined Impact”- a combination of hammering and pressing effort, in the moment of the impact the

potential inertia transforms itself into kinetic energy and jointly with the static force continue to perform pressing effort. Compared with a conventional machine the scope of the speed of the simple one is 6 – 9 m/s, high-speed 16-40 m/s. The IRE propelled hammer works within the full scope of deformation – 16-40 m/s and the working speed can be regulated using stepless control depending on the material and the technological requirements.

With the combined impact we can produce with one impact a differential conic gear wheel forged out of steel with weight 0,810 kg. Using the classic metalworking

machines we would need some different types of machines to produce the same detail.

Fig. 5. The first steel forged differential conic gear wheel with weight 0,810 kg.

3. Higher efficiency, Energy-conversion efficiency (ECE) is 20% higher.4. Simplified construction and decreased total mass – not less than 30%h.

Fig. 6. Working model of a horizontal Rocket Hammer without anvil with 2 free impact parts propelled by Rocket Engines with solid fuel. Forged aluminium preparations using

4 deformation shemes.

Technical data of Industrial Rocket Engine for propelling of pile hammers.

8000 years human kind is driving piles (pile is a postlike foundation, made of steel or concrete, which are driven into the ground to support and improve the stability of a structure) in the ground using free fall of a ram (passive). The proposed technology for the first time is using an active impact body moved by the IRE and the impact energy is a combination of the energy from the free fall using the gravitation + the energy from the rocket driving. It creates bigger power. We can make the conclusion that this is the first hammer for pile driving using an active ram! Another exceptional advantage of the new generation IRE propelling pile hammers is that when we use the IRE driving of the ram we can fix piles at various angles in the space (0° - 360° C).

This result can’t be achieved using the classical pile driving hammer for the reason that the gravitation direction of the impact body permits very small deviation of the angle of driving (0° - 75° C).

Economic aspect

The cost price for the implementation of 1 impact using the pile driving hammer is 50% lower than the price for the analogous impact using the classic hammer (more frequently diesel). The competition between the IRE pile driving hammer and the classical diesel hammer with angle in the scope of 75° – 360° is in favour of the first one by reason that the classical one doesn’t have the potential to fix piles at various angles in the space.

Speed of driving

The maximum speed of free fall impact body using classical diesel hammer is 7 m/s. With the IRE pile driving hammer the maximum speed is 12 m/s. We can see that the increase of the speed is 60%! And in addition the piles fixed with higher speed have bigger loading capacity!

Fig. 7. First Industrial Rocket

Engine for propelling of pile hammers

We have developed a module propelled by Industrial Rocket Engine, the system of the engine is working with fuel and oxidizer. With this module we can make modernization of a diesel hammer with mass 2250 kg.

Fig. 8. Scheme of the proposed modernization of diesel hammers (the same can be used for steam and hidraulic hammers)

1 - Guiding tube, 4 - Anvil, 8 - Pilot, 9 - Vent ports, 10 - Ram (Impact body), 12 - Rocket Engine 26 - Hoses for fuel and oxidizer

Fig. 9. Modernized tube diesel hammer

Use and application areas of the Pile Driving Hammer:

Implementation of the schemes for realization of the IRE-powered Pile Driving Hammer will enable to create new possibilities and to solve important global problems such as:

1. Consolidation of coasts and landslides; 2. Building and constructions in seismic areas; 3. Construction of bridges, highways, ports, quays, ocean petroleum and gas drilling

and producing platforms and other industrial buildings. 4. Construction of high buildings; 5. Fixing of drain pipes in landslides areas; 6. For exploitation in conditions with low-temperatures in the Arctic Circle, where the

diesel hammers are not capable to work; 7. Give the possibility to introduce new schemes using various angles of pile driving; 8. The innovation can perform the “Combined Impact”- a combination of hammering

and pressing effort, in the moment of the impact the potential inertia transforms itself into kinetic energy/force and jointly with the static force continues to perform pressing effort. Compared with a conventional machine the scope of the speed of the simple one is 6 – 9 m/s, high-speed 16-40 m/s. The IRE-propelled hammer works within the full scope of deformation – 16-40 m/s and the working speed can be regulated using a stepless control depending on the material and the technological requirements.

With its help, we can better cope with the rapid increase of climate-related disasters

worldwide, reclamation of the ocean floor and unique building projects on land.

Fig. 10. Various angles of fixing of the piles with a rocket-powered hammer

Table 1: Comparison between PDH (tube diesel pile hammer, ram of 1 250 kg or 2 756 lbs) and PDH+IRE

Angle

ParametersV E V E V E V E V E V E V E

m/s kgm m/s kgm m/s kgm m/s kgm m/s kgm m/s kgm m/s kgm

PDH 7,00 3120 6,50 2690 I M P R A C T I C A B L E

PDH+IRE 9,90 6360 9,61 6000 9,04 5310 8,60 4800 7,07 3240 5,76 2156 5,30 1825

1843 James Nasmyth, Scotland - GBPile driving steam hammer

1883 MENCK, Germany Pile driving with steam hammer

1923 DELMAG, GermanyDiesel pile driving hammer

1963 KRUPP, GermanyHydraulic pile driving hammer

2003 ROCKET HAMMER FOR PILE DRIVING

B+K, Bulgaria

We found the existence of the 40-years renovation cycle of the Pile Driving Hammer

Fig. 11 and 12. Assembly of Industrial Rocket Engine on a pile-driving hammer ram

Additional information:

The presented inventions will be of interest of metallurgical companies, building companies using technologies for strengthening and supporting in landslide and seismic areas.

Presentations of the inventions, prizes:

• 39 Salon International des Inventions de Geneve, 6>10 avril 2011, the invention “Industrial rocket engine” was awarded with Diplom and silver medal.

• 4-th place at The Wharton Business Competition, April 2002 – Pile driving and hammering using an industrial jet engine, ranked for the Grand Finales!

Academic publications:

• P. Bodurov, T. Penchev, Industrial rocket engine and its application for propelling of forging hammers, Journal of Materials Processing Technology 161(2005), 32, pp. 504-508.

• E. Schurenberg, (2002), It's Not Rocket Science. Or Is It?, BUSINESS 2.0, JULI 2002, p. 30.• Raketenantriebe für Schmiede-und Rammhämmer.(2009). UMFORM Technik, 2.2009, Juni, p. 34.• Wharton Business Plan Competition, (2002), 2001-2002

Patent protection:

The inventions are protected by the following patents for inventions: Bodurov P., et al., (1999), High Speed Hammer, BG Patent № 65 331/1999. Bodurov P., (2008). Device for pile anchoring, BG Patent № 65 331/2008. Bodurov P., (2011), Feeding rocket engine scheme with fuel and oxidant, BG Patent № 66 181/2011. Bodurov P., (2012). Rammgerät, DE Patent №10 2006 014 292/2013, (DE Patent for Pile driving hammer).

For further information, please contact:

Name: B+K Ltd., JET Technologies, 1504 Sofia, Oborishte Str. 1/A/17, Bulgaria E-mail: roumen.tomov@gmail.com, dmihaylov80@yahoo.de