Abstract:
A modular material handling system includes a base portion removably connectable to a machine tool frame, the base portion including a hollow stanchion with a first end to go against a machine frame coupled to a compression plate by a threaded mounting stud and a second end to couple to a hollow pivot post coupled by a thrust bearing, with a shaft extending through the stanchion and pivot post and coupled at a lower end to the mounting stud and at an upper end to a retaining nut, and further including an arm extending from the pivot post to carry a movable shuttle and lifting mechanism.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional Patent Application Ser. No. 611299,861. filed Jan. 29, 2010, which is hereby incorporated by reference into this application. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to improvements to material handling systems. More particularly, the present invention relates to a modular material handling system mountable to a stand alone machine in a machine shop or field worksite. 
       BACKGROUND 
       [0003]    Persons working in small machine shops, or at temporary job sites in the field, often face severe ergonomic problems and workplace safety concerns due to the limited space available in the shop compared to the foot print of material handling equipment. Workers and hobbyists frequently must load heavy work pieces, such as metal shafts, motors, engine blocks, axels, &amp; etc, onto the operating tables of stand alone machine tools such as milling machines, band saws, drill presses, and similar machines. However, limited shop space often prevents the use of portable lifts, which require wide bases for stability, to assist in placing heavy loads on the machine table, or in supporting and feeding heavy loads across the machine table. Gantry cranes may also be used, but are expensive and often require structural modifications to the shop building in order to mount. Even so, the range of motion of a typical gantry system is often very limited because the track system supporting the crane must be directly over the lift and placement spots. 
         [0004]    Feeding large work pieces, such as beams, pipes or shafts across a machine table can also be very problematic—for example, when milling a long keyway or channel along a long pump shaft. The work piece must be firmly supported at the free end to prevent twisting, pitching, rolling, and other out-of-axis movement, and the support system must move with the work piece as it moves across the machine table to ensure a clean, aligned cut. Often, a worker will try to “jerry rig” work benches or tables abutting the machine table, but the work benches may not be the correct height or length. The work bench surface may not be conducive to pushing work piece across its surface. Furthermore, such work benches and tables can interfere with the worker properly positioning himself or herself to guide the work piece and operate the machine, and they take up a great deal of shop floor footprint when not in use. 
         [0005]    Thus, there is a need for material handling apparatus and methods which provide the ability to assemble in a machine shop and mount directly to the frame of a machine, and which can provide both lifting support and the ability to feed material across a machine table. There is a need for material handling apparatus and methods which are modular so as to be easily assembled and disassembled within a machine shop or at a temporary job site, and which are relatively inexpensive so as to be accessible for small machine shop owners and hobbyists. 
       SUMMARY AND ADVANTAGES 
       [0006]    A modular material handling system, includes a base portion removably connectable to a machine tool frame, the base portion including a hollow stanchion having opposing first and second flanged ends and a first centerline channel extending there between, the first flanged end further having a central circular through passage and a face configured to receive a thrust bearing, the second flanged end to go against a portion of the machine frame and further including a closed end plate having a first receiving hole there through with diameter less than a main shaft diameter; a stanchion main shaft upper bushing to insert into the stanchion first end central through passage; a bottom compression plate to go against a portion of the machine frame in opposing manner to the stanchion second flanged end, the bottom compression plate having a second receiving hole there through; an elongated mounting stud having opposing first and second threaded ends, the mounting stud to insert through the first and second receiving holes and the machine frame portion; and, a base compression nut to couple to the mounting stud second threaded end against the bottom compression plate; a pivot post assembly to couple to the stanchion, the pivot assembly comprising a hollow pivot post having opposed first and second flanged ends and a second centerline channel extending there between, each of the first and second pivot post flanged ends including a central circular through passage, and the second pivot post flanged end further including a face configured to receive a thrust bearing; and first and second pivot post main shaft bushings insertable into the first and second pivot post central through passages, respectively; a thrust bearing to couple the base portion and the pivot post assembly between the stanchion first flange face and the pivot post second flange face; an elongated main shaft having a first end with opposing flats, a second end with a female threaded hole, and a circular cross section, the main shaft to insert through the first and second centerline channels within the main shaft bushings and the shaft second end going against the stanchion end plate to couple the female threaded hole with the mounting stud first threaded end through the first receiving hole, the shaft first end extending beyond the pivot post first end; a thrust washer to insert over the man shaft first end onto the pivot post first flanged end and the main shaft bushing within the pivot post first flanged end through passage; a set collar to insert over the main shaft first end against the thrust washer and secure to the main shaft; and, an elongated arm to rigidly couple to the pivot post so as to extend substantially normal from the pivot post, the elongated arm to receive a shuttle. A modular material handling system, includes a shuttle movably coupled to the arm, the shuttle movable along at least a portion of the length of the arm, the shuttle configured to receive a load lifting mechanism. A modular material handling system, includes a linear rail mounted along at least part of the length of the elongated arm, wherein the shuttle is mounted to the linear rail to move along the linear rail. 4 A modular material handling system, includes a lifting mechanism coupled to the shuttle. A modular material handling system, includes one or more gusset arms to couple between the elongated arm and the pivot post. A modular material handling system, includes wherein the base portion further comprises a stanchion main shaft lower bushing to insert into the first centerline channel against the end plate and to receive the main shaft second end therein. 
         [0007]    The material handling system of the present invention presents numerous advantages, including: (1) it is directly mountable to an existing milling machine; (2) it is modular so may be detached and disassembled; (conserves floor space in machine shop areas: (3) provides for safer handling in small machine shops; (4) it is simple and rugged; (5) provides for even feeding of linear loads through a milling machine. 
         [0008]    The simple, rugged and modular design of the material handling system present many advantages over existing systems, and provide a system that is optimized for small shops and field use where so many injuries occur. Additional advantages of the invention will be set forth in part in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims. Further benefits and advantages of the embodiments of the invention will become apparent from consideration of the following detailed description given with reference to the accompanying drawings, which specify and show preferred embodiments of the present invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    The accompanying drawings, which are incorporated into and constitute a part of this specification, illustrate one or more embodiments of the present invention and, together with the detailed description, serve to explain the principles and implementations of the invention. 
           [0010]      FIG. 1  shows a side view of an embodiment of a material handling system mounted to a stand-alone milling machine. 
           [0011]      FIG. 2  shows a view of a portion of a base of an embodiment of a material handling system mounted to a stand-alone milling machine. 
           [0012]      FIG. 3  shows a schematic view of the internal portions of an embodiment of a material handling system. 
           [0013]      FIG. 3A  shows a detail cross-section of the stanchion-to-pivot post coupling. 
           [0014]      FIG. 3B  shows a detail cross-section of the pivot post first end assembly. 
           [0015]      FIG. 4  shows a bottom plate of an embodiment of a material handling system. 
           [0016]      FIG. 4A  shows a side view of a bottom plate of an embodiment of a material handling system. 
           [0017]      FIG. 4B  shows a plan view of a bottom plate of an embodiment of a material handling system. 
           [0018]      FIG. 5  shows a main shaft of an embodiment of a material handling system. 
           [0019]      FIG. 5A  shows a side view of a main shaft of an embodiment of a material handling system. 
           [0020]      FIG. 5B  shoes a top end view of a main shaft of an embodiment of a material handling system. 
           [0021]      FIG. 6  shows a pivot post flange of an embodiment of a material handling system. 
           [0022]      FIG. 6A  shows a side view of a pivot post flange of an embodiment of a material handling system. 
           [0023]      FIG. 6B  shows a plan view of a pivot post flange of an embodiment of a material handling system. 
           [0024]      FIG. 7  shows a thrust washer of an embodiment of a material handling system. 
           [0025]      FIG. 7A  shows a side view of a thrust washer of an embodiment of a material handling system. 
           [0026]      FIG. 7B  shows a plan view of a thrust washer of an embodiment of a material handling system. 
           [0027]      FIG. 8  shows a mounting stud of an embodiment of a material handling system. 
           [0028]      FIG. 8A  shows a side view of a mounting stud of an embodiment of a material handling system. 
           [0029]      FIG. 8B  shows an end view of a amounting stud of an embodiment of a material handling system. 
           [0030]      FIG. 9  shows a stanchion bottom flange of an embodiment of a material handling system. 
           [0031]      FIG. 9A  shows a side view of a stanchion bottom flange of an embodiment of a material handling system. 
           [0032]      FIG. 9B  shows a plan view of a stanchion bottom flange of an embodiment of a material handling system. 
           [0033]      FIG. 10  shows a stanchion upper flange of an embodiment of a material handling system. 
           [0034]      FIG. 10A  shows a side view of a stanchion upper flange with a thrust bearing of an embodiment of a material handling system. 
           [0035]      FIG. 10B  shows a cutaway side view of a stanchion upper flange, without a thrust bearing of an embodiment of a material handling system. 
           [0036]      FIG. 10C  shows a plan view of a stanchion upper flange of an embodiment of a material handling system. 
           [0037]      FIG. 11  shows a stanchion tube of an embodiment of a material handling system. 
           [0038]      FIG. 11A  shows a side view of a stanchion tube of an embodiment of a material handling system. 
           [0039]      FIG. 11B  shows an end view of a stanchion tube of an embodiment of a material handling system. 
           [0040]      FIG. 12  shows a shaft bushing of an embodiment of a material handling system. 
           [0041]      FIG. 12A  shows a side view of a bushing of an embodiment of a material handling system. 
           [0042]      FIG. 12B  shows a plan view of a bushing of an embodiment of a material handling system. 
           [0043]      FIG. 13  shows a pivot post assembly of an embodiment of a material handling system. 
           [0044]      FIG. 13A  shows a side view of a pivot post assembly of an embodiment of a material handling system. 
           [0045]      FIG. 13B  shows a different side view of a pivot post assembly of an embodiment of a material handling system. 
           [0046]      FIG. 14  shows a plan view of an embodiment of a material handling system. 
       
    
    
     REFERENCE NUMBERS USED IN DRAWINGS 
       [0047]    Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, the figures illustrate the material handling system of the present invention, With regard to the reference numerals used, the following numbering is used throughout the various drawing figures: 
         [0048]    Item Number Description 
         [0049]      100  Embodiment 
         [0050]      110  Base Portion 
         [0051]      112  Stanchion 
         [0052]      114  Bottom Plate 
         [0053]      116  Mounting Stud 
         [0054]      118  Base Nut 
         [0055]      120  Stanchion Tube First End 
         [0056]      122  Stanchion Tube Second End 
         [0057]      124  Stanchion Tube Centerline Channel 
         [0058]      126  Mounting Stud First Threaded Portion 
         [0059]      128  Mounting Stud Second Threaded Portion 
         [0060]      130  Stanchion Bottom Range 
         [0061]      132  Female Threaded Hole 
         [0062]      134  Stanchion Tube 
         [0063]      136  (not used) 
         [0064]      138  Stanchion Upper Range 
         [0065]      140  Upper Range First Face 
         [0066]      142  Upper Range Second Face 
         [0067]      144  Bearing Race 
         [0068]      146  Bearing 
         [0069]      148  Upper Range Center Hole 
         [0070]      150  Main Shaft 
         [0071]      152  Main Shaft First End 
         [0072]      154  Main Shaft Second End 
         [0073]      156  Rats 
         [0074]      158  Pivot Post 
         [0075]      160  Pivot Post Tube 
         [0076]      162  Pivot Post Tube First End 
         [0077]      164  Pivot Post Tube Second End 
         [0078]      166  First End Range 
         [0079]      168  Second End Range 
         [0080]      170  First End Flange inner Diameter 
         [0081]      172  Second End Range Inner Diameter 
         [0082]      174  First Flange Thickness 
         [0083]      176  Second Flange Thickness 
         [0084]      178  Pivot Post Upper Main Shaft Bushing 
         [0085]      180  Shaft Bushing Depth 
         [0086]      182  Shaft Bushing Outer Diameter 
         [0087]      184  Shaft Busing Inner Diameter 
         [0088]      186  Main Shaft Outer Diameter 
         [0089]      188  Set Collar 
         [0090]      190  Jib Arm 
         [0091]      192  Back Strap 
         [0092]      194  Jib Arm Mounting Plate 
         [0093]      196  Linear Rail 
         [0094]      198  Shuttle 
         [0095]      200  Lifter 
         [0096]      202  Lifter Locking Hook 
         [0097]      204  Load Handler 
         [0098]      206  Flexible Connector 
         [0099]      208  Load Handler Locking Hook 
         [0100]      210  Thrust Washer 
         [0101]      212  Gusset Arms 
         [0102]      214  Main Shaft Threaded Bore 
         [0103]      216  Jib Arm Mounting Flange 
         [0104]      218  Bolt Holes 
         [0105]      220  Bottom Plate Hole 
         [0106]      222  Pivot Post Centerline Channel 
         [0107]      224  Stanchion Main Shaft Upper Bushing 
         [0108]    M Machine tool 
         [0109]    A Oiler ring 
         [0110]    F Machine tool frame 
         [0111]    H Machine tool head 
         [0112]    T Machine tool table 
       DETAILED DESCRIPTION 
       [0113]    Before beginning a detailed description of the subject invention, mention of the following is in order. When appropriate, like reference materials and characters are used to designate identical, corresponding, or similar components in differing figure drawings. The figure drawings associated with this disclosure typically are not drawn with dimensional accuracy to scale, i.e., such drawings have been drafted with a focus on clarity of viewing and understanding rather than dimensional accuracy. 
         [0114]    In the interest of clarity, not all of the routine features of the implementations described herein are shown and described. It will, of course, be appreciated that in the development of any such actual implementation, numerous implementation-specific decisions must be made in order to achieve the developer&#39;s specific goals, such as compliance with application- and business-related constraints, and that these specific goals will vary from one implementation to another and from one developer to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking of engineering for those of ordinary skill in the art having the benefit of this disclosure. 
         [0115]    A material handling system includes a base portion connectable to a machine tool frame, a pivot post rotatably connectable to said base portion, an arm connectable to said pivot post so as to extend horizontally from said base portion; a shuttle movably mounted to said arm, said shuttle movable along at least a portion of the length of said arm; a lifter connectable to said shuttle; and, a load handler flexibly connectable to said lifter. 
         [0116]    Referring to  FIGS. 1-13  an embodiment of a material handling system  100  is shown, mounted to a milling machine M, having a frame F, a head H, and a table T. Base portion  110  is removably connected to machine frame F at the rear of the machine. In this embodiment, frame F includes an oil reservoir mounting flange A, which provides a convenient mounting point. 
         [0117]    In the embodiment, base portion  110  includes stanchion  112 , bottom plate  114 , mounting stud  116 , and base compression nut  118 . Bottom plate  114  includes hole  220  for receiving mounting stud  116 . Stanchion  112  includes stanchion tube  134  with first and second ends  120  and  122 , respectively, and includes first centerline channel  124  extending from first to second ends  120  and  122 , respectively. Mounting stud  116  is provided with threaded first and second portions,  126  and  128 . In the embodiment, mounting stud  116  is a length of aft-thread, which provides infinite adjustability for clamping to a range of machines or brackets. Stanchion bottom flange  130  forms a closed end plate with centered receiving hole  132  for receiving mounting stud first threaded portion  126 . In the embodiment receiving hole  132  is threaded to provide direct coupling of mounting stud  116  to bottom flange  130 . Mounting stud first threaded portion  126  must be of sufficient length to provide a strong coupling to main shaft  150 , preferably extending at least 2 inches (51 mm) beyond bottom flange  130  into centerline channel  124 . Stanchion upper flange  138  is rigidly and concentrically connected to stanchion tube  134  at its first end. Stanchion upper flange  138  includes a first face  140  which goes against stanchion be first end  120  and an opposing second face  142 , which includes a bearing race  144  for receiving a thrust bearing  146 . In the embodiment thrust bearing  146  is a needle bearing, providing both thrust and radial support. Stanchion upper flange  138  is substantially torroidal with a center through passage  148  to insert stanchion main shaft upper bushing  224  to support main shaft  150 . 
         [0118]    Pivot post  158  includes a tube  160  with second centerline channel  222  extending from first to second ends  162  and  164 , respectively, and corresponding first and second pivot post flanges  166  and  168  rigidly and concentrically connected at first and second ends  162  and  164 . First and second pivot post flanges  166  and  168  include center through passages  170  and  172  having thicknesses  174  and  176  dimensioned to receive first and second main shaft bushings  178 , such that the outer diameters  182  of shaft bushings  178  match the inner diameters  170  and  172 , respectively, and the inner diameters  184  of shaft bushings  178  match the outside diameter  186  of main shaft  150 . Main shaft bushings  178  fit tightly into flanges  166  and  168  so as to substantially prevent rotation of the bushings during operation, and the depth  180  of shaft bushings  178  is approximately equal to or less than the thickness of flanges  166  and  168 . In the embodiment first and second main shaft bushings  166  and  168  are fabricated from brass, which is substantially softer than the material of main shaft  150  and readily replaceable. Other materials such as Teflon® coated steel may also be used to provide a self-lubricating surface. 
         [0119]    Main shaft  150  includes a first end  152  and a second end  154 , and has a circular cross section for most of its length. Main shaft first end  152  has opposing flats  156 . Main shaft second end  154  includes a female threaded hollow bore  214  for mating with mounting stud first portion  126 . In the embodiment, main shaft  150  is fabricated using a high strength steel allow, Acroloy  TM    4140  TGP, and polished or chromed to reduce friction. 
         [0120]    A third shaft main shaft bushing  178  is provided which inserts into base stanchion upper flange  138  to support main shaft  150 . 
         [0121]    Thrust washer  210  goes over main shaft first end  152  and rests on first main shaft bushing  178  and first pivot post flange  166 . Set collar  188  clamps main shaft first end  152  below flats  156  to retain thrust washer  210  in place. In the embodiment thrust washer  210  is fabricated from brass, which is substantially softer than the material of main shaft  150  and first pivot post flange  166  and readily replaceable. 
         [0122]    Jib arm  190  is rigidly connected to pivot post  158  and extends horizontally there from. In the embodiment, backstrap  192  is fixedly connected around pivot post tube  160  and mates with mounting plate  194  to provide a rigid connection point for jib arm  190 . Gusset arms  212  are removably connected between jib arm  190  and pivot post  158  providing added support for jib arm  190 . 
         [0123]    Linear rail  196  is mounted to the bottom of jib arm  190  and extends along a portion of the length of jib arm  190 . Shuttle  198  connects to linear rail  196  so as to be able to move along the length of linear rail  196 . 
         [0124]    Lifter  200  is removably connected to shuttle  198 . In the embodiment, lifter  200  is a manual chainfall hoist connected to shuttle  198  using locking hook  202  or rotating clevis arrangement. Load handler  204  is flexibly connectable to lifter  200  using chains  206 . In the embodiment, load handler  204  is a locking hook  208  attachable to an eyebolt on the load. Other lifter/load handler combinations may be used to customize the arrangement to the particular material and processing to be performed. 
         [0125]    In operation, the material handling system is modular and easily assembled and disassembled for field use or to conserve machine shop space. 
         [0126]    Base portion  110  is assembled and mounted to a convenient point on a machine, or on a truck other point for use at a construction site or other field location. Mounting stud first threaded portion  126  is threaded through stanchion bottom flange hole  132  so it projects beyond bottom flange  130  for coupling to main shaft  150 . 
         [0127]    When stanchion tube second end is mated to bottom flange  130  then mounting stud  116  projects into stanchion tube centerline channel  124 . Stanchion upper flange  138  is mated to stanchion tube first end  120 . In the embodiment, stanchion  112  is pre-assembled by welding stanchion bottom and upper flanges  130  and  138 , respectively, to stanchion tube  134 . Third main shaft bushing  178  is installed into stanchion upper flange  138 . 
         [0128]    Base portion  110  may be damped to its machine or bracket by inserting bottom plate  114  over mounting stud second threaded portion  128  and securing it with base nut  118  to hold the machine frame or bracket portion in compression. In the embodiment, mounting stud  116  is 0.75 inch (20 mm) steel allthread, and flanges and bottom plate are fabricated from 9/16 inch (14.3 mm) steel to provide adequate strength. 
         [0129]    Mainshaft  150  is installed by inserting it through upper flange  138  with third main shaft bushing  178  so that mainshaft second end  154  can be threaded onto mounting stud first threaded portion  126  projecting into stanchion tube centerline channel  124 . Mainshaft  150  is highly torqued against bottom flange  130  using main shaft flats  156  and a large torque wrench or other suitable tool. 
         [0130]    Pivot post  158  may be assembled separately by mating pivot post tube  160  to pivot post first and second end flanges  166  and  168  at first and second ends  162  and  164 , respectively. First and second main shaft bushings  178  are installed into end flanges  166  and  168 . Bearing  146  is installed in bearing race  144  and pivot post  158  can then be slipped over main shaft  150  until it rests on bearing  146 . Bearing  146  projects slightly above bearing race  144  so that stanchion upper flange  138  and pivot post second end flange  168  define a very narrow gap, but do not contact each other. Thrust washer  210  is then inserted over mainshaft first end  152  to rest on pivot post first end flange  166  and first shaft main shaft bushing  178 . Set collar  188  is installed over mainshaft first end  152  and against thrust washer  210  to retain the thrust washer  210  and prevent vertical displacement of pivot post  158 . In practice, stanchion  112  and pivot post  158  may be pre-assembled and joined together to be mounted as a single unit, or may be disassembled for separate stowage and carrying, so that individuals can manipulate the loads with relative ease. In the embodiment all flanges are welded to their respective tube ends for increased strength. 
         [0131]    Gusset arms  212  are bolted to pivot post  158 , and backstrap  192  and jib arm mounting plate  194  are mounted onto pivot post  158  in preparation for mounting jib arm  190 . In the embodiment, backstrap  192  and mounting plate  194  are permanently affixed to pivot post  158  by welding. In the embodiment jib arm  190  is provided with a corresponding mounting flange  216  with bolt holes  218  for ease of alignment. In the embodiment, linear rail  196  with shuttle  198  is pre-mounted to the underside of jib arm  190 . Lifter  200  is then connected to shuttle  198 , and load handler  204  is connected to flexible connector  206 , which in the embodiment is a chain suspended from a chain hoist  200 . 
         [0132]    Pivot post  158  with jib arm  190  freely rotates about mainshaft  150 , while mainshaft  150  and base portion  110  remain fixed in relation to the machine or bracket to which it is mounted. 
         [0133]    In use, with a material handling system  100  mounted to a stand alone milling machine, the user may rotate jib arm  190  and slide shuttle  198  to any point within reach of the jib arm, secure a load such as a motor using an appropriate load handler arrangement, lift the load using lifter  200 , and rotate/slide the load to the milling machine table with ease. 
         [0134]    Referring to  FIG. 14 , the inventor has discovered a unique advantage with this material handling system, however. The inventor has found that long work pieces can be easily fed through such a milling machine while maintaining an even depth and shape of cut in the work piece. With the work piece supported and gripped by load handler  204  at its free end, the operator can push the work piece across the milling machine table at the desired rate. Jib arm  190  will simply rotate freely about its axis while shuttle  198  moves along linear rail  196 , so that load handler  204  tracks a linear path through space. This allows a single machinist to, for example, mill a uniform keyway or lubrication channel along the length of a long pump shaft, without the risk that tipping or yaw of the shaft which can lead to non-uniform depth and cross-sections. By way of another example, carpenters can feed long work pieces into woodworking machinery without the need for large tables to support the free end of the piece as it is fed through. 
         [0135]    Those skilled in the art will recognize that numerous modifications and changes may be made to the preferred embodiment without departing from the scope of the claimed invention. It will, of course, be understood that modifications of the invention, in its various aspects, will be apparent to those skilled in the art, some being apparent only after study, others being matters of routine mechanical, chemical and electronic design. No single feature, function or property of the preferred embodiment is essential. Other embodiments are possible, their specific designs depending upon the particular application. As such, the scope of the invention should not be limited by the particular embodiments herein described but should be defined only by the appended claims and equivalents thereof.