MINER AUTOMATED HARDWARE INSTALLATION SYSTEM AND AUTOMATED BRATTICE INSTALLER

Abstract

An automated hardware and brattice installer system for mining units configured to enable autonomous installation of floor mounted belt hardware and brattice behind a continuous borer mining unit to allow for continuous, unmanned, and uninterrupted advancement of the miner.

Claims

1. A system comprising: a tow tub configured to couple to a rear portion of a mining machine while the mining mine advances through a mineshaft to mine a geological material; and an automated hardware installer (AHI) operably coupled to the tow tub, wherein the AHI is configured to install extensible mineshaft hardware into an interior surface of the mineshaft.

2. The system of claim 1, wherein the geological material comprises potash.

3. The system of claim 1, wherein the tow tub comprises a tail pulley configured to couple to the rear portion of the mining machine.

4. The system of claim 1, wherein the tow tub comprises: a hopper configured to receive the geological material from an inner conveyor of the mining machine and deposit the geological material onto a load plate of the tow tub; and the load plate, wherein the load plate is configured to deposit the geological material onto a belt segment of a floor-mounted conveyor belt.

5. The system of claim 1, wherein the tow tub is configured to feed belt segments for a floor-mounted conveyor belt to the AHI, and wherein the tow tub comprises a steering mechanism configured to align the belt segments relative to the AHI.

6. The system of claim 5, wherein the tow tub further comprises a belt storage magazine configured to receive and retain the belt segments.

7. The system of claim 1, wherein the tow tub comprises a laser plane receiver configured to orient the tow tub and the AHI relative to the mining machine.

8. The system of claim 1, wherein the tow tub comprises a winching system coupled to the AHI, wherein the winching system is configured to: in response to receiving a first signal from the mining machine indicating that the mining machine has advanced by a predetermined distance, release the AHI from the tow tub such that the AHI remains stationary relative to the interior surface of the mineshaft; and in response to receiving a second signal from the AHI indicating that the AHI has installed a portion of the extensible mineshaft hardware onto the interior surface of the mineshaft, retract the AHI toward the tow tub.

9. The system of claim 1, wherein the AHI comprises one or more arms configured to redirect external obstacles away from the AHI.

10. The system of claim 1, wherein the extensible mineshaft hardware comprises belt hardware for a floor-mounted conveyor belt, wherein the interior surface of the mineshaft comprises a floor of the mineshaft, and wherein the AHI comprises: a set of drills configured to drill holes in the floor; a storage rack configured to retain the belt hardware; a gripper assembly configured to transfer the belt hardware from the storage rack into the holes; and a set of troughing rollers configured to locate a load belt above the extensible mineshaft hardware retained in the storage rack.

11. The system of claim 1, wherein the extensible mineshaft hardware comprises a brattice, wherein the interior surface of the mineshaft comprises a ceiling of the mineshaft and a floor of the mineshaft, and wherein the AHI comprises: a nail assembly comprising a plurality of nail guns configured to nail a top edge of the brattice to the ceiling; an elevator boom configured to raise and lower the plurality of nail guns; and a mandrel configured to support a roll of the brattice.

12. The system of claim 11, wherein the AHI further comprises a pivot pin coupling the nail assembly to the elevator boom, such that the nail assembly can pivot laterally relative to the elevator boom by a predetermined angle in either rotational direction.

13. The system of claim 12, wherein the predetermined angle is between about 1 degree and about 10 degrees.

14. The system of claim 11, wherein the AHI further comprises a mounting bracket coupling the elevator boom to a rear portion of the AHI.

15. The system of claim 14, wherein the mounting bracket comprises a pair of U-shaped hooks.

16. The system of claim 11, wherein the plurality of nail guns comprises five nail guns.

17. The system of claim 11, wherein the AHI further comprises a hydraulic arm and a pair of guide rollers configured to move the nail guns between a retracted position and an extended position.

18. The system of claim 11, wherein the AHI further comprises an encoder assembly configured to orient the nail assembly relative to the ceiling.

19. The system of claim 18, wherein the encoder assembly comprises: an upper encoder wheel configured to measure a linear distance; and a lower encoder wheel configured to measure an angle of the ceiling relative to the encoder assembly based on a compression of a gas shock cylinder.

20. The system of claim 11, wherein each of the plurality of nail guns is configured to independently extend vertically relative to the nail assembly.

21. The system of claim 11, further comprising a plow configured to plow muck to seal a bottom edge of the brattice to the floor.

22. The system of claim 1, further comprising the mining machine.

23. The system of claim 22, wherein the mining machine comprises a continuous miner, a drum miner, a roadheader, or a rotary boring machine.

24. The system of claim 22, wherein the mining machine comprises a four-rotor continuous-borer mining unit.

25. The system of claim 22, wherein the mining machine comprises: a drive mechanism configured to proximally advance the mining machine along an intended excavation path through the mineshaft; a cutting mechanism configured to separate the geological material from a wall of the mineshaft along the excavation path; an auger configured to collect the separated geological material; an inner conveyor configured to transfer the collected geological material toward the rear portion of the mining machine; and a communication mechanism configured to transmit a signal to a winching system of the tow tub in response to the drive mechanism proximally advancing the mining machine by a predetermined distance.

26. The system of claim 25, wherein the cutting mechanism is configured to move laterally and vertically relative to a main body of the mining machine.

27. The system of claim 25, wherein the cutting mechanism comprises two or four rotary boring cutter heads.

28. The system of claim 25, wherein the mining machine is configured to adjust a yaw and a roll of the inner conveyor to align the inner conveyor substantially perpendicular to a face of the mining machine.

29. The system of claim 25, wherein the augur comprises counter-rotating rotors.

30. The system of claim 25, wherein the predetermined distance comprises about 10 feet.

31. A method comprising: receiving, by a tow tub, a first signal from a mining machine indicating that the mining machine has proximally advanced through a mineshaft by a predetermined distance; in response to receiving the first signal, releasing, by the tow tub, a winch coupled to an automated hardware installer (AHI); receiving, by the tow tub, a second signal from the AHI indicating that the AHI has installed a portion of an extensible mineshaft hardware onto an interior surface of the mineshaft; and in response to receiving the second signal, proximally retracting, by the tow tub, the winch.

32. A method comprising: actuating, by an automated hardware installer (AHI), an elevator boom to raise a nail gun toward a ceiling of a mineshaft; releasing, by the AHI, a portion of a brattice from a mandrel; actuating, by the AHI, the nail gun to secure a top edge of the portion of the brattice to the ceiling; lowering, by the AHI, a plow to plow a muck windrow onto a bottom edge of the portion of the brattice to a floor of the mineshaft; and transmitting, by the AHI, a signal to a tow tub to cause the tow tub to retract a winch coupled to the AHI.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Subject matter hereof may be more completely understood in consideration of the following detailed description of various embodiments in connection with the accompanying figures, in which:

[0023] FIG. 1A is a perspective view depicting an automated hardware installer system and miner according to an embodiment.

[0024] FIG. 1B is a side view depicting an automated hardware installer system and miner according to an embodiment.

[0025] FIG. 2A is a perspective view of a miner and tow tub according to an embodiment.

[0026] FIG. 2B is a side view of a miner and tow tub according to an embodiment.

[0027] FIG. 3 is a side view of a tow tub according to an embodiment.

[0028] FIG. 4A is a perspective view of an automated hardware installer according to an embodiment.

[0029] FIG. 4B is a side view of an automated hardware installer according to an embodiment.

[0030] FIG. 5A is an isometric view of an automated brattice installer coupled to an automated hardware installer according to an embodiment.

[0031] FIG. 5B is an exploded view of the automated brattice installer of FIG. 5A.

[0032] FIG. 6 is a top view of a nailing head comprising a plurality of nail guns of FIG. 5A.

[0033] FIGS. 7A-7D depicts various configurations of the nailing head of FIG. 6.

[0034] FIG. 8 depicts configuration of the encoder of the nailing head of FIG. 6.

[0035] FIGS. 9A-9C depict various configurations of the nail guns of the nailing head of FIG. 6.

[0036] FIG. 10 depicts brattice guiding of the brattice installer of FIGS. 5A and 5B.

[0037] FIGS. 11A and 11B depict a top view and a side elevational view, respectively, of a transfer plow and plow muck collection of the brattice installer of FIGS. 5A and 5B.

[0038] While various embodiments are amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the claimed inventions to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the subject matter as defined by the claims.

DETAILED DESCRIPTION OF THE DRAWINGS

[0039] According to embodiments, an automated hardware installer system for autonomously installing floor mounted belt hardware and an automated brattice installer system for autonomously installing a brattice and optional sacrificial webbing are disclosed.

[0040] Automated Hardware Installer

[0041] With respect to the AHI system, the system comprises a tow tub and an automated hardware installer (AHI). The system is configured to be used in combination with a continuous borer mining unit and a conveying assembly. Using the automated hardware installer system allows for continuous and uninterrupted advancement of the miner for up to 240 ft. or more without human interaction.

[0042] As depicted in FIGS. 1A and 1B, an automated hardware installer system 100 in accordance with an embodiment of the disclosure can comprise a tow tub 104 and an automated hardware installer 106 to be used in combination with a four rotor continuous borer mining unit 102 (hereinafter miner 102).

[0043] Referring to FIGS. 2A and 2B, a miner 202 attached to a tow tub 204 is depicted in accordance with an embodiment of the disclosure. In one non limiting example, the miner 202 can be used in underground potash mining to extract concentrated KCL containing ore in a sedimentary formation. The miner 202 can be, for example, any of a variety of prime movers with a cutting or mining mechanism, such as, for example, a rotary boring mining unit, roadheader, continuous or drum miner, or the like. The height of the miner can be complementary to the thickness of the seam or vein of geological material to be extracted. For example, the miner 202 can be of a height of 8 feet 2 inches, 8 feet 6 inches, or 9 feet. Other heights of the miner 202 are also contemplated.

[0044] In one embodiment, the miner 202 can further include a steerable drive mechanism (not pictured) as a prime mover. For example, in one embodiment, the steerable drive mechanism can include wheels and/or tracks configured to advance the miner 202 along an intended excavation path.

[0045] The miner 202 can further include a cutting mechanism 210. Cutting mechanism 210 can be configured to separate geological material from a wall or face of an excavation path. In some embodiments, the cutting mechanism 210 can be configured to move relative to a body of the mining unit through range of motion both laterally side to side and vertically up and down to effect separation of geological material from a wall of the excavation path. In some embodiments, the miner 202 can include either two or four rotary boring cutter heads, commonly referred to as two-rotor and four-rotor mining units. In a preferred embodiment the miner 202 includes four rotors. In an alternative embodiment a miner 202 can have more than 4 or less than two rotors. A cutting mechanism 210 including alternative quantities of cutter heads or alternative cutting mechanisms is also contemplated.

[0046] The miner 202 further includes an auger mechanism (not pictured) configured to collect the separated geological material for deposit on a conveyor mechanism 206. The conveyor mechanism 206 is configured to convey the collective geological material to tow tub 204.

[0047] A conveyor 206 and tow tub 204 can be operably coupled to the rear of miner 202. The conveyor 206 can be configured to convey the geological material to a hoper 208 of the tow tub 204. The conveyor 206 can be configured to be moved side-to-side (yaw) and/or rotated left-or-right (roll) in order to ensure it remains centered and aligned substantially perpendicular to the face of miner 202.

[0048] Referring to FIG. 3, tow tub 300 is operably coupled to miner 320 by tail pulley 312 and is enabled to receive geological material from the conveyor 302 of miner 320. In embodiments tow tub 300 includes hopper 306, load plate 308, belt 310, winching system 304, and a steering mechanism (not pictured). The steering mechanism can be configured to maintain precise alignment of belt 310 with the automated hardware installer system 322. Examples of such steering mechanisms are disclosed in U.S. Pat. No. 10,738,609, which is incorporated by reference herein in its entirety. In operation, hopper 306 of tow tub 300 receives geological material from conveyor 302 and the material is transferred to load plate 308 at the rear of tow tub 300. From load plate 308, belt 304 transfers geological material to automated hardware installer 322.

[0049] Tow tub 300 can further include a laser plane receiver 212, as illustrated in FIG. 2A. Laser plane receiver 212 can be configured to orient miner 202 with tow tub 300 and maintain alignment between the automated hardware installer system and the miner throughout the mining and hardware installation process.

[0050] Referring now to FIGS. 4A and 4B, an automated hardware installer 400 is depicted in accordance with an embodiment of the disclosure. In one embodiment, the AHI 400 can be used to autonomously install floor mounted belt hardware. The AHI 400 can include a set of drills, storage rack 406, a gripper and carriage assembly (not shown), and a set of troughing rollers (not shown), all of which are housed internally. The AHI 400 also can include a one or more arms 410 for use in guiding cords, hoses and other external pieces away from the machine. AHI 400 is connected to the tow tube (not pictured) by a winching system (not pictured). This connection allows the AHI 400 to remain stationary throughout operations. In one non-limiting example, the AHI 400 can house 24 sets of belt hardware that can be manually loaded onto the AHI 400. In an alternative embodiment, the AHI 400 can house more than 24 or less than 24 sets of belt hardware 402.

[0051] With references to FIGS. 1A and 1B, in operation, an automated hardware installer system 110 is comprised of a tow tub 104 and an AHI 106. The system 110 is connected to a miner 102 by a tail pulley 112. Tow tub 104 is connected to AHI 106 by a winching system 114. Accordingly, miner 102 is advanced along an intended excavation path while cutting geological material (e.g. ore), by forcing a cutting mechanism into the mining face. The liberated ore can then be augured into the center of the miner 102, for example, by counter rotating rotors of an auger mechanism (not pictured), and conveyed on conveyor section 116 to hopper 120 of tow tub 104. As the miner 102 advances, a steering mechanism, maintains precise alignment of belt 118 operably coupled to tow tub 104 and AHI 106.

[0052] At regular intervals of advancement, the miner 102 signals to the automated hardware installation system 110 to place a set of belt hardware 108 in the floor. After installation of a set of belt hardware 108, tow tub 104 begins to pay out its winches, allowing the AHI 106 to remain stationary while the miner 102 continues to advance. The AHI 106 then drills holes in the mining room floor, and a gripper carriage assembly selects a set of hardware from storage rack 130 and places hardware 108 in the drilled hole. A set of troughing rollers (not shown) then locate the loaded belt 118 above the assembled hardware in the storage rack 130. Once the AHI 106 has completed this cycle, it signals to tow tub 104, and is winched ahead by winching mechanism 114. The AHI 106 continues to follow tow tub 104 until the next advancement interval is achieved.

[0053] In embodiments according to the present invention and as illustrated in FIGS. 4A and 4B, it can be necessary to add belt to the belt storage magazine located near the head of conveyor belt. As the belt is added to the belt storage magazine, the storage rack 130 of AHI 106 can be restocked. According to embodiments, the process of installation of belt hardware 108 can advance for up to 240 ft. or more before storage rack 130 needs to be restocked, thereby reducing the need for human maintenance and interaction.

Automated Brattice Installer

[0054] Referring now to FIGS. 5A and 5B, an automated brattice installer 500 generally includes a nail head and guide assembly 502 coupled to an elevator boom assembly 504 via a pivot pin 506, the elevator boom assembly 504 being mounted or coupled to a rear portion of AHI 106 via a mounting bracket 508. Mounting bracket 508 can include an inverted U-shaped hook portion 510 on each sidewall 511, which hooks onto or over framework of AHI 106. Mounting bracket 510 can be permanently secured, such as by welding, to the framework, or coupled to the framework by a series of bolts or other fasteners (not shown). Mounting bracket 510 further comprises a brattice mandrel assembly 512 and optional rope guide 513 extending from a side of bracket 510 for mounting a supply roll of brattice curtain (not shown) and optional sacrificial webbing (not shown) thereon.

[0055] Nail head and guide assembly 502 generally comprises a plurality of pneumatic nail guns 514 mounted to a nail head 515. In the figures, five nail guns 514 in a single row are depicted (see, also, FIG. 6); however, more or less nail guns can be contemplated, and multiple rows of nail guns can be contemplated. Nail heads 514 are mounted on head 515 including guide rollers 516 and hydraulic arm 518 which allows assembly 502 to shift between from an extended position of nail guns 514 and a retracted position, which will be described in more detail infra. Brattice installer 500 further includes an encoder and guide subassembly 519, including an upper brattice guide 520 and an encoder assembly 522, which couples assembly 502 to elevator boom 504 via shackle 521. Encoder subassembly 519 works together to guide assembly 502 into different positions including, for example, a resting position, an operating position within a top of an operating range and a bottom of the operating range, and a fully compressed/transport position, which will be described in more detail infra.

[0056] As mentioned, nail gun and guide assembly 502 is coupled to elevator boom 504 via pivot pin 506. As shown in FIG. 6, pivot pin 506 allows assembly 502 to pivot in a lateral direction with respect to elevator boom 504. Assembly 502 can pivot in a range from about 1 to about 10 degrees on each side, and more specifically up to about 5 degrees on each side to allow assembly 502 to align with the last installed brattice.

[0057] Referring back to FIGS. 5A, 5B and 7B, elevator boom 504 includes a lift portion 523, on which assembly 502 is mounted, which is extendable in a vertical direction from a subcomponents assembly 524 in order to shift assembly 502 from a transport configuration to an engaged position, which will be described in more detail infra. Elevator boom 504 is mounted to subcomponents assembly 524, which in turn is mounted to backing body weldment 526 via a series of fastening components 527 such as, for example, hex bolts and washers. Backing body weldment 526 is welded to mounting bracket 508.

[0058] Brattice installer 500 also includes transfer plow and platform assembly 528 is coupled to a side of component assembly 524 opposite weldment 526 via plow lift cylinder 529, linkage weldment 530, and linkage pins 532 such that assembly 528 can articulate up and down relative to assembly 528. Assembly 528 includes a service platform 534 for supporting one or more persons thereon, and a transfer plow 536. As the mining machine, tow tub, AHI, and brattice installer 500 move toward the mine face and as the brattice B is installed, transfer plow 536 transfers muck from a natural muck windrow W onto and along a bottom edge of the brattice

[0059] B to create a seal with the floor of the mining room, as will be described in more detail infra.

[0060] Now referring to FIGS. 7A-7D and 8, brattice installer 500 includes an encoder assembly 522 including upper encoder wheel 802 for measuring linear distance and lower encoder wheel 804 measures angle of encoder assembly 522 against the room ceiling C based on a compression of a gas shock cylinder 806. Encoder assembly 522 orientates nail gun and guide assembly 502 with the mining room ceiling. Encoder assembly 522 generally has four main positions. First, in a resting position (FIG. 7A), upper encoder wheel 802 is not in contact with the ceiling, gas shock cylinder 806 is uncompressed, and nail gun and guide assembly 502 is lowered (e.g. elevator boom is nested) for transport of or resting of brattice installer 500. As shown in FIG. 7B, when a desired location is reached for installation of a brattice, elevator boom 523 is lifted, thereby placing encoder assembly 522 in contact with the ceiling C at a top of its operating range, while nail gun assembly 502 remains disengaged. Nail gun and guide assembly 502 is then lifted until guide rollers 516 are in contact with the ceiling C, in which the encoder assembly 522 is still at the top of its operating range and guide x is approximately 3 to 4 inches from the ceiling C, as depicted in FIG. 7C. Referring to FIG. 7D, upper encoder wheel 822 can be compressed against the ceiling C until guide 520 is at a desired position with respect to the ceiling C, such as for example, 1 to 2 inches, which is the bottom of the operating range of encoder assembly 522. Lower encoder 804 has a total operating range, i.e. from top to bottom, of about 12 to about 15 degrees. Once encoder assembly 522 is compressed such that it is beyond the predetermined operating range and guide 520 is too close to the ceiling C, nail gun and guide assembly 502 is not able to be operated or actuated to protect nail guns 514 from damage.

[0061] Now referring to FIGS. 9A-9C, when encoder assembly 522 is within the operating range, and guide is at a desired position with respect to the ceiling C for guiding a brattice (not shown) to be secured to the ceiling C, nail head 515 with nailing guns 514 are extending to position nailing guns 514 in contact with the ceiling. For example, in FIG. 9A, in the event ceiling is uneven, head 514 is spring centered and it can pivot with respect to boom arm 513 to ensure head 515 engages with the ceiling C. As shown in FIG. 9B, each nail gun 514 can independently lean to accommodate undulations in the ceiling C. In one embodiment, each gun 514 can lean up to about 10 degrees from a vertical plane, and more specifically about six degrees from the vertical plane. As shown in FIG. 9C, each nail gun 514 can independently extend vertically at different heights from head 515 to also accommodate differences in ceiling height. In one embodiment, each gun 514 can extend up to 2-3 inches from the top of guide rollers 516. Upon actuation, guns 514 can fire in series, i.e. one after another, simultaneously, or in any pattern as desired. For example, guns 514 can have a fraction of a second delay in firing sequence order starting at front of the room (first gun closes to AHI) to rear of the room (last gun in order).

[0062] Now referring to FIG. 10, brattice installer 500 is depicted with a brattice roll 540 coupled thereto. In this embodiment, brattice roll 540 is coupled to mandrel 512 (FIG. 5A) such that it unravels from the top quadrant; however, brattice installer 500 is configured such that brattice roll 540 can be unraveled from the bottom quadrant. In this embodiment, a top edge of brattice B extends through upper brattice guide 520, and over the top of engaged nail head and gun assembly 502. Once the top edge of brattice B is in position, nail guns 514 are actuated, securing the top edge of brattice B to the ceiling C.

[0063] A bottom edge of brattice B extends through lower leading guide 542, and through a lower trailing guide 544 to position the bottom edge on the floor. Plow 536 transfers muck from the natural muck windrow onto the bottom edge of brattice B, thereby sealing the bottom edge of the brattice B to the floor F of the mining room. Installer 500 continues to move forward, while additional brattice B is secured to the ceiling C and the floor F of the mining room.

[0064] Now referring to FIGS. 11A and 11B, to secure brattice B to the floor of the mining room, plow 536 is lowered with respect to platform 534 via linkages 530 and is positioned along the mining floor. As plow 536 is advanced, plow 536 transfers muck from the natural muck windrow to the bottom edge of brattice B. Once plowing is complete, plow 536 is raised via linkages 530 and secured in place via a pin 550 such that there is ground clearance between plow and platform assembly 528 and the floor F for transport. Plowing can be performed when simultaneously with securing the top edge of the brattice B to the ceiling C, or after it has been completed.

[0065] According to embodiments described, automated mining operations, including the automated installation of hardware via the AHI and the automated installation of the brattice via the brattice installer, allow mining operations to proceed with reduced manpower and human interaction. According to embodiments, a mining machine can be advanced up to 250 . . . without shutting down or without the need for human interaction. Various embodiments of systems, devices, and methods have been described herein. These embodiments are given only by way of example and are not intended to limit the scope of the claimed inventions. It should be appreciated, moreover, that the various features of the embodiments that have been described may be combined in various ways to produce numerous additional embodiments. Moreover, while various materials, dimensions, shapes, configurations and locations, etc. have been described for use with disclosed embodiments, others besides those disclosed may be utilized without exceeding the scope of the claimed inventions.

[0066] Persons of ordinary skill in the relevant arts will recognize that the subject matter hereof may comprise fewer features than illustrated in any individual embodiment described above. The embodiments described herein are not meant to be an exhaustive presentation of the ways in which the various features of the subject matter hereof may be combined. Accordingly, the embodiments are not mutually exclusive combinations of features; rather, the various embodiments can comprise a combination of different individual features selected from different individual embodiments, as understood by persons of ordinary skill in the art. Moreover, elements described with respect to one embodiment can be implemented in other embodiments even when not described in such embodiments unless otherwise noted.

[0067] Although a dependent claim may refer in the claims to a specific combination with one or more other claims, other embodiments can also include a combination of the dependent claim with the subject matter of each other dependent claim or a combination of one or more features with other dependent or independent claims. Such combinations are proposed herein unless it is stated that a specific combination is not intended.

[0068] Any incorporation by reference of documents above is limited such that no subject matter is incorporated that is contrary to the explicit disclosure herein. Any incorporation by reference of documents above is further limited such that no claims included in the documents are incorporated by reference herein. Any incorporation by reference of documents above is yet further limited such that any definitions provided in the documents are not incorporated by reference herein unless expressly included herein.

[0069] For purposes of interpreting the claims, it is expressly intended that the provisions of 35 U.S.C. 112(f) are not to be invoked unless the specific terms means for or step for are recited in a claim.