Abstract:
A guide assembly for a longwall shearer. The shearer includes an arm having an arm end and a cutting drum rotatably coupled to the arm end. The cutting drum rotates about a drum axis and engages a mine wall, and the cutting drum has a rear extent arranged in a plane substantially perpendicular to the drum axis. The guide assembly includes a guide member coupled to the arm and operable to guide material won from the mine wall. The guide member has a guide surface extending in a direction non-parallel to the plane and non-parallel to the drum axis. The guide member guides material along the guide surface away from the cutting drum.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Application No. 61/517,623, filed Apr. 22, 2011, the entire contents of which are incorporated herein by reference. 
    
    
     FIELD 
     The present invention relates to the field of mining machines. Specifically, the present invention relates to longwall shearing machines. 
     SUMMARY 
     Conventional longwall shearers include a chassis, at least one ranging arm, a cutting drum mounted on the ranging arm, and a face conveyor. The ranging arm articulates with respect to the chassis to position the cutting drum in a desired position for engaging a mine wall. The cutting drum rotates about an axis perpendicular to the mine wall and includes vanes extending along the cutting drum. Generally, a machine operator must be directly behind the cutting drum to ensure the drum is positioned properly and functioning properly. The ranging arm can raise the drum to mine material at heights in excess of 20 feet. When the drum is cutting in a high position, debris liberated from the wall is thrown in many directions, including toward the operator&#39;s work area, and could thus strike the operator. 
     In addition, the face conveyor is spaced a distance from the mine wall. In some instances, the conveyor is as far as 1 meter from the cutting drum in order to prevent contact between the conveyor and the cutting drum and to allow the conveyor to articulate as necessary as the longwall shearer advances through a mineral seam. As the cutting drum liberates material from the mine wall, the material scrolls along the vanes and moves toward the conveyor. Upon reaching the end of the vanes of the cutting drum at the end nearest the conveyor, the material falls to the mine floor and accumulates in a “windrow” of material between the mine wall and the conveyor. 
     The windrow causes difficulty in advancing the conveyor, either by blocking the conveyor or forcing the conveyor to rise up onto the loose material in the windrow. A cowl may be positioned around a circumferential portion of the cutting drum to deflect material that is cast in a direction parallel to the mine wall (radially from the cutting drum), but the windrow develops regardless of whether a cowl is provided. As much as a third of the material liberated from the mine wall may be deposited in the windrow reducing the amount of efficiency of the mining operation. 
     In one independent embodiment, a guide assembly for a longwall shearer is provided. The shearer includes an arm having an arm end and a cutting drum rotatably coupled to the arm end. The cutting drum rotates about a drum axis and engages a mine wall, and the cutting drum has a rear extent arranged in a plane substantially perpendicular to the drum axis. The guide assembly may generally include a guide member coupled to the arm and operable to guide material won from the mine wall. The guide member may extend substantially perpendicular to the drum axis and may be arranged to not cross the plane. 
     In another independent embodiment, the guide assembly may generally include a guide member coupled to the arm and operable to guide material won from the mine wall. The guide member may have a guide surface extending in a direction non-parallel to the plane and non-parallel to the drum axis. The guide member may guide material along the guide surface away from the cutting drum. 
     In yet another independent embodiment, the guide assembly may generally include a hub portion and a guide member. The hub portion may be coupled to the arm and pivotable about a hub axis. The guide member may be connected to and pivotable with the hub portion. The guide member may extend perpendicular to the drum axis and may be arranged to not cross the plane. The guide member may include a flap formed at least partially of a flexible material, and the flap may deflect material won from the mine wall and traveling in a direction non-parallel to the plane. 
     In still another independent embodiment, a longwall shearer for engaging a mine wall is provided. The shearer may generally include a body, an arm, a cutting drum, and a guide member. The arm includes a first end coupled to the body and a second end. The cutting drum is rotatably coupled to the arm end. The cutting drum rotates about a drum axis and engages a mine wall. The cutting drum has a rear extent arranged in a plane substantially perpendicular to the drum axis. The guide member may be coupled to the arm and operable to guide material won from the mine wall. The guide member may extend substantially perpendicular to the drum axis and may be arranged to not cross the plane. 
     Other independent aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a mining machine. 
         FIG. 2  is a perspective view of a cutting assembly. 
         FIG. 3  is a side view of the cutting assembly of  FIG. 2 . 
         FIG. 4  is a perspective view of a cutting assembly according to another independent embodiment, with a deflector in a deployed position. 
         FIG. 5  is a perspective view of the cutting assembly of  FIG. 4 , with the deflector in a stowed position. 
         FIG. 6  is a perspective view of a cutting assembly according to another independent embodiment. 
         FIG. 7  is a perspective view of a cutting assembly according to another independent embodiment. 
         FIG. 8  is a rear view of the cutting assembly of  FIG. 7 . 
         FIG. 9  is a perspective view of a deflector as shown in  FIG. 7 . 
         FIG. 10  is an exploded perspective view of the deflector of  FIG. 9 . 
         FIG. 11  is section view of the cutting assembly of  FIG. 7  taken generally along line  11 - 11 . 
     
    
    
     DETAILED DESCRIPTION 
     Before any independent embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other independent embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising” or “having” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “mounted,” “connected” and “coupled” are used broadly and encompass both direct and indirect mounting, connecting and coupling. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings, and can include electrical connections or couplings, whether direct or indirect. As described in subsequent paragraphs, the specific configurations illustrated in the drawings are intended to exemplify independent embodiments of the invention, and other alternative configurations are possible. 
       FIG. 1  illustrates a longwall shearer  10  including a chassis or base  14 , a pair of cutting assemblies  18 , and an armored face conveyor  22  ( FIG. 2 ). The base  14  is configured to tram along a wall (not shown) of material to be mined in a first direction  26  and a second direction  28 . As the base  14  moves in the first direction  26 , a first cutting assembly  18   a  is in a leading position and a second cutting assembly  18   b  is in a trailing position. The first cutting assembly  18   a  is elevated to cut material from an upper portion of the mine wall, while the second cutting assembly  18   b  is in a lower position to cut material from a lower portion of the mine wall. 
     As shown in  FIG. 2 , each cutting assembly  18  includes a ranging arm  30 , a cutting drum  34 , and a guide assembly  38 . The ranging arm  30  has a first end  46  pivotably coupled to the base  14  and a second end  50 . Referring to  FIGS. 2 and 3 , the cutting drum  34  includes a generally cylindrical body  54 , multiple vanes  58 , and multiple cutting bits  62 . The body  54  has a first end  70  and a second end  74 , and a drum axis  78  is defined therebetween. The first end  70  is pivotably coupled to the second end  50  of the ranging arm  30  and has a generally planar surface. As used herein, the term “axial” and variants thereof refer to a direction parallel to the drum axis  78  and the term “radial” and variants thereof refer to a direction perpendicular to the drum axis  78 . 
     The cutting drum  34  rotates about the drum axis  78  in a first direction  82  ( FIG. 2 ). Each vane  58  extends in a spiral manner along the periphery of the body  54 , between the first end  70  and the second end  74 . The cutting bits  62  ( FIG. 2 ) are positioned along the vanes  58 . 
     As shown in  FIGS. 2 and 3 , the guide assembly  38  includes a hub  86  and a guide member  90 . The hub  86  is coupled to the second end  50  of the ranging arm  30 . As shown in  FIG. 3 , the guide member  90  includes a first end  94  adjacent the first end  70  of the body  54 , a second end  98  proximate the conveyor  22 , and an angled portion  102 . In the illustrated embodiment, the angled portion  102  is inclined downwardly from the first end  94  toward the second end  98 . In other embodiments, the angled portion  102  may include multiple facets (see, for example,  FIG. 4 ), or may have a curved profile. 
     During operation of the longwall shearer  10 , the base  14  travels back and forth along the mine wall. Each ranging arm  30  is pivoted about its first end  46  to move the cutting drum  34  into contact with the mine wall. The cutting drum  34  rotates about the drum axis  78  and the cutting bits  62  engage the mine wall until the shearer  10  completes a pass along the wall. The cutting bits  62  liberate material from the wall, and the material scrolls along the vanes  58 , thereby transporting the material from the second end  74  of the body  54  toward the first end  70 . Upon reaching the first end  70 , material exits the vane  58  and engages the angled portion  102  of the guide assembly  38 . In the illustrated embodiment, the material slides along the angled portion  102  from the first end  94  to the second end  98 , at which point the material disengages the guide assembly  38  and falls onto the conveyor  22 . The guide assembly  38  thus directs the material from the cutting drum  34  and rearwardly onto the conveyor  22 . By directing material onto the conveyor  22 , the guide assembly  38  may reduce the amount of material falling between the cutting drum  34  and the conveyor  22 , which may be lost and/or added to the windrow. The guide assembly  38  may thereby increase the efficiency of the shearer operation. 
       FIGS. 4 and 5  show another independent embodiment of the guide assembly  338 . The guide assembly  338  is similar to the guide assembly  38  described above with respect to  FIGS. 1-3 , and only differences are described below. Common features have the same reference numbers, plus  300 . 
     In this embodiment, the hub  386  is pivotably coupled to the second end  50  of the ranging arm  30  such that the guide member  390  can be positioned in multiple orientations with respect to the body  54  and to the arm  30 . In the illustrated embodiment, the hub  386  pivots about the drum axis  78 . In other embodiments (not shown), the hub  386  may pivot around an axis that is offset from the drum axis  78  and/or an axis that is not parallel to the drum axis  78 . 
     In  FIG. 4 , the guide member  390  is shown in a deployed state in which the guide assembly  338  directs the material from the cutting drum  34  and rearwardly onto the conveyor  22 . As the arm  30  is pivoted to position and re-position the cutting drum  34 , the hub  386  may be pivoted to position/re-position the guide member  390  in an appropriate orientation to guide material onto the conveyor  22 . 
     As shown in  FIG. 4 , the angled portion  402  has a first angled section  402   a  at a first angle and a second angled portion  402   b  at a second angle different than the first. In the illustrated construction, the steeper first angled section  402   a  is positioned proximate the cutting drum  34 , and the shallower second angled section  402   b  is positioned proximate the conveyor  22 . In other constructions (not shown), the angled portion  402  may have only one or more than two angled sections. 
     In  FIG. 5 , the guide member  390  is shown in the stowed state. In this state, the guide member  390  engages against a surface of the arm  30  (the upper surface in  FIG. 5 ) and is generally moved out of the way. In other constructions (not shown), the guide member  390  may also be angled on its opposite surface so that any material falling on that surface also tends to move toward the conveyor  22 . In still other constructions (not shown), the hub  386  could be pivoted in the opposite direction to stow the guide member  390  against the lower surface of the arm  30 . 
     During operation, as the shearer  10  begins a new pass, the guide assembly  338  of the trailing cutting assembly  18   b  ( FIG. 1 ) is pivoted to a deployed state ( FIG. 4 ), and, in the deployed state, the guide assembly  338  loads material onto the conveyor  22 . Meanwhile, the guide assembly  338  of the leading cutting assembly  18   a  ( FIG. 1 ) may be pivoted to a stowed state ( FIG. 5 ) or deployed in a different position in order to improve the loading capability of the leading cutting assembly  18   a . With the pivotable guide assembly  338 , the guide member  390  may be moved to avoid contacting roof supports during operation of the longwall shearer  10 , thereby providing additional versatility for operation of shearer  10 . 
       FIG. 6  shows another independent embodiment of the guide assembly  638 . The guide assembly  638  is similar to the guide assembly  338  described above with respect to  FIGS. 4 and 5 , and only differences are described below. Common features have the same reference numbers, plus  300 . 
     In this embodiment of  FIG. 6 , the guide member  690  includes an arm  692  and a wing  696  pivotably coupled to the arm  692 . The wing  696  has an angled surface  702 . When the guide assembly  638  is pivoted to a deployed state, the wing  696  is pivoted relative to the arm  692  to a position to receive the material exiting the cutting drum  34 . 
     An operator can adjust the orientation of the wing  696  and the angle of the surface  702 , as necessary. Pivoting movement of the wing  696  may be, for example, driven hydraulically or positioned by a spring or cam. In addition, the wing  696  can be pivoted about the arm  692  to be approximately parallel with the hub  686 , allowing the guide member  690  to rotate 360° around the axis  78  and to be stowed inline with the ranging arm  30 . 
       FIGS. 7-11  show another independent embodiment of the guide assembly  938 . The guide assembly  938  is similar to the guide assembly  338  described above with respect to  FIGS. 4-5 , and only differences are described below. Common features have the same reference numbers, plus  600 . 
     As shown in  FIGS. 9-10 , the hub  986  is formed as a top portion  1004  and a bottom portion  1008 , both of which are coupled to a circular rim  1012 . The top portion  1004  and the bottom portion  1008  are removably coupled together, for example, by fasteners  1016 . The hub  986  includes a ring gear  1020  positioned adjacent the rim  1012 , and a bracket portion  1024 . In the illustrated embodiment, the ring gear  1020  extends partially along the circumference of the rim  1012 . The bracket portion  1024  includes a support arm  1028  extending away from the hub  986  in a direction perpendicular to the drum axis  78  ( FIG. 8 ). 
     Referring to  FIGS. 9-10 , the guide member  990  is formed as a flap  1032  coupled to the bracket portion  1024  and the support arm  1028 . The flap  1032  generally extends away from the drum axis  78  in a radial direction. As shown in  FIG. 8 , the flap  1032  extends radially beyond the circumference of the cutting drum  34 . The flap  1032  covers a sector of the cutting drum  34  (about 70° at the radial edge of the cutting drum  34 ). The flap  1032  deflects material cast by the cutting drum  34  in a direction away from the mine wall and directs that material downward toward the conveyor  22  or the mine floor, shielding the area behind the flap  1032  (e.g., the operator&#39;s station) from material that is cast by the cutting drum  34 . 
     The flap  1032  is made from a generally flexible material so that the flap  1032  can deform when the flap  1032  comes into contact with an object or structure (e.g., a mine surface, a component of the shearer  10 , a roof support (not shown), etc.). The flexible material allows the flap  1032  to absorb the impact from material without causing damage to the flap  1032 . 
     In the illustrated construction, the flap  1032  includes an edge portion  1036  that is folded over and secured to the bracket support arm  1028 . The support arm  1028  and/or the folded edge portion  1036  provide structural reinforcement for the flap  1032 , preventing the edge of the flap  1032  from bending under its own weight and coming into contact the cutting drum  34 . 
     Referring to  FIG. 11 , the second end  50  of the ranging arm  34  includes a motor  1040  and a groove  1044  for receiving the rim  1012  to secure the hub  986  against movement in a direction parallel to the drum axis  78 . The ring gear  1020  is also positioned within the groove  1044 . The motor  1040  drives a pinion gear  1048  that engages the ring gear  1020 . As the pinion gear  1048  rotates, the pinion gear  1048  moves the ring gear  1020  relative to the drum axis  78  ( FIG. 8 ), rotating the guide assembly  938  about the drum axis  78 . This allows the operator to pivot the guide member  990  to a desired position with respect to the cutting drum  34 . While not shown, a similar arrangement may be provided for the pivoting hub  386  or  686 , described above and shown in  FIGS. 4-5  or  FIG. 6 , respectively. 
     During operation, the operator actuates the motor  1040  to move the guide assembly  938  to a desired position. The ranging arms  30  move the cutting drums  34  to engage various portions of the mine wall, including upper wall portions. As the cutting drum  34  is raised and lowered, the guide member  990  is pivoted to a desired position to provide maximum coverage of an area behind the cutting drum  34  in which liberated material is likely to be cast. The guide member  990  is positioned so that the flap  1032  does not bend or press against a mine surface, or interfere with the cutting drum  34 . The flap  1032  intercepts material that is liberated from the mine wall and causes the material to fall toward the conveyor  22  or mine floor below. The flap  1032  can thus shield the operator from material that is cast from the wall. 
     Thus, the invention may provide, among other things, a guide assembly for a mining machine. The guide assembly may guide material away from the cutting drum toward a conveyor. The guide assembly may deflect material cast in a direction away from the mine wall. 
     Various independent features and independent advantages of the invention may be set forth in the following claims: