HEADPLATE AND A DRILLING RIG INCLUDING THE SAME

Description

RELATED APPLICATION DATA

This application claims priority under 35 U.S.C. § 119 to EP patent application Ser. No. 24/203,763.8, filed on Sep. 30, 2024, which the entirety thereof is incorporated herein by reference.

FIELD OF INVENTION

The present invention relates to a headplate and a drilling rig or bolter including the same for the installation of rock bolts and cable bolts and for different drilling applications in the mining industry.

BACKGROUND

In underground mining, civil engineering, and construction projects, drilling and bolting operations are essential for stabilizing rock formations and structures. These operations involve the use of rigs equipped with drilling heads and bolting systems to create boreholes and install support bolts, which ensure the integrity and safety of the working environment. The efficiency, accuracy, and safety of these operations are highly dependent on the design and functionality of the drilling and bolting rig components.

A key component of these rigs is the headplate. The headplate is mounted on top of the drill rig or bolter and is set to the rock surface by the operator. The headplate is used to secure the drill rig or roof bolter against the strata and to guide or grip the drill steel or bolt. The headplate's primary functions include guiding the drill steel or bolt into the precise location or providing a stable grip on the rock or material being worked on. Existing headplates often fall short in providing the desired versatility, i.e. often face challenges related to the grip and guide functionality. Existing Headplates are only able to grip or to guide the drill steel or bolt. For example, current headplates are not capable of providing the grip functionality and/or guide functionality at desired time. These issues can lead to reduced operational efficiency and safety risks.

Also, known designs often faces challenges with efficiently guiding a drill steel or bolt. Some types of headplates use the washer plate of the bolt to guide the drill steel or bolt, but that is not possible with all types of drill steels and bolts. Some types of headplates use their gripping jaws to guide the drill steel, but since this must be done manually, it is difficult to close the gripping jaws just enough, so that the drill steel gets guided but not gripped.

U.S. Pat. No. 6,116,118 uses one hydraulic function to grip the pipe, it is not possible to guide the drill steel during the drilling process with this device.

Considering these challenges, there is a need for an improved headplate design that enhances the guiding and gripping capabilities, reduces wear and tear, and can be easily integrated into existing drilling and bolting rigs.

SUMMARY OF THE INVENTION

When a longer bolt or a cable bolt needs to be set, e.g. in long hole drilling, extension drilling is needed to reach the necessary hole depth. During extension drilling a drill steel is used by a drill rig to drill the hole. Once a hole is created and a drill steel is fully inserted in the hole, a gripping pin in the headplate is used to grip and hold the drill steel in place before the next drill steel gets attached to it. When the next drill steel gets attached to the drill steel already in the hole, the drill process continues until the new drill steel is also fully inserted in the hole. Thereafter the process repeats again, until the desired hole depth has been reached.

It is an objective of the present invention to introduce a novel grip and guide headplate that improves the overall performance of drilling and bolting operations. The headplate of the present application is designed to provide superior stability, accuracy, and adaptability, ensuring safer and more efficient operations in various mining applications.

According to a solution of the present application, a pair of guiding jaws are used to guide the drill steel during drilling, when gripping is needed, an additional pin gets pushed against the drill steel and holds it in place. With this solution, it is now possible during the drilling process to guide and/or grip the drill steel as required with the help of two separate hydraulic mechanisms functions.

The solution of the present application allows for precise and efficient operation of the head plate apparatus. By eliminating and replacing manual operations, it enables automatic or semi-automatic control of the head plate apparatus, as well as automated control of the drilling or bolting rig.

According to a first aspect of the present invention there is provided a head plate apparatus for a drilling apparatus, which comprises:

• • (a) a support plate comprising an opening therethrough; and
  • (b) a guiding means supported by the support plate, for guiding a consumable, the guiding means comprises at least one guiding member configured to be movable between a park position and a work position, wherein in the work position the at least one guiding member or the at least one guiding member together with an inner edge of the support plate surrounding the opening defines and forms a substantial closed bore within the opening, the bore is configured to receive the consumable and permit movement of the consumable in an axial longitudinal direction of the bore relative to the guiding means while preventing the consumable from escaping the bore laterally; and
  • (c) a gripping means, supported by the support plate, for gripping the consumable, the gripping means is configured to be movable between a park position and a work position, wherein in the work position the gripping means is configured to exert a gripping force on the consumable, to limit or prevent relative movement of the consumable with respect to the gripping means.

The axial longitudinal direction of the bore is defined as the direction extending from the centre of the bore, as shown in FIGS. 1A and 1C, and is denoted as the z-axis. The guiding means, which may also be referred to as a guiding mechanism, can take the form of a jaw or similar structure. It may consist of a jaw working in cooperation with another jaw as its counterpart. The consumable could be rod-shaped, such as a drill steel or bolt.

The term “work position” of a guiding member refers to the position in which the guiding member is configured to guide a consumable. The term “park position” of a guiding member refers to the position in which the guiding member is moved out of the work position so that it does not obstruct the movement of the consumable, such as when an actuating cylinder is fully retracted.

Analogously, the term “work position” of a gripping means refers to the position in which the gripping means is configured to grip a consumable, i.e. to grasp and hold the consumable securely, keeping it stable or stationary. The term “park position” of gripping means refers to the position in which the gripping means is moved out of the work position so that it does not obstruct the movement of the consumable, such as when an actuating cylinder is fully retracted.

The term “guide” is understood to mean that the consumable, when positioned within the bore, is able to rotate and/or move both upwards and downwards (i.e. along axis z).

The term “grip” is understood to mean that the gripping means applies a gripping force on a surface of the consumable, preventing its rotation and any upward or downward movement (due to a friction force presented between the gripping means and the consumable).

The support plate may include a recess or slot configured to accommodate the guiding means and/or the gripping means respectively, for example, the guiding means and/or the gripping means are embedded in the support plate. The guiding means and/or the gripping means may slide within the recess or slot between its park position and its work position, respectively.

The guiding means and gripping means can be spaced circumferentially around the opening and situated substantially on the same plane in the axial longitudinal direction of the bore. The head plate apparatus should be as thin as possible because it limits the possible drill stroke of the drill rig. The present solution facilitates the new head plate apparatus to achieve a minimal or reduced thickness, thus maximize the drill stroke.

Optionally, the guiding means includes a pair of guiding members arranged opposite each other, which can move in opposite directions relative to one another. For example, the guiding means includes a pair of jaws arranged oppositely.

Each guiding member includes a curved surface spaced circumferentially around the opening (e.g. when the guiding member is in its park position) in said support plate, the curved surfaces define the bore in the work position of the guiding means. The surface can be curve-like, such as a segment of a polygon. In other words, each guiding member of the guiding means is configured to be concave on its front portion (i.e. the portion close to the opening) in the plane of the support plate defined by axes x & y for partly defining the bore.

The pair of guiding members may be symmetric about axis y—the central line of the head plate apparatus or about the centre of the bore. Alternatively, they may be asymmetric, with their lateral extensions (in direction of axis x) complementing each other and being form-fit.

The bore can be of circular form. Each guiding member includes a semi-circular edge on its front portion, such that, at the work position of the guiding member, the semi-circular edge cooperates with an opposite semi-circular edge of another guiding member to define the circular bore. Optionally, the inner edge of the support plate surrounding the opening may have an opposite semi-circular edge that cooperates with a semi-circular edge of the guiding member to define the circular bore.

Each guiding member of the guiding means includes a recess on its front portion (i.e. the portion close to the opening) such that the guiding member is configured, at its work position, to provide a passage or channel for allowing at least a portion of the gripping means to pass through thereby to reach inside the bore and grip the consumable. In other words, the passage acts as a guiding channel for the sliding movement of the gripping means, the gripping means can, when the guiding member is at its work position, slide through the channel and get into the bore. The recess is preferably located on the foremost portion or tip (the portion close to the opening) of the guiding member, so as not to obstruct the movement of guiding member in axis x when the gripping means is in its work position.

The gripping means is configured to move in a direction (axis y in FIG. 1B) perpendicular to the moving direction (axis x in FIG. 1B) of the guiding means. The longitudinal direction of gripping means may be aligned with axis y. In another embodiment, the longitudinal direction of the gripping means may be arranged in an acute angel relative to the longitudinal direction of the guiding means. The gripping means may be actuated by a separate actuator from an actuator driving the guiding means.

The support plate includes a plurality of hydraulic channels as fluid passages. The fluid passages build a hydraulic circuit for supplying fluid to the actuators. The head plate apparatus may include at least one valve that controls or regulates the hydraulic circuit and therefore the hydraulic actuators. In one embodiment, the head plate apparatus may include a hydraulic and/or electric control unit, which may be connected to a distance and/or pressure sensor, to regulate the at least one valve and/or the hydraulic circuit. This helps to achieve automatic operation and a compact head plate apparatus, without the need for extra hoses and fittings to be arranged.

The head plate apparatus further includes an actuator preferably embedded in the support plate for driving the guiding means and/or the gripping means. Preferably the actuator is a hydraulic means, such as a cylinder. The actuator may be an electrical actuator. This helps to achieve a compact and thin head plate apparatus, also it facilitates accurate operation of the guiding means and/or the gripping means.

The support plate includes two side plates defining the opening in-between. The two side plates may be arranged symmetric about a central line of the opening. Optionally, the support plate includes a base plate, and a single support plate or two side plates that is/are attached to the base plate.

The opening can be a slot allowing the consumable to enter laterally (i.e. along axis y).

The gripping means can be a wedge-shaped element connected to the support plate and arranged around the bore, configured to move upwards or downwards and/or laterally, actuated by the actuator. The wedge-shaped element may be guided by an inclined surface e.g. of the support plate. For example, during its upward movement, the wedge-shaped element moves away from the centre of the bore, thereby releasing the consumable.

According to a further aspect of the present invention there is provided a drilling or bolting rig for drilling and/or installing a bolt into a rock surface, the drilling or bolting rig comprising:

• • a base frame; and
  • a timber jack movably coupled to the base frame; and
  • a feed module movably coupled to the base frame; and
  • a drive unit coupled to the feed module and configured to receive and rotate a consumable; and
  • a head plate apparatus according to any one of above-described embodiments, coupled to the timber jack.

The timber jack may extend out of the base frame, once the timber jack is extended, the feed module may move from the base frame onto the timber jack.

In the present application, the terms “headplate” and “head plate apparatus” can be used interchangeably.

The foregoing summary, as well as the following detailed description of the embodiments, will be better understood when read in conjunction with the appended drawings. It should be understood that the embodiments depicted are not limited to the precise arrangements and instrumentalities shown.

BRIEF DESCRIPTION OF DRAWINGS

A specific implementation of the present invention will now be described, by way of example only, and with reference to the accompanying drawings in which:

FIG. 1A is a perspective view of a head plate apparatus according to a specific implementation of the present invention.

FIG. 1B is a plan view of a head plate apparatus according to a specific implementation of the present invention, with the cover plate being removed.

FIG. 1C indicates the axes.

FIG. 2 is a side view of a head plate apparatus of FIG. 1A.

FIG. 3 is a section view of section A-A indicated in FIG. 2.

FIG. 4 is a section view of section B-B indicated in FIG. 2, where the guiding jaws and gripping pin are both in the park position.

FIG. 5 is a section view of section C-C indicated in FIG. 4.

FIG. 6 illustrates a section view showing that the guiding jaws and gripping pin are both in the work position.

FIG. 7 is a perspective view of a drilling rig according to a specific implementation of the present invention.

FIG. 8 depicts a drilling rig of FIG. 7 in a fully retracted status.

FIG. 9 depicts a drilling rig of FIG. 7 in a fully extended status.

DETAILED DESCRIPTION

FIG. 1A is a perspective view of a head plate apparatus according to a specific implementation of the present invention, the head plate apparatus including a cover plate 106. FIG. 1B is a plan view of the head plate apparatus, with the cover plate 106 being removed. The head plate apparatus includes a base plate 105, and a support plate 101 arranged on the base plate 105, the support plate 101 is designed to accommodate and support a pair of guiding jaws 103 arranged opposite to each other, the pair of guiding jaws 103 is positioned within a space provided between the support plate 101 and the cover plate 106, and in FIGS. 1A & 1B the guiding jaw 103 is in a park position.

As seen in FIG. 1B, the left and right guiding jaws are asymmetric, the upper part of the left guiding jaw is protruding and the lower part is narrowed, to the contrary, the upper part of the right guiding jaw is narrowed and the lower part is protruding, with their lateral extensions (in direction of axis x) complementing each other and being form-fit.

The head plate apparatus further includes a gripping pin 104 arranged between the side plates 101. The pin is positioned between the two side plates and between the upper cover plate and the lower cover plate. The support plate 101 may include a pair of symmetric side plates arranged parallel to and adjacent to each other, the pair of plates are configured to define an opening 102 in-between. Alternatively, the support plate 101 may include a single member having a lateral opening 102. The minimal width d of the opening 102 is designed as larger than a diameter of a drill steel or a bolt. The opening 102 is open towards the axis y, departing away from the connection 107 to a timber jack 704. The axes x, y and z are indicated as in FIGS. 1A, 1B & IC.

FIG. 2 depicts a side view of the head plate apparatus of FIG. 1A. FIG. 3 is a section view of section A-A indicated in FIG. 2. FIG. 4 is a section view of section B-B indicated in FIG. 2, where the guiding jaws and pin are both in the park position.

The pair of guiding jaws 103, attached to the support plate 101, are movable relative to support plate 101 along axis x, each guiding jaw may be driven by a cylinder 301 to move between a park position (shown in FIG. 4) and a work position (shown in FIG. 6). In the work position the pair of guiding jaws 103 define a closed space 601 for accommodating a drill steel (or bolt) and for guiding the drill steel (or bolt) when it is driven to move in axis z. In the park position shown in FIGS. 1B & 4, the guiding jaws 103 are retracted and depart from each other thereby allowing the drill steel to freely move along axis y into or out of the opening 102.

The head plate apparatus includes a gripping pin 104, which has friction surface on its tip, and further includes hydraulic cylinder 402, or electrical actuator, for driving the gripping pin 104 to move along direction y and extend to apply a gripping force on the drill steel (or bolt) in a direction y.

Referring to FIGS. 4 & 5, on the side close to the bore 601, each guiding jaw 103 may have a recess 401 or passageway, such that, when both guiding jaws are in the work position, the recesses cooperate and form a sliding channel for accommodating the gripping pin 104, the sliding channel allows the pin 104 to move within it, and to extend in direction y and reach into the bore 601. In the work position the gripping pin 104 is configured to exert a gripping force on the drill steel, to prevent any relative movement (including rotation, sliding) of the drill steel with respect to the support plate, the force is predetermined to be sufficient to hold the drill steel from rotating. There are fluid passages 404 embedded within the base plate and support plate 101, fluid passages 404 are connected to the chambers 403 of respective cylinder 402 and 301 and form a hydraulic circuit for supplying fluid to the cylinders.

FIG. 6 illustrates, both guiding jaws and the gripping pin being in the work position, the cylinders are extended to move the guiding jaws and pin towards the bore.

FIG. 7 illustrates a drilling rig including a base frame 701 and a timber jack 704 slidably coupled to the base frame 701, the timber jack can extend out of the base frame 701 by means of the hydraulic cylinder and the guide rods 705 which terminate in an uppermost head plate apparatus 100; a feed module 702 slidably coupled to the base frame 701, the feed module may be moved relative to the frame by means of multiple hydraulic cylinders and telescopic mechanism; a drill head 703 coupled to the feed module 702 and configured to receive and rotate a drill steel (not shown), the drill head may be driven by a cylinder and a chain drive to move bidirectional along the feed module 702 between a upper plate 706 and a lower plate 707. The drilling rig includes a head plate apparatus 100 as described above, attached to the timber jack 704.

FIG. 8 depicts a drilling rig in a fully retracted status wherein the timber jack 704 is fully retracted within the base frame 701. FIG. 9 depicts a drilling rig in a fully extended status wherein the timber jack 704 is fully extended out of the base frame 701, the feed module 702 is moved upwards to the topmost position, and the drill head 703 moves upwards to the topmost position.

It is to be understood that the forms of the invention herewith shown and described are to be taken as the presently preferred embodiments. Various changes may be made to the shape, size, and arrangement of parts.

Although the present embodiment(s) has been described in relation to particular aspects thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. It is preferred therefore, that the present embodiment(s) be limited not by the specific disclosure herein, but only by the appended claims.