BULK RESIN INJECTION SYSTEM

Abstract

The present disclosure is directed to a resin injection system for a mining operation that includes a first tank configured to hold a first viscous fluid, a second tank configured to hold a second viscous fluid, a wand in communication with the first tank and the second tank, a first pump configured to drive the first viscous fluid from the first tank to the wand, and a second pump configured to drive the second viscous fluid from the second tank to the wand. The wand is configured to extend or retract from an initial position and to inject the first viscous fluid and the second viscous fluid into a hole. The first pump and the second pump are configured to operate independently.

Description

TECHNICAL FIELD

The present application relates to mining operations, and particularly a resin injection system for a bolter drill.

In conventional mining operations, resin and catalyst are contained in a cartridge. This cartridge is blasted with air into a drill hole. A bolt is then inserted and rotated to break the cartridge and allow the resin and catalyst to mix and cure around the bolt. These cartridges are prone to rupturing while traveling into the hole causing blockages. Additionally, this process can be time consuming.

SUMMARY

In one independent aspect, a resin injection system includes a first tank configured to hold a first viscous fluid, a second tank configured to hold a second viscous fluid, a wand in communication with the first tank and the second tank, a first pump configured to drive the first viscous fluid from the first tank to the wand, and a second pump configured to drive the second viscous fluid from the second tank to the wand. The wand is configured to extend or retract from an initial position and to inject the first viscous fluid and the second viscous fluid into a hole. The first pump and the second pump are configured to operate independently.

In another independent aspect, a bolting device includes a frame including a boom, a bolting attachment including a wand coupled to the boom, and a pump system in communication with the wand and configured to pump resin and catalyst thereto. The wand is configured to extend or retract with respect to an initial position. The pumping of resin and the pumping of catalyst by the pump system are performed independently.

In yet another independent aspect, a resin injection system includes a pressurized resin tank configured to hold a supply of resin and a pressurized catalyst tank configured to hold a supply of catalyst. The pressurized resin tank is in communication with a first continuous pump coupled to a first hydraulic cylinder, and the pressurized catalyst tank is in communication with a second continuous pump coupled to a second hydraulic cylinder. The resin injection system further includes a hydraulic source configured to supply a flow to the first hydraulic cylinder and the second hydraulic cylinder, a flow divider positioned between the hydraulic source and the first and second hydraulic cylinders, a wand in communication with the pressurized resin tank and the pressurized catalyst tank, a control panel configured to enable an operator to input one or more parameters associated with a particular application or operation, and a processor configured to receive the information input by the operator. The flow divider is configured to distribute the flow generated by the hydraulic source between the first and second hydraulic cylinders. The first and second pumps operate independently with respect to one another. The processor is configured to determine a desired ratio between resin and catalyst, a desired rate of retraction of the wand during an injection operation, or both. The ratio between resin injected via the wand and catalyst injected via the wand can be adjusted by altering a configuration of the flow divider.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an embodiment of a bulk resin injection system constructed according to the principles of the present disclosure installed on a frame for a bolter.

FIG. 2 is a perspective view of the bulk resin injection system of FIG. 1, with the frame removed.

FIG. 3 is a perspective view of a pump system of the bulk resin injection system of FIG. 1.

FIG. 4 is another perspective view of the pump system of FIG. 3.

FIG. 5 is an enlarged perspective view of a portion of the pump system of FIG. 3.

FIG. 6 is a section view of tanks and pumps of the pump system of FIG. 3.

FIG. 7 is a perspective view of a catalyst tank of the pump system of FIG. 3.

FIG. 8 is a schematic view of an embodiment of a bulk resin injection system constructed according to the principles of the present disclosure.

DETAILED DESCRIPTION

Before any embodiments are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of the configuration and arrangement of components set forth in the following description or illustrated in the accompanying drawings. The disclosure is capable of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof are meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings.

FIG. 1 illustrates a frame 4 of a bolter including a bulk resin injection system. In the illustrated embodiment, a pump system 2 is supported on the frame 4 adjacent a rear portion thereof. The frame further includes a boom 16 supporting a drilling and bolting attachment 8. In the illustrated embodiment, the bolting attachment 8 includes a drill and an injection member (e.g., a wand 6) in fluid communication with the pump system 2.

FIG. 2 illustrates the bulk resin injection system with the frame 4 wand 6, and bolting attachment 8 hidden. The bulk resin injection system may include one or more external conduits. For example, in the illustrated embodiment, the bulk resin injection system may include an external catalyst conduit 82 and an external resin conduit 86. The external catalyst conduit 82 and the external resin conduit 86 may each include one end that is coupled to the pump system 2, and another end coupled to a first external conduit fitting 146 or a second external conduit fitting 148. The first and second external conduit fittings 146, 148 may be designed to facilitate a connection between the external catalyst and resin conduits 82, 86 and the wand 6 (FIG. 1). For example, the first and second external conduit fittings 146, 148 may facilitate fluid communication between the pump system 2 and the wand 6 when the first and second external conduit fittings 146, 148 are connected to the wand 6.

The pump system 2 drives resin and catalyst from tanks supported on the frame 4 through the external catalyst and resin conduits 82, 86, through the first and second external conduit fittings 146, 148, and through the wand 6 in an unmixed state. The pump system 2 may be configured to pump fluid through the external catalyst conduit 82 and through the external resin conduit 86 independently. For example, the pump system 2 may simultaneously pump a first fluid (e.g., a catalyst) through the external catalyst conduit 82 at a first rate and a second fluid (e.g., a resin) through the external resin conduit 86 at a second rate that is either less than or greater than the first rate. The resin and catalyst are dispensed through a nozzle or opening at a distal end of the wand 6. Upon leaving the wand 6, the resin and catalyst are allowed to contact one another such that a curing process is initiated. The resin and the catalyst may be prevented from contacting one another while traveling through the wand 6.

In some embodiments, a control interface such as an injection control panel 142 can be positioned in an operator cab 12 (FIG. 1) and/or at another location where it can be operated by a user. The injection control panel 142 may include a touch screen or other display, and/or other actuators (e.g., buttons and switches). The injection control panel 142 may communicate with an electronic processor (not shown). A computer-readable storage media may be coupled to the processor and have instructions stored thereon which, when executed by the processor, cause the processor to perform operations. In the illustrated embodiment, the injection control panel 142 may be capable of controlling the feed (e.g., the extension and retraction) of the wand 6 into a hole, starting and stopping an injection operation of the pump system 2, and/or performing or controlling other functions and operations related to the bulk resin injection system or to the pump system 2.

As shown in FIGS. 3-7, the pump system 2 may include a catalyst tank 10 and a resin tank 14. The catalyst tank 10 and the resin tank 14 can be the same size or different sizes. As best shown in FIG. 4, the catalyst tank 10 may be in communication with a catalyst pump 26, and the resin tank 14 may be in communication with a resin pump 30 (FIG. 4) such that the catalyst pump 26 and the resin pump 30 are configured to draw fluid from the catalyst tank 10 and the resin tank 14, respectively. For example, the catalyst pump 26 may draw catalyst from the catalyst tank 10 via a catalyst input port 18, and the resin pump 30 may draw resin from the resin tank 14 via a resin input port 22. The catalyst pump 26 and the resin pump 30 may be independently operated by two hydraulic cylinders (e.g., a first hydraulic cylinder 50 connected to the catalyst pump 26 and a second hydraulic cylinder 54 connected to the resin pump 30).

In the illustrated embodiment, the catalyst tank 10 and the resin tank 14 are pressurized by an air source (e.g., a compressor—not shown) via a pressure regulator 96, air tubes 88, a catalyst air fitting 102, and a resin air fitting 106. Pressurizing the catalyst tank 10 and the resin tank 14 helps move resin and catalyst into the catalyst pump 26 and the resin pump 30, respectively. Additionally, pressurizing the catalyst tank 10 and the resin tank 14 may allow the system to pump viscous fluid like resin and catalyst more efficiently. Each of the catalyst air fitting 102 and the resin air fitting 106 may include an air safety relief valve, and an air pressure sensor to detect the air pressure in the resin tank 14 and catalyst tank 10.

The catalyst pump 26 and the resin pump 30 are each configured to pump a high viscosity liquid, such as resin or catalyst, during both an up-stroke and a down-stroke of the pump. The catalyst pump 26 and the resin pump 30 may each be provided in the form of a continuous pump. As best shown in FIG. 4, in the illustrated embodiment, the catalyst pump 26 is driven or operated by the first hydraulic cylinder 50 and the resin pump 30 is driven or operated by the second hydraulic cylinder 54. For example, the first hydraulic cylinder 50 may engage the catalyst pump 26 via a first connecting rod 140, and the second hydraulic cylinder 54 may engage the resin pump 30 via a second connecting rod 144.

In some embodiments, the catalyst pump 26 and the resin pump 30 may be driven independently of one another. As shown best in FIGS. 3 and 5, the first and second hydraulic cylinders 50, 54 may be in communication with a main hydraulic system (not pictured) via a hydraulic input hose 90 and a hydraulic return hose 94. As best shown in FIG. 5, a flow divider 118 controls a flow from the main hydraulic system to the first and second hydraulic cylinders 50, 54 such that a first portion of the flow is directed to the first hydraulic cylinder 50 and a second portion of the flow is directed to the second hydraulic cylinder 54. Depending upon a setting or configuration of the flow divider 118, the first portion may be less than, equal to, or greater than the second portion in terms of volume. The amount of the flow from the hydraulic source that is directed to the first hydraulic cylinder 50 may be proportional to the volume of fluid pumped from the catalyst tank 10 to the wand 6, and the amount of flow from the hydraulic source that is directed to the second hydraulic cylinder 54 may be proportional to the volume of fluid pumped from the resin tank 14 to the wand 6.

Thus, the flow divider 118 allows an operator to change a resin-to-catalyst mixture ratio that is delivered to the wand 6. In some embodiments, the flow divider 118 may be configured to receive two or more interchangeable cartridges 122, each of which corresponds to a particular resin-to-catalyst mixture ratio (e.g., a particular distribution of the flow from the hydraulic source between the first and second hydraulic cylinders 50, 54). For example, an operator may adjust the flow divider 118, thereby changing the resin-to-catalyst mixture ratio provided by the flow divider 118, by replacing a first cartridge 122 with a second cartridge 122 corresponding to a different ratio than the first cartridge 122. In some embodiments, the resin-to-catalyst mixture ratio may be 1:1, 1.5:1, or 2:1. For example, the a first cartridge 122 may correspond to a resin-to-catalyst mixture ratio of 1:1, a second cartridge 122 may correspond to a resin-to-catalyst mixture ratio of 1.5:1, a second cartridge 122 may correspond to a resin-to-catalyst mixture ratio of 2:1, and the first, second, and third cartridges 122 may be interchangeably installable on or couplable to the flow divider 118. In some embodiments, other ratios may be selected and the flow divider 118 may be adjusted in any manner.

As shown best in FIG. 4, catalyst is driven by the catalyst pump 26 into an internal catalyst conduit 58, and resin is driven by the resin pump 30 into an internal resin conduit 62. The internal catalyst conduit 58 may be connected to and in communication with the catalyst tank 10 via a first external conduit fitting 34, and the internal resin conduit 62 may be connected to and in communication with the resin tank 14 via a second external conduit fitting 38. In some embodiments, a first ball valve assembly 42 and a second ball valve assembly 46 may engage or may be operably connected to the internal catalyst conduit 58 and the internal resin conduit 62, respectively. For example, the ball valve assemblies 42, 46 may be operated to close a flow path, thereby preventing or restricting resin and/or catalyst from leaving the internal catalyst conduit 58 and the internal resin conduit 62.

The internal catalyst conduit 58 may be in communication with the external catalyst conduit 82, and the ball valve assembly 42 may be positioned between the internal catalyst conduit 58 and the external catalyst conduit 82. The internal resin conduit 62 may be in communication with the external resin conduit 86, and the ball valve assembly 46 may be positioned between the internal resin conduit 62 and the external resin conduit 86. Thus, if the ball valve assemblies 42, 46 are in an open position, resin may be permitted to flow through the internal resin conduit 62 and the external resin conduit 86 (e.g., to the wand 6), and catalyst may be permitted to flow through the internal catalyst conduit 58 and the external catalyst conduit 82 (e.g., to the wand 6).

In some embodiments, when the volume of resin in the resin tank 14 and/or the volume of catalyst in the catalyst tank 10 is below a predetermined level, the catalyst tank 10 and the resin tank 14 may be replenished using a catalyst fill connector 74 and/or a resin fill connector 78 (FIG. 3). For example, an external source of catalyst may be placed in fluid communication with the catalyst tank 10 via the catalyst fill connector 74, and an external source of resin may be placed in fluid communication with the resin tank 14 via the resin fill connector 78.

As best shown in FIG. 4, the pump system 2 may include a pump system control panel 66 designed to provide a user interface whereby a user can input information and/or control one or more aspects of the injection process. The pump system control panel may include an electronic processor (not shown) and a control screen 70 (e.g., a touch screen and/or other operator inputs such as buttons or switches). The processor may be in communication (e.g., electrical communication) with one or more components of the bulk resin injection system (or with one or more sensors positioned within the bulk resin injection system), and the control screen 70 may be configured to display information to an operator or to receive inputs from the operator. In response to receiving an input from an operator, the processor can determine the parameters for the bolt installation process. For example, the processor may calculate a total volume of resin and a total volume of catalyst necessary for an operation and a retraction rate of the wand 6 as the resin-catalyst mixture is dispensed into a hole. In some embodiments, an operator can enter a variety of operation parameters manually, and other parameters or other relevant information may be stored on a storage media or memory component of the processor.

In some embodiments, the processor may be configured to evaluate various parameters and make one or more determination based on the parameters (e.g., determining an optimal or appropriate retraction speed of the wand 6 during an injection operation). The parameters that may be evaluated by the processor include but are not limited to: catalyst temperature (e.g., a temperature within the catalyst tank 10), resin temperature (e.g., a temperature within the resin tank 14), a setting time associated with a particular resin-catalyst combination, pump pressure supplied by the catalyst pump 26 or the resin pump 30, hole diameter, hole length, bolt diameter, bolt length, ground conditions, rock temperature, ambient temperature, geological characteristics such as porosity and wetness, resin-to-catalyst mixture ratio, over-drill length, over-drill diameter, equipment condition, and the like. Information regarding the above-listed parameters and/or other relevant parameters may be manually input by an operator or may be stored on a storage media or memory component of the processor. Information regarding several parameters, whether input by the operator or stored locally by the processor, may be integrated, synthesized, and/or otherwise evaluated by the processor to make an informed determination regarding, for example, the appropriate retraction rate of the wand 6.

The operator may also use the pump system control panel 66 to initiate a priming operation, initiate tank replenishment or maintenance operations, initiate diagnostic operations, operate the ball valve assemblies 42, 46, manually pump resin and/or catalyst, or perform or initiate other actions and operations. In some embodiments, the control screen 70 may continuously or periodically monitor and display one or more parameters with respect to the catalyst tank 10 and/or the resin tank 14, such as fluid levels, air pressure, and the like.

As shown in FIG. 7, the catalyst tank 10 may have a viewing window 126, for example, to allow an operator to observe a level or volume of catalyst within the catalyst tank 10. In some embodiments, the catalyst tank 10 may include an ultrasonic sensor 130, a laser level sensor 134, a temperature sensor 138, and/or other sensors positioned on or integrated into the catalyst tank 10 and configured to monitor one or more conditions of the catalyst tank 10. The ultrasonic sensor 130, laser level sensor 134, and temperature sensor 138 may be in electrical communication with the processor (e.g., configured to transmit signals thereto). The temperature sensor 138 can provide a signal to the processor indicative of a temperature of the fluid within the catalyst tank 10. The ultrasonic sensor 130 and laser level sensor 134 can provide a signal to the processor indicative of a volume of fluid remaining in the catalyst tank 10, which can be used to ensure there is enough catalyst for an operation or to indicate that the catalyst tank 10 should be replenished. In some embodiments, the signals provided by the ultrasonic sensor 130, laser level sensor 134, and/or temperature sensor 138 may be displayed or communicated to an operator (e.g., via the control screen 70 of the pump system control panel 66). The resin tank 14 may be equipped with the same or similar features as the catalyst tank 10 (e.g., the resin tank 14 may also include an ultrasonic sensor 130, laser level sensor 134, a temperature sensor 138, and/or other sensors configured to monitor one or more conditions of the resin tank 14).

The data provided by the ultrasonic sensor 130, laser level sensor 134, and temperature sensor 138 may also inform determinations regarding, for example, the appropriate retraction rate of the wand 6. For example, the processor may evaluate signals or information regarding the catalyst tank 10 and/or the resin tank 14 received from one or more ultrasonic sensors 130, laser level sensors 134, and temperature sensors 138 in conjunction with the parameters input by the operator and/or other parameters or information stored locally by the processor.

Turning to FIG. 8, the pump system 2 is actuated by the first hydraulic cylinders 50 and the second hydraulic cylinder 54. The first and second hydraulic cylinders 50, 54 are each connected to (e.g., in communication with) a main hydraulic system 116. The flow divider 118 is positioned between the hydraulic system 116 and the first and second hydraulic cylinders 50, 54 such that the flow divider 118 is configured to divide and distribute a flow from the hydraulic system 116 to drive the first and second hydraulic cylinders 50, 54, as described above. The first hydraulic cylinder 50 operates the catalyst pump 26 to draw catalyst from the catalyst tank 10 and direct the catalyst to the wand 6 via the internal catalyst conduit 58 and the external catalyst conduit 82. The second hydraulic cylinder 54 operates the resin pump 30 to draw resin from the resin tank 14 and direct the resin to the wand 6 via the internal resin conduit 62 and the external resin conduit 86.

In some embodiments, information regarding the localized pressure in different areas within the pump system 2 may be used to monitor an injection operation or to inform operation of the pump system 2. For example, it may be desirable to monitor (1) the pressure of a fluid (e.g., catalyst or resin) after the fluid leaves the associated tank (e.g., catalyst tank 10 or resin tank 14), (2) the pressure of the fluid before the fluid enters the wand 6, and/or (3) the difference between (1) and (2).

Thus, in some embodiments, two pressure sensors may be positioned along the flow path between the catalyst tank 10 and the wand 6 and two pressure sensors may be positioned along the flow path between the resin tank 14 and the wand 6. For example, a pressure sensor may be positioned on each of the internal catalyst conduit 58, the internal resin conduit 62, the external catalyst conduit 82, and the external resin conduit 86. In the example of FIG. 8, a first resin pressure sensor 150 and a second resin pressure sensor 158 may be positioned along the flow path between the resin tank 14 and the wand 6. Likewise, a first catalyst pressure sensor 154 and a second catalyst pressure sensor 162 may be positioned along the flow path between the catalyst tank 10 and the wand 6.

In some embodiments, increasing a distance by which an associated pair of pressure sensors (e.g., the first and second resin pressure sensors 150, 158 or the first and second catalyst pressure sensors 154, 162) may improve the reliability, efficacy, resolution, and/or other characteristics of the data collected by the sensors. Indeed, increasing the distance between an associated pair of pressure sensors may increase the ability of that pair of pressure sensors to detect, for example, leaks and/or other faults in the pump system 2. Thus, the first and second resin pressure sensors 150, 158 and/or the first and second catalyst pressure sensors 154, 162 may be positioned so as to maximize or increase the distance by which they are separated from one another along the associated flow path.

In the illustrated embodiment, the first and second resin pressure sensors 150, 158 are both positioned along the external resin conduit 86. For example, the first resin pressure sensor 150 may be positioned at a first end of the external resin conduit 86 (e.g., proximate to the juncture between the external resin conduit 86 and the internal resin conduit 62), and the second resin pressure sensor 158 may be positioned at a second end of the external resin conduit 86 opposing the first end (e.g., proximate to the juncture between the external resin conduit 86 and the wand 6). However, in other embodiments, the first resin pressure sensor 150 may be positioned along the internal resin conduit 62 and the second resin pressure sensor 158 may be positioned along the external resin conduit 86. Alternatively, the first and second resin pressure sensors 150, 158 may be positioned in another manner.

In the illustrated embodiment, the first and second catalyst pressure sensors 154, 162 are both positioned along the external catalyst conduit 82. For example, the first catalyst pressure sensor 154 may be positioned at a first end of the external catalyst conduit 82 (e.g., proximate to the juncture between the external catalyst conduit 82 and the internal catalyst conduit 58), and the second catalyst pressure sensor 162 may be positioned at a second end of the external catalyst conduit 82 opposing the first end (e.g., proximate to the juncture between the external catalyst conduit 82 and the wand 6). However, in other embodiments, the first catalyst pressure sensor 154 may be positioned along the internal catalyst conduit 58 and the second catalyst pressure sensor 162 may be positioned along the external catalyst conduit 82. Alternatively, the first and second catalyst pressure sensors 154, 162 maybe positioned in another manner.

In some embodiments, the first and second resin pressure sensors 150, 158 may be positioned as far apart from one another as possible, and the first and second catalyst pressure sensors 154, 162 may be positioned as far apart from one another as possible. The pressure sensors (including the first and second resin pressure sensors 150, 158 and the first and second catalyst pressure sensors 154, 162) may each be configured to send an electric signal indicative of a localized pressure to the processor.

The first and second resin pressure sensors 150, 158 and the first and second catalyst pressure sensors 154, 162 may provide indications of a change in pressure along the flow path between the resin tank 14 and the wand 6 and between the catalyst tank 10 and the wand 6, respectively. In this way, the first and second resin pressure sensors 150, 158 and the first and second catalyst pressure sensors 154, 162 may assist an operator in detecting leaks or faults in the system. For example, each pair of associated pressure sensors may be configured to provide an indication when a pressure difference exceeding a predetermined threshold is detected. Once the operator is notified (e.g., via a message or indicator displayed by the pump system control panel 66), the operator may stop the operation.

In the example of FIG. 8, the injection control panel 142 is connected to the first hydraulic cylinder 50. However, in other embodiments, the injection control panel 142 may be connected to or in communication with the first hydraulic cylinder 50 and/or the second hydraulic cylinder 54 or may be positioned in another manner. While the pump system control panel 66 and the injection control panel 142 are provided as separate components in the illustrated embodiment, a single control panel can perform the function of both the pump system control panel 66 and the injection control panel 142 in other embodiments. For example, in some embodiments, the injection control panel 142 may be omitted and the pump system control panel 66 may perform the functions of the injection control panel 142.

As shown in FIG. 8, the wand 6 is operated (e.g., by an actuator) to extend and retract. In some embodiments, a motor 166 and a feed screw 170 may operate the wand 6. For example, the motor 166 may be a hydraulic motor configured to receive pressurized fluid (e.g., from the same hydraulic source as the pump system 2 or a separate system), or the motor 166 may be provided in another form. The motor 166 may rotate the feed screw 170, allowing the wand 6 to extend or retract from an initial position. In other embodiments, the wand 6 may be fully or partially extended and retracted by an actuator 174. The actuator 174 may be a hydraulic cylinder that receives pressurized fluid (for example, from the same hydraulic source as the pump system 2 or a separate system). A combination of the actuator 174, the motor 166, and/or the feed screw 170 may also be used. The wand 6 may be extended into a hole prior to an injection operation and retracted during the injection operation.

The wand 6 may be configured to inject catalyst via a catalyst conduit 180 and to inject resin via a resin conduit 182. For example, the wand 6 may be provided in the form of a substantially cylindrical or tubular structure. The catalyst conduit 180 may be a substantially cylindrical or tubular conduit extending through a central region of the wand 6, and the resin conduit 182 may be a substantially annular conduit extending through a peripheral region of the wand 6 (e.g., the resin conduit 182 may surround or encompass the catalyst conduit 180). In some embodiments, the wand 6 may be bifurcated so that a first side of the wand 6 is separated from a second side of the wand 6 such that the first side provides the catalyst conduit 180 and the second side provides the resin conduit 182. In other embodiments, the wand 6, catalyst conduit 180, and resin conduit 182 may be provided in any form.

The bulk resin injection system disclosed herein can be used with mining machinery such as a bolter drill (e.g., for performing or facilitating an injection operation to install a bolt in a mine face). Prior to use of the bolter drill, an operator may input one or more operation parameters into the control screen 70. The computer contained in the pump system control panel 66 can use the operation parameters provided by the operator, stored parameters, parameters obtained from the various sensors (e.g., ultrasonic sensors 130, laser level sensors 134, temperature sensors 138, pressure sensors 150, 154, 158, 162, and/or other sensors not specifically described herein), or combinations thereof to determine, for example, the volume of resin-catalyst mixture needed for the injection operation and the proper retraction speed of the wand 6.

Once the operation parameters are entered, an operator can use the bolter drill equipped with the bulk resin injection system of the present disclosure by using the bolting attachment 8 to drill a hole, flushing the hole using water or air mist, aligning the wand 6 with the hole, and starting the injection operation using the pump system control panel 66 or the injection control panel 142. The wand 6 may be controlled to retract at the calculated rate while injecting resin and catalyst into the hole via the catalyst conduit 180 and the resin conduit 182. The resin and catalyst may be kept separate while being injected into the hole and may only come into contact with one another upon exiting the wand 6. The operator may then align the bolter drill with the hole and insert the bolt. The bolt may be spun in the hole to mix the resin and catalyst together. Once the resin-catalyst mixture has cured, the bolt may be torqued to a specified value.

In other embodiments, other configurations are possible. For example, those of skill in the art will recognize, according to the principles and concepts disclosed herein, that various combinations, sub-combinations, and substitutions of the components discussed above can provide a cable tensioning and payout device.

Claims

1. A resin injection system, comprising: a first tank configured to hold a first viscous fluid;a second tank configured to hold a second viscous fluid;a wand in communication with the first tank and the second tank, the wand configured to extend or retract from an initial position and to inject the first viscous fluid and the second viscous fluid into a hole;a first pump configured to drive the first viscous fluid from the first tank to the wand; anda second pump configured to drive the second viscous fluid from the second tank to the wand,wherein the first pump and second pump are configured to operate independently.

2. The resin injection system of claim 1, wherein the first pump is in communication with the first tank and coupled to a first hydraulic cylinder, andwherein the second pump is in communication with the second tank and coupled to a second hydraulic cylinder.

3. The resin injection system of claim 2, further comprising: a hydraulic source in communication with the first hydraulic cylinder and the second hydraulic cylinder; anda flow divider coupled to the hydraulic source and configured to divide a flow from the hydraulic source into a first flow component directed to the first hydraulic cylinder and a second flow component directed to the second hydraulic cylinder.

4. The resin injection system of claim 3, wherein the flow divider can be adjusted to alter the ratio between the first flow component and the second flow component, thereby altering the ratio of the first viscous fluid and the second viscous fluid pumped to the wand.

5. The resin injection system of claim 1, further comprising: a control panel configured to enable an operator to input one or more parameters into the resin injection system relating to a particular application or operation; anda processor configured to make determinations by analyzing the parameters input by the operator.

6. The resin injection system of claim 5, wherein the processor determines a desired ratio of the first viscous fluid to the second viscous fluid, a desired rate of retraction of the wand, or both.

7. The resin injection system of claim 5, wherein the first tank and the second tank are each configured to receive air from a pressurized air source such that the first tank and the second tank are pressurized.

8. A bolting device, comprising: a frame including a boom;a bolting attachment including a wand coupled to the boom, the wand configured to extend or retract with respect to an initial position; anda pump system in communication with the wand and configured to pump resin and catalyst thereto,wherein the pumping of resin and the pumping of catalyst by the pump system are performed independently.

9. The bolting device of claim 8, wherein the pump system further comprises: a first tank configured to hold resin;a second tank configured to hold catalyst;a first flow path extending between the first tank and the wand and providing fluid communication therebetween;a second flow path extending between the second tank and the wand and providing fluid communication therebetween;a first pump in communication with the first tank and coupled to a first hydraulic cylinder, the first pump configured to pump resin from the first tank to the wand;a second pump in communication with the second tank and coupled to a second hydraulic cylinder, the second pump configured to pump catalyst from the second tank to the wand.

10. The bolting device of claim 9, further comprising: a first temperature sensor positioned on the first tank and configured to generate a signal indicative of a temperature of the resin;a first level sensor positioned on the first tank and configured to generate a signal indicative of a volume of resin contained in the first tank;a second temperature sensor positioned on the second tank and configured to generate a signal indicative of a temperature of the catalyst;a second level sensor positioned on the second tank and configured to generate a signal indicative of a volume of catalyst contained in the second tank.

11. The bolting device of claim 10, further comprising: two pressure sensors positioned along the first flow path; andtwo pressure sensors positioned along the second flow path,wherein each pressure sensor is configured to generate a signal indicative of a localized pressure at a location along the first flow path or the second flow path.

12. The bolting device of claim 11, further comprising: a control panel configured to enable an operator to input one or more parameters into the resin injection system relating to a particular application or operation.

13. The bolting device of claim 12, further comprising: a processor configured to receive and evaluate the signals generated by the first and second temperature sensors, the signals generated by the first and second level sensors, the signals generated by the pressure sensors, and the parameters input by the operator.

14. The bolting device of claim 13, wherein the processor is configured to make a determination regarding the appropriate ratio of resin to catalyst, the appropriate rate of retraction of the wand during an injection operation, or both based on the signals received from the first and second temperature sensors, first and second level sensors, and pressure sensors and the parameters input by the operator.

15. The bolting device of claim 9, further comprising: a hydraulic source configured to generate a flow that feeds the first hydraulic cylinder and the second hydraulic cylinder; anda flow divider that distributes the flow generated by the hydraulic source between the first hydraulic cylinder and the second hydraulic cylinder,wherein the flow divider can be adjusted to alter the ratio between a portion of the flow generated by the hydraulic source that is directed to the first hydraulic cylinder and a portion of the flow generated by the hydraulic source that is directed to the second hydraulic cylinder.

16. The bolting device of claim 15, wherein the flow divider is configured to receive two or more interchangeable cartridges, wherein each cartridge is associated with a desired ratio between the amount of resin supplied to the wand and the amount of catalyst supplied to the wand, and wherein an operator can adjust the flow divider by installing a new cartridge.

17. The bolting device of claim 9, wherein: the first flow path includes a first external conduit,the second flow path includes a second external conduit,a first pressure sensor is positioned proximate to a first end of the first external conduit and a second pressure sensor is positioned proximate to a second end of the first external conduit opposing the first end of the first external conduit, anda third pressure sensor is positioned proximate to a first end of the second external conduit and a fourth pressure sensor is positioned proximate to a second end of the second external conduit opposing the first end of the second external conduit.

18. The bolting device of claim 17, wherein the first and second pressure sensors aid an operator in identifying leaks or faults along the first flow path, and wherein the third and fourth pressure sensors aid the operator in identifying leaks or faults along the second flow path.

19. The bolting device of claim 8, wherein the wand includes a resin conduit through which resin may be injected and a catalyst conduit through which catalyst may be injected, and wherein the resin and the catalyst are kept separate until they exit the wand.

20. A resin injection system, comprising: a pressurized resin tank configured to hold a supply of resin, the pressurized resin tank in communication with a first continuous pump coupled to a first hydraulic cylinder;a pressurized catalyst tank configured to hold a supply of catalyst, the pressurized catalyst tank in communication with a second continuous pump coupled to a second hydraulic cylinder;a hydraulic source configured to supply a flow to the first hydraulic cylinder and the second hydraulic cylinder;a flow divider positioned between the hydraulic source and the first and second hydraulic cylinders, the flow divider configured to distribute the flow generated by the hydraulic source between the first and second hydraulic cylinders;a wand in communication with the pressurized resin tank and the pressurized catalyst tank, the wand configured to inject at least a portion of the supply of resin and at least a portion of the supply of catalyst into a hole;a control panel configured to enable an operator to input one or more parameters associated with a particular application or operation; anda processor configured to receive the information input by the operator,wherein the first and second pumps operate independently with respect to one another,wherein the processor is configured to determine a desired ratio between resin and catalyst, a desired rate of retraction of the wand during an injection operation, or both, andwherein the ratio between resin injected via the wand and catalyst injected via the wand can be adjusted by altering a configuration of the flow divider.