AU2023241265B1 - Resin injection device, system and method, use of the resin injection system, underground rock drilling machine, and rock anchor installation method - Google Patents

Abstract

RESIN INJECTION DEVICE, SYSTEM AND METHOD, USE OF THE RESIN INJECTION SYSTEM, UNDERGROUND ROCK DRILLING MACHINE AND ROCK ANCHOR INSTALLATION METHOD The invention proceeds from a resin injection device (60) for an underground rock drilling machine (10), for example a roof bolter, a cable bolter or a drilling jumbo, having at least one drifter (12) with a flushing head (14). It is proposed that the resin injection device (60) comprises an adaptor unit (16) implementing a flushing-fluid and resin manifold (18), which is configured to be interposed directly between a flushing port (20) of the (original) flushing head (14) and a flushing fluid feed line (22) of the underground rock drilling machine (10). (Fig. 5)

Description

RESIN INJECTION DEVICE, SYSTEM AND METHOD, USE OF THE RESIN INJECTION SYSTEM, UNDERGROUND ROCK DRILLING MACHINE AND ROCK ANCHOR INSTALLATION METHOD BACKROUND

[0001] This disclosure relates to a resin injection device for an underground rock drilling machine according to the preamble of claim 1, to a resin injection system according to claim 23, to an underground rock drilling machine according to claim 26, to a use of the resin injection system according to claim 27, to a resin injection method according to the preamble of claim 28 and to a rock anchor installation method according to claim 29.

[0002] From the prior art, various methods for an introduction of resin into drilled anchor holes in underground mines are known. However, these methods are often time consuming, such as the method in which resin cartridges are inserted into freshly drilled anchor holes, or costly, such as the method in which hollow self-drilling anchors are used for resin injection.

[0003] The present disclosure seeks to provide a method with advantageous characteristics regarding an efficiency of resin-assisted rock anchor installations, for example in underground mines.

SUMMARY

[0003a] It is an object of at least one embodiment of the present invention to: overcome, or at least ameliorate one or more shortcomings in the prior art, such as one or more of the above disadvantages; or at least to provide an alternative choice to the prior art.

[0003b] In accordance with a first aspect, there is provided a resin injection device for an underground rock drilling machine, having at least one drifter with a flushing head, which forms an integral part of the drifter and which is configured for supplying of a flushing fluid to an integrated flushing channel of a drill, wherein an adaptor unit implementing a flushing-fluid and resin manifold, which is la configured to be interposed directly between a flushing port of the flushing head and a flushing fluid feed line of the underground rock drilling machine, wherein the adaptor unit is configured for a fixed attachment to the flushing head of the drifter.

[0003c] In accordance with a second aspect, there is provided a resin injection system with a resin injection device according to the first aspect and with the flushing head.

[0003d] In accordance with a third aspect, there is provided an underground rock drilling machine, comprising a resin injection system according to the second aspect.

[0003e] In accordance with a fourth aspect, there is provided a use of a resin injection system according to the second aspect and/or of an underground rock drilling machine according to the third aspect for a resin grouted installation of full-material rock anchors.

[0003f] In accordance with a fifth aspect, there is provided a resin injection method for underground drilling machines, utilizing a drifter with a flushing head via a resin injection device according to the first aspect, wherein an adaptor unit, implementing a flushing-fluid and resin manifold, is directly interposed between a flushing port of the flushing head and a flushing fluid feed line of the underground rock drilling machine, wherein the adaptor unit is fixedly attached to the flushing head of the drifter.

[0003g] In accordance with a sixth aspect, there is provided an installation method for an installation of a rock anchor via a resin injection device according to the first aspect, wherein in a first method step, a hole is drilled into a rock surface by a drifter comprising a drill with at least one integrated flushing channel under constant or intermittent flushing of the hole, using a flushing fluid flowing through the flushing channel towards an outlet at a tip of the drill, wherein in a second method step the hole is filled with a resin mixture introduced into the hole from the outlet at the tip of the drill via the flushing channel, and wherein in a third method step the rock anchor is inserted into the resin filled hole.

[0004] The invention proceeds from a resin injection device for an underground rock drilling machine, for example a roof bolter, cable bolter or a drilling jumbo, having at least one drifter with a flushing head.

[0005] It is proposed that the resin injection device comprises an adaptor unit implementing a flushing-fluid and resin manifold, which is configured for a direct interposing between a flushing port of the (original) flushing head and a flushing fluid feed line of the underground rock drilling machine. Thereby, advantageous characteristics regarding an efficiency of resin-assisted rock anchor installations can be achieved. Advantageously, resin can be injected directly into freshly drilled anchor holes via a drill rod of the drifter, in particular without a need for hollow self-drilling anchors. Advantageously all types of bolts or rock anchors, including full-materials bolts, can be used with the proposed resin injection device. This may advantageously lead to a significant cost reduction. In addition, advantageously any type of drill rig can be used with the proposed resin injection device. Advantageously, a flushing channel integrated into the drill rod can also be used as a resin injection channel without affecting a reliability of the underground rock drilling machine, in particular of its drifter. Furthermore, by using the proposed resin injection device, advantageously an original length of the drill including the drifter can be retained, which is particularly advantageous for roof bolters in underground mines whose tunnels or drifts have a fixed ceiling height. Moreover, by using the proposed resin injection device, a particularly short installation time for the resin assisted installation of rock anchors can be achieved. Advantageously, average installation times that are in the order of less than five, preferably even less than three, minutes can be achieved, in particular compared to, for example, twelve minutes when using resin cartridges. In comparison to the use of resin cartridges, the rock anchor installation is sped up considerably, in particular because no switch between the drilling equipment and the cartridge insertion equipment is necessary before the installation of the rock anchor.

[0006] The underground rock drilling machine can be implemented as a roof bolter or a roof bolting rig which is configured for drilling holes and installing roof support bolts (rock anchors) in the ceilings of underground mining tunnels. The underground rock drilling machine can be implemented as a cable bolter which is configured for drilling holes and installing cable bolts in ceilings and walls of underground mining tunnels. The underground rock drilling machine can be implemented as a drilling jumbo or a drilling rig, which is in particular deployed for drilling and blasting operations at a mine face. Such underground rock drilling machines often comprise one or more movable booms, in particular drilling booms. Such a boom can be configured to hold, to centralize and/or to operate drilling equipment like the drifter and/or the drill / a drill rod. The drifter is in particular implemented as a rock drill, preferably as a hydraulic rock drill. The drifter comprises the flushing head, which is in particular configured for a supply of a flushing fluid, for example water or air, to the integrated flushing channel of the drill. The flushing operation is in particular configured for a removal of drill dust from a drill hole during or directly after a drilling operation of the drill. The flushing head is a standard OEM component. The flushing head preferably forms an integral part of the drifter. The flushing head remains unaltered by an installation of the resin injection device. In particular, no modification or alteration of the OEM flushing head of the drifter is required for the application and/or installation of the resin injection device. In particular, no reinstallation of the drill into the drifter is required for the application and/or installation of the resin injection device. The term "configured" is intended to mean, in particular, specifically programmed, designed and/or equipped. The fact that an object is configured for a specific function is in particular to mean that the object fulfills and/or executes this specific function in at least one application and/or operating state.

[0007] In particular, the resin injection device, preferably the adaptor unit, is to be installed upstream of the flushing head. Preferably, the adaptor unit is smaller than or equal in volume to the flushing head. Preferably the flow capacity of the adaptor unit is equal to or larger than the flow capacity of the flushing head. In particular, the flushing-fluid and resin manifold comprises a fluid chamber, which is branched into several channels or openings, one or more of which are intended for a resin flow, one or more of which are intended for a flow of a flushing fluid and one or more of which are intended for a flow of the resin and for a flow of the flushing fluid. At least one of the channels or openings of the flushing fluid and resin manifold is directly connected to the flushing port of the (OEM) flushing head. At least one of the channels or openings of the flushing-fluid and resin manifold is directly connected to the flushing fluid feed line of the underground rock drilling machine. At least one of the channels or openings of the flushing-fluid and resin manifold is directly connected to a first resin chemical feed line of the underground rock drilling machine. At least one of the channels or openings of the flushing-fluid and resin manifold is directly connected to a second resin chemical feed line of the underground rock drilling machine. The two resin chemicals can come into contact with each other within the fluid chamber of the flushing-fluid and resin manifold. In particular, the mixing of the two resin chemicals sets a resin-hardening reaction in motion. The flushing port of the (OEM) flushing head is preferably implemented as an access hole into an interior of the flushing head. The flushing fluid feed line is preferably implemented as a hose or a pipe providing a fluid connection to a flushing fluid supply (a source or a tank or similar). The flushing fluid feed line is preferably a flushing liquid feed line.

[0008] Furthermore, it is proposed that the adaptor unit is configured for a fixed attachment to the flushing head. Thereby, an easy installation can advantageously be achieved. Furthermore, a high operational safety can advantageously be achieved. Preferably the adaptor unit is attached to an outer housing of the flushing head. Preferably the adaptor unit is attached to an outer circumference of the outer housing of the flushing head. In particular, the adaptor unit is attached to a lateral surface of the flushing head, in particular if the flushing head is viewed from a direction of a rotational axis of the drifter. In particular, the adaptor unit is fixedly attached in such a way that an outer surface of the adaptor unit contacts an outer (lateral) surface of the flushing head.

[0009] Moreover, it is proposed that the resin injection device comprises at least one connection unit, for example a bolt or a screw or a fluid line (hose), for establishing the fixed connection with the flushing head. Thereby, a safe and easy installation can advantageously be achieved. The connection unit is in particular formed separately from the manifold. Preferably, the connection unit contacts the manifold and the flushing head for establishing the connection. Preferably, the connection unit penetrates the manifold for establishing the connection. Preferably, the connection unit penetrates an outer housing of the flushing head for establishing the connection. Alternatively, the connection unit could only contact an outer surface of the flushing head.

[0010] If the connection unit is implemented as a banjo bolt or as a banjo screw, a particularly advantageous fixation of the manifold to the flushing head can be achieved. In particular, this connection method provides a high simplicity and a very low number of separate parts. A banjo bolt is in particular a hollow bolt that allows a fluid transfer from its tip to a lateral opening on its radial circumference. The banjo bolt can be implemented with a threaded section or without a threaded section. At least the tip of the banjo bolt with a fluid opening is configured, at least in a mounted state, to reach into the flushing port of the (OEM) flushing head. The lateral opening(s) of the banjo bolt is/are connected to a channel or to a fluid chamber of the manifold. The banjo bolt is configured for penetrating the adaptor unit.

[0011] If alternatively the connection unit is implemented as a hydraulic (hose) coupling, a high flexibility of the connection unit can be achieved, which may advantageously provide a high flexibility and/or simplicity. The hydraulic coupling comprises a coupling element, which is to be fixedly attached to the flushing head. Preferably, via an opening of the coupling element, the flushing fluid and the resin chemicals can be transferred to the flushing head. Preferably, the hydraulic coupling comprises - in particular similarly to a banjo bolt - one or more openings on its radial circumference, which connect the hydraulic (hose) coupling to a channel or to the fluid chamber of the manifold.

[0012] In addition, it is suggested that the connection unit is configured for guiding a resin flow and a flushing fluid flow from the adaptor unit to the (original) flushing head. Thereby, resin injection into the flushing head can advantageously be achieved. Advantageously, a particularly easy construction, requiring a minimum number of separate parts can be achieved. Thereby size and cost of the resin injection device can advantageously be kept low. The resin flow preferably comprises at least one resin chemical or a mixture of at least two resin chemicals. The resin chemicals are preferably liquid precursor chemicals that form a solidifying synthetic resin when being mixed with each other. The resin chemicals are preferably synthetic resin chemicals that are known to a skilled person from the prior art. Preferably, the connection unit, in particular the banjo bolt or the hydraulic (hose) coupling, comprises an inner flow channel which is passable to the resin flow and to the flushing fluid flow, depending on a current setting of the resin injection device, and which is preferably flowed through by the flushing fluid during a flushing operation of the resin injection device / the underground rock drilling machine or by the resin flow during a resin grouting operation of the resin injection device / the underground rock drilling machine.

[0013] Additionally, it is proposed that the connection unit comprises a mounting element, for example a screw thread, which is basically identical to a standardized mounting element of the flushing fluid feed lines of underground rock drilling machines. Thereby a particularly easy handling and installation can advantageously be achieved. Preferably no further mounting adaptors are required. In particular, for an installation of the resin injection device it is sufficient to simply remove the normally installed flushing fluid feed line from the flushing head and to instead install the connection unit at the same interface which the flushing fluid feed line was installed at before. Furthermore, the removed flushing fluid feed line can subsequently be installed at an inlet channel of the adaptor unit / the manifold.

[0014] If the adaptor unit is configured for a lateral attachment to the flushing head, a space-saving installation can advantageously be achieved. Especially in confined underground mining environments, space is a highly important factor. Advantageously, an overall length of the boom of the underground rock drilling machine, in particular of the drifter-drill-combination of the underground rock drilling machine, can be preserved. In particular, the flushing head comprises a front side from which the drill, in particular a drill rod of the drill, sticks out in a mounted state. The lateral sides, which the adaptor unit is attached to surround a drill-receiving region of the flushing head radially with respect to a longitudinal extension direction of the drill-receiving region / to an imaginary rotational axis of the drill within the flushing head.

[0015] If, in addition, the adaptor unit is free from any contact with other parts of the drifter except the flushing head, a particularly high operational safety can be achieved.

Furthermore, a particularly easy installation and/or construction can advantageously be achieved.

[0016] Furthermore, it is proposed that the adaptor unit, in particular the manifold, comprises a first feed port for the flushing fluid and a second feed port for a resin chemical. This advantageously facilitates a (switchable) use of the flushing head as a resin feeder. The first feed port and the second feed port are separate from each other. The first feed port and the second feed port preferably open to separate channels of the manifold, both in turn leading to the fluid chamber of the manifold. The first feed port is preferably configured for a connection with the flushing fluid feed line of the underground rock drilling machine. The second feed port is preferably configured for a connection with a first resin chemical feed line of the underground rock drilling machine or of a resin chemical supply.

[0017] In addition, it is proposed that the adaptor unit, in particular the manifold, further comprises a third feed port for a second resin chemical, which is in particular different from the first resin chemical. This advantageously facilitates a (switchable) use of the flushing head as a resin feeder. The third feed port is separate from the first feed port and from the second feed port. The third feed port preferably connects to a channel of the manifold which is separate from the other two feed ports and in turn also leads to the fluid chamber of the manifold. The third feed port is preferably configured for a connection with a second resin chemical feed line of the underground rock drilling machine or of a second resin chemical supply. The resin chemical(s) preferably is (are) (a) liquid(s). The resin chemicals preferably only solidify when they come in contact with each other.

[0018] It is further proposed that the adaptor unit comprises a connection line which is in fluidic connection with at least the first feed port and the second feed port, and in particular with the third feed port. This advantageously facilitates a (switchable) use of the flushing head as a resin feeder. The connection line of the adaptor unit is in particular identical to the fluid chamber of the manifold. The connection line preferably implements a mixing line for a mixing of the resin chemicals with each other. Depending on the operation state of the resin injection device, the connection line either transports only flushing fluid or only transports the resin chemicals.

[0019] In addition, it is proposed that the adaptor unit comprises an, in particular single, discharge port. Thereby, an advantageously easy switching between flushing operation and resin grouting operation can be achieved. The discharge port is configured for discharging (only) the flushing liquid during a flushing operation of the drifter / the underground rock drilling machine. The discharge port is configured for discharging (only) the resin chemical(s) during a resin grouting operation of the underground rock drilling machine. Preferably, the adaptor unit is free of any further discharge ports. In particular, the discharge port is in fluidic connection with the connection line / the fluid chamber of the manifold.

[0020] If the discharge port also forms a mounting hole for the connection unit, for example the banjo bolt, an advantageously compact and simple construction can be achieved. In particular during mounting of the resin injection device to the flushing head, the connection unit, e.g. the banjo bolt or the hydraulic coupling, is put through the discharge port from a side opposite to the side that contacts the flushing head in the mounted state.

[0021] Moreover, it is proposed that an outflow direction of fluids, in particular liquids, preferably mixed resin chemicals, out of the adaptor unit is at least substantially perpendicular to, preferably all, inflow directions of fluids, in particular liquids, preferably unmixed resin chemicals, into the adaptor unit. Thereby, an advantageously compact construction can be achieved. Furthermore, a particularly easy handling of the resin injection device can be provided, with easily accessible feed ports. The expression "substantially perpendicularly" is here in particular to define an orientation of a direction relative to a reference direction, the direction and the reference direction, in particular when viewed in one plane, including an angle of 90° and the angle having a maximum deviation of in particular less than 80, in an advantageous manner less than 5° and in an especially advantageous manner less than 2°.

[0022] Additionally, it is proposed that the resin injection device comprises at least one check valve, which is configured for preventing a backflow of liquids, in particular of resin chemicals, counter to a feed direction / counter to the inflow direction into the adaptor unit. Thereby, a particularly high operational safety can advantageously be achieved. In particular, a backflow of resin chemicals into the flushing fluid feed line can advantageously prevented. In particular, a backflow of flushing fluid into the resin chemical feed line(s) can advantageously prevented. The check valve is preferably mounted at one of the feed ports.

[0023] If a first check valve is mounted to the first feed port and a second check valve is mounted to the second feed port, and preferably a third check valve is mounted to the third feed port, all possible backflow paths can advantageously be protected. Advantageously a high operational safety and/or a high operational reliability can be achieved. The first check valve is in preferably mounted to the fist feed port in an at least liquid-tight manner. The first check valve is in particular internally mounted to the adaptor unit, preferably by screwing the first check valve into an internal thread of the first feed port of the adaptor unit, in particular of the manifold. The second check valve is in preferably mounted to the second feed port in an at least liquid-tight manner. The second check valve is in particular internally mounted to the adaptor unit, preferably by screwing the second check valve into an internal thread of the second feed port of the adaptor unit, in particular of the manifold. The third check valve is in preferably mounted to the third feed port in an at least liquid tight manner. The third check valve is in particular internally mounted to the adaptor unit, preferably by screwing the third check valve into an internal thread of the third feed port of the adaptor unit, in particular of the manifold. The check valves are preferably embodied separately from each other.

[0024] It is further proposed that the check valve(s) comprise a, preferably spring-loaded, disc-like poppet for implementing the check mechanism. Thereby, a high operational safety and/or a high operational reliability can be achieved. A first side of the disc-like poppet provides a first actuation surface of the check valve. A second side of the disc-like poppet opposing the first side of the disc-like poppet provides a second actuation surface of the check valve. Depending on which side of the disc-like poppet the acting pressure is higher, the check valve is opened or closed. If, for example, the pressure is larger on the first side of the disc-like poppet, the poppet is pushed in a closing direction, thus preventing a flow through the check valve. If, for example, the pressure is larger on the second side of the disc-like poppet, the poppet is pushed in an opening direction, thus allowing a flow through the check valve. Preferably, the check valve comprises a spring which is tensioned when the poppet is actuated in the opening direction and which is relaxed when the poppet is actuated in the closing direction or vice versa. Preferably the check valves are implemented at least substantially identically to each other. Preferably, the check valves provide a normally-closed (NC) base state.

[0025] Furthermore, it is proposed that the disc-like poppet is arranged outside a flow tube of the check valve(s). Thereby, a high operational safety and/or a high operational reliability can advantageously be achieved. This is in particular due to the fact that an inflow of the flushing liquid, which in some cases could be water with a very high salinity, into the check valves, in particular into the flow tubes of the check valves, is prevented. In particular in check valves which occasionally or typically convey resin chemicals, such a highly saline water could cause encrustations inside the flow tube of the check valves and thereby lead to undesired blockages of the poppet, i.e. malfunctions of the check valve. In particular, the check valve is mounted into the respective feed port of the adaptor unit / the manifold with the poppet facing away from the respective feed lines / with the poppet facing towards the inside of the manifold / the fluid chamber / the connection line. Preferably, the check valves are implemented free of any closing balls or spheres. In particular the poppets of the check valves that are mounted to the second feed port and to the third feed port are configured to prevent an inflow of flushing fluid into the respective resin chemical feed lines and into the flow tubes of the check valves.

[0026] If the adaptor unit is implemented as a one-piece, in particular monolithic, component, a particularly simple, low-cost and stable construction can advantageously be achieved. The term "one-piece" is intended to mean, in particular, materially connected, such as through a welding process and/or gluing process, etc., and particularly advantageously formed such as through production from a single casting and/or through production in a single-component or multi-component injection molding process. A monolithic component, however, is preferably made of a coherent single piece.

[0027] It is additionally proposed that the adaptor unit, in particular the manifold, is made of a corrosion-resistant material. Thereby, a high lifetime, in particular in aggressive underground mining environments, can advantageously be achieved. In particular, the material of the adaptor unit, preferably the manifold, has a high corrosion resistance under highly saline conditions. The adaptor unit, in particular the manifold, could for example be made of aluminum or of a stainless steel.

[0028] If the adaptor unit is installable in such a way to the underground rock drilling machine that an original drill length is retained, a high usability in confined mining tunnel spaces can advantageously be achieved. In particular, the possibility of a drilling of vertical holes to install roof bolts with the underground rock drilling machine is not hampered by the resin injection device at all. The "drill length" is in particular to be understood as the overall length of the drill, including the drill bit, the drill rod and the drifter.

[0029] Furthermore, a resin injection system with the resin injection device, with the drifter having the flushing head and with a drill having at least one integrated flushing channel and/or the underground rock drilling machine, in particular the roof bolter, cable bolter or drilling jumbo, comprising the resin injection system is proposed. Thereby, advantageous characteristics regarding an efficiency of resin-assisted rock anchor installations can be achieved. Advantageously, average installation times that are in the order of less than five, preferably even less than three, minutes can be achieved. Furthermore, favorable usability in confined mining tunnel spaces can advantageously be achieved. The integrated flushing channel of the drill preferably extends centrally along the longitudinal extension of the drill throughout the entire drill.

[0030] In addition, it is proposed that the flushing head comprises at least one tell-tale hole, which is configured to indicate a presence of a failure state, in particular a clogged state and/or a leaking state. Thereby a high operational safety can advantageously be achieved. In particular, the tell-tale hole is configured to provide a signal or an indication when an internal flushing seal of the flushing head starts to fail, so that the feeding of resin chemicals can be stopped completely in order to avoid an entry of water into the drifter and/or into any hydraulic system of the underground rock drilling machine. The signal or indication provided by the tell-tale hole can be a leaking of flushing fluid from the tell-tale holes to the outside of the flushing head.

[0031] Furthermore, a use of the resin injection system and/or of the underground rock drilling machine for a resin grouted installation of full material rock anchors, which are in particular different from self-drilling anchors, is proposed. Thereby, a particularly fast, easy to set up and low-cost full-material rock anchor installation can advantageously be facilitated.

[0032] Moreover, a resin injection method for underground drilling machines, for example for roof bolters, cable bolters or drilling jumbos, utilizing a drifter with a flushing head, in particular via the resin injection device, is proposed, wherein an adaptor unit, implementing a flushing-fluid and resin manifold, is directly interposed between a flushing port of the flushing head and a flushing fluid feed line of the underground rock drilling machine, and is preferably fixedly attached to the flushing head. Thereby, advantageous characteristics regarding an efficiency of resin-assisted rock anchor installations can be achieved. Advantageously, resin can be injected directly into freshly drilled anchor holes via a drill of the drifter, in particular without a need for hollow self-drilling anchors. Advantageously, all types of bolts or rock anchors, including full-material bolts, can be used with the proposed resin injection device.

[0033] Additionally, an installation method for an installation of a rock anchor, in particular via the resin injection device is proposed, wherein in a first method step, a hole is drilled into a rock surface by a drifter comprising a drill with at least one integrated flushing channel under constant or intermittent flushing of the hole, using a flushing fluid flowing through the flushing channel towards an outlet at a tip of the drill, wherein in a second method step the hole is filled with a resin mixture introduced into the hole from the outlet at the tip of the drill via the flushing channel, and wherein in a third method step the rock anchor is inserted into the resin-filled hole. Thereby, advantageous characteristics regarding an efficiency of resin-assisted rock anchor installations can be achieved. Advantageously all types of bolts or rock anchors, including full-material bolts, can be used with the proposed resin injection device. Advantageously a high installation speed can be achieved.

[0034] The resin injection device according to the invention, the resin injection system according to the invention, the underground rock drilling machine according to the invention, the use of the resin injection system according to the invention, the resin injection method according to the invention and the installation method according to the invention described herein are not to be restricted to the applications and implementation forms described above. In particular, to fulfill a functionality herein described, the resin injection device according to the invention, the resin injection system according to the invention, the underground rock drilling machine according to the invention, the use of the resin injection system according to the invention, the resin injection method according to the invention and the installation method according to the invention may comprise a number of respective elements and/or structural components and/or units and/or method steps that differs from a number herein mentioned.

DRAWINGS

[0035] Further advantages will become apparent from the following description of the drawings. In the drawings, one exemplary embodiment of the invention is depicted. The drawings, the description and the claims contain a plurality of features in combination. Someone skilled in the art will purposefully also consider the features separately and will find further expedient combinations.

[0036] It is shown in:

[0037] a schematic side view of an underground rock drilling machine with a resin injection system,

[0038] a schematic sectional drawing of a portion of a state-of-the-art drifter of the underground rock drilling machine which comprises a flushing head,

[0039] a schematic transparent top view of a resin injection device of the resin injection system,

[0040] a schematic transparent side view of the resin injection device,

[0041] a schematic exploded view of the resin injection device,

[0042] a schematic perspective view of the resin injection device, with an adaptor unit of the resin injection device being fixedly attached to the flushing head,

[0043] a schematic flowchart of an installation method for an installation of a rock anchor via the resin injection device,

[0044] Fig. 8a a schematic representation of a first method step of the installation method,

[0045] Fig. 8b a schematic representation of a first part of a second method step of the installation method,

[0046] Fig. 8c a schematic representation of a second part of the second method step of the installation method,

[0047] Fig. 8d a schematic representation of a third method step of the installation method, and

[0048] Fig. 8e a schematic representation of the rock anchor installed entirely by means of the installation method.

DESCRIPTION OF THE EXEMPLARY EMBODIMENT

[0049] Fig. 1 shows a schematic side view of an underground rock drilling machine 10. The underground rock drilling machine 10 is exemplarily embodied as a roof bolter, which amongst other features is configured to install rock anchors 68 (also called rock bolts) into ceilings 86 of mining tunnels. The underground rock drilling machine 10 comprises a movable boom 80. The underground rock drilling machine 10 comprises a resin injection system 58. The resin injection system 58, in particular the underground rock drilling machine 10, comprises a drifter 12. The resin injection system 58, in particular the underground rock drilling machine 10, comprises a drill 62. The drifter 12 is configured to operate the drill 62. The drill 62 comprises a drill rod 88, which is inserted into the drifter 12 and rotationally driven by the drifter 12. The drill 62 is hollow. The drill 62 comprises an integrated flushing channel 64 (see Fig. 2). The drifter 12 comprises a flushing head 14. The flushing head 14 is configured to introduce a flushing fluid, e. g. water, salt-water or air, into the integrated flushing channel 64 of the drill 62. The drifter 12 is attached to the boom 80.

[0050] Figure 2 schematically shows a sectional drawing of the portion of the drifter 12 which comprises the flushing head 14. The flushing head 14 shown in Fig. 2 is a standard, state-of-the-art flushing head 14. The flushing head 14 shown in Fig. 2 is an original flushing head 14. The flushing head 14 shown in Fig. 2 is an OEM flushing head 14 as is commonly used in many drifters 12. The (original) flushing head 14 comprises a flushing port 20. The flushing port 20 is implemented as a through-hole through a radial outer shell of the flushing head 14. The underground rock drilling machine 10 comprises a flushing fluid feed line 22. The flushing fluid feed line 22 is connected with a flushing fluid source or with a flushing fluid tank (not shown). The flushing fluid feed line 22 is configured to supply the flushing fluid. In the standard configuration shown in Fig. 2, the flushing fluid feed line 22 is connected to the flushing ports 20 of the flushing head 14. In the embodiment of Fig. 2 an intermediate piece 90 acts as an adaptor between the end of the flushing fluid feed line 22 and the flushing port 20. A direct mounting of the end of the flushing fluid feed line 22 without the use of an intermediate piece 90 is also conceivable. The drill 62 comprises an inlet 92, which allows the flowing of flushing fluid from inside the flushing head 14 into the integrated flushing channel 64 of the drill 62. The drill 62 comprises an outlet 94 at the opposite end of the integrated flushing channel 64, in particular at a tip of the drill 62, through which the flushing fluid conveyed by the integrated flushing channel 64 can be / is ejected. The integrated flushing channel 64 of the drill 62 is not restricted to a conveying of flushing fluid. A liquid resin or liquid resin chemicals could also be conveyed by the integrated flushing channel 64 of the drill 62.

[0051] The resin injection system 58 comprises a resin injection device 60. Figure 3 shows schematically a transparent top view of the resin injection device 60. Figure 4 shows schematically a transparent side view of the resin injection device 60. Figure 5 shows schematically an exploded view of the resin injection device 60. The resin injection device 60 comprises an adaptor unit 16. The adaptor unit 16 implements a flushing-fluid and resin manifold 18. The adaptor unit 16 is configured to be interposed directly between the flushing port 20 of the (original) flushing head 14 and the flushing fluid feed line 22 of the underground rock drilling machine 10. Referring back to Figure 2, the adaptor unit 16 basically replaces the intermediate piece 90 of Fig. 2. The adaptor unit 16 is made of a corrosion-resistant material. The adaptor unit 16 is implemented as a one-piece component. The adaptor unit 16 is implemented as a monolithic component. The adaptor unit 16 is made of a metal, in particular aluminum.

[0052] The adaptor unit 16 comprises a first feed port 30. The first feed port 30 is configured for an inlet of the flushing fluid. The first feed port 30 is configured for a connection with the end of the flushing feed line 22 of the underground rock drilling machine 10. The first feed port 30 is connected to a first feed channel 84 of the manifold 18. Via the first feed channel 84 the flushing fluid is introduced into the manifold 18. The adaptor unit 16 comprises a second feed port 32. The second feed port 32 is configured for an inlet of afirst resin chemical. The second feed port 32 is configured for a connection with an end of afirst resin chemical feed line 96 of the underground rock drilling machine 10 or of an external source. The second feed port 32 is connected to a second feed channel 98 of the manifold 18. Via the second feed channel 98 the (liquid) first resin chemical is introduced into the manifold 18. The adaptor unit 16 comprises a third feed port 34. The third feed port 34 is configured for an inlet of a second resin chemical. The second resin chemical is different from the first resin chemical. When the first resin chemical and the second resin chemical are mixed, a hardening process of the resin is initiated, leading to a solidification of the initially liquid resin chemical within a short time period (several minutes to several tens of minutes). The third feed port 34 is configured for a connection with an end of a second resin chemical feed line 100 of the underground rock drilling machine 10 or of an external source. The third feed port 34 is connected to a third feed channel 102 of the manifold 18. Via the third feed channel 102 the (liquid) second resin chemical is introduced into the manifold 18. The feed channels 84, 98, 102 are implemented as bores.

[0053] The adaptor unit 16 comprises a connection line 36. The connection line 36 is fluidically connected with the first feed port 30. The connection line 36 is fluidically connected with the second feed port 32. The connection line 36 is fluidically connected with the third feed port 34. The connection line 36 forms a fluid chamber 82 of the manifold 18, connecting all feed channels 84, 98, 102 to a discharge channel 104 of the adaptor unit 16. The adaptor unit 16 comprises a singular discharge port 38. The discharge port 38 is configured for an outlet / a discharge of the fluid that has entered the connection line 36 through one or more of the feed channels 84, 98, 102. In a flushing operation mode of the resin injection device 60, flushing fluid is discharged from the discharge port 38. In a resin grouting operation mode of the resin injection device 60, a mixture of the first resin chemical and the second resin chemical is discharged from the discharge port 38. The discharge port 38 is configured for a connection with the flushing port 20 of the flushing head 14. The discharge port 38 is connected to the discharge channel 104 of the manifold 18. Via the discharge channel 104 the fluid from the connection line 36 is discharged and exits the manifold 18. The discharge channel 104 is implemented as a bore. The resin injection device 60 comprises a plug element 106, which is configured to close the bore that forms the connection line 36 against the outside (apart from the aforementioned channels 84, 98, 102, 104). The plug element 106 is in particular not a part of the monolithic adaptor unit 16 / manifold 18. The adaptor unit 16 defines inflow directions 44 for fluids, in particular liquids, preferably the unmixed resin chemicals and/or the flushing fluid. The adaptor unit 16 defines an outflow direction 42 for fluids, in particular liquids, preferably the mixed resin chemicals and/or the flushing fluid. The outflow direction 42 out of the adaptor unit 16 is perpendicular to the inflow directions 44 into the adaptor unit 16.

[0054] The resin injection device 60 comprises check valves 46, 50, 52. The check valves are configured for preventing backflows of liquids counter to their feed directions 48. A first check valve 46 is mounted to the first feed port 30. A second check valve 50 is mounted to the second feed port 32. A third check valve 52 is mounted to the third feed port 34. All three check valves 46, 50, 52 are embodied identically. The check valves 46, 50, 52 are screwed into the respective feed channels 84, 98, 102. The check valves 46, 50, 52 comprise a poppet 54 for implementing a check mechanism. The poppet 54 is disc shaped. The poppet 54 is spring loaded. The check valves 46, 50, 52 are normally-closed check valves 46, 50, 52. The check valves 46, 50, 52 each comprise a valve seat 108. When the respective poppet 54 of a check valve 46, 50, 52 sits on its valve seat 108, flows through the respective check valve 46, 50, 52 are blocked. When the respective poppet 54 of a check valve 46, 50, 52 is lifted off its valve seat 108, flows through the respective check valve 46, 50, 52 are enabled. The check valves 46, 50, 52 are installed in the respective feed channels 84, 98, 102 in such a way that the poppet 54 protrudes into the connection line 36. The check valves 46, 50, 52 each comprise a flow tube 56. On an outside a thread 110 for the installation of the check valves 46, 50, 52 by screwing them into the respective feed channels 84, 98, 102 is cut into the flow tube 56. The feed channels 84, 98, 102 each in turn comprise an inner thread 112 that is configured to correspond with the thread 110 of the check valves 46, 50, 52. Fluid passing the check valves 46, 50, 52 is conveyed through the respective flow tube 56. The poppet 54 is arranged outside the flow tube 56 of the respective check valve 46, 50, 52. The poppet 54 is arranged in front of the flow tube 56 of the respective check valve 46, 50, 52. The valve seat 108 is arranged at an inner end of the flow tube 56 of the respective check valve 46, 50, 52.

[0055] The adaptor unit 16 is configured for a fixed attachment to the flushing head 14. Figure 6 schematically shows the resin injection device 60, with the adaptor unit 16 being fixedly attached to the flushing head 14. The adaptor unit 16 is configured for a lateral attachment to the flushing head 14. The adaptor unit 16 is laterally attached to the flushing head 14. The adaptor unit 16 is installable in such a way to the underground rock drilling machine 10 that an original drill length of its drill 62 is retained. The adaptor unit 16 is free from any contact with other parts of the drifter 12 except the flushing head 14. The flushing head 14 comprises tell-tale holes 66. The tell-tale holes 66 are configured to indicate a presence of a failure state, in particular a clogged state and/or a leaking state, of the flushing head 14 and/or the resin injection system 58.

[0056] The resin injection device 60 comprises a connection unit 24. The connection unit 24 is configured for establishing a fixed connection of the adaptor unit 16 with the flushing head 14. The connection unit 24 is implemented as a bolt, in particular a screw bolt. The connection unit 24 is implemented as a banjo bolt 26 (see Figures 3, 4 or 5). Alternatively, the connection unit 24 could also be implemented as a fluid line (hose). In that case the connection unit 24 could be implemented as a hydraulic coupling. The connection unit 24, in particular the banjo bolt 26, penetrates the adaptor unit 16, in particular the manifold 18.

[0057] The connection unit 24 is configured for guiding a resin flow and a flushing fluid flow from the adaptor unit 16 to the (original) flushing head 14. The connection unit 24, in particular the banjo bolt 26, is partially hollow. The connection unit 24, in particular the banjo bolt 26, provides an internal flow channel 118. The internal flow path of the connection unit 24 leads from the connection line 36 / the fluid chamber 82 to the discharge port 38. The discharge port 38, in particular the discharge channel 104, also forms a mounting hole for the connection unit 24, in particular for the banjo bolt 26.

[0058] The banjo bolt 26 comprises a bolt head 40. The bolt head 40 is configured to seal the discharge channel 104 and/or the mounting hole for the connection unit 24 from a side 114 of the adaptor unit 16 opposing a side 116 of the adaptor unit 16 that contacts the flushing head 14 in the mounted state of the resin injection device 60. The bolt head 40 additionally comprises a tool surface for an application of an installation tool, e. g. a wrench. The banjo bolt 26 comprises one or more lateral inlet holes 120. The inlet holes 120 allow a fluid flow into the internal flow channel 118 of the banjo bolt 26. The inlet holes 120 are arranged in a middle region of the longitudinal extension of the banjo bolt 26. The inlet holes 120 of the banjo bolt 26 are arranged in a region of the banjo bolt 26 which in the mounted state is located inside the adaptor unit 16. The inlet holes 120 of the banjo bolt 26 are fluidically connected to the connection line 36 / the fluid chamber 82 in the mounted state. The banjo bolt 26 comprises an end region 122, which in the mounted state protrudes out of the adaptor unit 16. The end region 122 is configured to be installed into the flushing port 20 of the flushing head 14 in the mounted state. The connection unit 24 comprises a mounting element 28 for mounting the connection unit 24 to the flushing head 14, in particular to the flushing port 20 of the flushing head 14. The mounting element 28 can be implemented as a screw thread or as a press-fit element or similar. The mounting element 28 is basically identical to a standardized mounting element 124 (see e.g. Fig. 2) of the flushing fluid feed lines 22 of underground rock drilling machines 10. The end region 122 of the banjo bolt 26 comprises an opening 126 of the integrated flow channel 118 through which the fluids that entered the flow channel 118 through the inlet holes 120 can exit the flow channel 118. The opening 126 allows an outflow in a direction parallel to a longitudinal extension direction of the banjo bolt 26, in particular in the outflow direction 42 of the adaptor unit 16. The connection unit 24 may be the only element through which the fixed connection of the resin injection device 60 with the flushing head 14 is established. Alternatively, the resin injection device 60 could comprise additional connection elements besides the connection unit 24. The adaptor unit 16 shown in Figures 3 and 5 exemplarily comprises two further mounting holes 128, which could be used with such additional connection elements.

[0059] Figure 7 shows a schematic flowchart of an installation method for an installation of a rock anchor 68 via the resin injection device 60. The installation method comprises a resin injection method for underground rock drilling machines 10 that uses the resin injection system 58 of the underground rock drilling machine 10 for a resin grouted installation of the rock anchors 68. The installation method can be applied for all types of rock anchors 68. The installation method can be applied for full-material rock anchors 68. The installation method can be applied for rock anchors 68 that are different from self drilling anchors. Figures 8a to 8e schematically show important steps of the installation method.

[0060] In a first method step 70, a hole 72 is drilled into a rock surface 74 by the drifter 12 of the underground rock drilling machine 10. The drifter 12 comprises the drill 62 with the integrated flushing channel 64. In the first method step 70, the hole 72 is drilled under constant or under intermittent flushing of the hole 72 using the flushing fluid flowing through the integrated flushing channel 64 towards the outlet 94 at the tip of the drill 62 (see also Fig. 8a). During the first method step 70, the check valves 50, 52 that are installed at the second feed port 32 and the third feed port 34 are closed due to the pressure of the flushing fluid inside the connection line 36 being larger than the pressure in the resin chemical feed lines 96, 100. During the first method step 70, the check valve 46 that is installed at the first feed port 30 is open due to the pressure of the flushing fluid in the flushing fluid feed line 22 being approximately equal to or larger than the pressure in the connection line 36 and larger than the force with which the respective spring-loaded poppet 54 is held on its valve seat 108. These pressure differences and thus this setting state of the adaptor unit 16 are achieved by controlling the pressures inside the three feed lines 22, 96, 100 that are connected to the adaptor unit 16.

[0061] In a second method step 76, the hole 72 is then filled with the mixture of the two resin chemicals. The mixture of the two resin chemicals is introduced into the drilled and flushed hole 72 from the outlet 94 at the tip of the drill 62 via the flushing channel 64 (see also Fig. 8b). The switch from the ejection of flushing fluid to an ejection of the mixture of the two resin chemicals is controlled by the adaptor unit 16 and by adjusting the pressures inside the three feed lines 22, 96, 100 that are connected to the adaptor unit 16. During the second method step 76, the check valves 50, 52 installed at the second feed port 32 and the third feed port 34 are open due to the pressure of the resin chemicals in the respective resin chemical feed lines 96, 100 being approximately equal to or larger than the pressure in the connection line 36 and larger than the force with which the respective spring-loaded poppets 54 are held on their valve seats 108. During the second method step 76, the check valve 46 installed at the first feed port 30 is closed due to the pressure of the flushing fluid inside the flushing fluid feed line 22 being smaller than the pressure in the connection line 36. These pressure differences and thus this setting state of the adaptor unit 16 are achieved by adjusting the pressures inside the three feed lines 22, 96, 100 that are connected to the adaptor unit 16. In the second method step 76, the drill 62 is slowly pulled out of the hole 72 while continuously ejecting the mixture of the two resin chemicals into the hole 72 until the hole 72 is completely or almost completely filled with said mixture (see Fig. 8c).

[0062] In a third method step 78, the rock anchor 68 is inserted into the resin-filled hole 72 (see Fig. 8d). During the third method step 78, no fluid is ejected by the drill 62. All check valves 46, 50, 52 of the adaptor unit 16 are closed due to the pressures in all feed lines 22, 96, 100 being smaller than the force with which the spring-loaded poppets 54 of all check valves 46, 50, 52 are held on their valve seats 108. This setting state of the adaptor unit 16 is achieved by further adjusting the pressures inside the three feed lines 22, 96, 100 that are connected to the adaptor unit 16. The rock anchor 68 could be inserted using the same boom 80 of the underground rock drilling machine 10 that was used to drill the hole 72 or by another second boom 80' of the underground rock drilling machine 10. When the rock anchor 68 is inserted completely into the hole 72, the mixture of the two resin chemicals solidifies.

[0063] In a fourth method step 130, a holding plate 132 is attached to the part of the installed rock anchor 68 which sticks out of the hole 72 (see Fig 8e). The holding plate 132 could be secured by a nut 134 that is threaded onto the rock anchor 68. The holding plate 132 could be used to mount a net or a wire mesh or similar (not shown) to the rock surface

74. The described rock anchor installation process on average takes less than five minutes, preferably approximately three minutes.

REFERENCE NUMERALS

Underground rock drilling machine 12 Drifter 14 Flushing head 16 Adaptor unit 18 Manifold Flushing port 22 Feed line 24 Connection unit 26 Banjo bolt 28 Mounting element Feed port 32 Feed port 34 Feed port 36 Connection line 38 Discharge port Bolt head 42 Outflow direction 44 Inflow direction 46 Check valve 48 Feed direction Check valve 52 Check valve 54 Poppet 56 Flow tube 58 Resin injection system Resin injection device 62 Drill 64 Flushing channel 66 Tell-tale hole

68 Rock anchor Method step 72 Hole 74 Rock surface 76 Method step 78 Method step Boom 82 Fluid chamber 84 Feed channel 86 Ceiling 88 Drill rod Intermediate piece 92 Inlet 94 Outlet 96 Feed line 98 Feed channel 100 Feed line 102 Feed channel 104 Discharge channel 106 Plug element 108 Valve seat 110 Thread 112 Thread 114 Side 116 Side 118 Flow channel 120 Inlet hole 122 End region 124 Mounting element 126 Opening 128 Mounting hole

130 Method step 132 Holding plate 134 Nut

Claims (28)

1. Resin injection device for an underground rock drilling machine, having at least one drifter with a flushing head, which forms an integral part of the drifter and which is configured for supplying of a flushing fluid to an integrated flushing channel of a drill, wherein an adaptor unit implementing a flushing-fluid and resin manifold, which is configured to be interposed directly between a flushing port of the flushing head and a flushing fluid feed line of the underground rock drilling machine, wherein the adaptor unit is configured for a fixed attachment to the flushing head of the drifter.

2. Resin injection device according to claim 1, comprising at least one connection unit, for establishing a fixed connection with the flushing head.

3. Resin injection device according to claim 2, wherein the connection unit is selected from a bolt, screw, fluid line, hose, banjo bolt or hydraulic coupling.

4. Resin injection device according to any one of claims 2 to 3, wherein the connection unit is configured for guiding a resin flow and a flushing fluid flow from the adaptor unit to the flushing head.

5. Resin injection device according to any one of claims 2 to 4, wherein the connection unit comprises a mounting element, which is basically identical to a standardized mounting element (124) of the flushing fluid feed lines of underground rock drilling machines.

6. Resin injection device according to any one of the preceding claims, wherein the adaptor unit is configured for a lateral attachment to the flushing head.

7. Resin injection device according to any one of the preceding claims, wherein the adaptor unit is free from any contact with other parts of the drifter except the flushing head.

8. Resin injection device according to any one of the preceding claims, wherein the adaptor unit comprises a first feed port for the flushing fluid and a second feed port for a resin chemical.

9. Resin injection device according to claim 8, wherein the adaptor unit further comprises a third feed port for a second resin chemical, which is different from the first resin chemical.

10. Resin injection device according to claim 8 or 9, wherein the adaptor unit comprises a connection line, which is in fluidic connection with at least the first feed port and the second feed port.

11. Resin injection device according to claim 10, wherein the connection line is in fluidic connection with the third feed port.

12. Resin injection device according to any one of the preceding claims, wherein the adaptor unit comprises one or more discharge port(s).

13. Resin injection device according to claim 12 when appended from any one of claims 2 to 5, wherein the one or more discharge port(s) also forms a mounting hole for the connection unit.

14. Resin injection device according to any one of the preceding claims, wherein an outflow direction of fluids out of the adaptor unit is at least substantially perpendicular to inflow directions of fluids.

15. Resin injection device according to any one of the preceding claims, comprising at least one check valve, which is configured for preventing a backflow of fluids, in particular of resin chemicals, counter to a feed direction.

16. Resin injection device according to claim 15 when appended from claim 8, wherein a first check valve is mounted to the first feed port and that a second check valve is mounted to the second feed port; or, the resin injection device according to claim 15 when appended from claim 9, wherein a first check valve is mounted to the first feed port and that a second check valve is mounted to the second feed port and that a third check valve is mounted to the third feed port.

17. Resin injection device according to claim 15 or 16, wherein the check valve(s) comprises/comprise a, disc-like poppet for implementing a check mechanism.

18. Resin injection device according to claim 17, wherein the poppet is arranged outside a flow tube of the check valve(s).

19. Resin injection device according to any one of the preceding claims, wherein the adaptor unit is implemented as a one-piece and/or monolithic, component.

20. Resin injection device according to any one of the preceding claims, wherein the adaptor unit is made of a corrosion-resistant material.

21. Resin injection device according to any one of the preceding claims, wherein the adaptor unit is installable in such a way at the underground rock drilling machine that an original drill length is retained.

22. Resin injection system with a resin injection device according to any one of the preceding claims and with the flushing head.

23. Resin injection system according to claim 22, further comprising the drifter with the flushing head and a drill with at least one integrated flushing channel.

24. Resin injection system according to claim 22 or 23, wherein the flushing head comprises at least one tell-tale hole, which is configured to indicate a presence of a failure state.

25. Underground rock drilling machine, comprising a resin injection system according to any one of claims 22 to 24.

26. Use of a resin injection system according to any one of claims 22 to 24 and/or of an underground rock drilling machine according to claim 25 for a resin grouted installation of full-material rock anchors.

27. Resin injection method for underground drilling machines, utilizing a drifter with a flushing head via a resin injection device according to any one of claims I to 21, wherein the adaptor unit, implementing the flushing-fluid and resin manifold, is directly interposed between the flushing port of the flushing head and the flushing fluid feed line of the underground rock drilling machine, wherein the adaptor unit is fixedly attached to the flushing head of the drifter.

28. Installation method for an installation of a rock anchor via a resin injection device according to any one of claims 1 to 21, wherein in a first method step, a hole is drilled into a rock surface by a drifter comprising a drill with at least one integrated flushing channel under constant or intermittent flushing of the hole, using a flushing fluid flowing through the flushing channel towards an outlet at a tip of the drill, wherein in a second method step the hole is filled with a resin mixture introduced into the hole from the outlet at the tip of the drill via the flushing channel, and wherein in a third method step the rock anchor is inserted into the resin filled hole.

GEO 16915 AU 2023241265 03 Oct 2023

1/7 03 Oct 2023

Fig. 1

74,86 68 80 14 16 2023241265

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88 62 58

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