Rock bolt installation system, capsule, and rock bolt

Abstract

A rock bolt installation system (100) for drilling and fixing rock bolts (200), the system (100) including: a rock bolt installer (110) for mounting to a chuck (12) of a drill head (13) of a drilling rig (10), the installer (110) including: a proximal portion (120) having a proximal coupling (124) suitable for engagement with the chuck (12) of the bolt drilling rig (10), the proximal portion (120) having a cavity (122) for receiving a replaceable capsule (300) containing two or more substances (314, 324) that are combinable to form a fixing adhesive to be dispensed from a nozzle (340) of the replaceable capsule (300), and a distal portion (130) forming a lid (132) of the cavity (122), the distal portion (130) having a recess (136) for receiving a portion of the replaceable capsule (300) and a distal coupling (134) suitable for engagement with a rock bolt (200) for drilling the rock bolt (200) into a substrate (14); a hydraulic actuator (316, 326) for operating the replaceable capsule (300); a sequencing valve (150) attachable to a supply of pressurized fluid and configurable between a drilling configuration and an injection configuration, wherein, in the drilling configuration, the sequencing valve (150) directs the pressurized fluid to the distal coupling (134) to act as a drilling fluid; and wherein, in the injection configuration, the sequencing valve (150) directs the pressurized fluid to the hydraulic actuator (316, 326) for operating the replaceable capsule (300).

Description

ROCK BOLT INSTALLATION SYSTEM, CAPSULE, AND ROCK BOLTRELATED APPLICATIONS

[0001] The present application claims convention priority from Australian Provisional Patent Application No. 2024904195 the contents of which are incorporated herein in their entirety by reference thereto.FIELD

[0002] The present invention relates to a rock bolt installation system, rock bolt installer and capsule for drilling and fixing rock bolts, and rock bolt used therewith.BACKGROUND

[0003] The Applicant has previously disclosed injection systems for installing rock bolts in PCT Publication Nos. WO 2014 / 190382 and WO 2022 / 226592, the contents of which are incorporated herein in their entirety by reference thereto.

[0004] However, additional improvements in rock bolt drilling and fixing techniques remain possible. For example, one problem with previous designs was the appropriate restraint of the replaceable capsule when exposed to high pressure. Another problem resided in the collapsible design of previous replaceable capsules that was unreliable. Yet another problem resided in the engagement of the rock bolt with the drill head, which required an extra step during the fixing phase of rock bolt installation.SUMMARY

[0005] It is an object of the present invention to substantially overcome, or at least ameliorate, one or more of the disadvantages of the above-mentioned techniques, or at least provide a useful alternative to the previously disclosed arrangements.

[0006] There is disclosed a rock bolt installation system for drilling and fixing rock bolts, the system including: a rock bolt installer for mounting to a chuck of a drill head of a drilling rig, the installerincluding: a proximal portion having a proximal coupling suitable for engagement with the chuck of the bolt drilling rig, the proximal portion having a cavity for receiving a replaceable capsule containing two or more substances that are combinable to form a fixing adhesive to be dispensed from a nozzle of the replaceable capsule, and a distal portion forming a lid of the cavity, the distal portion having a recess for receiving a portion of the replaceable capsule and a distal coupling suitable for engagement with a rock bolt for drilling the rock bolt into a substrate; a hydraulic actuator for operating the replaceable capsule; a sequencing valve attachable to a supply of pressurized fluid and configurable between a drilling configuration and an injection configuration, wherein, in the drilling configuration, the sequencing valve directs the pressurized fluid to the distal coupling to act as a drilling fluid; and wherein, in the injection configuration, the sequencing valve directs the pressurized fluid to the hydraulic actuator for operating the replaceable capsule.

[0007] Optionally, the sequencing valve is located in the proximal portion of the installer and, when the sequencing valve is in the drilling configuration, the drilling fluid is directed from the sequencing valve into the proximal portion.

[0008] Optionally, the proximal portion includes a channel for receiving the drilling fluid from the sequencing valve, and the distal portion includes a channel for receiving the drilling fluid from the proximal portion and providing the drilling fluid to the distal coupling.

[0009] Optionally, the proximal portion includes an external thread and the installer further includes a screw nut having a pocket shaped to accommodate the distal portion, the screw nut including an internal thread engageable with the external thread of the proximal portion to connect the proximal and distal portions such that the channels are in fluid communication.

[0010] Optionally, the proximal portion includes a proximal lug and the distal portion includes a conforming distal lug such that, when the proximal and distal lugs are engaged the lugs resist separating movement of the proximal and distal portions with the channels of the proximal and distal portions being aligned to provide fluid communication.

[0011] Optionally, torque applied to the proximal portion in a drilling direction is resisted by the distal lug to transfer the torque from the proximal portion to the distal portion in the drilling direction.

[0012] Optionally, the distal portion includes one or more torque transfer lugs that engage a respective slot of the proximal portion to transfer torque applied to the proximal portion to the distal portion.

[0013] Optionally, the distal portion includes a locking pin to engage the proximal portion to transfer torque applied in a non-drilling direction from the proximal portion to the distal portion such that the distal portion is inhibited from rotating out of engagement with the proximal portion.

[0014] There is also disclosed a replaceable capsule for use with the disclosed rock bolt installation system, the replaceable capsule including: a first chamber having a first outlet, the first chamber containing a first substance and a piston operable to drive the first substance from the first chamber through the first outlet; a second chamber having a second outlet, the second chamber containing a second substance and a piston operable to drive the second substance from the second chamber through the outlet; a nozzle in fluid communication with the first and second outlet, the nozzle being configured for engagement with a port of a rock bolt to be fixed, the nozzle having a drilling fluid port to receive drilling fluid for drilling the rock bolt. wherein the first and second substance are combinable to produce an adhesive for fixing the rock bolt.

[0015] Optionally, the capsule further includes a check valve located between the nozzle and the outlets, the check valve being moveable from a drilling configuration, in which the check valve seals the outlets from the nozzle and the drilling fluid port, and an injection configuration, in which the check valve seals the drilling fluid port and allows fluid communication between the outlets and the nozzle.

[0016] Optionally, the check valve is moved from the drilling configuration to the injection configuration by pressure applied by the first and / or second piston to the first and / or second substance.

[0017] Optionally, the check valve includes a frangible membrane configured to withstand pressure sufficient to move the check valve from the drilling configuration to the injection configuration, and configured to fail at a higher pressure reached when the check valve has moved to the injection configuration and the pressure from the first and / or second piston is opposed by the check valve.

[0018] Optionally, the nozzle includes a recess for receiving the check valve in the injection configuration, the recess containing a protrusion to bear against the check valve to seal an interface between the nozzle and the check valve.

[0019] Optionally, the second chamber includes a separator, with the second substance located between the separator and the second outlet, and a third substance located between the second piston and the separator, wherein the third substance has a higher rate of reactivity than the second substance, wherein the second outlet is located at an offset from an end of the second chamber opposite the piston, such that when the separator abuts the end of the second chamber, the second piston is operable to drive the third substance from the second chamber through the second outlet.

[0020] Optionally, the capsule includes a body containing the first and second chamber, and the nozzle is attached to the body with a threaded connection.

[0021] There is also disclosed a rock bolt for use with the disclosed rock bolt installation system, the rock bolt including: a distal cutting end, configured to drill into the substrate with the assistance of a drilling fluid; a proximal end having a nut for engagement with the distal coupling of the installer; a shaft extending between the proximal and distal ends, the shaft including a cavity having a proximal opening for receiving drilling fluid from the installer and a distal opening for dispensing drilling fluid to the cutting end, wherein the proximal opening includes a seal for engaging the nozzle of the replaceable capsule, such that when the installer rotates to drill the rock bolt into the substrate, the nozzle rotates with the installer and the rock bolt so that the seal of the proximal opening is stationary relative to the nozzle.

[0022] Optionally, the nut at the proximal end is secured to the shaft with a pin extending from the nut into the shaft, wherein the pin is configured to fail above a torque applied to the nut that is higher than a torque for drilling the rock bolt into the substrate.

[0023] Optionally, the proximal opening has a shape congruent with a shape of the nozzle of the replaceable capsule.

[0024] Optionally, the shape of the proximal opening includes: a substantially cylindrical distal landing; a tapered proximal section, wherein the seal is located on the cylindrical landing or between the cylindrical landing and the tapered section.BRIEF DESCRIPTION OF THE DRAWINGS

[0025] For a more complete understanding of the present invention, exemplary embodiments of the invention are explained in more detail in the following description with reference to the accompanying drawing figures, in which like reference signs designate like parts and in which:

[0026] FIG. l is a side elevation view of a rock bolt installation system according to a preferred embodiment of the invention.

[0027] FIG. 2 is a side section view of the rock bolt installation system of FIG. 1.

[0028] FIG. 3 is bottom section view of a replaceable capsule of the rock bolt installation system of FIG. 1.

[0029] FIG. 4 is a side section view of the replaceable capsule of FIG. 3.

[0030] FIG. 5 is a side section view of the replaceable capsule of FIG. 4.

[0031] FIG. 6 is a side section view of a rock bolt used with the rock bolt installation system of FIG. 1.

[0032] FIG. 7 is a top section view of the rock bolt of FIG. 6.

[0033] FIG. 8 is a side section view of the capsule of FIG. 3 engaged with the rock bolt of FIG. 6.

[0034] FIG. 9 is a schematic view of the rock bolt installation system of FIG. 1 used with a drilling rig.

[0035] FIG. 10 is a detailed side section view of a distal portion of the rock bolt installation system of FIG. 1.

[0036] FIG. 11 is a detailed side view of a static mixer of the rock bolt of FIG. 6.

[0037] FIG. 12 is an image of a threaded port of a coupling of the rock bolt installation system of FIG. 1.

[0038] FIG. 13 is a side elevation view of a rock bolt installation system according to a second preferred embodiment of the invention.

[0039] FIG. 14 is a side section view of the rock bolt installation system of FIG. 13.

[0040] FIG. 15 is a detailed side elevation view of a distal portion of the rock bolt installation system of FIG. 13.DETAILED DESCRIPTION

[0041] FIG. 1 shows a rock bolt installation system 100 according to a preferred embodiment of the invention. The rock bolt installation system 100 is used to drill and fix a rock bolt 200, as shown in FIG. 6 and to be discussed in more detail further below, into a substrate 14, such as the roof of an underground mine, for securing the substrate 14. An installation of the rock bolt 200 according to previous practices includes the fixing of a drilling steel (not shown) to the chuck 12 of a bolt drilling rig 10. The drilling steel would then be drilled into the substrate 14 with the assistance of drilling fluid to create a bolt cavity 16, referred to as the drilling phase, schematically shown in FIG. 9. To fix the bolt 200 in the cavity 16, the drilling steel would be withdrawn from the bolt cavity 16 and a two-part adhesive would be inserted into the bolt cavity 16, typically in the form of long cylindrical sealed packages of adhesives affectionally referred to as “sausages.” The drilling steel would then be removed from the chuck 12 and the bolt 200fixed to the chuck. The bolt is then inserted into the bolt cavity 16 while being rotated to pierce and mix the sausages to mix and activate the two-part adhesive, referred to as the fixing phase. Once the adhesive is sufficiently cured, a nut 222 is tightened on the bolt against a roof plate (not shown) to create a tensile force between the roof plate and the bolt 200 fixed in the bolt cavity 16, referred to as the tensioning phase. The problem of the length of the bolt 200 and the time and labour-intensive process of removing the drill steel and inserting the bolt 200 into the cavity has been recognized in the Applicant’s earlier applications. The present specification disclosed further improved methods of conducting the drilling, fixing, and tensioning phases without removing the drill steel or changing tools on the chuck 12 of the bolt drilling rig 10. Preferably, the rock bolt 200 is a self-drill rock bolt 200.

[0042] Referring to FIG. 2, the rock bolt installation system 100 includes a rock bolt installer 110 for mounting to the chuck 12 of a drill head 13 of the bolt drilling rig 10. The rock bolt installer 110 includes a proximal portion 120 having a proximal coupling 124 suitable for engagement with the chuck 12 of the drill head 13. The proximal portion 120 includes a cavity 122 for receiving a replaceable capsule 300. The replaceable capsule 300 contains two or more substances that are combinable to form a fixing adhesive to be dispensed from a nozzle 340 of the replaceable capsule 300. The rock bolt installer 110 also includes a, preferably removable, distal portion 130 forming a lid 132 of the cavity 122. The distal portion 130 has a recess 136 for receiving a portion of the replaceable capsule 300 and a distal coupling 134 suitable for engagement with the rock bolt 200 for drilling the rock bolt 200 into the substrate 14. The rock bolt installation system 100 also includes a hydraulic actuator 140 for operating the replaceable capsule 300 and a sequencing valve 150. The sequencing valve 150 may be located in the proximal portion 120 of the rock bolt installer 110. The sequencing valve 150 is attachable to a supply of pressurized fluid and configurable between a drilling configuration and an injection configuration. In the drilling configuration, the sequencing valve 150 directs the pressurized fluid to the distal coupling 134 of the distal portion 130 to act as a drilling fluid. In the injection configuration, the sequencing valve 150 directs the pressurized fluid to the hydraulic actuator 140 for operating the replaceable capsule 300. The hydraulic actuator 140 may be biased by a spring to return it to the drilling configuration shown in FIG. 2, once the contents of the capsule 300 have been injected. When the sequencing valve 150 is in the drilling configuration, the drilling fluid may be directed from the sequencing valve 150 into the proximal portion 120. More specifically, the proximal portion 120 may include a channel 128 for receiving the drilling fluid from the sequencing valve 150. Correspondingly, the distal portion 130 may include achannel 138 for receiving the drilling fluid from the proximal portion 120 and providing the drilling fluid to the distal coupling 134 of the distal portion 130. When the distal portion 130 is fully engaged with the proximal portion 120, the channels 128, 138 align to provide fluid communication from the proximal portion 120 to the distal portion 130. To improve the integrity of the pressurized fluid conveying channels 128, 138, the proximal and distal portions 120, 130 may also be connectable by a screw nut 160 such that the channels 128, 138 are in fluid communication and are preferably sealed to inhibit fluid from leaking into the cavity 122 or undesirable drops in fluid pressure. A seal 162 may be located at a joint 164 between the channels 128, 138 to assist. The screw nut 160 may have a pocket shaped to accommodate the distal portion 120. The proximal portion 120 may include an external thread 126 and the screw nut 160 may include an internal thread 166 engageable with the external thread 126 of the proximal portion 120 to connect the proximal and distal portions 120, 130. The distal portion is shown in more detail in FIG. 10, showing torque transfer lugs 131 that extend into slots or grooves 121 of the proximal portion 120, so that torque that is applied to the proximal portion 120 by the chuck 12 is transferrable to the distal portion 130. The lugs 131 are preferably attached to the distal portion 130 using fasteners 133 to allow separate manufacture of the lugs 131 and the distal portion 130.

[0043] In one embodiment, as shown in FIG. 2, the sequencing valve 150 may include a valve head 152 having two or more ports 154. The valve head 152 may be rotatable to align one or more ports 154 with the channel 128 to direct the pressurized fluid to the distal coupling 134. The valve head 152 may also be translatable and / or rotatable on the basis of the fluid pressure applied to the valve 150. While the sequencing valve is in the drilling configuration, the ports 154 may align with the channel 128 to direct the pressurized fluid to the distal coupling 134 of the distal portion 130. In another position the valve head 152 may be rotatable and / or vertically movable to align one or more ports 154 with the hydraulic actuator 140. As shown in FIG. 12, the proximal coupling 124 may include a threaded port 125 to form a connection between the proximal coupling 124 and the chuck 12 for the delivery of the pressurized fluid to the sequencing valve 150. The pressurized fluid may have a first pressure in the drilling configuration of the sequencing valve 150 and a second pressure in the injection configuration of the sequencing valve 150, the second pressure being higher than the first pressure.

[0044] Moving now to FIG. 4 to examine the replaceable capsule 300 in more detail. The replaceable capsule 300 includes a first chamber 310 having a first outlet 312. The firstchamber 310 contains a first substance 314 and a first piston 316 to drive the first substance 314 from the first chamber 310 through the first outlet 312. The replaceable capsule 300 further includes a second chamber 320 having a second outlet 322. The second chamber 320 contains a second substance 324 and a second piston 326 to drive the second substance 324 from the second chamber 320 through the second outlet 322. In the preferred embodiment, the chambers 310, 320 are arranged concentrically. The second piston 326 may include a piston seal 327 to seal the interface between the second piston 326 and the second chamber 320. The chambers 310, 320 are preferably formed from continuous cylindrical walls 311 with constant cross section to allow the pistons 316, 326 to travel through the chambers 310, 320. The first and second pistons 316, 326 are preferably located such that when the sequencing valve 150 is in the injection configuration, pressurized fluid operates the hydraulic actuator 140 which operates the pistons 316, 326 driven by the pressurized fluid provided by the sequencing valve 150. The capsule 300 further includes the nozzle 340, which is in fluid communication with the first and second outlets 312, 322. The nozzle 340 is configured for engagement with a port 260 of the rock bolt 200. The nozzle 340 includes one or more drilling fluid ports 342 to receive drilling fluid for drilling the rock bolt 200. Preferably, the fluid drilling ports 342 are located radially to a dispensing axis of the nozzle 340. The drilling fluid ports 342 may be positioned to be aligned with the channel 138 of the distal portion 130 of the rock bolt installer 110. The nozzle 340 may protrude through the lid 132 of the distal portion 130 into the distal coupling 134, such that drilling fluid directed by the sequencing valve 150 through the channel 138 flows through the drilling fluid ports 342 and the nozzle 340 into the port 260 of the bolt 200. The ratio of the first substance 314 to the second substance 324 being dispensed through the nozzle 340 may be selected at manufacture of the capsule 300 by the relative proportions of the chambers 310, 320. Thus, a capsule 300 having an appropriate ratio for the given substrate 14 may be selected. The nozzle 340 may be dimensioned to be substantially congruent with the recess 136 of the distal portion 130, such that the capsule 300 is externally supported by the distal portion 130 against the internal pressure applied by the pistons 316, 326.

[0045] The capsule 300 may further include a movable cap 350, acting as a check valve, located between the nozzle 340 and the outlets 312, 322. The cap or check valve 350 is movable from a drilling configuration, shown in FIG. 4, to an injection configuration, shown in FIG. 5. In the drilling configuration, the cap 350 seals the outlets 312, 322 from the nozzle 340 and the drilling fluid port 342. In the injection configuration, the cap 350 seals the drilling fluid port 342 from the nozzle 340 and the outlets 312, 322, and allows fluid communication between the outlets312, 322 and the nozzle 340, to allow the first and second substance 314, 324 to be pushed by the pistons 316, 326 from the outlets 312, 322 through the nozzle 340 into the port 260 of the bolt 200. Preferably, the cap 350 is moved from the drilling configuration to the injection configuration by pressure applied by the first and / or second piston 316, 326 to the first and / or second substance 314, 324. The cap 350 may include a frangible membrane 352 configured to withstand pressure sufficient to move the cap 350 from the drilling configuration to the fixing configuration. The membrane 352 is located, in the drilling configuration, to seal the outlets 312, 322 from the nozzle 340 and the drilling fluid port 342. The membrane 352 is preferably configured to fail at a higher pressure reached when the cap 350 has moved to the injection configuration and the pressure from the first and / or second piston 316, 326 is opposed, or rather wholly opposed, by the cap 350 without movement of the cap 350 increasing the pressure on the membrane 352. The nozzle may include a recess 344 for receiving the cap 350 in the injection configuration. The recess 344 contains a protrusion 346 to bear against the cap 350 to seal an interface between the nozzle 340 and the cap 350 in the injection configuration, to assist with the sealing of the drilling fluid port 342 from the nozzle 340 and the outlets 312, 322. The cap 350 may include a first seal 354 located to seal the first substance outlet 312 in the drilling configuration. The cap 350 may also include a second seal 356 located to abut an internal wall 341 of the nozzle below the drilling fluid port 342, to seal the drilling fluid port 342 in the injection configuration. In this way, the second seal 356 seals below the drilling fluid port 342 and the protrusion 346 seals above the drilling fluid port, as shown in FIG. 5.

[0046] The second chamber 320 of the capsule 300 may include a separator 328 that is impervious to the second substance 324. The second substances 324 may be located between the separator 328 and the second outlet 322. A third substance 334 may be located between the second piston 326 and the separator 328, with the third substance 334 having a higher rate of reactivity than the second substance 324. The second outlet 322 may be located at an offset 330 from an end 332 of the second chamber 320 opposite the second piston 326. In this way, when the separator 328 is pushed towards the end 332 of the second chamber 320 by the second piston 326 acting on the third substance 334, the separator 328 urges the second substance 324 out of the second outlet 322. When the separator 328 abuts the end 332 of the second chamber 320, the third substance 334 is able to leave through the second outlet 322 and operation of the second piston 326 drives the third substances 334 from the second chamber 320 through the second outlet 322.

[0047] The replaceable capsule 300 preferably includes a body 302 containing the first and second chambers 310, 320. The nozzle may be attachable to the body 302, preferably with a threaded connection 304.

[0048] Having regard to FIG. 3, which shows the pistons 316, 326, each piston 316, 326 may include a pressure relief hole 360. The pressure relief hole 360 is required during assembly of the system 100, specifically the capsule 300, to allow displacement of air as the pistons 316, 326 are seated in the correct position. The holes 360 may be sealed using a screw cap, melted adhesive or polymer. Alternative methods of relieving the pressure during assembly have also been considered, such as a means of deforming the piston seal 327, for example with a lever (not shown).

[0049] Moving now to FIGS. 6 and 7 to discuss the rock bolt 200 in more detail. The rock bolt 200 includes a distal cutting end 210 configured to drill into the substrate 14 with the assistance of a drilling fluid. The rock bolt 200 also includes a proximal end 220 having the nut 222 for engagement with the distal coupling 134 of the rock bolt installer 110. In this way, the bolt 200 presents the male portion and the distal coupling 134 presents the female portion of the coupling between the bolt 200 and the installer 110. A shaft 230 extends between the proximal and distal ends 210, 220. The shaft 230 may be fabricated from metal, fibre glass, carbon fibre composite, or other engineering plastics. The shaft 230 includes a cavity 232 having a proximal opening 234 for receiving drilling fluid from the rock bolt installer 110 and a distal opening 236 for dispensing drilling fluid to the cutting end 210. It will be understood that the cavity 232 thus also functions to accept the substances 314, 324, 334 and convey the substances to the distal opening 236 to fill the bolt cavity (not shown) and fix the bolt 200 to the substrate 14. The shaft 230 may have an external texture or profile to improve the adhesive interface between the bolt 200 and the substrate 14. In other embodiments, the shaft 230 may be substantially smooth. The proximal opening 234 includes a seal 238 for engaging the nozzle 340 of the replaceable capsule 300. In this way, when the rock bolt installer 110 rotates to drill the rock bolt 200 into the substrate 14, or to disperse the substances 314, 324, 334 in the bolt cavity, the nozzle 340 rotates with the rock bolt installer 110 and the rock bolt 200 so that the seal 238 of the proximal opening 234 is stationary relative to the nozzle 340. The bolt 200 may further include a mixer 270, preferably a static mixer 270. The static mixer 270 is shown in more detail in FIG. 11. The static mixer 270 may include a plurality of rotationally offset helical surfaces 272a, 272b, 272c, 272d, such that a fluid path 274 through a proximal helical surface 272a-c impinges on asubsequent helical surface 272b-d, so as to promote thorough mixing of the ingredients flowing through the static mixer 270. Alternatively, if the mixer 270 is not desired or required, the rock bolt 200 may be spun to mix the ingredients after the rock bolt 200 has been drilled into the substrate 14.

[0050] As shown in FIG. 7, the nut 222 at the proximal end 220 is preferably secured to the shaft 230 with a pin 240 extending from the nut 222 into the shaft 230. The pin 240 is configured to fail, or shear, above a torque applied to the nut 222 that is higher than a torque for drilling the rock bolt 200 into the substrate 14. In this way, torque is applied by the installer 110 to the nut 222 to the bolt 200 via the pin 240, to drill the bolt 200 into the bolt hole in the substrate 14. Typically, this torque is reached once the substances 314, 324, 334 are sufficiently cured to fix the bolt 200 in the bolt cavity. The failing of the pin 240 then allows the nut 222 to be tightened against the roof plate placing the bolt 200 in tension.

[0051] As shown in FIGS. 2 and 8, the proximal opening 234 preferably has a shape 250 congruent with a shape of the nozzle 340 of the replaceable capsule 300, forming the port 260. The shape 250 of the port 260 may include a substantially cylindrical distal landing 252 and a tapered proximal section 254. The seal 238 is preferably located on the cylindrical landing 252, or between the cylindrical landing 252 and the tapered section 254.

[0052] It will be appreciated that the present invention could be practiced by integrating the rock bolt installation system 100 into the drill head 13 of the drill rig 10, rather than the presented preferred retrofit embodiment comprising the proximal coupling 124 to engage the chuck 12.

[0053] FIGS. 13 to 15 show a second preferred embodiment of the rock bolt installation system 100. As shown in FIG. 14, the system 100 is substantially similar to that shown in FIGS. 1 to 12, only the differences between the embodiments will be discussed. As shown in FIG. 13, the proximal portion 120 includes proximal lugs 170 and the distal portion 130 includes conforming distal lugs 180. The proximal and distal lugs 170, 180 together form a bayonet fitting between the proximal portion 120 and distal portion 130. When the proximal and distal lugs 170, 180 are engaged, the lugs 170, 180 resist separating movement of the proximal and distal portions 120, 130. As shown in FIG. 14, the channels 128 of the proximal and distal portions 120, 130 are aligned when the lugs 170, 180 are fully engaged to provide fluid communication between thesequencing valve 150 and the rock bolt 200. It is preferred that the bayonet fitting operates in a direction opposite the drilling direction of the bolt drilling rig 10, such that the drilling torque encourages engagement of the lugs 170, 180. In this way, torque applied to the proximal portion 120 in a drilling direction is resisted by the distal lug 180 to transfer the torque from the proximal portion 120 to the distal portion 130 in the drilling direction

[0054] The distal portion 130 may include a movable locking pin 190 to engage the proximal portion 120 to transfer torque applied in a non-drilling direction to the proximal portion 120 to the distal portion 130. In this way the distal portion 130 is inhibited from rotating out of engagement with the proximal portion 120 when torque is applied to the proximal portion 120 in the non-drilling direction. Because the distal portion 130 is inhibited from rotating out of engagement with the proximal portion 120, the proximal and distal lugs 170, 180 remain in engagement and inhibit separation of the distal and proximal portions 120, 130 along a drilling axis.

[0055] It will also be appreciated that in this document the terms “comprise”, “comprising”, “include”, “including”, “contain”, “containing”, “have”, “having”, and any variations thereof, are intended to be understood in an inclusive (i.e. non-exclusive) sense, such that the process, method, device, apparatus or system described herein is not limited to those features or parts or elements or steps recited but may include other elements, features, parts or steps not expressly listed or inherent to such process, method, article, or apparatus. Furthermore, the terms “a” and “an” used herein are intended to be understood as meaning one or more unless explicitly stated otherwise. Moreover, the terms “first”, “second”, etc. are used merely as labels, and are not intended to impose numerical requirements on or to establish a certain ranking of importance of their objects.

[0056] Integers:10 bolt drilling rig 122 cavity12 chuck 124 proximal coupling13 drill head 125 threaded port 12514 substrate 126 external thread16 bolt cavity 128 channel100 rock bolt installation system 130 distal portion110 rock bolt installer 131 torque transfer lugs120 proximal portion 132 lid121 grooves 133 fastenersdistal coupling 272 helical portions recess 274 fluid path channel 300 capsule hydraulic actuator 302 body sequencing valve 304 threaded connection valve head 310 first chamber ports 311 walls screw nut 312 first outlet seal 314 first substance joint 316 first piston internal thread 320 second chamber proximal lugs 322 second outlet distal lugs 324 second substance locking pin 326 second piston rock bolt 327 piston seal distal cutting end 328 separator proximal end 330 offset nut 332 end threaded shaft 334 third substance cavity 340 nozzle proximal opening 341 internal side wall distal opening 342 drilling fluid port seal 344 recess pin 346 protrusion shape 350 movable cap cylindrical landing 352 frangible membrane tapered section 354 first seal port 356 second seal mixer 360 pressure relief hole

Claims

CLAIMS:

1. A rock bolt installation system for drilling and fixing rock bolts, the system including: a rock bolt installer for mounting to a chuck of a drill head of a drilling rig, the installer including: a proximal portion having a proximal coupling suitable for engagement with the chuck of the bolt drilling rig, the proximal portion having a cavity for receiving a replaceable capsule containing two or more substances that are combinable to form a fixing adhesive to be dispensed from a nozzle of the replaceable capsule, and a distal portion forming a lid of the cavity, the distal portion having a recess for receiving a portion of the replaceable capsule and a distal coupling suitable for engagement with a rock bolt for drilling the rock bolt into a substrate; a hydraulic actuator for operating the replaceable capsule; a sequencing valve attachable to a supply of pressurized fluid and configurable between a drilling configuration and an injection configuration, wherein, in the drilling configuration, the sequencing valve directs the pressurized fluid to the distal coupling to act as a drilling fluid; and wherein, in the injection configuration, the sequencing valve directs the pressurized fluid to the hydraulic actuator for operating the replaceable capsule.

2. The rock bolt installation system of claim 1, wherein the sequencing valve is located in the proximal portion of the installer and, when the sequencing valve is in the drilling configuration, the drilling fluid is directed from the sequencing valve into the proximal portion.

3. The rock bolt installation system of claim 2, wherein the proximal portion includes a channel for receiving the drilling fluid from the sequencing valve, and the distal portion includes a channel for receiving the drilling fluid from the proximal portion and providing the drilling fluid to the distal coupling.

4. The rock bolt installation system of claim 3, wherein the proximal portion includes an external thread and the installer further includes a screw nut having a pocket shaped to accommodate the distal portion, the screw nut including an internal thread engageable with the external thread of the proximal portion to connect the proximal and distal portions such that the channels are in fluid communication.

5. The rock bolt installation system of claim 3, wherein the proximal portion includes a proximal lug and the distal portion includes a conforming distal lug such that, when the proximal and distal lugs are engaged the lugs resist separating movement of the proximal and distal portions with the channels of the proximal and distal portions being aligned to provide fluid communication.

6. The rock bolt installation system of claim 5, wherein torque applied to the proximal portion in a drilling direction is resisted by the distal lug to transfer the torque from the proximal portion to the distal portion in the drilling direction.

7. The rock bolt installation system of any one of claims 1 to 6, wherein the distal portion includes one or more torque transfer lugs that engage a respective slot of the proximal portion to transfer torque applied to the proximal portion to the distal portion.

8. The rock bolt installation system of any one of claims 1 to 7, wherein the distal portion includes a locking pin to engage the proximal portion to transfer torque applied in a non-drilling direction from the proximal portion to the distal portion such that the distal portion is inhibited from rotating out of engagement with the proximal portion.

9. A replaceable capsule for use with the rock bolt installation system of any one of claims 1 to 8, the replaceable capsule including: a first chamber having a first outlet, the first chamber containing a first substance and a piston operable to drive the first substance from the first chamber through the first outlet; a second chamber having a second outlet, the second chamber containing a second substance and a piston operable to drive the second substance from the second chamber through the outlet; a nozzle in fluid communication with the first and second outlet, the nozzle being configured for engagement with a port of a rock bolt to be fixed, the nozzle having a drilling fluid port to receive drilling fluid for drilling the rock bolt. wherein the first and second substance are combinable to produce an adhesive for fixing the rock bolt.

10. The replaceable capsule of claim 9, wherein the capsule further includes a check valve located between the nozzle and the outlets, the check valve being moveable from a drilling configuration, in which the check valve seals the outlets from the nozzle and the drilling fluidport, and an injection configuration, in which the check valve seals the drilling fluid port and allows fluid communication between the outlets and the nozzle.

11. The replaceable capsule of claim 10, wherein the check valve is moved from the drilling configuration to the injection configuration by pressure applied by the first and / or second piston to the first and / or second substance.

12. The replaceable capsule of claim 11, wherein the check valve includes a frangible membrane configured to withstand pressure sufficient to move the check valve from the drilling configuration to the injection configuration, and configured to fail at a higher pressure reached when the check valve has moved to the injection configuration and the pressure from the first and / or second piston is opposed by the check valve.

13. The replaceable capsule of any one of claims 9 to 12, wherein the nozzle includes a recess for receiving the check valve in the injection configuration, the recess containing a protrusion to bear against the check valve to seal an interface between the nozzle and the check valve.

14. The replaceable capsule of any one of claims 9 to 13, wherein the second chamber includes a separator, with the second substance located between the separator and the second outlet, and a third substance located between the second piston and the separator, wherein the third substance has a higher rate of reactivity than the second substance, wherein the second outlet is located at an offset from an end of the second chamber opposite the piston, such that when the separator abuts the end of the second chamber, the second piston is operable to drive the third substance from the second chamber through the second outlet.

15. The replaceable capsule of any one of claims 9 to 14, wherein the capsule includes a body containing the first and second chamber, and the nozzle is attached to the body with a threaded connection.

16. A rock bolt for use with the rock bolt installation system of any one of claims 1 to 15, the rock bolt including: a distal cutting end, configured to drill into the substrate with the assistance of a drilling fluid;a proximal end having a nut for engagement with the distal coupling of the installer; a shaft extending between the proximal and distal ends, the shaft including a cavity having a proximal opening for receiving drilling fluid from the installer and a distal opening for dispensing drilling fluid to the cutting end, wherein the proximal opening includes a seal for engaging the nozzle of the replaceable capsule, such that when the installer rotates to drill the rock bolt into the substrate, the nozzle rotates with the installer and the rock bolt so that the seal of the proximal opening is stationary relative to the nozzle.

17. The rock bolt of claim 16, wherein the nut at the proximal end is secured to the shaft with a pin extending from the nut into the shaft, wherein the pin is configured to fail above a torque applied to the nut that is higher than a torque for drilling the rock bolt into the substrate.

18. The rock bolt of claim 16 or 17, wherein the proximal opening has a shape congruent with a shape of the nozzle of the replaceable capsule.

19. The rock bolt of claim 18, wherein the shape of the proximal opening includes: a substantially cylindrical distal landing; a tapered proximal section, wherein the seal is located on the cylindrical landing or between the cylindrical landing and the tapered section.

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