Abstract:
An apparatus includes a platform positioned on the pallet, the platform having a load bearing surface including a first portion and a second portion. The second portion is movable relative to the first, such that the second portion overlies the first portion. A method of unloading articles from a pallet including arranging the loaded pallet with the second portion of the platform in the second position, unloading articles from the first portion of the platform, shifting the second portion of the platform to the second position, and unloading articles from the second portion of the platform. A method of loading articles on a pallet, including arranging the pallet with the second portion of the platform in the second position, loading articles onto the second portion of the platform, shifting the second portion of the platform to the first position, and loading articles onto the first portion of the platform.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The instant application claims priority under 35 U.S.C. §119(e) of prior U.S. Provisional Patent Application Ser. No. 61/673,826, filed 20 Jul. 2012 under the same title and having the same inventive entity as the instant application. The complete disclosure of the prior application is hereby incorporated herein by this reference in its entirely for all purposes. 
    
    
     BACKGROUND 
     Technical Field 
     The present disclosure relates to a method and apparatus for pick transfers of articles supported by a pallet. 
     Brief Discussion of Related Art 
     Pallets are used in transporting and storing articles. In particular, items to be shipped or stored are stacked and/or bound together into a large contiguous volume on a pallet. The pallet supports the items above the floor or other surface on which the items rest, while providing space beneath the items such that a mechanical device (e.g., pallet jack, forklift) as known in the art can lift the pallet, and the articles on it, to be moved. 
     Frequently, pallets of articles are stored in warehouses, stacked on pallet racks for efficiency of space. A manual picker will approach the pallet and remove some quantity of items from the pallet as they are needed, leaving the remainder. When articles are stored on the pallet in pallet racks, there are many difficulties for pickers inherent in picking articles not directly in front of them at the point of pick, for example, toward the back of the pallet and the rack. In part due to tight spacing of pallet racks, as a particular pallet is emptied of its contents, the picker must bend and reach to retrieve items, for example from the back of the pallet. These difficulties include pickers experiencing significant stress to the shoulders, upper back and lower back when picking the hard to reach articles by having to bend over, reach a great distance and/or pull out layers of articles. These bending and reaching motions can be a common cause of musculoskeletal injury to the picker. In addition to the human cost of such injuries to the worker, any worker lost-time injuries cost the employer in lost employee productivity, higher employee turnover, higher workers compensation insurance rates, just to name a few. In high-density storage applications, articles, pallets, etc. are stacked off the floor in racks that require a picker be lifted to the level of the items by a lift, for example by forklift, in order to access the articles. For safety, the picker must be tethered to the forklift to prevent a fall. This tether interferes with the picker&#39;s ability to reach into a pallet for items, reducing the pickers&#39; level of productivity. Allowing the picker to access articles without reaching from or leaving the lift would improve productivity. 
     Many prior art methods for addressing these concerns did so by providing additional space about the top and/or sides of the pallet and articles and/or by providing access to same from additional and/or all sides. These prior art solutions, come with a significant cost, in that they generally reduce warehouse storage density and may require that existing racks be redesigned. 
     SUMMARY 
     In order to overcome these and other drawbacks and disadvantages in the present state of the art, provided according to the instant disclosure is an article support platform, operatively connected to and supported by a pallet, and/or integrated into the article bearing surface of a pallet, wherein at least a portion of the article bearing surface of the platform is repositionable with respect to the pallet, so as to provide for repositioning of at least some of the articles and/or article bearing portions of the platform to enhance the unloading and/or loading of articles from pallets. 
     According to aspects illustrated herein, there is provided a method of using an article support platform, operatively connected to and supported by a pallet, and/or integrated into a pallet, wherein at least a portion of the article bearing surface of the platform is re-positional with respect to the pallet. The repositioning allows for article removal and loading to occur at the repositioned location so as to provide for ease in unloading and/or loading articles supported by the platform. The method comprising unloading and/or loading articles from positions useful for unloading and/or loading and then using the article support platform to reposition at least a portion of its surface so that additional positions are now available to the picker for ease in unloading and/or loading articles. 
     A first aspect of the present disclosure provides an apparatus for transferring articles on a pallet. The apparatus includes a platform positioned on the pallet, the platform having a load bearing surface including a first portion and a second portion. The second portion is movable relative to the first portion from a first position to a second position, such that in the second position the second portion of the platform at least partially overlies the first portion of the platform. 
     A further refinement of this embodiment includes a locking element selectively movable between an unlocked position wherein the second portion of the platform is free to move with respect to the first portion, and a locked position operative to selectively secure the second portion of the platform. The locking element may be operative to hold the second portion of the platform in one of the first position, the second position, or an intermediate position. Still further, alternately or additionally, one or more detents positioned to receive the locking element and restrict the movement of the second portion are provided. The one or more detents are positioned to hold the second portion in one of the first position, the second position, or an intermediate position. In such cases where the locking element is attached to the second portion of the platform, the locking element may further be operative as a handle by which the second portion is movable. Certain embodiments of the present disclosure comprise a stop operative to block fork pockets of the pallet when the locking element is in the unlocked position. 
     Optionally according to the first embodiment, the platform further comprises one or more roller bearings operative to support to second portion of the platform in motion between the first and second positions. Still further, one or more tracks corresponding to the one or more roller bearings may be provided to guide the second portion of the platform between the first and second positions. 
     Also provided according to an aspect of the present disclosure is a method of unloading articles on a loaded pallet. The disclosed method contemplates the pallet having a platform with a load bearing surface including a first portion and a second portion, the second portion being movable relative to the first portion from a first position to a second position, such that in the second position the second portion of the platform at least partially overlies the first portion of the platform. The method comprises arranging the loaded pallet with the second portion of the platform in the first position, unloading loading articles from the first portion of the platform, shifting the second portion of the platform to the second position, and unloading articles from the second portion of the platform. Optionally, the method further comprises arranging the platform with the second portion of the platform being closer to a side of the platform from which articles are loaded the second position than in the first position. 
     In still further embodiments, the platform comprises a locking element selectively movable between an unlocked position wherein the second portion of the platform is free to move with respect to the first portion, and a locked position operative to selectively secure the second portion of the platform, and the method further includes moving the locking element from a locked position to an unlocked position before shifting the second portion of the platform, and moving the locking element from the unlocked position to the locked position before unloading articles from the second portion of the platform. 
     In such cases where the locking element is attached to the second portion of the platform, the locking element being further operative as a handle by which the second portion is movable, the method further includes shifting the second portion of the platform by use of the locking element as a handle. Optionally, the disclosed method further comprising blocking fork pockets of the pallet when the locking element is in the unlocked position. 
     According to yet another aspect of the present disclosure, a method of loading articles on a pallet is disclosed, the pallet having a platform with a load bearing surface including a first portion and a second portion, the second portion being movable relative to the first portion from a first position to a second position, such that in the second position the second portion of the platform at least partially overlies the first portion of the platform. The method of loading includes arranging the unloaded pallet with the second portion of the platform in the second position, loading articles onto the second portion of the platform, shifting the second portion of the platform to the first position, and loading articles onto the first portion of the platform. Optionally, the method further comprises arranging the platform with the second portion of the platform being closer to a side of the platform from which articles are loaded the second position than in the first position. 
     In still further embodiments, the platform comprises a locking element selectively movable between an unlocked position, wherein the second portion of the platform is free to move with respect to the first portion, and a locked position operative to selectively secure the second portion of the platform. The method further includes moving the locking element from a locked position to an unlocked position before shifting the second portion of the platform, and moving the locking element from the unlocked position to the locked position before loading articles onto the first portion of the platform. 
     In such cases where the locking element is attached to the second portion of the platform, the locking element being further operative as a handle by which the second portion is movable, the method further includes shifting the second portion of the platform by use of the locking element as a handle. Optionally, the disclosed method further comprising blocking fork pockets of the pallet when the locking element is in the unlocked position. 
     In a second embodiment, repositioning of the surface of the platform is accomplished by the rotation of the surface of the platform with respect to the pallet. 
     The re-positioning of the platform surface allows for portions of the platform surface, including articles supported by or to be supported by those portions of the platform surface, to become more easily accessible by pickers for unloading and/or loading articles thereon. Some of the advantages of picking off and loading on the apparatus of the present disclosure when compared to picking off a pallet are: safety, a greatly reduced reach results in better ergonomics and picking positions off the ground may not require climbing into the rack; storage density, the entire surface can be used to store articles, as there is no need to leave space between the articles or above the articles for picker access, rack beam levels can be closer together because additional clearance is no longer needed between levels for reaching in; and labor costs, as it is easier to reach articles, the articles are picked more efficiently resulting in more picks in less time. 
     Even when not in a space-limited environment, the methods and apparatuses allow for the picker to remain facing one side of the pallet in unloading and loading, and thus in certain case eliminating the need for the picker to reposition themselves and/or articles in order to unload and/or load another side of the pallet. This is a particular benefit in the case of a raised and tethered picker, as discussed above. Thus, embodiments of the present disclosure may be positioned on a pallet on the floor and used to create an ergonomic advantage for a person picking boxes from a specific position and/or positioned in an elevated pallet rack location that will be picked with assistance from either a fork truck, order picker, or similar type device. 
     Additionally, by way of example and not limitation, embodiments of the apparatuses and methods of the present disclosure may be used: on pallets located in pallet rack, still accessible by a worker on the floor, to reduce reaching; when loading pallets in the reverse order which grants both time savings and ergonomic benefits; and/or in industrial environments such as alongside assembly lines to aid in ergonomics. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and other purposes, goals and advantages of the present disclosure will become apparent from the following detailed description of example embodiments, read in connection with the accompanying drawings. Some embodiments are illustrated by way of example and not limitation in the figures of the accompanying drawings, in which like reference numerals refer to like structures across the several views, and wherein: 
         FIG. 1  is an front view drawing of a first embodiment of the apparatus of the present disclosure; 
         FIG. 2  is an illustrative side view drawing of a first embodiment of the apparatus of the present disclosure; 
         FIG. 3  is an illustrative top view drawing of a first embodiment of the apparatus of the present disclosure; 
         FIG. 4  illustrates a first embodiment of the apparatus of the present disclosure, showing two such apparatuses each on pallets and in a two pallet rack configuration, the view being generally from the side of the pallet rack; 
         FIG. 5  illustrates the first embodiment of the apparatus of the present disclosure showing the apparatus on a pallet in a pallet rack, the view being generally looking into the front side of the pallet rack; 
         FIG. 6  illustrates the first embodiment of the apparatus of the present disclosure showing the apparatus on a pallet in a pallet rack, the view being generally in a downward direction to the apparatus from a side and front of the pallet rack; 
         FIG. 7  illustrates the first embodiment of the apparatus of the present disclosure showing the apparatus on a pallet in a pallet rack in more particular detail, wherein a second portion ( 14 ) has been repositioned to overlap the first portion ( 12 ), looking in a downward direction to the apparatus at an angle to the front of the rack; 
         FIG. 8  illustrates the first embodiment of the apparatus of the present disclosure showing articles on the first and second portions of the apparatus; 
         FIG. 9  illustrates the first embodiment of the apparatus of the present disclosure after the articles on the first portion ( 12 ) of the apparatus shown in  FIG. 8  have been removed; 
         FIG. 10  illustrates the first embodiment of the apparatus of the present disclosure shown in  FIG. 9  after the second portion ( 14 ) has been repositioned to partially overlap the first portion ( 12 ); 
         FIG. 11  illustrates the first embodiment of the apparatus of the present disclosure shown in  FIG. 10  after the second portion has been repositioned to more completely overlap the first portion and an article is in the process of being removed from the repositioned second portion; 
         FIG. 12  illustrates the first embodiment of the apparatus of the present disclosure shown in  FIG. 11  after the article has been removed from the repositioned second portion; 
         FIG. 13  illustrates a second embodiment of the apparatus of the present disclosure and a pallet; 
         FIG. 14  illustrates a second embodiment of the present disclosure showing the apparatus positioned on the pallet, the apparatus loaded with boxes; 
         FIG. 15  illustrates the second embodiment of the present disclosure showing the pallet and apparatus after the first few boxes are picked; 
         FIG. 16  illustrates a further embodiment of the present disclosure showing the pallet and apparatus after half the boxes are picked; 
         FIG. 17  illustrates the second embodiment of the present disclosure showing the apparatus after its top part has been rotated approximately 45 degrees; 
         FIG. 18  illustrates the second embodiment of the present disclosure showing the apparatus after its top part has been rotated 180 degrees and is ready for continued picking; 
         FIG. 19  illustrates the second embodiment of the present disclosure showing the apparatus after it has been rotated 180 degrees and after some additional picking; 
         FIGS. 20A, 20B and 20C  illustrate the second embodiment of the present disclosure, showing a second embodiment of the hinged stop or detent of the apparatus, which is used to stop the apparatus from rotating, with the detent shown successively in a locked position in  FIG. 20A , an intermediate position in  FIG. 20B , and an unlocked position in  FIG. 20C ; 
         FIG. 21  illustrates a rotating platform ( 120 ) and the turntable bearing ( 130 ) components of a second embodiment of the present disclosure over a pallet. 
         FIG. 22  illustrates the second embodiment of the present disclosure showing the apparatus with the platform removed; 
         FIG. 23  illustrates the second embodiment of the present disclosure showing the apparatus with the platform removed, and further showing the cylindrical rollers; and 
         FIG. 24  illustrates the second embodiment of the present disclosure showing the apparatus with the platform removed, and further showing the bearing wheels which provide the ability for the platform to rotate. 
     
    
    
     DETAILED DESCRIPTION 
     First Embodiment 
     Translational Repositioning 
     Referring generally to  FIGS. 1-12 , a first embodiment of the apparatuses and methods of the present disclosure provides a platform  10  including functionality for translational repositioning of articles and/or one or more portions of the apparatus with respect to the pallet  100 . In one version of this embodiment, taking for example  FIG. 1 , the surface  13  of the platform  10  is divided into two portions, a first portion  12  and a second portion  14 . In a first orientation of the platform  10 , the first portion is made more accessible for unloading and loading articles as compared to the second portion  14  in the first orientation. For example, see  FIGS. 4-6 . Reorienting the surface  13  of the platform  10  is accomplished by translation of the second portion  14  so as to at least partially overlap the first position  12 . In certain embodiments of the present platform  10 , one or more rollers  21  are provided to support the second portion  14  of the platform  10  and facilitate movement of the second portion  14  with respect to the first portion  12 . Rollers  21  may also work in conjunction with one or more tracks  23  that receive and guide the rollers  21 . In the depicted embodiment, the rollers  21  are connected with the second portion  14 , and the guides  23  in the first portion  12 . This could easily be reversed without departing from the scope of the present disclosure. 
     In this embodiment, a lever  16  controls the engagement of locking element  17 . Locking element  17  in turn engages one or more detents  19  provided at predetermined locations of the platform  10 . The locking element  17  engaged in the detent  19  holds the second portion  14  of the surface  13  in position. Moving the lever  16  disengages the locking element  17 . A user, for example, the picker, then may pull or push on the lever  16 , or otherwise urge the second portion  14 , for example by urging parcels located thereon, to reposition the second portion  14  with respect to the first portion  12 .  FIGS. 1, 2 and 3  show illustrative front, side and top view drawings, respectively, of an embodiment of the translational repositioning apparatus. 
       FIGS. 4, 5 and 6  show illustrations taken from different positions with respect to the pallet  100  and the platform  10 . As shown in  FIGS. 4, 5 and 6 , the first portion  12  and second portion  14  are in a non-overlapping orientation, and unloaded state having no items thereon.  FIG. 6  shows the lever  16 , useful to reposition the second portion  14 , in its down and locked state. 
       FIG. 7  shows the platform  10  having the second portion  14  in an orientation overlapping the first portion  12 , and with the lever  16  in the down position such that the locking element  17  in engaged in a detent  19 . The lever  16  may be rotated to the unlocked position, in which case the second portion may be repositioned between non-overlapped, partially overlapped and overlapped positions. 
     In  FIGS. 1-12 , the lever  16  is shown rotating about an axis parallel with the direction of travel of the second portion  14 . This means that additional space will be required laterally of the platform  10  to transition the lever  16  between locked and unlocked positions. It will be apparent however, to one or ordinary skill in the art being apprised on the instant disclosure, that the direction of rotation may be altered to avoid this necessity, for example to make the axis of rotation of the lever  16  in releasing or engaging the locking element  17  transverse to the direction of movement of the second portion  14 , while maintaining the functionality of the lever  16  and locking element  17 , all without departing from the scope of the instant disclosure. 
     With reference to the discussion of the second embodiment, infra, it may be likewise advantageous in the present embodiment to block the fork pockets  102  of the pallet  100  while the moving second portion  14  is unlocked, in order to prevent the pallet  100  from being lifted while the second portion  14  is free to move. Lifting the pallet  100  with the second portion  14  unlocked may lead the second portion and the articles thereon to shift suddenly, possibly falling, leading to damaged goods, and even injury of workers in the vicinity. 
       FIG. 8  shows the platform  10  having first portion  12  and second portion  14  in the non-overlapped orientation, and moreover both first portion  12  and second portion  14   14  are loaded with articles, collectively reference  200 , and individually  200   a ,  200   b ,  200   c , etc. In particular, articles  200   a ,  200   b  rest on the first portion  12 , and the remaining ones of articles  200  rest on the second portion  14 .  FIG. 9  shows the platform  10  of  FIG. 8  after articles  200   a ,  200   b  on the first portion  12  have been unloaded.  FIG. 10 , in turn, shows the platform of  FIG. 9  after lever  16  has been rotated to the unlocked position, and further a pulling force applied to lever  16 . thereby repositioning the second portion  14  so as to partially overlap the first portion  12 . This brings the articles  200   c ,  200   d ,  200   e , etc. resting on the second portion  14  closer to the picker. 
       FIG. 11  shows the platform  10  of  FIG. 10 , with the second portion  14  overlapping the first position  12 , the lever  16  being moved into a down and locked position thereby engaging the locking element  17  in a detent  19 .  FIG. 12  shows the platform  10  from  FIG. 11  after article  200   c  has been unloaded from the platform  10 . While the above depiction and description entails articles  200  stacked on the platform  10  in a single layer only, it will be apparent that more layers of articles  200  can be included if they are so stacked on the pallet. 
     According to the foregoing unloading method, articles  200  are brought nearer to a front of the platform  10 , and thus nearer to the picker. This reduces or eliminates bending or stretching for articles  200  on a back of the pallet. 
     In many circumstances, articles  200  will arrive in the warehouse facility palletized in contiguous bundles on pallets  100  and/or platforms  10 , and are subsequently removed from the pallet  100  and platform  10  separately on demand. However, it may be necessary to load or reload a pallet  100  with articles  200  as the pallet  100  sits on the pallet rack. It will be apparent to one of ordinary skill in the art that the unloading of the platform  10 , described above with respect to  FIGS. 8-12 , can be reversed in order to load articles  200  on to the platform  10 , again while reducing or eliminating bending, reaching etc., on the part of the picker. 
     Second Embodiment 
     Rotational Repositioning 
     A second embodiment of the apparatuses and methods of the present disclosure, depicted generally in  FIGS. 13-24 , provides for rotational repositioning of articles and supporting platform preferably in 90 degree or 180 degree increments, however, other embodiments provide for almost any amount of rotation from 0 degrees to 360 degrees, or more. The apparatus may also be provided with a mechanism to rotationally lock it in place after the desired rotation. 
     The apparatus comprises a turntable or other rotating means, affixed to a pallet and a platform or flat surface on which to stack the articles. In another embodiment, the apparatus is integrated into the pallet. In still another embodiment, the apparatus, comprises a turntable, separate from the pallet, but positioned on the load bearing side of the pallet. In this case, the apparatus may be permanently or temporarily secured to the load bearing face of the pallet, or may merely be placed upon said load bearing pallet face. Thus, after the combination of pallet, apparatus and articles are placed in pallet racks, the present disclosure allows for the articles to be rotatably repositioned while remaining in the pallet rack, and thus provide for easier access to said articles for ergonomic and efficient picking. 
     In this embodiment, rotational repositioning of the platform and/or articles may require additional clearance as the turntable portion swings through its arc, this is addressed in some embodiments simply by reducing the size of the turntable to increase clearance based on beam dimensions. 
       FIG. 13  shows the second embodiment of the present disclosure, in this embodiment the apparatus comprises the pallet cover ( 110 ) mounted on the pallet ( 100 ), the turntable bearing ( 130 ) mounted on the pallet cover, and the turntable cover ( 120 ).  FIG. 14  shows the articles or boxes ( 200 ) three high, four deep and five across positioned on the turntable cover ( 120 ). 
       FIG. 15  shows the pallet and apparatus after the first few boxes are picked.  FIG. 16  shows the pallet and apparatus after half the boxes are picked.  FIG. 17  shows the apparatus after its top part bearing the boxes has been rotated approximately 45 degrees.  FIG. 18  shows the apparatus after its top part (in this case the turntable cover  120 ) has been rotated 180 degrees and is ready for continued picking.  FIG. 19  shows the pallet and apparatus after some additional picking, which has occurred after the 180 degrees rotation of the apparatus and boxes shown in  FIG. 18 . 
     While the second embodiment above is disclosed in connection with removing boxes or articles from a pallet, the method and apparatus also provides for the loading of articles, including boxes in a similar manner. 
     In the second embodiment as shown, the detent or stop  140  shown in  FIGS. 20A, 20B, and 20C  is a full width piece of sheet metal bent in a right angle and hinged to the pallet cover across the front of the unit. In other embodiments, any suitable material may be substituted for sheet metal without departing from the scope of the present disclosure. When in the locked position, e.g.,  FIG. 20A , the turntable cover  120  cannot rotate in either direction due to interference with the detent. The stop may be rotated about its hinge or pivot  170 , as shown for example in  FIG. 20B . When the stop is rotated approximately 270 degrees, as for example in  FIG. 20C , it no longer prevents the turntable cover from rotating. Also shown is the turntable or carousel carriage  125 . In one embodiment, the stop acts as a safety device, by blocking the fork pockets of the pallet, and thus preventing the pallet from being lifted while the turntable cover  120  is unlocked. To lock the device, the user simply flips the lock back into the upright position, with the turntable cover  120  positioned square to the front of the unit.  FIG. 21  shows an exploded assembly view of this second embodiment of the present disclosure  10 , the pallet  100 , the pallet cover  110  with turntable bearing  130  and stop  140 , the turntable or carousel carriage  125 , and the turntable cover  120 . 
       FIG. 22  is an illustrative drawing of another embodiment of the present disclosure showing the apparatus with the platform removed, wherein the bearing function is carried out by wheels  180  provided as part of a manual carousel, which is manufactured by Vestil Manufacturing Corp., 2999 North Wayne Street, Angola, Ind. 46703, and has part number Manual Carousel CA-30-2. In this embodiment, the pallet measures 42 inches×48 inches and the rotating platform is 37.5 inches×37.5 inches. Of course depending on the use and articles other carousels, turntables or other rotation devices may be used. In one embodiment, the pallet cover has one or more downwardly extending edges  150 , and when the pallet cover is mounted on the pallet said one or more downwardly extending edges face one or more sides of the pallet. 
       FIG. 23  is an illustrative drawing of one embodiment of the present disclosure showing the apparatus with the platform removed, wherein the bearing function is carried out by steel rollers  190 , such as those provided by Unex Manufacturing Inc., 50 Progress Place, Jackson, N.J. 08527. 
       FIG. 24  is an illustrative drawing of one embodiment of the present disclosure showing the apparatus with the platform removed, wherein the bearing function is carried out by bearing wheels  175  provided by Unex Manufacturing Inc., 50 Progress Place, Jackson, N.J. 08527. 
     Although embodiments of the present disclosure have been described above in detail, it is desired to emphasize that this has been for the purpose of illustrating and describing the disclosure, and should not be considered as necessarily limitative of the disclosure, it being understood that many modifications can be made by those skilled in the art while still practicing the invention, which is defined solely according to the following claims.