Pumpable Resin System for Mine Roof Bolt Anchoring
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Solution Overview
Problem
Current methods for installing mine roof bolts using resin bonding materials face challenges in efficiently delivering and mixing two-component resin systems within boreholes, particularly in ensuring proper ratio calibration and reaction control to achieve effective anchoring.
Innovation Solution
A pumpable resin system comprising a resin reservoir, catalyst reservoir, and delivery line with a static mixer, inhibitor system, and hydraulic piston control, allowing for precise delivery and mixing of resin and catalyst, along with an inhibitor to create fast and slow set sections within the borehole.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If two-component resin cartridges are inserted into boreholes and mixed by rotating the roof bolt, then the resin bonding material can adhere the roof bolt to the rock formation, but the mixing ratio and reaction timing cannot be precisely controlled
Solution Approach 1:
The resin and catalyst are delivered through separate lines (resin line and catalyst line) from separate reservoirs, allowing independent control of each component's delivery. This segmentation enables precise ratio control while maintaining manageable system complexity through modular design
Solution Approach 2:
The system incorporates a control system that monitors and adjusts the delivery rates of resin and catalyst to maintain the correct mixing ratio. This feedback mechanism ensures precise ratio control while automating the process to offset the increased device complexity
2Productivity
If resin and catalyst are delivered simultaneously to the borehole, then the mixing process can begin immediately, but the reaction timing cannot be controlled to create different set sections
Solution Approach 1:
The system delivers inhibitor to specific zones within the borehole to create different reaction characteristics in different sections. The fast set section receives catalyst without inhibitor while the slow set section receives catalyst with inhibitor, enabling localized control of reaction timing to optimize both installation speed and anchoring performance
Solution Approach 2:
An inhibitor substance is introduced as an intermediary to delay the catalyst-resin reaction in specific zones. This inhibitor acts as a mediator that allows the system to control reaction timing without changing the fundamental simultaneous delivery mechanism, maintaining productivity while adding controlled complexity
3Ease of operation
If the resin cartridge is ruptured by rotating the mine roof bolt, then the components are mixed and fill the annular area, but the mixing process lacks precision and control
Solution Approach 1:
The system replaces the mechanical mixing method (rotating the bolt to shred the cartridge) with a pump-based delivery system that uses hydraulic or electric pumps to meter and deliver resin and catalyst at controlled rates. This substitution maintains ease of operation through automated delivery while achieving precise ratio control through metering mechanisms
Solution Approach 2:
A static mixer or T-mixer is introduced as an intermediary device where resin and catalyst are combined after separate delivery. This intermediary mixing zone ensures thorough and consistent mixing while allowing precise control of the mixing ratio through the separate delivery lines, improving manufacturing precision without complicating the overall operation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This system ensures robust anchoring of mine roof bolts by controlling the resin and catalyst ratio and reaction timing, enhancing the stability and speed of the installation process.
Implementation Method 1
The resin cylinder pump and the catalyst cylinder pump are slaved together and controlled by a hydraulic piston and hydraulic pump
Implementation Method 2
The resin line and the catalyst line may be received by a static mixer
Implementation Method 3
an inhibitor line in fluid communication with the inhibitor pump arrangement, with the inhibitor line configured to deliver inhibitor from the inhibitor reservoir to the borehole to define a fast set section and a slow set section within a borehole
Implementation Method 4
The mixed resin cures and binds the mine roof bolt to the surrounding rock
Data Source
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AI summary
A rock bolt system includes a fitting having a main body defining a central opening configured to receive a rock bolt, with the main body defining a grout opening in fluid communication with the central opening, and a grout body defining a space between the main body and the grout body. The main body is rotatable relative to the grout body, with the grout body defining a resin port and a catalyst port. The resin port and the catalyst port are in fluid communication with the space and the grout opening of the main body. A rock bolt defines a central opening, with the central opening of the rock bolt configured to be in fluid communication with the central opening of the fitting when the rock bolt is secured to the fitting.