System and Method of Producing Mine Roof Bolts

Abstract

A method of producing a mine roof bolt includes: providing a plurality of bars of a predetermined length, moving the plurality of bars along a conveyor and indexing the position of the plurality of bars, and passing a portion of each of the bars through a processing station, where the processing station comprises at least one of a header assembly, an extruder assembly, and a threading assembly. The method further includes processing a portion of each of the bars with the processing station. A system for producing a mine roof bolt includes a conveyor configured to index and transport a bar, a feed arrangement configured to continuously deliver bars to the conveyor, a processing station comprising at least one of a header assembly, an extruding assembly, and a threading assembly, where the processing station is positioned along the conveyor and configured to receive and process a portion of the bars.

The invention claimed is: 
     
         1 . A method of producing a mine roof bolt comprising:
 providing a plurality of bars of a predetermined length;   moving the plurality of bars along a conveyor and indexing the position of the plurality of bars;   passing a portion of each of the plurality of bars through a processing station, wherein the processing station comprises at least one of a header assembly, an extruder assembly, and a threading assembly; and   processing a portion of each of the plurality of bars with the processing station.   
     
     
         2 . The method of  claim 1 , wherein a longitudinal and lateral position of the plurality of bars is indexed. 
     
     
         3 . The method of  claim 1 , wherein the processing station comprises a header assembly, and wherein processing the portion of each of the plurality of bars comprises:
 heating a portion of a first bar of the plurality of bars;   passing the portion of the first bar through the header assembly; and   forging a head at an end of the first bar.   
     
     
         4 . The method of  claim 3 , further comprising:
 actuating clamping assemblies to fix the position of the first bar during forging.   
     
     
         5 . The method of  claim 1 , wherein the processing station comprises an extruder assembly, and wherein processing the portion of each of the plurality of bars comprises:
 passing a portion of a first bar of the plurality of bars through the extruder assembly;   actuating a die cylinder to move a die holder assembly toward the first bar; and   extruding a portion of the first bar.   
     
     
         6 . The method of  claim 5 , further comprising:
 actuating clamping assemblies to fix the position of the first bar during the extruding.   
     
     
         7 . The method of  claim 5 , further comprising:
 after extruding the portion of the first bar, moving the first bar along the conveyor toward a second extruder assembly;   passing the portion of the first bar of the plurality of bars through the second extruder assembly;   actuating a die cylinder to move a die holder assembly toward the first bar; and   further extruding the portion of the first bar.   
     
     
         8 . The method of  claim 1 , wherein providing the plurality of bars comprises:
 moving each of the plurality of bars from a feed rack to the conveyor using a feed delivery device.   
     
     
         9 . The method of  claim 8 , wherein movement of the conveyor and the feed delivery device are synchronized. 
     
     
         10 . The method of  claim 1 , further comprising:
 after processing the portion of the bar, continuing to move the bar along the conveyor and depositing each of the plurality of bars into a receptacle.   
     
     
         11 . A system for producing a mine roof bolt comprising:
 a conveyor configured to index and transport a bar;   a feed arrangement configured to continuously deliver bars to the conveyor;   a processing station comprising at least one of a header assembly, an extruding assembly, and a threading assembly,   wherein the processing station is positioned along the conveyor and configured to receive and process a portion of the bars.   
     
     
         12 . The system of  claim 11 , wherein the feed arrangement comprises a feed rack and a feed wheel positioned adjacent to the feed rack, the feed wheel configured to receive bars from the feed rack and to deliver the bars to the conveyor. 
     
     
         13 . The system of  claim 12 , wherein the conveyor comprises a drive member and at least two drive sprockets, the drive member forming a continuous loop and extending circumferentially around the at least two drive sprockets. 
     
     
         14 . The system of  claim 13 , wherein the drive member includes a plurality of indexing clamps, the plurality of indexing clamps is configured to receive the bars and index a lateral position of the bars relative to adjacent bars. 
     
     
         15 . The system of  claim 11 , further comprising a heating source configured to heat a portion of the bar, wherein the processing station comprises a header assembly, the header assembly comprising:
 a frame assembly, upper and lower clamp assemblies, and at least one header die assembly, the upper and lower clamp assemblies configured to engage a portion of the bar, the at least one header die assembly comprising a die cylinder, a die holder, and a tool received by the die holder, the die holder moveable between a retracted and extended position via the die cylinder, wherein the header assembly is configured to form a head at an end of the bar.   
     
     
         16 . The system of  claim 11 , wherein the processing station comprises an extruder assembly, the extruder assembly comprising:
 a frame assembly, upper and lower clamp assemblies, and at least one extruder die assembly, the upper and lower clamp assemblies configured to engage a portion of the bar, the at least one extruder die assembly comprising a die cylinder, a die holder, and a tool received by the die holder, the die holder moveable between a retracted and extended position via the die cylinder, wherein the extruder assembly is configured to extrude a portion of the bar.   
     
     
         17 . The system of  claim 16 , wherein the processing station further comprises a threading assembly, the threading assembly comprising:
 a frame assembly, a moving die assembly, and a stationary die assembly, the moving die assembly is movable relative to the frame assembly and the stationary die assembly via a threading die cylinder, the moving die assembly and the stationary die assembly are configured to form threads on a portion of the rod.   
     
     
         18 . The system of  claim 17 , wherein the threading assembly further comprises a support stand having first and second paddles, the first and second paddles are each configured to initially support the rod prior to forming threads on a portion of the rod, the first and second paddles are movable in a downward direction. 
     
     
         19 . The system of  claim 11 , further comprising an index cylinder and a stop plate that are configured to index the longitudinal position of a bar positioned on the conveyor, the index cylinder moveable between first and second positions and configured to move a bar until the bar contacts the stop plate. 
     
     
         20 . The system of  claim 14 , further comprising a receptacle positioned adjacent to an end of the conveyor, the plurality of indexing clamps is configured to release the bars and deposit the bars into the receptacle.