U.S. patent application number 13/746432 was filed with the patent office on 2014-02-06 for method and apparatus for continuous bulbing of stranded cable.
This patent application is currently assigned to FCI Holdings Delaware, Inc.. The applicant listed for this patent is FCI Holdings Delaware, Inc.. Invention is credited to Mark M. Brandon.
Application Number | 20140033782 13/746432 |
Document ID | / |
Family ID | 48873845 |
Filed Date | 2014-02-06 |
United States Patent
Application |
20140033782 |
Kind Code |
A1 |
Brandon; Mark M. |
February 6, 2014 |
Method and Apparatus for Continuous Bulbing of Stranded Cable
Abstract
A method of forming a bulb in a cable bolt includes providing
cable from a cable source, advancing the cable in a first
direction, and forming a bulb in a portion of the cable while the
portion of the cable is continuously advanced and while the cable
is continuously provided from the cable source.
Inventors: |
Brandon; Mark M.; (Gibsonia,
PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
FCI Holdings Delaware, Inc.; |
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|
US |
|
|
Assignee: |
FCI Holdings Delaware, Inc.
Wilmington
DE
|
Family ID: |
48873845 |
Appl. No.: |
13/746432 |
Filed: |
January 22, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61590010 |
Jan 24, 2012 |
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Current U.S.
Class: |
72/185 ;
72/184 |
Current CPC
Class: |
D07B 7/187 20150701;
B21F 45/06 20130101; E21D 21/006 20160101 |
Class at
Publication: |
72/185 ;
72/184 |
International
Class: |
B21F 45/06 20060101
B21F045/06; D07B 7/02 20060101 D07B007/02 |
Claims
1. A method of forming a bulb in a cable bolt, the method
comprising: providing cable from a cable source; advancing the
cable in a first direction; forming a bulb in a portion of the
cable while the portion of the cable is continuously advanced and
while the cable is continuously provided from the cable source.
2. The method of claim 1, wherein the bulb is formed by moving a
bulb forming mechanism along with the cable.
3. The method of claim 1, further comprising cutting the cable to a
preset length while the cable is continuously advanced by moving a
cutting device along with the cable.
4. The method of claim 3, wherein the cutting device has a first
position and a second position spaced from the first position, the
cutting device moving between the first and second positions while
cutting the cable to the preset length.
5. The method of claim 1, wherein the cable source comprises a
spool having a length of cable, and wherein the cable is provided
from an inner portion of the spool.
6. The method of claim 2, wherein the bulb forming mechanism is
movable between a first position and a second position spaced from
the first position, the bulb forming mechanism moving from the
first position to the second position while forming the bulb.
7. The method of claim 3, further comprising spooling the cable
after being cut to a preset length onto a spooler.
8. The method of claim 6, wherein the bulb forming mechanism moves
from the second position to the first position after forming the
bulb.
9. The method of claim 1, further comprising forming a plurality of
bulbs in spaced apart portions of the cable.
10. The method of claim 2, wherein the bulb forming mechanism
comprises first and second clamps, the first clamp engaging the
cable as the bulb forming mechanism moves along with the cable, the
second clamp moving relative to the first clamp to form the
bulb.
11. The method of claim 1, wherein the cable is advanced via a
drive mechanism.
12. The method of claim 3, wherein an entire portion of the cable
extending from the cable source is continuously advanced until the
cable is cut to the preset length.
13. An apparatus for forming a bulb in a cable bolt, the apparatus
comprising: a drive mechanism configured to continuously advance a
length of cable; and a bulb forming mechanism movable along a
longitudinal axis defined by the length of the cable between a
first position and a second position spaced from the first
position, wherein the bulb forming apparatus is configured to form
a bulb on a cable while moving along with the advancing cable.
14. The apparatus of claim 13, further comprising a cable source
configured to provide a length of cable.
15. The apparatus of claim 14, wherein the length of cable extends
to the drive mechanism and from the drive mechanism to the bulb
forming mechanism.
16. The apparatus of claim 13, further comprising a cutting device
configured to cut a length of cable to a preset length.
17. The apparatus of claim 16, wherein the cutting device is
movable between a first position and a second position spaced from
the first position.
18. The apparatus of claim 13, wherein the bulb forming mechanism
comprises first and second clamps, the first clamp configured to
engage a cable as the bulb forming mechanism moves along with the
cable, the second clamp being movable relative to the first clamp
to form a bulb on the cable.
19. The apparatus of claim 18, wherein the bulb forming mechanism
comprises a motor to move the bulb forming mechanism between the
first and second positions.
20. The apparatus of claim 19, further comprising a cable source
configured to provide a length of cable, wherein the length of
cable extends to the drive mechanism and from the drive mechanism
to the bulb forming mechanism.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/590,010, filed Jan. 24, 2012, the entire content
of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to cable bolts, in particular,
to a method and apparatus for forming a bulb in a stranded cable
bolt.
[0004] 2. Description of Related Art
[0005] Cable bolts are used in the mining industry for their ease
of handling and installation. Cable bolts are generally easier to
fit into a borehole than the elongated rods of conventional rod
bolt systems. Regardless of the height limitations in a mine, cable
bolts may be adapted to boreholes of any length due to their
flexibility. The strength capacity of cables exceeds that of
conventional rod bolts and, therefore, cable is the preferred
reinforcement for certain roof conditions.
[0006] Cable bolts are typically installed by placing a resin
cartridge including catalyst and adhesive material into the blind
end of a borehole, inserting the cable bolt into the borehole so
that the upper end of the cable bolt rips open the resin cartridge
and the resin flows in the annulus between the borehole and the
cable bolt, rotating the cable bolt to mix the resin catalyst and
adhesive, and allowing the resin to set about the cable bolt. In
such cable bolts, the resin is typically set at an upper portion of
the cable bolt at the blind end of the borehole. The cable bolts
are typically formed with one or more bulbs to increase the bonding
between the bolts and the resin.
SUMMARY OF THE INVENTION
[0007] In one embodiment, a method of forming a bulb in a cable
bolt includes providing cable from a cable source, advancing the
cable in a first direction, and forming a bulb in a portion of the
cable while the portion of the cable is continuously advanced and
while the cable is continuously provided from the cable source.
[0008] The bulb may be formed by moving a bulb forming mechanism
along with the cable. The method may further include cutting the
cable to a preset length while the cable is continuously advanced
by moving a cutting device along with the cable. The cutting device
may have a first position and a second position spaced from the
first position, with the cutting device moving between the first
and second positions while cutting the cable to the preset length.
The cable source may include a spool having a length of cable, and
the cable may be provided from an inner portion of the spool. The
bulb forming mechanism may be movable between a first position and
a second position spaced from the first position, with the bulb
forming mechanism moving from the first position to the second
position while forming the bulb. The method may further include
spooling the cable after being cut to a preset length onto a
spooler. The bulb forming mechanism may move from the second
position to the first position after forming the bulb. The method
may further include forming a plurality of bulbs in spaced apart
portions of the cable. The bulb forming mechanism may include first
and second clamps, with the first clamp engaging the cable as the
bulb forming mechanism moves along with the cable and the second
clamp moving relative to the first clamp to form the bulb. The
cable may be advanced via a drive mechanism. An entire portion of
the cable extending from the cable source may be continuously
advanced until the cable is cut to the preset length.
[0009] In a further embodiment, an apparatus for forming a bulb in
a cable bolt includes a drive mechanism configured to continuously
advance a length of cable, and a bulb forming mechanism movable
along a longitudinal axis defined by the length of the cable
between a first position and a second position spaced from the
first position. The bulb forming apparatus is configured to form a
bulb on a cable while moving along with the advancing cable.
[0010] The apparatus may further include a cable source configured
to provide a length of cable. The length of cable extends to the
drive mechanism and from the drive mechanism to the bulb forming
mechanism. The apparatus may further include a cutting device
configured to cut a length of cable to a preset length. The cutting
device may be movable between a first position and a second
position spaced from the first position. The bulb forming mechanism
may include first and second clamps, with the first clamp
configured to engage a cable as the bulb forming mechanism moves
along with the cable and with the second clamp being movable
relative to the first clamp to form a bulb on the cable. The bulb
forming mechanism may include a motor to move the bulb forming
mechanism between the first and second positions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a schematic view of an apparatus for forming a
bulb in a cable bolt according to one embodiment of the present
invention, showing a first position of a bulb forming mechanism and
cutting mechanism.
[0012] FIG. 2A is a schematic view of a spool of cable according to
another embodiment of the present invention.
[0013] FIG. 2B is a schematic view of a spool mechanism according
to a further embodiment of the present invention.
[0014] FIG. 3 is a schematic view of the apparatus shown in FIG. 1,
showing a second position of the bulb forming mechanism and cutting
mechanism.
[0015] FIG. 4 is a plan view of a bulb forming mechanism according
to one embodiment of the present invention, showing a cable bolt
prior to bulbing.
[0016] FIG. 5 is a plan view of the bulb forming mechanism of FIG.
4, showing the cable bolt after a bulb has been formed.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] For purposes of the description hereinafter, the terms
"upper", "lower", "right", "left", "vertical", "horizontal", "top",
"bottom", and derivatives thereof, shall relate to the invention as
it is oriented in the drawing figures. However, it is to be
understood that the invention may assume various alternative
variations and step sequences, except where expressly specified to
the contrary. It is also to be understood that the specific devices
and processes illustrated in the attached drawings, and described
in the following specification, are simply exemplary embodiments of
the invention. Hence, specific dimensions and other physical
characteristics related to the embodiments disclosed herein are not
to be considered as limiting.
[0018] Referring to FIGS. 1-3, an apparatus 10 for forming a bulb
in a cable bolt includes a spool 12 having a length of stranded
cable 14 wound around to the spool 12 and configured to pay off
cable from the spool 12 as indicated by direction A by rotating the
spool 12. Although the cable 14 is shown being advanced from an
outer portion of the spool 12, the cable 14 may also be spooled
such that the cable 14 is advanced from a center or eye of a coil
of cable as shown in FIG. 2A. A drive mechanism 16 receives the
cable 14 and is configured to advance the cable 14 in a direction
corresponding to a longitudinal axis of the cable 14. The drive
mechanism 16 includes a measuring device (not shown), such as a set
of measuring wheels, which allows the formation of bulbs at preset
and varying intervals along the length of the cable 14. In
particular, the measuring device may include an encoder wheel
driven by the moving cable that includes an optical sensor that
provides pulses of light with each revolution of the encoder wheel.
The length of cable 14 advanced is determined by the quantity of
revolutions experienced by the encoder wheel. A programmable logic
controller (PLC) (not shown) detects when a certain length of cable
14 has been advanced and controls the apparatus to form bulbs 20 at
preset and varying intervals along the length of the cable 14.
[0019] Referring again to FIGS. 1-3, a bulb forming mechanism 18
receives the cable 14 from the drive mechanism 16 and forms one or
more bulbs 20 along the length of the cable 14 as controlled by the
PLC or other suitable arrangement. The bulb forming mechanism 18 is
mounted on a sliding frame shown schematically at 22 such that the
bulb forming mechanism 18 is movable as indicated at B along a
direction corresponding to the longitudinal axis of the advancing
cable 14 to allow the bulb forming mechanism 18 to travel with the
cable 14. In particular, the bulb forming mechanism 18 is
configured to form a bulb 20 on the cable 14 while the cable 14 is
continuously advanced by moving with the cable 14 while forming the
bulb 20. In one embodiment, the bulb forming mechanism 18 includes
a pair of clamps generally indicated at 24 that releasably engage
the cable 14. One of the clamps 24 is movable relative to the other
clamp to buckle the strands of the cable 14 thereby forming the
bulb 20 in the cable 14. When the PLC initiates the bulbing
sequence, the bulb forming mechanism 18 will clamp onto the cable
14 and travel along with the cable 14 while forming a bulb 20 at a
specified location as determined by the measuring device and
PLC.
[0020] Once the bulb 20 is formed, the cable 14 will be released by
the bulb forming mechanism 18 and the bulb forming mechanism 18
will move to its original position. Thus, the bulb forming
mechanism 18 has a first position (shown in FIG. 1) at the start of
the bulb forming sequence and a second position (shown in FIG. 3)
spaced from the first position at the end of the bulb forming
sequence. The bulb forming mechanism 18 will return to the first
position after forming a bulb 20. Because the bulb forming
mechanism 18 is movable, the spool 12 and drive mechanism 16 can be
continuously operated such that the cable 14 is continuously
advanced without stopping any portion of the cable 14 to form the
bulbs 20. Such a continuous operation improves efficiency of the
bulb forming operation by not having to start and stop the drive
motors (not shown) powering the spool 12 and drive mechanism 16 and
by not having stoppage time while the bulbs 20 are being
formed.
[0021] Referring again to FIGS. 1 and 3, in one embodiment, after
forming one or more bulbs 20, the cable 14 will continue passing
through a cutting device 26, such as a cut off saw, although other
suitable cutting devices may be utilized. The cutting device 26 is
mounted on a sliding table arrangement 28 in a similar manner as
described above in connection with the bulb forming mechanism 18
such that the cutting device 26 is movable as indicated at C along
a direction corresponding to the longitudinal axis of the advancing
cable 14. The cutting device 26 is configured to automatically cut
the bulbed cable 14 to preset lengths, which are then bundled and
packaged as shown at 30. In another embodiment, as shown in FIG.
2B, the cable 14 may also be passed through the cutting device 26
to a rewind spooler 32 to allow for spooling of longer bulbed cable
bolts as indicated by direction D of the spooler 32. The cutting
device 26 has a first position (shown in FIG. 1) at the start of
the cutting process and a second position (shown in FIG. 3) spaced
from the first position at the end of the cutting process. The
cutting device 26 will return to the first position after
performing the cutting process. The movement of the cutting device
26 allows the cable 14 to be continuously advanced thereby allowing
the cable 14 to have a positive velocity throughout the
process.
[0022] Referring to FIGS. 4 and 5, one embodiment of the bulb
forming mechanism 18 is shown in more detail. The bulb forming
mechanism 18 is supported by a frame 40 having a pair of parallel
racks 42. The bulb forming mechanism 18 includes a first clamp set
44 fixedly mounted to a base. 46 and a second clamp set 48 movably
mounted to the base 46. The second clamp set 48 is supported by a
sliding bush and shaft arrangement 50, 52. Each clamp set 44, 48
includes a pair of hydraulically operated mutually opposed jaws 54,
56 which are releasably engagable with the cable 14. However, other
suitable clamping arrangements may be utilized to grip the cable
14. Double acting hydraulic cylinders 58, 60 are used to activate
the first and second clamp sets 44, 48 to clamp the cable 14
therebetween. However, the double acting hydraulic cylinders 58, 60
may be substituted by single acting cylinders which activate the
first and second clamp sets 44, 48 to clamp the cable 14
therebetween.
[0023] The bulb forming mechanism 18 includes an actuator 62 in the
form of a hydraulic piston with one end fixedly mounted to the base
46 and the other end movably mounted to the second clamp set 48.
The piston 62 provides movement of the second clamp set 48 towards
the first clamp set 44 during the bulbing process. Alternatively,
the single actuator 62 may be substituted by two actuators located
on either side of the cable 14 with each actuator having one end
fixedly mounted to the base 46 and the other end movably mounted to
the second clamp set 48. Other power sources, such as electricity,
may be utilized to power the actuators.
[0024] The bulb forming mechanism 18 includes a set of driven front
pinions 64 and a complementary pair of rear idler pinions 66 in
gearing engagement with the parallel racks 42 for enabling the
clamp sets 44, 48 to move along with the cable 14 during the bulb
forming process as described above. The front pinions 64 are
preferably driven by a reversible, variable speed, hydraulic motor
68 with a built-in brake. A reversible, variable speed, electric
motor with a brake could also be used for this purpose. Although
the bulb forming mechanism 18 is movably mounted to the frame 40,
the bulb forming mechanism 18 may also be movably mounted to a
ceiling rail, or other suitable arrangement, which runs parallel to
the cable 14. The bulb forming mechanism 18 includes one or more
proximity sensors (not shown) for measuring the radial displacement
of the bulb formed in the cable. The bulb forming mechanism 18 also
includes an encoder 70 for controlling the movement of the pinions
64, 66 along the racks 42.
[0025] In use, the cable 14 is advanced across the length of the
frame 40 with a portion of the cable 14 extending through the jaws
54, 56 of the first and second clamp sets 44, 48. Oil pressure is
then applied to the double acting hydraulic cylinders 58, 60 to
respectively clamp the cable 14 between the jaws 54, 56 of the
first and second clamp sets 44, 48, as shown in FIG. 4. The
hydraulic piston 62 is then activated to move the second clamp set
48 towards the first clamp set 44 forming a bulb 20 in the cable
14, as shown in FIG. 5. As the cable 14 is clamped by the first and
second clamp sets 44, 48, the hydraulic motor 68 drives the pinions
64 to move the bulb forming mechanism 18 along with the cable 14 in
a direction corresponding to the longitudinal axis of the cable 14.
Thus, the portion of the cable 14 where the bulb 20 is formed is
continuously advanced. Radial displacement of the cable 14 may be
controlled by the PLC using one or more proximity sensors (not
shown) to limit the radial displacement of the bulb 20. Once the
first bulb is formed, oil pressure is applied to the hydraulic
cylinders 58, 60 to release the cable 14 from the jaws 54, 56 of
the first and second clamp sets 44, 48. Oil pressure is then
applied to the topside of the hydraulic piston 62 which in turn
moves the second clamp set 48 back to its starting position, as
shown in FIG. 4. After the bulbing process, the bulb forming
mechanism 18 is in the second position as shown in FIG. 3 and
described above. The motor 68 then drives the pinions 64 along the
racks 42 to move the bulb forming mechanism 18 to the first
position, as shown in FIG. 1 and described above, for performing
further bulb forming processes. Although the first and second
positions are generally mentioned, the bulb forming mechanism 18
may be moved as necessary to form one or more bulbs 20 on the cable
14 at predetermined positions while the cable 14 is continuously
advanced.
[0026] The bulb forming mechanism 18 described above and shown in
the figures may take other forms as long as the mechanism for
forming the bulbs is movable to allow the portion of the cable
where the bulb is formed to be continuously advanced. In
particular, the bulb forming mechanism 18 may be embodied as the
bulb forming mechanism shown and described in U.S. Patent
Application Publication No. 2011/0259072 to Evans et al. and U.S.
Pat. Nos. 5,344,256 to Hedrick and 6,820,657 to Hedrick, which are
each incorporated by reference in their entirety.
[0027] Although the invention has been described in detail for the
purpose of illustration based on what is currently considered to be
the most practical and preferred embodiments, it is to be
understood that such detail is solely for that purpose and that the
invention is not limited to the disclosed embodiments but, on the
contrary, is intended to cover modifications and equivalent
arrangements that are within the spirit and scope of the
description. For example, it is to be understood that the present
invention contemplates that, to the extent possible, one or more
features of any embodiment can be combined with one or more
features of any other embodiment.
* * * * *