HIGH POWER LASER TUNNELING MINING AND CONSTRUCTION EQUIPMENT AND METHODS OF USE
20230321749 · 2023-10-12
Assignee
Inventors
- Daryl L. Grubb (Houston, TX)
- John F. Volkmar (Boulder, CO)
- Mark S. Zediker (Castle Rock, CO)
- Shararth K Kolachalam (Highlands Ranch, CO, US)
- Ryan J. Norton (Conifer, CO)
- Mark S. Land (Houston, TX)
- Brian O. Faircloth (Evergreen, CO)
- Ronald A. De Witt (Katy, TX)
Cpc classification
B23K37/0294
PERFORMING OPERATIONS; TRANSPORTING
B23K26/1476
PERFORMING OPERATIONS; TRANSPORTING
B23K26/03
PERFORMING OPERATIONS; TRANSPORTING
E21D9/08
FIXED CONSTRUCTIONS
B23K26/402
PERFORMING OPERATIONS; TRANSPORTING
E01C23/12
FIXED CONSTRUCTIONS
B23K26/40
PERFORMING OPERATIONS; TRANSPORTING
E21C27/24
FIXED CONSTRUCTIONS
E21C25/64
FIXED CONSTRUCTIONS
B23K26/0093
PERFORMING OPERATIONS; TRANSPORTING
B23K26/0626
PERFORMING OPERATIONS; TRANSPORTING
B23K37/0288
PERFORMING OPERATIONS; TRANSPORTING
B23K26/14
PERFORMING OPERATIONS; TRANSPORTING
B23K26/0676
PERFORMING OPERATIONS; TRANSPORTING
E01C23/08
FIXED CONSTRUCTIONS
E21D9/1073
FIXED CONSTRUCTIONS
E21C25/66
FIXED CONSTRUCTIONS
E21C37/16
FIXED CONSTRUCTIONS
B23K2103/50
PERFORMING OPERATIONS; TRANSPORTING
International classification
B23K26/00
PERFORMING OPERATIONS; TRANSPORTING
B23K26/70
PERFORMING OPERATIONS; TRANSPORTING
B23K26/03
PERFORMING OPERATIONS; TRANSPORTING
B23K26/06
PERFORMING OPERATIONS; TRANSPORTING
B23K26/067
PERFORMING OPERATIONS; TRANSPORTING
B23K26/14
PERFORMING OPERATIONS; TRANSPORTING
B23K26/40
PERFORMING OPERATIONS; TRANSPORTING
B23K26/402
PERFORMING OPERATIONS; TRANSPORTING
B23K37/02
PERFORMING OPERATIONS; TRANSPORTING
E01C23/08
FIXED CONSTRUCTIONS
E21C25/64
FIXED CONSTRUCTIONS
E21C27/24
FIXED CONSTRUCTIONS
Abstract
There are provided high power laser and laser mechanical earth removing equipment, and operations using laser cutting tools having stand off distances. These equipment provide high power laser beams, greater than kW to cut and volumetrically remove targeted materials and to remove laser affected material with gravity assistance, mechanical cutters, fluid jets, scrapers and wheels. There is also provided a method of using this equipment in mining, road resurfacing and other earth removing or working activities.
Claims
1-59. (canceled)
60. A high power laser mechanical earth removing machine, the machine comprising: a. a source of high power laser energy, a source of a fluid, and an optics package; b. the optics package comprising a cooling means, and an optics assembly; c. the optics assembly configured to provide a laser beam from the tool, the beam having a focal length, a spot size, a spot shape, and a waist having a focal point and a distal end and a proximal end defining a waist length therebetween; d. a means for mechanically removing laser effected earth; and, e. wherein the spot size of the beam waste is less than about 2.0 cm.sup.2, and the waist length is at least about 4 ft.
61. The machine of claim 60, whereby the tool has a stand off distance of at least about 10 ft.
62-72. (canceled)
73. The machine of claim 60, wherein the earth removing machine is a laser tunneling apparatus.
74. The machine of claim 60, wherein the earth removing machine is a laser mechanical boring machine.
75. The machine of claim 60, wherein the earth removing machine is a laser mechanical road resurfacing machine.
76. The machine of claim 60, wherein the earth removing machine comprises a movable cutting assembly.
77. The machine of claim 60, wherein the earth removing machine comprises a movable cutting assembly.
78. The machine of claim 60, wherein the earth removing machine is a laser mechanical continuous miner.
79. The machine of claim 60, wherein the earth removing machine is a laser mechanical shear plow.
80. The machine of claim 60, wherein the earth removing machine comprises a long wall mining system.
81. (canceled)
82. A laser tunneling machine, comprising: three laser cutting tools, each tool capable of generating at least about a 10 kW laser beam having a spot size having a diameter of 3 cm or less; a tunneling housing laser assembly having a plurality of cutting members having a plurality of cutters.
83. The laser tunneling machine of claim 82, characterized as a Class I product.
84. A laser road machine, comprising: a laser cutter capable of generating at least about a 10 kW laser beam having a predetermined self-limiting beam characterization and a laser beam shield.
85. The laser road machine of claim 84, characterized as a Class 1 product.
86. A laser mechanical earth removing machine, comprising: a movable cutting assembly, the cutting assembly having a laser cutter capable of generating at least about a 10 kW laser beam having a spot size of less than about 3 cm diameter, a rotating mechanical cutting roller, the roller having a cutting wheel, the laser cutter providing a beam path cooperatively positioned with the cutting wheel.
87. The machine of claim 86, characterized as a Class 1 product.
88. The machine of claim 86, characterized as a Class IIa product.
89. The machine of claim 86, characterized as a Class II product.
90. The machine of claim 86, characterized as a Class IIIa product.
91. The machine of claim 86, characterized as a Class IIIb product.
92. A laser mechanical continuous mining machine, comprising: a rotating head having a cutting wheel; an adjustment means whereby the position of the rotating head is adjusted; an inlet chute for receiving a laser affected ore; and outlet chute for discharging a laser affected ore; a laser cutting assembly; a laser support bar, whereby the laser cutting assembly is affixed to the mining machine; and a high power laser cable in optical communication with the laser cutting assembly.
93. The machine of claim 92, characterized as a Class 1 product.
94. The machine of claim 92, characterized as a Class IIa product.
95. The machine of claim 92, characterized as a Class II product.
96. A laser mining system, the system comprising a high power laser truck, a laser robot, the laser robot having a means for directing a laser beam in a substantially vertical direction.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0117] In general, the present inventions relate to the delivery of high power laser beams over a distance to assist in performing a laser operation on the work surface. These distances, e.g., the stand off distance, may be greater, and may be substantially larger than typically occurs, or is obtainable, in laser cutting operations. Further, and preferably, the present inventions provide the ability to perform these distant cuts without the need for, with a minimum need for, or with a reduced need for a fluid jet to remove the laser effected material, e.g., dross, slag, or molten material, created by the laser operation. Thus, among other things, the longer stand off distances, alone or in conjunction with, minimizing the need for mechanical cleaning of the cut, e.g., fluid jet, provides the ability to perform laser operations in the field, including in hostile and remote locations, such as, a quarry, a tunnel, a pit, a mine, a well bore, or a nuclear reactor. The laser operations may include, for example, treating, fracturing, tunneling, weakening, melting, ablating, spalling, vaporizing, cooking, charring, welding, heating, annealing, cutting, removing, drilling, penetrating, perforating and combinations and various of these.
[0118] Turing to
[0119] The laser mechanical tunneling machine has a series of rams 2404 that have shoes 2460, which are adjacent to, and engage the wall segments 2403. Thus, the machine 2401 is driven forward, and driven into engagement with the face of the tunnel, by the rams 2404 pushing against the tunnel wall segments 2403.
[0120] Forward, distally to the rams 2404, is the tunneling housing laser assembly 2405. This assembly has a transverse cutting member 2406 that has several, e.g., 2, 4, 10, 20 or more cutters, e.g., 2407 positioned on it for engagement with the face of the tunnel. The assembly has additional transverse cutting members 2408, 2410, 2412, that have their respective cutters, e.g., 2409, 2410, 2411, 2413. Thus, in this embodiment the tunneling housing laser assembly has 4 transverse cutting members. Two of the cutting members 2408 and 2410 are positioned in a cross or X fashion with the center of the X being on the axis of rotation for the housing 2405. The other two cutting member 2406 and 2412 are positioned in a cross or X fashion with the center of the X being on the axis of rotation for the housing 2405. The X 2408-2410 is positioned distally with respect to the X 2406-2412, (i.e., X 2408-2410 is in front of X 2406-2412 and thus close to and first to engage the face of the tunnel). In being understood that other types, configurations, and numbers of cutting members may be used.
[0121] There are also provided a circular kerf cutting member 2414 that has several, e.g., 2, 4, 10, 20 or more cutters, e.g., 2415 positioned on it for engagement with the face of the tunnel. The tunneling housing laser assembly 2405 rotates in the direction as shown by arrow 2416. Thus, when rotated, the kerf cutters cut essentially along the circumference of the face of the tunnel, e.g., they cut continuously adjacent to essentially the outer surface of the tunnel. The other cutting members rotate around engaging the inner portions of the wall face. Force is applied to engage these cutters against the wall face and cut the face, removing material, by the rams 2404 pushing the the shoes 2406 against the wall segments 2403 and thus driving the tunneling laser housing assembly 2405 forward.
[0122] In this embodiment laser cutting tools 2417, 2418, 2419, 2420, 2421, 2422, 2423 and 2124 are associated with the tunneling housing laser assembly 2405. Preferably the laser tools are located with the housing proximal to one or both of the X configurations of cutting members. In this manner the laser tools are removed from and the face of the tunnel and protected from damage and debris. Each of the laser cutting tools is located a head of a respective cutting member, which enable the cutting member to in essence follow the laser beam. Each laser tool respectively delivers a high power laser beam 2417b, 2418b, 2419b, 2420b, 2421b, 2422b, 2423b and 2124b, that has predetermined laser beam properties, along a respective laser beam path 2417a, 2418a, 2419a, 2420a, 2421a, 2422a, 2423a and 2124a that are aimed at a predetermined location on the face of the rock wall relative to the cutting members and cutters.
[0123] More or less laser cutting tools may be used. The sources of the laser beams may be located in the tunneling housing laser assembly 2405, in which case they will rotate with the housing, or they may be located in the frame 2451 of the machine 2401 at, near, or far removed from the housing 2405. Each laser beam may have a power of at least about 5 kW, at least about 10 kW, at least about 20 kW and at least about 50 kW or more. Each laser beam may have the same or different laser beam properties. The beam paths may be relatively aimed at the same or different relative locations. The laser tools may be positioned at different locations along and in the housing 2405. If high power long distance optical fibers are used or needed, one, two, three, four or more fibers may be used or contained in a single umbilical or each may be in its own separate cable structure.
[0124] Additionally, associated with the frame is a conveyor system 2450 for removing the laser effect and other debris, e.g., waste, form the tunneling activity. There are also provided movement and advancement supports, e.g., 2453, that provide for the movement, e.g., follow of the frame behind the housing 2405 as it advances forward. This embodiment of the tunnel boring machine is large, having a diameter of at about 25 feet. Other size diameters may be used from about 5 feet to about 25 feet, greater than about 10 feet, greater than about 15 feet, and greater than about 30 feet.
[0125] Turning to
[0126] Thus, the apparatus 2201 can be positioned, and locked in place either with a mechanical device or with a braking system, then the shaft 2215 is rotated and extended to it reaches its maximum length, which would the maximum amount of distance that can be bored from that particular position of the apparatus. The apparatus 2201 would then be moved forward and the process repeated. Because the laser energy weakens and fractures the rock less mechanical force is need to cut and remove it. Thus, rather than, or in conjunction with, this start and stop process, the boring process can be continuous with the apparatus 2201 being driven forward by the track assembly 2204; and the extension of the shaft 2215 being used for finer, or secondary, force control.
[0127] The laser mechanical cutting assembly 2213 has three laser tools contained inside. Distal opening 2207 for a laser tool has a laser beam path 2207a and a laser beam 2207b. Distal opening 2208 for a laser tool has a laser beam path 2208a and a laser beam 2208b. Distal opening 2209 for a laser tool has a laser beam path 2209a and 2209b. The laser mechanical cutting assembly 2213 has mechanical cutters, e.g., 2214 associated with the face, or distal end of the assembly.
[0128] Each laser tool respectively delivers a high power laser beam that has predetermined laser beam properties, along a respective laser beam path that are aimed at a predetermined location on the face of the rock wall relative to the cutting members and cutters. More or less laser tools may be used. Each laser beam may have a power of at least about 5 kW, at least about 10 kW, at least about 20 kW and at least about 50 kW or more. Each laser beam may have the same or different laser beam properties. The beam paths may be relatively aimed at the same or different relative locations. The laser tools may be positioned at different locations along and in the laser mechanical cutting assembly. The embodiment of
[0129] Turning to
[0130] The laser tool laser support housing 2106 contains six laser tools contained inside. Distal opening 2107 for a laser tool has a laser beam path 2107a and a laser beam 2107b. Distal opening 2108 for a laser tool has a laser beam path 2108a and a laser beam 2108b. Distal opening 2109 for a laser tool has a laser beam path 2109a and 2109b. Distal opening 2210 for a laser tool has a laser beam path 2110a and 2110b. Distal opening 2111 for a laser tool has a laser beam path 2111a and 2111b. Distal opening 2112 for a laser tool has a laser beam path 2112a and 2112b. In the embodiment the laser tools do rotate. The mechanical cutting assembly 2113 has mechanical cutters, e.g., 2114 associated with the face, or distal end of the assembly. The mechanical cutting assembly 2113 has three arms 2113a, 2113b and 2113c. The placement of the laser tools, beam paths and firing sequence of the laser tools, relative to the arms of the assembly 2113 should be such so that the laser beams do not strike the arms. Thus, the laser tools can be fired when the arms are not rotating and the beam paths are clear of the arms as shown in
[0131] Thus, the apparatus 2101 can be positioned, and locked in place either with mechanical device or with a braking system, then the shaft 2215 is rotated and extended to it reaches its maximum length, which would the the maximum amount of distance that can be bored from that particular position of the apparatus. The apparatus 2101 would then be moved forward and the process repeated. Because the laser energy weakens and fractures the rock less mechanical force is need to cut and remove it, the mechanical boring part of this laser mechanical process can be continuous until all of the laser effected rock is removed, at which point the laser can be fired again.
[0132] Turning to
[0133] The use of lasers for road and construction related activities, can greatly reduce the amount of noise that is associated with such activities. Thus, the use of lasers, and their associated noise reduction, can provide for the ability to conduct road repairs, or construction activities, in evening hours, in urban areas, and in particular dense urban areas, such as large cities, without annoyance, or with minimal noise nuisance, for personals living or working in near the construction area.
[0134] Turning to
[0135] The cutting assembly 2302 has a hood assembly 2311. Within the hood assembly 2311 are four laser cutting tools, corresponding to the four cutting wheels 2304, 2305, 2306, 2307. Each laser cutting tool has a laser beam path 2312a, 2313a, 2314a and 2315a and is capable of firing a laser beam 2312b, 2313b, 2314b, 2315b along its respective laser beam path. The laser beam paths are positioned to correspond with the cutting wheels, with out damaging them. In this manner as the hood assembly 2311 is positioned the laser beam paths will also be positioned, and similarly as the cutting assembly, roller and wheels are positioned so will the beam paths be positioned. Thus, provided for one positioning means, e.g., the hydraulic cylinder assembly 2309, to position both the mechanical cutters and the laser beam paths.
[0136] Turning to
[0137] Turning to
[0138] The track conveyor 1701 guides the laser shear 1700 as it moves along the mining face 1702, moves the laser shear 1700 into engagement with lead mining face 1703, which is advanced as face 1704 is removed by the laser mechanical plow shear 1700. The conveyor 1701 also serves to move the mined (e.g., laser affected removed materials or ores) materials to another location or further transport. The laser mechanical shear plow 1701 has a first cutting tool 1709, which is a wheel with cutters on it, and a second cutting tool 1710, which is a wheel with cutters on it. The plow also has a laser tool housing 1708, which has the high power laser tool. A high power laser, for providing the high power laser beam to the laser tool, may be in the laser tool housing, adjacent the laser tool housing and in its own protective housing, or removed from the opening and put in optical communication with the laser tool by a high a power long distance optical fiber.
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[0140] Turning to
[0141] The track conveyor 1801 guides the mechanical shear 1800 as it moves along the mining face 1805, removing laser affected material. The conveyor 1801 also serves to move the mined (e.g., laser affected removed materials or ores) materials to another location or further transport. The mechanical shear plow 1801 has a first cutting tool 1809, which is a wheel with cutters on it, and a second cutting tool 1810, which is a wheel with cutters on it. A laser cutting tool 1802 is positioned on a laser cutting tool sled 1803, which moves along a laser cutting tool sled track 1804. The laser tool 1802 fires laser beam 1812 along beam path 1813 to cut the mining face 1805.
[0142] The laser tool is optically associated with a high power laser, for providing the high power laser beam to the laser tool. The high power laser may be in on the laser tool sled, on its own sled traveling in concert with the laser tool sled, or removed from the opening and put in optical communication with the laser tool by a high a power long distance optical fiber.
[0143] In this laser laser mechanical shear plow system 1820 the laser tool may be moved separately from the sled having the mechanical cutters, thus provided for a greater number of laser mechanical deliver patterns, sequences and operations.
[0144] Turning to
[0145] It should be noted that the mining, tunneling, road working and earth moving equipment of the embodiments shown in
[0146] It should further be noted that although one, two or more processes and techniques for laser assisted mining, drilling, boring or otherwise using the embodiments of laser equipment illustrated in the various figures of this specification, many other processes, operations and combination of these are contemplated and may occur. Thus, for example, start and stop, continuous, and semi continues processes and operations are contemplated, in which the laser is fired during the entire operation or at predetermined times, or intervals, during the operation to obtain the desired enhancements to the process or operation from using the laser energy. Further, although laser-mechanical operations are presently preferred, there may be processes in which laser energy alone is sufficient, and could further be preferred. Additionally, as set forth subsequently in greater detail each laser tool may have its own positioning and aiming device, which then allows the laser beam path to be adjusted, or changed, before of during the movement, positioning or rotation of the various housing and assemblies that hold the laser tools. In this manner, for example, the laser beam angle may be maintained at a desired or predetermined angle during rotation or other movement of the equipment or housing in which the laser tool is positioned.
[0147] Turning to
[0148] Turning to
[0149] Further, each laser tool respectively delivers a high power laser beam that has predetermined laser beam properties, along a respective laser beam path that are aimed at a predetermined location on the surface of earth. More or less laser tools may be used. Each laser beam may have a power of at least about 5 kW, at least about 10 kW, at least about 20 kW and at least about 50 kW or more. Each laser beam may have the same or different laser beam properties. The beam paths may be relatively aimed at the same or different relative locations. The laser tools may be position at different locations along the mining face. If high power long distance optical fibers are used or needed, one, two, three, four or more fibers may be used or contained in a single umbilical or each be in its own separate cable structure.
[0150] Turning to
[0151] In
[0152] The gas inlet section body 1005, has a gas inlet line 1009 and connector 1010, for securing the gas inlet line 1009 to the gas inlet section body 1005. The gas inlet section body 1005 has a back end piece 1018, which has a fitting 1011 for an optical fiber cable 1012. The back end piece 1018, also has an auxiliary fitting 1013 for data line 1014, and data line 1015.
[0153] Turning to
[0154] Generally, the various body sections of the tool may be separate components or they may be integral. They may be connected by any means available that meets the use requirements for the tool. Preferably, the tool, as assembled, should be sufficiently rigid to withstand anticipated vibration and mechanical shocks so that the optical components will remain in optical alignment. The tool body may be made from a single component or tube, it may be made from two, three or more components that are fixed together, such as by threaded connections, bolts, screws, flanges, press fitting, welding, etc. Preferably, the tool, as assembled, should meet the anticipated environmental conditions for an intended use, such as temperature, temperature changes, moisture, weather conditions, and dust and dirt conditions. The tool body, and body sections may be made from metal, composite materials, or similar types of materials that provide the requisite performance capabilities.
[0155] As used herein, unless specified otherwise, the terms front, and distal, are used to refer to the side or portion of a body, component, or structure that is the laser discharge side, is closer to the laser discharge end of the tool, or is further from the source of the laser beam, when the tool is assembled. The terms back or proximal, as used herein and unless specified otherwise, are used to refer to the side or portion of a body, component, or structure that is the back side, is further from the laser discharge end of the tool, or is closer to the source of the laser beam, when the tool is assembled.
[0156] Returning to
[0157] Turning to
[0158] In this embodiment of the tool, the optics package 1024 has lenses that provided for a long focal length, e.g., greater than about 100 mm (3.94″), greater than about 150 mm (5.91″), greater than about 250 mm (9.84″), greater than about 50 mm (19.68″), greater than about 1,000 mm (39.37″), greater than about 1,500 mm (59.06″), greater than about 2,000 mm (78.74″), greater than about 22,860 mm (75′) and greater; and from about 250 mm to about 1,500 mm, and about 500 mm to about 1,000 mm. Thus, turning to
[0159] The stand off distance, which is the distance from the face or distal end 1030 of the laser tool 1000 to the work surface can be greater than about 0.5 feet, greater than about 1 foot, greater than about 3 feet, greater than about 4 feet, and greater. As laser power increases, and laser beam properties are selected the stand off distance may be about 10 feet and greater. Further, as laser power increases, laser beam properties are selected, and if needed means for assisting the laser beam path from the tool to the work surface are used, e.g., a special atmosphere, a jet, or a means to keep the beam path clear, even greater stand off distances may be used, e.g., 50 feet, 75 feet, 100 feet, or more. Generally, across the stand off distance the laser beam path will be in free space, e.g., the laser beam would not be traveling through any solid components, e.g., an optical fiber core, a lens, a window. Thus, for example, the laser beam could be traveling through the atmosphere, e.g., the environmental conditions at a work site, upon exiting the tool at opening 1008 until it strikes the intended work surface.
[0160] Turning to
[0161] Having a laser beam path angle greater than zero, in conjunction with the laser beam power and other beam properties allows for the laser beam to penetrate deeply into a target material, e.g., the earth, rock, hard rock, and concrete. The laser beam can penetrate over 1 foot into a target material, e.g., hard rock, at least about 2 feet, at least about 5 feet, at least about 10 feet, at least about 50 feet and at least about 100 feet and more. Generally, the laser beam upon striking the work surface of the target material heats and melts that material (vaporization may also take place, and as discussed further below, spallation and thermal-mechanical cracking may also arise as a result of the laser heating of the target material). Because the beam angle is greater than 0° the laser beam forms a hole in the target material that has a slope, i.e., down toward the work surface and up into the target material). Thus, the molten material can flow down and out of the hole, clearing the hole so that the laser beam is continually striking the bottom or end of the hole, melting and thus removing additional target material and lengthening the hole.
[0162] The attachment and control assemblies for the laser cutting tools when they are mounted or otherwise associated with rotating components of equipment can be configured to maintain the drilling angle at greater than zero, and at a predetermined greater than zero value, for example 12, 15, 20 or 25 degrees as the laser tool is rotated. Generally, for example, when the laser tool is rotated it is rotated about an axis that is generally perpendicular to the mine, wall or rock face that is being bored; as is the case, for example, in the embodiments of
[0163] Turning to
[0164] Turning to
[0165] In general it is preferred that the optimum portion of the laser beam, e.g., beam waist 1064 of
[0166] The beam waist in many applications is preferably in the area of the maximum depth of the cut. In this manner the hole opens up toward the face (from surface), which further helps the molten material to flow from the hole. This effect is further shown in
[0167] Turning to
[0168] Turning to
[0169] Turning now to
[0170] In general, the airflow within the tool preferably is sufficient to keep the distal end of the optics package and of the tool clear of debris and dirt from the environment. The airflow may also be used for cooling the optical package, optical components or other portions of the tool. A separate fluid, gas, or other type of cooling or thermal management system may be employed with the tool depending upon such factors as laser power, likely stand off distances, and environment temperatures, e.g., if the target material is a glacier in Antarctica compared to a rock face deep within an underground gold mine. For example, air flows of from about 15 scfm to about 50 scfm, about 20 scfm to about 40 scfm, about 20 scfm, and about 30 scfm can be utilized. Greater air flows may be used, but may not be necessary to cool and keep the optics clean. Ambient air from a compressor, bottled or compress air, nitrogen or other gasses may be used. Preferably the gas is clean, and substantially free from, or free from, any grease, oil or dirt that could adversely effect the optics when the laser beam is being propagated.
[0171] Turning to
[0172] It should be further noted that once this self limiting depth control has occurred, the laser tool can be moved closer to the material and then have the process continue to advance the hole until the new self limiting depth is reached, at which if desired the tool could be move close, and this may be repeated until the tool is essentially upon the face of the target material. A beam profile providing for a self-limiting depth for example may be used in the laser road machine embodiment of
[0173] Turning to
[0174] The fractures 5090a, 5090b, 5090c and 5090d are merely schematic representation of the laser induced fractures that can occur in the target material, such as rock, earth, rock layer formations and hard rocks, including for example granite, basalt, sandstone, dolomite, sand, salt, limestone, ores, minerals, overburden, marble, rhyolite, quartzite and shale rock. In the target material, and especially in target materials that have a tendency, and a high tendency for thermal-mechanical fracturing, in a 10 foot section of laser cut hole there may be about 10, about 20, about 50 or more such fractures, and these fractures may be tortious, substantially linear, e.g., such as a crack along a fracture line, interconnected to greater and lessor extents, and combinations and variations of these. These laser fractures may also be of varying size, e.g., length, diameter, or distance of separation. Thus, they may vary from micro fractures, to hairline fractures, to total and extended separation of sections having considerable lengths.
[0175] The depth or length of the hole can be controlled by determining the rate, e.g., inches/min, at which the hole is advanced for a particular laser beam, configuration with respect to the work surface of the target material, and type of target material. Thus, based upon the advancement rate, the depth of the hole can be predetermined by firing the laser for a preset time.
[0176] The rate and extent of the laser fracturing, e.g., laser induced crack propagation, may be monitored by sensing and monitoring devices, such as acoustical devices, acoustical geological sensing devices, and other types of geological, sensing and surveying type devices. In this manner the rate and extent of the laser fracturing may be controlled real time, by adjusting the laser beam properties based upon the sensing data.
[0177] In doing assays of a formation, for example, to determine a mineral or precious metal content, a laser hole can be cut into the face of the formation and advanced into the formation to a predetermined depth, for example 100 feet. Samples of the molten material flowing from the hole can be taken at set time intervals, which would correspond to set distances from the face (based upon the advancement rate for the hole). The molten sample can be analyzed at the location or solidified and stored, for later analysis. In this manner, if a series of holes are laser cut into the rock face at predetermined intervals an analysis of the entire formation can be performed. For example, since the laser can be used to melt the target material, e.g., a rock, it is also possible to collect the molten rock in for example a crucible. By keeping the rock molten for a few minutes, (the laser may be used for this purpose, a second laser may be used, or conventional heaters, e.g., flame, electric, may be used) the heavier desired metal, e.g., gold, silver, copper, and other heavy metals can sink to the bottom of the crucible giving the operator a real time method for assaying the potential of the formation. The laser can also be used to melt a predetermined surface or volume of rock for the purpose of assaying the formation independent of any drilling or cutting process. The spectral emissions from the laser rock process may also be used to determine the presence of trace elements. In this example, preferably a sophisticated spectral analysis technique, known to those of skill in the spectral analysis arts, can be employed, to sort out the spectral signatures of the desired or sought after materials that may be buried in the background blackbody radiation signal.
[0178] Cuts in, sectioning of, and the volumetric removal of the target material can be accomplished by delivering the laser beam energy to the target material in preselected and predetermined energy distribution patterns. These patterns can be done with a single laser beam, or with multiple laser beams. For example, these patterns can be: a linear cut; a circular cut; a spiral cut; a pattern of connected cuts; a pattern of connected linear cuts, such as a grid pattern, a pattern of radially extending cuts, e.g., spokes on a wheel; a circle and radial cut pattern, e.g., cutting pieces of a pie and cutting around the pie pan; a pattern of spaced apart holes, such as in a line, in a circle, in a spiral, or other pattern, as well as other patterns and arrangements. The patterns, whether lines, staggered holes, others, or combinations thereof, can be traced along a feature of the target material, such as, a geologic feature of a formation, a boarder of an ore seam, or a joint in a structure. The patterns can be traced along a feature intended to be created in the target material, such as a side wall or roof of a tunnel or shaft. The forgoing are illustrative examples of the types and nature of laser cuts, sectionings and volumetric removals that the can be performed; and that additional, other, varied, as well as combinations and variations of the forgoing are contemplated. Additionally, the timing and sequence of the creation of the holes, cuts and volumetrically removed sections, can be predetermined to enhance, and take advantage, the laser fracturing of the target material, as well as the laser affected zones in the material. The predetermined timing sequence can also provide the ability to enhance other non-laser operations that may be taking place before, after or in conjunction with the laser operations.
[0179] Thus, for example, in determining a laser beam delivery pattern to provide a predetermined and preselected laser beam energy distribution pattern, the spacing of cut lines, or staggered holes, in the target material, preferably may be such that the laser affected zones are slightly removed from one another, adjacent to one another but do not overlap, or overlap only slightly. In this manner, the maximum volume of the target material will be laser affected, i.e., weakened, with the minimum amount of total energy.
[0180] It is further believed that when comparing the energy delivered from the present laser operations, as compared to conventional blasting using explosives, substantially less energy is being used. Further, the present laser operations avoid the peripheral environment damage, and structural damage to surround structures, e.g., homes and business, that may occur from the use of explosive in mining, quarrying, tunneling and construction activities. The present inventions provide a further benefit by eliminating risk to personnel from the use and handling of explosives; thus eliminating the need to vacate all personnel during the mining operation. Unlike explosive use, the use of the present laser operations may not require the clearing of large areas and the stopping of other operations, while the cutting and fracturing operations are ongoing.
[0181] Preferably, when the laser tool is configured for performing a laser operation on a target material the laser beam path from the front of the tool to the surface of target material should be isolated. This may be accomplished by the use of a barrier that prevents the laser light from escaping or from reaching the location where personnel may be present. For example the laser beam path may be isolated by using a light weight metal tube, having an internal diameter that is large enough to not interfere with the laser beam, that is optically sealed to the laser tool, i.e., no laser light can escape, and that extends from the laser tool to the work surface, where it is optically sealed to the work surface. It may be isolated by using a temporary, semi-permanent or permanent shielding structure, e.g., stands holding welding blankets or other light blocking materials, a scaffold supporting light blocking materials, a telescoping or extendable housing that is placed over the beam path or more preferably the tool and the beam path. It may also be isolated by constructing a temporary, semi-permanent or permanent barrier to optically isolate the beam path, and more preferably to isolate the tool, the work surface and the target material from personnel, e.g., a temporary barrier in a tunnel, optically sealing against the tunnel walls, behind the laser tool as it is advancing the tunnel face.
[0182] Preferably, the laser equipment will meet the requirements of 21 C.F.R. § 1040.10 (Revised as of Apr. 1, 2012), the entire disclosure of which is incorporated herein by reference, to be considered Class Ill, more preferably Class II, and still more preferably Class I.
[0183] As used in this specification a “Class I product” is equipment that will not permit access during the operation of the laser to levels of laser energy in excess of the emission limits set forth in Table I. Thus, preferably personnel operating, and in the area of operation, of the equipment will receive no more than, and preferably less than, the following exposers in Table I during operation of the laser equipment.
TABLE-US-00001 TABLE I CLASS I ACCESSIBLE EMISSION LIMITS FOR LASER RADIATION Wavelength Emission duration Class I-Accessible emission limits (nanometers) (seconds) (value) (unit) (quantity)** ≥180 <3.0 × 10.sup.4 - - - 2.4 × 10.sup.−5k.sub.1k.sub.2* Joules(J)* radiant energy but >3.0 × 10.sup.4 - - - 8.0 × 10.sup.−10k.sub.1k.sub.2* Watts(W)* radiant power ≤400 >400 >1.0 × 10.sup.−9 to 2.0 × 10.sup.−5 - - - 2.0 × 10.sup.−7k.sub.1k.sub.2 J radiant energy but >2.0 × 10.sup.−5 to 1.0 × 10.sup.1 - - - 7.0 × 10.sup.−4k.sub.1k.sub.2t.sup.3/4 J radiant energy ≤1400 >1.0 × 10.sup.1 to 1.0 × 10.sup.4 - - - 3.9 × 10.sup.−3k.sub.1k.sub.2 J radiant energy >1.0 × 10.sup.4 - - - 3.9 × 10.sup.−7k.sub.1k.sub.2 W radiant power and also (See paragraph (d)(4) of this section) >1.0 × 10.sup.−9 to 1.0 × 10.sup.1 - - - 10k.sub.1k.sub.2t.sup.1/3 Jcm.sup.−2sr.sup.−1 integrated radiance >1.0 × 10.sup.1 to 1.0 × 10.sup.4 - - - 20k.sub.1k.sub.2 Jcm.sup.−2sr.sup.−1 integrated radiance >1.0 × 10.sup.4 - - - 2.0 × 10.sup.−3k.sub.1k.sub.2 Wcm.sup.−2sr.sup.−1 radiance >1400 >1.0 × 10.sup.−9 to 1.0 × 10.sup.−7 - - - 7.9 × 10.sup.−5k.sub.1k.sub.2 J radiant energy but >1.0 × 10.sup.−7 to 1.0 × 10.sup.1 - - - 4.4 × 10.sup.−3k.sub.1k.sub.2t.sup.1/4 J radiant energy ≤2500 >1.0 × 10.sup.1 - - - 7.9 × 10.sup.−4k.sub.1k.sub.2 W radiant power >2500 >1.0 × 10.sup.−9 to 1.0 × 10.sup.−7 - - - 1.0 × 10.sup.−2k.sub.1k.sub.2 Jcm.sup.−2 radiant exposure but >1.0 × 10.sup.−7 to 1.0 × 10.sup.1 - - - 5.6 × 10.sup.−1k.sub.1k.sub.2t.sup.1/4 Jcm.sup.−2 radiant exposure ≤1.0 × 10.sup.6 >1.0 × 10.sup.1 - - - 1.0 × 10.sup.−1k.sub.1k.sub.2t Jcm.sup.−2 radiant exposure *Class I accessible emission limits for wavelengths equal to or greater than 180 nm but less than or equal to 400 nm shall not exceed the Class I accessible emission limits for the wavelengths greater than 1400 nm but less than or equal to 1.0 × 10.sup.6 nm with a k.sub.1 and k.sub.2 of 1.0 for comparable sampling intervals. **Measurement parameters and test conditions shall be in accordance with paragraphs (d)(1), (2), (3), and (4), and (e) of this section.
[0184] As used in this specification a “Class IIa product” is equipment that will not permit access during the operation of the laser to levels of visible laser energy in excess of the emission limits set forth in Table II-A; but permit levels in excess of those provided in Table I.
TABLE-US-00002 TABLE II-A CLASS IIa ACCESSIBLE EMISSION LIMITS FOR LASER RADIATION CLASS IIa ACCESSIBLE EMISSION LIMITS ARE IDENTICAL TO CLASS I ACCESSIBLE EMISSION LIMITS EXCEPT WITHIN THE FOLLOWING RANGE OF WAVELENGTHS AND EMISSION DURATIONS: Wavelength Emission duration Class IIa-Accessible emission limits (nanometers) (seconds) (value) (unit) (quantity)* >400 >1.0 × 10.sup.3 3.9 × 10.sup.−6 W radiant power but ≤710 *Measurement parameters and test conditions shall be in accordance with paragraphs (d)(1), (2), (3), and (4), and (e) of this section.
[0185] As used in this specification a “Class II product” is equipment that will not permit access during the operation of the laser to levels of laser energy in excess of the emission limits set forth in Table II; but permit levels in excess of those provided in Table II-A.
TABLE-US-00003 TABLE II CLASS II ACCESSIBLE EMISSION LIMITS FOR LASER RADIATION CLASS II ACCESSIBLE EMISSION LIMITS ARE IDENTICAL TO CLASS I ACCESSIBLE EMISSION LIMITS EXCEPT WITHIN THE FOLLOWING RANGE OF WAVELENGTHS AND EMISSION DURATIONS: Wavelength Emission duration Class II-Accessible emission limits (nanometers) (seconds) (value) (unit) (quantity)* >400 >2.5 × 10.sup.−1 1.0 × 10.sup.−3 W radiant power but ≤710 *Measurement parameters and test conditions shall be in accordance with paragraphs (d)(1), (2), (3), and (4), and (e) of this section.
[0186] As used in this specification a “Class IIIa product” is equipment that will not permit access during the operation of the laser to levels of laser energy in excess of the emission limits set forth in Table III-A; but permit levels in excess of those provided in Table II.
TABLE-US-00004 TABLE III-A CLASS IIIa ACCESSIBLE EMISSION LIMITS FOR LASER RADIATION CLASS IIIa ACCESSIBLE EMISSION LIMITS ARE IDENTICAL TO CLASS I ACCESSIBLE EMISSION LIMITS EXCEPT WITHIN THE FOLLOWING RANGE OF WAVELENGTHS AND EMISSION DURATIONS: Wavelength Emission duration Class IIIa-Accessible emission limits (nanometers) (seconds) (value) (unit) (quantity)* >400 >3.8 × 10.sup.−4 5.0 × 10.sup.−3 W radiant power but ≤710 *Measurement parameters and test conditions shall be in accordance with paragraphs (d)(1), (2), (3), and (4), and (e) of this section.
[0187] As used in this specification a “Class IIIb product” is equipment that will not permit access during the operation of the laser to levels of laser energy in excess of the emission limits set forth in Table III-B; but permit levels in excess of those provided in Table III-A.
TABLE-US-00005 TABLE III-B CLASS IIIb ACCESSIBLE EMISSION LIMITS FOR LASER RADIATION Wavelength Emission duration Class IIIb-Accessible emission limits (nanometers) (seconds) (value) (unit) (quantity)* ≥180 ≤2.5 × 10.sup.−1 - - - 3.8 × 10.sup.−4k.sub.1k.sub.2 J radiant energy but >2.5 × 10.sup.−1 - - - 1.5 × 10.sup.−3k.sub.1k.sub.2 W radiant power ≤400 >400 >1.0 × 10.sup.−9 to 2.5 × 10.sup.−1 - - - 10k.sub.1k.sub.2t.sup.1/3 Jcm.sup.−2 radiant exposure but >2.5 × 10.sup.−1 - - - to a maximum value Jcm.sup.−2 radiant exposure ≤1400 of 10 W radiant power 5.0 × 10.sup.−1 >1400 >1.0 × 10.sup.−9 to 1.0 × 10.sup.1 - - - 10 Jcm.sup.−2 radiant exposure but >1.0 × 10.sup.1 - - - 5.0 × 10.sup.−1 W radiant power ≤1.0 × 10.sup.6 *Measurement parameter and test conditions shall be in accordance with paragraphs (d)(1), (2), (3), and (4), and (e) of this section.
[0188] The values for the wavelength dependent correction factors “k1” and “k2” for Tables I, IIA, II, IIIA, IIIB are provided in Table IV.
TABLE-US-00006 TABLE IV VALUES OF WAVELENGTH DEPENDENT CORRECTION FACTORS k.sub.1 AND k.sub.2 Wavelength ( nanometers) k.sub.1 k.sub.2 180 to 302.4 1.0 1.0 >302.4 to 315
[0189] The measurement parameters and test conditions for Tables I, IIA, II, IIIA, and IIIB, which are referred to by paragraph numbers of “this section,” are as follows, and are provided with their respective paragraph numbers “b” and “e” as they appear in 21 C.F.R. § 1040.10 (Revised as of Apr. 1, 2012):
[0190] (b)(1) Beam of a single wavelength. Laser or collateral radiation of a single wavelength exceeds the accessible emission limits of a class if its accessible emission level is greater than the accessible emission limit of that class within any of the ranges of emission duration specified in tables I, II-A, II, Ill-A, and III-B.
[0191] (b)(2) Beam of multiple wavelengths in same range. Laser or collateral radiation having two or more wavelengths within any one of the wavelength ranges specified in tables I, II-A, II, Ill-A, and III-B exceeds the accessible emission limits of a class if the sum of the ratios of the accessible emission level to the corresponding accessible emission limit at each such wavelength is greater than unity for that combination of emission duration and wavelength distribution which results in the maximum sum.
[0192] (b)(3) Beam with multiple wavelengths in different ranges.” Laser or collateral radiation having wavelengths within two or more of the wavelength ranges specified in tables I, II-A, II, Ill-A, and III-B exceeds the accessible emission limits of a class if it exceeds the applicable limits within any one of those wavelength ranges.
[0193] (b)(4) Class I dual limits. Laser or collateral radiation in the wavelength range of greater than 400 nm but less than or equal to 1.400 nm exceeds the accessible emission limits of Class I if it exceeds both: (i) The Class I accessible emission limits for radiant energy within any range of emission duration specified in table I, and (ii) The Class I accessible emission limits for integrated radiance within any range of emission duration specified in table I.
[0194] (e) (1) Tests for certification. Tests shall account for all errors and statistical uncertainties in the measurement process. Because compliance with the standard is required for the useful life of a product such tests shall also account for increases in emission and degradation in radiation safety with age.
[0195] (e)(2) Test conditions. tests for compliance with each of the applicable requirements of paragraph (e) shall be made during operation, maintenance, or service as appropriate: (i) Under those conditions and procedures which maximize the accessible emission levels, including start-up, stabilized emission, and shut-down of the laser product; and (ii) With all controls and adjustments listed in the operation, maintenance, and service instructions adjusted in combination to result in the maximum accessible emission level of radiation; and (iii) At points in space to which human access is possible in the product configuration which is necessary to determine compliance with each requirement, e.g., if operation may require removal of portions of the protective housing and defeat of safety interlocks, measurements shall be made at points accessible in that product configuration; and (iv) With the measuring instrument detector so positioned and so oriented with respect to the laser product as to result in the maximum detection of radiation by the instrument; and (v) For a laser product other than a laser system, with the laser coupled to that type of laser energy source which is specified as compatible by the laser product manufacturer and which produces the maximum emission level of accessible radiation from that product.
[0196] (e)(3) Measurement parameters. Accessible emission levels of laser and collateral radiation shall be based upon the following measurements as appropriate, or their equivalent: (i) For laser products intended to be used in a locale where the emitted laser radiation is unlikely to be viewed with optical instruments, the radiant power (W) or radiant energy (J) detectable through a circular aperture stop having a diameter of 7 millimeters and within a circular solid angle of acceptance of 1*10-3steradian with collimating optics of 5 diopters or less. For scanned laser radiation, the direction of the solid angle of acceptance shall change as needed to maximize detectable radiation, with an angular speed of up to 5 radians/second. A 50 millimeter diameter aperture stop with the same collimating optics and acceptance angle stated above shall be used for all other laser products. (ii) The irradiance (W cm-2) or radiant exposure (J cm-2equivalent to the radiant power (W) or radiant energy (J) detectable through a circular aperture stop having a diameter of 7 millimeters and, for irradiance, within a circular solid angle of acceptance of 1**10-3steradian with collimating optics of 5 diopters or less, divided by the area of the aperture stop (cm-2). (iii) The radiance (W cm-2sr-1) or integrated radiance (J cm-2sr-1) equivalent to the radiant power (W) or radiant energy (J) detectable through a circular aperture stop having a diameter of 7 millimeters and within a circular solid angle of acceptance of 1*10-5steradian with collimating optics of 5 diopters or less, divided by that solid angle (sr) and by the area of the aperture stop (cm-2).
[0197] In general, for embodiments of laser-mechanical and laser earth moving, tunneling, boring, road-working, mining and quarrying equipment, they may have, and it is preferable that embodiments include, for example, protective housing or shields, safety interlocks, remote interlock connectors, key controls, emission indicators, beam attenuators, remote controls, remote camera and display systems for viewing the laser and laser-mechanical operations and work zones, scanning safeguards, warning signs, stickers and designations and combinations and variations of these. Examples of some embodiments of control and monitoring systems for high power laser systems and operations are disclosed and taught in Published U.S. Patent Application Publication Numbers: 2012/0248078 and 2012/0273269, the entire disclosures of each of which are incorporated by reference herein.
[0198] The protective housing or shielding may be of an expandable or deployable nature, or it may be fixed. If deployable, it may be expanded or positioned, against the floor, walls, and roof of a shaft or opening to optically seal, or substantially optically seal, the area of laser operation. In this manner the expandable or deployable shield prevents excess laser light form escaping the shield, and optically contained area, where the laser operation is being performed. These expandable shields may be made out of composite materials, metal and carbon fiber bases materials to name a few. It is preferred that the materials that are used have a high absorption for the wavelength(s) of laser energy that are being used, have sufficient durability and heat resistance that they are not quickly (instantly) destroyed if the laser beam should strike them, and they should be durable enough and conformable enough to for optical seals against the surrounding material. In the expandable type of shield, for example, they could be made from an expandable shirt, such as the shirts that are used in hovercraft. They may also be made from material and technology used in oil field packers, and packer systems; if they are inflated with a fluid, expanded, or if internal void spaces are present, they may be preferably be filled with fluid, or other material that is absorbent, and more preferably highly absorbent to the laser wavelengths being used. They may be made out of steel, metal, carbon-based material and may be multi-layer and multi-material based.
[0199] Turning to
[0200] A preferable configuration, and use, for an adjustable optics package will be for use with a 300 m optic system so that the beam waist can be driven, e.g., advanced forward by changing focal length, into the borehole as the borehole advances.
[0201] Turning to
[0202] In
[0203] In the embodiment of
[0204] Generally, the various body sections of the tool 9000 may be separate components or they may be integral. They may be connected by any means available that meets the use requirements for the tool. Preferably, the tool, as assembled, should be sufficiently rigid to withstand anticipated vibration and mechanical shocks so that the optical components will remain in optical alignment. The tool body, body section, the beam tube and the prism section may be made from a single component or tube, it may be made from two, three or more components that are fixed together, such as by threaded connections, bolts, screws, flanges, press fitting, welding, etc. Preferably, the tool, as assembled, should meet the anticipated environmental conditions for an intended use, such as temperature, temperature changes, moisture, weather conditions, and dust and dirt conditions. The tool body, body sections, and beam tube, and prism sections may be made from metal, composite materials, or similar types of materials that provide the requisite performance capabilities.
[0205] The optical fiber cable 9012 extends into the gas inlet section body 1005 and the gas flow passage 9019. The optical fiber cable 9012 is optically and mechanically associated with optical connector 9022, which is positioned in optical connector receptacle 9023. The optical connector receptacle has a plurality of fins, e.g., 9025, which extend into gas flow passage 9019, and which provide cooling for the optical connector 9022 and the optical connector receptacle 9023. The laser beam path is represented by dashed line 9026, and extends from within the core of the optical fiber cable 9012 to a potential target or work surface. (The totality of the optical path would start at the source of the laser beam, and extend through all optical components, and free space, that are in the intended path of the laser beam.) At the distal end 9022a of optical connector 9022, the laser beam path 9026 is in free space, e.g., no solid components are present, and travels from the distal connector end 9022a to the optics package 9024, where the laser beam is optically manipulated to predetermined laser beam parameters for providing long stand off distance capabilities. The laser beam path 9026 exits the distal end 9024a of the optics package 9024, and travels in free space in the flow carry over section 9020, in the front section of the optical section body 9028, and into beam path tube section 9003 which has beam tube 9003, and enters TIR prism 9050 where it is reflected at a right angle, exiting through opening 9008. In operation the laser beam 9027 would be propagated by a laser, e.g., a source of a laser beam, and travel along the laser beam path 9026. The TIR (total internal reflection) prism 9050 is of the type taught and disclose in U.S. Patent Application Ser. No. 61/605,434 the entire disclosure of which is incorporated herein by reference, and which can be configured to provide other angles in addition to 90°.
[0206] Other types of reflective mirrors may be used. Thus, the mirror may be any high power laser optic that is highly reflective of the laser beam wavelength, can withstand the operational pressures, and can withstand the power densities that it will be subjected to during operation. For example, the mirror may be made from various materials. For example, metal mirrors are commonly made of copper, polished and coated with polished gold or silver and sometime may have dielectric enhancement. Mirrors with glass substrates may often be made with fused silica because of its very low thermal expansion. The glass in such mirrors may be coated with a dielectric HR (highly reflective) coating. The HR stack as it is known, consists of layers of high/low index layers made of SiO.sub.2, Ta.sub.2O.sub.5, ZrO.sub.2, MgF, Al.sub.2O.sub.3, HfO.sub.2, Nb.sub.2O.sub.5, TiO.sub.2, Ti.sub.2O.sub.3, WO.sub.3, SiON, Si.sub.3N.sub.4, Si, or Y.sub.2O.sub.3 (All these materials would work for may wave lengths, including 1064 nm to 1550 nm). For higher powers, such as 50 kW actively cooled copper mirrors with gold enhancements may be used. It further may be water cooled, or cooled by the flow of the gas. Preferably, the mirror may also be transmissive to wavelengths other than the laser beam wave length. In this manner an optical observation device, e.g., a photo diode, a camera, or other optical monitoring and detection device, may be placed behind it.
[0207] In the embodiment of the tool in
[0208] Further examples and types of long laser cutting tools, optic assemblies, laser beam paths, and laser beam delivery assemblies are taught and disclosed in U.S. patent application Ser. No. 14/080,722 the entire disclosure of which is incorporated by reference.
[0209] The nozzles or distal end opening of the tools may have opens of about 1 cm diameter for a focusing optic with a short focal length to 40 cm diameter for the long focal length optics assemblies.
EXAMPLES
[0210] The following examples are provide to illustrate various devices, tools, configurations and activities that may be performed using the high power laser tools, devices and system of the present inventions. These examples are for illustrative purposes, and should not be view as, and do not otherwise limit the scope of the present inventions.
Example 1
[0211] The laser mechanical tunneling machine of the embodiment of
Example 2
[0212] An embodiment of an optics assembly for providing a high power laser beam for cutting and drilling a target material from a stand off distance of 100 feet is provided in
[0213] Turning to
Example 2a
[0214]
[0215] In an example of an embodiment of this optical assembly, the fiber may have a core of about 200 μm, and the NA of the connector distal face is 0.22. The beam launch assembly (fiber 1410/connector) launches a high power laser beam, having 20 kW of power in a pattern shown by the ray trace lines, to a secondary mirror 1416. The diverging mirror 1416 is located 11 cm (as measured along the total length of the beam path) from the launch or distal face of the beam launch assembly. The secondary mirror 1416 has a diameter of 2″ and a radius of curvature 143 cm. For distances of about 100 feet the primary mirror 1418 has a diameter of 18″ and a radius of curvature of 135 cm. In this embodiment the primary mirror is shaped, based upon the incoming beam profile, to provide for a focal point 100 feet from the face of the primary mirror. This configuration can provided a very tight spot in the focal plain, the spot having a diameter of 1.15 cm. Moving in either direction from the focal plane, along the beam waist, for about 4 feet in either direction (e.g., an 8 foot optimal cutting length of the laser beam) the laser beam spot size is about 2 cm. For cutting rock, it is preferable to have a spot size of about ¾″ or less (1.91 cm or less) in diameter (for laser beam having from about 10 to 40 kW). In an example of an embodiment during use, the diverging mirror could have 2 kW/cm.sup.2 and the primary mirror could have 32 W/cm.sup.2 of laser power on their surfaces when performing a laser perforation operation.
Example 2b
[0216] In this embodiment a 20 kW laser beam is launched into the laser optics assembly of the embodiment of Example 2, the secondary mirror would have 1 kW/cm.sup.2 and the primary mirror would have 16 W/cm.sup.2. 16 of these laser delivery assemblies are located around the inner surface of the kerf cutting ring of an embodiment of
Example 2c
[0217] In this embodiment a 40 kW laser beam is launched into the laser optics assembly of the embodiment of Example 2, the secondary mirror would have 2 kW/cm.sup.2 and the primary mirror would have 32 W/cm.sup.2. 12 of these laser delivery assemblies are located around the inner surface of the kerf cutting ring of an embodiment of
Example 2d
[0218] In this embodiment a 40 kW laser beam is launched into the laser optics assembly of the embodiment of Example 2a, the diverging (secondary) mirror would have 2 kW/cm.sup.2 and the primary mirror would have 32 W/cm.sup.2, which is used with a laser cutting tool system of the type shown in
Example 2e
[0219] In this embodiment 3 optical assemblies of the configuration of Example 2a are used, with a separate fiber each providing a 20 kW laser beam to the assemblies. The three assemblies are positioned to direct three laser beams into a 2 cm.sup.2 spot, having a combined power of about 60 kW at a distance of 100 feet from the tool, which is used with a laser cutting tool system of the type shown in
Example 2f
[0220] In this embodiment 3 optical assemblies of the configuration of Example 2a are used, with a separate 200 μm core fiber, each providing a 40 kW laser beam to the assemblies. The three assemblies are positioned to direct three laser beams into a 2 cm.sup.2 spot, having a combined power of about 120 kW at a distance of 100 feet from the tool.
Example 3
[0221] Turning to
[0222] Differing types of lens may be used, for example in an embodiment Lens 830 has a focal length of 500 mm and lens 840 has a focal length of 500 mm, which provide for a focal length for the optics assembly of 250 mm. The NA of the connector face is 0.22. Lens 810 is a meniscus (f=200 mm). Lens 820 is a plano-convex (f=200 mm). Lens 830 is a plano-convex (f=500 mm). Lens 840 is a menisus (f=500 mm).
Example 4
[0223] Turning to
Example 5
[0224] Turning to
Example 6
[0225] The embodiment of
Example 7
[0226] In this embodiment the lens configuration and types of the embodiment of
Example 8
[0227] In this embodiment lens 3 has a 1,000 mm focus and a diameter of 50.8 mm and lens 4 is not present in the configuration of
Example 9
[0228] In this embodiment the lens configuration of the embodiment of
Example 10
[0229] In this embodiment the lens configuration of
Example 11
[0230] The embodiment of the system of
Example 12
[0231] The embodiment of the system of
Example 13
[0232] The embodiment of the system of
Example 14
[0233] The embodiment of the system of
Example 15
[0234] Turning to
Example 16
[0235] A laser tool was used to cut perforations in rock samples. The laser power was 15.3 kW, the beam angle was 15°, the standoff distance was 3 feet, and a laser tool of the general type shown in
TABLE-US-00007 Depth Time Rate Run No. (in) (s) (ft/hr) Sandstone 1 2 210 2.86 2 4.5 210 6.43 3 4.75 210 6.79 Granite 1 9 330 8.18 2 9 230 11.74 3 9 255 10.59 Brohm 1 12 720 5.00 2 12 720 5.00 3 12.5 745 5.03
Example 17
[0236] A laser tool was used to cut perforations in Brohm rock samples. The laser power was 15 kW, the beam angle was 15°, the standoff distances were varied, and a laser tool of the general type shown in
TABLE-US-00008 Depth Time Rate Run No. (in) (s) (ft/hr) Standoff distance 3 ft 1 9.125 180 15.21 2 9.25 180 15.42 Standoff distance 4.5 ft 1 8.9375 180 14.90 2 8.875 180 14.79 Standoff distance 6 ft 1 8 180 13.33 2 8.25 180 13.75
Example 18
[0237] A laser tool was used to cut perforations in Brohm rock samples. The laser power was 15 kW, the beam angle was 15°, the standoff distances were varied, and a laser tool of the general type shown in
TABLE-US-00009 Standoff Depth Time Rate Run No. ft (in) (s) (ft/hr) 1 3 13.25 249 15.96 2 7.75 6.5 180 10.83
Example 19
[0238] A laser tool was used to cut perforations in Brohm rock samples. The laser power was 15.3 kW, the beam angle was 30°, the standoff distance was 3 feet, and a laser tool of the general type shown in
TABLE-US-00010 Depth Time Rate Run No. (in) (s) (ft/hr) 1 7.875 102 23.16 2 7.375 98 22.58 3 7.375 95 23.29 4 6.625 88 22.59 5 10.5 243 12.96 6 10.375 220 14.15 7 9.75 233 12.55 8 8.5 115 22.17
Example 20
[0239] A laser tool was used to cut perforations in limestone rock samples. The laser power was 15.3 kW, the beam angle was 15°, the standoff distance was 3 feet, and a laser tool of the general type shown in
TABLE-US-00011 Depth Time Rate Run No. (in) (s) (ft/hr) 1 4.5 240 5.63 2 2.5 60 12.50 3 2.5 120 6.25
Example 21
[0240] A laser tool was used to cut perforations in limestone rock samples. The laser power was varied, the beam angle was 30°, the standoff distance was 3 feet, and a laser tool of the general type shown in
TABLE-US-00012 LP Depth Time Rate Run No. kW (in) (s) (ft/hr) 1 15 4.375 240 5.47 2 10 6 196 9.18 3 10 4.5 240 5.63
Example 22
[0241] A laser tool was used to cut perforations in rock samples. The laser power was 15.3 kW, the beam angle was 15°, the standoff distance was 3 feet, and a laser tool of the general type shown in
TABLE-US-00013 Depth Time Rate Run No. (in) (s) (ft/hr) 1 13.5 410 9.88 2 14.5 780 5.58
Example 23
[0242] A laser tool was used to cut perforations in rock samples. The laser power was varied, the beam angle was 30°, the standoff distance was 3 feet, and a laser tool of the general type shown in
TABLE-US-00014 LP Depth Time Rate Run No. kW (in) (s) (ft/hr) 1 15 11.5 319 10.82 2 10 10.5 227 13.88 3 10 10.375 319 9.76 4 5 10.25 600 5.13 5 2.5 5.25 600 2.63
Example 24
[0243] Turning to
Example 25
[0244] Turning to
Example 26
[0245] Turning to
Example 27
[0246] Turning to
Example 28
[0247] Turning to
Example 29
[0248] Turning to
Example 30
[0249] A laser-mechanical equipment of the type shown in
Example 31
[0250] A laser-mechanical equipment of the type shown in
Example 32
[0251] A laser-mechanical equipment of the type shown in
Example 33
[0252] A laser-mechanical equipment of the type shown in
Example 34
[0253] A laser-mechanical equipment of the type shown in
Example 35
[0254] Turning to
[0255] Thus, and generally, a laser mining systems for use in example laser caving operations could have a laser unit 7020, a chiller 7021, a control unit 7022, a compressor or source of high pressure air 7023, a generator 7024 and a laser robot 7000. The laser beam would be transmitted from the laser to the laser robot 7000 by way of one or more high power laser fibers. (Additionally, it should be understood that one, two, three or more laser robots may be used in a single laser system, further a laser robot may have one, two, three or more laser cutters.) Turning to
[0256] Some of the Examples illustrate the integration of long distance high power laser cutting tools with large earth moving, boring, tunneling, removing, etc., equipment. In general, the laser energy is used to soften, weaken or remove, the rock in predetermined and preselected locations and patterns enabling the mechanical cutters to more easily remove the material, which can have many benefits, including for example increase speed, reduced noise, reduced vibration, reduced costs, longer mechanical equipment life, greater control over the removal process, greater control of the surface of the remaining material. Moreover, because the targeted laser energy can substantially reduce the hardness of the rock, or earth, much smaller, and less expensive, equipment can be used in situations where it might otherwise not have been able to be used. These examples are provided as illustrative embodiments of these general types of laser-equipment, it being recognized that other combinations and variations of these and other equipment may be utilized.
[0257] In addition to these, examples, the high power laser systems, tools, devices, equipment and methods of the present inventions may find other uses and applications in activities such as: off-shore activities; subsea activities; decommissioning structures such as, factories, nuclear facilities, nuclear reactors, pipelines, bridges, etc.; cutting and removal of structures in refineries; civil engineering projects and construction and demolitions; concrete repair and removal; mining; surface mining; deep mining; rock and earth removal; surface mining; tunneling; making small diameter bores; oil field perforating; oil field fracking; well completion; precise and from a distance, in-place milling and machining; heat treating; and combinations and variations of these and other activities and operations.
[0258] In addition to the foregoing examples, figures and embodiments, other optics assemblies and configurations may be used to focus the laser beam and provide long stand off distance operations. Such optics assemblies would include zoom optics based on a moveable lens, zoom optics based on a movable mirror, zoom optics based on an adaptive optic, and combinations and variations of these.
[0259] For example, and preferably gravity can be used as the motive force to remove the molten material by drilling the laser at a slight upward angle, this angle can be as small as a few degrees or as much as 90 degrees from horizontal, i.e., a vertical hole. In general, the greater the angle, the faster the flow rate of the molten rock. For example, the temperature for the melting point for quartz is about 2,100° C. This effect is shown in the chart of
[0260] A single high power laser may be utilized in the system, tools and operations, or there may be two or three high power lasers, or more. High power solid-state lasers, specifically semiconductor lasers and fiber lasers are preferred, because of their short start up time and essentially instant-on capabilities. The high power lasers for example may be fiber lasers or semiconductor lasers having 10 kW, 20 kW, 50 kW or more power and, which emit laser beams with wavelengths in the range from about 455 nm (nanometers) to about 2100 nm, preferably in the range about 800 nm to about 1600 nm, about 1060 nm to 1080 nm, 1530 nm to 1600 nm, 1800 nm to 2100 nm, and more preferably about 1064 nm, about 1070-1080 nm, about 1360 nm, about 1455 nm, 1490 nm, or about 1550 nm, or about 1900 nm (wavelengths in the range of 1900 nm may be provided by Thulium lasers).
[0261] An example of this general type of fiber laser is the IPG YLS-20000. The detailed properties of which are disclosed in US patent application Publication Number 2010/0044106.
[0262] Examples of lasers, conveyance structures, high power laser fibers, high power laser systems, optics, optics housings to isolate optics from vibration and environment conditions, break detection and safety monitoring, control systems, connectors, cutters, and other laser related devices, systems and methods that may be used with, in, or in conjunction with, the various embodiments of devices systems, tools, activities and operations set forth in this specification are disclosed and taught in the following US patent application publications and US patent applications: Publication Number 2010/0044106; Publication Number 2010/0044105; Publication Number 2010/0044103; Publication Number 2010/0215326; Publication Number 2012/0020631; Publication Number 2012/0074110; Publication No. 2012/0068086; Publication No. 2012/0248078; Ser. No. 13/403,723; Ser. No. 13/403,509; Ser. No. 13/486,795; Ser. No. 13/565,345; Ser. No. 61/605,429; and Ser. No. 61/605,434, the entire disclosures of each of which are incorporated herein by reference.
[0263] In addition to the use of high power electromagnetic energy, such as high power laser beams, other forms of directed energy or means to provide the same, may be utilized in, in addition to, or in conjunction with the devices systems, tools, activities and operations set forth in this specification. Such directed energy could include, for example, non-optical stimulated emission electromagnetic energy, non-optical coherent electromagnetic energy, microwaves, sound waves, millimeter waves, plasma, electric arcs, flame, flame jets, steam and combinations of the foregoing, as well as, water jets and particle jets. It is noted, however, that each of these other such directed energies, has significant disadvantages when compared to high power laser energy. Nevertheless, the use of these other less desirable directed energy means is contemplated by the present inventions as directed energy means.
[0264] These tools, systems and operations provide a unique laser drilling and cutting methods for performing many activities such as prepping blast holes or cutting out the slope of a rock face, they also provide the ability to reduce the need for, if not to eliminate the need for the use of explosives in construction, demolition, decommissioning, mining, and other types of activities where explosives and large equipment are utilized. It being understood, that precision activities of a very fine nature may also be performed, such as precision cutting of a part or component in a high hazardous environment, such as within a nuclear reactor containment structure. For example a high power laser, of 1 kW or greater, can be used to drill a hole directly in a rock face. A laser, when drilling into a vertical wall or ceiling can penetrate to the maximum limit of the laser beam's intensity, as long as, fresh material is being exposed to the laser beams energy. Thus, by way of example, it is preferable that there is room for the melted rock to flow from the laser drilled hole, and if necessary and preferably that some means be employed to force or assist in the melted rock being removed from the laser drilled hole, or from the laser beam path as it progress into and advances the hole.
[0265] Depending upon the target material being cut, the location of the cutting, e.g., in a confined area or in the open, it may be advisable or preferable to have a system for handling, managing, processing and combinations and variation of these, the gases, fumes, and other air born or gaseous materials that are created during or by the laser operation. Thus, for example and preferably, a high volume vacuum system can be located near the exit of the drilling or cutting region to be able to remove any toxic fumes from the molten region.
[0266] The shape of the laser beam, the laser beam spot on the surface of the target material, and the resultant hole that is created by the laser beam in the target material may be circular, square, v-shaped, circular with a flat bottom, square with a rounded bottom, and other shapes and configurations that may be utilized and can be based upon the flow characteristics of the molten target material, and selected to maximize the removal of that material.
[0267] The various embodiments of devices systems, tools, activities and operations set forth in this specification may be used with various high power laser systems and conveyance structures and systems, in addition to those embodiments of the Figures in this specification. The various embodiments of devices systems, tools, activities and operations set forth in this specification may be used with: other high power laser systems that may be developed in the future: with existing non-high power laser systems, which may be modified, in-part, based on the teachings of this specification, to create a high power laser system; and with high power directed energy systems. Further, the various embodiments of devices systems, tools, activities and operations set forth in this specification may be used with each other in different and various combinations. Thus, for example, the configurations provided in the various embodiments of this specification may be used with each other; and the scope of protection afforded the present inventions should not be limited to a particular embodiment, configuration or arrangement that is set forth in a particular embodiment, example, or in an embodiment in a particular Figure.
[0268] The invention may be embodied in other forms than those specifically disclosed herein without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive.