Water spray assembly

A water spray assembly especially adapted for control of dust suppression in mining machines has a manifold with one or a number of nozzles mounted thereon. The manifold provides communication between the nozzles and a manifold inlet, the manifold inlet being adapted to connect to a supply of water. The manifold with one half of a quick connect coupling cooperates with a nozzle block having a bore sized to receive at least a portion of the manifold and the other half of the quick connect coupling. The use of quick connect coupling half with the block allows easy removal and insertion of the manifold.

This application claims priority under 35 USC 119(e) based on provisional patent application No. 60/547,881 filed on Feb. 27, 2004.

FIELD OF THE INVENTION

The present invention is directed to a water spray assembly, and in particular to a water spray assembly for mining equipment employing a removable manifold to facilitate changing of spray nozzles in difficult to reach areas.

BACKGROUND ART

In the prior art, water sprays are used in mining equipment, especially coal mining equipment, to suppress dust and wet the mined product. The sprays include nozzles, which are removably attached to manifolds or blocks, the blocks fixedly mounted to the mining machines at various locations. One problem with these sprays is plugging of the nozzles due to the coal, coal dust, iron oxide, and other foreign matter. The sprays must be continually cleaned for safety reasons and such maintenance reduces mining production.FIG. 1shows a prior art spray system with a block1mounted on a portion of a continuous mining machine3. The block1has a number of nozzles5. A supply line7provides water to the nozzles for spraying purposes via a channel9within the block1. Since these applications and types of mining machines are well known, a further description is not necessary for understanding of the invention.

SUMMARY OF THE INVENTION

It is a first object of the present invention to provide an improved water spray assembly, particularly one that is adapted for use on a mining machine.

Another object of the invention is a water spray assembly that permits easy removal for cleaning and repair.

One other object of the invention is a water spray assembly that utilizes a nozzle block and a manifold that is easily removed from the nozzle.

The invention allows the system to be continuously purged of plugging contaminants which otherwise would accumulate as occurs in prior art systems.

Other objects and advantages of the present invention will become apparent as a description thereof proceeds.

In satisfaction of the foregoing objects and advantages, the present invention provides an improvement in water sprays assemblies, particularly those that are mounted to mining machines for wetting and dust suppression.

The water spray assembly comprises a manifold containing one or more spray nozzles mounted thereto. The manifold has a passageway, which connects inlets of the nozzles to a manifold inlet. The manifold inlet is adapted to connect to a source of pressurized water via a hose or the like.

The manifold is received and supported by a nozzle block or housing. In a preferred embodiment, the housing is adapted to be attached to a location on a mining machine to spray water as part of the mining operation. One or more housings can be attached to the mining machine in a number of orientations and locations depending on the mining machine configuration. Of course, the housing and manifold could be adapted to mate with other components that utilize water sprays.

The nozzle block is configured to removably receive the manifold while providing one or more openings to allow the one or more spray nozzles of the manifold to direct the water spray in a given direction and/or orientation. By having the housing removably receive the manifold, the manifold can be easily removed when the one or more sprays become clogged. Another manifold with unobstructed nozzles can be inserted in the nozzle block while the manifold with the clogged nozzles is cleaned. Moreover, the nozzle block can be positioned on the machine so that an operator or user has ready access to the manifold for easy removal and reinstallation of another manifold.

The manifold can employ one or more nozzles and the nozzles can vary in spray pattern, flow rate, direction of spray and/or a combination of these variables. Virtually any nozzle can be employed in combination with the manifold.

The nozzles can be attached to the manifold by a threaded connection or any other connection as would be within the skill of the art.

The manifold shape is preferably circular in cross section of cylindrical in shape. Other cross sectional shapes could also be employed such as square, octagonal or the like.

The manifold material can be any material suitable for a particular application, but is preferably a material that is corrosion resistant while being capable of removably receiving the nozzles. One example is a nylon block which can be machined with threaded opening for the nozzles and water supply connection.

The water supply to the manifold can be provided by a hose having a threaded fitting which would connect to a threaded opening in the manifold. The connection between the manifold and hose could also be a quick connect fitting to facilitate removal of the manifold from the water supply hose for nozzle cleaning and/or replacement.

The inventive water spray assembly can be used in methods of spraying water, particularly for dust suppression in mining environments such as coal mines. The methods also involve the ability to remove the manifold component of the spray assembly for cleaning and repair, while leaving the housing place.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The invention offers significant advantages over prior art water spray heads and the like which are fixedly mounted on machines or other equipment, particularly mining machines. The invention eliminates the need to remove one or more nozzles in cramped areas or hard-to access areas on a machine such as a mining machine for nozzle cleaning or replacement. With the inventive water spray assembly, the manifold is easily removed from the housing and replaced with another manifold having clear nozzles. No or hardly any time is lost as part of the nozzle replacement operation, thereby avoiding losses in productivity. In addition, personnel are kept out of harm's way via ease of the replacement procedure.

FIGS. 2-4show one embodiment of the invention.FIG. 2shows the manifold21having three nozzles23. The nozzles23are threaded at25to mate with complementary threaded portions27of the manifold. The manifold has a passageway29interconnecting the nozzle channels31with an inlet33.

The inlet is preferably threaded to receive a complementary threaded fitting35. The fitting35interconnects the passageway29to a supply hose37to supply pressurized water to the nozzles23. The supply hose37threads to the fitting35.

Referring toFIG. 3, the nozzle block is designated as41and has a bore43sized to receive the manifold21. The block41also has a slot45which allows travel of the nozzles when the manifold21is inserted into the bore43of the block. The manifold21can friction fit into the bore43or be locked in with some type of a locking mechanism, e.g., a pin, a detent mechanism or the like.

The slot45of the block can be sized as shown inFIG. 4so that the nozzles are recessed from the block outer surface. In this way, the nozzles are more protected from impact from coal, coal dust, and other machinery, thereby lessening the chances of nozzle plugging or damage. Of course, the nozzles could be flush with the outer surface of the block or even extend outwardly therefrom is so desired.

The block41also can have a cutout47which is sized to accommodate the connection between the water supply and the manifold21. The cutout47is shown at about a 90° from the slot45but other orientations could be used, e.g., the slot45could be opposite the cutout47. In other embodiments, the cutout could be optional, e.g., the fitting35was not a 90°-type fitting but was aligned with a longitudinal axis of the manifold.

FIG. 4shows a partial insertion of the manifold21into the block41.

FIGS. 5a-cand6a-dshow other embodiments of the block and manifold. TheFIGS. 5a-5cembodiment shows the block with a threaded portion for connection with the manifold.FIG. 5ashows a back view of an exemplary 2.5″ O.D.×1.5″ I.D. steel tube nozzle block60showing two end slots61, and63. The end view ofFIG. 5bshows the slots61and63arranged at a 90° angle. The slots61and63are preferably 1.5″ long, and the end66of the tube has a threaded interior portion68.FIG. 5cshows a third slot65, which runs almost the length of the tube. The end70opposite end66has a chamfered edge72, preferably a ⅛″ chamfer. Each slot preferably terminates with a ⅜″ radius shape.

TheFIGS. 6a-6cshow a manifold21′ with an inlet71and outlet73. The manifold is preferably a 1.5″ O.D. nylon rod. This differs from theFIG. 2embodiment wherein the manifold has only an inlet. The manifold21′ preferably has a 4.5″ deep bore with an opening tapped ¾″ deep to ½″ pipe. The outlet73is drilled and tapped to ½″ pipe.FIG. 6bshows the relationship between the inlet71and the outlet73, withFIG. 6cshowing the channels75which correspond to the channels31ofFIG. 2.FIG. 6dshows a sectional view wherein the relationship between channels75and the outlet73are shown. The channels are preferably drilled and left hand tapped to ¼″ straight pipe, typically in four places. In the embodiment shown inFIGS. 5 and 6, the assembly can be positioned so that water entering inlet71can exit outlet73and be directed to other sprays or the like.

Although not shown, the manifold21could also have an outlet so that it could be connected to another manifold for a serial hook-up of nozzles.

The manifold could also employ a puller bar on one end thereof to facilitate removal from the block.

The block can be mounted by any means such as welding, fasteners, or the like, and can be either fixedly mounted are adjustably mounted.

FIGS. 7a-11show another embodiment of the invention wherein the manifold has one half of quick connect fitting on one end and the block has the other half of the quick connect fitting associated with it and disposed at an end thereof. This arrangement is much more advantageous that the arrangement shown in the previous embodiments because the block and one half of the quick connect coupling can be secured at a desired location in a more permanent fashion, and only the manifold needs to be removed to clean or replace the spray nozzles.

Referring toFIGS. 7a-7d, the entire system is designated by the reference numeral100. The system further includes a manifold101with nozzles103, and a quick connect male fitting half105of a quick connect coupling that extends from manifold end118. The manifold101is similar to that shown above with a bore providing communication between the openings in the nozzles103and source of water connected to the quick connect male fitting105. The nozzle block is designated by the reference numeral109, with the slot111for the nozzles and bore112, and openings113for locking the manifold in place using the pin115. The block109is sized so that the pin arms117fit around the recess107at the end of the manifold to hold the manifold in place. The other half of the quick connect coupling as the female fitting is designated by the reference numeral119. The female fitting119has a first opening123to receive the male end125attached to the end118of the manifold. The fitting119also has an inlet127to provide communication between the manifold and a source of water for spraying.

FIGS. 8a-8cshow the female quick connect fitting119attached to the end131of the block. Although not shown, the block end131, seeFIG. 7a, has an opening, which aligns with the opening123in the fitting119so that the end125of male fitting105can connect with female fitting119.

FIG. 9shows the manifold101partially inserted into the bore112of the block109, with the pin115partially entering the openings113. Notice that the nozzles103align with the slot111.

FIGS. 10aand10bshow quick connect fittings105and119connected outside of the block109to more clearly show the engagement between the pin arms117and the recess107on the male fitting105.

FIG. 11shows the system completely assembled wherein the male fitting105and female fitting119are joined so that the nozzles103are in communication with inlet127of the fitting119so that water can be supplied to the nozzles103for spraying.

The manifold in theFIG. 7embodiment with the one or more nozzles has the quick connect fitting aligned with an axial bore of the manifold, unlike the embodiments shown above, wherein the manifold includes an elbow so that an axis of the quick connect fitting is perpendicular to the axial bore of the block. In addition, the block is open on each end, one end allowing insertion and removal of the manifold, with the other end being open so that the quick connect fitting half on the manifold can engage the other half of the fitting which is located adjacent the other open end of the block.

The invention entails both the combination of the block and the manifold, as well as the manifold itself as uniquely adapted to interface with the block. While the male fitting is shown on the manifold with the female fitting associated with the block, the nozzle and manifold could be sized so that the manifold would contain the female fitting with the male fitting associated with the block. However, it is preferred that the manifold contain the male fitting since the alternative arrangement requires the nozzle bore and manifold to be larger to handle the female fitting.

The attachment between the block and fitting can be done in any manner, for example, welding or mechanical attachment. As an alternative, the block could be attached to another structure, with the quick connect fitting placed in the proper position with respect to the block and attached to other structure as well, thus leaving the block and fitting unattached. Preferably though, the block and quick connect fitting are attached together.

Another aspect of the invention entails providing a wire mesh basket which fits over the inlet at the male fitting end125that receives water for spraying. The wire mesh basket acts as a filter to prevent particles from passing through the manifold and clogging the nozzle openings. The basket is attached to the male end in such a way so that the quick connect fitting can still function, but debris in the water being supplied to the manifold is filtered prior to entering the nozzles. A cross section of the end125of the manifold ofFIG. 7Dis shown inFIG. 12as one example of the mesh basket embodiment. The basket is designated by the reference numeral130, and has a collar131that interfaces with a lip133formed on an interior of the inlet135of the male fitting end125. The lip can be formed by boring out the inlet to a diameter sized to receive the collar131of the mesh basket130. The depth of the bore is made to match the height of the collar131so that when the basket130is installed, the basket top is flush with the end face of the male fitting end125. The mesh part137of the basket130extends within the manifold inlet135, so as to prevent debris from entering the inlet135and clogging the nozzles103, seeFIG. 7D. The wire basket collar131can be distorted in one mode to snugly fit into the inlet135so that fasteners are not required. However, fasteners could be employed to keep the basket in place, if desired. Of course, other ways as would be known to those of skill in the art can be employed to combine the basket with the male end125. It should be also understood that the mesh basket could be employed on the embodiment shown inFIGS. 1-6, and particularly in conjunction with the threaded fitting35. The same design could be employed on fitting35wherein the inlet would be modified to receive the wire mesh basket.

While the mesh size of the basket can vary depending on the nozzle sizes and target impurity sizes, a preferred mesh size of 30 mesh, although smaller or larger meshes, e.g., 18, 20, and 24, 35, 40, 50, 60 and so on, can be employed.

As such, an invention has been disclosed in terms of preferred embodiments thereof which fulfills each and every one of the objects of the present invention as set forth above and provides new and improved water spray assembly and its use with mining machine.

Of course, various changes, modifications and alterations from the teachings of the present invention may be contemplated by those skilled in the art without departing from the intended spirit and scope thereof. It is intended that the present invention only be limited by the terms of the appended claims.