Barrel elevator including shielded actuation mechanisms

A barrel elevator system for vertically moving barrels of liquid between a ground floor and any one of a number of floors at a warehouse for storage of the barrels. The barrel elevator system includes a support frame located in an elevator shaft and a series of cradle assemblies supported between a pair of lifting chains. A loading station is located on the ground floor for receiving barrels to be stored or for removing barrels after storage. Each floor includes a unloading station that allows barrels to be removed from the cradle for storage and returned to the cradles after storage. Each of the loading and unloading stations includes a shield assembly to restrict access to the elevator shaft. A rail section and handle are used to load and unload barrels from the cradles. The handle extends through the shield assembly for access by an operator.

BACKGROUND

The disclosed system generally relates to a barrel elevator for moving barrels of liquid, such as whiskey, from one level of a warehouse or storage location to another level of the warehouse. More specifically, the present disclosure relates to a barrel elevator that includes shielded loading and unloading stations that include rails coupled to a linkage to allow loading and unloading of barrels.

In whiskey warehousing operations, it has been the practice in the past to utilize a building that includes several individual floors. Each floor contains two to three rows of barrel-receiving racks or dunnage. An elevator shaft is located in the warehouse in which a tray or cradle-type elevator is situated. This consists of an endless conveyor trained over upper and lower sprockets, including a series of trays or cradles vertically suspended from the conveyor by hanger members. Thus, the barrels are loaded into the warehouse on the ascending side of the elevator and unloaded on the descending side of the elevator. At the point of loading or unloading, the barrels of whiskey are rolled to one of several levels of barrel-receiving racks and the barrels then remain in said racks for a period of four years or more. Such a system is shown in U.S. Pat. No. 3,557,940.

Although this type of barrel elevator has been used, there are many drawbacks and problems with the loading and unloading of barrels onto the moving cradles. One prominent drawback is the use of loading/unloading rails that are manually positioned to allow the barrels to be either loaded onto the moving cradles or removed from the moving cradles. The present disclosure addresses many of these problems while providing a system that more easily allows for loading and unload of barrels at multiple floors of the warehouse.

SUMMARY

The present disclosure relates to an elevator system for moving barrels of alcohol between floors of a storage warehouse. The elevator system allows for the efficient movement of barrels between a ground floor and multiple storage floors while reducing access to an elevator shaft including the elevator.

The elevator system includes a support frame that extends between and upper end and a lower end. The support frame is designed and sized to be contained within an elevator shaft having a loading side and an unloading side. The support frame creates a support structure for a pair of laterally spaced lifting chains. Each of the lifting chains extends between the upper and lower ends of the support frame. The lifting chains extend around sprockets that can be driving in opposite first and second directions.

A plurality of cradle assemblies are each connected to the pair of lifting chains such that the cradle assemblies move with the movement of the lifting chains. The cradle assembly includes a pair of cradle arms that are designed to support one of the barrels of alcohol. The cradle assemblies are used to support the barrels during movement of the barrels between floors of the warehouse.

The elevator system includes a loading station at the ground floor of the warehouse. The loading station is positioned on the loading side of the elevator shaft. The loading station includes a rail section that is coupled to a handle. The handle is used to move the rail section between a loading position and a storage position. When the rail section is in the loading position, barrels can be loaded onto the cradle assemblies. When the rail section is in the storage position, the rail section is spaced from the movement path of the cradles and supported barrels.

The elevator system includes a plurality of unloading stations, each located at one of the floors of the warehouse. The unloading stations are positioned on the storage side of the elevator shaft. Each unloading station includes a rail section that is coupled to a handle. The handle is used to move the rail section between a loading position and a storage position. When the rail section is in the loading position, barrels can be unloaded from the cradle assemblies. When the rail section is in the storage position, the rail section is spaced from the movement path of the cradles and supported barrel.

The elevator system further includes a shield assembly positioned at each of the loading and unloading stations. The shield assembly includes a barrel opening sized to allow the barrels to pass through the shield assembly. The shield assembly restricts access to the elevator shaft while allowing for loading and unloading of barrels from the series of support cradles.

DETAILED DESCRIPTION

FIG. 1illustrates a barrel elevator10constructed in accordance with the present disclosure. The barrel elevator10shown inFIG. 1is located within a warehouse that includes an elevator shaft12that extends between multiple different floors14within the warehouse. The warehouse includes a ground floor16that is typically used to load and unload barrels of alcohol, such as whiskey, to and from the warehouse either before or after the storage term for the alcohol. As indicated previously, each floor14generally includes barrel receiving racks that are used to store the barrels of alcohol for extended periods of time, such as one to twenty or more years. Typically, the ground floor16is serviced by a loading dock that allows barrels of alcohol from the manufacturing facility to be transported to the warehouse for storage. After the barrels have been stored for the storage term, the barrels are removed from the warehouse for bottling and ultimately, for sale to the consuming public.

In the embodiment shown inFIG. 1, the barrel elevator10includes a single loading station18included on the ground floor16and a series of unloading stations20located at each of the individual floors14. In the embodiment shown inFIG. 1, the warehouse includes four floors in addition to the ground floor16. The ground floor16is shown including its own unloading station20that allows barrels of the alcohol to be stored not only on the individual floors but also on the ground floor if desired. It is contemplated that the unloading station20on the ground floor16could be eliminated in many embodiments.

The barrel elevator10includes a support frame22that extends between au upper end24and a lower end26, where the lower end26is supported on the ground28. In the embodiment shown, the lower end26is below ground level and is received in a pit29. The support frame22is used to support a pair of laterally spaced lifting chains30that each pass over an upper sprocket32and a lower sprocket. The pair of upper sprockets32are mounted to a common drive shaft that is driven by one or more drive motors. The rotation of the upper sprockets32cause the pair of lifting chains30to move in either a first direction or an opposite second direction. The two directions of movement allow barrels to move in either direction within the storage warehouse.

The barrel elevator10further includes a plurality of cradle assemblies34that are supported between the pair of spaced lifting chains30. When the lifting chains30are moving in a first direction, the cradle assemblies34on the right side of the support frame22shown inFIG. 1are moving upward while the cradle assemblies34on the left side of the support frame22are moving downward. This first direction of movement is used to load barrels from the loading station18to each of the individual unloading stations20at the individual floors14. During an unloading process, in which barrels are moved from the individual floors14back to the loading station18, the direction of movement of the pair of lifting chains30is reversed to the second direction. Further details of this operation will be described in greater detail below with reference to the loading station18and the series of unloading stations20.

In the embodiment illustrated inFIG. 1, the elevator shaft12includes both a storage side36and a loading side38. The storage side36includes an elevator shaft outer wall40while the loading side38includes an outer wall42. Since the storage side36includes the plurality of unloading stations20, the wall40must have openings at each of the floors that allow barrels to be removed from the barrel elevator10during unloading. After the barrels have been stored, the opening at each floor allows the barrels to be returned to the barrel elevator10for return to the loading station18on the ground floor16. Since the elevator shaft12extends over multiple floors, it is desirable to include some type of shielding assembly at each of the loading and unloading stations to restrict access to the elevator shaft12.

Referring now toFIG. 2, the loading station18is shown at the ground floor16. The loading station18includes a shield assembly44that is generally aligned with an access opening45formed in the back wall42of the elevator shaft. Although not shown inFIG. 2, an access door must typically be opened to provide access to the elevator shaft. In some embodiments, the access door is a fire rated door as is required by building codes. The access door is connected to door switch that provides a signal to a control unit as to whether the access door is open or closed. In the embodiment illustrated, the shield assembly44includes an outer frame46that defines a barrel opening48. The barrel opening48allows a barrel to be rolled through the shield assembly44and onto one of the cradle assemblies34.

The shield assembly44further includes a pair of handle openings50positioned on opposite sides of a center viewing window52. The viewing window52includes a transparent material, such as glass, plastic or perforated metal, that allows an operator to view into the elevator shaft without providing unrestricted access to the elevator shaft. A pair of lower windows54are positioned beneath each of the handle openings50to provide additional opportunity to view the interior of the elevator shaft. The handle opening50allows a handle56to extend through the shield assembly44for operation by an operator. In the embodiment shown inFIG. 2, the entire shield assembly44is mounted to the floor14and supported by a pair of beams58that are connected to the support frame22of the barrel elevator.

FIG. 3illustrates additional details of the loading station18and the cradle assembly34. As seen inFIG. 3, the cradle assembly34includes a pair of cradle arms60each supported between a pair of hanger arms62. The hanger arms62are each mounted to one of the lifting chains30. The cradle arms60are designed to have a radius of curvature that generally matches the outer diameter of one of the barrels64that are being loaded utilizing the barrel elevator of the present disclosure. The cradle arms60provide for secure engagement of the barrel during the bi-directional movement between the multiple floors at the warehouse.

When a barrel64is to be loaded onto one of the cradle assemblies34, the barrel64is moved in the direction shown by arrow66. The barrel64passes through the barrel opening48formed in the shield assembly44and passes over the edge of outer wall42that defines the loading side of the elevator shaft. The barrel64travels onto a support track68and is ultimately supported by a pair of rails70of a movable rail section72. In the embodiment shown inFIGS. 3 and 4, the rail section72is shown in its loading position that allows each individual barrel64to move into position for loading on one of the cradle assemblies34.

When the barrel64is in the proper position for loading onto the conveyor, as shown inFIG. 3, the user can grab the handles56and move the handle56upward as shown inFIG. 4. This upward movement of the handle56causes the rail section72to move upward into a loading position. When the rail section72moves into the loading position, the rail section changes the state of an loading station rail switch (not shown) that provides a signal to a control unit indicating whether rail section72is in the loading/unloading position or located away from the moving conveyor. When the rail section72is in the loading position, the user can push the barrel64further forward until the barrel is in position to be received on the cradle arms60when the cradle arms move past the loading station18, as shown inFIG. 4. As the cradle assembly34moves upward and away from the loading station18, the barrel64is supported by the cradle arms60. In the embodiment shown, the drive motor can slow down as the cradle assembly34approaches the loading station18to more smoothly pick up the barrel. In such an embodiment, the drive motor is a variable speed drive motor. However, it is contemplated that the drive motor could be operated at a constant speed, thereby eliminating the need and cost of a variable speed drive motor.FIG. 1illustrates a plurality of barrels64being moved from the loading station18to the desired floor and desired unloading station20.

Referring back again toFIG. 2, the shield assembly44prevents the operator from moving past the shield assembly while providing for the required barrel opening48and handle openings50.

As illustrated inFIGS. 3 and 4, the handle56is part of a larger handle section74that includes a plurality of linkages that allow an operator to move the rail section72between loading and unloading positions. The linkage between the handle56and the rail section72allows for remote positioning of the rails, thus allowing the use of the shield assembly44. When the rail section72is in the loading position, one of the barrels can be moved by the operator from a staging position shown inFIG. 3to the loaded position shown inFIG. 4. This process is continuously repeated as each individual barrel64is loaded onto one of the cradle assemblies34.

FIG. 5illustrates one of the plurality of unloading stations20that are each positioned at one of the plurality of floors14of the warehouse. As with the loading station20discussed above, an access door must typically be opened to provide access to the elevator shaft on the floor of the unloading station. In some embodiments, the access door is a fire rated door as is required by building codes. The access door is connected to door switch that provides a signal to a control unit as to whether the access door is open or closed. Like the loading station18shown inFIG. 2, the unloading station20includes a similar shield assembly44that includes a barrel opening48, a viewing window52, a pair of handle openings50and a pair of lower windows54. The shield assembly44again restricts a user/operator from entering into the elevator shaft while still allowing the operator to control the function and operation of each of the individual unloading stations20. In the embodiment shown inFIG. 5, a first handle56and a second handle84are each accessible through one of the handle openings50.

FIGS. 6 and 7illustrate the movement of one of the barrels64as the barrel is unloaded at a specific floor. As shown inFIGS. 6 and 7, each floor includes a pair of guide rails79that are used to roll a barrel along the floor to a desired location for movement and ultimately for storage.FIG. 6illustrates the pair of laterally spaced lifting chains30that are each used to support opposite hanger arms62of each cradle assembly34. The top view shown inFIG. 7illustrates that the cradle arms60are each connected to a transverse bar78which provides additional support for the barrel when the barrel is received on the cradle assembly34. In the embodiment shown inFIG. 7, the movable rail section72is in the loading position such that each individual barrel64can be received along the rails80at the unloading station20. In this manner, each barrel64can be rolled away from the barrel elevator for storage at the individual floor. When the rail section72moves into the loading position, the rail section changes the state of an unloading station rail switch (not shown) that provides a signal to a control unit indicating whether rail section72is in the loading/unloading position or located away from the moving conveyor.

FIGS. 8-10illustrate the sequence of steps and operation utilized to remove one of the barrels64from the cradle assembly34. As illustrated inFIG. 8, each of the cradle assemblies34and the associated lifting chains30are moving in a downward direction illustrated by arrow81.FIG. 8illustrates the unloading station20when the rail section72is in its raised, storage position. In this storage position, the rail section72is moved away from the path of the cradle assemblies34such that the barrels can move past the floor on which the unloading station is located. As can be understood inFIG. 1, each of the unloading stations20would be in this condition except for the single floor where barrels are going to be unloaded. The series of unloading station rail switches provide an indication of the status of the rail sections at each unloading station to a control unit.

Referring now toFIG. 9, the unloading station20is shown at the floor where barrels are to be unloaded. At this floor, the rail section72is moved to the loading position in which the rail section extends to the path of the moving cradle assembly34. The rail section72has a width that is less than the distance between the pair of cradle arms60, as best shown in the top view ofFIG. 7. In this loading position, the rail section72contacts the barrel64as the cradle assembly34moves downward past the unloading station20. As discussed previously, the cradle assemblies34can be moved at a constant speed or can be slowed slightly as the cradle assembly34approaches the floor including the unloading station20where barrels are going to be stored.

In the view shown inFIG. 10, the rail section72is moved into an inclined unloading position. In this inclined unloading position, once the barrel64is supported on the rail section72, barrel rolls away from the cradle assembly34along the rail section72under the force of gravity. The handle56is moved downward as illustrated by arrow82which causes the rail section72to move upward into the inclined, unloading position as illustrated by arrow83. This upward movement of the rail section72allows the barrel64to roll away from the lifting chains30due to gravity.

In this manner, the pair of handles56and84can be used to actively unload a barrel from the moving cradle assembly34. As can be understood in the above description, individual barrels can be moved from the unloading station18shown inFIG. 1to one of the unloading stations20at the desired floor14. The unloading stations20at floors not being loaded are operated such that the rail section does not cause a barrel to be unloaded at the desired floor. Once all of the barrels have been loaded to a desired floor, the unloading station20is returned to the storage condition shown inFIG. 8and an operator moves to the next desired floor to move the rail section72into the unloading position shown inFIG. 9. This process continues at each selected floor until the barrels have loaded into the desired location from the loading station.

After barrels have been stored at a desired floor for a desired storage time, such as five or more years, the barrels can be unloaded from each individual floor by reversing the steps shown and described above. Further, at this time, the rotating direction of each of the lifting chains is reversed. With reference toFIG. 9, if the moving direction of the lifting chains30are reversed, the barrels would be loaded onto each of the cradle assemblies34and moved in an upward direction until the barrels eventually were returned to the loading station18. When the barrels reach the loading station18, the downward movement of the cradle assembly causes the barrel to be discharged at the loading station18in a similar manner as described for each of the unloading stations. In this manner, the barrel elevator can be utilized to not only load barrels to desired floors of a warehouse but also to retrieve barrels after storage.

FIG. 13is a schematic illustration of the control system used to operate the conveyor system of the present disclosure. As shown, the control system includes a control unit100that operates to control all of the functions of the conveyor system. The control unit100is in operative communication with the variable speed and direction drive motor102. The drive motor102controls the direction and speed of movement of the lifting chains30and the associated cradle assemblies34as discussed above. This control allows the user to control the loading and unloading of barrels through a user input device104. The user input device104can be any type of input device, such as a touch screen, that allows the user to communicate with the control unit100. The input device104could be hardwire connected to the control unit100or could communicate using conventional wireless communication techniques, such as WiFi or Bluetooth.

In addition to the input device104, a display106is shown connected to the control unit100. It is contemplated that the display106could be separate or integrated with the input device104, such as through a touch screen. The display106allows the control unit to communicate the status of the conveyor system to the user during operation.

As discussed above, a loading station rail switch108and a loading station door switch110are located on the floor that includes the loading station. The rail switch108provides a signal to the control unit100indicating the current position of the rail section at the loading station, while the door switch110provides an indication of the current state of the access door on the floor of the loading station.

As also discussed above, an unloading station rail switch112and an unloading station door switch114are located on each floor that includes an unloading station. In the embodiment shown, a total of “n” floors are at the facility that includes the conveyor system of the present disclosure. The rail switches112each provide a signal to the control unit100indicating the current position of the rail section at the unloading station at each of the floors, while the door switches114each provide an indication of the current state of the access door on the floor of the unloading station.

During operation of the conveyor system, the control unit100monitors the rail switches and the door switches to properly operate the conveyor system. The control unit100is programmed such that the drive motor102will operate when only one of the rail sections at the plurality of unloading stations are in the raised, loading/unloading position. This insures that barrels will be unload at only the single, desired floor. If more than one rail section is extended, the control unit100will stop operation of the drive motor102and provide an indication to the user either through an alarm or indicator on the display106.

In addition to monitoring the position of the rail sections, the control unit100also monitors the position of the access doors on each floor of the storage facility. The control unit100will allow operation of the drive motor102only when the door to the desired floor is open and all other doors are closed. In this manner, the control unit100can control the operation of the conveyor system by knowing the state of the rail sections and access doors on each floor.