Abstract:
A mining system for advancing and retrieving a mining vehicle such as a miner, material transfer units or, shields into and out of mines. The system includes a platform from which the vehicle is advanced into a mine by means of a pusher. Subsequent vehicles are placed onto the platform, connected to the preceding vehicle and then advanced into the mine. If desired, shields and a miner or material transfer unit may be simultaneously advanced into the mine in the same manner. To retrieve the vehicle, the pusher is reversed and pulls each vehicle from the mine in reverse order. If desired, the shields may remain in the mine and the miner and transfer units may be pulled from within the shields. The platform further includes a system for removing the mined ore from the transfer units as it is delivered from the mine.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]    The present application claims priority from U.S. Provisional Application Ser. No. 60/475,974, filed Jun. 5, 2003. The present application is related to copending U.S. patent applications Ser. No. ______, entitled “Shield System For Coal Mining” and Ser. No. ______, entitled “Advancer For Coal Mining System” filed Jun. 7, 2004, both herein incorporated by reference in their entirety. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    The invention is generally related to an improved system for coal mining. More particularly, the invention is directed to a platform for high wall mining.  
         DESCRIPTION OF RELATED ART  
         [0003]    Highwall mining is generally a method of mining whereby a remote controlled continuous miner is sent into a face of coal, or other ore, from an outside bench to mine or cut such ore out from under the overburden above. The continuous miner will generally cut out the ore in widths ranging from six to twelve feet in width and up to fourteen feet in height, depending on the size of miner used. As the miner is remotely controlled from outside into the ore, units for transferring the mined ore, called “cars” or “beams,” are sequentially sent into the mine, forming a continuous train and transferring the ore from car to car to the outside bench. Various methods are incorporated into the units for transferring the ore, including conveyors, chains and screws. Likewise various methods are used to power the transferring units, including electrical, hydraulics and/or mechanical drive shafts. The cars or beams are generally either coupled or pinned together, allowing some degree of deflection between them to improve negotiation of the rough surface in the mine.  
           [0004]    On the outside of the mine, a launch platform is positioned to receive the transferred material as it is discharged from the rear car or beam and direct it either to a truck or stockpile via belt conveyors and/or chain conveyors. The launch platform also acts as a staging area to insert and retrieve the cars as needed and also act as a drive station to either hydraulically, electrically or mechanically drive or push the cars into the mine.  
           [0005]    Additional roof problems are created by not controlling the direction of the miner precisely as it is driven into the mine. If the mine is not steered properly, the pillar or rib in between two mines can be cut. When the system cuts through the pillar exposing the width of two cuts, which can be as much as twelve feet in width each, twenty feet or more of unsupported roof is exposed. This greatly increases the potential for major roof falls, thus increasing the potential for entrapment.  
           [0006]    Systems commonly used today require significant force to push the transfer units and mine into particularly deep mines. In deep mines, this force often causes the cars to buckle up and down throughout the hole binding. Because of this, the depth to which they can be pushed is limited.  
           [0007]    Current disclosed methods of remote mining in ore deposits such as coal generally employ a mining machine that excavates mine openings to some distance from the seam exposure on the surface and a system for conveying the mined ore to the surface. In most of the present systems, the system for conveying consists of multiple conveyors which are advanced into the mine openings from the surface. U.S. Pat. Nos. 6,644,753 and 6,220,670 issued to Mraz disclose a method and apparatus for mining of aggregate material from a seam which includes a mining apparatus and a self-propelled conveyor capable of advancing or retreating in the seam on its own power and an advancing and steering arrangement for the mining apparatus.  
           [0008]    U.S. Pat. Nos. 5,112,111, 5,232,269, 5,261,729 and 5,364,171 to Addington at al. disclose an assembly of conveyors and a mining machine advanced into the seam without interrupting the flow of aggregate material by separate means designed to pull at the forward end and push at the rearward end. Similarly, U.S. Pat. No. 5,609,397 to Marshall at al. discloses an assembly of conveyors interconnected with a mining machine and a driving device located outside the seam and consisting of rack and pinion or, alternately, reciprocating cylinders, linear tracks, linear or rotary drives, chains, cables or other mechanical devices. U.S. Pat. No. 5,692,807 to Zimmerman discloses a guidance assembly for extending and retracting an assembly of conveyors into and out of the seam. U.S. Pat. No. 3,497,055 to Oslakovic at al. discloses a multi-unit train of conveyors having a self-propelled unit at each end coupled to intermediate units, each end unit being capable of towing the intermediate units. U.S. Pat. No. 2,826,402 to Alspaugh at al. discloses a train of wheeled conveyor sections pulled into the mine opening and pushed out of it by a self-propelled mining machine. Buckling of the train is avoided by the grooves made by the mining machine in the floor, said grooves spaced the same distance as the treads of the wheels carrying the conveyor sections.  
           [0009]    At present, material transfer units, such as cars and beams, are pushed from a platform external to the mine into the mined hole by cylinders. The strong forward push of the cylinder moves the units into the mine while the weak backward pull of the cylinder is used to retrieve the units from the mine. In fact, more force is often needed to retrieve the units from the mine in the event rock has fallen on top of the units or, more particularly, in the event the units become entrapped by a roof cave in.  
           [0010]    Accordingly, it is an object of the present invention to provide an improved system for pushing material transfer units for mined material into and out of mines.  
           [0011]    It is another object of the present invention to provide an improved system for pushing shielded or unshielded material transfer units into and out of mines with equal force.  
           [0012]    It is another object of the present invention to provide a system for removing a miner and/or material transfer units from within a mine in the event they become entrapped.  
           [0013]    It is another object of the present invention to provide an improved mining system which reduces or eliminates down time caused by falling rocks or cave-ins.  
           [0014]    It is a further object of the present invention to provide an improved mining system which provides increased control of the transfer units at greater mine depths.  
           [0015]    It is yet a further object of the present invention to provide an improved mining system which provides greater directional control of the miner and transfer units.  
           [0016]    Finally, it is an object of the present invention to accomplish the foregoing objectives in a safe and cost effective manner.  
         SUMMARY OF THE INVENTION  
         [0017]    A mining system for pushing a mining vehicle, such as a miner, material transfer unit or shield, into a mine and for retrieving the mining vehicle from the mine, includes a platform, an advancing means for advancing the mining vehicle into a mine and a retrieving means for retrieving the mining vehicle from the mine. The platform preferably includes a device for leveling the platform as well as controls for controlling a miner, power and water supply to the miner, and miner hydraulics. The mining vehicle is preferably connected to and advanced by an apparatus with at least one drive gear, drive gear belt and a motorized means for driving the drive gear while retaining the drive gear in contact with the drive gear belt. The drive gear is preferably a sprocket and the drive gear belt is a chain which accepts the sprocket. In a particularly preferred embodiment, the drive gear is driven by a planetary gear box. The advancing means may be connected to the mining vehicle by a hook and pin system. To retrieve the mining vehicle from the mine, the motorized means operates in reverse. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0018]    [0018]FIG. 1 a  is a side view of the preferred embodiment of the present invention;  
         [0019]    [0019]FIG. 1 b  is an exploded side view of the preferred embodiment of the present invention;  
         [0020]    [0020]FIG. 1 c  is an exploded side view of an alternate embodiment of the present invention, shown in further detail in FIGS. 8 a - 8   f;    
         [0021]    [0021]FIG. 2 is plan view of the preferred embodiment of the present invention;  
         [0022]    [0022]FIG. 3 is a cross sectional view of a miner and material transfer units inside a mine;  
         [0023]    [0023]FIG. 4 a  is an exploded side view of connection system as used in the preferred embodiment of the present invention;  
         [0024]    [0024]FIG. 4 b  is an exploded side view of connection system as used in the preferred embodiment of the present invention;  
         [0025]    [0025]FIG. 5 a  is an end view of the preferred embodiment of the present invention;  
         [0026]    [0026]FIG. 5 b  is an exploded side view of the preferred embodiment of the present invention;  
         [0027]    [0027]FIG. 5 c  is an exploded, cross-sectional side view of the present invention;  
         [0028]    [0028]FIG. 5 d  is an exploded, cross-sectional side view of the present invention;  
         [0029]    [0029]FIG. 6 a  is an end view of a material transfer unit which can be used with the preferred embodiment of the present invention;  
         [0030]    [0030]FIG. 6 b  is an end view of a material transfer unit which can be used with the preferred embodiment of the present invention;  
         [0031]    [0031]FIG. 6 c  is an end view of a material transfer unit which can be used with the preferred embodiment of the present invention;  
         [0032]    [0032]FIG. 6 d  is an end view of a material transfer unit which can be used with the preferred embodiment of the present invention;  
         [0033]    [0033]FIG. 6 e  is an end view of a material transfer unit which can be used with the preferred embodiment of the present invention;  
         [0034]    [0034]FIG. 7 a  is an end view of an alternate embodiment of the present invention;  
         [0035]    [0035]FIG. 7 b  is an exploded side view of the alternate embodiment of the present invention shown in FIG. 7 a;    
         [0036]    [0036]FIG. 7 c  is an exploded side view of the alternate embodiment of the present invention shown in FIG. 7 a;    
         [0037]    [0037]FIG. 7 d  is an exploded side view of another alternate embodiment of the present invention;  
         [0038]    [0038]FIG. 7 e  is an end view of the alternate embodiment of the present invention shown in FIG. 7 d;  and  
         [0039]    [0039]FIG. 7 f  is an exploded side view of the alternate embodiment of the present invention shown in FIG. 7 d.   
     
    
     ELEMENT LIST  
       [0040]    [0040] 101  Corner post  
         [0041]    [0041] 103  Crawlers  
         [0042]    [0042] 105  Car support  
         [0043]    [0043] 110  Control booth  
         [0044]    [0044] 112  Catwalks  
         [0045]    [0045] 114  Ladders  
         [0046]    [0046] 115  Cable reels  
         [0047]    [0047] 120  Platform roof  
         [0048]    [0048] 125  Switch box  
         [0049]    [0049] 130  Motors  
         [0050]    [0050] 137  Chain  
         [0051]    [0051] 138  Beam/plate  
         [0052]    [0052] 140  Side discharge conveyor  
         [0053]    [0053] 145  Shield  
         [0054]    [0054] 150  Platform belly conveyor  
         [0055]    [0055] 155  Highwall  
         [0056]    [0056] 160  Bench  
         [0057]    [0057] 165  Piggy-back conveyor  
         [0058]    [0058] 170  Bridge  
         [0059]    [0059] 200  Driver/puller  
         [0060]    [0060] 203  Planetary gear boxes  
         [0061]    [0061] 207  Frame  
         [0062]    [0062] 209  Drive sprockets  
         [0063]    [0063] 213  Beam flange  
         [0064]    [0064] 215  Rollers  
         [0065]    [0065] 300  Miner  
         [0066]    [0066] 305  Miner head  
         [0067]    [0067] 401  Side supporters of shield  
         [0068]    [0068] 403  Connecting pin for shield  
         [0069]    [0069] 405  Top plate of shield  
         [0070]    [0070] 408  Bottom plate of shield  
         [0071]    [0071] 411  Mine floor  
         [0072]    [0072] 414  Mine roof  
         [0073]    [0073] 430  Side frame of material transfer unit  
         [0074]    [0074] 433  Top belt rollers  
         [0075]    [0075] 435  Bottom belt return roller  
         [0076]    [0076] 437  Top (carry) belt  
         [0077]    [0077] 439  Bottom (return) belt  
         [0078]    [0078] 441  Pin  
         [0079]    [0079] 443  Wheel roller  
         [0080]    [0080] 445  Spring (upwardly biased)  
         [0081]    [0081] 447  Roller guides (belt alignment)  
         [0082]    [0082] 450  Head pulley  
         [0083]    [0083] 451  Tail pulley  
         [0084]    [0084] 452  Inner hook  
         [0085]    [0085] 453  Hook on material transfer unit  
         [0086]    [0086] 454  Outer hook  
         [0087]    [0087] 455  Keeper pin  
         [0088]    [0088] 457  Driver bar  
         [0089]    [0089] 459  Blade  
         [0090]    [0090] 501  Material transferring unit  
         [0091]    [0091] 503  Shuttle car on wheels  
         [0092]    [0092] 504  Movable transfer floor  
         [0093]    [0093] 505  Tire/wheel  
         [0094]    [0094] 506  Material transfer unit on rails  
         [0095]    [0095] 507  Roller guides  
         [0096]    [0096] 508  Cable carriers  
         [0097]    [0097] 509  Rail  
         [0098]    [0098] 510  Rope guide  
         [0099]    [0099] 511  Railroad wheels  
         [0100]    [0100] 512  Nonmovable floor  
         [0101]    [0101] 514  Opening  
         [0102]    [0102] 550  Continuous belt transfer unit  
         [0103]    [0103] 913  Push cylinder  
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0104]    Referring now to the drawings, FIGS. 1 a - 7   f  show several embodiments of the present invention. As shown, the invention can be used with different types of material transfer units, shielded or unshielded, or shields alone, all capable of being driven or pulled from a mine. While the preferred embodiment is specifically described for a shielded material transfer unit, the invention is clearly applicable to material transfer units used without shields.  
         [0105]    Referring to FIGS. 1-3, FIGS. 1 a - 1   c  show a side view and FIG. 2 shows a plan view of the outside launch platform  105  which acts as a staging unit for inserting shielded material transfer units  145  &amp;  501  into the mined opening. As the shields  145  and material transfer units  501  are fed into the mined opening behind the miner  300  (see FIG. 3), the material transfer units  501  are hooked together as shown in FIGS. 4 a  and  4   b.  A hook  453  from one material transfer unit  501  is placed over a pin  441  on the next material transfer unit  501 . A retaining pin  455  may be used to ensure that the hook  453  is retained on the pin  441 . This hook and pin connection causes the material transfer units  501  to be pulled behind the miner  300  in succession. The shields  145  may be hooked together in a similar manner. The shields  145  and material transfer units  501  are either pushed into or pulled out of the hole by the driver/puller  200 . The driver/puller  200 , shown in detail in FIGS. 5 a - 5   d  and  7   a - 7   f,  rides in chain  137  on beam/plate  138  which travels forward and back along the length of the platform  105 . As the driver/puller  200  pushes or pulls the shields  145  and material transfer units  501  in or out, mined material from within the shielded material transfer units  145  &amp;  501  can be discharged onto a belly conveyor  150  running the length of the platform  105 . The belly conveyor  150  will then carry the mined material to a side discharge conveyor  140  which will transfer the mined material to a stacking conveyor or stockpile. Many different types of material transfer units can be used within the shields  145 . One type of transfer unit is shown in FIGS. 1 a  and  1   b.  Multiple piggyback conveyors  165  are attached independently within the shields  145 . These conveyors  165  transfer material from one conveyor  165  to another until the material reaches the outside platform  105 . Many other types of material transfer units can be used independently within the shields  145 ; some examples are shown in FIGS. 6 a - 6   e.  These examples are not exhaustive of the types of material transfer units which may be used with the present invention.  
         [0106]    The platform  105  sits on a bench  160  adjacent to the highwall  155  and, if needed, has a bridge  170  to provide transition from the platform  105  over to the mouth of the mine hole. The platform  105  can also carry and support electrical transformers, if needed, in electrical support room  125 , cable reels  115  for miner cable, water hoses, control cables and a hydraulic room  130  including pumps, valves and controls. Also, it may carry a control cab  110 . A roof  120  can be provided to shield the platform  105  from weather. The platform  105  can have leveling jacks  101  on the corners for stability, leveling and/or raising the platform  105  to the seam height. The platform  105  can be moved laterally by using either walking plates placed under the corner jacks  101 , by crawlers  103  or by a trailer (not shown) located under the platform  105  depending on the needs of the user.  
         [0107]    [0107]FIG. 3 shows the miner  300  underground cutting the ore and feeding the mined material back to a conveyor  165  within a shield  145 , which ore is ultimately fed back to the platform  105 . The present invention can be used with many types of miners, including but not limited to the type of miner shown in FIG. 3.  
         [0108]    [0108]FIGS. 4 a  and  4   b  show the preferred means for connecting multiple material transfer units  501 . A connecting arm  453  from a first material transfer units  501  fits over a pin  441  on a second material transfer unit  501 ′, connecting the end of the first material transfer unit  501  to the second material transfer unit  501 ′ and a shear pin  455  is preferably inserted above the connecting arm  453  to keep the arm  453  from raising off the pin  441 . Multiple shields  145  may be connected together in a similar manner.  
         [0109]    [0109]FIG. 5 a  shows a front view of the driver/puller  200 . The driver/puller  200  is preferably comprised of two planetary gear boxes  203  supported by a frame  207 . The frame  207  is a solid structure carrying the two planetary gear boxes  203  from side to side along the length of the platform. The planetary gear boxes  203  drive sprockets  209  forward and reverse in a sprocket chain  137  which is attached to a beam or plate  138  running the length of the platform  105  allowing the same force to be applied the total travel in forward or reverse. To keep the sprocket  209  teeth from walking up and out of the chain  137 , heavy-duty rollers  215  are preferably attached around a beam flange  213  or hold down plate.  
         [0110]    For pushing, two inner hooks  452  and two outer hooks  454  are recessed into the face of the frame  207  when the shielded material transfer units  145  &amp;  501  and the driver/puller  200  are located at same elevation. When pulling the shielded material transfer units  145  &amp;  501  in reverse, the hooks  452  and/or  454  are connected to pins  403  and  441  on the shields  145  and material transfer units  501 . Either the hooks  452  and  454  can be used simultaneously to pull out the shields  145  and material transfer units  501  together or the inner hooks  452  can be used alone to pull out just the material transfer units  501  and, if desired, the miner  300 , from within the shields  145 .  
         [0111]    [0111]FIG. 5 b  shows a side cut view looking in behind the sprockets  209  showing the frame  207 , the heavy-duty roller wheels  215  attached above and below the beam flange  213 , inner hooks  452  and outer hooks  454  recessed in frame  207  and the shielded material transfer units  145  &amp;  501  at same elevation as driver/puller  200 .  
         [0112]    [0112]FIGS. 5 c  and  5   d  show a side view of the driver/puller  200  and the planetary gear box  203  with drive sprocket  209  attached and riding in a heavy-duty crawler tractor type chain  137 . FIG. 4 c  shows outer hook  454  in the up (or recessed) position and FIG. 4 d  shows outer hook  454  in the down and locked position over pin  403  as used for pulling the shield  145  from the hole.  
         [0113]    [0113]FIGS. 6 a - 6   e  show several types of material transfer units which can be used independently within the shields  145 . These examples are not exhaustive of the types of material transfer units which may be used with the present invention.  
         [0114]    [0114]FIG. 7 a  shows an alternate method of using the driver/puller  200  to drive the shielded material transfer units  145  &amp;  501  from above rather than having the driver/puller  200  and the shielded material transfer units  145  &amp;  501  at the same elevation as described above, see also FIG. 1 c.  The heavy-duty rollers  215  are attached to a beam flange  213  or plate above the driver/puller  200  and apply pressure downward to keep the sprockets  209  from walking up and out of the chain  137 .  
         [0115]    [0115]FIG. 7 b  shows pusher arms  457  that are employed when a shielded material transfer unit  145  &amp;  501  is driven from above as shown in FIG. 7 a.  If desired, the pusher arms  457  may be designed to rotate to an up position. This orientation of the pusher arms  457  allows a shielded material transfer unit  145  &amp;  501  to be positioned while the driver/puller  200  is still pushing the prior shielded material transfer unit  145  &amp;  501  into the mine. Once the prior unit  145  &amp;  501  has been pushed completely forward and the subsequent shielded material transfer unit  145  &amp;  501  is positioned on the platform  105 , the pusher arms  457  can be raised and returned to a location behind the next unit  145  to be pushed forward into the mine. The pusher arms  457  are then lowered, as shown in FIG. 7 c  and are available to push the next shielded material transfer unit  145  &amp;  501  into the mine, once it has been hooked to the prior shielded material transfer unit  145  &amp;  501 . As shown in FIGS. 7 d - 7   f,  the pusher arms  457  can support a blade  459  across the width of a material transfer unit  501  which can be lowered into the unit  501  to push or scrape material out the rear of a material transfer unit  501 . FIGS. 7 d  and  7   e  show the blade  459  in the down or scraping position. FIG. 7 f  shows the blade  459  in the raised position, allowing a shielded material transfer unit  145  &amp;  501  to pass beneath the blade  459 .  
         [0116]    While the description above refers to particular embodiments of the present invention, it will be understood that many modifications may be made without departing from the spirit thereof. The accompanying claims are intended to cover such modifications as would fall within the true scope and spirit of the present invention.