Patent Publication Number: US-9903160-B2

Title: Rod manipulator for a mining drill rig

Description:
RELATED APPLICATION DATA 
     This application is a § 371 National Stage Application of PCT International Application No. PCT/EP2015/054797 filed Mar. 9, 2015 claiming priority of EP Application No. 14162337.1, filed Mar. 28, 2014. 
     FIELD OF INVENTION 
     The present invention relates to a mining drill rig mountable at a mobile mining machine and in particular, although not exclusively, to mining apparatus to install roof and/or sidewall bolts in a mining environment. 
     BACKGROUND ART 
     In order to maximise excavation and mineral recovery efficiency, mining machines have been developed for specific purposes. Whilst some machines are configured exclusively to cut the mineral from a deposit or seam, other machines are configured to tunnel within the subterranean depth to effectively create the mine and provide passageways for the mineral cutters. In particular, mobile mining machines have emerged as successful apparatus to both provide direct cutting at the seam and as a means of rapid entry roadway development. For example, a mobile mining machine comprises a rotatable cutting or mining head having cutting bits provided on rotating drums to contact the mineral face. The cutting head is conventionally mounted at a moveable boom so as to be adjustable in height relative to the mine floor. As the cutting head is rotated and advanced into the seam, the extracted mineral is gathered by a gathering head and then conveyed rearwardly by the mobile machine via conveying apparatus to create discharged stock piles for subsequent extraction from the mine. 
     Those machines that are adapted to create the mine passageways are typically fitted with roof and rib bolting rigs. The roof and rib bolts reinforce the roof and walls of the mine by interconnection with reinforcement formations. Due to the confined space in which the machine is operating, the bolting rigs are typically positioned immediately behind the cutting head and are required to be as small as possible whilst allowing access for personnel to interchange the drill rod used to create the borehole and the roof or rib bolt that is then driven into the as formed hole. Other mobile machines that employ drill and/or bolting rigs include dedicated bolters, roadheaders, platform bolters and the like. Example drill and bolting rigs are described in US 2003/066665; DE 102007038265; EP 1533470 and EP 0470061. 
     As will be appreciated, it is typically required to take out the drill rod to one side of the drilling centre whilst the bolt is installed into the borehole. Conventional arrangements are disadvantageous as they restrict access to the drill unit making it difficult to interchange the rod and bolt. Additionally, conventional rigs are typically bulking and are not easily accommodated in the restricted space available at the mining machine. Accordingly, what is required is a mining bolting drill rig that solves these problems. 
     SUMMARY OF THE INVENTION 
     It is an objective of the present invention to provide a bolting drill rig mountable at a mining machine and in particular a mobile mining machine that provides the automated or semi-automated manipulation of the drill rod towards and from the drilling position to allow convenient and rapid interchange of the drill rod and drilling bolt whilst minimising the space requirement for the rig at the machine. It is a further specific objective to provide a rod manipulator assembly at a bolter miner drill rig that does not increase significantly the overall size of the drill rig and is effective to provide unhindered access to the region of the drilling drive unit for convenient interchange of the drill rod and roof or rib bolt. 
     The objectives are achieved via a manipulator assembly mounted at the drill rig that carries a manipulator arm movable in a first lengthwise direction along the rig and a second lateral direction to transfer a drill rod between a drilling position and a laterally displaced storage position (to one side of the drilling position) via an automated or semi-automated movement mechanism. 
     The present manipulator assembly is configured specifically to minimise the additional space required at the region of the bolter drill rig so as to allow retro fitting to existing bolter drill rigs and mobile mining machines. 
     According to a first aspect of the present invention there is provided a manipulator assembly mountable at a bolting drill rig for a mobile mining machine, the manipulator assembly comprising: a manipulator frame; a manipulator arm mounted to move in a first lengthwise direction along the frame between a rod storage position and a rod drilling position; and a releasable rod engager provided at the arm to grip the rod for coupled movement with the arm during movement in the first lengthwise and second lateral directions; characterised in that: at least a part of the arm is mounted to move in a second lateral direction substantially perpendicular or transverse to the first direction between a retracted state to provide a drill rod in a storage position laterally to one side of a drive unit and an extended state to provide the drill rod in a drilling position centred with the drive unit. 
     According to a second aspect of the present invention there is provided a bolting drill rig mountable at a mining machine, the rig comprising: an elongate main frame; a drill drive unit to provide rotational drive to a drill rod used to create a bore hole in a mine roof or wall to receive a bolt; a head movably mounted at the frame being configured to brace against the roof or wall of the mine during drilling; and the drill rod manipulator assembly as claimed herein mountable at the frame; the manipulator arm mounted to move in the first lengthwise direction along the main frame between the rod storage position away from the head and the rod drilling position towards the head relative to the lengthwise direction of the main frame; the at least a part of the arm mounted to move in the second lateral direction substantially perpendicular or transverse to the first direction between the retracted state to provide the rod in the storage position laterally to one side of the drive unit and the extended state to provide the rod in the drilling position centred with the drive unit. 
     Advantageously, the manipulator frame is mounted rigidly to the main frame of the rig and is generally elongate to enable linear travel of the manipulator arm in a direction to one side and parallel to the linear advancing movement of the drill rod drive unit. 
     Optionally, the assembly may further comprise a linear actuator to drive linear movement of the arm in the first direction. According to further optional implementations, the arm may be driven by other conventional actuators such as chain drives, spools, cables, rack and pinion, hydraulic, pneumatic and/or electro-mechanical actuators. Such arrangements are advantageous to minimise the volume/space occupied by the manipulator assembly and to provide a generally compact construction at the drill rig. 
     Preferably, a distance by the manipulator assembly projects laterally from the main frame of the rig is equal to or less than a distance by which the drill drive unit projects laterally from the main frame. Preferably, a distance by which the manipulator assembly projects laterally from the main frame of the rig, is approximately equal to or less than a thickness of the main frame in a direction perpendicular to a length of the main frame. The manipulator assembly is accordingly compact in the direction perpendicular to the length of the main frame so as to enable convenient mounting at existing bolting drill rigs and to provide unhindered access to the axial centre of the drill drive unit mounted at an adjacent side of the drill rig. 
     Preferably, the drive unit is mounted at a first side of the main frame and the manipulator assembly is mounted at a second side of the main frame; wherein the arm is configured to move laterally in the second direction and to pivot between the retractor state and the extended state such that in the retracted state it does not obscure an axis centred on the drive unit and in the extended state provides the drill rod in the position centred with the drive unit. Such an arrangement is advantageous to provide unhindered access to the axial centre region of the rotational drive unit to allow personnel to quickly and conveniently interchange the drill rod and the roof or rib bolts. 
     Preferably, the drive unit is mounted at the main frame via a shuttle carriage to enable the drive unit to move lengthwise along the main frame relative to the head. Preferably, the head is mounted at the main frame via at least one linear actuator and configured to be extended from or retracted at the main frame relative to the drive unit. 
     Preferably, the manipulator arm comprises a base part mounted at and configured to slide along the manipulator frame; and an extender part capable of extending laterally from the base part in the second direction substantially perpendicular or transverse to the length of the main frame. The base part is capable of shuttling back and forth along the manipulator frame and comprises a low profile configuration to minimise occupied space. Similarly, the extender part may comprise a corresponding plate-like configuration to provide a low profile construction and to be capable of projecting laterally outward from the plate-like base part. Accordingly, the extender part is capable of sliding over and in near touching contact with the base part during lateral sideways extension and retraction. 
     Preferably, the manipulator assembly further comprises at least one linear actuator connecting the base part and the extender part to drive movement of the extender part in the second direction. Additionally, the assembly may further comprise at least one linear actuator connected between the base part and the manipulator frame to drive linear movement of the base part in the first direction along the manipulator frame. According to further specific implementations, the actuator configured to drive movement of the arm in both the first and second directions may comprise a chain drive, spools, cables, rack and pinion, hydraulic, pneumatic and/or electro-mechanical actuators. 
     The extender part is coupled to the base part via conventional mechanical linkages including pivot pins, pinions, cams, rockers, linear actuators, lug and slot arrangements and the like as will be appreciated to enable a predetermined mechanical movement of the extender part relative to the base part. 
     Preferably, the rod engager comprises a single jaw or a pair of opposed jaws to open and close to release and grip the drill rod. The opposed jaws enable the convenient and reliable grasping and release of the drill rod via an actuating mechanism that is triggered by the position of extension and pivoting of the extender part of the manipulator arm relative to the base part using conventional mechanical linkages involving pivot pins, pinions, cams, guide slots and the like as will be appreciated. 
     The drill rig and in particular the rod engager is also configured and compatible for use with roof/rib bolts and resin insertion devices (i.e., resin loading sticks) of various types. The present rig is accordingly capable of transporting the various elongate elements (drill rod, bolt, resin stick) between the use position, aligned with the drive motor, and the storage position. 
     The assembly may further comprise at least one actuator to drive a movement of the jaws to open and close about the drill rod. 
     Preferably, the assembly further comprises at least one pivot mounting connecting the base part to the extender part to enable the extender part to pivot relative to the base part. Preferably, the extender part is configured to pivot through 20 to 70° relative to the base part. The configuration of the extender part to pivot relative to the base part is advantageous to enable positioning of the manipulator assembly at an adjacent side of the drill rig relative to the drive unit. Accordingly, the present manipulator assembly does not obstruct or hinder access to the part of the drill rig that mounts the drill rod in the drilling position centred at the drive unit. 
     Optionally, a length of the manipulator frame is at least half a length of the main frame such that the arm is capable of moving in the first direction over at least half of the length of the main frame to move the rod in a direction away from the head. Such an arrangement is advantageous to provide sufficient linear travel of the manipulator arm away from the head plate of the rig so as to allow rearward transport of the drill rod into the storage position. The drill rig is therefore enabled to operate to allow the drive unit to drill the roof or rib bolt into the as-formed bore created by the drill rod. 
     According to a third aspect of the present invention there is provided a mobile mining machine for roof or wall bolting comprising a rig as claimed herein. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       A specific implementation of the present invention will now be described, by way of example only, and with reference to the accompanying drawings in which: 
         FIG. 1  is a perspective view of a mobile mining machine comprising a pair of bolter drill rigs mounted immediately behind a cutting and gathering head provided at a forward end of the machine according to a specific implementation of the present invention; 
         FIG. 2  is an external perspective view of the bolter drill rig of  FIG. 1  having a manipulator assembly configured to transport a drill rod between a drilling and a storage position according to a specific implementation of the present invention; 
         FIG. 3  is a further perspective view of the rig of  FIG. 2 ; 
         FIG. 4  is a further perspective view of the rig of  FIG. 3 ; 
         FIG. 5  is a perspective view of the manipulator assembly with parts removed for illustrative purposes; 
         FIG. 6  is a further perspective view of the manipulator assembly of  FIG. 5  with parts removed for illustrate purposes; 
         FIG. 7  is a further perspective view of the manipulator assembly of  FIG. 6  with parts removed for illustrate purposes; 
         FIG. 8  is a further perspective view of the manipulator assembly of  FIG. 7  with parts removed for illustrate purposes; 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENT OF THE INVENTION 
     The subject invention will be described with reference to a specific implementation mounted upon a bolter miner being an electrically powered, track-mounted continuous mining machine designed to excavate roadways and install roof bolts simultaneously. However, as will be appreciated, the present rig and manipulator arm may be mounted on a variety of mining machines that employ drill and/or bolting rigs including dedicated bolters, roadheaders, platform bolters and the like. 
     Referring to  FIG. 1 , a mining machine  100  comprises a main frame  101  that provides support for an undercarriage or chassis  109  that supports a pair of endless driven tracks  113  for propelling the machine  100  over the ground and along a tunnel to advance forwardly through a material deposit seam. Main frame  101  comprises a generally forward end  102  and a generally rearward end  103 . A conveyor  104  extends substantially from forward end  102  to rearward end  103  and is adapted to carry material dislodged from the cutting face for subsequent discharge and stock piling at a remote location optionally using additional conveying and mining apparatus. A movable cutting boom  105  is pivotally mounted at one end  112  to main frame  101  via a pivot mounting  110  and comprises a second end  106  mounting a cutting head  115  that in turn mounts a plurality of rotatable drums  107 . Cutting bits  108  project radially from each drum  107  and are specifically adapted to cut into and dislodge the mineral material to be mined from the seam. Boom  105  and in particular end  106  is capable of being raised or lowered relative to main frame  101  and endless tracks  113  to enable machine  100  to cut the seam face over a varying height range above the ground of the mine tunnel. Boom  105  is operated by hydraulic rams and other associated components as will be appreciated by those skilled in the art. Machine  100  further comprises a gathering head  117  mounted at forward end  102  of main frame  101 . Head  117  is configured to collect material removed from the deposit seam by the cutting action of head  115 . The cut material is then transported rearwardly from gathering head  117  via conveyor  104 . 
     A canopy  111  comprises a vertically uppermost region having a generally planar configuration and is adapted for being raised vertically upward from frame  101  in a manner similar to cutting head  115  so as to contact the mine roof to provide structural support as necessary during the cutting and roof bolting operations. Additionally, a tail section  114  projects rearwardly from the rearward end  103  of frame  101  to carry rearwardly conveyor  104  to a discharge end  116  representing a rearwardmost part of the continuous machine  100 . Cutting head  115  is mounted at the forwardmost end  106  of cutting boom  105  and is positionally supported by a pair of gear carriers  302  that extend from boom  105  and couple head  115  to machine  100 . A pair of bolter drilling rigs  10  is mounted at the frame forwardmost end  102  immediately behind cutting and gathering heads  115 ,  117  and laterally to either side of boom  105 . Each rig  10  is configured for operation in two modes including a first drilling mode in which a drill rod is driven into the mine roof or sidewall to create a borehole and a second mode in which a roof or rib bolt is driven by the same drive motor into the as-formed borehole. 
     Referring to  FIGS. 2 to 8 , the bolter rig  10  comprises an elongate main frame to mount various moving components of the rig and various static components. The main frame comprises, in part, a pair of parallel elongate support struts  11  extending lengthwise along a frame gantry  29 . A rotational drive motor indicated generally by reference  15  is mounted via a carriage shuttle  28  to gantry  29 . A chain drive  41  provides a movable link between carriage  28  and gantry  29  to enable drive motor  15  to move linearly in a longitudinal direction x along the main frame  11 ,  29 . 
     Each of the support struts  11  mounts internally a respective linear actuator  12  capable of liner extension and retraction relative to struts  11 . A head plate  13  is attached to respective endmost regions of each actuator  12  such that by actuation, head plate  13  is capable of lengthwise extension in direction x from struts  11  and gantry  29 . Head plate  13  is configured specifically for positioning in contact with a mine roof or wall during drilling and bolting procedures. Plate  13  comprises an aperture  19  through which a drill rod  14  and a roof or rib bolt (not shown) are capable of passing during drilling and bolting operations. Aperture  19  is centred on a longitudinally axis of drive unit  15  corresponding to the axis of rod  14  when installed and positioned at the drive unit  15  for drilling parallel to x direction. In a typical drilling operation, drive unit  15  is configured to engage drill rod  14  and then to advance linearly along frame parts  11 ,  29  towards head plate  13  that is maintained in an extended position from frame  11 ,  29  in contact with the mine roof or wall. Once a borehole is created, rod  14  is retracted via a reverse linear movement of drive unit  15  (via chain drive  41 ) along frame  11 ,  29 . A roof or rib bolt (not shown) is then installed and centred at drive unit  15  which is advanced a second time towards head plate  13  to embed the bolt into the as-formed bore at the mine roof or wall. 
     The present bolter mining rig  10  is configured specifically for the automated or semi-automated displacement of the drill rod relative to drive unit  15  to enable convenient and rapid interchange of the drill rod and the roof or rib bolt. In particular, rig  10  comprises a drill rod manipulator assembly represented generally by reference  16 . The assembly comprises a pair of spaced apart and parallel elongate bars  18  mounted at respective first and second ends via respective attachment braces  17 . Each brace  17  is rigidly mounted to one side of main frame gantry  29  in an orientation such that bars  18  are aligned parallel with struts  11 . Braces  17  are mounted at one side of the drill rig  10  whilst the drive unit  15  and carriage  28  are positioned at an adjacent second side of the rig  10  to allow unhindered longitudinal travel of the drive unit  15  in the x direction towards and from head plate  13 . Bars  18  and braces  17  are substantially rigidly mounted at rig  10  so as to be stationary. Manipulator assembly  16  further comprises a shuttling component that is configured to shuttle linearly along bars  18  in a parallel direction of travel relative to drive unit  15 . In particular, the movable components comprises a manipulator arm having a base part represented generally by reference  26  and an extender part represented generally by reference  21 . Base part  26  is movably mounted on each bar  18  via a first pair and a second pair of spaced apart sleeves  36  capable of sliding linearly along each bar  18 . Base part  26  comprises a flange  43  that mounts one end of a linear actuator  27  mounted at an opposite end to a boss  30  rigidly mounted to actuator frame base  17 . Accordingly, actuator  27  via linear extension and retraction is configured to drive sliding movement of base part  26  along bars  18  in the x direction towards and away from drive unit  15  and head plate  13 . 
     Base part  26  further comprises a rear wall  34  and a front wall  35  extending in a lengthwise direction of base part  26 . A pair of guide rails  32  extends between walls  34  and  35  at each opposite lengthwise end of base part  26  in a direction perpendicular to bars  18 . A bridge plate extends lengthwise between rails  32  and is mounted for sliding movement along rails  32  via a pair of respective mounting sleeves  33  provided at each end of bridge plate  31 . Base part  26  further comprises a pair of widthwise extending walls  24 , each comprising a curved elongate slot  25  extending in a direction between the front and rear walls  35 ,  34 . 
     The extender part  21  of the manipulator arm is movably mounted at base part  26  via a linear actuator  22 . Extender part  21  is connected to bridge plate  31  such that actuation of bridge plate  31  for travel along the rails  32  imparts a lateral extension of extender part  21  from base part  26  in a direction z perpendicular to bars  18  and the x direction of travel of drive unit  15 . Extender part  21  extends laterally outward from base part  26  via an aperture  42  formed in the front wall  35  of base part  26 . 
     Extender part  21  further comprises a mount wall  38  extending in the z direction parallel to rails  32  and comprising an elongate slot  39  provided at one end. A pivot pin  40  mounts a pair of hinging scissor arms  37  capable of opening and closing about pivot  40 . Each of the scissor arms  37  mount a respective first jaw  20   a  and a second jaw  20   b  configured to open and close relative to one another to release and grip drill rod  14  via a claw like engaging action. Jaws  20   a ,  20   b  are actuated by a linear actuator  23  mounted at extender part  21  that is mounted in turn at support mount wall  38 . That is, actuator  23  provides displacement of pivot pin  40  within slot  39  that acts to pivot scissor arms  37  to open and close jaws  20   a ,  20   b.    
     Extender part  21  is hingebly mounted at base part  26  with the hinging facilitated via engagement of a pair of lugs (not shown) configured to travel within the elongate curved slots  25 . When actuated, bridge plate  31  is configured to move along rails  32  to force extender part  21  laterally outward from base part  26  in the z direction perpendicular to bars  18  orientated in the x direction. Via the pivot mounting of extender part  21  at base part  26 , the extender part  21  is configured to pivot downwardly (or upwardly) relative to base part  26  out of plane with the base part  26  and bars  18 . This pivoting action occurs when the extender part  21  is displaced laterally sideward and is moved to its fully extended position. In the fully extended position, jaws  20   a ,  20   b  are approximately centred on the drilling axis of drive unit  15  corresponding to the longitudinal axis of drill rod  14  when engaged in position for drilling. 
     Manipulator assembly  16  is advantageously mounted at a different and adjacent side of drill rig  10  relative to the drive unit  15  and carriage  28  to allow unhindered access to the region of the longitudinal axis centred on drive unit  15  for interchange of the drill rod  14  with a roof or rib bolt (not shown). Such a configuration necessitates a manipulator arm assembly  16  configured to ‘reach’ sideways (in the z direction and then to pivot and travel in the y direction) from the region of mounting of the manipulator  16  towards the axial centre of drive unit  15 . Accordingly, extender part  21  is capable of moving laterally sideways to be brought into position at the appropriate side of the rig  10  to either remove or deliver a drill rod  14  to the axially centred position at drive unit  15 . Additionally, in order to provide unhindered roof or rib bolting once the borehole has been created by drill rod  14 , the manipulator arm is configured to shuttle rearwardly away from head plate  13  in the x direction towards drive unit  15  so as to carry rod  14  to a storage position both at the side of mounting of the manipulator assembly  16  and also a linearly retracted position away from head plate  13 . Accordingly, the present manipulator arm is configured to reliably transport drill rod  14  between a drilling position centred at unit  15  and a storage position displaced laterally to one side of drive unit  15  and axially rearward from head plate  13 . 
     According to the subject invention, manipulator assembly  16  comprises a compact construction so as to minimise the occupied volume at the mounting side of main frame  11 ,  29 . In particular, a distance in the y direction by the manipulator assembly  16  projects laterally from the main frame  11 ,  29  is less than a distance in the y direction by which drive unit  15  projects laterally from main frame  11 ,  29  (including carriage  28 ). Additionally, the distance in the y direction by which the manipulator assembly  16  projects laterally from main frame  11 ,  29  is approximately equal to or less than a thickness of the main frame  11 ,  29  in the y direction perpendicular to a length of the main frame in the x direction. The present manipulator  16  may therefore be conveniently mounted at an existing bolter drill rig  10  and mobile mining machine  100  without modification so as to be positioned immediately behind heads  115 ,  117  and adjacent boom  105 .