Field of the invention

[001] The present invention relates to long wall mining, and, in particular, to components that facilitate the introduction and/or installation of liners, like geosynthetics or the like, into longwall mines, and also, methods of installing the liners.

Background of the invention

[002] Any reference herein to known prior art does not, unless the contrary indication appears, constitute an admission that such prior art is commonly known by those skilled in the art to which the invention relates, at the priority date of this application.

[003] The following basic overview of longwall coal mining is made with reference to figures 19 and 20 which provide simplified schematics of the general parts and processes. In long wall mining, a shearer (1) runs along a coal face (2) and, with each pass, progressively removes slices or 'webs' of coal. Sheared coal is captured by a conveyor (3) which transports it to 'roadways' or 'gates' (4, 5) that travel perpendicular to the coal face (2). A series of roof supports (500), often referred to as 'chocks' or 'powered roof supports', are lined up along the coal face (2) to support the roof area (7) immediately in front of the coal face (1). The conveyor (3) and shearer (1) are protected beneath the canopies/shields (501) of the roof supports/chocks (500). With each pass of the shearer (3), the coal face (1) recedes, and the roof supports (500) and other equipment are progressed forward. With forward progression of the roof supports/chocks (500) the roof area trailing the supports (8), which is no longer supported, collapses.

[004] Once shearing/mining is complete, removal of the roof supports/chocks (500) from a longwall mine can be dangerous, as the roof area previously supported is at risk of collapse. One method to assist with removal is to line the roof area with a stabilizing liner, like, for example, a geogrid, which effectively establishes a protective cocoon. The liner (6) is introduced at or near to completion of shearing and fed over the roof supports (500) in a multi-step process that includes sequentially progressing the roof support/chocks (500) to pin the liner against the roof area. Once the liner is in place, removal of the chocks can commence safely, as the liner acts to support the roof area. Typically, with the removal of each roof support/chock (500), fixed supports are erected in their place, to maintain the liner in place against the roof area.

[005] As the coal face of a longwall mine can be hundreds of meters long, introducing and/installing the liner is difficult. The sheer size of the liner makes it heavy and difficult to manage. Present methods introduce the liner (6) in a rolled up form. The liner is introduced to the coal face line/roadway from one of the perpendicular gates/roadways (e.g. 4, 5) that lead thereto. To facilitate this, guides (7) may be installed to assist with directing the liner around bends/corners e.g. between the gates and the coal face.

[006] At the coal face, the liner is fed into hangers suspended at the underside of each support/chock canopy. Once in position in the hangers, the liner is progressively unrolled/unraveled with the aid of winches at each chock. The winches pull the leading edge of the liner close to the tip of the support/chock canopies (501). The canopies are then sequentially lowered and progressed forward before being re-elevated to pin the liner against the roof area of the mine. This process is repeated until the liners extend completely over the roof support/chocks (500). In some cases, to facilitate the pinning process, an additional extension element may be fitted to the support/chock canopy tip, which allows the liner to be pulled further out from the canopy tip. In addition, some support/chock canopies, like flipper canopies, have powered hinged tips and that can facilitate pinning of the liner.

[007] Current hanger components have disadvantages at least in that, when they are no longer needed, they have to be manually removed from the supports/chocks. This can consume considerable time and man power, and often, hangers can get lost or left behind in the mine once removed. Also, prior to mounting to the supports/chocks, it is necessary to separately transport the numerous hangers into the mine. Similarly, guide components need to be manually installed/dissembled as required.

[008] The present invention seeks to provide and improved components and methods for longwall mining, and, in particular, methods and components that facilitate the introduction and/or installation of stabilising liners into long wall mines. Summary of the Invention

[009] In one broad form, the present invention provides a guide for facilitating introduction and/or installation of a liner into a long wall mine, the guide including: a mount portion; and a guide portion for guiding the liner.

[010] In one form, the guide portion is movable between retracted position and a deployed position. In one form, the guide portion is hingedly connected to the mount portion so as to allow movement between the retracted position and the deployed position.

[Oil] In one form, the guide portion includes a column about which the liner is guided. In one form, in use, the column is suspended in a substantially vertical orientation. In one form, the column includes a substantially smooth curved surface for contactingly directing the liner. In one form, the column is substantially cylindrical.

[012] In one form, the column includes an arm laterally protruding therefrom, the arm for supporting the liner in an elevated position.

[013] In one form, the column or a portion thereof is rotatable about the elongate axis of the column.

[014] In one form, the guide portion is substantially L-shaped.

[015] In one form, the guide portion includes a stopper portion located thereon that abuts the mount portion to prohibit over rotation of the guide portion beyond the deployed position.

[016] In one form, the liner is a geogrid.

[017] In one form, the mount portion is integral with a canopy portion of a roof support. In one form, the mount portion is configured to be secured to a canopy portion of a roof support. In one form, the roof support is a hydraulic roof support or chock. [018] In a further broad form, the present invention provides a roof support including a guide as in any one of the forms described herein.

[019] In a further broad form, the present invention provides a method for lining a long wall mine with a stabilizing liner, the method including the steps of:

a. introducing two or more rolls of liner into a long wall mine;

b. unraveling a first of the two or more rolls of liner and pinning same to the mine ceiling; c. securing the trailing edge of the first roll to the leading edge of a subsequent roll; and d. unraveling the subsequent roll and pinning same to the mine ceiling.

[020] In one form, the leading and/or trailing edges of the rolls include a rigidifying member that extends therealong. In one form, the rigidifying member is a metal cable or wire, sewn into the liner edge.

[021] In a further broad form, the present invention provides a hanger for facilitating introduction and/or installation of a liner into a long wall mine, the hanger including: a mount portion; and a hanger portion for suspending the liner in an elevated position, wherein the hanger portion is moveable between a stowed position and a deployed position.

[022] In one form, the hanger portion includes a base with a roller. In one form, the hanger portion further includes a connector member that connects the base to the mount portion. In one form, the connector member is hingedly connected between the base and mount portion.

[023] In one form, in the stowed positon, the base is folded against the connector member. In one form, in the deployed position, the hanger portion has a substantially L-shaped profile.

[024] In one form, the hanger further includes at least one extendable arm pivotally connected between the mount and hanger portions, the at least one extendable arm operable to move the hanger portion between the stowed and deployed positions. In one form, the extendable arms are hydraulically powered. [025] In one form, the liner is a geogrid.

[026] In one form, the mount portion is integral with a canopy portion of a roof support. In one form, the mount portion is configured to be secured to a canopy portion of a roof support. In one form, the roof support is a hydraulic roof support or chock.

[027] In a further broad form, the present invention provides a roof support including a hanger as described in any one of the forms herein.

[028] In a further broad form, the present invention provides a stabilizing liner, like a geosynthetic or the like, including a rigidifying member extending along at least one edge thereof.

Brief description of the drawings

[029] A detailed description of embodiments of the invention will follow, by way of example only, with reference to a selection of the accompanying figures, in which:

Figure 1 is an isometric view of one example of a guide according to the invention, with guide portion thereof in a deployed position;

Figure 2 is a front view of the guide of figure 1, with guide portion thereof in a deployed position;

Figure 3a is a side view of the guide of figure 1, with guide portion thereof in a deployed position;

Figure 3b is an enlarged side view of the guide of figure 1, with guide portion thereof in a deployed position;

Figure 4 is an isometric view of the guide of figure 1, with guide portion thereof in a transitory position, between a deployed position and a retracted position;

Figure 5 is a front view of the guide of figure 1, with guide portion thereof in a transitory position, between a deployed position and a retracted position;

Figure 6a is a side view of the guide of figure 1, with guide portion thereof in a transitory position, between a deployed position and a retracted position;

Figure 6b is an enlarged side view of the guide of figure 1, with guide portion thereof in a transitory position, between a deployed position and a retracted position; Figure 7 is an isometric view of the guide of figure 1, with guide portion thereof in a retracted position;

Figure 8 is a front view of the guide of figure 1, with guide portion thereof in a retracted position;

Figure 9a is a side view of the guide of figure 1, with guide portion thereof in a retracted position;

Figure 9b is an enlarged side view of the guide of figure 1, with guide portion thereof in a retracted position;

Figure 10 is an isometric view of one example of a hanger according to the invention, with the hanger portion thereof in the deployed position;

Figure 11 is a front view of the hanger of figure 10, with the hanger portion thereof in the deployed position;

Figure 12a is a side view the hanger of figure 10, with the hanger portion thereof in the deployed position;

Figure 12b is an enlarged side view of the hanger of figure 10, with the hanger portion thereof in the deployed position;

Figure 13 is an isometric view of the hanger of figure 10, with the hanger portion thereof in a transitory position, between a deployed position and a stowed position;

Figure 14 is a front view of the hanger of figure 10, with the hanger portion thereof in a transitory position, between a deployed position and a stowed position;

Figure 15a is a side view of the hanger of figure 10, with the hanger portion thereof in a transitory position, between a deployed position and a stowed position;

Figure 15b is an enlarged side view of the hanger of figure 10, with the hanger portion thereof in a transitory position, between a deployed position and a stowed position;

Figure 16 is an isometric view of the hanger of figure 10, with the hanger portion thereof in a stowed position;

Figure 17 is a front view of the hanger of figure 10, with the hanger portion thereof in a stowed position;

Figure 18a is a side view of the hanger of figure 10, with the hanger portion thereof in a stowed position;

Figure 18b is an enlarged side view of the hanger of figure 10, with the hanger portion thereof in a stowed position; Figure 19 is top schematic view of a longwall mine, showing roof support/chock arrangement along a coal face; Figure 20 is a simplified side schematic view of longwall mining;

Figure 21 is 3d rendering showing an example of roof supports lined up along a coal face with hangers according one example of the invention located thereon;

Figure 22 is 3d rendering illustrating a liner roll being drawn through hangers according one example of the invention;

Figure 23 is a 3d rendering illustrating a liner roll being unwound from a hanger according to one example of the invention; and

Figure 24 is a 3d rendering showing an example of the process of canopy pinning a liner against a roof area.

Detailed description

[030] Embodiments of the present invention provide improved methods and components for longwall mining that facilitate the installation and/or introduction of stabilising liners, like geosynthetics, geogrids or the like.

[031] In one aspect, the present invention provides an improved guide for facilitating the introduction and/or installation of a liner into a long wall mine. The guide is typically for facilitating direction of the liner around a bend or corner. The guide includes a mount portion and a guide portion for guiding the liner. Generally, the mount portion is secured or integrally formed with a roof support/chock (typically to the canopy). In typical use, the guide would be located at a roof support/chock at the end of the support/chock line (e.g. 500a), near to a bend/corner leading in to the coal face from an adjacent gate/roadway (e.g. 4, 5).

[032] The guide portion of the guide is movable between a retracted position and deployed position. This provides that, rather than having to remove/dissemble the guide, as was the case with prior art guides, the presently described guide can simply be retracted when not in use. Generally, the guide portion is hingedly connected to the mount portion so as to allow movement between the retracted position and the deployed position.

[033] It will be appreciated that, in varying forms, the guide may be secured to or may be integral with a roof support/chock. Generally though, the mount portion of the guide is configured to be secured to the canopy portion of a roof support/chock. It will also be appreciated that the mount portion may be configured to mount to other parts of the roof support/chock.

[034] The guide portion of the guide, that extends from the mount portion, typically includes a column about which the liner is guided. In use, the column is suspended in a substantially vertical orientation and the liner is drawn around the column as the liner is pulled/drawn around a bend. The column includes a substantially smooth curved surface for contactingly directing the liner, which, as previously described, is generally in a rolled up form. Typically, the column is substantially cylindrical.

[035] It will be appreciated that, in the absence of a guide, additional manpower would be needed to guide the liner roll around a bend, or the liner could come into contact with the corners between mine passages/roadways and get damaged/torn.

[036] To assist with keeping the liner elevated above the mine floor, the column of the guide portion may include a support/arm laterally protruding therefrom. The roll of liner, as it travels about the column, typically rests or is supported by the support/arm. The guide portion of the guide (comprising column and support/arm) typically has an L- shape. To allow implementation of the guide in a "right-turn" or "left-turn" mode, the column or part thereof may be rotatable such that the support/arm can be reoriented. Accordingly, the guide can be adjusted to receive a liner roll coming from different directions (i.e. around a left turn bend/right turn bend) without having to be disassembled and re-installed. In some examples, the support/arm may be hingedly connected to the column such that it may fold up substantially against the column and fold out to provide the L-shape.

[037] The guide may also have a stopping mechanism that prohibits over rotation of the guide portion beyond the deployed position i.e. after transition from the retracted position. Typically, to achieve this, a stopper is located on the guide portion to abut the mount portion as it reaches the deployed position. [038] One particular example of a guide for directing a roll of liner (6) around a bend within a long wall mine is shown in figures 1 to 9. The guide (100) as shown includes a mount portion (102) for securement of the guide (100) to the canopy (501) of a roof support/chock (500). In this example, the mount potion (102) includes two substantially perpendicular plates (102a, 102b) configured to respectively meet the sidewall and underside of the canopy (501) of a roof support (500).

[039] A guide portion (103) is hingedly connected to the mount portion (102), and, as previously described, is for guiding a roll of liner (6) around a bend. Typically the guide (100) is secured to a roof support/chock at the end of a chock line (e.g. 500a), to facilitate entry of the liner from the mine gates/roadways (e.g. 4, 5) that travel perpendicular to the coal face. The guide portion (103) is substantially L-shaped comprising a column (104) and an arm (105) extending laterally therefrom. In use, the liner is supported on the arm (105) in an elevated position above the mine floor and drawn around the column (104). The column (104) is substantially cylindrical such that it provides a curved, substantially smooth surface to contact the liner as it is drawn there around. The smoothness/curvature of the column is such that the liner, as it is drawn around the column (104), is not damaged. The top surface (105a) of the arm is also curved, to prevent damage to the liner.

[040] To allow reorientation of the arm (105) such that the guide (100) can be in a "left- turn" or "right-turn" mode (i.e. to permit the liner roll to be drawn around a left turning bend or right turning bend), the column (104) includes a rotatable sleeve portion (104a) that is rotatable about inner member (104b) to reorient the arm (105).

[041] The guide portion (103) is movable between a deployed position, as is shown in figures 1 to 3, and a retracted position, as is shown in figures 7 to 9. Figures 4 to 6 show a transitory position between the retracted and deployed positions. In the deployed position, the column (104) is suspended in a substantially vertical orientation, beneath the roof support/chock canopy (501). In the retracted position, the column (104) is lifted to extend laterally from the chock canopy (i.e. to be in a substantially horizontal plane). It is thus apparent, that when retracted, the guide portion (103) will not interfere with people/equipment beneath the canopy (501). To facilitate with lifting of the guide portion (103) to the retracted position, linker elements (107) are included for engagement, for example, with hydraulic rams.

[042] To prohibit over rotation from the retracted position beyond the deployed position, the column (103) includes a stopper (106) protruding from an upper portion thereof, in the direction of the roof support/chock canopy (501) (i.e. stopper protrudes from the canopy facing side of column). The stopper (106) includes a top surface (106a) configured to engage with the underside of mount portion plate (102b) that is secured to the underside of the canopy (501). It will be appreciated that, in other forms, such as when the guide (100) is secured to the canopy by other means, or is integral thereto, the stopper (106) may simply abut the underside of the canopy (501) to prohibit over rotation of the guide portion beyond the deployed position.

[043] It will be appreciated that the guide portion (103) may be stowed/deployed/rotated non-manually, such as, for example, via electronic and/or hydraulic control. Manual control may also be possible.

[044] It will also be appreciated that as the guides as described herein may be fixedly secured or integral with the roof support/chock canopies, they can simply be deployed and retracted as required. This is advantageous over prior art guides which were typically onerous to transport, install and remove. The guides as described herein can also be easily re oriented/rotated between "right turn" and "left turn" modes.

[045] According to a further aspect the present invention provides an improved hanger for facilitating introduction and/or installation of a liner into a longwall mine. The hanger includes a mount portion and hanger portion for suspending liner in an elevated position. The hanger portion is movable between a stowed position and deployed position.

[046] It will be appreciated that the mount portion may be configured to be secured to a roof support/chock or may be integral therewith. Typically, the mount portion is located such that the hanger portion is suspended from the underside of the roof support/chock canopy. [047] The hanger portion of the hanger generally includes a base with a roller, on which the liner is supported. It will be appreciated that in typical use, multiple neighboring hangers on respective neighboring roof supports/chocks would support an elongate length of rolled up liner (see for example Figures 21 and 22). The roller/s allow/s the liner to be more readily drawn through/over the hanger/s, such as, for example when being pulled along the coal face.

[048] Typically, the hanger portion includes a connector member that connects the base to the mount portion, and is hingedly connected therebetween. This allows movement of the hanger portion between the stowed and deployed positions. In the stowed position, the hanger portion typically lies substantially flat against the underside of the canopy of the roof support/chock. Generally, to achieve this, the base is folded against the connector member. Typically, in the deployed position, the hanger portion is unfolded such that the base and connector member provide a substantially L-shaped profile.

[049] To facilitate movement between the stowed and deployed positions, the hanger may include at least one extendable arm pivotally connected between the mount portion and the hanger portion. The at least one extendable arm being operable to drive the hanger portion between the stowed position and deployed positions. The at least one extendable arm may be, for example, hydraulically powered. It will also be appreciated that the extendable arm(s) may be connected between parts of the roof support/chock and the hanger portion, to move the hanger portion between deployed and stowed positions.

[050] One particular example of a hanger (200) is shown in figures 10 to 18. Figures 10 to 12 show the hanger (200) in the deployed position. The hanger includes a mount portion (201), via which the hanger is secured to the underside of a roof support/chock canopy (501). The mount portion (201) is formed of a rectangular frame (201a) and crosspiece (201b) that extends between the elongate sides of the frame (201a).

[051] A hanger portion (202) extends from the mount portion (201), and includes a connector member (203) and base (204). The connector member (203) is located between and connects the base (204) to the mount portion (201). At the proximal end thereof, the connector member (203) is hingedly connected to the mount portion (201), whilst at the distal end, it hingedly connects with the base (204). In this example, both the connector member (203) and base (204) take the form of rectangular frames.

[052] The base (204) is for supporting the liner thereon, and includes a roller (205) to facilitate travel/conveyance of the liner over/though the hanger. The roller ends (205a) have an increased diameter such that the roller is cradle-like. This provides that any liner roll supported by the roller is encouraged toward the centre of the roller and is less likely to "de rail". Whilst the distal end of the connector member/frame (203) is also hingedly connected to the base (204), the connection therebetween is restricted such that the hanger portion (202) does not extend beyond a substantially L-shaped profile. The hanger portion (202) is thus moveable between a deployed position, where it has an L-shaped profile (i.e. as in figures 10-12) and a stowed position where it lays substantially flat against the underside of the canopy (501) (i.e. as in figures 16 to 18). As shown, in the stowed positon, the frames for the mount portion (201), connector member (203), and base (204) are substantially stacked/aligned.

[053] To arrive in the stowed position, the base (204) is first folded to lay against the connector member (204), and then both components further folded to lay against or in line with the mount portion (201). Figures 13 to 15 show a transitory position of the hanger portion (200) with the base (204) partially folded toward the connector member (203).

[054] To facilitate deployment and stowage of the hanger portion (202), two extendable arms (206) in the form of hydraulic rams are pivotally coupled between the mount portion (201) and the connector member (203) such that, on extension of the arms (206), the hanger portion (202) is moved into the stowed position and, on retraction of the arms (206), the hanger portion (206) is moved into the deployed position. The arms (206) may also be implemented to limit over rotation of the connector member (203) such that, on deployment of the hanger portion (202), the connector member (203) does not rotate beyond a substantially vertical alignment beneath the canopy (501). [055] It will be appreciated that the hanger portion (202) may be stowed/deployed non- manually, such as, for example, via electronic and/or hydraulic control. Manual control may also be possible.

[056] Figures 21 to 24 show typical implementation of the hangers (200). Figure 21 shows roof supports/chocks (500) lined up along a coal face each with a hanger (200) located respectively thereon. Figure 22 illustrates how a roll of liner (6) is typically drawn through the hangers (200). Typically the roll of liner is connected to a rope/cable (400) which in turn is either secured to the shearer (which moves along the coal face pulling the liner along with it) or a winch (not shown) located at the end of the coal face (which operates to pull the liner through hangers). As can be seen the liner roll rests on top of the rollers, which rotate to facilitate movement of the liner through the hangers.

[057] Figure 23 illustrates how the liner (6) is typically progressively unrolled/unraveled with the aid of winches (502) at each chock. The winches (502) pull the leading edge of the liner (6) close to the tip of the support/chock canopies (501). To facilitate pinning of the liner, an additional extension element (503) may be fitted to the some of the roof supports/chock canopy tips, so as to allow the liner to be pulled further out beyond the canopy tips. As shown in figure 24, the canopies (501), typically in a predetermined sequence, are lowered and progressed forward before being re-elevated to pin the liner against the roof area of the mine. This process is repeated until the liners extend completely over the roof support/chocks (500).

[058] It will be appreciated that as the hangers as described herein may be fixedly secured or integral with the roof support/chock canopies, they can thus simply be deployed and stowed as required. This is advantageous over prior art hangers which were typically loosely hooked or hung to the support/chock canopies when required and thereafter had to be manually removed. Prior art hangers where also prone to swaying, which made loading of the liner difficult. The open L-shaped profile of the hanger portions as described herein also allow for a greater width of base, and so, multiple rolls of liner may be supported and drawn through the hangers simultaneously. It will be appreciated the multiples rolls may be formed in a single piece/sheet/grid of liner, or may be separate pieces/sheet/grids individually rolled up. [059] It will also be appreciated to a skilled person that the stabilizing liner as referred to herein may take a variety of forms and may be any suitable sheet, mesh, grid, liner, cloth, fabric for supporting the roof area of a mine. Typical examples are geosynthetics, like geogrids or the like. Similarly, it will be appreciated that the roof support/chocks, conveyors, shearers and other equipment may also take a variety of the forms. The roof support is typically a hydraulic roof support or chock.

[060] A further aspect of the invention, in which the above described hangers and guides may be implemented, relates to the introduction/installation of more than one liner roll into the hangers before unravelling and pinning same to the mine roof/wall. Prior methods only place a single liner roll into the hangers.

[061] A two or more liner roll process/system/method, provides that multiple smaller and lighter rolls may be used, as opposed to one larger and relatively heavier roll. As would be appreciated, smaller and lighter rolls are easier to handle and are therefore easier to introduce into the mine. In addition, smaller diameter rolls can be unraveled in less time.

[062] In a two roll system, for example, each roll of liner is sequentially drawn into the hangers (e.g. by the shearer or by a winch). As described previously, guides may be used to guide the rolls around corners/bends within the mine as they are introduced. The two rolls are located side by side in the hangers, such that they extend parallel to one another along the length of the coal face.

[063] The roll located closest to the coal face is first unraveled and pinned to the mine roof (e.g. by sequential chock/support/canopy movement), before the second roll is unraveled and pinned. To facilitate roof pinning and securement of the rolls/sheets together, the leading and/or trailing edges of the rolls/sheets include a rigidifying member that extends therealong. In one example, the rigidifying member is a metal wire or cable that is sewn into the liner edge. This provides a level of rigidity to the leading and/or trailing edges of the rolls/sheets such that they may be more easily pinned to the mine roof and secured together. [064] For example, once the first roll is unraveled, the trailing edge thereof is aligned with the leading edge of the second roll. The rigidity provided by the metal cable/wire that extends along the neighboring edges facilitates alignment of the edges, and allows securement clips (i.e. to secure the edges together) to be spaced further apart. Furthermore, when securing the joined edges to the roof/ceiling of the mine, using roof bolts or the like, there is less sagging. Often a single roof bolt (like a T-shaped bolt) may be inserted between the join securing both neighboring edges to the roof/ceiling (i.e. trailing edge of first roll, and leading edge of subsequent roll).

[065] Having the leading edges more rigid also provides advantages in that during initial pinning of the liners, by the chock/support canopy tips, there is less sagging. Also, once the liner has fully extended over the roof supports/chocks, to the areas where the roof has collapsed, the rigidity of the liner aids to pinning the liner in place, e.g. amongst the rubble/fallen rock.

[066] It will be appreciated that a further aspect of the invention also relates to a novel stabilizing liner that includes a rigidifying member extending along at least one of it edges. Typically, for liner rolls that are to be inserted in a long wall mine, a rigidifying member extends along the leading and trailing edge of the liner. It will also be appreciated methods/process/systems may be implemented where more than 2 liner rolls are introduced and sequentially unrolled, connected and pinned to the roof area.