Abstract:
A feed rail for a rock drill is composed of two segments, a first beam defining a first rail segment and a second beam defining a second rail segment. The second beam may be detachably connected to the first beam so that the second beam can be removed altogether from the first beam. This invention enables the feed rail to be shortened, thereby making the feed rail much easier to maneuver in mines.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 12/757,913 filed Apr. 9, 2010. 
    
    
     TECHNICAL FIELD 
     The present invention relates generally to mining equipment and, in particular, to hydraulic feed systems for rock drills. 
     BACKGROUND 
     A hydraulic feed system is a hydraulically powered apparatus that is used to linearly displace a rock drill along a feed rail. The hydraulic feed system may be mounted on a wheeled frame or vehicle for transport. 
     A recurring problem in the mining industry is the manoeuvrability of machinery inside the narrow drifts (underground road ways) inside mines. Not only are the drifts in mines typically very narrow, but they frequently have sharp corners, making it very hard to manoeuvre large machines. This is a serious problem with so-called “jumbos”, i.e. large wheeled hydraulic feed systems that have long feed rails. The feed rails must be long enough to accommodate a rock drill, drill string, hose drum and centralizers. A traditional jumbo feed composed of a single long rail is thus exceedingly difficult to manoeuvre inside the drifts. A need therefore exists for an effective solution to this technical problem. 
     SUMMARY 
     In broad terms, the present invention provides a novel detachable feed rail for a rock drill. The feed rail comprises a first beam defining a first rail segment and a second beam defining a second rail segment that can be detached from the first beam. This enables the feed rail to be shortened for easier storage and transport. This also affords greater manoeuvrability, which is particularly important when moving the feed rail around tight corners inside mine drifts. The ability to shorten the feed rail also enables the rock drill to be used in applications where a shorter feed rail is desirable or necessary. 
     Accordingly, one main aspect of the present invention is a feed rail for a rock drill feed system, the feed rail comprising a first beam forming a first channel that defines a first rail segment and a second beam forming a second channel that defines a second rail segment, the first and second channels having substantially identical shapes to enable a rock drill to be fed along the first and second rail segments when the first beam is aligned with the second beam, wherein the second beam is detachably connected to the first beam such that the second beam can be disconnected and removed from the first beam. 
     Another main aspect of the present invention is a method of operating a hydraulic feed system for a rock drill, the method comprising assembling a feed rail by connecting a first beam defining a first rail segment to a second beam defining a second rail segment, locking the second beam to the first beam to ensure alignment of the first and second rail segments, operating the feed system to displace the rock drill along the first and second rail segments of the feed rail, and drilling rock using the rock drill. 
     Yet a further main aspect of the present invention is a hydraulic feed system for rock drilling, the system comprising a first beam defining a first rail segment, a second beam defining a second rail segment having a channel shape substantially identical to the first rail segment, wherein the second beam is detachably connected to the first beam such that the second beam can be disconnected and removed from the first beam, a rock drill and a hydraulic feed system connected to the rock drill for hydraulically feeding the rock drill along the first and second rail segments. 
     Still another main aspect of the present invention is a method of installing ground support. The method entails installing rock bolts, re-bar, split sets or equivalent for ground support using only a first rail segment of a feed rail of a hydraulic feed system. The method involves providing a feed rail having a first rail segment and a second rail segment for feeding a rock drill for drilling rock, disconnecting the second rail segment from the first rail segment to shorten the feed rail, and installing rock bolts for ground support using only a first rail segment of the feed rail of a hydraulic feed system. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Further features and advantages of the present invention will become apparent from the following detailed description, taken in combination with the appended drawings, in which: 
         FIG. 1  is an isometric view of a novel feed rail in accordance with an embodiment of the present invention, the feed rail being shown in an aligned, locked and operative position; 
         FIG. 2  is an isometric view of the feed rail of  FIG. 1 , the feed rail being shown in a partially folded position; 
         FIG. 3  is an exploded (assembly) view of the feed rail of  FIG. 1 ; 
         FIG. 4  is an enlarged isometric view of the hinge portion identified by the circle in  FIG. 2 ; 
         FIG. 5  is a top plan view of a fully folded hydraulic feed system for a rock drill; 
         FIG. 6  is a top plan view of a feed system in which one segment has been detached from another segment in accordance with another embodiment of the present invention; 
         FIG. 7  is an isometric view of a first rail segment connected to a second (detachable) rail segment; and 
         FIG. 8  is an exploded (assembly) view of the first and second rail segments of  FIG. 7 . 
     
    
    
     It will be noted that throughout the appended drawings, like features are identified by like reference numerals. It should furthermore be noted that the drawings are not necessarily to scale. 
     DETAILED DESCRIPTION 
     In general, and by way of introduction, the present invention provides a foldable or detachable feed rail for a hydraulic feed system for a rock drill. The feed rail is composed of two segments. One segment may be folded relative to the other or, alternatively, disconnected from the other segment. This enables the feed rail to be shortened for greater manoeuvrability, storage or operations where a shorter feed rail would be desirable. 
       FIG. 1  is an isometric view of a novel feed rail in accordance with an embodiment of the present invention. The novel feed rail, which is generally designated by reference numeral  10 , is shown in this figure in an aligned, locked and operative position. The feed rail  10  comprises, in general, a first beam  20  forming a first channel  22  that defines a first rail segment  24  and a second beam  30  forming a second channel  32  that defines a second rail segment  34 . The first and second channels have substantially identical shapes to enable a rock drill (not shown) to be fed along the first and second rail segments  24 ,  34  when the first beam  20  is aligned with the second beam  30 . The second beam  30  is movable between an operative position (shown in  FIG. 1 ) in which the second beam  30  is aligned with the first beam  20  and an inoperative position (shown for example in  FIG. 5 ) in which the second beam  30  is not aligned with the first beam  20 . 
     In one embodiment, the second beam  30  is pivotally connected to the first beam  20  by a hinge  40  as shown in  FIG. 2 . This hinge  40  enables the second beam  30  to be folded relative to the first beam  20 .  FIG. 2  shows the feed rail  10  in a partially folded position. In other words,  FIG. 2  shows the second beam  30  pivoted relative to the first beam  20  about the hinge  40 . Although a hinge is shown, other pivoting or rotational mechanisms may be employed to achieve a similar end result. Regardless of the mechanism, the ability to fold the feed rail facilitates transport, storage and enhances manoeuvrability. 
     In one embodiment, the second beam is hinged to the first beam to enable the second beam to be folded ninety degrees relative to the first beam such as shown by way of example in  FIG. 5 . 
     In the embodiment depicted in  FIG. 2 , the second beam  30  is shorter than the first beam  20 , although this is not necessarily so. 
     In another embodiment, the second beam  30  is detachably connected to the first beam  20  such that the second beam  30  can be disconnected and removed from the first beam  20 . The second beam can be detachably connected to the first beam using locking pins, bolts or other threaded fasteners, clamps, or any other suitable mechanism or attachment means. 
       FIG. 3  is an exploded (assembly) view of the feed rail of  FIG. 1 , showing the various components in the novel feed rail.  FIG. 3  shows that the first and second beams  20 ,  30  are supported by respective support platforms  26 ,  36 . As further depicted in  FIG. 3 , the first and second support platforms  26 ,  36  may be rotatably connected by a pin joint  42  to support the second beam  30  relative to the first beam  20  during rotation. 
     As further depicted in  FIG. 3 , the first and second beams  20 ,  30  may optionally comprise ball and socket alignment devices  27 ,  37  for aligning the second beam relative to the first beam. The ball and socket may be replaced with cones, pins, plates or similar line-up parts. 
     AS further depicted in  FIG. 3 , the feed rail may optionally further comprise a locking mechanism having brackets  44  attached to both the first and second beams on sides opposite the hinge. The locking mechanism may have a threaded fastener  46  for locking the first and second beams together by connecting to the brackets  44 . Other locking mechanisms could be substituted, e.g. clamps, hydraulic cylinders, etc. 
       FIG. 4  is an enlarged isometric view of the hinge portion identified by the circle in  FIG. 2 . This enlarged view shows the ball and socket alignment device in greater detail. 
       FIG. 5  is a top plan view of a fully folded hydraulic feed system for a rock drill. The foldable hydraulic feed system comprises the first beam defining the first rail segment, the second beam defining the second rail segment. The second beam is movable between the operative aligned position and the inoperative (disconnected or folded) position. In addition to the foldable/detachable feed rail, the system includes a rock drill and a hydraulic feed system connected to the rock drill for hydraulically feeding the rock drill along the first and second rail segments. The system may also include a drill string, hose drum and centralizers. 
     A further embodiment of this invention is depicted in  FIG. 6  to  FIG. 8 . These figures show a detachable feed rail system  10  having a first rail segment  20  and a second rail segment  30  that is detachable from the first rail segment  10  as illustrated in  FIG. 6 . Removing or detaching the second rail segment  30  from the first rail segment  20  shortens the feed rail system  10 . The first and second rail segments, when reattached, may appear as shown in  FIG. 7 . The first and second rail segments may be locked to one another by a locking pin, bolt or other fastener system, hydraulic cylinders, clamps, etc, or any combination thereof. By way of example only,  FIG. 8  shows a bolt  46  that fits through the holes in brackets  44  and is affixed in place by nut  48 . 
     The novel feed rail and system described above enable a novel method of operating a foldable hydraulic feed system for a rock drill. This novel method comprises unfolding (or reattaching) a feed rail having a first beam defining a first rail segment and a second beam defining a second rail segment by moving the second beam relative to the first beam. The second beam is locked to the first beam to ensure alignment of the first and second rail segments. Finally, the feed system is operated to displace the rock drill along the first and second rail segments of the feed rail. 
     When rock drilling is complete, the method may further involve unlocking the second beam from the first beam, and folding the second beam relative to the first beam (or detaching the second beam from the first beam), and then transporting the hydraulic feed system to a new location. In its shortened state, it is easy to manoeuvre, transport and store. 
     Alternatively, after the unlocking and folding (or detaching) steps, the hydraulic feed system may be used to feed the rock drill along only the first beam. With only the first beam defining the first rail segment installed, the shortened feed rail can be used for a variety of applications such as, for example, tramming or drilling the roof or walls for ground support. Specifically, one important application of this foldable/detachable feed rail technology is in the realm of rock bolting, i.e. installing rock bolts for ground support. To install rock bolts for ground support using this novel technology, the foldable/detachable feed rail is first folded or disconnected to shorten the feed rail to just a single rail segment. Rock bolts (or other such ground support devices) are then installed using the shortened feed rail. Optionally, a magazine storage device for the rock bolts could be mounted to the side of the feed to automate the process. Once the ground support has been completed, the extension beam (i.e. second rail segment) would be installed to lengthen the feed rail. This would enable a longer drill string to be used to drill the next round in the tunnel face for blasting. This detachable/foldable or detachable feed rail thus provides a substantial advantage over the two prior-art techniques that have traditionally been used. The first prior-art technique uses a bolter to install ground support. The bolter has a shorter feed to enable it to drill into the walls and the roof. Once the ground support is installed, the bolter is moved away and a new machine known as the drill jumbo is brought in to drill the tunnel face. This drill jumbo uses a longer feed because it is drilling in the same direction as the tunnel. The second prior-art technique is to use a drill jumbo fitted with a telescopic feed for collapsing the feed rail to install the rock support. The feed is then telescopically extended to drill the face. This telescopic drill jumbo does not function as well as the bolter and standard drill jumbo. Furthermore, the telescopic jumbo is bulky and has more moving parts to maintain. In contrast, the present invention provides a far superior rock bolting solution. The foldable or detachable feed rail provides the full-size of the jumbo in its lengthened configuration, but also the compactness and manoeuvrability of the bolter in its shortened configuration. This novel rock bolting apparatus is more compact than the telescopic feed and is more reliable and requires less maintenance as it has fewer moving parts. An optional bolt magazine can be added to the apparatus for easy storing and loading of rock bolts. 
     Another advantage of this invention is that the feed rail can be extended to allow for a longer drill string to be used. In other words, using modular components (i.e. modular rail segments or sections) enables the total length of the feed to be adjusted (shortened or lengthened). As long as the rail segments or rail sections share a common channel profile, they can be assembled and aligned along a common longitudinal axis to enable the rock drill and its carriage to slide along the rail. The rail segments (section) can be made in various lengths to provide any desirable incremental length. The user can then adjust the length of the feed for a given application and a given environment. This facilitates transport and storage, and improves manoeuvrability and versatility. Clearly, this represents a radical improvement over the fixed-length feeds known in the prior art which could be neither shortened nor lengthened. 
     Although the foregoing describes a feed rail composed of two components, i.e. a first beam and a second beam, it should be appreciated that the principles disclosed herein can be extrapolated to provide a feed rail having two or more components, i.e. two or more beams. For example, a feed rail may be composed of three beams, i.e. a first beam defining a first rail segment, a second beam defining a second rail segment and a third beam defining a third rail segment. Such an arrangement could includes a first hinge connecting the first and second beams and a second hinge connecting the second and third beams. As will be appreciated, this could also be extrapolated to a feed rail made of four, five or more components. Similarly, a detachable feed rail may be made with three, four, five or more beams that can be disconnected from one another. Although any number of articulations can in theory be utilized, the two-beam feed rail is believed to be the best mode of implementing the invention. 
     The feed rail, hinge mechanism, locking mechanism, and other components depicted in the figures may be made of steel, stainless steel, aluminum, or any suitable alloy. As will be appreciated by those skilled in the art of mechanical engineering, non-metallic materials, e.g. composite materials and polymers, may be used for some of the parts instead of metal. As will be further appreciated by those of ordinary skill in the art, various minor modifications to the construction and design of the feed rail and associated components may be made without departing from the inventive concept(s). 
     The present invention has been described in terms of specific embodiments, examples, implementations and configurations which are intended to be exemplary or illustrative only. Other variants, modifications, refinements and applications of this innovative technology will become readily apparent to those of ordinary skill in the art who have had the benefit of reading this disclosure. Such variants, modifications, refinements and applications fall within the ambit and scope of the present invention. Accordingly, the scope of the exclusive right sought by the Applicant for the present invention is intended to be limited solely by the appended claims and their legal equivalents.