WO2002018749A1

WO2002018749A1 - An apparatus for installing a support assembly for a rock structure

Info

Publication number: WO2002018749A1
Application number: PCT/AU2001/001095
Authority: WO
Inventors: Jock Bernard Cunningham; Ian David Gipps
Original assignee: Commonwealth Scientific and Industrial Research Organization CSIRO
Current assignee: Commonwealth Scientific and Industrial Research Organization CSIRO
Priority date: 2000-09-01
Filing date: 2001-08-31
Publication date: 2002-03-07
Anticipated expiration: 2003-03-01
Also published as: AUPQ989600A0

Abstract

An apparatus for installing a support assembly for a rock structure, the apparatus comprising a data collection means (30) for collecting rock data, being data relating to a rock structure to be supported, a transmitter (35) for transmitting the rock data to a processor (33), which is adapted to process the rock data and output support assembly data, being data for installing a preferred support assembly for the rock structure, installation means (13, 18, 20) for installing the preferred support assembly and a controller for communicating with the processor (38) and controlling the installation means to install the preferred support assembly.

Description

AN APPARATUS FOR INSTALLING A SUPPORT ASSEMBLY FOR A ROCK

STRUCTURE FIELD OF THE INVENTION

The present invention relates to the mining industry but is also applicable to other industries where the provision of adequate rock support is an issue.

It should be noted that reference to "rock" should be interpreted broadly and is intended to cover any geological substance or material . BACKGROUND OF THE INVENTION

Ground support installation is an important part of the mining cycle in underground mining and civil excavation. It is an essential component in the cycle to ensure that the areas that have been excavated and that will be used for movement of people, materials and equipment are safe. The development cycle for excavating underground tunnels consists of three components: a) Rock breakage (either drill and blast or mechanised rock cutting) ; b) Excavation (broken rock removal); and c) Installation of ground support. The rock surrounding excavations in underground mining and tunnelling normally needs support to prevent unintended collapse of the rock structure. Such collapse is hazardous to people and equipment. The ground support is often provided by rockbolts or cablebolts of various types and also may include, meshing and/or strapping made from various materials including steel, sprayed cement mixtures, concrete, sprayed support plastic coatings, steel and/or wood sets, synthetic fibres or other similar mechanisms. Use of prior apparatus and methods for the installation of these various rock support means can expose the operators involved in the process to the risk of injury or death if rock fails before the support is fully installed. Both the operators involved in the installation and other mine operators are also at risk of injury or death if the support/reinforcement is insufficient to secure the rock.

Current systems to remove rock and install rock support are deficient because there may be an unacceptable level of risk of injury or death to operators and damage to equipment during the installation. The evidence for this can be found in mining accident records.

For example scaling machines are required for preparing a rock face before installation of ground support . Such machines are large and inherently very- dangerous because the operator's cabin may be only five metres away from the working head of the sealer.

When the scaling operation is completed a bolting machine is then required. As with the scaling machine the bolting machine requires an operator cabin which forms a significant proportion of the machine.

Because the boom works some distance away from the operator cabin the machine requires counter balance control and this leads to an overall bulky and heavy machine which is cumbersome to use.

A further deficiency with the current process for installation of ground support arises at the design stage. Currently a high proportion of installed ground support is in excess of the necessary requirements to maintain stability. Uncertainty about the requirements arise because of inadequate information about the rock characteristics in the specific location of interest. Therefore the design is often based on typical conditions for the area concerned. Typically, this can lead to excess ground support being installed in some areas and insufficient in other areas, or the ground support is installed according to a standard pattern that is in excess to almost all requirements in order to minimise hazards. This current method represents a waste of resources .

The present invention is aimed at providing an alternative apparatus and method for dealing with issues relating to installation of support for a rock structure such as a rock face.

According to the present invention there is provided an apparatus for installing a support assembly for a rock structure, the apparatus comprising a data collection means for collecting rock data, being data relating to a rock structure to be supported, a transmitter for transmitting the rock data to a processor which is adapted to process the rock data and output support assembly data, being data for installing a preferred support assembly for the rock structure, installation means for installing the preferred support assembly and a controller for communicating with the processor and controlling the installation means to install the preferred support assembly.

It is preferred that the apparatus is mobile. According to one embodiment the apparatus is in the form of a vehicle having various components for installing a support assembly. The controller preferably controls the data collection means and the transmitter.

The apparatus may include the processor.

Alternatively the processor is remotely located from the apparatus and is able to communicate with the controller.

Preferably the processor is adapted to produce a model support assembly for the rock structure .

The controller may be adapted to control the installation means to install a support assembly in accordance with the model support assembly.

Preferably the support assembly includes a structure, frame, individual supports, a system or any predetermined arrangement of items required to support a rock structure . Preferably the controller controls movement of the apparatus .

Preferably the apparatus includes a navigation means for navigation of the apparatus from one location to another.

According to another embodiment the apparatus is remote controlled. According to an alternative embodiment the apparatus includes a driving cabin for an operator to control operations of the apparatus .

According to another embodiment the apparatus is fully automated and has a degree of intelligence to enable it to install a support assembly for a rock structure.

The navigation means may include a visual monitoring means for monitoring features surrounding the apparatus .

Preferably the visual monitoring means comprises at least one or more independent digital cameras.

According to another embodiment the navigation means includes two digital cameras spaced apart to provide stereo vision imaging.

The monitoring means preferably includes a monitor for monitoring operation of devices of the apparatus .

Preferably the processor means includes a first reference means including a first set of rules based on operational experience, rock data and experimentation to determine which surface rocks must be removed prior to installation of the rock support assembly.

The processor means may include a means for surveying to locate jointing sets of the rock structure.

The processor means may include a second reference means including a second set of rules to estimate jointing characteristics of rock behind the surface of the rock structure .

Preferably the processor means includes a third reference means including a third set of rules to estimate the stability of the rock structure.

According to another embodiment of the present invention the processor means includes a fourth reference means including a fourth set of rules to determine type, location and arrangement of bolts and mesh which are to be installed by the installation means .

The navigation means may include a map memory for storing a map of an area in which the apparatus is to operate .

Each of the reference means preferably include stored algorithms which are adapted to determine different aspects of operation of the apparatus. The navigation means may include laser profiling or photogrammetry to reach an area in which a support assembly is required.

The data collection means may include detection means for detecting the location of any existing rock support.

The data collection means preferably includes visual/optical sensors for recording data relating to a surface profile of the rock structure.

The data collection means preferably includes sensors for detecting structural flaws/weaknesses in the rock structure .

The data collection means include sensors for detecting geometrical features of the rock and including the pattern of jointing between separate rock components that join together to comprise the rock face. Typical rock surfaces comprise the packing and interlocking of smaller rocks into an assembly of rocks that form the rock face.

The processor may include means for processing feed back data from the installation means.

The controller preferably controls components of the apparatus in accordance with instructions which may be stored in the processor or alternatively received from a remote control source. The data collection means may include sensors on one or more arms .

The data collection means preferably includes sensors with optical, or electromagnetic sources for measuring reflected electromagnetic radiation.

The data collection means preferably includes a first scanning laser for scanning the rock structure whereby scanning data transmitted by the scanning laser to the processor can be used by the processor to generate- a three dimensional map of the rock structure and preferably the location of components of the apparatus relative to a reference point . Preferably the transmitter is part of the data collection means.

Installation means preferably includes a drilling and bolting device.

The installation means may also include a grouting device.

The installation means may also include a mesh device for supplying support mesh across the face of the rock structure .

The mesh device may include a roll for holding the support mesh.

Preferably the mesh device includes a joint arm for manipulating the support mesh when it is being installed.

The installation means preferably includes a scaling device.

The scaling device preferably comprises an arm with a working tool located on its distal end.

The apparatus preferably includes a scanning means for stopping operation of the installation means. The scanning means is preferably adapted to sense movement of a person and stop operation of the installation means if movement of a person is detected.

The scanning means may comprise a beam of electromagnetic radiation which triggers a switch if the beam is interrupted.

It is preferred that the installation means includes means for drilling holes into the rock for the anchorage system.

It is preferred that the installation means includes a device for installing an anchorage system into said holes in the rock structure and/or installing plates at the hole entrance to support the rock and hold any mesh in position.

It is preferred that the installation means includes means for placing grout into the hole for securing the bolt.

Grout may also be included with the anchorage means in a pre-packed capsule that alleviates the need for placing means .

It is preferred that the processor is adapted to produce a model layout/arrangement of support devices required in the support assembly for the rock structure. It should be noted that the support assembly is intended to be interpreted broadly to cover any type of support devices or components.

The words "comprising, having, including" should be interpreted in an inclusive sense, meaning that additional features may also be added.

According to another aspect of the present invention there is provided a method of installing a support assembly for a rock structure, the method including the step of providing an apparatus according to any one of the previously described embodiments, controlling the apparatus to move to a predetermined location opposite a rock structure, collecting rock data form the data collection means, processing the rock data collected, producing a model preferred support assembly for the rock structure and operating the installation means to install the preferred support assembly for the rock structure .

BRIEF DESCRIPTION OF THE DRAWINGS

A preferred embodiment of the present invention will be described by way of example only with reference with the accompany drawings in which:

Figure 1 shows a schematic diagram of a vehicle in accordance with the preferred embodiment of the present invention in a first mode of operation;

Figure 2 shows the vehicle shown in Figure 1 in a second mode of operation; Figures 3a to 3d show different modes of operation of the vehicle shown in Figure 1; and

Figure 4 shows a schematic diagram of control and instrumentation functions of the vehicle shown in Figure 1. DETAILED DESCRIPTION OF THE DRAWINGS

As shown in Figures 1 and 2 the vehicle 10 consists of a vehicle chassis 11 with four wheels 12.

It is preferred that the vehicle uses four wheel drive and steering to provide maximum manoeuvrability. It is preferred that each wheel has independently controlled wheel motors. This has the advantage of providing an opportunity to control the slip on each wheel and provide accurate turning and traction with the road way. The wheels 12 on the front axial may be aligned independently from the rear axial before or during motion. This also provides the capability of crab-like motion that will be useful to position the vehicle accurately. * The vehicle 10 also includes a scaling arm 13 which is located at one end 14 of the vehicle 10.

The scaling arm 13 is jointed to allow articulation to obtain the correct angle of attack for rotary cutter 15 located on its distal end.

The rotary cutter 15 may be of various designs and can be hydraulically, pneumatically or electrically driven.

In addition the rotary cutter may be a water-jet cutter or pick.

A drilling and bolting tool assembly 16 is located at the same end of the vehicle 10. This assembly includes three tools, each to drill, bolt and grout.

These tools are indexed into position as required and controlled by a control computer.

Support arm extensions or stingers (not shown) that extend between the assembly and adjacent rock walls hold the tools in a stable position during operation. The support arm 18 for the assembly is jointed so that the assembly can be manipulated into the correct orientation.

A spare drill steel and bit assembly will be loaded on the drifter arm to be used as required. Support mesh is supplied from a roll 19. A jointed (articulated) arm 20 is used to unroll the mesh from the roll 19 across the rock face which is to be supported.

Instruments mounted in all or some of the joints and hydraulic cylinders used to manipulate the components, measure the extent of movement from the initial position.

The control computer integrates data from each of the components described above and assists in calculation of the position of each component (tool) . As shown in Figure 4, an instrument pod 30 is located on the vehicle as part of the driver canopy. This includes a scanning laser 31 that projects a laser beam towards the rock face and scans it through an arc of 180° from side to side at a rate of approximately 25 per seconds. When the beam strikes a target (rock of a part of the vehicle or implements) the range is determined using the time-of-flight of the laser light and the bearing of the target is determined from a rotary encoder. The laser assembly is then rotated to direct the virtual laser plane from front to back of the vehicle through an arc (azimuth) that is determined by the control computer according to requirements .

The range and bearing and azimuth is recorded and used to build a three dimensional map (geometry) of the surrounding rock face and the location of the machine implements relative to a datum point on the machine.

The scanning laser 31 is used with the joint instrumentation to provide geometrical information about each tool at a rate suitable for guiding and controlling the vehicle and implements-typically ten times per second.

A second scanning safety laser 39 mounted at the opposite end of the vehicle 10 from the bolting and scaling arms is oriented to face towards the approach access when the vehicle is positioned to install the ground support system.

The plane of the laser is directed so that a person who approaches the vehicle when it is in automatic or remote control mode will cross the beam of the laser, raising an alarm that will cease all operation of the machine .

Two digital cameras 32 are also mounted on the instrument pod 30 and these are used to measure the geometry of the surrounding rock to a finer scale but a slower rate than offered by the scanning laser.

The cameras 32 are spaced apart to provide two photographs of the rock to create stereo photogrammetric images that are recorded digitally by control computer 33 that may also compute the rock joint-set characteristics.

An operator platform 37 is mounted at one end of the vehicle and is fitted with control actuators so that a person can manually drive the vehicle 10 for the purpose of locomotion when autonomous location is prohibited or not appropriate .

Video cameras 34 are mounted on the vehicle 10 to monitor operation of the moving components and for driving (locomotion) of the vehicle 10 by teleoperation if required.

At least one camera 34 has provision for zoom, pan and tilt control.

The control computer 33 is connected to a communication system 35 that transmits to and receives from the remote operators control cabin 36. The remote operators cabin 36 may be located at any convenient and safe location according to operation requirements. From this location the operator may operate the equipment in a teleoperation mode or supervise the autonomous operation.

In teleoperation mode the operator controls the vehicle by watching video images from the cameras 34 mounted on the vehicle.

A typical operating cycle for the machine is described as follows with a typical diagrammatic sequence shown by Figure 3A to Figure 3D. Thus the vehicle will advance towards the final location using either remote operation or automated control .

During the advance the computer system 33 logs data from the scanning laser 31, photogrammetry sensors 32, wheel steering angle and odometry instrumentation.

At suitable periods that are related to the speed of the vehicle, a geometrical map of the excavation, the location of the vehicle with respect to the geometry, and the location of the existing ground support is identified and logged.

The final location will be an area in which no existing support is present or in which existing support is not sufficient to meet future requirements.

In order to determine this location the machine monitors the presence and quantity of bolts and mesh (and other support systems) on the walls and roof and compares this with the requirements.

The existing support (or lack of) is measured by locating mesh and rock bolts, concrete and steel or wood sets using optical recognition.

Once the vehicle 10 has reached the area that needs rock support as shown in Figure 3A and reinforcement photogrammetric images of the rock surface are recorded from the stereo cameras . The images are processed using algorithms from

Siro- oint Technology (or similar algorithms) thus providing statistical data that describes the manner in which rocks are jointed together. A set of rules based on operational experience and experimentation is applied to the geometrical shape, texture and joint-set data of the rock face to identify which surface rocks must be removed prior to ground support installation. Once the identified rock has been removed from the rock surface the area may be resurveyed using photogrammetry to locate the jointing sets of the rock surface. Another set of rules based on operational experience and experimentation is applied to joint set data to estimate the jointing characteristics of the rock behind the surface and thus predicts the stability of the rock face using algorithms from Rock Technology that have been programmed into the central control computer 33. From the rock stability data, a further set of rules that is programmed into the central computer 33 are used to determine the type and arrangement of bolts and mesh and the precise location of the bolts and mesh that is required to support the surface. This support design may be transmitted back to the human operator for authorisation or modification. If such an option is exercised, the remainder of the cycle is initiated by the human operator by returning the modified pattern by the communication means or by returning a GO signal. The machine then begins the installation of the ground support. At this time the vehicle is supported by the support jacks 38.

As shown in Figure 3B if mesh support is required the meshing arm is extended up and moves forward to the front of the machine so that the mesh can be placed near the rock surface above the bolting arm. Some mesh will then be advanced out of the mesh holder so that it can be held against the rock face by the bolting arm while the first bolts are placed.

As shown in Figure 3C the bolting arm will position itself to first drill a hole, insert any required grout and then place a bolt, or bolt and anchor, with attached plate. If post grouting is to be installed during the process it will be pumped in after the bolt has been inserted. In the preferred configuration the hole will be drilled and the bolt with grout or anchor inserted without moving the boom away from the hole . After the start of the mesh has been fixed in position by the initial bolts, the mesh roll advances ahead of the bolting boom laying mesh across the rock surface. As the mesh advances past the position assigned for the bolt, the advance is paused and another bolt is installed. When all the bolts and mesh in the arc have been installed, the mesh is cut and the arms return to their travel positions.

The preferred embodiment of the invention has been described in relation to a wheeled vehicle as shown in Figures 1 to 4. It should also be noted that the invention encompasses tracked vehicles, vehicles on rails and a portable apparatus which is able to be located on a moveable platform.

In addition the location of the various moveable components, such as arm supporting the mesh roller, the drilling and bolting tool and the rotary cutter 15 may also be varied to suit a particular application of the apparatus. Furthermore the invention contemplates additional features being added to the apparatus/vehicle 10.

It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or in any other country.

Claims

1. An apparatus for installing a support assembly for a rock structure, the apparatus comprising a data collection means for collecting rock data, being data relating to a rock structure to be supported, a transmitter for transmitting the rock data to a processor, which is adapted to process the rock data and output support assembly data, being data for installing a preferred support assembly for the rock structure, installation means for installing the preferred support assembly and a controller for communicating with the processor and controlling the installation means to install the preferred support assembly.

2. The apparatus as claimed in claim 1 including motion means to permit the apparatus to move from one location to another.

3. The apparatus as claimed in claim 1 or 2 including a navigation means for navigation of the apparatus from one location to another.

4. The apparatus as claimed in claim 3 wherein the navigation means includes a visual monitoring means for monitoring the features surrounding the apparatus .

5. The apparatus as claimed in claim 4 wherein the visual monitoring means comprises at least one or more independent digital cameras.

6. The apparatus as claimed in any one of the preceding claims wherein the monitoring means includes a monitor for monitoring operation of devices of the apparatus .

7. The apparatus as claimed in any one of the preceding claims including the processor which is adapted to produce a model support assembly for the rock structure .

8. The apparatus as claimed in claim 7 wherein the processor includes a first reference means including a first set of rules based on operational experience, rock data and experimentation which is able to be utilised to determine which surface rocks must be removed prior to installation of the rock support assembly.

9. The apparatus as claimed in claim 7 or 8 wherein the processor includes a means for surveying two or more located jointing sets of the rock structure.

10. The apparatus as claimed in claim 9 wherein the processor includes a second reference means including a second set of rules to estimate jointing characteristics of rock behind the surface of the rock structure.

11. The apparatus as claimed in claim 10 wherein the processor includes a third reference means including a third set of rules to estimate the stability of the rock structure.

12. The apparatus as claimed in claim 11 including a fourth reference means including a fourth set of rules to determine type, location and arrangement of bolts and mesh which are to be installed by the installation means.

13. The apparatus as claimed in claim 5 wherein the navigation means includes a memory for storing a map of an area in which the apparatus is to operate.

14. The apparatus as claimed in claim 12 wherein each of the reference means incliides stored algorithms which are adapted to determine different aspects of operation of the apparatus.

15. The apparatus as claimed in claim 13 wherein the navigation means includes laser profiling or photogrammetry to reach an area in which a support assembly is required.

16. The apparatus as claimed in any one of the preceding claims wherein the data collection means includes detection means for detecting the location of any existing rock support.

17. The apparatus as claimed in claim 16 wherein the data collection means includes optical sensors for recording data relating to a surface profile of the rock structure.

18. The apparatus as claimed in claim 17 wherein the data collection means includes sensors for detecting structural flaws in the rock structure.

19. The apparatus as claimed in claim 17 or 18 wherein the data collection means includes sensors for detecting geometrical features of the rock and including the pattern or jointing between separate rock components that joint together to comprise the rock face.

20. The apparatus as claimed in any one of the preceding claims wherein the controller controls components of the apparatus in accordance with instructions which may be stored in the processor.

21. The apparatus as claimed in claim 20 wherein the data collection means includes a first scanning laser for scanning the rock structure whereby scanning data transmitted by the scanning laser to the processor can be used by the processor to generate a three dimensional map of the rock structure and the location of components of the apparatus relative to a reference point.

22. The apparatus as claimed in any one of the preceding claims wherein the installation means includes a drilling and bolting device.

23. The apparatus as claimed in claim 22 wherein the installation means includes a grouting device.

24. The apparatus as claimed in claim 23 wherein the installation means includes a mesh device for supplying support mesh across the face of the rock structure.

25. The apparatus as claimed in claim 24 wherein the mesh device includes a roll for holding the support mesh.

26. The apparatus as claimed in claim 25 wherein the mesh device includes a joint arm for manipulating the support mesh when it is being installed.

27. The apparatus as claimed in claim 26 wherein the installation means includes a scaling device having an arm with a working tool located on its distal end .

28. The apparatus as claimed in claim 27 including a scanning means for stopping operation of the installation means.

29. The apparatus as claimed in claim 28 wherein the scanning means is adapted to sense movement of a person and stop operation of the installation means if movement of a person is detected.

30. The apparatus as claimed in claim 29 wherein the scanning means comprises a beam of electromagnetic radiation which is adapted to trigger a switch if the beam is interrupted.

31. The apparatus as claimed in claim 27 wherein the installation means includes means for drilling holes into the rock for an anchorage system to be installed.