Bar stock loading table and apparatus

A bar stock loader for an elongate member and a method for use is includes a support apparatus with a support surface for supporting the elongate member and a translation apparatus proximate to the support apparatus. The translation apparatus is moveable and has an arm and a lifting mechanism for raising and lowering the arm. The translation apparatus is moveable between a first and second position whereby, when the translation apparatus is in the first position, the arm is positioned overlapping the support surface for receiving the elongate member, and when in the second position the arm is horizontally displaced from the support surface.

TECHNICAL FIELD

This patent relates to handling bar stock members in a manufacturing environment, and in particular to a bar stock loading table and mechanism.

BACKGROUND

Bar stock, which generally comes in the form of solid bars of metal, such as steel or copper (but which may be formed of other materials), is used as a source of starting material in numerous manufacturing processes. Typically, bar stock is delivered to a manufacturing facility in the form of elongate members, such as bars, which are circular in cross section and in the nature of six feet or longer in length. However, bar stock members may be formed in any desired shape and length. Within the manufacturing facility, the bar stock is provided from a storage area to a work area at which a cutting or machining tool may be used to cut the bar stock into smaller pieces of material or to machine the bar stock. When divided into smaller pieces of material, the bar stock may be melted, machined, etc. to produce components of a device being manufactured. Because bar stock is usually made of solid metal, an individual piece of bar stock is typically very heavy. Moreover, because bar stock is generally formed as elongate members with circular cross sections, bar stock rolls very easily and is difficult to stack on a flat table, thereby presenting a safety hazard when stored on a table or shelf above the floor.

Because of its elongated size and its weight, bar stock must generally be moved from a storage location within a manufacturing facility to a work area (at which a working tool is located) using a fork lift or other large and cumbersome mechanical means. Fork lifts, however, do not provide for fine control or adjustment, and it is therefore often difficult to deliver a piece of bar stock to a working tool at the precise location and orientation required by the working tool. As a result, a person must generally manually assist in such a transfer, which puts the person in harms way should the bar stock roll off of the fork lift, or should the fork lift operator accidentally cause sudden movement of the fork lift during the transfer process. Still further, this transfer process typically requires at least two persons.

In some situations, an inclined table may be used to facilitate parallel placement and movement of bar stock from a storage location to a working area. Several mechanisms for lifting or pushing the bar stock from a storage location to a final working position using an inclined table are shown in U.S. Pat. Nos. 5,108,245 and 4,503,807. However, because bar stock may be large, both in diameter and length, the bar stock has a great deal of weight and inertial mass. Uncontrolled movement down an inclined table may result in the bar stock having too much kinetic energy as the bar stock rolls into the final desired position. This kinetic energy may cause damage to the working tool, or may result in the bar stock jumping off of the table or working tool, creating a serious safety hazard. Lifting mechanisms that rely on an inclined table on the receiving portion for imparting motion to a bar have similar disadvantages.

SUMMARY OF THE DISCLOSURE

A bar stock loading mechanism has a table for supporting one or more bar stock members and a translation apparatus for lifting the bar stock members from the table and moving them to a work area. The table is generally flat and level to allow rolling the bar stock into position. Pins can be used to stop the bar stock members from rolling out of position or off the table. The translation apparatus, which may have at least one pair of arms for vertically lifting a bar stock member, may be moved, for example, on rails, to present the bar stock member at a work area. When the bar stock member is aligned with the work area, the arms are lowered to position the bar stock member onto rollers associated with an apparatus in the work area. Rollers built into the arms of the translation apparatus or an auxiliary roller can be used to facilitate unloading of the bar stock member onto the work area.

DETAILED DESCRIPTION

FIG. 1illustrates a bar stock loading mechanism100that may be used to store, at a first location, bar stock material102, particularly items weighing more than an ordinary person can lift or move unaided, and to move the bar stock material102from the first location to a second location such as that associated with a working area104at which a working tool, such as a cutting machine (not shown) may be located. The bar stock loading mechanism100may generally be operated by a single person to move a particular bar stock member102to a precise location needed by a tool at the working area104, without a significant safety hazard being caused by the loss of control of the bar stock102during the transfer process. As further discussed below, various principles are advantageously employed to optimize the handling of bar stock in a manufacturing or machining environment using the loading mechanism100. In particular, the apparatus100allows loading and unloading bar stock from either end of a storage area while maintaining control of the kinetic energy of the bar stock at all stages during the transfer from the storage area to a working tool. For example, bar stock can be loaded onto the storage table from a cart at one end of the table and unloaded to a work area at the other end of the table. In another example, bar stock can be placed onto the storage area by overhead crane and unloaded to work areas at either end of the storage table. The length of the storage table and range of travel of the translation apparatus can be adapted to the different requirements of each installation.

As illustrated inFIGS. 1 and 2, the bar stock loading mechanism100includes two principle elements, namely, a support apparatus106and a translation apparatus108. The support apparatus106, also referred to as a support table, has two horizontal support members112supported by legs114, which are preferably fixedly attached to the floor. Each of the support members112includes a top support surface110that supports the elongate bar stock members102. The support members112, illustrated inFIGS. 1 and 2as I-beams, may include spaced-apart beams, bars or other suitable members that are able to withstand the load of one or more elongate bar stock members102. Of course, more or fewer support members112may be used, as long as adequate support is provided for the bar stock members102placed thereon. The exact dimensions of the support members112may vary according to the number, size and density of items to be supported and the calculation of the suitable dimensions is within the skill of one of ordinary skill in the mechanical arts. The support surface110is sufficiently flat to allow rolling of the bar stock members102when the bar stock members112are circular or round in cross section.

As illustrated inFIGS. 1 and 2, holes134disposed within the support members112are adapted to receive one or more retaining members128, which may be for example, pins. The retaining members128, when placed in the holes134, extend above the support surface110to limit motion of the bar stock members102and thereby prevent the bar stock members102from accidentally rolling off of the ends of the support table106. If desired, the retaining members128may be removeably disposed in the holes134to enable control over the limits of movement of the bar stock members102. In another embodiment, the retaining members128may be directed up from below the support surface110when in use and lowered below the support surface110when not in use.

Generally speaking, the translation apparatus108includes a support frame121, one or more sets of arms122disposed on the support frame and a movement device that enables the support frame121to be moved horizontally with respect to the support table106. Generally speaking, each of the arms122includes a vertical riser130disposed within a guide chamber131and a contact member132disposed at the top of the riser130. The contact member132receives and supports the elongate members102, and may be arcuate or V-shaped, for example, to be adapted for use with bar stock members102that are round or circular in cross section. Of course, the shape and construction of the contact members132should be suited to the type of bar stock being handled. For example, a U-shaped or flat contact member132may appropriate for square bar stock. Additionally, it may be desirable to have rollers133built into or disposed on the contact members132to enable a bar stock member102to move in an axial direction when the bar stock member102is disposed on or being support by the arms112. These rollers133may supplement or replace an auxiliary support roller126which, as illustrated inFIGS. 1 and 2, is disposed on the frame121between two of the arms122.

Still further, a lifting mechanism123is coupled to one of more of the sets of arms122to cause the risers130of the arms122to raise or lower with respect to the support table106. In the embodiment illustrated inFIGS. 1 and 2, the lifting mechanism includes a hydraulic motor (not shown) connected via pressure hoses124to one or more hydraulically actuated pistons (not shown) disposed within the guide chambers131in a manner that moves the risers130up and down with respect to the floor or the support frame121. While the lifting mechanism is illustrated inFIGS. 1 and 2as being a hydraulically actuated lifting mechanism, other lifting mechanisms could be used instead or in addition, including motor driven (for example, electric motor driven) mechanisms, pneumatic mechanisms, and manual mechanisms, such as manually operated screws, foot pumps, etc. Of course, the lifting mechanism123may include whatever pistons, belts, gears etc. are needed to raise and lower the risers130. The lifting mechanism123may be configured to control movement of the risers130in pairs, but may also control the risers130independently if so desired.

In the embodiment illustrated inFIGS. 1 and 2, the translation apparatus108includes wheels116mounted on the support frame121and tracks118in which the wheels116ride. The tracks118may have a closed end120, or a block (not depicted), to prevent the wheels116, and thereby the translation apparatus108, from moving beyond a desired point. Furthermore, the tracks118serve to guide the wheels116along a straight line or along any other predetermined path to ultimately keep the support frame121and thereby the arms122aligned with a working tool in the working area104. If desired, rollers may be used instead of the wheels116depending on the anticipated load and the surface under the translation apparatus108. Likewise, guides may be used instead of tracks. In another embodiment, ball bearings may be disposed in the tracks118or on a lower surface of the support frame121to provide easy movement of the support frame121with respect to the tracks118. While helpful to provide fixed movement of the support frame121between the support table106and the working area114, the tracks118are not necessary in all uses.

In operation, one or more bar stock members102are first loaded onto the support table106for storage. The bar stock members102may be loaded using, for example, a forklift, the translation apparatus108(in a manner reverse to the use of the translation apparatus108described below) or in any other desired manner. At an appropriate time, such as when a bar stock member102is needed at the working area104, the translation apparatus108is used to lift a bar stock member102off of the support table106and to move the bar stock member102to the working area104so that the bar stock member102is aligned with the working tool. In particular, the translation apparatus108may be moved from a first position (such as that illustrated inFIG. 1) generally beneath the support apparatus106to a second position (such as that illustrated inFIG. 2) wherein the bar stock member102can be moved onto the machining station of the working area104. When in the first position illustrated inFIG. 1, the translation apparatus108is proximate to and may be disposed beneath the support apparatus106. To attain this position, the translation apparatus108may be moved along the tracks118in, for example, a manual manner, to a position in which one of the sets of arms122aligns with a bar stock member102to be used while the bar stock member102rests on the support table106. If needed, an operator may manually shift the bar stock member102on the support table106to align the bar stock member102with the set of arms122. If severly misaligned, one arm of the set of arms122may be used to lift one end of the bar stock member102to aid in shifting it into alignment. The lifting mechanism123may then be operated to cause the risers130of the set of arms122to move upward until the support members132engage either side of the bar stock member102and lift the bar stock member102off of the support surfaces110.

If desired, the bar stock member102may be lifted to be higher than the retaining members128or the retaining members128may be lowered or removed from the table106so that the retaining members128do not interfere with movement of the bar stock member102off of the end of the table106. Next, the translation apparatus108is moved along the tracks118to a second position, such as that illustrated inFIG. 2, in which the bar stock member102is aligned with the working tool at the working area104. The translation apparatus108may be moved manually, such as by being pushed by the operator, or may be articulated by a motor or winch (not depicted). The lifting mechanism123may be operated to vertically adjust the risers130to align the bar stock member102with the working tool at the working area104. In some cases, one or more adjustable height auxiliary rollers126may be used to aid in moving the elongate member102from the translation apparatus108to rollers127associated with the working tool at the working area104. As will be understood, the auxiliary roller126can be raised and lowered, generally by a screw-type mechanism, to an appropriate height with respect to the one or more rollers127associated with the working tool at the working area104. The auxiliary roller127does not generally need adjustment once set because the work area rollers127are usually fixed in height.

The elongate member102can then-be moved to the machining apparatus as required. For example, the elongate member102can be pushed to the machining apparatus or working tool or may be captured and pulled by the working tool itself. Movement to the working tool is further facilitated if the contact member132has rollers133, as discussed above. However, if the rollers133are not used, the lifting mechanism may be lowered so that the bar stock member102comes to rest on the auxiliary roller126and one or more of the rollers127associated with the machining or working tool at the working area104. In either case, the rollers126,127and, if present,132allow the bar stock member102to be easily pushed into the working area in a manner in which the bar stock is properly aligned with the working tool.

Referring toFIG. 3, a loading device300similar to that ofFIGS. 1 and 2is shown having the same general features of the loading apparatus100, except that the table310includes a flat top312disposed between the supports114. In this case, the tracks118are on the outside of the supports114so that bar stock members longer than width of the table top may be lifted off of the table using the first set of arms122adisposed in the rear of the translation device108(as illustrated in the perspective view ofFIG. 3) and so that bars longer than or shorter than the table top312may be rolled onto the set of arms122bdisposed in the near part of the translation device108(as illustrated in the perspective view ofFIG. 3). The table310may be useful for handling shorter bar stock or for re-orienting bars before machining.

The apparatus and method discussed above are intended to and will alleviate problems caused by prior art bar stock loading devices. Using these principles will improve the handling of bar stock or other elongate members, particularly items of substantial size and weight that are difficult or impossible for a person to transport manually. Still further, the ability to move a translation apparatus108from a loading or storage area to a working area helps to assure that bar stock items are readily available for use. Still further, the loading devices illustrated and described herein generally enable a single person to store, move and load bar stock, even when the bar stock is very heavy or cumbersome.

Various embodiments of methods and apparatus for storing and moving bar stock and other elongate members have been discussed and described. It is expected that these embodiments or others in accordance with the present disclosure will have application to many kinds of manufacturing environments where personnel may wish to manage the movement and use of items substantially heavier than previously possible without the use of forklifts, cranes and other specialized equipment requiring advanced skill and training. Using the inventive principles and concepts disclosed herein advantageously allows or provides for an improved manufacturing floor environment from both safety and productivity standpoints.