A portion of the disclosure of this document contains material subject to copyright protection. No objection is made to the facsimile reproduction of the patent document or this disclosure as it appears in the Patent and Trademark Office files or records, but any and all rights in the copyright(s) are otherwise reserved.
The present invention relates to the mining arts and, more particularly, to apparatuses, systems, and methods for use in underground mining.
During underground mining, it is a requirement for purposes of safety as well as federal law to install roof support at various intervals. This is often done using a machine known in the vernacular as a “roof' bolter (even though it is capable of installing bolts in faces besides the roof of a mine passage, such as the ribs). Typically, such a roof bolter is capable of both forming (drilling) boreholes in the faces of the passageways of underground mines and then installing roof anchors or “bolts” in the boreholes. Usually, the bolter is employed after a mining machine used to win the coal or other minerals from the mine face is withdrawn from the entry thus formed.
In an effort to improve efficiency and save space in the confines of the underground mine environment, proposals have been made to couple the roof bolting functionality with that of the mining machine. Examples of such combined machines may be found in U.S. Pat. Nos. 4,753,486, 4,953,914, and 6,942,301. However, the requirement for an operator manning the drills in order to perform the bolting operation remains in all of these proposals. This places the operator in an obviously undesirable position (that is, below unsupported roof and along side of a heavy, working drill).
Canopies and other “automated” temporary roof supports (ATRS) have been proposed for alleviating this condition. However, these structures are costly and sometimes take significant time and effort to deploy. Also, since the bolting can be done using a single machine while the miner is recovering the desired material, a limitation is placed on the speed with which the entire operation can be accomplished.
Proposals have also been made in the past for operating mining and drilling machinery by way of remote control (see, e.g., U.S. Pat. Nos. 4,398,850; 4,192,551 and, more recently, 6,871,712). While remote control advantageously removes the operator from the location where the work is occurring, limitations still exist. For one, the use of such control in the past does not prevent the operator from coming within a predetermined proximity of the work location while the machinery is operational.
Accordingly, a need exists for mining apparatuses and related methods of mining that are more efficient and potentially eliminate the exposure of the operator of a bolter to unsupported roof (and, most preferably, without requiring a canopy or other type of temporary roof support). A need also exists for a manner for remotely controlling a drilling or bolting operation, and ceasing the operation if it is determined that the operator comes within a predetermined proximity of the work location. Coupling these and other features of a remote bolter with a miner would also provide numerous advantageous benefits.
In accordance with a first aspect of the invention, a system assists an operator in controlling a machine including a drill head for drilling a borehole in a face of a mine passage and installing a bolt therein. The system comprises a controller for controlling the operation of the drilling or bolting machine. A transmitter transmits to the controller control signals from the operator at a remote location from the drill head. One or more sensors generate an output signal to the controller when the operator is within a predetermined proximity of the active drill head.
In one particularly preferred embodiment, the controller receives the output signal and generates a warning signal to the operator. Another option is for the control to disable the drilling or bolting machine upon receiving the output signal. In any event, the chance of the operator unknowingly approaching the drill head is substantially reduced.
Preferably, the transmitter comprises a wireless device for emitting the control signals received by the controller. The sensor may comprise a proximity detector for detecting one of the operator or the transmitter.
The system may further include a miner for advancing the mine passage. In such case, the transmitter may transmit the control signals from the operator at the remote location to control the miner. The controller upon receiving the output signal from the sensor may disable the operation of the miner or the drill module. Still another alternative is for the controller to disable the activation of any automated temporary support.
In accordance with another aspect of the invention, a system for assisting the operator in mining materials to form a mine passage having a face into which a borehole is formed for receiving a bolt to support for the face is provided. The system comprises a miner capable of advancing the mine passage and forming the face. A drilling module supported by the miner for drilling the face forms the borehole and installs the bolt therein to form the supported face. A transmitter transmits to the controller control signals for controlling at least the drilling module from the operator at a remote location from the drilling module and below the supported face. Preferably, the transmitter is wireless and also transmits control signals for controlling the miner.
Yet another aspect of the invention is a system assisting an operator in mining materials for forming a mine passage having a face and forming a borehole in the face for receiving a bolt. The system comprises a miner for advancing the mine passage and forming the face, as well as a drilling module for drilling the face to form the borehole and generating output signals representative of one or more drilling parameters. A controller is provided for receiving the one or more drilling parameters, determining a characteristic of the material forming the face based on the drilling parameters, and instructing the operation of the miner based on the characteristic. Preferably, the controller instructs the operation of the miner by displaying the characteristic of the material forming the face on a display for viewing by the operator.
Still a further aspect of the invention is a system for assisting an operator in mining materials for forming a mine passage having a face into which a borehole is formed for receiving a bolt. The system comprises a miner for advancing the mine passage and forming the face, as well as a drilling module for drilling the face to form the borehole and installing the bolt in the borehole during a first period of time. A controller is provided for controlling the miner to advance the mine passage a predetermined distance within a second period of time substantially matching the first period of time.
Another aspect of the invention is a system assisting an operator in mining materials for forming a mine passage having a face into which a borehole is formed for receiving a bolt. The system comprises a miner for advancing the mine passage and forming the face, as well as a drilling module for drilling the face to form the borehole and installing the bolt in the borehole. A controller is provided for controlling the miner, as is a transmitter for transmitting to the controller control signals from the operator at a remote location from the face. Sensor(s) sense when the operator is within a predetermined proximity of the miner and generate an output signal.
An additional aspect of the invention is a method of operating a mining machine with a drill head for use by an operator in forming a borehole in a face of a mine passage and installing a bolt therein. The method comprises, from a location remote from the drill head, operating the machine with the drill head to form the borehole. The method further comprises generating an output signal if the operator is within a predetermined proximity of the drill head.
In the case where the operating step comprises operating the machine to form the borehole adjacent a rib of the mine passage so as to create a gap between the machine and the rib, the method comprises generating the output signal when the gap is occupied. The method may further comprise stopping the machine if the operator occupies the gap. Alternatively, the operating step may comprise actuating a temporary support to engage the face, and the method includes stopping the machine from actuating the temporary support if the operator approaches the temporary support from the remote location, as determined by the output signal.
Yet an additional aspect of the invention is a method of assisting an operator in mining materials for forming a mine passage having a face. The method comprises drilling the face to form a borehole. Based on the drilling step, the method further comprises determining a characteristic of the material comprising the face. The mine passage is then advanced based on the characteristic (which may be a height of a first material that is soft relative to a second material forming the face, in which case the advancing step may comprise raising a cutter drum of a miner to mine substantially to the height of the first material).
Still another aspect of the invention is a method for assisting an operator in mining materials for forming a mine passage having a face into which a borehole is formed for receiving a bolt. The method comprises drilling the face to form the borehole and installing the bolt in the borehole during a first period of time, and advancing the mine passage in a second period of time substantially matching the first period of time. Preferably, the drilling step comprises drilling the borehole with a drilling module associated with a miner.
Another aspect of the invention is a method of mining a face in a mine passage, comprising forming an entry in the face using a mining machine. While forming the entry, the method includes installing roof support using a first bolter separate from and capable of passing by the mining machine in the entry. Preferably, the step of forming the entry comprises making a first cut into the mine face using the mining machine, withdrawing the mining machine from the passage formed during the first cut, and making a second, adjoining cut into the mine face using the mining machine (in which case the step of installing roof support is performed while making the second cut to complete the entry).
The invention in a different aspect comprises a method of mining a face in a mine passage. The method in this case includes the steps of forming a first entry in the face to a predetermined advance distance and then forming a second entry in the mine face adjoining the first entry to about the predetermined advance distance. While forming the second entry, roof support is installed in the first entry.
A further aspect of the invention is a method of mining a face in a mine passage, comprising: forming an entry in the face using a mining machine. The method comprises the step of installing roof support in the entry using first and second remotely controlled bolters. The method may further include the step of withdrawing the mining machine from the entry after the step of forming the entry but before the installing step. Preferably, the step of installing roof support comprises transmitting radio signals from a transmitter to a receiver associated with one of the first and second bolters.
a is a top plan schematic view of a mine entry including two remotely controller bolting machines working in tandem;
a-2d are front, rear, top, and side views of a bolting machine forming one aspect of the invention;
Reference is now made to
Rather than using a bolter associated with the miner M or installing bolts in the roof or rib(s) only once the miner is withdrawn from the entry E, one aspect of the inventive mining method shown in
A further aspect of the invention is to operate the bolter R remotely. This can be done by an operator O standing alongside or adjacent the bolter R, as shown in
In either case, several advantages arise from the practice of this aspect of the invention. For one, the operator O is advantageously not constantly exposed to unsupported roof, as may be the case if the bolter R were manually operated and coupled to the miner M. Moreover, the operator O is not positioned ahead of or on the miner M, but rather behind it and to one side, relatively far away from the face and the drum D or other implement used for advancing the passage. Yet another advantage is providing the operator with the ability to operate the bolter R from the side of it facing away from the rib, which helps to protect from deleterious rib rolls.
Typically, air pressure (typically negative) is used to flush the cuttings and debris from the borehole during the drilling operation. A side benefit of removing the operator O from the immediate drilling area is that it becomes possible to use water to flush the borehole during drilling. Additionally, with the operator O removed, higher pressure water can be used for flushing. The benefits of higher pressure flushing may lead to a lesser volume of water being required to drill as compared to regular water-assisted drilling.
An exemplary bolter R for particular use in remote control operation of the type described above is shown in
Tramming of the bolter R about the entry E may be accomplished using ground engaging means, such as low profile crawler tracks K, and a corresponding drive motor. The tram function is also used to position the bolter R from side to side. Furthermore, one or more supports may be provided for engaging the face(s) of the mine passage prior to or during installation of the bolts. These operations, as well as operation of the drill module G to achieve the drilling and bolting function, can all be remotely controlled by the operator, as described in the foregoing passage.
As noted above, use of the remote control technique means that the operator should never be under unsupported roof during proper operation. Accordingly, the canopy and temporary roof support can be optionally deployed, as in the bolter R of
In accordance with a further aspect of the invention, a sensor S may be provided to generate an output signal to the controller N to take automatic action (e.g., shut down the drilling functions and/or provide a warning) if the operator comes within a certain proximity to the bolter R forming the borehole in the unsupported roof from the remote location or if the transmitter T becomes positioned too closely to the drill module G incorporating the drill head H. This may be desirable to ensure compliance with regulations requiring the maintenance of a certain distance between the operator O and the drill module G during the drilling or bolting routine. The sensor S may comprise a receiver C (e.g., an RF receiver) that receives signals and thereby senses the position of the transmitter T carried by the operator 0. Alternatively, a proximity sensor may be used, such as one using infrared energy to detect the position of the operator O or transmitter T.
Accordingly, with reference to
Another possible application of this type of sensor arrangement can limit an operator's ability to operate any machine remotely from undesirable locations. For example, in the case of having one or more remote bolter R on the miner M itself to form a unitary mining machine, this type of sensor arrangement can be used to disable operation if the operator O remotely controlling was to move to an undesirable position (i.e., in the gap V between the machine and the rib; see
This type of sensor arrangement could also be used for disabling the miner M itself, should the operator O get within a predetermined proximity of the working face being mined. For example, the sensor S and controller N could form part of the miner M (see
Likewise, if remote radio control is used on a conventional drilling or bolter with an automated temporary roof support (such as a stab jack J; see
In yet another aspect of the invention, and with reference to
The drilling module G used with the bolter R of
The program may generate the profile of the material being drilled based on one or more drilling parameters. For example, during drilling, thrust and torque may be monitored using sensors (various types of which are known in the art) and used for determining the location of voids and fractures, since these parameters react sharply upon encountering such. Likewise, to identify the interface between adjacent layers (e.g., coal and rock), the rotational acceleration of the drill rotational speed can be used, since this speed is normally affected near the interface (depending on the rock types that the drill is drilling away or into softer or stronger rock). Changes in the feed or rotation rate for a given thrust may also be indicative of the relative hardness of the material being drilled. Additional details of an exemplary mapping program are provided in Applicant's U.S. Pat. No. 6,637,522, the disclosure of which is incorporated herein by reference.
As the bolter R forms a borehole B using the drilling module G, it may relay information about the face, such as characteristic of the material being drilled (that is, whether it is soft or hard based on the feed rate for a given level of thrust), back to the controller N for visualization on the display Y. Aside from being of value during the drilling operation and in connection with the development of a good roof control plan, this information on the characteristic may be used to instruct the operator O how to advance the miner M to maximize recovery while minimizing wear and tear.
Specifically, and by way of illustration only, the information displayed may instruct the operator O or a controller how high to raise the cutter drum D in order to maximize the coal recovery while avoiding contacting harder material overlying the coal (such as some types of rock). Thus, as shown on the exemplary screen shot of
In many cases, a bolt may take longer to install than the shear cycle of a mining machine, such as a drum miner M. If the drilling module G of a bolter R used to form the boreholes and install the bolts therein and the miner M together form part of a unitary mining machine movable about the mine passageways (as shown in
Thus, in accordance with a further aspect of the invention, the bolting operation could be tied to control the miner shear rate (that is, the rate at which the miner M shears the material). For example, if it takes a given amount of time in which to install one or more roof bolts (which may be empirically determined), as necessary to provide proper support, the shear rate of the miner M would be controlled to shear the next cut of material in a period that substantially matches the amount of time required for the bolting. Having the shear cycle and the bolt cycle time correspond provides a smother flow of cut material and produces less machine shock. This also may reduce the wear and tear on the miner M, and results in a more stable operation.
As a further aspect of the invention, the miner M and bolter R (whether combined or otherwise) may have interlocks that promote safety. For instance, the control could prevent the miner M from advancing or otherwise tramming when the operator is in an undesirable location, such as in the path, as detected by an associated proximity sensor S (see
As noted above, the remote and control aspects this design may be employed to eliminate the need for physical barriers to the roof and ribs, such as an ATRS (which may comprise any known device for engaging a face of a mine passage to provide temporary support). By reducing the need for such systems, the miner M incorporating the bolter R can be somewhat smaller and lighter, thereby improving maneuverability. This will also reduce machine complexity and improve maintainability.
The foregoing descriptions of various embodiments of the invention are provided for purposes of illustration, and are not intended to be exhaustive or limiting. Modifications or variations are also possible in light of the above teachings. The embodiments described above were chosen to provide the best application to thereby enable one of ordinary skill in the art to utilize the disclosed inventions in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention.
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/844,892, the disclosure of which is incorporated herein by reference.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/US2007/078627 | 9/17/2007 | WO | 00 | 3/13/2009 |
Number | Date | Country | |
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60844892 | Sep 2006 | US |