U.S. patent application number 13/850094 was filed with the patent office on 2013-08-22 for continuous-extraction mining system.
The applicant listed for this patent is Joy MM Delaware, Inc.. Invention is credited to Tyler Good, David Kevin Herdle, Joseph J. Zimmerman.
Application Number | 20130214585 13/850094 |
Document ID | / |
Family ID | 48279887 |
Filed Date | 2013-08-22 |
United States Patent
Application |
20130214585 |
Kind Code |
A1 |
Zimmerman; Joseph J. ; et
al. |
August 22, 2013 |
CONTINUOUS-EXTRACTION MINING SYSTEM
Abstract
A material extraction system is provided for an underground
mine. The mine includes a roadway entry and a draw-bell entry
intersecting the roadway entry and affording access to a draw-bell.
The system generally includes a loader movable from the roadway
entry into the draw-bell entry for removing material from the
draw-bell, a sizer coupled to the loader for sizing the removed
material, and a material collector operable to collect the sized
material. The material collector places the sized material at a
substantially elevated position relative to a mine floor. A shuttle
car is operable to receive the collected material from the material
collector. The shuttle car is movable along the roadway entry for
transferring the collected material so as to facilitate a
substantially continuous extraction of the material.
Inventors: |
Zimmerman; Joseph J.;
(Franklin, PA) ; Herdle; David Kevin; (Franklin,
PA) ; Good; Tyler; (Pleasantville, PA) |
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Applicant: |
Name |
City |
State |
Country |
Type |
Joy MM Delaware, Inc.; |
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US |
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Family ID: |
48279887 |
Appl. No.: |
13/850094 |
Filed: |
March 25, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13739368 |
Jan 11, 2013 |
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13850094 |
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13179285 |
Jul 8, 2011 |
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13739368 |
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13179266 |
Jul 8, 2011 |
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13739368 |
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61362949 |
Jul 9, 2010 |
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61435121 |
Jan 21, 2011 |
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61362949 |
Jul 9, 2010 |
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61435121 |
Jan 21, 2011 |
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Current U.S.
Class: |
299/18 ;
241/101.5; 299/67 |
Current CPC
Class: |
E02F 7/04 20130101; E21F
13/00 20130101; E21F 13/063 20130101; E21F 13/025 20130101; E02F
7/026 20130101; E02F 3/966 20130101; E21F 13/002 20130101; E02F
7/06 20130101; E02F 3/962 20130101 |
Class at
Publication: |
299/18 ; 299/67;
241/101.5 |
International
Class: |
E21F 13/00 20060101
E21F013/00; E21F 13/06 20060101 E21F013/06; E21F 13/02 20060101
E21F013/02 |
Claims
1. A material extraction system for an underground mine, the mine
including a roadway entry and a draw-bell entry intersecting the
roadway entry and affording access to a draw-bell, the system
comprising: a loader movable from the roadway entry into the
draw-bell entry for removing material from the draw-bell; a sizer
coupled to the loader for sizing the removed material; a material
collector operable to collect the sized material, wherein the
material collector places the sized material at a substantially
elevated position relative to a mine floor; and a shuttle car
operable to receive the collected material from the material
collector, the shuttle car being movable along the roadway entry
for transferring the collected material so as to facilitate a
substantially continuous extraction of the material.
2. The system of claim 1, wherein the sizer includes a discharge
conveyor for discharging the sized material onto the material
collector.
3. The system of claim 1, wherein the sizer is configured to size
the removed material on a substantially continuous basis.
4. The system of claim 1, wherein the sizer includes a
self-contained power supply.
5. The system of claim 4, wherein the material collector is movable
along a mine floor.
6. The system of claim 1, wherein the material collector includes
wheels engageable with a mine floor.
7. The system of claim 1, wherein the loader includes a chassis and
a loading arm movably coupled to the chassis and operable to move
material from the draw-bell toward the chassis.
8. The system of claim 7, wherein the chassis includes a feed
conveyor, and wherein the loading arm moves the removed material
onto the feed conveyor.
9. The system of claim 7, wherein the loader includes a rock
breaker mounted to an end of the loading arm.
10. The system of claim 7, wherein the loader further includes a
carriage movable along the chassis, and wherein the loading arm is
coupled to the carriage for movement therewith.
11. The system of claim 1, wherein the shuttle car comprises
steerable wheels engageable with a mine floor.
12. The system of claim 1, wherein the shuttle car and material
collector are dimensioned such that the shuttle car is positioned
substantially below at least a part of the material collector for
receiving the collected material therefrom.
13. The system of claim 1, wherein at least a portion of the
shuttle car comprises a chromium carbide overlay plate.
14. A method of extracting material for an underground mine, the
mine including a roadway entry and a draw-bell entry intersecting
the roadway entry and affording access to a draw-bell, the method
comprising: moving a loader from the roadway entry into the
draw-bell entry; removing material from the draw-bell using the
loader; sizing the removed material using a sizer that is coupled
to the loader; collecting the sized material on a material
collector, wherein the sized material is placed at a substantially
elevated position relative to a mine floor; and transferring the
collected material along the roadway entry using a shuttle car so
as to facilitate a continuous extraction of the material.
15. The method of claim 14, wherein the material collector is
movable along the mine floor.
16. The method of claim 14, wherein the sizer includes a discharge
conveyor, and the sized material is conveyed using the discharge
conveyor for discharging onto the material collector.
17. The method of claim 14, wherein the removed material is sized
on a substantially continuous basis.
18. The method of claim 14, wherein the material collector engages
the mine floor with wheels.
19. The method of claim 14, wherein the shuttle car engages the
mine floor with steerable wheels.
20. A material extraction system for an underground mine, the mine
including a roadway entry and a draw-bell entry intersecting the
roadway entry and affording access to a draw-bell, the system
comprising: a loader movable from the roadway entry into the
draw-bell entry for removing material from the draw-bell; a sizer
coupled to the loader for sizing the removed material on a
substantially continuous basis; a material collector operable to
store the sized material; and a shuttle car operable to receive the
collected material from the material collector, the shuttle car
including steerable wheels engageable with the mine floor for
moving along the roadway entry for transferring the collected
material so as to facilitate a substantially continuous extraction
of the material.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and is a continuation of
prior application Ser. No. 13/739,368, filed Jan. 11, 2013, which
is a continuation-in-part of prior application Ser. No. 13/179,285,
filed Jul. 8, 2011, which claims the benefit of U.S. Provisional
Application No. 61/362,949, filed Jul. 9, 2010, and U.S.
Provisional Application No. 61/435,121, filed Jan. 21, 2011. Prior
application Ser. No. 13/739,368 also claims priority to and is a
continuation-in-part of prior application Ser. No. 13/179,266,
filed Jul. 8, 2011, which claims the benefit of U.S. Provisional
Application No. 61/362,949, filed Jul. 9, 2010, and U.S.
Provisional Application No. 61/435,121, filed Jan. 21, 2011.
Application Ser. No. 13/179,285 published as Publication No.
2012/0007413 on Jan. 12, 2012, and application Ser. No. 13/179,266
published as Publication No. 2012/0007412 on Jan. 12, 2012. The
entire contents of each of the foregoing applications are
incorporated by reference herein.
BACKGROUND
[0002] In underground hard-rock mining, a process called block
caving can be used. In this process, an ore body is typically
preconditioned by fracturing the ore via various methods. Conical
or tapered voids are then drilled at the bottom of the ore body,
and the void is blasted. The fractured ore body above the blast
will cave, and, through gravity, fall or settle down into
collection areas called draw-bells. The draw-bells serve as
discharge points to an entryway. Load-haul-dump vehicles typically
tram through the entryway to load ore from the draw-bell. The
vehicles haul the ore through various other entryways to a
centrally-located dump point and dump the ore into an underground
crusher that has been installed at the dump point. The crushed ore
subsequently is fed to a conveyor system to be conveyed out of the
mine. As more ore is removed from the draw-bells, the ore body
caves in further, providing a continuous stream of ore.
SUMMARY
[0003] In some embodiments, a material extraction system is
provided for an underground mine. The mine includes a roadway entry
and a draw-bell entry intersecting the roadway entry and affording
access to a draw-bell. The system generally includes a loader
movable from the roadway entry into the draw-bell entry for
removing material from the draw-bell, a sizer coupled to the loader
for sizing the removed material, and a material collector operable
to collect the sized material. The material collector places the
sized material at a substantially elevated position relative to a
mine floor. A shuttle car is operable to receive the collected
material from the material collector. The shuttle car is movable
along the roadway entry for transferring the collected material so
as to facilitate a substantially continuous extraction of the
material.
[0004] In other embodiments, a method of extracting material is
provided for an underground mine. The mine includes a roadway entry
and a draw-bell entry intersecting the roadway entry and affording
access to a draw-bell. The method generally includes moving a
loader from the roadway entry into the draw-bell entry, removing
material from the draw-bell using the loader, sizing the removed
material using a sizer that is coupled to the loader, and
collecting the sized material on a material collector. The sized
material is placed at a substantially elevated position relative to
a mine floor. The collected material is transferred along the
roadway entry using a shuttle car so as to facilitate a continuous
extraction of the material.
[0005] In still other embodiments, a material extraction system is
provided for an underground mine. The mine includes a roadway entry
and a draw-bell entry intersecting the roadway entry and affording
access to a draw-bell. The system generally includes a loader
movable from the roadway entry into the draw-bell entry for
removing material from the draw-bell, a sizer coupled to the loader
for sizing the removed material on a substantially continuous
basis, a material collector operable to collect the sized material,
and a shuttle car operable to receive the collected material from
the material collector. The shuttle car includes steerable wheels
engageable with a mine floor for moving along the roadway entry for
transferring the collected material so as to facilitate a
substantially continuous extraction of the material.
[0006] Other aspects of the invention will become apparent by
consideration of the detailed description and accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a schematic diagram of a block caving mining setup
depicting an ore body, draw-bells, and undercut entryway.
[0008] FIG. 2 is a top view of a first type of block-caving
infrastructure with a chevron-type draw-bell layout, showing a
first continuous-extraction system.
[0009] FIG. 3 is a top perspective view of the first
continuous-extraction system shown in FIG. 2.
[0010] FIG. 4 is an elevational view of the first
continuous-extraction system shown in FIG. 2.
[0011] FIG. 5 is a bottom perspective view of a loader suitable for
use with the first continuous-extraction system of FIG. 3.
[0012] FIG. 6 is a top perspective view of an alternative
embodiment of the loader of FIG. 5.
[0013] FIG. 7 is a perspective view of an alternative embodiment of
the loader of FIGS. 5 and 6.
[0014] FIG. 8 is a rear perspective view of the
continuous-extraction system of FIG. 3, showing a cable-handling
system for powering the continuous-extraction system.
[0015] FIG. 9 is a perspective view of a second
continuous-extraction system including a feeder, a material
collector, and a bridge conveyor that feed material to an elevated
and cantilevered haulage conveyor.
[0016] FIG. 10 is an end view of the continuous-extraction system
of FIG. 9.
[0017] FIG. 11 is a top view of the continuous-extraction system of
FIG. 9.
[0018] FIG. 12 is a top view of an alternative
continuous-extraction system.
[0019] FIG. 13 is a perspective view of a continuous-extraction
system according to still another embodiment of the invention,
including a loader, a sizer, a material collector, and a shuttle
car.
[0020] FIG. 14 is a perspective view similar to FIG. 13,
illustrating the shuttle car positioned adjacent the material
collector for receiving collected material from the material
collector.
[0021] FIG. 15 is a perspective view similar to FIG. 13,
illustrating the loader, sizer, and material collector as being
moved along a roadway entry.
DETAILED DESCRIPTION
[0022] Before any embodiments of the invention are explained in
detail, it is to be understood that the invention is not limited in
its application to the details of construction and the arrangement
of components set forth in the following description or illustrated
in the following drawings. The invention is capable of other
embodiments and of being practiced or of being carried out in
various ways. Also, it is to be understood that the phraseology and
terminology used herein is for the purpose of description and
should not be regarded as limited. The use of "including,"
"comprising" or "having" and variations thereof herein is meant to
encompass the items listed thereafter and equivalents thereof as
well as additional items. The terms "mounted," "connected" and
"coupled" are used broadly and encompass both direct and indirect
mounting, connecting and coupling. Further, "connected" and
"coupled" are not restricted to physical or mechanical connections
or couplings, and can include electrical connections or couplings,
whether direct or indirect.
[0023] FIG. 1 illustrates a block-caving mining process, where
fractured ore body 2, such as copper or gold ore, caves and falls
by gravity toward a series of draw-bells 4. The draw-bells 4 are
discharge points to roadway entries 6 that extend below the
fractured ore body 2 and lead to other underground entries that
permit material extracted from the draw-bells 4 to be transported
to the surface. With reference also to FIG. 2, a block-caving
infrastructure 8 typically includes a plurality of draw-bells 4
(e.g., sixteen, as shown) distributed through a mining block. The
block-caving infrastructure 8 can be several hundred or several
thousand meters underground. In the illustrated infrastructure 8,
each draw-bell 4 is connected to adjacent roadway entries 6 by a
pair of angled draw-bell entries 9. The draw-bell entries 9 leading
to each draw bell 4 are oriented at an obtuse angle relative to the
adjacent roadway entry 6 to form a chevron pattern, as can be seen
in FIG. 2. This chevron pattern simplifies movement of mining
equipment between the roadway entries 6 and the draw-bell entries
9, as discussed further below. Each roadway entry 6 leads to a
transverse transport entry 11, which in turn leads to other entries
that allow material removed from the draw-bells 4 to be transported
to the surface.
[0024] Referring also to FIGS. 3-4, a continuous-extraction system
10 is moveable along the roadway entries 6 and into the draw-bell
entries 9 for removing fractured ore 2 from the draw-bell 4. The
continuous-extraction system 10 is an interconnected set of
railcars and includes a primary drive and power center 12, a
material collector in the form of a crusher or sizer 14, a bridge
conveyor 16, and a loader or loading machine 18. The loading
machine 18 is positioned at the front end 20 of the
continuous-extraction system 10. The continuous-extraction system
10 can traverse fore and aft on track rails 22 that run through the
block-cave infrastructure 8. As best shown in FIG. 4, the track
rails 22 include an integrated conveyor system 24 positioned below
the rails 22. The continuous-extraction system 10 thus runs on
track rails 22, below which the conveyor system 24 runs in a
substantially parallel manner. The conveyor system 24 can be a belt
or chain-type conveyor. By way of example only, the figures depict
a belt-type troughing conveyor.
[0025] As shown in FIG. 2, sets of track rails 22 extend along each
of the roadway entries 6 and provide access to the draw-bells 4. At
each draw-bell entry 6, a rail spur 23 diverges away from the track
rails 22 and extends into the draw-bell entry 9. To access each
draw-bell 4 from a given track rail 22, the continuous-extraction
system 10 can make alternating left and right turns at obtuse
angles into the draw-bell entries 9. In this regard, the
continuous-extraction system 10 includes track switches (not shown)
that allow the continuous-extraction system 10 to turn onto the
rail spur 23 and advance into the draw bell-entry 9. The track
switch can be mounted anywhere on the track rails 22.
[0026] In some embodiments, including those illustrated in FIGS. 3
and 4, the loading machine 18 advances into the draw-bell entry 9
while the power center 12 and crusher 14 remain on the track rails
22. General operation of the continuous-extraction system 10 is as
follows--the loading machine 18 gathers material from the draw-bell
4 and deposits it onto the bridge conveyor 16, which extends
rearwardly from the loading machine 18. The bridge conveyor 16
extends from the draw-bell entry 9 into the roadway entry 6 and
transports ore 2 gathered from the draw-bell 4 by the loading
machine 18 to the crusher 14.
[0027] The crusher 14 crushes the ore 2 to an acceptable size and
discharges the crushed ore 2 onto the conveyor 24 that runs below
the track rails 22. The conveyor 24 conveys the crushed ore to the
transverse transport entry 11 (see FIG. 2) and out of the mine. The
ore 2 thus continuously moves from the loading machine 18, to the
bridge conveyor 16, to the crusher 14, to the conveyor 24, and then
outside the mine.
[0028] Depending on the material being mined and the type of
material preconditioning that is performed, some mining
environments may not require the use of the crusher 14. In such
instances, the crusher 14 can be replaced by a simplified material
collector for receiving material from the loading machine 18 and
depositing the material onto the conveyor 24 without further
crushing or sizing of the material. Such a material collector may
include intermediate conveyors or other powered material transport
devices, or may include one or more funnels or chutes for guiding
material received from the loading machine 18 onto the conveyor 24.
Like the illustrated crusher 14, the material collector can be
separate from the primary drive and power center 12 or, in some
embodiments, the crusher 14 or the material collector can be
integral with the primary drive and power center 12.
[0029] The continuous-extraction system 10 includes one or more
drive mechanisms for tramming along the track rails 22 and the rail
spurs 23. After completing an operation at a given draw-bell 4, the
continuous-extraction system 10 can tram backwards until the
loading machine 18 is once again positioned on the track rails 22.
The continuous-extraction system 10 then advances to the next
draw-bell 4 to repeat the ore-loading process. One or both of the
primary drive and power center 12 and crusher 14 (if required) can
include a suitable drive mechanism for moving the
continuous-extraction system 10 along the track rails 22 and for
pushing and pulling the loading machine 18 into and out of the rail
spurs 23. In a block-cave infrastructure 8 with multiple draw-bells
4, a plurality of continuous-extraction systems 10 can be employed
to improve production rates.
[0030] Referring also to FIGS. 5 and 6, the loading machine 18
includes a chassis 38 that rides along the track rails 22 and the
rail spur 23. The chassis 38 is substantially wedge-shaped and
includes a conveyor 26 extending from a front end to a rear end of
the chassis 38. The front end of the chassis 38 also includes a
collection tray 27 optionally including a pair of rotating
collector wheels 28 that guide material onto the conveyor 26. The
conveyor 26 receives the material removed from the draw bell 4,
transports it rearwardly and upwardly, and deposits it onto the
bridge conveyor 16.
[0031] The loading machine 18 also includes a carriage assembly 31
that is moveable in the fore and aft direction along the chassis 38
and has mounted thereto a backhoe-type loading arm 30. The loading
arm 30 is operable to reach beyond the front end of the chassis
into the draw-bell 4 and to move (e.g., to pull) material onto the
collection tray 27. The illustrated loading arm 30 also includes a
rock breaker 32 operable to break down large lumps of ore 2 that
would be too large for the loading arm 30 to collect and maneuver
onto the collection tray 27. In the illustrated embodiment, the
rock breaker 32 is in the form of a jack hammer, but other
embodiments may include other types of rock breakers such as
drills, shearing type devices, and the like.
[0032] In operation, ore 2 is pulled from the draw-bell 4 by the
backhoe-type loading arm 30, onto the collection tray 27 where the
optional rotating collector wheels 28 help guide the material onto
the conveyor 26. The conveyor 26 then conveys the material
rearwardly and upwardly and deposits it onto the bridge conveyor
16. In the illustrated embodiments, both the conveyor 26 and the
bridge conveyor 16 employ a plate-type conveyor.
[0033] As shown in FIG. 7, some embodiments of the invention may
include an alternative type of loading machine 18 that is able to
move off of and onto a flatbed or "lowboy" rail car 15 positioned
on the track rails 22. In such embodiments, instead of
rail-car-type wheels for movement over rails, the loading machine
18 includes treads or wheels 17, 19 (wheels are shown in FIG. 7)
for movement over the mine floor. As such, the rail spurs 23 that
extend into the draw-bell entries 9 can be eliminated. The
alternative loading machine 18 includes sets of transfer members in
the form of the wheels 17, 19 that are operable to move the front
end 20 of the loading machine 18 toward the draw-bell entry 9. The
transfer wheels 17, 19 are rotatable about a generally vertical
axis 21 for movement in a variety of directions. The transfer
wheels 17, 19 also are vertically moveable relative to the chassis
38 of the loading machine 18 and are able to "step off' of the
lowboy rail car 15 and engage the mine floor 65. For example, the
transfer wheels 17, 19 move the loading machine 18 sideways until
the first transfer wheel 17 is off the lowboy rail car 15 while the
other transfer wheel 19 remains on the lowboy rail car 15. The
first transfer wheel 17 is then moved downwardly until it engages
the mine floor 65, and both transfer wheels 17, 19 then operate to
move the loading machine 18 generally laterally until the second
transfer wheel 19 is positioned off of the lowboy rail car 15 and
can be lowered onto the mine floor 65. Once all of the transfer
wheels 17, 19 are positioned on the mine floor 65, the transfer
wheels 17, 19 lower the chassis 38 toward the mine floor 65 and
then rotate about the axes 21 for movement in a generally forward
direction into the draw-bell entry 9. In alternative embodiments
the loading machine 18 may include a separate set of fixed wheels
configured for forward movement into the draw-bell entry 9. In such
embodiments, the transfer wheels 17, 19 can be moved vertically
upwardly a sufficient amount to remain out of the way while the
fixed wheels maneuver the loading machine 18 to collect material
from the draw-bell 4. The operation is performed in reverse to
return the loading machine 18 to the lowboy rail car 15.
[0034] Referring back to FIG. 5, a first crowding mechanism 39 that
helps the loading machine 18 gather material from the draw-bell 4
is illustrated. The crowding mechanism 39 is an optional feature
that can help urge the loading machine 18 and the rest of the
continuous-extraction system 10 closer to the draw-bell 4, thereby
making it easier for the loading arm 30 to maneuver ore 2 onto the
collection tray 27 and enhancing the loading operation. The
crowding mechanism 39 of FIG. 5 includes a telescoping hydraulic
cylinder 34 coupled to the chassis 38 of the loading machine 18 and
a movable portion in the form of a hook 36 positioned on an end of
the hydraulic cylinder 34. The hook 36 is configured to engage a
fixed member in the form of a bar 40 that is fixed relative to the
mine floor 65 at a location within the draw-bell entry 9. In other
constructions, the bar 40 could instead be positioned in the
roadway entry 6. In the illustrated embodiment, the bar 40 is
coupled to a portion of the rail spur 23. In other embodiments, the
bar 40 is anchored to the mine floor 65. In operation, the hook 36
engages the bar 40 and the hydraulic cylinder 34 is actuated to
pull or push (depending on the specific configuration and location
of the hook 36 relative to the loading machine 18) the loading
machine 18 toward the draw-bell 4. As the loading machine 18 moves
toward the draw-bell 4, some ore 2 may be pushed onto the
collection tray 27 without requiring use of the loading arm 30.
Once the loading machine 18 has been advanced as far into the
draw-bell 4 as possible, the loading arm 30 can then be used to
maneuver additional ore 2 onto the collection tray 27.
[0035] FIG. 6 illustrates a second crowding mechanism 41 that can
be an alternative or a supplement to the first crowding mechanism
39 of FIG. 5. The second crowding mechanism 41 includes a movable
portion in the form of a pinion 42 coupled to the loading machine
18 and a fixed portion in the form of a rack 44 that is fixed
relative to the mine floor 65 and that is engaged by the pinion 42.
The rack 44 can be anchored directly to the mine floor 65 or can be
mounted on a portion of the rail spur 23. The pinion 42 is coupled
to a drive mechanism 45 that is operable to drive the pinion 42. In
some embodiments, the pinion 42 is driven by the same drive
mechanism that drives the wheels of the loading machine 18. When
the pinion 42 is driven while engaged with the rack 44, the pinion
42 urges the loading machine 18 toward the draw-bell 4. While FIG.
6 shows the pinion 42 coupled to a rear wheel of the loading
machine 18, in other embodiments the pinion 42 can be separate from
the wheels or coupled to more and/or other wheels of the loading
machine 18, such as the front wheels, rear wheels, or combinations
thereof.
[0036] Referring to FIG. 8, in some embodiments, the
continuous-extraction system 10 is powered by overhead cables that
are enclosed within a Bretby-type cable handling system 46. The
Bretby-type cable handling system 46 is a flexible carrier
consisting of a series of flat plates. The plates are paired, one
forming a bottom and the other a top, and the sides are connected
by pins. The top and bottom plates and the side pins encase an area
where cables can be handled. Each pair of plates is then connected
to an adjacent pair of plates, forming a chain that resembles
continuous tracks on heavy equipment. Power cables 47 can drop down
from an overhead cable trough 48 to the power center 12. The power
center 12 is typically the last car of the continuous-extraction
system 10 and powers elements of the continuous-extraction system
10, such as the crusher 14, conveyor 16, loading machine 18, and
various controls associated therewith. In other embodiments, a
monorail overhead with trolleys can be used in place of the
Bretby-type cable handling system 46.
[0037] In other embodiments, the continuous-extraction system 10 is
powered by electrical plug-in stations at each draw-bell 4. The
continuous-extraction system 10 can be equipped with cable reels
that reel in and pay out cables that connect to nearby plug-in
stations along the roadway entry 6 and supply power to the system
10. In operation, an onboard operator initially plugs in the
electrical cable to a proximal plug-in station, thus powering the
system 10 through a cable from the proximal plug-in station. As the
system 10 moves from a proximal plug-in station to a distal plug-in
station, the onboard operator can plug another electrical cable to
the distal plug-in station. The operator or system then
reconfigures the internal power management system so that the
system 10 is powered through cables from the distal plug-in
station. After the internal power management has been reconfigured,
the operator can unplug the cable to the proximal plug-in station.
This way, each cable does not run the entire length between plug-in
stations, and therefore in some embodiments the length of cable
needed on the reels can be minimized. The plug-in stations can be
disposed on the floor or wall of the mine at each draw-bell 4 or
mounted on a supporting structure.
[0038] In still other embodiments, the continuous-extraction system
10 includes a self-contained power supply for moving from one
draw-bell 4 to another after being disconnected from an external
source of power, such as the Bretby-type cable handling system 46
discussed above. In some embodiments, the continuous-extraction
system 10 is powered through batteries, a small diesel power unit,
or a hybrid unit. The system 10 can be powered for example through
multiple batteries, where one or more batteries are being charged
while the others are being used. In some embodiments, the system 10
can be powered by a hybrid of diesel engine and batteries, where a
diesel engine runs to charge the battery, for example between high
load demands, between shifts, at break times, and the like. The
batteries, small diesel power unit, or hybrid unit can be used to
drive electric and/or electro-hydraulic motors and drive systems.
Because it remains substantially stationary, the conveyor system 24
that runs through the block-cave infrastructure 8 can be powered
from stationary power centers that are independent from the
overhead power cables or other power sources associated with the
continuous-extraction system 10.
[0039] Some embodiments can also include automation equipment
operable to position the continuous-extraction system 10 at
draw-bells 4 and to control other movements as needed. For example,
remote cameras can be employed to help operate the backhoe-type
loading arm 30 and maneuver and operate the continuous-extraction
system 10 into the draw-bell 4 from a remote location. Radio or
cable communication links can be used to a similar extent, with or
without the remote operation cameras. In some embodiments, an
operator for the remote operation cameras, communication links, or
both, can be located underground. In other embodiments, the
operator can be located above ground. An above ground operator can
be many kilometers away from the mine. In yet other embodiments,
the continuous-extraction system 10 can contain position-sensing
devices for automation, remote operation, or both.
[0040] FIGS. 9 and 10 illustrate an alternative form of a
continuous-extraction system 50. The continuous-extraction system
50 includes a loader in the form of a load-haul-dump machine
("LHD") 52, a feeder 54, a combined power center and material
collector in the form of a mobile crusher 56, a bridge conveyor 58,
and an elevated and cantilevered haulage conveyor 60. Unlike the
continuous-extraction system 10 described above, which includes
tracks 22 and a conveyor 24 that occupy the mine floor 65, the
continuous-extraction system 50 utilizes a haulage conveyor 60 that
is elevated above the mine floor 65 and cantilevered from one of
the walls 62 of the roadway entry 6 (see FIG. 10). This
configuration allows for substantially unrestricted access to all
areas of the block-caving infrastructure 8 because the mine floor
65 remains unobstructed. By having the mobile crusher 56 positioned
within the roadway entry 6 proximal to the draw-bell 4 from which
the LHD 52 is extracting ore 2, the amount of time spent tramming
by the LHD 52 is dramatically reduced compared to known systems
that utilize massive, centrally-located underground dump points
with large, immovable crusher assemblies.
[0041] Although various configurations are possible, the
illustrated LHD 52 includes a front end 64 with a moveable load
bucket 66 operable to collect, carry, and dump ore 2. The front end
64 is pivotally coupled to a rear end 68 of the LHD 52. The pivotal
coupling allows the LHD 52 to be articulated in two parts and helps
negotiate curves. The rear end 68 includes an operator cab 70 and
an integrated drive mechanism and power source 72. Like the loading
machine 18, the LHD 52 can include a rock breaker such as a jack
hammer on the front end 64 to break down large lumps of ore 2 that
would otherwise be too large for the bucket 66 to collect. Although
FIG. 8 illustrates a single moveable load bucket 66 on the front
end 64 of the LHD 52, other LHD 52 embodiments can include a bucket
66 on both the front end 64 and the rear end 68, with the operator
cab 70 and the power source 72 interposed between the two buckets
66. The LHD 52 may also be configured for remote operation, thereby
eliminating the need for the operator cab 70.
[0042] The drive mechanism and power source 72 may be electrical or
electro-hydraulic, and may be powered by batteries or by an
external power source. In some embodiments, each wheel of the LHD
52 may include its own dedicated electronic drive that comprises,
for example, an electric motor and accompanying gearbox. In this
way, each wheel can be controlled independently by an associated
variable frequency drive system or a chopper drive system, thus
reducing or eliminating the need for mechanical transfer cases and
differentials. Where external power is used, the LHD 52 is provided
with a suitable cable handling system. Because of the mobile
crusher 56, the LHD 52 is only required to tram the relatively
short distance between the draw-bells 4 and the mobile crusher 56,
which enables the use of batteries as a means of powering the LHD
52. In the illustrated construction, the power source 72 at the
rear end 68 of the LHD 52 is made up of a battery tray.
Alternatively, the LHD 52 may be powered by a diesel engine. In
some embodiments, the LHD 52 is driven or powered at least in part
by a "drop-in" diesel-electric power pack or similar generator set
that includes an internal combustion engine coupled to a generator
or other suitable device for producing electrical power from the
work performed by the engine. Such a generator set may supplement
an otherwise primarily electrical drive mechanism and power source
and may be capable of driving and powering all operations of the
continuous miner without the need for external power.
[0043] With continuing reference to FIG. 9, feeder 54 includes a
gather portion 74 where it receives ore 2 from the LHD 52, and a
conveyor portion 76 where it transports the ore 2 to the mobile
crusher 56. The gather portion 74 includes wings 78 that are
attached to the left and right sides of the feeder 54 and guide the
ore 2 to the conveyor portion 76. In some embodiments, the wings 78
are pivotally attached to the gather portion 74 and can fold up as
the ore 2 is transported to the mobile crusher 56. The foldable
wings 78 can help guide and feed the ore 2 to the conveyor portion
76. The conveyor portion 76 of the feeder 54 can employ a
plate-type conveyor, an armored-face conveyor, or other conveyors
that are known in the art. In some constructions, the feeder 54 is
driven by its own integrated drive system (not shown). Other
constructions of the feeder 54 can be towed by mobile crusher 56.
Although FIG. 9 illustrates a single feeder 54 transporting the ore
2 to the mobile crusher 56, in other embodiments more than one
feeder 54 can transport the ore 2 to the mobile crusher 56, for
example from opposing sides of the mobile crusher 56.
[0044] With continuing reference to FIGS. 9 and 10, mobile crusher
56 or sizer is operable to crush or size the material and deposit
the material onto the bridge conveyor 58. The crusher 56 includes a
crusher portion 80 that is mounted on drive treads 82. One or more
cylindrical rollers 83 with associated bits are mounted in the
crusher portion 80 and crush or size the ore 2. The crusher 56 is
moveable along the mine floor 65 and can be positioned anywhere
along the length of the haulage conveyor 60. Although FIG. 9
illustrates the mobile crusher 56 with drive treads 82, other
embodiments can include track-type crawlers, rubber-tired wheels,
or substantially any other type of support that allows for movement
of the crusher 56. In some embodiments, movement of the mobile
crusher 56 is controlled by an automated system using inertial or
other types of navigation or guidance, such that the mobile crusher
56 is automatically advanced along roadway entry 6 in sequence with
movement of the LHD 52. The mobile crusher 56 is operatively driven
by a primary drive and power center that may be or include
electrical, electro hydraulic, or a combination of electric and
hydraulic motors, and in some embodiments may be powered at least
in part by diesel power. As discussed above, depending on the
mining environment in which the system 50 is deployed, material
extracted from the draw-bells 4 may be such that a crusher or sizer
is not required. In such cases, the crusher portion 80 can be
replaced by a somewhat simplified material collector that may
include intermediate conveyors, funnels and/or chutes for
collecting material received from the LHD 52 and transferring it to
the bridge conveyor 58.
[0045] With continuing reference to FIGS. 9 and 10, bridge conveyor
58 extends generally upwardly toward the roof 63 of the roadway
entry 6 from a location proximal to the floor 65. The bridge
conveyor 58 upwardly conveys material received from the mobile
crusher 56 and deposits the material onto the haulage conveyor 60.
The bridge conveyor 58 can contain portions with different slopes.
Some embodiments of the bridge conveyor 58 may also include support
legs. The bridge conveyor 58 may be separate from or integral with
the mobile crusher 56, and may be driven or powered by its own
independent drive system or by the drive system of the crusher 56.
The bridge conveyor 58 is therefore moveable along the mine floor
65 and can be positioned anywhere along the length of the haulage
conveyor 60. In the illustrated construction, the bridge conveyor
58 is based on an endless belt-type conveyor; however, other
conveyor types may also be used. In some constructions, the bridge
conveyor 58 is pivotable with respect to the mobile crusher 56 or
is otherwise adjustable to the right or left to accommodate
different mine configurations.
[0046] With continuing reference to FIGS. 9 and 10, the elevated
and cantilevered haulage conveyor 60 is positioned proximal to the
roof 63 and coupled to one of the sidewalls 62 of the roadway entry
6 in a cantilevered manner. In some embodiments, the haulage
conveyor 60 is supported solely by the wall 62. In further
embodiments, the haulage conveyor 60 is positioned at least half
way up the wall 62 between the roof 63 and the floor 65. In other
embodiments, the haulage conveyor 60 is positioned at least
two-thirds of the way up the wall 62 between the roof 63 and the
floor 65. In further embodiments, the roadway entry 6 includes a
centerline, and the entire haulage conveyor 60 is positioned to one
side of the centerline. Stated slightly differently, the haulage
conveyor 60 is off-center when viewed in the longitudinal direction
of the roadway entry 6.
[0047] The illustrated haulage conveyor 60 is a trough conveyor and
includes a set of trough rollers 84 that support the conveying run
of the conveyor belt 61, and a set of lower rollers 86 that support
the return run of the conveyor belt 61. The haulage conveyor 60 is
supported by a plurality of L-brackets 88. Each L-bracket 88 has a
substantially vertical leg that is coupled to the mine wall 62, and
a substantially horizontal leg that extends beneath and supports
the haulage conveyor 60. Because the haulage conveyor 60 is
elevated from the mine floor 65, the presence of undulations or
other deformation of the mine floor 65 does not hinder performance
of the conveyor 60. The elevated and cantilevered haulage conveyor
60 receives crushed ore from the bridge conveyor 58 and conveys the
crushed ore to the transverse transport entry 11 (see FIG. 2) and
out of the mine.
[0048] Referring to FIG. 11, in operation, the LHD 52 moves into
the draw-bell 4 via the draw-bell entry 9 to collect ore 2 with the
moveable load bucket 66. To this end, the bucket 66 is first
crowded into the draw-bell 4 and then pivotably swung about a
transverse axis. As the bucket 66 is loaded, the LHD 52 trams
backwards until the LHD 52 is once again positioned on the roadway
entry 6. The LHD 52 then advances to the feeder 54, which is
positioned in the roadway entry 6 beyond the draw-bell entry 9, and
the LHD 52 dumps the ore 2 from the load bucket 66 into the gather
portion 74 of the feeder 54. The feeder 54 moves the ore 2 from the
gather portion 74 to the conveyor portion 76, and the conveyor
portion 76 drops the ore into the crusher 56. The crusher 56
crushes or sizes the ore 2 (if necessary), and deposits the ore
onto the bridge conveyor 58. The bridge conveyor 58 transports the
crushed ore upwardly and away from the crusher 56 to the elevated
haulage conveyor 60. The haulage conveyor 60 then transports the
crushed ore to the transverse transport entry 11 (see FIG. 2),
where it is subsequently carried away and out of the mine. After
dumping the ore 2 in the feeder 54, the LHD 52 trams backwardly
along the roadway entry 6 beyond the draw-bell entry 9, and then
trams forwardly and turns into the draw-bell entry 9 to return to
the draw-bell 4 for removal of additional material. The LHD 52 then
repeats the ore-loading process. When the LHD 52 finishes
collecting material from one draw-bell 4, the continuous-extraction
system 50 moves along the roadway 6 to the next draw-bell entry 9.
Specifically, the feeder 54, the mobile crusher 56, and the bridge
conveyor 58 of the continuous-extraction system 50 tram beyond the
next draw-bell entry 9, and thereby provide the LHD 52 with access
to the next draw-bell 4. In a block-cave infrastructure 8 with
multiple draw-bells 4, a plurality of continuous-extraction systems
50 can be employed to improve production rates.
[0049] FIG. 12 illustrates a modified version of the
continuous-extraction system 50 shown in FIG. 11 whereby the LHD 52
is replaced with a loader in the form of a loading machine 118
similar to the loading machine 18 illustrated in FIG. 7. The
continuous-extraction system 150 of FIG. 12 includes a
crawler-mounted or wheel-mounted material collector 156, which may
include a crusher portion 180, as illustrated. The system 150 also
includes a bridge conveyor 158 that carries material from the
material collector 156 upwardly to an elevated and cantilevered
haulage conveyor 160 that is cantilevered from the sidewall 62 of
the roadway entry 6. Although the illustrated construction does not
include a feeder, a feeder similar to the feeder 54 discussed above
may also be included in the continuous-extraction system 150.
[0050] The loading machine 118 includes a chassis 138 including a
conveyor 126 extending from a collection end 139 to a discharge end
140 of the chassis 138. The collection end 139 of the chassis 138
also includes a collection tray 127 optionally including a pair of
rotating collector wheels (not shown) that guide material onto the
conveyor 126. The loading machine 118 also includes a carriage
assembly 131 that is moveable in the fore and aft direction along
the chassis 138 and has mounted thereto a backhoe-type loading arm
130. The loading arm 130 is operable to reach beyond the front end
of the chassis into the draw-bell 4 and to move (e.g., to pull)
material onto the collection tray 127. The loading arm 130 can also
include a rock breaker (not shown but similar to the rock breaker
32 of FIGS. 3-8) operable to break down large lumps of ore 2 that
would be too large for the loading arm 130 to collect and maneuver
onto the collection tray 127. The loading machine 118 also includes
steerable treads or wheels 117 (wheels are shown in FIG. 12) for
movement over the mine floor. The wheels 117 are rotatable about a
generally vertical axis for movement in a variety of directions,
and are also vertically moveable relative to the chassis 138 of the
loading machine 118 for raising and lowering the chassis relative
to the mine floor 65.
[0051] The discharge end 140 is pivotally coupled to the material
collector 156 and may include a funnel or other guide member 142
for guiding material from the conveyor 126 into the crusher section
180. The pivotal coupling between the discharge end 140 and the
material collector 156 allows the loading machine 118 to be pushed
or pulled by the material collector 156 for movement into and out
of the draw-bell entries 9 and for movement along the roadway
entries 6. In operation, the wheels or treads of the material
collector 156 are operated to move the material collector 156 and
the loading machine 118 in the fore and aft direction. The wheels
117 of the loading machine 118 are then steered as needed to guide
the loading machine into and out of the draw-bell entries 9. When
the collection end 139 of the loading machine 118 is positioned
adjacent the draw bell 4, the loading arm 130 pulls material onto
the collecting tray 127 and the material is then conveyed
rearwardly by the conveyor 126 and dropped into the material
collector 156. The material is then crushed (if necessary) by the
crusher section 180 and transferred to the bridge conveyor 158 and,
finally, to the haulage conveyor 160, which transports the material
to along the roadway entry 6 and eventually out of the mine. The
continuous-extraction system 150 is thus able to move along the
roadway entry 6 under the motive power provided by the material
collector 156 and position the loading machine 118 into a draw-bell
entry 9. After the loading machine 118 has finished gathering
material from the draw-bell 4, the material collector 156 and the
steerable wheels 117 are operated in a coordinated manner to remove
the loading machine 118 from the draw-bell entry 9, tram further
along the roadway entry 6 to the next draw-bell entry 9, position
the loading machine 118 into the next draw-bell entry 9, and repeat
the process.
[0052] FIGS. 13-15 illustrate the continuous-extraction system 200
according to still another embodiment of the invention. This
embodiment employs much of the same structure and has many of the
same features as the embodiments of the continuous-extraction
systems 10,50,150 described above in connection with FIGS. 1-12.
Accordingly, the following description focuses primarily upon the
structure and features that are different than the embodiments
described above in connection with FIGS. 1-12. Reference should be
made to the description above in connection with FIGS. 1-12 for
additional information regarding the structure and features, and
possible alternatives to the structure and features of the
continuous-extraction system 200 illustrated in FIGS. 13-15 and
described below. Structure and features of the embodiments shown in
FIGS. 13-15 that correspond to structure and features of the
embodiments of FIG. 1-12 are designated hereinafter with like
reference numbers.
[0053] The continuous-extraction system 200 in this embodiment
includes a loader 202, a sizer 204, a material collector 206 in the
form of a surge car or bunker car, and a shuttle car 208. The
loader 202 in this embodiment is similar to the loading machine 118
illustrated in FIG. 12. In the illustrated embodiment, the loader
202 comprises steerable wheels or treads 210 (wheels are shown in
FIGS. 13-15) engageable with the mine floor 65. As such, the track
rails 22 that extend into the roadway entries 6 can be eliminated.
In the illustrated embodiment, the loader 202 includes the chassis
138 and the loading arm 130 movably coupled to the chassis 138. In
particular, the loader 202 includes the carriage assembly 131
movable along the chassis 138, and the loading arm 130 is coupled
to the carriage 131 for movement therewith. The loading arm 130 is
operable to move material from the draw-bell 4 toward the chassis
138. The chassis 138 includes a feed conveyor 126, and the loading
arm 130 is operable to move the removed material onto the feed
conveyor 126. In the illustrated embodiment, the loader 202
includes the rock breaker or lump breaker 32 mounted to an end of
the loading arm 130. The rock breaker 32 is operable to break down
large lumps of ore 2 that would otherwise be too large for the
loading arm 130 to collect and maneuver onto the collection tray
127. In the illustrated embodiment, the rock breaker 32 is in the
form of a jack hammer, but other embodiments may include other
types of rock breakers such as drills, shearing type devices, and
the like.
[0054] The sizer 204 is coupled to the loader 202 for sizing the
removed material. In the illustrated embodiment, the sizer 204
includes a discharge conveyor 212 for discharging the sized
material onto the material collector 204. Although FIGS. 13-15
illustrate the sizer 204 as being integral with the loader 202, in
some embodiments, the sizer 204 can be separate from the loader
202. For example, the sizer 204 can be coupled to the loader 202 in
an articulated or coordinated manner. In some embodiments, the
sizer 204 includes a self-contained power supply or drive mechanism
(not shown) for moving the sizer 204 along the roadway entries 6
and pushing and pulling the loader 202 for movement into and out of
the draw-bell entries 9. In this regard, the sizer 204 disclosed
herein is a mobile sizer unit; i.e., the sizer 204 is movable along
the mine floor 65 and can be positioned anywhere along the length
of the roadway entries 6. The sizer 204 can be driven or powered by
electrical, electro hydraulic, or a combination of electric and
hydraulic motors, and in some embodiments may be powered at least
in part by diesel power. As explained below, the sizer 204 is
configured to size the removed material on a substantially
continuous basis.
[0055] The material collector 206 is operable to collect the sized
material. In the illustrated embodiment, the material collector 206
has a loading end 214 and a discharge end 216, and a material
transport device 218 extending therebetween. The material transport
device 218 can employ a plate-type conveyor, an armored-face
conveyor, an endless-belt type conveyor, or other conveyors that
are known in the art. In other embodiments, the material collector
206 may include one or more funnels, chutes, and/or other guide
members for collecting material from the sizer 204 and guiding the
collected material onto the material transport device 218. The
material transport device 218 may be separate from or integral with
the material collector 206, and may contain portions with different
slopes.
[0056] In some embodiments, the material collector 206 may include
no drive mechanisms for tramming along the roadway entries 6, and
may instead be hitched, towed, pushed, or pulled like a trailer,
e.g., by the mobile sizer 204 or a maintenance vehicle (not shown).
The material collector 206 is therefore movable along the mine
floor 65 and can be positioned anywhere along the length of the
roadway entries 6. In other embodiments, the material collector 206
may be powered or driven at least in part by the self-contained
power supply or drive mechanism of the sizer 204. In the
illustrated embodiment, the material collector 206 includes wheels
220 engageable with the mine floor 65. Although FIGS. 13-15
illustrate the material collector 206 as including four wheels 220
rotatably coupled thereto, other embodiments may utilize other
numbers of wheels 220. For example, the material collector 206 may
include four to eight wheels 220. In some embodiments, at least
some of the wheels 220 may be rotatably coupled to the material
collector 206 via a hydraulic suspension.
[0057] The shuttle car 208 is operable to receive the collected
material from the material collector 206. Moreover, the shuttle car
208 is movable along the roadway entry 6 for transferring the
collected material so as to facilitate a substantially continuous
extraction of the material. In the illustrated embodiment, the
shuttle car 208 comprises steerable wheels or treads 222 (wheels
are shown in FIGS. 13-15) engageable with the mine floor 65. In
some embodiments, the shuttle car 208 may instead comprise
rail-car-type wheels for movement over rails. In some embodiments,
the shuttle car 208 comprises a chromium carbide overlay plate,
which may allow for a relatively thick plating so as to facilitate
receiving dense or heavy material.
[0058] Referring to FIG. 13, the loader 202 and sizer 204 of the
continuous-extraction system 200 are positioned at the illustrated
draw-bell 4 to remove and size material. The loading arm 130 pulls
the removed material onto the collecting tray 127 and the material
is then conveyed rearwardly (to the left in FIG. 13) by the feed
conveyor 126 and dropped into the sizer 204. The material is then
sized by the sizer 204 and transferred to the discharge conveyor
212 and to the material collector 206. While the material is thus
being removed, sized, and collected, the shuttle car 208 trams or
advances toward the material collector 206 and sizer 204.
[0059] Referring also to FIG. 14, once the shuttle car 208 is
adjacent the material collector 206 and sizer 204, the sized
material is transferred by the material transport device 218 from
the material collector 206 to the shuttle car 208. In some
embodiments, the shuttle car 208 can receive the sized material
directly from the sizer 204 rather than via the material collector
206. The material collector 206 can act as a surge capacitor for
the sized material. For example, if the continuous-extraction
system 200 is in an overfeed or upset situation exceeding the
desired feed rate of removed and/or sized material, the material
collector 206 can act as a buffer or capacitor to hold the sized
material until the material feed rate in the continuous-extraction
system 200 is reduced to a desired range.
[0060] Referring also to FIG. 15, after the transport of the sized
material is completed, the shuttle car 208 can tram backwards
toward the transverse transport entry 11. While the shuttle car 208
is tramming, the loader 202, sizer 204, and material collector 206
of the continuous-extraction system 200 can continue removing and
sizing the material, and then advance or tram further along the
roadway entry 6 in a coordinated manner to the next draw-bell 4 to
position the loader 202 into the next draw-bell entry 9 and repeat
the ore-loading process. The ore 2 thus continuously moves from the
loader 202 to the sizer 204, the material collector 206, and/or to
the shuttle car 208, and then outside the mine. Instead of
repeatedly tramming from the draw-bells 4 to a centrally-located
crusher or sizer, the shuttle car 208 is required to tram only a
relatively short distance between the transverse transport entries
11 and the mobile sizer 204 and material collector 206, which can
save time and improve production rates.
[0061] In a block-caving infrastructure 8 with multiple draw-bells
4, a plurality of continuous-extraction systems 200 can be employed
to further improve production rates. Some embodiments can also
include automation equipment operable to position the
continuous-extraction system 200 at draw-bells 4 and to control
other movements as needed. For example, radio or cable
communication links can be used for automation, remote operation,
or both.
[0062] Although the invention has been described in detail with
reference to certain preferred embodiments, variations and
modifications exist within the scope and spirit of one or more
independent aspects of the invention as described.
* * * * *