Note: Descriptions are shown in the official language in which they were submitted.
CA 02590589 2007-05-18
IMPROVED REBAR INSERTION DEVICE
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is related to our pending application CA 2460497 filed
on 2004/03/09.
TECHNICAL FIELD
The present invention relates generally to mining ground support and
particularly to an improved apparatus and method for inserting ground
support members during mining ground support operations.
BACKGROUND
Ground support apparatus and methods using combined mechanical and
chemical means are well known in the mining, tunneling and construction
industries. Basically, a hole is drilled in the surrounding rock formation
from unstable to stable strata. Packaged resin compounds are inserted
into the drilled hole. A ground support member is then inserted into the
drilled hole which punctures the resin packages. The member is rotated
to ensure that the resin mixes and fills the annulus between the member
and the inside surface of the drill hole. The resin hardens and then the
member is tensioned to a predetermined load. To facilitate the ground
support operation a variety of machines have been proposed to insert the
ground support member into the drill hole. One such machine is
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described in our pending patent application CA 2460497 Rebar Insertion
Device by John Fifield filed on 2004/03/09. This device works well in
many ground support applications but it has a number of weaknesses
that have become apparent from field use. For example, a significant
amount of force is required to push a ground support member into a
pre-drilled hole and through packaged resin. This force is applied by the
pusher leg or jackleg which is a pneumatic or hydraulic piston to which
the drill is attached. As this force is applied to the ground support
member lateral forces are created in the pusher leg and in the supports
of the pusher leg which have been found to destabilize the apparatus
because it is not supported for these loads. This causes the drill and
pusher leg to move and swivel which can damage the ground support
member and create a worker hazard. Therefore there is a need to resolve
this problem to prevent damage to the ground support member which
may compromise its structural integrity and to prevent injury to the drill
operator.
SUMMARY OF THE INVENTION
The problem is solved by the provision of an improved ground support
member insertion device comprising means for attaching the device to a
jackleg drill, a clutch assembly disposed adjacent to the attaching means
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and adapted for holding a ground support member while it is being
inserted into a first drill hole; and, anchoring means disposed opposite
the clutch assembly and adapted for temporarily anchoring the device for
stabilization in a rock formation during insertion of the ground support
member. The attaching means is separated from the clutch assembly by
a rectangular channel welded between the clutch assembly and the
anchoring means. The rectangular channel further comprises a front, a
back, a first side and a second side. The clutch assembly comprises a
rectangular housing welded to the front of the rectangular channel and a
roller housed within the rectangular housing. The roller is adapted for
frictional rolling engagement with the ground support member. The
roller is eccentrically mounted on an axle for limited pivoting movement
about the axle. The rectangular housing comprises an open bottom, a
partially closed top, a first side, a second side, a back and a front. The
open bottom facilitates insertion of the ground support member into the
device. The partially closed top comprises a top plate adapted to permit
passage of the ground support member through the rectangular housing
while impeding debris from entering the rectangular housing by way of
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the partially closed top. The first side is at least partially enclosed by a
first side plate. The second side is at least partially enclosed by a second
side plate. The first side plate and the second side plate are adapted to
guide the movement of the roller within the rectangular housing. The
front is enclosed by a front plate attached to at least one of the first and
second side plates. The front plate has a flat outside surface and an
inside surface having a groove adapted for frictional siding engagement
with the ground support member as it passes through the housing. The
back is enclosed by a back plate attached to the front of the rectangular
channel. The first and second side plates comprise respective first and
second apertures disposed opposite to each other for mounting the axis
of the roller. The first and second side plates further comprise respective
third and fourth apertures disposed opposite to each other for mounting
a tensionable reinforcing member that also acts as a bottom stop for the
roller. The tensionable reinforcing member is further adapted to ensure
parallel alignment of the first and second side plates. The anchoring
means comprises a first projecting member fixed to the back of the
rectangular channel. The member has a first end disposed downward for
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attachment to the jackleg drill and a second threaded end disposed
upward for threaded attachment to an anchoring member for insertion
into a second predrilled hole having a depth in the rock formation and
adapted for temporarily receiving the anchoring member. There is a
second projecting member fixed to the back of the rectangular channel
adjacent to the first projecting member and disposed downward for
reinforcement in order to impede device rotation during the insertion of
the ground support member. The anchoring member comprises a first
end adapted for inserting into the second predrilled hole and a second
threaded end adapted for threaded engagement with the threaded
second end of the first projecting member. The anchoring member has a
length less than the depth of the second predrilled hole. The anchoring
member is adapted to resist lateral forces resulting from resistance to the
ground support member being inserted into the first predrilled hole. The
ground support member is inserted between the roller member and the
groove in the inside surface of the front plate act in frictional
engagement, so that when the ground support member receive a thrust
from the jackleg drill it is pushed towards the first hole and the roller
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pivots upwards in a releasing action permitting frictional movement of
the ground support member, and so that when the thrust is removed,
gravity will pull the ground support member down thereby permitting the
roller to pivot downwards and into a position wherein it acts in a pinching
combination with the groove to generate a pinch force capable of holding
the ground support member stationary against the force of gravity.
A ground support member insertion kit for use in combination with a
jackleg drill is also provided and comprises a ground support member
insertion device comprising attaching means for attaching the device to a
jackleg drill, a clutch assembly disposed adjacent to the attaching means
and adapted for holding a ground support member while it is being
inserted into a first drill hole that has been pre-loaded with resin,
anchoring means disposed opposite the clutch assembly and adapted for
temporarily anchoring the device in a rock formation during insertion of
the ground support member; and, an impact tool temporarily fixable to
the jackleg drill and adapted for engaging the proximate end of the
ground support member by engagement means and transmitting
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percussive and rotational movement to the ground support member
during insertion into the resin.
There is also provided a system for installing a ground support member
with resin comprising a rock drill for drilling a first hole for permanently
accepting the ground support member and resin in combination and a
second hole for temporarily accepting an anchoring member for
stabilization, ajackleg drill for mounting the rock drill and for providing
thrust to the ground support member during insertion into the first hole
and resin, a ground support member insertion device temporarily
mounted to the jackleg drill for holding the ground support member
during insertion into the first hole. The device acts in cooperation with
the anchoring member to stabilize the jackleg drill during insertion. The
system further includes an impact tool temporarily fixable to the rock
drill and adapted for engaging the proximate end of the ground support
member by engagement means and transmitting percussive and
rotational forces from the rock drill to the ground support member
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during insertion into the resin and tensioning of the ground support
member.
There is also a method for inserting a ground support member
permanently into a first hole filled with resin comprising the steps of:
a. drilling the first hole having a first depth using ajackleg drill;
b. inserting a bonding agent including resin into the first hole;
c. drilling a second hole having a second depth using the
jackleg drill wherein the second depth is less than the first
depth;
d. installing a ground support member insertion device onto the
jackleg drill, the ground support member insertion device
comprising:
i. attaching means for attaching the device to the jackleg
drill;
ii. a clutch assembly disposed adjacent to the attaching
means and adapted for holding a ground support
member while permitting movement of the ground
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support member in a distal direction and preventing
movement in a proximate direction; and,
iii. anchoring means disposed opposite the clutch
assembly, the anchoring means comprising an
anchoring member adapted for temporarily anchoring
the device in the second hole during insertion of the
ground support member for stability;
e. temporarily fixing the anchoring member to the ground
support member insertion device;
f. maneuvering the jackleg drill so that the anchoring member
is inserted into the second hold and the ground support
member insertion device is poised below the first hole;
g. inserting a ground support member into the clutch assembly,
wherein the ground support member comprises a distal end
for insertion into the first hole and a proximate end adapted
to receive thrust from the jackleg drill, and wherein the
ground support member is held stationary within the clutch
until a first thrust is applied from the jackleg drill;
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h. applying a first thrust from the jackleg drill to the proximate
end of the ground support member thereby forcing it
through the clutch and into the first hole a first distance so
that the distal end of the ground support member engages
the binding resin;
i. withdrawing the jackleg drill a second distance thereby
removing thrust from the ground support member and
engaging the clutch so that the grounds support member is
held stationary;
j. applying a second thrust to the proximate end of the ground
support member in order to move it a second distance into
the first hole;
k. repeating steps h to j until the ground support member is in
a desired location;
I. allowing the resin to set in a binding relationship with the
ground support member;
m. removing the ground support member insertion device from
the jackleg drill;
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n. installing an impact tool on the jackleg drill whereby the
distal end of the impact tool engages the proximate end of
the ground support member by engagement means thereby
permitting the transmission of percussive and rotational
forces from the jackleg drill to the ground support member
until a desired tension is achieved within the ground support
member.
DESCRIPTION OF THE DRAWINGS
Figure 1 is a schematic drawing of a jackleg leg drill and invention in a
mine.
Figure 2 is a schematic drawing of the top of one example of the
invention.
Figure 3 is the same figure as Figure 2.
Figure 4 is a schematic side view of a reinforcing member in one example
of the clutch assembly.
Figure 5 is another schematic view of a reinforcing member in one
example of the clutch assembly.
Figure 6 is a bottom view of one example of the invention.
Figure 7 is a side view of the one example of the invention.
Figure 8 is a view of one example of the anchoring member of the
invention.
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Figure 9 is a view of one example of the impact tool of the invention.
DETAILED DESCRIPTION
Referring to Figure 1, there is shown a schematic view of one example of
our invention being an improved ground support member insertion
device (10) comprising means (24) for attaching the device to a jackleg
drill (14). A clutch assembly (16) is disposed adjacent to the attaching
means (24) and separated from the attaching means by a rectangular
spacing member (26) adapted to provide proper spacing between the drill
and the clutch assembly. The clutch assembly (16) is adapted for holding
and guiding a ground support member (18) insertion while it is being
inserted into a first drill hole (20) within a rock body (22). The jackleg
drill is also called a pushleg drill and is a pneumatic or hydraulic assisted
device used to provide thrust to the drill bit in drilling operations.
Typically the jackleg drill will be installed upon a tripod (23) support or
some other type of support for stability.
Referring to Figure 1 and Figure 2, in another example (10) of the
invention there is illustrated schematically in a top view other elements of
the invention including anchoring means (24) disposed opposite the
clutch assembly (16). The anchoring means are adapted for temporarily
anchoring the device (10) in the rock body (22) during insertion of the
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ground support member (18) and for attaching the device (10) to the
jackleg drill.
Rectangular channel member (26) is welded (27) between the clutch
assembly (16) and the anchoring means (24). The rectangular channel
member comprises a front (28), a back (30), a first side (32) and a second
side (34). The rectangular channel member provides spacing between
the clutch assembly (16) and the end (36) of the jackleg drill (14).
Referring now to Figure 3, which is identical to Figure 2, the clutch
assembly (16) comprises a rectangular housing (40) welded (27) to the
front (28) of the rectangular channel member (26). Within the rectangular
housing is housed a roller (42). The roller is adapted for a frictional
rolling engagement with the ground support member (18) as more fully
explained below.
Referring to Figure 4 and Figure 5, the roller (42) is eccentrically mounted
on an axle (44) within the clutch housing (16). The axle (44) provides for
a limited pivoting movement between a first engaged position (46) when
the roller is acting to prevent the ground support member (18) from
moving backwards (47) by moving in a clockwise (49) rotation about the
axis in order to pinchingly engage the ground support member (18)
within the groove (51).
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Referring to Figure 5, there is a second disengaged position (48). In the
disengaged position (48) the roller (42) is rotated counter clock-wise (54)
about the axle (44) so that it disengages the ground support member
5(18) and permits one-way movement (56) of the ground support member
towards the first hole. The surface (50) of the roller is always in a
frictional engagement with the grounds support member (18) while it is
moving so that should forces of gravity act on the ground support
member the roller will automatically engage into its engagement position
thereby locking the ground support member in place. The surface (50) of
the roller is adapted for frictional engagement with a steel ground
support member and in one example of the invention it may be knurled.
Other types of surface patterns are also possible to obtain the same
gripping effect between the surface of the roller and the surface of the
ground support member.
Referring to Figures 1 to 6, the ground support member (18) is inserted
between the roller (42) and the groove (51) in the inside surface (84) of
the front plate (70) and cooperate in a frictional engagement, so that
when the ground support member (18) receives thrust from the jackleg
drill (14) it is pushed towards the first hole (20) and the roller pivots
upwards (54) in a releasing action permitting frictional movement of the
ground support member through the housing (16). When the thrust is
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removed, gravity (47) will pull the ground support member down thereby
permitting the roller to pivot downwards (49) and into a position wherein
it acts in a pinching combination with the groove (51) to generate a pinch
force capable of holding the ground support member stationary against
the force of gravity.
Still referring to Figure 6, there is shown a bottom view of the ground
support member insertion device (10). The rectangular housing (16)
comprises an open bottom (60), a partially closed top (62 Figure 3), a
first side (64), a second side (66), a back (68) and a front (70). The open
bottom (60) facilitates insertion of the ground support member (18) into
the groove (5 1) in front of the roller (42). The partially closed top (62)
comprises a top plate (72 Figure 3) adapted to permit passage of the
ground support member (18) through the rectangular housing (16) while
impeding debris from entering the rectangular housing by way of the
partially closed top. The first side (64) is at least partially enclosed by a
first side plate (74). The second side (66) is at least partially enclosed by
a second side plate (76). The first side plate (74) and the second side
plate (76) are adapted to guide the movement of the roller (42) within the
rectangular housing (16). The front (70) is enclosed by a front plate (80)
attached to at least one of the first and second side plates. The front
plate (80) has a flat outside surface (82) and an inside surface (84) having
groove (51) adapted for frictional siding engagement with the ground
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support member (18) as it passes through the rectangular housing (16).
The back (68) is enclosed by a back plate (86) that is attached by welding
(27) to the front (28) of the rectangular channel (26). The first (74) and
second (76) side plates comprise respective first (90) and second (92)
apertures disposed opposite to each other for mounting the axle (44) of
the roller (42). The first and second side plates further comprise
respective third (94) and fourth (96) apertures disposed opposite to each
other for mounting a tensionable reinforcing member (98) that also acts
as a bottom roller stop. The tensionable reinforcing member (98) is
further adapted to ensure parallel alignment of the first and second side
plates.
Referring to Figure 7, there is shown another example of the ground
support member insertion device in a first side view. The anchoring
means (24) comprises a first projecting member (100) fixed to the back
(30) of the rectangular channel (26). The first projecting member is a
single length of steel rod. The first projecting member (100) has a first
end (102) disposed downward (104) for attachment to the jackleg drill.
The first projecting member has a second threaded end (106) disposed
upward (108) for threaded attachment to an anchoring member (110)
further described in Figure 8.
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Referring back to Figure 1, there is a second predrilled hole (112) having
a depth (114) in the rock formation (22) that is adapted for temporarily
receiving the anchoring member (110). Depth (114) is generally greater
than the length (120) of the anchoring member (110).
Referring back to Figure 7, there is illustrated a second projecting
member (1 16) fixed to the back of the rectangular channel adjacent to
the first projecting member and disposed downward for reinforcement
and to impede device rotation while fixed to the jackleg during the
insertion of the ground support member.
Referring to Figure 8, the anchoring member (110) comprises a length
(120) of solid steel comprising a first end (122) adapted for inserting into
the second predrilled hole (112) and a second threaded end (124)
adapted for threaded engagement with the threaded end (106) of the first
projecting member (100). The anchoring member has a length (120) less
than the depth (114) of the second predrilled hole (112). Once the
anchoring member is inserted into the second predrilled hole it is
adapted to resist lateral forces resulting from resistance to the ground
support member (18) being inserted into the first predrilled hole (20) by
the jackleg (14) thrust.
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In another example of the invention, the improved ground support
member insertion device is used in combination with ajackleg drill. The
device comprises means for attaching the device to the jackleg drill and a
clutch assembly disposed adjacent to the attaching means. The clutch
assembly is adapted for holding a ground support member while it is
being inserted into a first drill hole. Anchoring means is disposed
opposite the clutch assembly for temporarily anchoring the device in a
second hole in the rock formation during insertion of the ground support
member.
In another example of the invention there is provided a ground support
member insertion kit for use in combination with ajackleg drill. The
insertion kit comprises a ground support member insertion device
comprising means for attaching the device to a jackleg drill, a clutch
assembly disposed adjacent to the attaching means and adapted for
holding a ground support member while it is being inserted into a first
drill hole and anchoring means disposed opposite the clutch assembly for
temporarily anchoring the device in a rock formation during insertion of
the ground support member.
Referring to Figure 9 and Figure 10, a there is also provided in the kit is
an impact tool (150) that is temporarily fixable to the jackleg drill. The
impact tool has a first end (152) and a second end (154). The first end
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(152) is adapted for connection with the jackleg drill and the second end
(154) is adapted for connection with a torquing nut on the end of a
reinforcing member. Between the first end and the second end is a
flange (156) that is adapted to sit on the end of the jackleg drill so
separate the drill from the second end (154). The shaft (158) of the
impact tool is manufactured from steel that may have a hollow core (160)
and is generally six-sided for better gripping by the jackleg drill chuck.
The second end (154) includes a socket (162) that is adapted to fit over
an eight-pointed nut. The socket is removable from the shaft of the
impact tool and other sockets for six-point nuts (hexnuts) or four-point
nuts (square nuts) may be placed on the end of the shaft. The impact
tool is adapted for engaging the proximate end of the ground support
member and transmitting percussive and rotational movement to the
ground support member during insertion through the resin. Field tests
show that the use of this tool on the end of the jackleg drill increases the
insertion rate of the reinforcing member through the resin.
In another example of the invention there is provided a system for
installing a ground support member comprising a jackleg drill for drilling
a first hole for permanently accepting the ground support member and a
second hole for temporarily accepting an anchoring member. The jackleg
drill is also used to provide thrust to the ground support member during
insertion into the first hole. There is further provided a ground support
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member insertion device temporarily mounted to the jackleg drill for
holding the ground support member during insertion into the first hole.
The device acts in cooperation with the anchoring member to stabilize
the jackleg during insertion. The system further comprises an impact
tool temporarily fixable to the jackleg drill for engaging the proximate
end of the ground support member and transmitting percussive and
rotational forces from the rock drill to the ground support member
during installation.
In another example of the invention, there is a method for inserting a
ground support member permanently into a first hole comprising the
steps of:
a. Drilling a first hole having a first depth using a rock drill
mounted to ajackleg;
b. Inserting a binding resin into the first hole;
c. Drilling a second hole having a second depth using the rock drill
wherein the depth of the second hole is less than the depth of
the first hole;
d. Installing a ground support member insertion device onto the
jackleg drill, wherein the ground support member insertion
device comprises:
i. Attaching means for attaching the device to the jackleg
drill;
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ii. A clutch assembly disposed adjacent to the attaching
means for holding a ground support member while
permitting movement of the ground support member in a
distal direction and preventing movement in a proximate
direction; and,
iii. Anchoring means disposed opposite the clutch assembly
wherein the anchoring member comprises an anchoring
member adapted for temporarily anchoring the device in
the second hole during insertion of the ground support
member;
e. Temporarily fixing the anchoring member to the ground support
member insertion device;
f. Maneuvering the jackleg drill so that the anchoring member is
inserted into the second hold and the ground support member
insertion device is poised below the first hole;
g. Inserting a ground support member into the clutch assembly,
wherein the ground support member comprises a distal end for
insertion into the first hole and a proximate end adapted to
receive thrust from the jackleg drill, and wherein the ground
support member is held stationary within the clutch until a first
thrust is applied from the jackleg drill;
h. Applying a first thrust from the jackleg drill to the proximate
end of the ground support member thereby forcing it through
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the clutch and into the first hole a first distance so that the
distal end of the ground support member engages the binding
resin;
i. Withdrawing the jackleg drill a second distance thereby
removing thrust from the ground support member and
engaging the clutch so that the ground support member is held
stationary;
j. Applying a second thrust to the proximate end of the ground
support member in order to move it a second distance into the
first hole;
k. Repeating steps j and k until the ground support member is in a
desired location;
1. Removing the ground support member insertion device from the
jackleg drill;
m. Installing an impact tool on the drill whereby the distal end of
the impact tool engages the proximate end of the ground
support member thereby permitting the transmission of
percussive and rotational forces from the rock drill to the
ground support member until a desired tension is achieved
within the ground support member.
Although the description above contains much specificity, these
should not be construed as limiting the scope of the invention but
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as merely providing examples of the invention. Thus the scope of
the invention should be determined by the appended claims and
their legal equivalents.
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