Abstract:
This invention relates to the control of a machine for performing drilling or bolting operation, such as in an underground mine. In one aspect, the invention comprises a system including an input device for manually controlling at least one aspect of the drilling or bolting operation and a controller associated with at least one neutral switch. An actuator actuates the drilling or bolting operation and includes a valve associated with the input device and the neutral switch. The input device is operative for controlling the drilling or bolting operation only when the valve is in a neutral position according to the neutral switch. Related input devices and methods are also disclosed.

Description:
This application claims the benefit of U.S. Provisional Application Ser. No. 60/485,566, filed Jul. 8, 2003, the disclosure of which is incorporated herein by reference. 

   TECHNICAL FIELD 
   The present invention relates to the drilling art and, more particularly, to a drilling or bolting machine including a control system having a manual operator input device for controlling at least one aspect of the drilling or bolting operation. 
   BACKGROUND OF THE INVENTION 
   Drills using rotatable bits for penetrating into the earth are in widespread use. One application of such drills is in conjunction with a machine known in the vernacular as a “roof bolter” capable of both forming boreholes in the faces of the passageways of underground mines and then installing roof anchors or “bolts” in the boreholes. As is well-known in the art, the bolts once installed provide support for the adjacent portion of the mine face (typically the roof and ribs), thereby reducing the incidence of catastrophic cave-ins. 
   In the typical bolting operation, once the borehole is created using the drill, a resin cartridge is inserted. The drill head is then used to insert a roof bolt into the borehole to rupture the resin cartridge. Once ruptured, the bolt is rotated using the drill head to mix the resin, which is designed to quickly set and form a secure bond with the material surrounding the borehole. 
   Oftentimes, a manual operator input device, such as a joystick, is used to control the operation of the drill head, both during the drilling and bolting cycles of the operation. A single joystick may be associated with a manual control valve such that movement in a first direction (i.e., forward) results in drill head feed, rotation, or both. Alternatively, two independent joysticks may be used: one for controlling feed and the other, rotation. Using a manual control valve also allows the speed and direction of rotation or feed to be easily controlled by simply pivoting the joystick. However, electronic, solenoid-operated proportional control valves may also be used, if desired. 
   While an input device such as a joystick provides an intuitive and easy-to-use interface for controlling the drilling and bolt insertion operations, it has been discovered that the operator sometimes inadvertently moves the input device (joystick) for causing rotation when only feed is desired. Likewise, the operator may desire to rotate the chuck at a slow speed to assist in coupling the bolt head with a wrench or socket in a drill “pot,” but inadvertently move the joystick to a position such that a higher rotational speed results. Both of these occurrences essentially require the operator to repeat the procedure and, consequently, decrease the efficiency of the operation. 
   Accordingly, a need is identified for a manual input device or system for use in controlling a drilling operation, such as during the forming boreholes in one or more faces of a passageway in an underground mine. The input device would be simple to operate using only one hand, yet would prevent inadvertent actuation of the drill head (feed, rotation, or both). The input device would provide failsafe operation and would be tamper-resistant to prevent operator override. The input device would also be easily retrofitted onto existing drilling machines. The use of a neutral switch to prevent movement (tramming) of a drilling machine on power up is also disclosed. 
   SUMMARY OF THE INVENTION 
   In accordance with a first aspect of the invention, a system for controlling a drilling or bolting operation is disclosed. The system comprises an input device for manually controlling at least one aspect of the drilling or bolting operation, a controller associated with at least one neutral switch, and an actuator for actuating the drilling or bolting operation. The actuator includes a valve associated with the input device and the neutral switch. The input device is operative for controlling the drilling or bolting operation only when the valve is in a neutral position according to the neutral switch. 
   In one embodiment, the manual input device includes an enable switch associated with the controller. Preferably, the manual input device is operative for controlling the drilling or bolting operation only when the valve is in the neutral position and the enable switch is closed. However, it is also possible that the manual input device is operative for controlling the drilling or bolting operation only when the enable switch is closed before the valve is moved from the neutral position. In either case, the enable switch may be opened once the valve is moved from the neutral position with the enable switch closed without rendering the manual input device inoperative. 
   In another embodiment, the controller includes a circuit for evaluating whether the enable switch is open or closed at predetermined intervals. Using this circuit, the input device is rendered inoperative for controlling the drilling or bolting operation if the controller determines that the enable switch is closed for a predetermined number of intervals. 
   The manual input device is preferably a joystick associated with the valve and the enable switch is closed by a trigger associated with the joystick. The actuator preferably includes a valve package for selectively permitting a fluid flow to reach the valve once the controller determines that: (1) an enable switch associated with the input device is closed; and (2) the neutral switch is closed. In a more particular embodiment, the actuator includes at least one fluid-operated motor for controlling a feed or a rotation of either: (1) a drill bit for performing the drilling operation; or (2) a roof bolt used in the bolting operation. 
   In accordance with a second aspect of the invention, a manual input device for a drilling or bolting machine is disclosed. The device is designed for use by a single hand of an operator having a palm and fingers. The device comprises a support, a head associated with the support and including an upper portion and a lower portion defining an interface, and a low-profile trigger positioned adjacent the interface. The trigger includes a body having a generally semi-circular face for engagement by at least one of the operator&#39;s fingers when the palm is positioned on or generally adjacent the upper portion of the head. A switch for controlling some aspect of the drilling or bolting machine or its operation is also associated with the trigger. 
   In one embodiment, the upper portion of the head is hemispherical, the lower portion is frusto-conical, and the two portions are secured together using fasteners recessed in the upper portion. The face of the trigger is rounded from a top edge to a bottom edge of the body. A slot is defined at the interface and a portion of the trigger body projects through the slot in a home position and when the switch is in an open condition. A spring biases the trigger toward the home position, and the support is an elongated shaft pivotally mounted to a stable support structure. 
   In accordance with a third aspect of the invention, a different manual input device for use by a single hand of an operator having a palm and fingers is disclosed. The device comprises a support, a head associated with the support and including first and second separable portions defining an interface. A trigger is pivotally mounted adjacent the interface, and includes a magnet and a face for engagement by at least one of the operator&#39;s fingers when the palm is positioned on or generally adjacent the head. A magnetically-actuated switch is associated with the head and the magnet of the trigger in an actuated position. Accordingly, the presence of dust or water adjacent the head does not impair actuation of the switch by the trigger. 
   In accordance with a fourth aspect of the invention, a system for controlling a machine for use in performing a drilling or bolting operation is disclosed. The system comprises a fluid-operated motive device for moving the machine; a valve for controlling fluid flow to the motive device; an input device for manually controlling the position of the valve; and a neutral switch associated with the valve. The motive device is capable of moving the machine only when the valve is in a neutral position according to the neutral switch. In one embodiment, the input device includes an enable switch, and the motive device is capable of moving the machine only when the enable switch is closed before the neutral switch is closed. 
   In accordance with a fifth aspect of the invention, an input device for controlling a position of first and second valve spools is disclosed. The input device comprises a lever, a first ball joint supporting the lever, a first linkage connecting the lever to the first spool, and a second linkage connecting the lever to the second spool. Movement of the lever to and fro in a first direction results in corresponding movement of the first spool and movement in a second direction results in corresponding movement of the second spool. 
   In one embodiment, movement in the first direction and the movement in the second direction occur simultaneously. In another, movement in the first direction occurs before the movement in the second direction. Preferably, the first and second directions are generally perpendicular, but the first and second spools move generally parallel. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  schematically illustrates a control system forming one aspect of the invention; 
       FIG. 2  presents a side view of an operator input device forming another aspect of the invention; 
       FIG. 2   a  is a top view of the input device of  FIG. 2 ; 
       FIGS. 3   a - 3   d  present various views of a neutral switch for intended use in the control system of  FIG. 1 ; 
       FIGS. 4   a - 4   d  present various views of another embodiment of an operator input device; 
       FIG. 5  schematically illustrates a control system forming another aspect of the invention; and 
       FIGS. 6   a - 6   e  present different views of yet another operator input device. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Reference is now made to  FIG. 1 , which schematically depicts a system  10  for manually controlling a drilling operation. In the illustrated embodiment, the system  10  includes a manual operator input device  12 , such as a joystick capable of pivoting movement about at least one axis (see  FIG. 2 ). As will be understood further upon reviewing the description that follows, the input device  12  controls at least one aspect of the drilling or bolting operation, such as the rotation of the drill head, the feed of the drill head, or the movement (tramming) of the corresponding machine to which the drill head is attached. 
   The system  10  further includes a controller  14  and an actuator  16  for actuating the drilling and/or bolting operation based on the manual input received, such as by rotating and feeding either a drill steel and bit into the earth to form a borehole or a roof bolt into the borehole once formed. In the illustrated embodiment, the actuator  16  includes separate fluid-operated motive devices or motors  18 ,  20  for providing the feed and rotational forces to the drill head (not shown). The fluid flow to the motors  18 ,  20  may be regulated or controlled by a valve package  21  (see  FIG. 1 ) associated with manually operated feed and rotation control valve  22  (see  FIG. 1 ) also forming part of the actuator  16 . The valve  22  may include multiple sections  22   a  . . .  22   n  (see, e.g.,  FIGS. 6   a  and  6   b  and note directional arrows labeled  22   a  and  22   b ), each of which may control or regulate the flow of fluid to a single motor. For example, as shown in  FIG. 1 , the control valve  22  may include separate feed and rotation sections  22   a ,  22   b.    
   A switch  24  is associated with the feed and rotation control sections  22   a ,  22   b  of the valve  22  and the controller  14 . When open, the switch  24  indicates that the valve  22  (or, more specifically, the spool  23 ) is in the neutral position. These “neutral” switches  24  may be conventional position or proximity switches, various types of which are well known in the art, and may be positioned adjacent to the valve  22 . An exemplary neutral switch  24  including a detent ball  24   a  seated in a circumferential groove  23   a  formed in the valve spool  23  of a single valve section  22   a  is shown in  FIGS. 3   a - 3   d . When the ball  24   a  is moved as the result of the translation of the spool  23  (which may be connected directly to the input device  12 ), a signal propagates to the controller  14  indicating that the valve  22  (or valve section  22   a  or  22   b ) is no longer in the neutral position. 
   The preferred embodiment of the input device  12  in the form of a joystick  30  is shown in  FIG. 2 . As noted above, the joystick  30  is mounted to a stable support structure (not shown) such that pivoting movement about at least one axis is permitted. The mounting is preferably such that the joystick  30  is normally held at or biased to a neutral position, with movement in two opposite directions overcoming the biasing force and manually opening the control valve  22 . The biasing force is preferably such that it may be easily overcome by the operator, but sufficiently high to preclude movement as the result of inadvertent bumping or jarring. 
   The joystick  30  includes an elongated body or shaft  32  that supports an oversized head  34 . The head  34  includes a generally rounded or hemispherical upper portion  34   a  adapted for being comfortably received in the cupped hand of the operator, generally in engagement with the palm. A generally tapered or frusto-conical lower portion  34   b  of the head  34  provides support for the upper portion  34   a  and serves as the interface with the shaft  32 . As a result of the frusto-conical shape, the lower portion  34   b  provides a flat, slightly recessed resting place for the tips of the operator&#39;s fingers when the corresponding hand is positioned adjacent to the joystick  30 , such as during manual engagement. The upper and lower portions may be secured together via fasteners F. As shown in  FIG. 2 , the heads of the fasteners F may be recessed in the upper portion  34   a  to ensure maximum operator comfort. 
   In accordance with one aspect of the invention, the input device  12  includes an enable switch  36  for preventing inadvertent actuation of the actuator  16  (i.e., the motors  18 ,  20 ). In the most preferred embodiment, as shown in  FIG. 2 , the enable switch  36  is normally open and associated with a trigger or button  38  provided on the joystick  30 . This positioning is desirable, since it allows the operator to simultaneously engage both structures using a single hand. As also shown in  FIGS. 2 and 2   a , the button  38  may be a low-profile, generally semi-circular piece of material positioned in a slot  37  formed at the interface between the upper portion  34   b  and the frusto-conical, lower portion  34   a  of the head  34 . In the home position, the button  38  projects from the slot  37 . Accordingly, when the palm of the operator&#39;s hand is resting on or adjacent to the head  34 , one or more fingers overlie the button  38  (which as shown in  FIG. 2  preferably has a rounded face  38   a  to ensure comfort). This allows for the button  38  to be depressed or engaged in a simple fashion, such as by simply squeezing the head  34  of the joystick  30 . 
   The button  38  serving as the trigger is preferably biased toward a non-engaged or home position by a spring or like biasing means (not shown) positioned within the head  34 . As is the case with the joystick  30 , the biasing force supplied should be low enough that it is easily overcome by finger action. However, it should not be sufficiently high to prevent inadvertent actuation, such as by being bumped or jarred by the operator or contacted by a falling object. 
     FIGS. 4   a - 4   d  show an alternate embodiment of a head  40  for the joystick  30 . This head  40  is comprised of two mating halves  40   a ,  40   b  secured together by a fastener F. The mated halves  40   a ,  40   b  form a receiver  42  for a shaft (not shown) carrying a torsion spring  44 . These halves  40   a ,  40   b  also provide support for a pivot pin  46  carrying a trigger in the form of a button  48 . The button  48  is normally biased outwardly by the spring  44 , and carries a magnet  48   a . An adjacent magnetically activated switch  49  (preferably zero volume) actuates upon engaging the magnet  48   a  when the button  48  is pressed (in which case a signal propagates along line L). The button  48  in this embodiment thus associates with the enable switch  36 . The use of a magnetically actuated switch is preferable, since it is resistant to the effects of water and dust. 
   As briefly noted above, movement of the joystick  30  from a neutral or home position results in the opening of the control valve  22  and the closing of one or both of the neutral switches  24 . However, unless the enable switch  36  is closed (such as by depressing the button  38  or  48 ) before the joystick  30  is moved from the neutral position (as determined by the closing of the neutral switch(es)  24 ), the controller  14  does not actuate (energize) the valve package  21 . Consequently, no flow to the valve  22  results. In other words, if the joystick  30  moves from the neutral position before the enable switch  36  is closed (i.e., before the button  38  is engaged), the controller  14  does not signal the valve package  21  to allow additional fluid flow to reach the corresponding valve  22  (which means that the feed or rotation motors  18 ,  20  do not actuate). 
   Likewise, if the enable switch  36  is closed while the joystick  30  is moved from the neutral position, no actuation occurs even if the joystick is returned to the neutral position with the enable switch closed and then moved from the neutral position again with the switch closed. However, the logic arrangement in the controller  14  may be such that, once the joystick  30  is moved from the neutral position with the enable switch  36  closed, it thereafter may be opened (such as by releasing the button  38  or  48 ) without incident. 
   To prevent the operator from defeating the function provided by the enable switch  36  (such as by jamming the button  38  or  48  in the engaged position), the system  10  may include a “watchdog” circuit  50  (see  FIG. 1 ). This circuit  50  checks at a predetermined interval (e.g., every five seconds) the condition of the enable switch  36 , such as to see if it is open. If the switch  36  does not open after one or more of the intervals pass (the number required may be varied), the controller  14  may act to prevent flow to the valve  22 . 
   In accordance with a second aspect of the invention, and as shown in  FIG. 5 , a similar arrangement of neutral switches  24  may also be used in conjunction with a controller  14  and an actuator  16  associated with the valve or valve sections  62 ,  64  that supply the fluid for operating the hydraulic motor(s)  66 ,  68  used to move or “tram” the drilling or bolting machine. In this arrangement, the controller  14  prevents the machine from starting or moving until the valve sections  62 ,  64  are in the neutral position (which is accomplished by moving a corresponding manual input device  12  (i.e., a joystick, lever, or handle) to the neutral position), as determined by the neutral switches  24 . This guards against unexpected movement of the machine at power up in the event the input device  12  is not in the neutral position (in other words, if the input device  12  is jammed in a position that would cause movement in the forward direction and an attempt is made to start the machine). 
   As also shown in  FIG. 5 , an enable switch  36  of the type described above may also be used in conjunction with the neutral switches  24  for preventing a valve package  65  upstream of the valve sections  62 ,  64  from opening. As above, the enable switch  36  may be associated with the input device  12 , preferably on the handle, lever, or joystick used to control the movement (tramming) of the machine. The controller  14  requires the closing of the enable switch  36  when the input device  30  is in a neutral or home position before actuation. The controller  14  also does not signal the valve package  65  to open when the enable switch  36  is closed after the input device  12  is moved from the home or neutral position. However, once the signal is generated to open the valve package  65 , the enable switch  36  may be opened without incident. A watchdog circuit (not shown) similar or identical to the one described above may also form part of the controller  14  to ensure that the enable switch  36  is not defeated. 
     FIGS. 6   a - 6   e  illustrate an alternative input device  12  in the form of a lever  30  that may be used to control simultaneously two distinct valve sections  22   a ,  22   b . The lever  30  includes a first linkage  70  extending between a body or shaft  32  and a valve spool  23   a  associated with a first valve section  22   a . A second, generally transverse linkage  72  extends between the body  32  and a post  74 . A pivotally mounted connector  76  connects the post  74  to a second valve spool  23   b  associated with a second valve section  22   b . Both the post  74  and lever  30  are mounted using ball joints  78  to permit movement along at least two different axes in the same plane. 
   As should be appreciated, the input device  12  of this embodiment allows for simultaneous control of two different valve spools  23   a ,  23   b  using the same input device  30  (lever). More specifically, the second linkage  72  is rotatable about the shaft  32  such that it moves to and fro when the lever  30  is manipulated (pivoted) in a first direction (D 1  in  FIG. 6   e ) to pull the first linkage  70  and open the first valve spool  23   a . However, this movement of the lever  30  does not open the second valve spool  23   b , since the post  74  simply pivots as a result of the ball joint  78 . 
   Movement of the lever  30  to the left (that is, in a second direction D 2  perpendicular to the first direction) causes the connector body  76  to pivot about a pivot point P defined by a clevis  78  connected to a support structure  80  (see action arrow A in  FIG. 6   d ), which causes the corresponding valve spool  23   b  to move in a direction parallel to the other spool  23   a  and open. The result is the same even when the lever  30  is first pivoted such that the first valve spool  23   a  is opened. Pivoting of the lever  30  to the right likewise causes the second valve spool  23   b  to move to a position such that flow through the corresponding valve section  22   b  may be reversed. Forward movement of the lever  30  likewise may cause the first valve spool  23   a  to move to a reverse-flow position, and combined left or right movement results in a corresponding repositioning of the second valve spool  23   b.    
   As should be appreciated, by associating the first valve spool  23   a  with drill head rotation and the second valve spool  23   b  with feed, it is possible to commence the former without the latter. However, both feed and rotation may result by pulling the lever  30  back and then moving it to the left. Likewise, rotation and feed can be simultaneously reversed by moving the lever forward and to the right. Other combinations are of course possible in light of the foregoing description. By using neutral switches and providing an enable switch on the input device, this arrangement may also be used in conjunction with the controller  14  to create a lockout condition unless the switches are actuated in a certain sequence, as outlined in detail in the foregoing description. 
   As should be appreciated, any of the above manual operator input devices may be retrofitted onto an existing drilling or bolting machine to replace the existing input device. Any adjustments necessary to provide a corresponding controller can also be made to implement the overall control systems disclosed. 
   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. For example, other manual input devices, such as those including simple proximity switches for detecting the presence of the operator near the controller (see, e.g., U.S. Pat. No. 6,501,198, the disclosure of which is incorporated herein by reference) may be used instead of those described. 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 as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled.