Rock drill bit sharpening system with bit holder with macro / micro adjusting locking means

Abstract

A rock drill bit sharpening system is disclosed, designed to enhance torque and power efficiency for sharpening carbide button inserts, including those with polycrystalline diamond (PCD) enhancements. The system integrates an outrunner motor and a VESC motor controller to address the technical problem of maintaining performance in compact applications. The control system communicates with the VESC motor controller to adjust operational parameters, offering flexibility with power sources ranging from 24-48 VDC or 100-260 VAC. The system includes an RFID reader for precision control and Wi-Fi connectivity for remote monitoring. This system is particularly useful for mobile and compact sharpening applications, providing performance levels typically associated with larger machines. The resharpening machine features a modular design for easy component replacement, enhancing the system's adaptability and efficiency in various operational environments.

Description

TITLE: ROCK DRILL BIT SHARPENING SYSTEM WITH BIT HOLDER WITH MACRO / MICRO ADJUSTING LOCKING MEANSFIELD OF THE INVENTION

[0001] The present disclosure pertains to rock drill bit sharpening systems that utilize a bit holder with macro / micro adjusting locking means and discrete tilt mechanism as a coordinated system enabling fast clamping and precise fine alignment. The bit holder of the present disclosure has a compact geometry that maintains clearance below the bit holder for an under-mounted water recycling system. The design is intended to optimize, ergonomic, environmental, safety and sustainability considerations.DESCRIPTION OF THE PRIOR ART

[0002] In drilling operations, the cutting teeth (buttons) on rock drill bits or cutters become flattened (worn) after continued use. A factor contributing to premature rock drill bit failure and poor drilling performance is operating beyond the reconditioning point. Failure to sharpen in time can prove costly. Regular maintenance of the rock drill bit or cutter by sharpening the buttons to restore them to substantially their original profile enhances the bit / cutter life, speeds up drilling and reduces drilling costs. Sharpening should be undertaken when the wear of the buttons is optimally one third to a maximum of one-half the button diameter.

[0003] Regular maintenance on rock drill bits is important to maintain maximum penetration rates and to avoid overheating the bit, as this can destroy its metallurgical properties. Re-profiling the carbide button and removing excess steel optimizes drill bit service life, enhances the performance of the entire drilling operation and keeps down the drilling and grinding costs.

[0004] A range of different manual and semi-automatic sharpening apparatus have been developed including handheld grinders, single arm and double arm grinding machines and grinders designed specifically for mounting on drill rigs, service vehicles or set up in the shop.

[0005] These types of machines utilize a grinding machine having a spindle or rotor rotated at high speed. A sharpening tool or grinding cup, mounted on the end of the rotor or spindle, grinds the button and typically the face of the bit / cutter surrounding the base of the button to restore the button to substantially its original profile for effective drilling. In addition to the rotation of the sharpening tool, these types of grinding machines may include features where the grinding machine is mounted at an angle to the longitudinal axis of the button and the grinding machine is rotated to provide orbital motion with the center of rotation lying in the center of the sharpening tool. When sharpening the buttons, the centering aspects of the grinding machine tend to center the grinding machine over the highest point on the button.

[0006] Existing solutions often struggle to provide the characteristics required for sharpening a diverse array of button sizes. Furthermore, the integration of advanced systems capable of real-time data monitoring and remote operation is limited, hindering the ability to optimize performance and ensure consistent quality. These limitations highlight the need for an innovative approach that addresses these challenges, offering a streamlined and efficient solution for modern resharpening needs.

[0007] In the field of resharpening, there is a growing demand for compact and mobile solutions that can deliver the performance levels typically associated with larger, stationary machines. Traditional systems often rely on bulky components, which limit their portability and efficiency. These systems may also lack the flexibility to operate across a wide range of power sources, making them less adaptable to various operationalenvironments. Additionally, the need for increased automation and precision in the resharpening process is becoming increasingly important, especially as the industry moves towards more sophisticated and automated operations.SUMMARY OF THE INVENTION

[0008] The present invention provides a bit holder for a rock drill bit sharpening system for holding one or more rock drill bits for sharpening, the bit holder comprising (a) an aperture formed by a housing having opposite peripheral side walls, a front side, and a rear side, configured to seat one or more rock drill bits with a button oriented for sharpening; (b) a macro adjustment mechanism including an outer tube carried by the housing and a clamping lever operably coupled to the outer tube to provide coarse clamping of the one or more rock drill bits within the aperture; (c) a micro adjustment mechanism including an inner tube coaxial with the outer tube and a micro adjustment lever operably coupled to the inner tube to provide fine positional adjustment of the rock drill bit after coarse clamping, and (d) a tilt mechanism supporting the bit holder, the tilt mechanism having a tilt control lever with a shaft having a ratchet head at the end of the shaft, the ratchet head operably configured to engage with a gear plate to index and lock the bit holder at preferred tilt angles. The housing, the macro adjustment mechanism, the micro adjustment mechanism and tilt mechanism are configured with a compact profile that maintains clearance below the bit holder for an under-mounted water recycling system.

[0009] In one embodiment the outer tube of the macro adjustment mechanism is movable longitudinally within an opening on a guide block on the front side of the aperture housing and an opening in the front side of the aperture housing by compressing the clamping lever to move a pressure plate toward the rear side of the aperture for coarse holding adjustment.

[0010] The inner tube of the micro adjustment mechanism is actuated by an eccentric cam with detents at an end of the micro adjustment lever in contact with a roller at a free end of the inner tube, the other end of the inner tube is connected to the pressure plate, wherein rotation of the micro adjustment lever slides the inner tube within the outer tube to secure the pressure plate against the one or more drill bits.

[0011] In another embodiment, the present invention includes an under mounted water recycling system for use with a rock drill bit sharpening system of the present invention mounted on drill rigs and service vehicles and having a bit holder in accordance with the present invention. The under mounted water recycling system is provided below the bit holder to catch cooling water flushing the surface of one more bits during sharpening. In one embodiment the water recycling system comprises a V-shaped trough connected to the rear side of the bit holder, a rubber collection bag under mounted to the trough and a filter bag in the rubber collection bag.

[0012] In a further embodiment the present invention provides a method for securing and aligning a rock drill bit for button sharpening, comprising: (a) placing one or more rock drill bits into an aperture of a bit holder having a V-shaped rear side and opposite side walls; (b) actuating a clamping lever to release a macro adjustment mechanism that moves a pressure plate into contact with the one or more rock drill bits and releasing the clamping lever to hold the rock drill bits within the aperture; (c) actuating a micro adjustment lever to operate a micro adjustment mechanism that finely adjusts the bit position to align a selected button along a sharpening axis; and (d) setting a tilt angle of the bit holder by engaging a ratchet heat using a tilt control lever to orient the button for a desired sharpening profile, wherein the macro adjustment mechanism is configured with a compact geometry that preserves clearance for an under mounted water recycling system.

[0013] In another embodiment the method sharpening rock drill bits according to the present disclosure includes cooling water and removed metal bits are flushed from a button being sharpened and drained into an undermount water recycling system. The undermount water recycling system comprises a V-shaped trough connected to the rear side of the bit holder, a rubber collection bag under mounted to the trough and having a filter bag in the rubber collection bag, wherein the filter bag screens out the metal bits so that cooling water can be recycled from the rubber collection bag.

[0014] In another embodiment the invention provides a retrofit kit for a rock drill bit holder, comprising: (a) an outer tube and clamping lever assembly configured to provide coarse clamping when mounted to a holder frame; (b) an inner tube and micro adjustment lever assembly configured to provide fine alignment when mounted coaxially within the outer tube; and (c) a tilt ratchet sub-assembly comprising a gear plate and pawl with an operator tilt control lever. The retrofit kit is configured to mount to a rock dill bit holder and to preserve a clearance region under the holder for a water recycling system.

[0015] These and other features will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings and claims.

[0016] Further features of the invention will be described or will become apparent in the course of the following detailed description.BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order that the invention may be more clearly understood, an embodiment will now be described in detail by way of example, with reference to the accompanying drawings, in which:

[0018] FIG. 1 is a perspective view from the front right side of one embodiment of a rock drill bit sharpening system with an outrunner motor and VESC controller according to the present invention.

[0019] FIG. 2 is perspective view from the front left side of the rock drill bit sharpening system of Fig. 1.

[0020] FIG. 3 is a rear perspective view of the rock drill bit sharpening system of Fig. 1.

[0021] FIG. 4 is a left side plan view of the rock drill bit sharpening system of Fig. 1.

[0022] FIG. 5 is a front plan view of the front of the rock drill bit sharpening system of Fig-1-

[0023] FIG. 6 is a cross-section of the support arms, control box, and grinding motor assembly for a rock drill bit sharpening system of Fig. 5 thru line A-A.

[0024] FIG. 7 is an enlarged front perspective view of the control box of the rock drill bit sharpening system of Fig. 1.

[0025] FIG. 8 is a cross section of the control box of Fig. 7.

[0026] FIG. 9 is an enlarged view in cross-section of the rock drill bit sharpening machine in Fig 6.

[0027] FIG. 10 is an enlarged plan view of the sharpening system thru line F-F in Fig. 5.

[0028] FIG. 11 is a side plan view of the motor housing for the resharpening machine of Fig 9.

[0029] FIG. 12 is a cross-section of motor housing of Fig. 11 thru line C-C.

[0030] FIG. 13 is an is an enlarged perspective schematic view from the top front side of the bit holder with macro / micro locking means illustrated in the rock drill bit sharpening system of FIG 1.

[0031] FIG 14 is a perspective view from the bottom right side of the bit holder with macro / micro locking means of FIG 13.

[0032] FIG 15 is a perspective view from the left side of the bit holder with macro / micro locking means of FIG 13.

[0033] FIG 16 is a perspective view from the left side of a stripped down version of the macro / micro locking means of FIG 13 showing the macro adjustment means and tilt mechanism.

[0034] FIG 17 is a parts diagram for the bit holder with macro / micro locking means of FIG 13.

[0035] FIG 18 is a perspective view from the front right side of the rock drill bit sharpening system of FIG 1 with one embodiment of an under-mounted water recycling system.

[0036] FIG 19 is an enlarged side perspective view of the under mounted water recycling system, bit holder and water pump of FIG 18.

[0037] FIG 20 is an enlarged right side perspective view of the under mounted water recycling system and bit holder of FIG 19.

[0038] FIG 21 is a parts diagram for the under mounted water recycling system of FIG 19.

[0039] Similar references are used in different figures to denote similar components.

[0040] Further features of the invention will be described or will become apparent in the following detailed description.DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0041] Referring to Figs 1 - 12, an embodiment of a compact rock drill bit sharpening system optionally suitable for mobile applications according to the present invention is illustrated. The rock drill bit sharpening system is generally indicated at 20. The sharpening system 20 includes a sharpening (grinding) machine 21, means for holding one or more bits to be sharpened generally indicated at 22 and a support system generally indicated at 23. The sharpening machine 21, means for holding the bits 22 and support system 23 are arranged to permit relative movement been the sharpening machine 21 and the bit to be ground to permit alignment of the sharpening machine 21 with the longitudinal axis of the buttons on the bit. The sharpening system 20 has a control system having a programmable operator control panel 24 that enables the operator to input data and a programmable control card provided attached to the rear of the operator control panel having a circuit board containing a central processor (i.e. microprocessor or microcontroller) for the control system of the rock drill bit sharpening system. In the embodiment illustrated the control system is located within control box 25 and is capable of directly or indirectly monitoring and adjusting one or more operational parameters. The operational parameters of most interest are selected from the group consisting of feed pressure, grinding cup RPM and grinding time.

[0042] In the embodiment of the sharpening system 20 shown in Figs. 1-12, the sharpening machine 21 is carried by support system 23 which includes an arm or lever system 26 attached to frame 27. Frame 27, in the embodiment illustrated has an open front box configuration, having a left side panel 28, right side panel 29, top panel 30 and a backpanel 31. A canopy 32 is pivotally connected at points 33,34 to the left side panel and right side panel adjacent the top panel.

[0043] In the embodiment shown in Fig. 1-6, the arm or lever system 26 for carrying and positioning the sharpening machine 21 as noted previously is attached to the frame 27. The arm or lever system 26 consists of a pair of parallel arms 35,36 with one end 37,38 of each arm 35,36 pivotally mounted to the frame 27. The other end 39,40 of each arm 35,36 is pivotally connected to the backside 41 of a control box 25. The arm system 26 controls the vertical movement of the sharpening machine 21 up and down.

[0044] Within frame 27, is means 42 to provide a balance pressure to the portion of the support system 23 that controls the movement of the grinding machine 21 in the direction of the longitudinal axis of the button or bit when not in use and feed pressure when in use. In the embodiment shown, the means 42 to provide feed pressure is an actuator, generally indicated at 43 pivotally connected to arm 35. In the embodiment illustrated the actuator 43 is an electro-mechanical linear actuator having a screw whose length and speed of travel is controlled by an electric motor 44.

[0045] High feed forces in conventional self-centering sharpening machines could potentially cause the sharpening machine to fall off the button with great force. To produce the high feeds safely, and control the feed pressure, means are provided to monitor and control the feed pressure. In the embodiment illustrated the means to monitor the feed pressure is a load cell 45 provided between the end of the linear actuator 43 and the point of connection 46 to the arm 35. The load cell measures the feed pressure of the sharpening machine 21 against the drill bit. An output signal from the load cell is delivered to the control system. The control system controls the movement of the screw of the linear actuator through the motor 44 and thereby controls the feed pressure. The combination of control system, linear actuator and load cell also allow for feed (grinding)pressure to start from zero. This differs significantly from conventional grinding machines as the minimum feed pressure in conventional grinding machines is equal to the weight of the grinding machine and support system. Where the load cell signals an abrupt reduction in load, possibly due to the grinding cup moving off the button being ground, the control system may be programmed to shut down the grinding operation or other procedure to minimize danger to the operator.

[0046] To accommodate the fact that the surface of the button to be ground may be worn unevenly, means are provided to enable the sharpening machine 21 to move slightly during grinding over the uneven button surface without adjustment by the linear actuator. In the embodiment illustrated the means to enable the grinding cup to move slightly is provided by is provided by the design of the arms 35, 36 together with the means for holding one or more bits to be sharpened 22 to provide some give or flex. Alternatively, a spring working together with the load cell 45 to maintain mean target feed value on the button.

[0047] Figs 1-12 shows the sharpening machine 21 attached to plates 47 below the control box 25. The sharpening machine 21 is locked in place by alien key bolts or levers.

[0048] A water-cooled electric motor, generally indicated at 49, has an exterior housing 50 defining a chamber in which the rotor 51 and stator 52 are located. A drive coupling 53 at the bottom of the housing 50 permits attachment of a spindle assembly. With reference to the Figs 6 and 9 one embodiment of a spindle assembly, generally indicated at 54, for a sharpening machine for grinding the hard metal inserts or working tips of rock drill bits (percussive or rotary), tunnel boring machine cutters (TBM) and raised bore machine cutters (RBM) and more specifically, having an outrunner motor 60 is illustrated. The drive coupling 53 is inserted into the mating drive coupling 55 on spindle assembly 54. The spindle assembly 54 has an output drive shaft 56 to which a grinding cup / sharpeningtool 57 can be connected. The spindle assembly 54 is attached to the motor housing 51 by bolts. Coolant water for delivery to the sharpening tool / grinding cup surface is provided by tubing 62 from a water pump 58 and water source connection 59. In one embodiment as shown in Fig 19, cooling water is filled into a water tank or collection bag on an undermount water recycling system 200 and recycled by water pump 58 from the water tank or collection bag 201 to the water inlet 83 on the electric motor 49. Using the under undermount water recycling system 200 provides significant reduction in water consumption and collection from filters in the water recycling system of the expensive metal bits that can be recycled.

[0049] The rock drill bit resharpening machine 21, shown in the Figs. 6, 9-12, includes an outrunner motor 60 and a VESC motor controller 61. The rock drill bit resharpening machine 21 is engineered to improve torque and power characteristics, making the machine appropriate for sharpening a diverse range of carbide button insert sizes, including inserts with polycrystalline diamond (PCD) enhancements. Figs 6, 9-12 demonstrate the integration of various components, including the control system, which is set up to communicate with the VESC motor controller for adjusting operational parameters based on collected data.

[0050] The outrunner motor 60 serves as an important component of the sharpening machine 21, providing the necessary torque and power for effective sharpening. This motor is configured to handle a variety of insert sizes, ensuring versatility in the machine's application. The design of the motor allows for efficient operation, contributing to the machine's overall performance.

[0051] The electric motor 49, 60 in the embodiment illustrated is a brushless motor of the so-called outrunner type and comprises an internal stator 52 and rotor 51 located within a motor housing 50. The stator 52 is connected to or forms part of a static component ofthe electric motor 60. The electric motor 60 further comprises an external rotor 51. The rotor 51 rotates externally around the stator 52 about the longitudinal axis during operation of the electric motor 60. An industrial outrunner brushless motor typically consists of the following components: stator 52 (with windings), rotor 51 (with permanent magnets), motor shaft, bearings, position sensors (like Hall sensors), and an electronic controller. In the embodiment illustrated the electronic controller is a VESC controller 61. In the outrunner design the rotor, holding the magnets, is located on the outside of the stator, allowing it to rotate around the stationary stator windings. The position sensors are embedded within the stator and detect the rotor position by sensing the magnetic field from the permanent magnets. Due to the larger diameter of the rotor, outrunner motors can generate high torque compared to in runner motors with similar size. The exposed rotor surface allows for better heat dissipation.

[0052] A VESC motor controller 61 as shown in Fig 10 is operatively connected to the outrunner motor 60, and the control system to control motor speed and torque. The controller can operate on a power source ranging from 24-48 VDC or 100-260 VAC, offering flexibility in different operational environments. Power input is located at connection 82. The advanced capabilities of the controller enable precise adjustments, enhancing the machine's efficiency and effectiveness. The VESC motor controller 60, which stands for "Vedder Electric Speed Controller," works by receiving input signals from the control system, processing them with a microcontroller, and then precisely controlling the power delivered to the electric motor 60 through a complex algorithm, allowing for fine-tuned speed and direction adjustments based on the input, all while utilizing advanced control strategies like Field Oriented Control (FOC) for optimal efficiency and performance; essentially acting as an interface between the power source and the motor 60, regulating the current flow to achieve the desired motor behavior. The VESC motor controller takes input from the control system specifying desired motorspeed and direction. A microcontroller within the VESC interprets the input signal and calculates the optimal control strategy for the motor. It uses advanced algorithms like FOC to precisely control the magnetic field within the motor, resulting in smooth and efficient operation. Utilizes Pulse Width Modulation (PWM) to regulate the voltage supplied to the motor 60, allowing for fine-tuned speed control. A feedback mechanism in the form of sensors like Hall effect sensors or encoders monitor motor performance and ensure accurate control.

[0053] VESC technology is open-source, allowing developers and enthusiasts to customize and modify the software to suit specific applications. It can implement complex motor control algorithms like field weakening for high-speed operation.

[0054] Figs 1-5 show different views of one embodiment of the rock drill bit sharpening system 20 of the present invention. They show the relative location of the sharpening (grinding) machine 21, means for holding one or more bits to be sharpened generally indicated at 22 and support system 26 attached to frame 27. Location of main power input 64 is best shown in Fig 2 - 4 as well as water input 59 and water pump 58 and means for holding one or more bits to be sharpened 22 in the form of bit holder 90.

[0055] The compact VESC motor controller enables wider range of VDC operating voltages to perform meet the operational requirements. The sharpener illustrated is rated 24-48 VDC. Because the VESC motor controller with outrunner motor is VDC rated, the use of AC / DC converters allows for the 24-48 VDC sharpener with outrunner motor to be operated from a 100-260 VAC, 50 / 60Hz, 1 Ph power source using a appropriately sized AC / DC power supply that puts out 24-48 VDC, 48VDC being preferred due to the lower current during operation. The use of a three-phase power supply is also possible.

[0056] The control system is configured to communicate with the VESC motor controller to cause the motor to operate at preferred controlled variable speed and torque, whilealso gathering operational data during operation (such as motor voltage, motor current, motor temperature, motor controller temperature, etc. A Hall sensor is an integral part of monitoring and adjusting rpms under load.

[0057] The control system (with connected VESC motor controller) will have the same capability to scan RFID tags of grinding cups (now referred to as sharpening tools) and operator ID cards. This therefore allows for precision control of VESC motor controller and Outrunner motor to match operational data specific to RFID data on individual sharpening tools.

[0058] The control system is also Wi-Fi enabled and will be utilizing CME Connect to monitor and gather operational data for analytical and reporting purposes.

[0059] The operational and performance data of the VESC motor controller, as well as the Outrunner Motor, will be an integral part of remote online Wi-Fi based troubleshooting / monitoring of the button bit sharpening system.

[0060] The control system will also enable software updates off all components connected to the control system, including the VESC motor controller.

[0061] Fig 6 provides a cross-sectional view of the button bit sharpening machine 21, control box 25, arms 35,36 and linear actuator 37 thru line A-A in Fig 5, highlighting its compact design and the integration of the outrunner motor 60 and illustrates the arrangement of key components, emphasizing the machine's portability and efficiency.

[0062] Fig 7 provides a perspective front view of the control box 25 for the sharpening system 20 showing an RFID reader 70, stop 71 start 72 buttons, display panel 85, WiFi antenna 73 visor 74 and left side joystick 75. Handles 76 are provided for assisting with manual alignment of the sharpening machine 21 with the button to be ground.

[0063] FIG 8 is cross-sectional side view of the control box 25 showing the motor 60 and components including motor 77 for providing orbital rotation of the sharpening machine. It also shows the plates 37 and slots for attachment of the sharpening machine 21 to the control box 25.

[0064] FIG 9: This front cross-sectional view of the resharpening machine shows the positioning of the sharpening tool / grinding cup 57, servomotor 78 for the splash guard 79 and other operational parts.

[0065] FIG 10: This figure is an enlarged plan view of the sharpening system thru line F-F in Fig 5. It shows the location of the VESC motor controller 61 and cooling fan 80.

[0066] FIG 11: This figure provides a side plan view of the motor housing 50, illustrating the motor coupling 53, cooling flange 81 and water input 83.

[0067] FIG 12: This figure provides a cross section of the motor housing thru line C-C in Fig 11. It provides a detailed view of this component's integration into the overall system including VDC Input 86 from VESC motor controller 61.

[0068] As noted above, the rock drill bit sharpening system has a control system, has a programmable operator control panel capable of directly or indirectly monitoring and adjusting one or more operational parameters. A programmable control card is provided attached to rear of operator control panel, having a circuit board containing the central processor (ie. microprocessor or microcontroller) for the control system of rock drill bit sharpening system. The central processor can be located anywhere suitable for the application and can be suitably interconnected with other sub-processors to monitor various functions as deemed necessary for proper function. The overall control system includes systems and controls that together with a microprocessor or microcontroller can control all aspects of the rock drill bit sharpening system including grinding time on eachbutton, rotational speed of the sharpening tool / grinding cup, grinding pressure, bit holder tilt function, operating lights and coolant flow. The microprocessor or microcontroller and the control system can be used to provide other functions either manual or automatic. The microprocessor or microcontroller and control system can also control the flow of coolant to the face of the button during sharpening / grinding.

[0069] In addition, the control panel software can be configured such that the user could select for example whether long grinding cup life or high material removal rate of the grinding cup is preferred.

[0070] When using a sharpening tool / grinding cup equipped with an RFID tag, an RFID reader is provided connected to the control system. The control system in the embodiment illustrated further comprises a touch screen display. When a sharpening tool / grinding cup equipped with an RFID tag, the grinding cup is positioned adjacent the RFID reader a proximity sensor detects the RFID tag and scans the data on the tag. The data preferably includes a specific ID identifier for the particular sharpening tool / grinding cup and the number of grinding cycles over which it has been used to date. The ID identifier data includes the sharpening tool / grinding cup size and grinding surface profile. Once the RFID tag has been scanned the data is transmitted to the programmable microprocessor and the grinder size and profile can be displayed on the touch screen.

[0071] The control system and the programmable control card provided attached to the rear of the operator control panel having a circuit board containing a central processor (i.e. microprocessor or microcontroller) for the control system of the rock drill bit sharpening system have circuit inputs for the outrunner motor, VESC controller, water pressure, orbital rotation of the sharpening machine, spindle tightening, and controlling linear actuator function providing feed pressure. The control panel is illustrated withjoysticks 75 on both the left and right side of the control box 25. The joysticks provide a means to achieve two-hand control when deemed necessary for reasons such as safety, etc. The joysticks may be used to scroll down the menu as well as select various functions. Two-hand control may be achieved by requiring that the operator move both joysticks to activate the desired function.

[0072] The control system of rock drill bit sharpening system may be provided with a transmitter and a receiver configured to enable rock drill bit sharpening system to communicate over the internet to a server or virtual server located remotely from the rock drill bit sharpening system. The illustrated embodiment of the rock drill bit sharpening system shows a WiFi connection thru WiFi antenna 73 but other forms of connection such as cellular are possible.

[0073] In a preferred embodiment of rock drill bit sharpening system, each operator is required to login before using the rock drill bit sharpening system and log out after use. Login can be by way of the touch screen display on the rock drill bit sharpening system or a token containing operator ID data such as in the form of key fob, that can be scanned or connected when in proximity to the rock drill bit sharpening system. Requiring operator login insures only persons trained in the proper and safe operation of the rock drill bit sharpening system are utilizing same. A further benefit to management is that hard data can be communicated from the rock drill bit sharpening system on operator performance and efficiency.

[0074] After the operator has logged in the rock drill bit sharpening system is set up for normal operation, the operator puts a bit into the means 22 on the rock drill bit sharpening system for holding the bits to be ground. In the embodiment illustrated, the means 22 for holding the bits to be ground is a bit holder 90 having a housing with opposite peripheral side walls 104,105, a front side 106 and a V-shaped rear side 107. Theperipheral side walls 104, 105, front side 106 and V-shaped rear side 107 define a pentagonal shaped aperture 108 into which one or more bits to be ground are placed. In the embodiment illustrated the front side 106 is adapted to support a manual locking means generally indicated 93 having a macro adjustment means and a micro adjustment. The manual locking means 93 has a modified macro adjustment to save space due to the water recycling system being installed under the bit holder 90. A clamping lever 94 is for macro adjustment of an outer tube 118, the micro adjustment lever 95 is for adjustment of an inner tube 113. There is a tilt mechanism generally indicated at 165 having a ratchet action to control the tilt of the bit holder 90 with tilt control lever 96 controlling the ratchet action.

[0075] With reference to Figs 13-17 while the present invention is applicable to all grinding apparatus having a grinding machine carried for vertical and horizontal adjustment by an arm or lever system journaled on a stand or frame and with a tiltable means for holding the bit to be ground, the sharpening system, generally indicated at 20, shown in FIG 1 is of the type intended to be mounted on drill rigs, service vehicles or set up in the shop, optionally installed inside a cabinet enclosure.

[0076] In the embodiment illustrated in FIGS 13-18, bit holder 90 has manual locking means generally indicated at 93. The bit holder 90 has a manual locking means assembly including a pressure plate 110 having a generally rectangular configuration and with a pad 111, made preferably from an elastomeric material, attached to a first face 112 of the pressure plate 110 intended to be facing one or more bit(s) inserted into aperture 108 on bit holder fixture 90. This pad 111 helps hold the bit(s) securely as it conforms to the shape of the bit as pressure is applied. A first tube (inner tube) 113 has one end 114 attached perpendicular to the second face 115 of pressure plate 110. The other end 116 of the inner tube 113 is adapted to retain a roller 117. The inner tube 113 slides within a second tube 118 (outer tube) having an internal cross-section slightly larger than the external cross-section of the inner tube 113 so that the inner and outer tubes 113,118 can slide relative to each other. The end 119 of the outer tube 118 remote from pressure plate 110, is adapted to support a micro adjustment lever 95 having a handle 121 on one end of a shaft 122 and a cam 123 at the other end of shaft 122. A shaft 124 extends laterally through each side of cam 123 and through the outer tube 118 to permit the micro adjustment lever 95 to rotate around the eccentric axis defined by shaft 124. Upper and lower slots 128,129 in the outer tube 118 allow the micro adjustment lever 95 with cam 123 to rotate. A pair of return springs 130,131 have one end 132,133 connected to an anchor 134,315 on the second face 115 of pressure plate 110 and the other end 136,137 to the distal ends 126, 127 of shaft 124 extending through the outer tube 118. The return springs 130,131 retain the cam 123 in contact with roller 117 on the end of the inner tube 113.

[0077] The locking means 93 assembly as described above is supported within a guide box 138 mounted on the front side 106 of bit holder fixture 90. The outer tube 118 slides within an opening 139 on guide box 138 sized and shaped to correspond to the cross section of the outer tube 118. A corresponding opening 140 in the front side 106 of the bit holder 90 is aligned with the opening 139 on guide box 138.

[0078] A clamping lever 94 has one end inserted into slot 141 on the left side wall 142 on guide block 138. The clamping lever 94 extends through slot 143 on the right side wall 144 of guide block 138. An opening 145 in clamping lever 94 is generally aligned and sized and shaped in match the opening 139 on guide box 138 and opening 140 on the front side 106 of the bit holder 90. The free end of clamping lever 94 is spring biased into a locking position where the edges of opening 145 engage with the outer sides of the outer tube 118. Pressing the locking lever 94 towards a matching tab extension 194 extending outwardly on the front side 106 of bit holder fixture 90 unlocks the outer tube 118 relative to guide box 138 by aligning openings 139, 140 and 145 and dis-engaging the edges of opening 145 with the outer sides of the outer tube 118. With clamping lever 94 pressedtowards tab extension 194, the outer tube 118 slides through guide box 138 permitting pressure plate 110 to be moved into contact with the body of a bit (not shown) within aperture 108. Releasing clamping lever 94 spring biases it into a locking position, locking the outer tube 118 in place. This acts as the macro adjustment of the locking means 93.

[0079] Once the macro adjustment is completed, micro adjustment lever 95 can be moved, causing cam 123 to rotate around shaft 124. Rotating the cam 123, causes the inner tube 113, to slide longitudinally within the outer tube 118 pushing pressure plate 110 towards the skirt or shank of the bit(s) within the aperture 108. The cam 123 maintains the pressure applied until it is rotated so as to release the pressure. The cam 123 is locked in the preferred position by roller 117 fitting within one of the seats or indentations on cam 123. The preferred embodiment has one or more indentations within the cam 123 that allows the roller 117 to seat. This movement of the pressure plate 110 by operation of lever 95 acts as the micro adjustment.

[0080] A safety cover 154 has a top plate portion 155 and front depending flange 156. The top plate 155 is attached to a top edge 157 of pressure plate 110. Slots 158,159 in the top plate portion 155 and front depending flange 156 permit movement of the shaft 122 of lever 95 to be unimpeded by safety cover 154. The safety cover 154 protects the internal mechanisms of locking means 93 from dirt while also protecting the operator from the internal moving parts. In the embodiment shown in FIG 17, the top plate portion 155 includes three position indicators 255 calibrated to assist in indexing one or more rock drill bit buttons relative to a nominal centerline of the sharpening machine; wherein the center position indicator 256 is used when only one bit is inserted into the bit holder 90 and all three position indicators 255 are used when multibit adapter is utilized.

[0081] The manual locking means of the present invention minimizes operator time when grinding multiple bits of the same size as the macro adjustment needs to be doneonly once then the micro adjustment is used to lock or release the bits from the bit holder fixture. If small bits are being sharpened bottom plate 160 can be inserted into the bottom of aperture 108 as shown in Fig 14. Bottom plate 160 has tabs on the rear end of bottom plate 160 that fit in slots in the V-shaped rear side 107 of bit holder 90. The front end of bottom plate 160 is held against the guide box 138. When small bits are being ground a multi-bit adapter can be utilized. The multi-bit adapter permits up to three bits to be secured in the bit holder at one time. If grinding down-the-hole bits with a long shank the bottom plate 160 can be removed.

[0082] The sharpening machine 21, in order to properly regrind a worn button, should be aligned with the longitudinal axis of the button. When sharpening gauge buttons, the bit holder 90 is tilted to correspond to the angle at which the buttons are mounted in the bit. The bit is then indexed in the bit holder so that the grinding machine is rotated to provide orbital motion with the center of rotation of the output shaft of the spindle assembly around the longitudinal axis of the gauge button to be ground.

[0083] In the embodiment illustrated in Figs 14-17 the bit holder 90 has a tilt mechanism generally indicated at 165. The tilt mechanism comprises a gear plate 167 mounted to arm 262 by upper and lower flanges 269, 270. Gear plate 167 has a plurality of gear teeth or indentations 168 on its front edge 271. A tilt control lever 96 has a shaft 272 pivotally connected to side wall 104 at pivot 273. Below pivot 273 is a ratchet head 274 with teeth facing and engaging the indentations 168 on gear plate 167. Below ratchet head 274 is a pawl 169 pivotally connected to side wall 104 at pivot 275. Pawl 169 has teeth facing and engaging the indentations 168 on gear plate 167. An arm extension 276 on shaft 272 above pivot 273 and a spring arm 277 on pawl 169 are connected at their free ends by spring 278. When tilt control lever 96 is moved upwardly, the end of shaft 272 rotates and engages with and rotates pawl 169 to disengage the teeth on both the ratchet head 274 and pawl 169 from the indentations 168 on gear plate 167. This permits the bit holder 90to tilt around rod 267 that extends through hole 279 on gear plate 167. The end of rod 267 remote from arm 262 is connected to side wall 104. The end of rod 267 adjacent arm 262 is inserted in a cylindrical housing on arm 262. Rod 267 can rotate within the cylindrical housing. When tilt control lever 96 is released spring 278 biases the ratchet head 274 and pawl 169 back into engagement with the indentations 168 on gear plate 167. Without a bit in the bit holder 90, the bit holder 90 tends to a zero tilt angle with the ratchet head 274 and pawl 169 disengaged from with the indentations 168 on gear plate 167. When one or more bits are placed in bit holder 90, the weight of the bits tend to 90 to tilt around rod 267 with the ratchet head 274 and pawl 169 disengaged from with the indentations 168 on gear plate 167. A scale 171 with arcuate slot 166 is preferably provided on gear plate 167 to indicate the angle at which the bit holder fixture 90 is tilted. Once set, the angle is fixed and doesn't have to be reset for each gauge button mounted at the same angle in the bit. The micro adjustment lever 95 does need to be released to permit the bit to be manually rotated to align the next gauge button being resharpened with the output drive shaft and sharpening tool on the sharpening machine. Rotation of the micro adjustment lever releases the pressure plate 110 from locking engagement with the bit to allow easy repeat release, indexing and clamping of one or more bits.

[0084] To set up the bit holder for use and release it from its stored passion in Fig 4. First unlock the bit holder 90 by pulling up the latch 172 attached to back panel 31 of frame 27. The bit holder 90 has a macro adjustment and a quick clamp function. The macro adjustment is adjusted by compressing the clamping lever 94 and using the clamping lever 94 to open and close aperture 108 as required. Adjust the outer tube 118 assembly leaving enough space for the bit(s) to be inserted and easily rotated in the bit holder 90. The micro adjustment lever 95, should be in the up or down position to properly adjust the macro adjustment. Clamp the bit by pivoting the micro adjustment lever 95 to a horizontal position as shown. Release the pressure plate 110 by pivoting microadjustment lever 95 to its up or down position. To adjust the bit table angle, use the tilt control lever 96.

[0085] The bit holder 90 is attached to a pair of arms 261,262 When the arm is folded as shown in FIG 4 the bit holder 90 can be stowed securely against the frame of the grinder using latch 172. This ensures that the bit holder 90 will not be damaged in transport when installed in mobile applications such as that of a drilling rig. Arm 261 has one end journaled to the frame 27 of the grinding apparatus on post 263. The arm 262 is pivotally mounted to the end 264 of arm 261 remote from frame and post 263 at pivot 265. The bit holder 90 is pivotally connected to the other end 266 of arm 262 at pivot 268. This provides three articulations in the arms 261, 262 and bit holder 90 allowing better positioning of the bit holder 90 in both the stored and operative positions.

[0086] An under mounted water recycling system, generally indicated at 200, is provided below the bit holder 90 to catch cooling water flushing the surface of the bit during sharpening. When the rock drill bit sharpening systems are mounted on drill rigs, service vehicles etc. the water recycling system 200 comprises a V-shaped trough 204 connected to the rear side 107 of the bit holder 90, a rubber collection bag 201 under mounted below the bit holder 90 and having a filter bag 202 in the rubber collection bag 202. Before commencing sharpening the rubber collect bag is filled with water. The top edge of the rubber collection bag is contoured to enable access to the macro adjustment, micro adjustment and tilt mechanism on bit holder 90. The cooling water and removed metal bits are flushed from the button being sharpened and drain into the water recycling system. Filter bag 202 screens out the metal bits so that clear water can be pumped from the rubber collection bag 201 by water pump 58 through water line 203, then pumped to the water inlet 83 on the cooling flange 81 on the bottom of outrunner motor 60. A water outlet 84 and attached water line connects to the spindle housing 54 on the sharpening machine 21 to provide the colling water to the face of the bit during grinding.

[0087] When the rock drill bit sharpening systems are mounted on a stand set up in a shop the water recycling system can be mounted on the stand below the bit holder 90. A water tank can be provided with a horizontal filter tray to screen out the metal bits. The filtered water is pumped from the bottom of the water tank by water pump then to the water inlet 83 on the cooling flange 81 on the bottom of outrunner motor 60.

[0088] Once the bit is secure the operator selects a sharpening tool / grinding cup having the proper size and profile of the buttons on the bit that are to be ground. When using a sharpening tool / grinding cup equipped with an RFID tag, when the sharpening tool / grinding cup is brought into proximity of the RFID reader a proximity sensor detects the RFID tag and scans the data on the tag. The data preferably includes a specific ID identifier for the particular grinding cup and the number of grinding cycles over which it has been used to date. The ID identifier data includes the sharpening tool / grinding cup size and grinding surface profile. Once the RFID tag has been scanned the data is transmitted to the programmable microprocessor and the grinder size and profile can be displayed on the touch screen to confirm the operator has selected the correct size and profile of grinding cup. The control system will track the use of the particular sharpening tool / grinding cup and the grinding apparatus it is being used on and records the number of cycles it has been used.

[0089] The operator then detachably connects the sharpening tool / grinding cup to the output drive shaft of the sharpening machine and aligns the sharpening tool / grinding cup about the longitudinal axis of the first one of the working tips to be ground.

[0090] The control system of the rock drill bit sharpening system sets a rotational speed of the output drive and a feed pressure based on the data scanned from the RFID tag and communicates that to the VESC Controller to control the rotational speed and torque ofthe outrunner motor and based on the connected power source ranging from 24-48 VDC or 100-260 VAC.

[0091] Sharpening commences on a first button / working tip to be ground at the rotational speed, feed and grinding time determined by the central processor. After grinding a first working tips to be ground, the operator then aligns the sharpening tool / grinding cup about the longitudinal axis of another one of the working tips to be ground having the same size and profile of the first working tip, then sharpening / grinding the second working tips to be ground at the rotational speed, feed and grinding time determined by the central processor;

[0092] These steps in para

[0088] to

[0091] are repeated until all of the working tips on the rock drill bit of the same size and profile have been ground. The control system monitors and tracks the number of rotations the sharpening tool / grinding cup is used during grinding until the operator removes the sharpening tool / grinding cup from the output drive shaft of the sharpening machine.

[0093] When the operator has finished using a particular sharpening tool / grinding cup he disconnects it from the output drive shaft and the sharpening tool / grinding cup is brought into proximity to the RFID reader so that data on the number of cycles it has been used may be transcribed to the RFID tag and / or transmitted to a server.

[0094] The use of the control system of the present invention provides the management of the grinding facility with valuable data on the operation, performance and life of not only the grinding cups but the grinding apparatus and can compare performance of different grinding apparatus in the same or different facilities.

[0095] The control system of the grinding apparatus can be pre-programmed with recommended operational parameters for different sizes and profiles of grinding cups.On reading the RFID tag associated with a particular grinding cup, the control system can automatically set the grinding time and feed pressure for the grinding cup. The operator can be provided with an override ability to increase or decrease grinding time and or feed pressure where the button wear is more or less than normal.

[0096] By connecting each grinding apparatus to a network and to the internet, the control system equipped with transmitter and receiver capability allows the equipment manufacturer to be advised of error messages during operation of the grinding apparatus and either fix the error and / or schedule maintenance on the grinding apparatus. It also provides a means for the manufacturer to quickly install software upgrades or fixes. Finally, the data received by the manufacturer assists in designing further improvements to the equipment.

[0097] Having illustrated and described a preferred embodiment of the invention and certain possible modifications thereto, it should be apparent to those of ordinary skill in the art that the invention permits of further modification in arrangement and detail and is not restricted to the specific semi-automatic grinding apparatus illustrated.

[0098] It will be appreciated that the above description related to the preferred embodiment by way of example only. Many variations on the invention will be obvious to those knowledgeable in the field, and such obvious variations are within the scope of the invention as described and claimed, whether or not expressly described.

Claims

CLAIMS1. A bit holder for a rock drill bit sharpening system, comprising:• a housing defining an aperture bounded by opposite peripheral side walls, a front side, and a rear side configured to hold one or more rock drill bits with a button / working tip oriented for sharpening;• a macro adjustment mechanism including an outer tube carried by the frame and a first clamping lever operably coupled to the outer tube to provide coarse clamping adjustment of the one or more rock drill bits within the aperture;• a micro adjustment mechanism including an inner tube coaxial with the outer tube and a micro adjustment lever operably coupled to the inner tube to provide fine positional adjustment and clamping of the one or more rock drill bits after coarse clamping adjustment, and• a tilt mechanism supporting the bit holder, the tilt mechanism having a tilt control lever with a shaft having a ratchet head at the end of the shaft, the ratchet head operably configured to engage with a gear plate to index and lock the bit holder at preferred tilt angles,wherein the frame, the macro adjustment mechanism, the micro adjustment mechanism and tilt mechanism are configured with a compact profile that maintains clearance below the bit holder for an under -mounted water recycling system.

2. The bit holder of claim 1 wherein the aperture has a V shaped rear side.

3. The bit holder of claim 2, wherein the V-shaped rear side provides two or more points of contact that center cylindrical and multi-faceted bit bodies within the aperture.

4. The bit holder of claim 1, wherein the outer tube is movable longitudinally within an opening on a guide block on the front side of the aperture housing and an opening in the front side of the aperture housing by compressing the clamping lever to move a pressure plate toward the rear side of the aperture for coarse holding adjustment.

5. The bit holder of claim 1, wherein the inner tube provides a micro adjustment actuated by an eccentric cam with detents at an end of the micro adjustment lever in contact with a roller at a free end of the inner tube, the other end of the inner tube connected to the pressure plate, wherein rotation of the micro adjustment lever slides the inner tube within the outer tube to secure the pressure plate against the one or more drill bits.

6. The bit holder of claim 1, wherein the micro adjustment lever is rotated to release the pressure plate to allow easy repeat release, indexing and clamping of one or more bits.

7. The bit holder of claim 2, wherein the tilt mechanism comprises a gear plate having a plurality of indentations on its front edge, a tilt control lever having a shaft pivotally connected to a side wall of the aperture housing, a ratchet head on a free end of the shaft with teeth facing and engaging the indentations on the gear plate, a pawl pivotally connected to the side wall of the aperture housing below the ratchet head, the pawl having teeth facing and engaging the indentations on the gear plate wherein rotation of the tilt control lever disengages the ratchet head and pawl from the indentations on the gear plate to permit the bit holder tilting.

8. The bit holder of claim 7 , further comprising a bias spring that maintains engagement of the pawl and ratchet head with the indentation on the gear plate.

9. The bit holder of claim 1, further comprising replaceable wear inserts at theV-shaped rear side and at a clamp contact surface to maintain accurate seating over repeated cycles.

10. The bit holder of claim 1, wherein bit holder with its micro adjustment mechanism includes one or more position indicators calibrated to assist in indexing rock drill bit button relative to nominal centerline of sharpening machine, [need to add text to description]11. The bit holder of claim 1, wherein the outer tube and inner tube are prevented from relative rotation by guides in the bit holder housing, and the inner tube translates relative to the outer tube to effect fine adjustment and clamping of bits.

12. The bit holder of claim 2, wherein the pentagonal aperture accommodates multiple bit geometries, and the V-shaped rear wall defines a vertex angle selected to seat standard percussion bit bodies.

13. The bit holder of claim 1, further comprising a quick-release for the macro adjustment mechanism configured to rapidly allow for moving the outer tube to accommodate different sizes of bits to be inserted into the bit holder and relieve or reapply locking force to the outer tube when the clamping lever is actuated to clamp or release one or more drill bits being sharpened.

14. The bit holder of claim 1, wherein the micro adjustment mechanism allows bidirectional fine indexing of one or more rock drill bits to correct both over- and under indexing errors.

15. The bit holder of claim 1, wherein the macro adjustment mechanism is capable of maintaining the clamping force generated by the micro adjustment mechanism and is sufficient to resist feed forces during sharpening at the bit interface.

16. The bit holder of claim 2, further comprising lateral guides on the opposite side walls that limit lateral motion of the bit body during macro and micro clamping.

17. An under mounted water recycling system for use with a rock drill bit sharpening system mounted on drill rigs and service vehicles and having a bit holder in accordance with claim 1, the under mounted water recycling system provided below the bit holder to catch cooling water flushing the surface of one more bits during sharpening, the water recycling system comprising a V-shaped trough connected to the rear side of the bit holder, a rubber collection bag under mounted to the trough and having a filter bag in the rubber collection bag.

18. A method for securing and aligning a rock drill bit for button sharpening, comprising:• placing the one or more rock drill bits, optionally with a multi-bit adapter, into an aperture of a bit holder having a V-shaped rear side and opposite side walls;• actuating a quick release locking mechanism that enables a macro adjustment that coarsely holds one or more rock drill bit within the aperture;• actuating a first lever to drive a micro adjustment mechanism to enable adjusting or indexing and clamping of bit positions to align a selected button along a sharpening axis; and• setting a tilt angle of the bit holder by engaging a ratchet head using a tilt control lever to tilt the bit holder so that the longitudinal axis of button being sharpened aligns with the combined longitudinal axis of the sharpening machine, wherein themacro and micro adjustment mechanism is configured with a compact geometry that preserves clearance for an under -mounted water recycling system.

20. The method of claim 19, further comprising verifying alignment by referencing a sight mark or position indicator on the bit holder associated with the micro adjustment mechanism.

21. The method of claim 19, wherein setting the tilt angle comprises selecting one of a plurality of detent positions on the gear plate corresponding to preferred angles of the button being sharpened, and locking the bit holder at the selected position using the ratchet head and a pawl.

22. The method of claim 19, further comprising releasing the clamp or pressure plate by actuating the first lever lock or release position to enable rapid bit replacement or indexing.

23. The method of claim 19 wherein cooling water and removed metal bits are flushed from a button being sharpened and drained into an undermount water recycling system, the undermount water recycling system comprising a V-shaped trough connected to the rear side of the bit holder, a rubber collection bag under mounted to the trough and having a filter bag in the rubber collection bag, wherein the filter bag screens out the metal bits so that cooling water can be recycled from the rubber collection bag.

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