Abstract:
A system and method is used to automatically process the contents of a containers. The contents may be bulk materials used by a business or organization. The container enters the system via a tow assembly mechanism, a grasping mechanism clasps the container, a lid secures the contents, the container is lifted and rotated to allow the contents of the container to exit the container.

Description:
RELATED APPLICATION  
       [0001]     The present application is related to and claims the priority of U.S. Provisional Application No. 60/287,022 filed Apr. 30, 2001, in the name of Carl SMITH, and titled ADVANCED BULK AUTOMATED CONTAINER UNLOADING SYSTEM, the entire contents of which are fully incorporated herein by reference. 
     
    
     TECHNICAL FIELD  
       [0002]     This invention relates generally to the automated processing of large containers of bulk material.  
       BACKGROUND  
       [0003]     In industry today, production, manufacturing, and distribution facilities for any business utilize automated services to quickly and efficiently handle bulk materials. These bulk materials may include anything from products sold by a company to bulk mail sent and received by businesses and other organizations. In the case of bulk mail, many businesses and organizations specializing in mail delivery have bulk mail facilities, which process and sort mail according to certain user defined criteria (e.g., recipient&#39;s name, ZIP code, street address, etc.). These facilities can exist for any type of business. The purpose of having a facility designed for processing materials in bulk is to improve the entire assembly line process of getting materials to and from the business or organization efficiently so that the consumer may realize a cost savings or receive a higher quality product or service. Handling materials in bulk is more efficient and cost effective than handling materials individually, and businesses and other organizations constantly seek to improve the steps in existing methods and systems to make the entire process more efficient and cost-effective.  
         [0004]     One step in processing bulk materials, for example, is the initial step of receiving the incoming materials at the bulk material processing facility. Current methods of transporting bulk materials, for example unloading the contents of a truck onto a loading dock, may be slow and require too much human exertion to be cost effective and efficient. Furthermore, increased human intervention, even in automated processes, in handling bulk materials increases the risk of harm to employees or workers of the bulk material processing facility. Current methods of automated transporting of bulk materials are not user friendly, may cause delays in the entire production, manufacturing, or distribution process, and may have a high risk of harm to workers when manual attention is needed.  
         [0005]     It is therefore desirable to provide systems and methods to allow for the safe, efficient, cost effective, and automated transportation of bulk materials to the facilities engaged in processing those bulk materials.  
       SUMMARY  
       [0006]     There is provided a system for automatically processing contents of a first container, comprising a system for automatically processing contents of containers, comprising a tow assembly for advancing a first container to a first predetermined position; a grasping mechanism for securely clasping the first container at the first predetermined position; a lifting mechanism, coupled to the grasping mechanism, for moving the first container between the first predetermined position and a second predetermined position, and to begin rotating the container, at the second predetermined position, to a third predetermined position; and a lid mechanism for covering the contents of the first container at the first predetermined position and moving apart to allow the contents to be released from the container at the third predetermined position.  
         [0007]     There is also provided A method for automatically processing contents of containers; comprising advancing a first container, in an upright position, along a path with a tow assembly mechanism; grasping the first container at a first predetermined position; lifting the container to a second predetermined position, while the contents are secured inside the first container by a lid; rotating the first container to a third predetermined position and moving the lid sufficiently to allow the contents to exit from the first container; returning the first container, in the upright position, to the first predetermined position; and advancing the first container along the path so that a second container may be processed.  
         [0008]     Additional features and advantages will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the claims. The advantages will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims.  
         [0009]     It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the appended claims. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]      FIG. 1  is a flowchart of a method of processing a bulk container, consistent with the present invention;  
         [0011]      FIG. 2  is a front view of a system for processing a bulk container;  
         [0012]      FIG. 3  is a cross sectional view of  FIG. 2 ;  
         [0013]      FIG. 4  is a front view of  FIG. 2 , showing a step involved in processing bulk containers;  
         [0014]      FIG. 5  is a front view of  FIG. 2 , showing a step involved in processing bulk containers;  
         [0015]      FIG. 6  is a front view of  FIG. 2 , showing a step involved in processing bulk containers; and  
         [0016]      FIG. 7  is a front view of  FIG. 2 , showing a step involved in processing bulk containers.  
     
    
     DETAILED DESCRIPTION  
       [0017]     Referring now to the drawings, in which the same reference numbers will be used throughout the drawings to refer to the same or like parts,  FIG. 1  is a flowchart of a method for automatically processing bulk materials, for example, unloading a large and heavy container of packages. A method for processing bulk materials in a container begins at Stage  102 , where a user places a container full of packages, using the example from above, in a position accessible to a tow assembly, so that the tow assembly advances the container to a predetermined first position. The tow assembly may be a chain in the floor which attaches to the container and pulls the container along a track. The container may include a securing component, such as a net or lid, to prevent the contents from spilling from the container.  
         [0018]     The predetermined first position is a user defined station where the container is placed in order to fulfill the other stages within the method of processing materials in a bulk container. The first predetermined position can be inside a system or machine designed to implement the stages described herein.  
         [0019]     Once the container is at the first predetermined position, a grasping mechanism, such as a set of arms, securely grip the container at Stage  104 , so that the container is securely fastened within the mechanism. The arms can be made of high pressured vulcanized rubber or another suitable material to hold and handle the container.  
         [0020]     Once the arms have securely gripped the container, the container is lifted, at Stage  106 , to a second predetermined position. The second predetermined position may be directly above the first predetermined position, so that the container is suspended at a height suitable for rotation about a horizontal axis.  
         [0021]     At Stage  108 , the lid is opened and the container is rotated about a horizontal axis to an angle to allow the contents of the container. A suitable angle for this purpose may be approximately 155 degrees from the initial orientation of the container at the second predetermined position. A guide may be used to ensure that the contents are safely removed from the container without damage. In addition, the container may be jostled or shaken, to allow trapped contents to unfasten and fall from the container.  
         [0022]     Once the contents have been discharged from the container, the container is rotated back to an upright position and returned to the first predetermined position at Stage  110 . At Stage  112 , the container is advanced further along the track by the tow assembly and the method is repeated for other containers that need to be processed in this manner.  
         [0023]      FIG. 2  is a front view of a system  200  for processing bulk containers, using, for example, the method outlined in  FIG. 1 . System  200  may include a support structure  202  mounted on a platform  204 , a lifting mechanism  206 , a track  208 , pusher  210 , container  212 , and a repository  218 . Container  212  may further include wheels  214  and a pin  216 . The contents of container  212  may constitute anything that needs processing under the method of  FIG. 1 , including bulk mail packages.  
         [0024]     Lifting mechanism  206  may further include a guide  219 , a lid  220 , and clamps  222 .  FIG. 2  shows lifting mechanism  206  in an up position, as lifting mechanism  206  waits for container  212  to advance to the first predetermined position, which may be a position directly underneath lifting mechanism  206  on platform  204 . Lifting mechanism  206  is described in further detail below.  
         [0025]     Container  212 , using wheels  214 , is moved onto platform  204  along track  208 . As container  212  advances to the first predetermined position, pin  216 , which may be located on the bottom side of container  212 , engages a pusher  210 , so that container  212  may be secured to follow track  208 .  
         [0026]     System  200  may also include structures to guard against an overflow of containers from entering. There may be a situation where other containers to be processed precede container  212  in a process queue. Container  212  may not be processed until all preceding containers are processed. This may be implemented by using an overflow limit switch in track  208  to prevent system  200  from accepting container  212  if another container is already being processed.  
         [0027]      FIG. 3  shows system  200  in greater detail. In  FIG. 3 , container  212  is inside system  200  and on top of platform  204 . Pin  216 , attached to the bottom of container  212  engages pusher  210 , so that container  212  is secured to track  208 . Pusher  210  advances container  212  to proceed along track  208 . A towline assembly may also be included in track  208 . The towline assembly may include a chain attached to pusher  210  that pulls container  212  into system  200  after pin  216  engages pusher  210 , but may include anything capable or suitable to pull container  212 .  
         [0028]      FIGS. 4 through 7 , front views of previously described system  200 , show in greater detail the method outlined in  FIG. 1 .  FIG. 4  is a front view of system  200  using, for example, the method outlined in  FIG. 1 .  FIG. 4  shows system  200  lowered over container  212  at the first predetermined position. After container  212  enters system  200 , pin  216  engages pusher  210 , lifting mechanism  206  lowers over container  212  and lid  220  closes (or remains closed) to secure the contents of container  212 . The contents of container  212  may be packaged bulk mail, which is being transported to a conveyor belt or a storage bin.  
         [0029]     Next, referring to  FIG. 5 , clamps  222  securely grasp container  212  in preparation of lifting container  212 . The position of container  212 , when still on platform  204 , may be a user defined first predetermined position, as previously described.  
         [0030]     Referring to  FIG. 6 , pusher  210  disengages pin  216  and lifting mechanism  206  lifts container  212  to a user defined second predetermined position. The second predetermined position can be above the first predetermined position to allow lifting mechanism  206  and container  212  to rotate.  
         [0031]     Next, in  FIG. 7 , lifting mechanism  206  rotates about an axis perpendicular to the plane of  FIG. 7 , in order to empty container  212 . The lifting mechanism may rotate either way, but should rotate to angle that allows the contents to safely fall from container  212 . Once lifting mechanism  206  and container  212  have reached that angle, lid  220  is opened and the contents of container  212  fall into repository  218 . Also, guide  219  may be used in guiding the contents of container  212  into repository  218 , to ensure all the contents reach repository  218  without damaging the contents. Repository  218  may be any suitable device used in conjunction with transporting bulk materials (e.g., a bin, a loading truck, or a conveyor belt). Lifting mechanism  206  may also have sensors located on either side of the opening to container  212 . This allows system  200  to sense whether the contents have all been removed from container  212 . Lifting mechanism  206  may also jostle or shake container  212  to loosen trapped contents. Once all the contents have been removed from container  212 , lifting mechanism rotates back into the second predetermined position and then subsequently lowered to the first predetermined position (see  FIG. 5 ). If sensors are used, lifting mechanism  206  can return to the first predetermined position after the sensors indicate that the flow of materials exiting container  212  has ended. At the second predetermined position, clamps  222  disengage from container  212  ( FIG. 4 ) and lifting mechanism  206  raises to its up position (see  FIG. 3 ), leaving processed container  212  on platform  204 . Pin  216  engages pusher  210  and container  212  is advanced out along track  208 .  
         [0032]     Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the appended claims disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit being indicated by the following claims.