Apparatuses and methods for dispensing, assembling and installing bolts

Abstract

There is provides an apparatus and method for dispensing bolts. The bolt dispensing apparatus comprises a frame, a bolt store configured to store a plurality of bolts, each bolt having a head and a shaft, wherein the heads of the plurality of bolts are positioned near a first end of the bolt store and the tips of the plurality of bolts are positioned near a second end of the bolt store opposite the first end, a bolt singulator attached to the frame for retrieving a bolt from the bolt store, the singulator comprising a bolt pickup configured to engage the bolt at a first location on the bolt, and a separator configured to engage the bolt, and move in a longitudinal direction from an initial position proximate to the bolt pickup to a second position distal to the bolt pickup. The dispensed bolts may be assembled into a bolt assembly.

Description

APPARATUSES AND METHODS FOR DISPENSING, ASSEMBLING AND INSTALLING BOLTSFIELD OF THE INVENTION

[0001] The invention relates to apparatuses and methods for dispensing bolt assemblies. In particular, the invention relates to apparatuses and methods for dispensing and assembling components of bolt assemblies.BACKGROUND

[0002] In mining, tunneling, and other underground excavations, rock bolts (also known more generally as anchor bolts), are used to support and stabilize excavations. Stresses induced through excavation can cause fractures and separation of geological material from the roof and sidewalls. This can lead to dangerous ground falls -- collapses of portions of the roof or sidewalls -- causing damage to equipment and potentially fatal injuries to people. In some instances, rock bolts transfer load from unstable exterior rocks to confined (and more stable) interior rocks. By “knitting” the disjointed rock mass together, it remains locked in place preventing failure. In other instances, the boundaries between layers of sedimentary rock form planes of weakness. Rock bolts laminate multiple thin, weak layers of rock into a stronger and more stable beam.

[0003] A rock bolt is typically installed as a bolt assembly 10 that includes a bolt 20, plate 30, and an expansion shell anchor 40 (see FIG. 13A). The bolt 20 includes a head 22 at a proximal end 22A and a shaft 24 terminates at a tip on a distal end 24A. The shaft may include threads 25 at the distal end 24A to engage the expansion shell anchor 40. The bolting machine must be reloaded after a bolt assembly is installed. This may require a mining machine to be paused to prevent it from removing too much material and extending the bore without sufficient reinforcement of the roof and / or walls. Additionally, the bolting machine may need to be moved away from the mining face to a location where the operator can reload the bolting machine with bolt assemblies with less risk of the collapse of the roof and / or walls. Although some conventional bolting machines have small carousels loaded with pre-assembled bolt assemblies 10 that are dispensed to the bolting machine in operation, the carousels often have limited capacity and must still be frequently reloaded.

[0004] Further, bolt assemblies are often assembled manually at a location away from an active mining site and brought to the site. These assemblies are irregularly shaped and not easily packed in a space-efficient configuration that reduces volume. This can make transportation of the assemblies a resource intensive exercise, especially if multiple trips are required to transportmaterials in underground mining operations where there are limited numbers of elevators to transport materials from the surface to a mining location.

[0005] Although components of the bolt assembly 10 may be packed separately to reduce their bulk, for example, by stacking plates 30, and gathering the bolts 20 and anchors 40 into piles, these components would still need to be assembled at the mining location, which can introduce significant labour.

[0006] There exists a need for improved methods of installing bolt assemblies.SUMMARY

[0007] In an aspect, there is provided a bolt dispenser. The bolt dispenser comprises a frame, a bolt store configured to store a plurality of bolts, and a bolt singulator attached to the frame for retrieving a bolt from the bolt store. Each bolt has a head at one end and a shaft that terminates in a tip at the other end, and the heads of the plurality of bolts are positioned near a first end of the bolt store and the tips of the plurality of bolts are positioned near a second end of the bolt store opposite the first end. The bolt singulator comprises a bolt pickup configured to engage the bolt at a first location on the bolt, and a separator configured to engage the bolt, and move in a longitudinal direction from an initial position proximate to the bolt pickup to a second position distal to the bolt pickup.

[0008] In some embodiments, the bolt dispenser further comprises a positioner connected to the frame, the positioner configured to move the bolt pickup in a lateral direction. In some embodiments, the positioner comprises a gantry.

[0009] In some embodiments, the gantry comprises a longitudinal rail and a trolley for moving the separator in the longitudinal direction from the first position to the second position along the longitudinal rail.

[0010] In some embodiments, the gantry comprises a vertical rail for moving the bolt pickup in a vertical direction that is orthogonal to the longitudinal direction and the lateral direction.

[0011] In some embodiments, the bolt pickup comprises a hook configured to rotate about a longitudinal axis for engaging the bolt at the first location.

[0012] In some embodiments, the bolt dispenser further comprises a sensor to detect a position the plurality of bolts, wherein the positioner moves the bolt pickup based on the position the plurality of bolts. In some embodiments, the sensor is an optical sensor, an infrared sensor, an ultrasonic sensor, a magnetic sensor, a laser sensor, a contact sensor, or a combination thereof.

[0013] In some embodiments, the separator comprises two opposing jaws, where at least one of the opposing jaws moves toward the other jaw from an open position to a closed position. In some embodiments, the opposing jaws include a biased surface that, when in the closed position, aligns the bolt in an aligned position.

[0014] In some embodiments, the bolt dispenser further comprises a bolting rig, and an assembly transferer for transferring the bolt from the bolt singulator to the bolting rig.

[0015] In some embodiments, the bolt is part of a bolt assembly.

[0016] In some embodiments, the bolt dispenser is configured for dispensing and installing bolts at a mining face.

[0017] In another aspect, there is provided a bolt assembler for assembling a bolt assembly. The bolt assembler comprises a bolt singulator, a plate dispenser, and a bolt driver. The bolt assembler has an assembly position where the bolt driver is aligned to drive a bolt held by the bolt singulator through a hole of a plate held by the dispenser.

[0018] In some embodiments, the bolt assembler further comprises an anchor dispenser, wherein the bolt driver is aligned to drive the bolt held by the bolt singulator through the bore of an anchor held by the anchor dispenser, wherein the anchor is distal to the plate relative to the bolt.

[0019] In some embodiments, the plate dispenser comprises a container for receiving a stack of plates. In some embodiments, the container comprises a lid for positioning the plate held by the dispenser into the assembly position. In some embodiments, the plate dispenser further comprises a plate drive for advancing the plate held by the dispenser from the stack of plates to the lid.

[0020] In some embodiments, the anchor dispenser comprises a magazine for holding a plurality of anchors. In some embodiments, the plurality of anchors are contained within a clip. In some embodiments, the magazine is a rotary magazine.

[0021] In some embodiments, the anchor dispenser includes a pick positioner for laterally moving the magazine to position the anchor held by the anchor dispenser in the assembly position.

[0022] In some embodiments, the anchor dispenser comprises an aligner for aligning portions of the anchor held by the anchor dispenser prior to assembly.

[0023] In some embodiments, the bolt assembler further comprises a bolting rig, and an assembly transferer for transferring the bolt assembly from the bolt singulator to the bolting rig.

[0024] In some embodiments, the bolt assembler is configured to assemble and install bolts at a mining face.

[0025] In some embodiments, the bolt singulator is set out in the first aspect.

[0026] In another aspect, there is provided a method for singulating a bolt from a pile of bolts with a bolt singulator comprising a bolt pickup and a separator. The method comprises engaging the bolt by at a first position on the bolt with the bolt pickup, lifting the first position on the bolt to a first height, engaging the bolt at a second position on the bolt with a separator, the second position at a second height lower than the first height, and moving the separator along the shaft of the bolt from the second position to a third position on the bolt that is distal from the first position, wherein the movement of the separator to third position lifts the other end of the bolt to a height approximately the same as the first height and disentangles the bolt from other bolts in the pile, wherein the bolt at the first height is free of the pile of bolts.BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The features of the invention will become more apparent in the following detailed description in which reference is made to the appended drawings wherein:

[0028] FIG. 1 shows an embodiment of a bolt dispensing apparatus;

[0029] FIG. 2 shows an embodiment of a positioner and bolt singulator;

[0030] FIG. 3 shows an embodiment of a bolt driver;

[0031] FIG. 4A shows an embodiment of a bolt singulator;

[0032] FIG. 4B shows an embodiment of a separator;

[0033] FIG. 5A shows an embodiment of a plate dispenser in a plate receiving position;

[0034] FIG. 5B shows the embodiment of the plate dispenser of FIG. 5A in an assembly position;

[0035] FIG. 5C shows a plate dispenser in an assembly position according to another embodiment;

[0036] FIG. 5D shows the plate positioner of the plate dispenser of FIG. 5C;

[0037] FIG. 6A shows the anchor dispenser according to the embodiment of the apparatus shown in FIG. 1 ;

[0038] FIG. 6B shows the clip that may be loaded into the magazine of the anchor dispenser according to the embodiment of the apparatus shown in FIG. 1 ;

[0039] FIG. 6C shows a front perspective view of another embodiment of the clip;

[0040] FIG. 6D shows a rear perspective view of another embodiment of the clip;

[0041] FIG. 7A shows an embodiment of the bolting rigs of an apparatus;

[0042] FIG. 7B shows the bolting rigs according to the embodiment of the apparatus shown in FIG. 1 , where the bolting rig that was shown in FIG. 7A at the receiving location, is now at a bolting location;

[0043] FIG. 7C shows an environmental view of the bolting rigs of FIGS. 7A and B in the context of a mine;

[0044] FIG. 8 shows an embodiment of a frame and hopper without a jib crane;

[0045] FIG. 9 shows an embodiment of a frame, hopper with a jib crane for installing and removing the hopper;

[0046] FIG. 10 shows an embodiment of a plate dispenser and anchor dispenser in an assembly position;

[0047] FIG. 11 shows an aligner for the anchor dispenser according to an embodiment;

[0048] FIG. 12 shows an embodiment of an assembly transferer of the machine;

[0049] FIG. 13A shows an embodiment of an assembled bolt assembly;

[0050] FIG. 13B shows an exploded view of the assembled bolt assembly of FIG. 13A;

[0051] FIG. 13C shows an embodiment of an anchor that is properly aligned for assembly;

[0052] FIG. 13D shows the anchor of 13C where it has been misaligned, such as after being jostled during transport.DETAILED DESCRIPTION

[0053] The embodiments herein will now be described in more detail with reference to the accompanying drawings, in which example embodiments are shown. Disclosed features of example embodiments may be combined. Like numbers refer to like elements throughout.

[0054] As used herein, the term “bolt” refers to any cast in place anchors or post-installed anchor bolts, such as the rock bolts and rock anchors, normally installed into very hard materials such as, but not limited to, the walls or roofs of mines, stone, masonry, or concrete. In some preferred embodiments, the bolt is a post-installed anchor.

[0055] Cast-in-place anchors are positioned and, if necessary, secured in place prior to pouring a base material, for example, concrete.

[0056] Post-Installed anchors are installed in existing base materials, often inserted into predrilled hole, held in place with mechanical friction or bonded in place using adhesives. Post-installed anchors include powder-actuated anchors, screw anchors, expansion anchor bolts, undercut anchors and bonded anchor bolts. Powder-Actuated Anchors use a propellant to fire a fastener into a base material. Plastic deformation of the base material accommodates the fastener and provides the friction necessary to retain the fastener. Screw Anchors thread into a pre-drilled hole. Pressure between the threads and the circumference of the hole, or the cutting of threads into the base material provide the mechanical hold of the anchor. Expansion anchor bolts rely on an expansion anchor to maintain friction with the walls of the hole, and can be categorized into two classes, Pre-expanded and Unexpanded. Pre-expanded Mechanical Anchors are constructed to be larger than hole they are driven into. The compression of the anchor in the hole creates the friction force that retains the components. Examples of these types of anchors includes split drive anchors and Spike™ anchors. Unexpanded anchors are inserted into a drilled hole first, and then are set in place through the use of mechanical force. This can be done by driving a wedge, such as is done with Hammer Drive Anchors, Strike Anchors, and Machine Screw Anchors, by applying a screw force such as is done with, Wedge Anchors, Drop- In Anchors, Sleeve Anchor, Single Expansion Anchors, Double Expansion Anchors or Lag Shields, or by inflating the diameter of the anchor with a very high pressure such as is done with Inflatable Rock Bolts. Undercut Anchors are similar to expansion anchors, except that they use a drilled hole that is flared at the bottom. The expansion sleave uses a bearing force (not friction) to transfer load to the base material. Bonded anchor bolts are fastened in place using adhesives such as (but not limited too) Grouts, resins and epoxies to set anchors bolts in place. In the case of mining, “sausages” of two-part epoxy are often inserted into the hole prior to the insertion of the bolt. The act of inserting, and then spinning the bolt causes the two parts to mix and flow out and fully encapsulate the length of the bolt.

[0057] Conventional systems for picking up and / or dispensing cylindrical objects (such as with logs, straws, or pipes) rely on the objects sitting substantially flat and parallel with one another, and picking up both ends of the cylindrical object simultaneously. However, since bolts have a head 22 and a shaft 24, a pile of bolts cannot be placed with their shafts being substantially parallel when their heads are placed at one end of a bolt store due to the larger diameter of the bolt at the proximal end as compared to the distal end. Instead, a pile of bolts will often stack in such a way that their shafts 24 are slightly angled with respect to one another and there may be a longitudinal offset in the bolts due to their heads 22 not being flush at the end. Bolts 20 being picked up and / or dispensed using conventional systems are thus susceptible to entanglement and require monitoring to correct operation when entanglements occur.

[0058] Having reference to FIG.1 there is disclosed an embodiment machine 100 that assembles and / or dispenses mechanical rock bolts. The machine 100 comprises a frame 101 , a bolt store 170 for storing bolts 20, a bolt singulator 400 for retrieving a bolt 20 from the bolt store170, and a positioner 200 attached to the frame 101 for positioning the bolt singulator 400 to retrieve bolts 20 from the bolt store 170.

[0059] Having reference to Fig.2, the positioner 200 (depicted as a gantry) includes a first rail 230 (such as a runway rail) aligned along a lateral direction 240, for example, in a direction that is generally lateral to the shafts of the bolts 1501 stored in the bolt store 170. The gantry 200 also includes a second rail 232 (such as a bridge rail) coupled to the first rail 230 and aligned along a longitudinal direction 242. The longitudinal direction 242 may be generally parallel to the longitudinal direction of the shafts of the bolts 1501 stored in the bolt store 170 and perpendicular to the lateral direction 240. The second rail 232 may be movable along the first rail 230. In some embodiments, the lateral direction 240 is substantially normal to the mining face, and the longitudinal direction 242 is parallel to the mining face. In other embodiments, the positioner comprises a robotic arm, such as a multi-axis robotic arm.

[0060] Having reference to FIG. 4A, the bolt singulator 400 includes a bolt pickup 410. In an embodiment, the bolt pickup 410 includes body 412 that rotates about an axis 414 that is generally parallel to the longitudinal direction 242 and a hook motor 413 that powers such rotation. The hook motor may power the rotation of the body, or indirectly, such as by belt, chain, gearing, or the like. The body 412 includes a hook 416 positioned at the circumferential perimeter of the head 412. The bolt pickup 410 is configured to be moveable in a vertical direction 244, for example, in a direction that is generally lateral to the shafts 24 of the bolts 20 stored in the bolt store 170, and perpendicular to the lateral direction 240 and the longitudinal direction 242. In some embodiments, the body 412 is lowered or raised from the second rail 232 by a lifter 418. The bolt pickup 410 is configured to be lowered such that the body 412 is positioned slightly above the bolts 20 contained in hopper 170, such as by the lifter 416. The hook motor 413 is configured to rotate the body 412 to cause the hook 416 to engage and pick up one bolt 20 at a first location on the shaft 24. In some embodiments, once the bolt pickup 410 is configured to be lowered into position by lifter 418 and then moved in the lateral direction 240 during or before the rotation of the body 413. Once the hook 416 engages the bolt 20, the bolt pickup 410 may be raised, for example, to lift the bolt 20 out of the pile of bolts 20 stored in the bolt store 170. The continuous rotation of the hook 416 about the body 412 allows the bolt pickup 410 to attempt to engage a bolt 20 without having to reset or reposition the bolt pickup 412 if an attempt to engage the bolt 20 fails, for example, if it bounces over the pile of bolts 20. In other embodiments, the bolt pickup comprises a suction gripper, a jaw, a claw or a magnetic pickup.

[0061] In some embodiments, the bolt pickup 410 includes a height sensor to detect the height of a between the bolt pickup 410 and one or more bolts 20 stored in the bolt store 170. The bolt pickup 410 may be raised and lowered to the bolts 20 based on the signal received from the height sensor. The sensor may be a pressure transducer, a magnetic sensor, an opticalsensor, an ultrasonic sensor, a laser sensor, a force feedback sensor, or the like. In dusty environments, such as a mine, a sensor not using electromagnetic waves (e.g. not optical sensors) may be preferred. In some particularly preferred embodiments, the hook 416 has lower fidelity requirements from the sensor than with other mechanisms as the continuous operation allows it to easily make additional attempts to pick up a bolt if an attempt fails without necessarily needing to reacquire sensor data. For example, a pressure transducer or force feedback sensor to detect the height of a pile of bolts is sufficient and does not need to analyze a 2- or 3- dimensional image captured by the sensor to determine how and where the bolt pick up 410 will attempt to pick up a bolt 20. Further, the requirements for height detection of the bolts for use with a hook is relatively low as detailed imaging isn’t required to detect the edges and heights of an individual bolt to plan the lifting of the bolt. As such the positioner 200 does not have to be moved in different directions along the lateral or longitudinal directions 240, 242 to create a height map of the pile of bolts. In some embodiments, the sensor, such as a force feedback sensor, is integral to a motor of the lifter 418.

[0062] In some embodiments, a misalignment take-up 402 allows auxiliary movement of the body 412 in the vertical direction 244, such as to move up slightly to ride over obstacles, or down slightly to assist with the capture of a bolt 20.

[0063] Lifting a bolt 20 by the shaft 24 at a first location, does not necessarily free or separate the bolt 20 from a pile of bolts. For example, the other end of the bolt 20 may not be lifted due to gravity, due to entanglement with the bolts remaining in the pile, or both. As a result, the bolt 20 will be lifted at the first position with the opposing end of the bolt 20 positioned lower (such as in the pile, the hopper, the ground, etc.). Accordingly, in some embodiments, the bolt singulator 400 includes a separator 404. The separator 404 is configured to engage the bolt 20 at a second location on the shaft 24 and lift the end of the bolt 20 opposite the first position. This may, for example, position the shaft of the bolt 20 to a generally horizontal orientation. In some embodiments, the separator 404 is configured to engage and align the bolt 20 such that the shaft 24 is generally aligned along an axis parallel to the longitudinal direction 242. In some embodiments, the separator 404 includes a centralizer 405 that is configured to engage the shaft 24 of a bolt 20 lifted by the bolt pickup 410 at the second location of the bolt 20, generally at a lower vertical position than the first location of the bolt 20 and move the bolt 20 such that the bolt is generally horizontal. In the embodiment shown in FIG. 4A, the centralizer 405 comprises a clamp with two opposing jaws 405A and 405B (not shown) that are moveable such that the shaft of a bolt can pass between the jaws or be retained by the jaws. The jaws 405A and 405B include angled faces that are configured to close to retain the shaft 24 of the bolt 20, defining a channel where the shaft 24 sits. In some embodiments, the jaws 405A and 405B are slightly offset and can extend past each other when closing such that the channel is positioned higher in the vertical direction 244 such that a shaft 24 of a bolt retained in the channel is raised in the verticaldirection 244. In some embodiments, the centralizer 405 includes a centralizer lift that will raise and lower the centralizer 405. In some embodiments, the bolt pickup 410 includes a capture sensor 406 to detect the engagement of a bolt 20 by the bolt pickup 410.

[0064] In some embodiments, the gantry 200 includes a third rail 234 (such as a vertical rail) coupled to the second rail 232. The third rail 234 is aligned along the vertical direction 244. In such embodiments, the lifter 418 is configured to move along the third rail 234 thereby moving the bolt pickup 410 in the vertical direction 244. In other embodiments, the lifter 418 is a hoist or a cylinder coupled to the second rail 232.

[0065] In some embodiments, once the bolt pickup 410 has engaged the shaft 24 of a bolt 20 lifted by the bolt pickup 410, the separator 404 will move away from the bolt pickup 410 in the longitudinal direction 242 from the second position on the bolt to a third position on the bolt that is distal to the first position. This may, in some instances, assist in freeing and / or separating the bolt 1501 from a pile of bolts from which the bolt was lifted, and to provide additional stability to the bolt lifted by the bolt singulator 400. In some embodiments, the separator 404 moves in the longitudinal direction 242 such as along a separator slide 404A. In other embodiments, the separator 404 moves along the second rail 232. In those embodiments where the separator moves along the separator slide 404A, the separator slide is coupled to the second rail 232 at a fixed vertical distance, for example, being suspended below the second rail 232. The movement of the centralizer 405 in the vertical direction 244 may be performed independently, simultaneously, or concurrently with its movement in the longitudinal direction 242. In some embodiments, the separator 404 includes a separator sensor 407 for detecting the position of the separator 404 in the longitudinal direction 242. In some embodiments, the separator 404 includes a centralizer position sensor 408 to detect the position of jaws 405A and 405B. In other embodiments, the separator 404 includes a sweep (not shown) that moves in the longitudinal direction while the centralizer 405 is at a fixed longitudinal position.

[0066] In other embodiments, the centralizer 405 comprises a hook or a retainer bar with a channel configured to be lowered in the vertical direction 242 in a lowering configuration generally parallel with the shaft of the bolt 20, and rotate about a vertical axis to an engagement configuration generally laterally with the shaft of the bolt in the hook or the channel of the retainer bar, and then raised in the vertical direction 242.

[0067] In certain situations, bolts 20 may be so askew with respect to the pile that when bolt pickup 410 engages the shaft of a bolt, the jaws 405A and 405B cannot engage the bolt. Accordingly, in an embodiment shown on FIG. 4B, separator 404' includes one or more alignment sensors 409'. If the bolts are sufficiently parallel, the shaft of the bolt will raise between sensors 409' and be captured by the jaws 405A' and 405B'. However, if the bolt is misaligned or askew, the shaft will be detected by (e.g. contact) one of the sensors one of the sensors 409'. Ifthe sensors 409' detects the shaft 24 of bolt 30, the separator 404' is moved along the first rail until the bolt is no longer detected by a sensor 409'. In an alternative embodiment, the sensors 409' detect the range of movement of jaws 405A and 405B, such that they will be able to engage the bolt at the second position on the shaft. If the sensors 409' do not detect the bolt, the separator 404' can be moved along the first rail until the bolt detected by the sensors 409'.

[0068] Having reference now to FIG. 8, in some embodiments, the bolt store 170 is a hopper 171 that is removably couplable to the frame 101 at a hopper receiver 173. The hopper receiver includes a positioner 174, such as retaining pins, to positively align, retain, or both, the hopper 171 with the hopper receiver 173. Removing the hopper 171 from the frame 101 allows the hopper 171 to be moved to a more convenient location for replenishment, or to replace a first empty hopper with a second, filled hopper. Having reference to FIG. 9, in some embodiments, a jib crane 900 is attached to the frame 101 for installing and removing the hopper 171. The crane 900 is powered by hydraulic cylinder 901. A jib home sensor 902 detects when the jib crane 900 is in a storage position, such that the jib crane 900 will not interfere with the operation of other portions of the machine 100. Removing the hopper 171 from the frame 101 allows the hopper 171 to be moved to a more convenient location for replenishment, or to replace a first empty hopper with a second, filled hopper.

[0069] In some embodiments, the bolt store 170 contains pre-assembled bolt assemblies 10 and the bolt singulator 400 retrieves the bolt assembly 10 by the bolt 20. In other embodiments, the bolts 20 in the bolt store 170 are not preassembled into an assembly 10 and are assembled by the machine 100. In such embodiments, the machine 100 includes a plate dispenser 500 and an anchor dispenser 600. The bolt singulator 400, the plate dispenser 500, and the anchor dispenser 600 position the bolt 20, plate 30, and anchor 40 for assembly by machine 100 into the bolt assembly 10.

[0070] Having reference to FIG. 5A, dispensing of a plate 30 by plate dispenser 500 will now be described in further detail. The plate dispenser 500 includes canister 501 having a base 502, a top 503 and walls 504 that a volume 506 configured to receive a stack of plates 30. The base 502 and walls 504 may be separate components or integrally formed. In some embodiments, the walls 504 limit rotation of the plates 30 in the stack. For example, a canister for square plates can have four walls slightly larger than the perimeter of a square plate such that rotation of the square plate would contact the walls, whereby the walls prevent further rotation of the square plate.

[0071] In some embodiments, the plate dispenser 500 includes a plate drive 510, to move the stack of plates 30 in the volume 506 toward the top 503 of the canister 101 . The plate drive 510 includes a platform 512 residing within the volume 506 on which the bottom of the stack of plates 30 can abut and can move in a direction normal to the plates 30. In some embodiments,the platform 512 is coupled to a plate drive rail 514 of the plate drive 510 for movement along the rail in a direction normal to the stack of plates 30. In some embodiments, the plate drive rail 514 is located outside of the volume 506 and one of the walls 504 defines an aperture 504A through which the platform 512 couples to the plate drive rail 514 by a linkage 516. In other embodiments, the plate drive rail 514 is located within the volume 506.

[0072] In some embodiments, the plate dispenser 500 includes a spring 518 coupled to the base 502 and exerts a force normal to the stack of plates 30 at the bottom plate. In embodiments where the plate dispenser is oriented vertically, the spring 520 may be matched to the weight of the plates. In embodiments with both a plate drive 510 and a spring 520, the spring 520 assists the plate drive 510, reducing the drive force required by the plate drive 510 to move platform 512.

[0073] The plate dispenser 500 includes a plate positioner 507 (shown as a canister lid) coupled to the top 503 of the canister 501. Plate clamps 508 coupled to the canister lid 507 are configured to secure the plate 30 that is next to the lid (such as the top plate of the stack when the canister 101 is oriented vertically). The canister lid 507 is coupled to the canister 101 and can move from a plate receiving configuration (see FIG. 5A) to a plate dispensing configuration (see FIG. 5B) where the plate 30 is aligned to be assembled into the bolt assembly 10. In some embodiments, the canister lid 507 is coupled to the top 503 of the canister 501 such that a plate 30, when in the plate dispensing configuration, is perpendicular to the plates inside the volume 503. In some embodiments, the canister lid 507 is hingedly coupled to the top 503 of the canister 501 . Where there is a vertical stack of plates in volume 503, where the faces of the plates are oriented horizontally, the plate dispensing configuration may orient the plate to be dispensed vertically. In some embodiments, the canister lid 507 is rotatably connected to the top 503 of the canister 501 and swivels about an axis that is parallel to the canister 501 such that the plate to be dispensed is parallel to the stack of plates in the volume 506. In yet other embodiments, the canister lid 507 slides across the top 503 such that the plate to be dispensed is parallel to the stack of plates in the volume 506. In some embodiments, the canister lid 507 includes guides to align a plate 30 that is receives. In other embodiments, the plate positioner comprises a suction gripper or a magnetic pickup rather than a clamp.

[0074] Having reference to FIG. 10, in some embodiments, the plate dispenser 500 includes an alignment guide 530 for aligning the shaft 24 of a bolt 20 with the hole of the plate 30 in an assembly position. The alignment guide is generally tubular, with a bore that is cylindrical or conical such that it tapers at an end distal to the head 22, when in the assembly position. In some embodiments, the bore is conical and the conical bore funnels head of the bolt toward the tapered end to align the bolt during assembly.

[0075] In some embodiments, the plate alignment guide 530 includes two opposing jaws 532 defining grooves, that, when the jaws are engaged, define the tubular bore. The jaws 532are operated by an actuator 534. A position sensor 536 detects whether the jaws 532 are open or closed.

[0076] Having reference to FIGS. 5C and 5D, an alternative embodiment of a plate dispenser is shown. Where manufacturing tolerances of plates 30 are not sufficiently tight, the position of the hole may be formed in different positions on a plate 30, such that the holes of some plates 30 do not align axially with guide 530 when lifted by clamps 508. When this occurs, the shaft 24 of the bolt 20 may not traverse the plate 30 properly. To help ensure proper alignment, the plate dispenser 500' includes an indexer 510' to ensure that the holes of plates 30 are aligned with the alignment guide 530' when lifted by plate positioner. The indexer 510' may be a rod where plates 30 may be stacked through their holes, so that all of the holes of plates 30 are aligned. A plate positioner 507' includes electromagnets 508' used to secure plates 30 for lifting. In the embodiment shown in FIG. 5D, three electromagnets 508' are present, but other embodiments may have more or fewer electromagnets. In yet other embodiments, both electromagnets 508' and plate clamps 508 may be present. Electromagnets 508' help ensure that the holes stay relatively in the same position when secured to the positioner 507'. For example, the clamping by a clamp 508 of different plates may result in misalignment with the guide 530 if the holes were at slightly different positions on their respective plates. Thus, electromagnets 508' and indexer 510' cooperate to align the holes of the plates 30 with the guide 530' rather than positioning the plates themselves at a particular position. In other embodiments, a translator, such as a pinion system on the positioner 507', aligns the hole of the plates with the guide.

[0077] Having reference to FIG. 6A and 6B, dispensing of an anchor 40 by anchor dispenser 600 will now be described in further detail.

[0078] Anchors 40 may be loaded into clips 610. Each clip includes a body 612 defining a plurality of chambers 614 for receiving anchors 40. In some embodiments, the chambers 614 are shaped orient the anchors 40. For example, the chambers 614 may be shaped to prevent an anchor 40 from being installed backwards, to prevent rotation, or a combination thereof. In some embodiments, the clips comprise a retainer to prevent anchors stored within the chambers 614 from falling out of the clip. In some embodiments, the chambers 614 are arranged in rows 616, columns 618 or both. As depicted, the clip 610 includes ten chambers 614 arranged with five rows and two columns. Clips may be loaded with anchors at a location away from the mining location and facilitate transport of the anchors. In some embodiments, the clips are stackable.

[0079] The clips 610 may be loaded into a magazine 602 of the anchor dispenser 600. The anchor dispenser includes a magazine drive 603 for advancing the magazine 602 in set increments, corresponding with the spacing between the columns 618 of the clips 610, and a pick positioner 604 for moving the magazine 602 in increments corresponding to the spacingbetween the rows 616. In some embodiments, the anchor dispenser 600 includes an anchor presence sensor 605 to detect whether an anchor is positioned inside the chamber that is disposed in an assembly position. In some embodiments, the anchor dispenser 600 includes a pick position sensor 607 to determine position of the magazine 602 due to operation of the pick positioner 604.

[0080] In some embodiments, the magazine 602 is a rotary magazine. In such embodiments, magazine drive 603 rotates the magazine 602, the columns 618 and rows 618 of the clips are spaced according to radial and angular distances rather than in perpendicular rows and columns, and the pick positioner 604 moves the magazine laterally.

[0081] Each anchor 40 includes a plurality of wedges 42 that can deflect outwardly to bias against a bore, a retaining band 44, and a bore 46. Anchors are often provided by suppliers loose and in boxes, and, during transport, are often jostled such that wedge portions 42, retaining bands 44, or both, of an anchor 40 may be pushed from proper alignment for installation (see FIG. 13C) into an improper alignment (see FIG. 13D). Even when seated and oriented in the chambers of the clip, it is possible that the wedges of the anchor are not properly aligned for installation. Accordingly, in some embodiments, the anchor dispenser 600 includes an aligner 620 to ensure that the wedges are concentric and that the anchors 40 are fully seated in the clip 610. Having reference to Fig. 11 , the aligner 620 includes an alignment pin 622 for aligning the wedges 42 of an anchor 40. The alignment pin 622 has a conical end and is configured to move at least partially into the bore 46. As the alignment pin 622 moves into the bore, it urges the wedges 42 outwardly and into alignment within the chamber 614. In some embodiments, the aligner 620 includes a band driver 624 to press the retaining band 46 into the correct location. In some embodiments, the alignment pin 622 and the band driver 624 are driven by cylinder 626. In some embodiments, a shell alignment sensor 628 detects the position of the aligner 620. In some embodiments, the aligner 620 has a number of alignment pins 622 equal to the number of rows 616 of a clip 610 such that when the magazine drive 603 advances the magazine 602, the aligner 620 can align all of the anchors of a column 618 simultaneously. In other embodiments, the aligner 620 aligns the anchor 40 in the chamber 614 that is in the assembly position.

[0082] Having reference to FIG. 6C, in some embodiments where a clip 610' is formed of plates joined together (e.g. not made from casting, 3D printing, milling, etc.), chamber 614' is not a solid bore and may include gaps. The use of plates can decrease costs and weight of the clip. For example, clip 610 may include a front plate, a rear plate, and a middle support plate secured to side walls, with each plate having holes aligned such that the holes define a chamber. As there are gaps between the plates, the insertion of shell anchors through the holes defining the chamber may result in the shell anchor catching and snagging on the holes. In some embodiments, a clip 610' includes sleeves 630' that orient expansion shell anchors 40 withinchambers 614' and prevent the expansion shell anchors 40 from rotating (see FIG. 6C) or catching on anything within chambers 614' during the extraction of the fully assembled bolt. The sleeves 630' may be inserted through aligned holes through plates of clip 610', thereby creating bores traversing the plates defining chambers 614'. The sleeves 630' are formed such that shell 40 may be easily extracted from after the bolt 24 is threaded into them.

[0083] Having reference to FIG. 6D, in some embodiments, a rear face of a clip 610" includes magnets 632" for retaining expansion shell anchors 40. The magnets help prevent expansion shell anchors 40 from vibrations during transport that can jostle the anchors out of position and not fully seated in the clip. If the shells were jostled out of position such that the shell protrude from the clip, the alignment would potentially result in a clamping over the end of the expansion shell and prevent it from closing. In some embodiments, the chambers 614" are not open at the rear, but include small apertures to allow protruding features on shell anchors 40 to be seated to aid in alignment and additionally allow for better contact of magnets 632" with the bodies of shell anchors 40.

[0084] In some embodiments, plate dispenser 600 includes an anchor alignment guide 630 for aligning the shaft 24 of the bolt 20 with the bore 46 of the anchor 40 and the hole of the plate 30 in an assembly position. In some embodiments, the alignment guide 630 retains the anchor to prevent it from rotating as a bolt 20 is driven into the anchor 40 during the assembling of the bolt assembly 10. In some embodiments, the alignment guide includes two opposing jaws defining grooves, that, when the jaws are engaged, define a generally tubular bore, such as a cylindrical or conical bore. The jaws are operated by an actuator. A position sensor detects whether the jaws are open or closed. In some embodiments, the closing of the opposing jaws clamps the anchor to prevent it from spinning and also to keep the wedges aligned.

[0085] In some embodiments, the machine 100 includes a bolt drive 300 for driving the bolt 20 through the hole of the plate 30 and into the anchor 40, thereby forming the bolt assembly 10. Having reference to FIG. 3, the bolt drive 300 includes a drive socket 301 is driven by a motor 302. The bolt drive 300 is configured such that the drive socket 301 is coaxial with the shaft 24 of the bolt 20, the hole of the plate 30 and the bore 46 of the anchor 40 in an assembly position. In some embodiments, the bolt drive 300 is coupled to the gantry 200, such as a trolley thereof, at a fixed vertical height. Engagement sensors 304 are configured to detect movement of the drive socket 301 along the axis of a spring take-up 303.

[0086] Having reference to FIG.12, the machine 100, according to an embodiment, includes an assembly transferer 700 to deliver a bolt assembly 10 from the bolt singulator 400 to the bolting rig 800. In this embodiment a fully assembled bolt assembly 10 is deposited by the bolt singulator 400 onto a transfer holder 702 having magnets 704 to align and retain the bolt assembly 10. The assembly transferer includes a linear slide 706 for moving the bolt assembly10 toward a bolting rig 800 positioned at a refill location 713. The transferer includes an entrance ramp 708 for lifting the bolt assembly 10 off the magnets 704, a push plate 710 for driving the bolt assembly it into retainers 803 of the bolting rig 800, and a transfer position sensor 712 for detecting the position of the transfer holder 702.

[0087] Having reference to FIG. 7A, a bolting rig 800 includes a frame 805, a body 801 coupled to the frame 805, the body having a drill 802 for creating holes in rock, retainers 803 (such as clips or clamps) for receiving bolt assemblies 10 and a bolt drive 804 for installing the bolt assemblies into holes drilled by the drill 802. A bolt detection sensor 806 detects whether a bolt assembly is received by retainers 803. A positioning arm 807 couples the body 801 to the frame 805. The positioning arm is connected to the frame at joint 808. As shown in in FIG. 7B the positioning arm 807 rotates about joint 808 along two axes to move the body 801 outwardly (e.g. yaw) and to rotate the body along the longitudinal axis of the positioning arm 807 (e.g. roll). The arm 807 includes an extender 809 for moving the body 801 outwardly and away from the joint 808. A combination of linear 810 and rotational 811 sensors provide feedback.

[0088] In some embodiments, the machine 100 includes at least one bolting rig 800 and at least one assembly transferer 700. As shown in FIG. 7C the mining location 1 is shown with roof 2 and walls 4. In this embodiment, the machine 100 includes a single assembly transferer 700, whose refill location 713 is used by both bolting rigs 800 arranged on opposite sides of the bolting rig at approximately the same distance from the mining face. This arrangement allows for pattern bolting 714 as the machine 100 travels forward in a straight line along the direction of mining.

[0089] In operation, according to an embodiment, the anchor presence sensor 605 detects whether an anchor 40 is present in the chamber 614 positioned in an assembly position in the magazine 602. If no anchor is detected, pick positioner 604 will advance to position the next chamber 614 in the row 618 in the assembly position. If all the chambers 614 in the column 616 are empty, the magazine drive 603 will advance the magazine 602 to the next column 616. Where the magazine drive 603 incrementally moves the magazine 602, the aligner 620 is operated to correct misalignment of anchors in the column. This process is repeated until an anchor 40 is present in the assembly position.

[0090] Next, the plate drive 510 drives the plates 30 stacked within the volume 506 towards the lid 507 until the plate sensor 509 confirms a plate 30 is in position to be captured by the plate clamp 508. Once captured, the canister lid 507 moves the plate 30 into the assembly position.

[0091] To capture a bolt 20 the gantry 200 moves the bolt singulator 400 in the lateral direction 240 to a position near the heads 22 of the bolts 20, and a height sensor detects the height of the pile of bolts 20 in the bolt store 170. The gantry moves the bolt singulator 400 in a lateral direction beyond the pile and in a vertical direction just above the pile. The bolt pickup 410is lowered to a height just above the pile and the hook motor 413 rotates the body 412 and the hook 416. The gantry 200 then moves in the lateral direction toward the pile of bolts. Once capture sensor 406 detects that a bolt 20 has been engaged by the hook, the hook motor stops and the bolt pickup 410 is moved to a known height. Centralizer 405 is then positioned near the bolt pickup and jaws 405A and 405B and close beneath the bolt at a second position. The action of closing the jaws 405A and B and the moving the separator in a longitudinal direction to a third position on the shaft 22 of the bolt 20 frees of the bolt 20 from entanglements with other bolts in the hopper 108, and raises the shaft 22 to the height of the first position.

[0092] The alignment guides 530 and 630 then move into position, and the gantry 200 moves the bolt singulator 400 to an assembly position that aligns the shaft of the bolt, the hole of the plate, and the bore of the anchor along the same axis.

[0093] The bolt drive 300 moves the bolt 20 through the plate alignment guide 530, the plate 30, and the anchor alignment guide 630 until the engagement sensor 304 detects that the bolt 20 has contacted the anchor 40. Once contact has been established the bolt drive motor 302 begins rotating until the engagement sensor 304 detects that the components are threaded together to the correct depth forming the bolt assembly 10.

[0094] Once the bolt assembly 10 is formed, the plate alignment guide 530 retracts, and the gantry 200 moves in the longitudinal direction 242 to remove the anchor 40 from the anchor dispenser 600 and to an unloading position above the assembly transferer 700, where the bolt singulator releases the bolt, such as by driving hook motor 412 to rotate the hook to free the shaft of the bolt at the first location is released, and to disengage the jaws 405A and 405B to release the shaft free the of the bolt at the third location.

[0095] The assembly transferer 700 transfers the bolt assembly to the refill location 713 where it is received by the bolting rig 800 in the retainers 803 of body 801 .

[0096] The positioning arm 807 moves the body 801 to the bolting location, where it can be installed into the walls or roof of the formation.

[0097] The operation may be controlled, for example, using one or more controllers, such as a PLC, a computer, a circuit, manual controls, or the like. In some embodiments, the machine and the bolting rig are controlled by separate controllers.

[0098] Although the invention has been described with reference to certain specific embodiments, various modifications thereof will be apparent to those skilled in the art without departing from the spirit and scope of the invention as outlined in the claims appended hereto. Additionally, although the machine is shown as assembling expansion anchor bolts, it may generally be used to singulate and pick up other objects having elongated shafts placed in a pile,such as cast-in-place anchors, post-installed anchors, screw anchors, undercut anchors or bonded anchor bolts.

[0099] Further, with certain other types of anchor bolts, such as screw anchors, or bonded anchor bolts, the bolts may be fastened in place using friction, or with adhesives that will set and fix the bolt in a hole (such as one made by drill 802) rather than by using an anchor. In such cases, the anchor and anchor dispenser may be omitted.

[0100] Further, although bolt assemblies 10 are described as being used to secure walls and roofs of mines, they may be used to secure and reinforce other structures, such as roofs and walls of concrete structures, or to secure other elements into concrete, such as girders or beams. Additionally, non structural elements may be secured using anchor bolts, such as posts, signs, facades, or HVAC, plumbing or electrical infrastructure.

[0101] Further still, although the bolt assembly is described as including a plate 30, other retaining devices may be dispensed by plate dispenser 500, such as retaining clips, P-clips, clamps, hangers, mounting plates, rock bolt bearing plates, or washers. The retaining devices may be used to secure a variety of equipment, including ventilation tubes, fans, conveyor belts and belt drives, water lines, power lines, communication lines, transformers, junction boxes.

Claims

CLAIMS1 . A bolt dispenser comprising a frame; a bolt store configured to store a plurality of bolts, each bolt having a head and a shaft, wherein the heads of the plurality of bolts are positioned near a first end of the bolt store and the tips of the plurality of bolts are positioned near a second end of the bolt store opposite the first end; a bolt singulator attached to the frame for retrieving a bolt from the bolt store, the singulator comprising: a bolt pickup configured to engage the bolt at a first location on the bolt; and a separator configured to engage the bolt, and move in a longitudinal direction from an initial position proximate to the bolt pickup to a second position distal to the bolt pickup.

2. The bolt dispenser of claim 1 further comprising a positioner connected to the frame, the positioner configured to move the bolt pickup in a lateral direction.

3. The bolt dispenser of claim 2, wherein the positioner comprises a gantry.

4. The bolt dispenser of claim 3, wherein the gantry comprises a longitudinal rail and a trolley for moving the separator in the longitudinal direction from the first position to the second position along the longitudinal rail.

5. The bolt dispenser of claim 3, wherein the gantry comprises a vertical rail for moving the bolt pickup in a vertical direction that is orthogonal to the longitudinal direction and the lateral direction.

6. The bolt dispenser of claim 1 , wherein the bolt pickup comprises a hook configured to rotate about a longitudinal axis for engaging the bolt at the first location.

7. The bolt dispenser of claim 1 further comprising a sensor to detect a position the plurality of bolts, wherein the positioner moves the bolt pickup based on the position the plurality of bolts.

8. The bolt dispenser of claim 7, wherein the sensor is an optical sensor, an infrared sensor, an ultrasonic sensor, a magnetic sensor, a laser sensor, a contact sensor, or a combination thereof.

9. The bolt dispenser of claim 1 , wherein the separator comprises two opposing jaws, wherein at least one of the opposing jaws moves toward the other jaw from an open position to a closed position.

10. The bolt dispenser of claim 9, wherein the opposing jaws include a biased surface that, when in the closed position, aligns the bolt in an aligned position.

11. The bolt dispenser of claim 10, further comprising a bolting rig, and an assembly transferer for transferring the bolt from the bolt singulator to the bolting rig.

12. The bolt dispenser of claim 11 , wherein the bolt is part of a bolt assembly.

13. The bolt dispenser of claim 12, wherein the bolt dispenser is configured for dispensing and installing bolts at a mining face.

14. A bolt assembler for assembling a bolt assembly comprising: a bolt singulator, a plate dispenser, and a bolt driver wherein the bolt assembler has an assembly position where the bolt driver is aligned to drive a bolt held by the bolt singulator through a hole of a plate held by the dispenser and a bore of an anchor held by the anchor dispenser.

15. The bolt assembler of claim 14, further comprising an anchor dispenser, wherein the bolt driver is aligned to drive the bolt held by the bolt singulator through the bore of an anchor held by the anchor dispenser, wherein the anchor is distal to the plate relative to the bolt.

16. The bolt assembler of claim 14, wherein the plate dispenser comprises a container for receiving a stack of plates.

17. The bolt assembler of 16, wherein the container comprises a lid for positioning the plate held by the dispenser into the assembly position.

18. The bolt assembler of 17, wherein the plate dispenser further comprises a plate drive for advancing the plate held by the dispenser from the stack of plates to the lid.

19. The bolt assembler of claim 14, wherein the anchor dispenser comprises a magazine for holding a plurality of anchors.

20. The bolt assembler of claim 19, wherein the plurality of anchors are contained within a clip.

21. The bolt assembler of claim 19, wherein the magazine is a rotary magazine.

22. The bolt assembler of claim 19, wherein the anchor dispenser includes a pick positioner for laterally moving the magazine to position the anchor held by the anchor dispenser in the assembly position.

23. The bolt assembler of 14, wherein the anchor dispenser comprises an aligner for aligning portions of the anchor held by the anchor dispenser prior to assembly.

24. The bolt assembler of 14 further comprising a bolting rig, and an assembly transferer for transferring the bolt assembly from the bolt singulator to the bolting rig.

25. The bolt assembler of claim 14, wherein the bolt assembler is configured to assemble and install bolts at a mining face.

26. The bolt assembler of claim 1 , wherein the bolt singulator is as defined in claim 1 .

27. A method for singulating a bolt from a pile of bolts with a bolt singulator comprising a bolt pickup and a separator, the method comprising: engaging the bolt by at a first position on the bolt with the bolt pickup; lifting the first position on the bolt to a first height; engaging the bolt at a second position on the bolt with a separator, the second position at a second height lower than the first height; and moving the separator along the shaft of the bolt from the second position to a third position on the bolt that is distal from the first position, wherein the movement of the separator to third position lifts the other end of the bolt to a height approximately the same as the first height and disentangles the bolt from other bolts in the pile, wherein the bolt at the first height is free of the pile of bolts.

Images