Abstract:
A rotatable end deflector for an abrasive water jet drill is provided. The end deflector includes two wear resistant plates which direct portions of the water jet in opposite forward directions. Preferably, the abrasive water jet drill includes a source of high pressure water and a high pressure water outlet from which a stream of water is expelled. A venturi device is provided adjacent the water outlet for creating a vacuum. A feed device feeds an abrasive particular material to the venturi device so that the abrasive material is entrained in the stream of water. Thereafter, the stream of water is collimated in a rotating tube which produces a rotating cylindrical water jet which is then deflected before it impinges on the rock to drill the rock. The abrasive material is preferably sand and the tube including the deflector is easily replaceable.

Description:
This application is a continuation-in-part of application Ser. No. 699,513 filed Feb. 6, 1985, (now abandoned), and Ser. No. 809,651 filed Dec. 16, 1985 now U.S. Pat. No. 4,663,893. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to the cutting of hard rock in quarries and underground mines, and in particular to a rotatable jet deflector for an abrasive water jet drill which deflector causes a wide hole to be cut in hard rock in quarries and underground mines. 
     BACKGROUND OF THE INVENTION 
     Many underground metal mines remove large volumes of waste rock along with the metal values during the mining cycle. This occurs because these ore bodies occur in the form of thin beds or veins, the thickness of which is much smaller than the smallest practical size for entry headings necessary for mining operations. The resulting dilution of the ore values is very undesirable because it increases costs for handling and milling of the ores. 
     The underground metal mining industry has long sought an effective means of selectively mining or separating the ore values from waste during the mining cycle. Many attempts have been made to achieve this capability using various types of mechanical cutters and picks. These approaches have met with little success because of difficulties in gaining access to the vein beyond a short distance from the face in hard rock. 
     In order to cut hard rock in quarries and underground mines to mine veins, various mechanical devices have been used which use bits. However, these devices show severe wear when used in hard rock. Abrasive water jet designs have also been proposed for use in hard rock. However, such devices have been unable to make deep cuts because of significant energy losses and dispersion as the abrasive slurry moves away from the high pressure water nozzle. In addition, normal kerf cutters and high pressure water jet drills require excessively high pressures (50,000 psi) for cutting hard rock. Because of these high pressures, these devices tend to be unreliable. Usually, the most unreliable part is the swivel because the seals fail so readily under the pressures and rotation rates. 
     One prior art mining cutter using water jet pressure is disclosed in U.S. Pat. No. 4,280,735 (Lobbe). In this patent, a tool for a mineral winning machine is disclosed having a flat plate-like body with a bore containing a nozzle insert and a hard metal cutting region or blade. High pressure water is conveyed through the bore and nozzle insert to discharge as a jet which is directed to impinge against the mineral or coal face. 
     Another prior art water jet mining device is disclosed in U.S. Pat. No. 4,265,487 (Barker). According to the disclosure of this patent, a machine is provided in which a plurality of nozzle modules are mounted. Each nozzle module contains a high pressure water jet nozzle disposed to oscillate in a particular plane. The nozzle modules are oriented to cut in vertical and horizontal planes on the leading edge of the machine and the coal so cut is cleaved off by a wedge-shaped body. 
     Still another hydraulic cutting tool is disclosed in U.S. Pat. No. 4,240,664 (Mahyera et al). The device disclosed in this patent is designed for cutting kerfs in rocks and other hard formations by provision of divergent hydraulic jets in a cutter implement. The cutter implement cuts clearance for passage of the implement into the kerf being cut. The cutting implement includes a generally elongate nozzle housing with longitudinally spaced apart and transversely directed jet nozzles therein. 
     Disclosed in U.S. Pat. No. 4,119,160 (Summers et al) is an apparatus for water jet drilling of rocks including a nozzle. This nozzle is rotated and includes two outlets. One outlet is directed in a direction of movement of the nozzle while the other outlet is directed in an angle to this direction. In this manner, a cylindrical bore is drilled in the rock. A variety of other outlet designs is also disclosed in U.S. Pat. No. 3,796,371 (Taylor et al). 
     A combination abrasive-fluid jet apparatus and rotary drill bit is disclosed in U.S. Pat. No. 4,534,427 (Wang et al). The rotating drill bit is provided with a plurality of high-velocity abrasive fluid jets which cut multiple concentric grooves in an underlying rock. The mechanical cutters on the drill bit then remove the material between the grooves. 
     Disclosed in parent U.S. patent application Ser. No. 699,513 is an abrasive water jet slot cutter including an elongate tube from which the water jet exits. Although this water jet slot cutter has proven especially effective, the collimated abrasive water jet cuts too narrow a kerf to permit the collimating tube to follow into the cut. Thus, in order to advance the kerf to the depths required in many mining applications, two parallel kerfs have to be cut and the intervening rock rib removed. Mechanically, this created the requisite clearance so that the collimator could be advanced in the kerf to continue cutting deeper into the rock. However, this was a continuous, two-step process which was unduly time consuming. An improved water jet slot cutter of this type is disclosed in parent U.S. patent application Ser. No. 809,651. A wider cut is provided according to that invention by affixing end deflectors on the tube end. 
     SUMMARY OF THE INVENTION 
     In accordance with the present invention, a rotating deflector for deflecting a cylindrical jet of abrasive fluid is provided. The abrasive jet of fluid is used to drill into hard rocks and exits from an elongate tube having an outlet. The deflector includes a first and a second wear resistant plate and a means for mounting these plates on the outlet of the tube. These plates are mounted such that a portion of the jet is deflected in a first forward direction and another portion of the jet is deflected in a forward direction opposite to the first mentioned direction. Preferably, one plate is mounted on one side of the outlet and the other plate is mounted on the other side of the outlet. In addition, the plates are preferably separated from one another so that still another portion of the jet passes between the plate undeflected. The tube is also simply mounted for rotation using a simple seal and a suitable means is provided for rotating the tube. 
     Also in accordance with the present invention, an abrasive water jet drill having a rotating deflector such as described above is provided. The water jet drill includes a source of high pressure and a high pressure water outlet adjacent to the source of high pressure from which a stream of water is expelled. A venturi means is also provided adjacent the water outlet for creating a vacuum. A feed means feeds an abrasive particular material into the venturi means whereby the abrasive material is entrained in the stream of water. A collimating means is then used for collimating the abrasive entrained stream of water into a cylindrical water jet which impinges on hard rock to drill the hard rock. 
     In the preferred embodiment of the present invention, the collimating means is an elongate tube. In addition, the pressure of the source of high pressure water is about 10,000 psi and the abrasive material is sand. Preferably, the sand is fed at an acute angle to the stream of water and the high pressure outlet and the tube are coaxial. 
     In the preferred embodiment, the elongate tube is rotatably held in the device by a tube holding means by which the tube is mounted for rotation. The tube holding device includes a simple seal between the tube and the surrounding housing and so that the tube can be easily released from the device in order to substitute a new tube and deflector. Any abrasive wearing of the tube and deflector is easily compensated for by replacement with a new tube as necessary. 
     It is an advantage of the present invention that a simple and convenient drilling in underground mines is accomplished. 
     It is also an advantage of the present invention that harder rocks can be drilled. 
     It is a further advantage of the present invention that frictional wear between the tool and the rocks does not occur. 
     Still another advantage of the present invention is that the collimating abrasive water jet can cut to distances over 6 feet and up to 10 feet from the end of the water jet tube without significant loss of power. Therefore, deep holes can be drilled. 
     In addition, as the rotating deflector provides for a wide hole in the rock of sufficient size to receive the tube, the length of the tube can also be inserted into the hole for even deeper cuts. 
     Yet another advantage of the present invention is the abrasive wear caused by the abrasive slurry is limited to an inexpensive, easily changed, throwaway collimating tube or pipe. This tube is simply mounted and uses only a simple low pressure O-ring seal. No precisely manufactured constricting nozzles are required for the abrasive slurry. 
     Other features and advantages of the present invention are stated in or apparent from a detailed description of a presently preferred embodiment of the invention found hereinbelow. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 a side perspective view of an abrasive water jet slot cutter. 
     FIG. 2 is a side cross-sectional view of a portion of the slot cutter depicted in FIG. 1. 
     FIG. 3 is a side perspective view of the end deflector of the present invention. 
     FIG. 4 is a side perspective view of a water jet drill of the present invention. 
     FIG. 5 is a side cross-sectional view of the tube sealing of the embodiment of the invention depicted in FIG. 4. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     With reference now to the drawings in which like numerals represents like elements in the views, an abrasive water jet slot cutter 10 is depicted in FIG. 1. Slot cutter 10 includes a source 12 of high pressure water. With the present invention, the source 12 of high pressure water is approximately 10,000 psi. Source 12 of high pressure water is connected via a coupling member 14, which is attached to a flat base 16, to a restrictor 18. 
     As shown in more detail in FIG. 2, restrictor 18 is threadably received in a housing 20 which is attached to flat base 16. Housing 20 includes a venturi means 22 including an outwardly opening outlet 24 in restrictor 18 and a cavity 26. Also connected to venturi means 22 is a feed means 28. Feed means 28 includes a source 20 of abrasive particle 32. Preferably, abrasive particles 32 are dry sand or a water-sand slurry. As shown, source 30 is connected to a threaded connector 34 which includes an outlet 36 in housing 20. Preferably, water connector 34 is disposed at an acute angle to a stream 38 of water exiting outlet 24 of restrictor 18 as shown in FIG. 2. 
     Due to the vacuum created by venturi means 22, stream 38 of water entrains abrasive particles 32 therein. Thereafter, stream 38 of water together with abrasive particles 32 are received in a collimating means 40. Collimating means 40 includes an elongate tube 42 as shown. Tube 42 is received in housing 20 in a complimentary sized hole 44. Disposed in hole 44 is an O-ring 46 which seals the outer periphery of tube 42 and hole 44. 
     In order to hold tube 42 in hole 44, a holding means 48 is provided. Holding means 48 includes two blocks 50 which are used to clamp tube 42 to flat base 16 by means of bolts 52. By use of holding means 48, tube 42 is easily replaced by loosening bolt 52 and withdrawing tube 42 from between blocks 50 and flat base 16. A new tube 42 is then easily inserted in place of old tube 42 and bolts 52 tightened. 
     As shown in greater detail in FIG. 3, tube 42 includes an outlet 60 from which the water jet 56 exits. Where tube 42 is moved laterally, a first wear resistant plate 62 and a second wear resistant plate 64 are located on opposite lateral sides of outlet 60. Conveniently, plates 62 and 64 are attached to tube 42 by welding. 
     As shown, plate 62 is angled downwardly so that a portion 66 of water jet 56 is deflected downwardly upon exiting outlet 60. Similarly, plate 64 is angled upwardly so that portion 68 of water jet 56 is deflected upwardly. It should also be noted that plate 62 and 64 are separated laterally from one another so that a portion 70 of water jet 56 is undeflected and continues straight ahead of tube 42. 
     In operation, slot cutter 10 functions in the following manner. Initially, it should be appreciated that flat base 16 of slot cutter 10 is preferably attached (as by suitable bolts through attaching holes 54) onto a suitable carrier such as the articulated arm of a drill carrier. Such a drill carrier is remotely operated so that the operator is kept out of the back wash of slot cutter 10. 
     Upon actuation of slot cutter 10 by raising source 12 of water to the operating pressure, source 12 supplies water to restrictor 18 and creates stream 38 in cavity 26 of venturi means 22. Stream 38 creates a vacuum in cavity 26 and thereby draws abrasive particles 32 from source 30 into stream 38. Thereafter, stream 38 containing abrasive particles 32 is received in collimating means 40 including tube 42. Tube 42 collimates stream 38 so that a high pressure abrasive fluid is conducted in tube 42 as a cylindrical water jet 56. Finally, at outlet 60, plates 62 and 64 cause water jet 56 to be split into a lower portion 66, an upper portion 68, and a straight ahead portion 70. By a continuous side to side motion of tube 42, a deep kerf 72 is cut into rock 74 as shown. It should be appreciated that the height of the cut made in rock 74 (indicated by the opposed arrows) is large enough to permit the length of tube 42 extending beyond flat base 16 to be extended into the cut rock and thereby produce very deep kerfs in the hard rock. 
     It should also be appreciated that slot cutter 10 of the present invention separates the ore values using water jet 56 to cut deep slots along the ore waste contact zone. This enables the ore to be selectively removed either by blasting or through the action of a wedge. 
     It should further be appreciated that the use of slot cutter 10 with a source 12 of high pressure water of approximately 10,000 psi enables slot cutter 10 to make use of reliable pumps, hoses, and fittings which are available at a reasonable price. 
     It should still further be appreciated that the coaxial alignment of restrictor 18 and tube 42 provides slot cutter 10 with an essentially linear flow of high pressure water therethrough. Therefore, no swivel is necessary which is apt to fail under the high pressures needed for operation of the present invention. In addition, slot cutter 10 produces a single water jet which is easily translated and which does not interfere with its own operation. 
     Depicted in FIG. 4 is a water jet drill 100 which is broadly similar to slot cutter 10 discussed above. For this reason, the parts of water jet drill 100 which are the same as the parts of slot cutter 10 have been depicted with the same identifying numerals. Thus, water jet drill 100 includes source 12 of high pressure water which is suitably fed to a venturi means mounted within a housing 20 on a base 16. A source 30 of abrasive particles leads into the housing 20 so as to be entrained in the stream of water which is introduced into collimating means 40. Collimating means 40 takes the form of a tube 42 having deflecting plates 62 and 64 of the outlet thereof. 
     In this embodiment of the present invention, water jet 100 is designed to rotate tube 42 such that the abrasive slurry exiting from tube 42 acts to drill a hole in the adjacent rock. In order to rotate tube 42, an air motor 102 is mounted on housing 20 as shown. Air motor 102 is suitably powered to rotate a shaft 104 on which a belt 106 is mounted. Belt 106 is also located about a pulley 108. Pulley 108 is secured to tube 42 by a suitable set screw or the like. 
     Tube 42 is mounted for rotation by use of a bearing means 110 attached to base 16. Tube 42 is prevented from moving laterally toward or away from housing 20 by use of collar 112 extending out of bearing means 110 which is attached to tube 42 by a suitable set screw or the like. 
     Depicted in FIG. 5 is a mounting means 114 for tube 42 inside of housing 20. As shown, housing 20 includes an aperture 116 through which tube 42 extends. On the inside of housing 20, aperture 116 includes a shoulder 118. Located in shoulder 118 is a sealed bearing 120. Located around the outside of sealed bearing 120 is an O-ring 122. O-ring 122 is maintained on the outside of sealed bearing 120 in a suitable depression machined therein. A matching depression is also provided in shoulder 118. Thus, sealed bearing 120 is maintained in shoulder 118 by use of O-ring 122 which fits into the mating depression provided thereon. O-ring 122 also acts to seal the area between shoulder 118 and sealed bearing 120. 
     Located on the inside of sealed bearing 120 is an O-ring 124. O-ring 24 provides a suitable seal around tube 42 extending therethrough. Thus, it will be appreciated that by use of O-rings 122 and 124, the interior of housing 20 is suitably sealed in order to assure the maintenance of a vacuum in housing 20 for the functioning of the venturi means. 
     In operation, water jet drill 100 functions in the following manner. As soon as source 12 is activated and it is desired to drill a hole, air motor 102 is similarly activated to cause tube 42 to rotate. Tube 42 is suitably rotated at approximately 400 rpm by air motor 102. Even though tube 42 is rotated, the stream of water and abrasive particles created in the venturi means enters tube 42 as depicted in FIG. 2. At the other end of tube 42, the water jet exits tube 42 and is deflected by plates 62 and 64 to cut into the associated rock. By rotating tube 42, a drilling action using the water jet is achieved in the rock which is highly effective. 
     If tube 42 or plates 62 and 64 become worn, it is a simple matter to replace tube 42. This is accomplished by simply loosening the set screw in collar 112 which holds tube 42 thereto. At the same time the set screw holding puley 108 to tube 42 is also losened. Then, tube 42 is simply withdrawn through bearing means 110, pulley 108, and past O-ring 124 in sealed bearing 120. A new tube 42 is then inserted in place of the old tube 42 and set screws in pulley 108 and collar 112 are again tightened. Water jet drill 100 is then again ready for operation. 
     It should be appreciated that water jet drill 100 makes use of a high pressure water in the same manner as slot cutter 10. However, even though tube 42 rotates, no high pressure seals or the like are necessary. Instead, simple O-ring seals are sufficient as the high pressure stream is collimated by tube 42. 
     Although the present invention has been described with respect to an exempliary embodiment thereof, it will be understood by those of ordinary skill in the art that variations and modifications can be effected within the scope and spirit of the invention.