I AUSTRALIA Patents Act 1990 SOUTHERN ENGINEERING SERVICES PTY LTD COMPLETE SPECIFICATION INNOVATION PATENT Invention Title: Improvements relating to cutting tools for mining machines The following statement is a full description of this invention including the best method of performing it known to us:- 2 The present application is related to Australian Provisional Patent Application No. 2010901134, International Patent Application No. PCT/AU2010/000314 (International Publication No. W02011/113113), Australian Patent Application No. 2011229158 and Australian Patent Application No. 2012200898, the entire disclosures 5 of which are incorporated herein by way of reference. The present disclosure relates to improvements to cutting tools for mining machined and more particularly to a tool and a tool system for mining machines. The tool system and tool have been developed primarily for use in longwall coal mining machines and iron ore mining machines. However, it will be appreciated that the tool 10 system and tool may also be used in other mineral winning machines, or indeed in excavation equipment, such as road headers, surface miners, continuous miners or tunnel boring machines. Known tool systems typically include a tool holder and a cutting tool mountable in the tool holder. The cutting tool typically includes a shank that engages a socket in 15 the tool holder to mount the tool to the tool holder. Tool systems in known longwall coal mining machines are mounted on a shearer drum comprising a barrel around which extends a helical vane. The tool system is mounted on a radially outer edge of the helical vane and faceplate. Tool systems in known iron ore mining machines are mounted directly on the 20 cutterhead, commonly in a generally helical pattern along the length of the drum. A problem with known tool systems is that it can be difficult to replace a failed tool, particularly in cases where tool failure occurs in the shank of the tool. Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is not to be taken as an admission that 25 any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention as it existed before the priority date of each claim of this application. Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated 30 element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps. In a first aspect, the present disclosure provides a tool system comprising a tool and a tool holder, the tool holder comprising: 35 a body having a socket therein; the tool comprising: 3 a cutting end for winning mineral from an ore body, a mounting end comprising a shank complementary with and engageable in the socket, a laterally extending flange between the mounting end and the cutting end, 5 the flange being engageable by a lever to facilitate removal of the tool from the tool holder, and a line of weakness in the tool defining a predetermined failure point, the line of weakness being positioned on the cutting end side of the flange, such that the tool is adapted to fail at a position that leaves the flange intact. 10 The line of weakness may extend laterally across the tool. The line of weakness may be created by removal of material from the tool. The line of weakness may be in the form of a groove in the tool. The tool holder may be adapted for connection to a rotatable head on a mining machine or may be integrally formed in a rotatable head on a mining machine. In some 15 embodiments, the rotatable head may be, for example, a shearer drum on a mining machine for winning the likes of coal, potash, phosphate, salt or trona, or a cutter head on a mining machine. In other embodiments, the rotatable head may be, for example, a cutter head on a mining machine for winning minerals the likes of iron ore in harder ore bodies. 20 In a second aspect, the present disclosure provides a tool for a tool system for a mining machine, the tool comprising: a cutting end for winning mineral from an ore body, a mounting end comprising a shank complementary with and engageable in a socket of a tool holder, 25 a laterally extending flange between the mounting end and the cutting end, the flange being engageable by a lever to facilitate removal of the tool from the tool holder, and a line of weakness in the tool defining a predetermined failure point, the line of weakness being positioned on the cutting end side of the flange, such that the tool is 30 adapted to fail at a position that leaves the flange intact. The line of weakness may extend laterally across the tool. The line of weakness may be created by removal of material from the tool. The line of weakness may be in the form of a groove in the tool. The tool may be adapted for use on a rotatable head on a mining machine or 35 may be integrally formed in a rotatable head on a mining machine. In some embodiments, the rotatable head may be, for example, a shearer drum on a mining 4 machine for winning the likes of coal, potash, phosphate, salt or trona, or a cutter head on a mining machine. In other embodiments, the rotatable head may be, for example, a cutter head on a mining machine for winning minerals the likes of iron ore in harder ore bodies. 5 Embodiments of a tool system according to the present disclosure will now be described, by way of example only, with reference t the accompanying drawings, in which: Fig. 1 is a perspective view of an embodiment of a tool system in accordance with the present disclosure; 10 Fig. 2 is a side view of the tool system of Fig. 1; Fig. 3 is a front view of the tool system of Fig. 1; Fig. 4 is a top plan view of the tool system of Fig. 1; Fig. 5 is a cross-sectional view taken along line 5-5 of the tool system of Fig. 4; Fig. 5a is an enlarged view of the circled portion of Fig. 5; 15 Fig. 6 is a perspective view of a front side of the tool of the tool system of Fig. 1; Fig. 7 is a side view of the tool of Fig. 6; Fig. 8 is a front view of the tool of Fig. 7; Fig. 9 is a top plan view of the tool of Fig. 7; 20 Fig. 10 is a rear view of the tool of Fig. 7; Fig. 11 is a perspective view of a rear end of the tool holder of the tool system of Fig. 1; Fig. 12 is a perspective view of a front view of the tool holder of Fig. 11; Fig. 13 is a front view of the tool holder of Fig. 11; 25 Fig. 14 is a side view of the tool holder of Fig. 11; Fig. 15 is a top plan view of the tool holder of Fig. i1; Fig. 16 is an exploded top plan view of the two parts of the tool holder of Fig. 11; Fig. 17 is a perspective view of a wear part of the tool system of Fig. 1; 30 Fig. 18 is a front view of the wear part of Fig. 17; Fig. 19 is a top plan view of the wear part of Fig. 17; Fig. 20 is a side view of the wear part of Fig. 17; Fig. 21 is a perspective view of the spray unit of the tool system of Fig. 1; Fig. 22 is a side view of the spray unit of Fig. 21; 35 Fig. 23 is a longitudinal cross sectional view of the spray unit of Fig. 21; Fig. 24 is a perspective view of a pin for securing the tool in the tool holder; 5 Fig. 25 is a perspective view of a pin for securing the wear part to the tool holder; Figs. 26 and 27 are perspective views of the removable metal plate of the tool system of Fig. 1; 5 Fig. 28 is a perspective view of a front side of an alternative embodiment of a cutting tool in accordance with the present disclosure; Fig. 29 is a side view of the tool of Fig. 28; Fig. 30 is a front view of the tool of Fig. 28; Fig. 31 is a top plan view of the tool of Fig. 28; and 10 Fig. 32 is a rear view of the tool of Fig. 28. Referring to the drawings, and initially to Figs. 1-5, there is shown a tool system 10 for a longwall coal mining machine. The tool system 10 comprises a tool holder 12 and a tool 14. The tool 14 has a cutting end 16 for winning mineral from an ore body, a tapered mounting end comprising a shank 18 adapted for engagement in a 15 correspondingly tapered socket 20 of the tool holder 12 for securing the tool 14 to the tool holder 12, a front end 14a and a heel end 14b. The cutting end 16 terminates in a tungsten carbide tip, which is retained by laid on in a slot or slug in a hole in the tool 12. The tool 14 has a streamlined shape, as shown in Fig. 4. As shown in Fig. 5, a recess 22 is defined by a space formed between the tool 14 and the tool holder 12 when 20 the tool and the tool holder are engaged, with the recess 22 being located adjacent a heel end 14b of the tool 14. As shown in Figs. 1, 4 and 5, a wear part 24 is adapted for captive engagement with the recess 22 so as to be positioned adjacent the heel end 14b of the tool 14, between the tool 14 and the tool holder 12. The wear part 24 is shown in more detail in Figs. 17-20, where it can be seen that retention projections 24a extend 25 from lateral edges of the wear part 24. As can be seen in Figs. 11 and 12, corresponding recesses 12c are provided in the tool holder 12, with the projections 24a being engageable with the recesses 12c to facilitate attachment of the wear part 24 to the tool holder 12. As shown in Figs. 1, 4 and 5, a spray unit 25 is provided that has a lower end engageable in a bore 26 in the tool holder 12 and an upper end that extends through an 30 opening 24b in the wear part 24. The spray unit 25 is shown in more detail in Figs. 21 23 and has an outlet 25a to direct fluid from the spray unit 24 toward the cutting end 16 of the tool 14. A first laterally extending groove is 27a provided in the tool holder 12 adjacent the bore 26 and, as shown in Fig. 5, aligns with a corresponding second laterally extending groove 27b on the spray unit 25. The first and second grooves 35 together define a laterally extending opening 27 for receiving a pin 28 to lock the spray unit 25 in the bore 26.
6 As shown in Figs. 6-10, the tool 14 has a first lateral projection 29 formed on a removable plate 30 formed from spring steel and engageable with a lateral edge 31 of the mounting end 18 of the tool 14. As shown in Fig. 5, the tool holder 12 has a corresponding first lateral indent 32 that is engageable with the first projection 29 to 5 facilitate securing of the tool 14 to the tool holder 12. The first lateral projection 29 is resiliently snap-lockingly engageable with the first lateral indent 32. The plate 30 is connected to the mounting end 18 of the tool 14 by appropriate fasteners, such as buttons 33 that extend through holes 34 in the plate 30. The buttons 33 also gap fill the space between the mounting portion 18 of the tool 14 and the tool holder 12 to facilitate 10 secure retention of the tool 14 in the tool holder 12. In other embodiments, however, the fasteners connecting the plate 30 to the tool 14 may comprise threaded bolts or press studs (not shown), or flanges formed on the plate 30 frictionally engaging corresponding slots in the tool 14. A set of plates 30 of various lateral dimensions is provided for use with the tool 14. A plate 30 of larger lateral dimension may be 15 installed as the mounting end 18 of the tool 14 wears to take up the increased space between the mounting portion 18 and the tool holder 12 caused by the tool wear. A second lateral projection, in the form of a button 36, extends from an opposite lateral side of the mounting portion 18 to the first lateral projection 29. The button 36 is engageable with an inner wall of the socket 20 of the tool holder 12 to urge the tool 14 20 toward the first lateral indent 34. As best seen in Figs. 5, 7 and 14, a first laterally extending opening 38 is provided in the mounting end 18 of the tool 14 and is aligned with a second lateral opening 40 in the tool holder 12 when the tool is engaged in the tool holder. The second opening 40 is open to an external surface of the tool holder 12, such that a pin 25 42 may be engaged in both the first and second openings 38, 40 to secure the tool 14 in the tool holder 12. As shown in Fig. 2, the tool 14 comprises a laterally extending flange 14d that is engageable by a lever to facilitate removal of the tool 14 from the tool holder 12. A line of weakness, in the form of a groove 44, is provided in the tool to define a 30 predetermined failure line extending laterally across the tool 14. The line of weakness 44 is positioned so as to facilitate failure of the tool 14 at a location that does not unduly inhibit removal of the tool 14 from the tool holder 12. Specifically, the line of weakness is positioned above the laterally extending flange 14d, such that the tool 14 is adapted to fail at a position that leaves the laterally extending flange 14d intact, so that 35 a lever can be engaged with the flange 14d even if the tool 14 has failed.
7 The line of weakness 44 also causes the tool 14 to fail at a predetermined load, which helps to protect the internals of ranging arm gearcases on longwall shearers, continuous miners, surface miners, road planers or any other type of mineral winning machinery using the cutting tool 14. The load limiting characteristic of the line of 5 weakness 44 also helps to protect the following equipment: a. Torque shafts. b. Gear trains. c. Individual gears. d. Gear shafts / pins. 10 e. Bearings and bearing systems. In other words, the line of weakness 44 on the cutting tool 14 acts as a torque / force limiting device to facilitate tool 14 failure at a predetermined value. This limits the torque / forces / stresses experienced in the drive equipment that provides power to a cutting system incorporating the tool 14. 15 As shown in Fig. 2, the tool holder 12 has an abutment surface 12f that is engaged by a corresponding abutment surface 14f of the tool 14 when the tool shank 18 is fully engaged with the socket 20. The laterally extending flange 14d is spaced apart from the abutment surface 14f of the tool 14, and from the tool holder 12, toward the cutting end of the tool, so as to define a space 80 for insertion of a lever to engage the 20 flange 14d to facilitate removal of the tool 14 from the tool holder 12. The wear part 24 is formed of a plastics material, such as polyoxymethylene (POM), typically known as Acetyl, Nylon or PTFE, that is less wear resistant than the tool holder, such that the wear part wears sacrificially to reduce wear of the tool holder. The plastics material of the wear part is also more wear resistant than the tool, such that 25 the tool wears sacrificially to reduce wear of the wear part. As shown in Figs. 21-23, the spray unit 25 includes a fluid fitting 25b, formed from nylon or a corrosion resistant metal, such as aluminium bronze. The outlet 25a is provided at one end of the fitting 25b and an inlet 25c is provided at the other end of the fitting 25b. The fitting 25b is housed in a longitudinal opening or bore 46 in the tool 30 holder 12. 0-rings 25d are provided around the fitting 25b, at locations above and below the point of connection of the fitting 25b to an inlet 48 in the tool holder 12, to provide a seal between the fitting 25b and the tool holder 12. This arrangement of 0 rings 25d balances fluid pressure above and below the connection point between the fitting 25b and the inlet 48 and stabilises the fitting 25b in the longitudinal opening 46. 35 The fluid fitting 25b directs fluid supplied to the inlet 48 to the outlet 25a for ejection toward the cutting end 16 of the tool 14. As shown in Fig. 5, the inlet 48 extends 8 diagonally upwardly from a base of the tool holder 12 to intersect with the longitudinal opening 46. As shown in Fig. 16, the tool holder 12 is formed in two pieces 12a, 12b for ease of manufacture. The two pieces 12a, 12b are secured together by fasteners, in the form 5 of dowels 12d and by welding. In the illustrated embodiment, which is for use in a longwall coal mining machine for winning minerals the likes of coal, potash, phosphate, salt or trona, the tool holder 12 is adapted for connection to a rotatable shearer drum of the mining machine. It will be appreciated that the provision of the wear part 24 between the tool 14 10 and tool holder 12 advantageously reduces wear of the tool holder 12 and tool 14 due to the wear part 24 wearing sacrificially. Moreover, when the wear part 24 becomes worn, it can be replaced without requiring the entire tool holder 12 or tool 14 to be replaced, thereby reducing expense and down time. Furthermore, providing opening 24b in the wear part 24 for receiving the spray unit 25 creates a space between the spray unit 25 15 and the wear part 24 to facilitate replacement of the spray unit 25 without requiring removal of the wear part 24. Also, by locating the spray unit 25 in the tool holder 12, spray liquid is directed close to the tool tip 16. Prior art systems which do not position the spray on the tool holder lose this advantage. A further advantage of the illustrated tool system 10 is the provision of the line of weakness 44 in the tool 14, which 20 promotes failure of the tool 14 at a convenient location. Without the line of weakness 44, there is a risk that the tool 14 will fail below the flange 14d, which would make removal of the failed tool 14 from the tool holder 12 difficult. The streamlined shape of the tool 14 provides reduced flank wear, reduced power consumption and reduced dust creation. 25 An alternative embodiment of a cutting tool 14' is shown in Figs. 28-32 and has many features in common with the tool embodiment described above, where corresponding reference numerals indicate corresponding features with corresponding functionality. In the alternative embodiment of Figs. 28-32, however, the heel end 14b of the tool 14' extends rearwardly from the shank 18. The heel end 14b includes an 30 opening 80 for receiving a spray unit 25. As such, wear part 24 is omitted in tool systems where the alternative tool embodiment is used. The removable plate 30 is also omitted in this alternative embodiment. The front end 14a of the tool includes a recess 36' in which a button 36 is installed. In the embodiment shown in Figs. 28-32, the opening 38 of the Fig. 1-27 embodiment is replaced with a figure 8 shaped opening 82. 35 The opening 82 is adapted to receive a swinging riblock that engages the socket of a 9 complementary tool holder to secure the tool 14' in the tool holder in a manner as is well understood in the art. It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the specific embodiments described above 5 without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive. Examples of possible modifications include, but are not limited to: " the tool holder 12 may be integrally formed in, or connected to the rotatable cutting head of a mining machine for winning minerals such as iron ore from 10 harder ore bodies; " the pin 42 extendable through the first lateral openings 38, 40 in the tool 14 and tool holder 12 may be replaced or supplemented by another locking mechanism, such as a pin, staple, or buckle, that is resiliently slidably engaged in an opening in the tool holder 12 and biased into engagement with an opening in the tool 14 15 to secure the tool in the tool holder; " the wear part 24 and spray unit 25 may be integrally formed, such that the wear part and spray unit are a single unit and are replaced as a single unit; " the pin 42 and openings 38, 40 may be oriented at 90 degrees to the orientation shown in the accompanying drawings; 20 * the recesses 12c may be omitted and the removable plate 30 may be adapted to retain the spray unit 24; " the removable plate 30 may be omitted; " the projection 29 on the removable plate 30 may be omitted; " the removable plate 30 may be fastened to the tool holder 12 and snap-lockingly 25 engageable with a corresponding lateral indent on the tool 14; * the socket 20 of the tool holder 12 may be fitted with a gap filling device, such as a sleeve, in which the tool 14 is engaged, which may act as an adaptor to allow the tool holder 12 to be used with a differently configured tool; * the line of weakness 44 may take an alternative form (eg. may be defined by a 30 reduced thickness portion of the tool body, a hollow portion of the tool body, or a notch in the tool body); " the streamlined shape of the tool 14, 14' may be omitted; " the wear part 24 may be formed from steel of other materials; * plate 30 being formed from other materials, such as stainless steel or plastics 35 (e.g. acetyl); and/or 10 the spray unit 25 may be omitted, in which case the opening 24b in the wear part 24 may be omitted.