Material handling apparatus

A material handling apparatus for use with a material carrier board including an aperture, the material handling apparatus being configured to couple to a lifting portion of a lift truck that includes forks, the material handling apparatus including a mount configured to be coupled to the lifting portion of the lift truck, a backrest having a bottom edge and a front face, a scissor structure coupled to the mount and to the backrest, the scissor structure being configured to operate between extended and retracted states, wherein when the scissor structure is operated from the retracted state to the extended state, the backrest is extended from a proximal end of the forks towards a distal end of the forks, the stop plate being attached to the backrest such that the horizontal planar portion is substantially perpendicular to the front face of the backrest, the vertical planar portion is substantially parallel to and offset from the front face of the backrest, the horizontal planar portion of the stop plate forming an aperture, a first actuator coupled to the mount and the scissor structure being configured to actuate the scissor structure between the extended and retracted states, a second actuator coupled to the backrest, a stud and configured to operate between extended and retracted states, the stud being configured to extend through the aperture formed in the carrier board when the stud is actuated from the retracted to the extended state, wherein the material handling apparatus is configured to pull the carrier board onto the forks by, when the stud is in the extended state, actuating the scissor portion from an extended state to a retracted state.

BACKGROUND

Today, many forms of goods are transported through the supply chain from manufacturers and growers to distributors and retailers. The manufacturers and suppliers typically use material handling devices, such as pallets and slip sheets, to move the products through the supply chain. Material handling devices are typically moved about using material handling vehicles, such as forklifts, pallet jacks, orderpickers, robots, etc. The material handling vehicles typically place the material handling devices, along with the product, into a conventional warehouse racking system. Employees and/or consumers can retrieve the products from the racking system.

SUMMARY

In general, in an aspect, the invention provides a material handling apparatus for use with a material carrier board including an aperture, the material handling apparatus being configured to couple to a lifting portion of a lift truck that includes forks, the material handling apparatus including a mount configured to be coupled to the lifting portion of the lift truck, a backrest having a bottom edge and a front face, a scissor structure coupled to the mount and to the backrest, the scissor structure being configured to operate between extended and retracted states, wherein when the scissor structure is operated from the retracted state to the extended state, the backrest is extended from a proximal end of the forks towards a distal end of the forks, a stop plate including horizontal and vertical planar portions, the stop plate being attached to the bottom edge of the backrest, the stop plate being attached to the backrest such that the horizontal planar portion is substantially perpendicular to the front face of the backrest, the vertical planar portion is substantially parallel to and offset from the front face of the backrest, the horizontal planar portion of the stop plate forming an aperture, a first actuator coupled to the mount and the scissor structure being configured to actuate the scissor structure between the extended and retracted states, a second actuator coupled to the backrest, a stud coupled to the second actuator and configured to operate between extended and retracted states along an axis that is substantially parallel to the front face of the backrest, the stud being configured to extend through the aperture formed in the stop plate and through the aperture formed in the carrier board when the stud is actuated from the retracted to the extended state, wherein the material handling apparatus is configured to pull the carrier board onto the forks by, when the stud is in the extended state, actuating the scissor portion from an extended state to a retracted state.

Embodiments of the invention may provide one or more of the following features. The horizontal and vertical planar portions are configured in an L-shape. The stud includes a tapered portion that is positioned on a distal end of the stud, wherein the tapered portion is configured to aid alignment of the stud and the aperture in the carrier board. The actuation of the scissor portion is controlled by a three-way control. The actuation of the stud is controlled by a three-way control. The actuation of the scissor portion and the stud are controlled by a single three-way control. The apparatus further includes a plurality of guide blocks coupled to the stop and configured to align the stud with the aperture formed in the horizontal portion of the stop.

In general, in another aspect, the invention provides a method for handling a load disposed on a carrier board using a lift truck including a lifting portion that includes forks, the method including approaching the carrier board at a first location with the lift truck, positioning the lifting portion to a height such that a top surface of the forks is lower than a bottom of the carrier board, extending a backrest portion towards a distal end of the forks, the backrest portion including a stud configured to be received by an aperture in the carrier board, actuating the stud such that the stud extends at least partially through the aperture in the carrier board, retracting the backrest portion towards a proximal end of the forks such that the carrier board is pulled onto the forks by the stud, wherein the carrier board is supported by the forks, relocating the carrier board to a second location, positioning the lifting portion such that the top surface of the forks is at least as high as a surface of interest onto which the carrier board will be placed, and extending the backrest portion towards the distal ends of the forks such that a stop portion of the backrest pushes the carrier board onto the surface of interest.

Embodiments of the invention may also provide one or more of the following features. The method further includes retracting the stud from the aperture. Extending the backrest portion towards the distal ends of the forks such that a stop portion of the backrest drives the carrier board onto the surface of interest includes driving the carrier board into a racking system. The method further includes controlling the operation of the lift truck using hand operator controls. The method further includes controlling the operation of the lift truck using an automated controller. The method further includes controlling the operation of the backrest using a three-way control. The method further includes controlling the operation of the stud using a three-way control. The method further includes controlling the operation of the backrest and the stud using a single three-way control.

Various aspects of the invention may provide one or more of the following capabilities. A load of material can be handled without an ordinary pallet. Individual tiers of material can be handled using carrier boards. Load handling efficiency can be increased. A push-pull assembly can be used to handle a load of material disposed on a carrier board. Ordinary pallets and carrier boards can be handled by a single lift truck.

These and other capabilities of the invention, along with the invention itself, will be more fully understood after a review of the following figures, detailed description, and claims.

DETAILED DESCRIPTION

Embodiments of the invention provide techniques for providing an apparatus that is configured to handle material carrier boards used in material handling systems. The apparatus is an attachment that is configured to be used with a standard forklift truck or automated material handling system. The handling apparatus is further configured to be used with a carrier board that includes gripping apertures. The handling apparatus includes a backrest portion, an actuating portion, and a scissor portion. The actuating portion includes a stud that that is configured to be actuated in first and second positions such that in the second position the stud extends through the gripping aperture in the carrier board. The scissor portion can be actuated to extended and retracted positions such that when the stud is extended, and the scissor portion is actuated from the extended position to the retracted position, the stud is configured to pull the carrier board onto the forks of the forklift. Other embodiments are within the scope of the invention.

Referring toFIGS. 1-8, a carrier board handling system1includes an extendable push-pull assembly5, forks10, and a lift truck12. The lift truck12is, for example, a forklift, a slipsheet machine, an order picker, a tractor, or a reach truck. The lift truck12includes a lifting portion13. The lifting portion13extends vertically and is configured to lift the forks10and the push-pull assembly5to a desired height (e.g., the height of a bay in a racking system). The push-pull assembly5is configured to attach to the lift truck12either removably or permanently. For example, the push-pull assembly5can be attached to the lift truck12using hooks, fasteners (e.g., bolts), can be welded to the lift truck12, or can be coupled to the lift truck12using a “quick connect” system. The push-pull assembly5is configured to be actuated in outward and inward directions (relative to the front of the lift truck12), although other directions are possible. For example, the push-pull assembly5is extended away from the front of the lift truck12towards a distal end of the forks10by actuating the push-pull assembly5in the outward direction. The push-pull assembly5is retracted towards the lift truck12by actuating the push-pull assembly in the inward direction. The push-pull assembly5is configured to be controlled by an operator of the lift truck12using, for example, a hand controller.

The push-pull assembly5includes a stop15, an extendable stud20(not visible inFIG. 1), a scissor portion25, and a backrest30. The push-pull assembly5is configured to be operable using hydraulic, pneumatic, electrical, and/or electromechanical power provided by the attached lift truck and/or can be self powered. The scissor portion25is, for example, a pantograph device. The backrest30can vary in size (e.g., a few inches tall to a few feet tall). The stop15and the stud20are supported by the push-pull assembly5. The stop15is preferably about the same width as the backrest30, although other configurations are possible (e.g., the stop15can be split into two sections). To retrieve a carrier board35, the push-pull assembly5is preferably configured to extend at least about as far as the end of the forks10(e.g., as shown inFIGS. 2-3) and is configured to extend the stud20into and/or through an aperture40provided by the carrier board35to “attach” the carrier board35to the push-pull assembly5(e.g., as shown inFIGS. 4-5). The push-pull assembly5is configured to retract, with the stud20extended, to pull the attached carrier board35onto the support members10(e.g., as shown inFIG. 6). The system1is configured to securely grip the attached supported carrier board35such that the lift truck can move about without the attached supported carrier board35becoming separated from the system1.

The push-pull assembly5is also configured to unload a carrier board35that is supported by the forks10. The push-pull assembly5is configured to (e.g., using the stop15) push the carrier board35off of the forks10onto, for example, a racking system. Upon placing the carrier board35onto a racking system, the operator can disengage the stud20from the aperture40of the carrier board35(e.g., as shown inFIG. 7) and retract the push-pull assembly5, leaving the carrier board35on the racking system. The stud20, however, can be retracted at other times as well.

The push-pull assembly5is configured to be operated using several methods. The operation of the push-pull assembly5and the stud20can be controlled by respective hand and/or foot controls. For example, one three-way switch (e.g., extend, stop, and retract) can control the operation of the push-pull assembly5, and another three-way switch can control the operation of the stud20. Likewise, a single three-position can be used to control the operation of the push-pull assembly5and the stud20jointly. For example, the operator can extend the push-pull assembly5by moving the switch to the extend position. Once the push-pull assembly5is fully extended, the operator can maintain the switch in the extend position to extend the stud20. Other control configurations are possible.

Referring toFIGS. 8-12, the stud20is disposed on the backrest30and is configured to actuate between retracted and extended positions using an actuator50that is coupled to a plate55. The actuator50is preferably hydraulic, although other types of actuators can be used. The plate55is disposed on the backrest30and is configured to attach to the actuator50. Guides60are disposed on the stop15and the backrest30and are configured to position the stud20relative to an aperture65in the stop15. The aperture15is sized such that the stud20can pass therethrough when actuated by the actuator50. The guides60include channels70that are sized to receive the peripheral edges of the stud20and are configured to align the stud20relative to the aperture65. The actuator50and the guides60are configured such that when the actuator50actuates the stud20between the retracted and extended positions, the stud20moves in a substantially vertical direction (e.g., arrow75) that is parallel to the backrest30(e.g., perpendicular relative to the direction of travel of the push-pull assembly5).

The push-pull assembly5is configured to facilitate alignment of the stud20with a carrier board35which is to be handled by the system1. The stud20is configured to be adjustable in multiple directions and is configured to compensate for a misaligned carrier board35relative to the stud20. The stud20includes rounded portions21and is tapered to facilitate alignment and insertion of the stud20into the aperture40. For example, the channels70can be “loose-fit” to the stud20(e.g. represented by the dashed lines inFIG. 10) such that as the stud20is extended towards the aperture40of the carrier board35, the rounded portions21are configured to cause the stud20to self-align with the aperture40.

Additional hydraulic actuators can also be used to align the stud20relative to the aperture40of the carrier board35. For example, the guide blocks60can be coupled to hydraulic actuators such that the stud20can move in a direction perpendicular to the backing plate30(e.g., in the same direction as the direction of travel of the push-pull assembly5). Furthermore, hydraulic actuators can also be configured to actuate the guide blocks60such the stud20can move in a direction parallel to the backing plate (e.g., side-to-side as shown by arrow80). The additional actuators can be configured to be controlled by an operator of the lift truck12using a hand-control.

The push-pull assembly5is configured to be stowed (e.g., in the retracted position) such that the lift truck12can function normally (e.g., the push-pull assembly5can remain attached to the lift truck12while the lift truck12handles ordinary pallets). For example, a manufacturer could supply a pallet of goods that includes multiple levels of carrier boards (e.g., every tier of product on the pallet is on a separate carrier board). A single unit could unload the pallet of carrier boards from a truck, and place the carrier boards in the racking system without having to use a separate lift truck, or change lift truck attachments.

In operation, referring toFIG. 13, with further reference toFIGS. 1-12, a process100for retrieving and unloading a carrier board using the system1includes the stages shown. The process100, however, is exemplary only and not limiting. The process100may be altered, e.g., by having stages added, removed, or rearranged. The process100is configured to be used with carrier boards such as the carrier board35shown inFIGS. 14A-14B, although other carrier boards can be used.

At stage105, the lift truck12driven by an operator approaches a carrier board35. The operator generally aligns the lift truck12with the carrier board35. The carrier board35can be located in a racking system, or in a stack (e.g., a carrier board layer, a material layer, a carrier board layer, a material layer, etc.), although other configurations are possible. The remainder of the description pertaining to the process100assumes that the carrier board35is located in a racking system.

At stage110, the operator retrieves the carrier board35from the racking system. Preferably, the operator adjusts the lift truck12such that the distal ends of the forks10are close (e.g., within a few inches) of the carrier board35and such that the top of the forks10are positioned slightly below the bottom of the carrier board35. The operator extends the push-pull assembly5to at least about the end of the forks10such that one edge of the carrier board35is preferably in contact with the stop15. The operator extends the stud20through the aperture40of the carrier board35. The operator retracts the push-pull assembly5such that the carrier board35is pulled onto the forks10by the stud20. Preferably, the operator retracts the push-pull assembly5such that the carrier board is fully supported by the forks10.

At stage115, the operator relocates the carrier board to a desired location using the lift truck12. While relocating the carrier board35to the desired location, the stud20is preferably extended thereby reducing the likelihood that the carrier board35will become displaced from the forks10.

At stage120, the operator unloads the carrier board35from the lift truck. Preferably, the operator adjusts the lift truck12such that the distal ends of the forks10are slightly above the surface upon which the carrier board35will be supported on once unloaded from the lift truck12. The operator extends the push-pull assembly5such that the stop15pushes the carrier board35away from the lift truck12into the desired location (e.g., in a bay of a racking system). The operator retracts the stud20from the aperture40of the carrier board35and retracts the push-pull assembly5.

Other embodiments are within the scope and spirit of the invention. For example, due to the nature of software, functions described above can be implemented using software, hardware, firmware, hardwiring, or combinations of any of these. Features implementing functions may also be physically located at various positions, including being distributed such that portions of functions are implemented at different physical locations.

While “forks”10have been described herein, other configurations are possible. For example, the forks can be other support means capable of supporting the weight of a load placed thereupon (e.g., slip sheet forks or an extendable table).

While the push-pull assembly5is described herein as being attached to forklift truck12, other configurations are possible. For example, the push-pull assembly5can be configured to attach to a lift truck such as an automated material handling system (e.g., a robotic material handling system).

Further, while the description above refers to the invention, the description may include more than one invention.