This invention is related to remote controlled vehicles for mine maintenance and service. More particularly this invention is related to a remote controlled vehicle that rides on the push beams in high-wall mining shafts.
One example of an application for the apparatus of the present invention is highwall mining. During the past forty years, highwall mining has proven to be an efficient method of mining coal, or other sought after material, that would not be mined by other methods. Highwall mining is a form of mining frequently used to supplement strip mining.
Strip mining is used when the sought after material deposits, such as coal, occur relatively close to the surface. In strip mining, the top several layers of earth over a coal deposit are removed to gain access to the coal deposit. The material of the covering layers is called overburden. When the coal to overburden ratio falls below a certain ratio, the process becomes unprofitable and strip mining ceases to be the economically preferred technique at that location. At that point in time, the strip mining has produced a large pit with seams of coal extending from the surface of the walls of the pit back into the earth. Highwall mining is a type of mining used to extract, or mine, the coal in the seams terminating at the walls of the pit.
In highwall mining, a highwall mining machine is located on the pit floor in alignment with a coal seam and a remote operated cutter module is forced into the coal seam. The cutter cuts a series of parallel rectangular cuts back into the seam up to 1,000 feet from the face of the wall. This is considered too dangerous for the insertion of any personnel and the cutter modules are directed and operated remotely. The coal mined by the cutter module is transported from the cutter module to the surface area by augers or conveyor belt systems.
Typically, the cuts and the entries to the cuts are rectangular. The width of the entry to a cut is dependent on the type of cutter module used, and the width may vary from 9-½ feet to 12 feet. The height of the entry is more dependent on the coal seam's thickness, and the height may vary from 28 inches to more than 15 ft.
As the high-wall miner progresses back into the mountain, a specialized form of conveyor is built behind it. This conveyor is comprised of multiple sections of push-beams. These push-beams are low profile and hollow on their interior. Within their hollow interior is at least one auger, but most typically, there are two augers. The first push-beam behind the high-wall miner receives coal, or other mined material from the high-wall miner and the augers within this first push-beam pulls the material back towards the push-beam behind it. Each push-beam receives the mined material from the one preceding it in the mine and the augers within it pull the material onward out of the mine until the material is conveyed fully out of the mine to a station at the floor of the mine pit. The augers are usually driven by the station at the exit of the mine shaft. As the mining machine recedes further underground, additional push-beams are added and pushed back in along with the machine.
This is a highly automated process and no personnel are allowed back into the high-wall mine shaft. The high-wall miner and the push-beam augers are operated and powered from the station external to the high-wall mine shaft. On occasion, the high-wall miner may become lodged in the high-wall mine shaft or some problem may arise with the push-beam conveyor back in the high-wall mine shaft. When this occurs, personnel are not allowed in to troubleshoot or inspect the source of the problem. Therefore, operators are left to blindly manipulate the high-wall miner to attempt to free it. This is frequently not successful. This can result in a highly expensive piece of capital equipment being irretrievably lodged within the high-wall mine shaft. There is a need for an apparatus which can travel back into the high-wall mine shaft and provide a visual of the situation as well as having the capabilities to perform certain functions to free the high-wall miner from its lodged position. Alternatively, the apparatus could disconnect the high-wall miner from the push-beam conveyor system, as the push-beam conveyor is itself a highly expensive piece of equipment. Each section of push-beam conveyor that can be retrieved would by itself provide a considerable savings even if the high-wall miner itself were lost.
At present time, it is estimated that there are more than one hundred highwall miners being operated in the coal industry, each one producing multiple cuts during an operating day. They all have the same problems to varying degrees. A need exists for a system capable of recovering, or assisting, lodged high wall mining machines and associated conveyors. Substantial monetary gains may be achieved by recovering the lodged components. In some cases, the seam being mined may be more fully exploited when the miner is freed or otherwise serviced.
Additionally, once a disabled miner, and or conveyor, is recovered and the cut cleared, a highwall miner can return to the cut to further exploit the seams at that location for further monetary benefit. For monetary purposes, the system must be efficient, reliable, and not labor intensive. For safety purposes, the system must not require personnel to be exposed at or near the highwall of the pit. The system should be able to work in close proximity with high wall miners.
U.S. Pat. No. 6,633,800 by Ward is for a “Remote control system.” An apparatus and method for a control unit allows for autonomous, manual and tele-operation of mining vehicles. The control unit has a robust system design to withstand the harsh environment of underground mines. The control unit allows a tele-operator, in a remote tele-operator station, to use image and operational data, joysticks and foot pedals to remotely control the mining vehicle. In another aspect, the control unit provides safety features such as supervising its operation for operational errors and providing status, warning and error information to the tele-operator station.
U.S. Pat. No. 6,109,699 by Mraz is for a “Tow Line Equipped Remote Mining Machine and Method.” Mraz discloses a method and apparatus for advancing cables and hoses to a remotely operated mining machine and retrieval of the machine in the case of accident. The apparatus supports remote haulage of material in a self-propelled vehicle guided within a mine opening, so as to avoid interference with cables and hoses and the walls of the mine opening.
U.S. Pat. No. 4,708,395 by Petry, et al. is for a “Remotely sensing of excavation cavity during mining.” Petry discloses a method and apparatus for hydraulically mining a location using a hydraulic monitor which has a horizontal and vertical positionable control apparatus. The hydraulic monitor is connected to a source of high pressure water. Distance and direction measuring equipment are mounted on the monitor and controlled in a manner to scan the location. The output from the distance and direction measuring equipment is inputted to a computer and a visual video display monitor. The computer converts the information from the distance and direction measuring equipment to a visual representation of the cavity being mined. The hydraulic monitor includes a means for diverting the high velocity jet during the distance measuring period so that the water pressure is not varied in the high pressure pipe, and the mined material is continuously washed toward the collection apparatus during the measuring period. All hydraulic monitor functions are controlled from the remote operator location.
U.S. Pat. No. 4,192,551 by Weimer, et al. is for “Remote control system for mining machines.” Weimer discloses a system that controls all miner hydraulic and electrical functions from a hand held miner remote control pendant. Pendant control devices provide on/off control signals to interfaces with miner drive and pump controllers, as well as a group of +−6 VDC differential proportional and on/off control signals to respective electronic valve drivers. Valve driver outputs are fed to respective force motors on pilot stage valves which control each hydraulic function. Each valve driver output is modified by offset and dither signals to overcome power stage valve dead band and frictional characteristics. Pilot stage valves have an internal feedback sleeve co-acting with a pilot valve spool in a hydraulic servo circuit. Pilot stage valves operate in a pilot oil system which may be isolated from power oil systems.
In at least one embodiment of the invention, a vehicle frame approximately the width of the push-beam conveyor has multiple axels along its length. These axels run transverse to the push-beam conveyor, across the vehicle body. Each axel has multiple wheels upon it and these wheels are spaced to accommodate features in the push-beam conveyor section, so that the vehicle can ride on top of the push-beam conveyor as a track. For example, some types of push-beam conveyors have troughs in them for accommodating power cables, hydraulic cables, and other elements for servicing the high-wall mining machine, and in some cases, the push-beam conveyor sections.
The surface control station includes many components to allow the system a high level of independent operation. As a foundation, all of the other components of the surface control station are located on a wheeled chassis. In some embodiments, this wheeled chassis may be a trailer. This wheeled chassis is highway ready with all required safety features as well as a suitable hitch when necessary, such as a fifth wheel type hitch, for connecting to a highway vehicle. The wheeled chassis also has stabilizing capabilities, such as outriggers, for operating at mine sites. Among the components that may be located on the wheeled chassis are: an operator station with controls and monitoring screens; an electrical generator; a hydraulic power unit; a battery charger; a transformer; circuit breakers; an air compressor; a crane; a battery charging station; a retrieval winch; an electric welder; and an optical alignment device, such as a laser alignment device. A cable on the retrieval winch attaches to the recovery vehicle to retrieve it should the vehicle become disabled, and the optical alignment device provides an efficient gauge for aligning the surface control station with a respective highwall cut to keep the retrieval winch and cable effective.
Because the high-wall mining machine follows the coal seam, the path of the high-wall mining shaft may vary up and down. This can cause the push-beam conveyors to form an irregular track for a vehicle that may try to ride upon the conveyor. In at least one embodiment of the invention, the vehicle body has at least one hinge along its length so that it may more easily follow the undulations of the push-beam conveyor. The vehicle frame of the remote controlled service vehicle carries a variety of components for several systems.
A hydraulic pump driven by an electric pump motor provides hydraulic power for the various motive elements of the recovery vehicle, such as hydraulic cylinders and motors, while a programmable controller operates a hydraulic manifold to convert signals from the surface control stations to actions of the recovery vehicle. For control purposes, a signal cable connects the recovery vehicle to the surface control station. A reel at the surface control station carries the signal cable and turns to take up and feed out the cable as the equipment recovery vehicle travels. On some embodiments, a moving guide would wind the cable on the reel in a balanced or level manner. A camera mounted on the equipment recovery vehicle provides information for an operator on screens at the operator station. The camera provides a forward view in front of the equipment recovery vehicle to allow an operator to access the status within the mine shaft.
Additionally, some embodiments of the equipment recovery vehicle have an operable recovery implement capable of remote operation by an operator, and at least one embodiment of the recovery vehicle will have a towing feature. The particular recovery implement on the recovery vehicle will depend on the particular application. To free a piece of equipment, the implement may be a hydraulic hammer. To cut away the push-beam conveyor, the implement may be a saw. To clean up fallen rock, the implement may be a pulverizer. For coal or material recovery, the recovery implement may be a scoop. For equipment recovery, the recovery implement may be a grapple, manipulator, cutter, or a combination of these.
Additional utility and features of the invention will become more fully apparent to those skilled in the art by reference to the following drawings, which illustrate some of the primary features of preferred embodiments.
Component mounting plate 32 is attached to tilt plate 34 (see
Component 36 mounts to component mounting plate 32 at the front of equipment recovery vehicle 20. In the embodiment shown in
Although mounted component 36 in
At the right end of equipment recovery vehicle 20, in proximity to the connecting point of communication cable 24 are electrical control boxes 48. Electrical control boxes 48 contain the necessary processors, relays, switches, etc. to convert the instructions received over communications cable 24 to the actions desired by the operator. In at least one embodiment communications, cable 24 may be an Ethernet cable and in those cases, the electrical control boxes 48 will also comprise an Ethernet extender for boosting and filtering the signals over communications cable 24.
In the right hand portion of the equipment recovery vehicle 20, a battery tray assembly 50 is located. In
In this side view of
In the embodiment in
Generator 68 provides power requirements for the elements of equipment recovery system 10 mounted on self propelled control vehicle 62 beyond those of the self propelled control vehicle 62 itself. Generator 68 provides electrical power, via power distribution center 63, to operator station 80 and its attendant electrical controls, batteries 52 in battery tray assembly 50 of equipment recovery vehicle 20, hydraulic power supply 65, and to winch 66 and cable reel 67, when they are powered by electricity. For some embodiments of self propelled control vehicle 62, winch 66 and cable reel 67 may be hydraulically powered. In those embodiments, hydraulic power supply 65 would supply the hydraulic power needed. Boom 69 may also be hydraulically powered.
Although specific embodiments of the invention have been described with specificity, the embodiments described should not be considered exhaustive of the possible embodiments of the invention and should not be held as limiting the scope and range of the claims. Similarly the drawings are not exhaustive depictions of embodiments of the invention and the abstract is intended to allow a person to quickly gain the general field of the invention and should not be taken as limiting the scope of the claims.
This application claims priority from U.S. Provisional Application No. 61/552,915, filed on Oct. 28, 2011. The entire disclosure contained in U.S. Provisional Application 61/552,915, including the attachments thereto, is incorporated herein by reference.
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Number | Date | Country | |
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20130104768 A1 | May 2013 | US |
Number | Date | Country | |
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61552915 | Oct 2011 | US |