Abstract:
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.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application claims the benefit of U.S. Provisional Patent Ser. No. 60/560,506 which was filed on Apr. 8, 2004, the entire disclosure of which is hereby expressly incorporated by reference herein. 

   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. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views and which together with the detailed description below are incorporated in and form part of the specification, serve to further illustrate various embodiments and to explain various principles and advantages all in accordance with the present invention. 
       FIG. 1  is a perspective view of a bar stock loading mechanism having a translation device disposed in a first position; 
       FIG. 2  is a perspective view of the bar stock loading mechanism of  FIG. 1  having the translation device disposed in a second position; and 
       FIG. 3  is a perspective view of an alternate embodiment of a bar stock loading mechanism. 
   

   DETAILED DESCRIPTION 
     FIG. 1  illustrates a bar stock loading mechanism  100  that may be used to store, at a first location, bar stock material  102 , particularly items weighing more than an ordinary person can lift or move unaided, and to move the bar stock material  102  from the first location to a second location such as that associated with a working area  104  at which a working tool, such as a cutting machine (not shown) may be located. The bar stock loading mechanism  100  may generally be operated by a single person to move a particular bar stock member  102  to a precise location needed by a tool at the working area  104 , without a significant safety hazard being caused by the loss of control of the bar stock  102  during 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 mechanism  100 . In particular, the apparatus  100  allows 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 in  FIGS. 1 and 2 , the bar stock loading mechanism  100  includes two principle elements, namely, a support apparatus  106  and a translation apparatus  108 . The support apparatus  106 , also referred to as a support table, has two horizontal support members  112  supported by legs  114 , which are preferably fixedly attached to the floor. Each of the support members  112  includes a top support surface  110  that supports the elongate bar stock members  102 . The support members  112 , illustrated in  FIGS. 1 and 2  as 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 members  102 . Of course, more or fewer support members  112  may be used, as long as adequate support is provided for the bar stock members  102  placed thereon. The exact dimensions of the support members  112  may 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 surface  110  is sufficiently flat to allow rolling of the bar stock members  102  when the bar stock members  112  are circular or round in cross section. 
   As illustrated in  FIGS. 1 and 2 , holes  134  disposed within the support members  112  are adapted to receive one or more retaining members  128 , which may be for example, pins. The retaining members  128 , when placed in the holes  134 , extend above the support surface  110  to limit motion of the bar stock members  102  and thereby prevent the bar stock members  102  from accidentally rolling off of the ends of the support table  106 . If desired, the retaining members  128  may be removeably disposed in the holes  134  to enable control over the limits of movement of the bar stock members  102 . In another embodiment, the retaining members  128  may be directed up from below the support surface  110  when in use and lowered below the support surface  110  when not in use. 
   Generally speaking, the translation apparatus  108  includes a support frame  121 , one or more sets of arms  122  disposed on the support frame and a movement device that enables the support frame  121  to be moved horizontally with respect to the support table  106 . Generally speaking, each of the arms  122  includes a vertical riser  130  disposed within a guide chamber  131  and a contact member  132  disposed at the top of the riser  130 . The contact member  132  receives and supports the elongate members  102 , and may be arcuate or V-shaped, for example, to be adapted for use with bar stock members  102  that are round or circular in cross section. Of course, the shape and construction of the contact members  132  should be suited to the type of bar stock being handled. For example, a U-shaped or flat contact member  132  may appropriate for square bar stock. Additionally, it may be desirable to have rollers  133  built into or disposed on the contact members  132  to enable a bar stock member  102  to move in an axial direction when the bar stock member  102  is disposed on or being support by the arms  112 . These rollers  133  may supplement or replace an auxiliary support roller  126  which, as illustrated in  FIGS. 1 and 2 , is disposed on the frame  121  between two of the arms  122 . 
   Still further, a lifting mechanism  123  is coupled to one of more of the sets of arms  122  to cause the risers  130  of the arms  122  to raise or lower with respect to the support table  106 . In the embodiment illustrated in  FIGS. 1 and 2 , the lifting mechanism includes a hydraulic motor (not shown) connected via pressure hoses  124  to one or more hydraulically actuated pistons (not shown) disposed within the guide chambers  131  in a manner that moves the risers  130  up and down with respect to the floor or the support frame  121 . While the lifting mechanism is illustrated in  FIGS. 1 and 2  as 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 mechanism  123  may include whatever pistons, belts, gears etc. are needed to raise and lower the risers  130 . The lifting mechanism  123  may be configured to control movement of the risers  130  in pairs, but may also control the risers  130  independently if so desired. 
   In the embodiment illustrated in  FIGS. 1 and 2 , the translation apparatus  108  includes wheels  116  mounted on the support frame  121  and tracks  118  in which the wheels  116  ride. The tracks  118  may have a closed end  120 , or a block (not depicted), to prevent the wheels  116 , and thereby the translation apparatus  108 , from moving beyond a desired point. Furthermore, the tracks  118  serve to guide the wheels  116  along a straight line or along any other predetermined path to ultimately keep the support frame  121  and thereby the arms  122  aligned with a working tool in the working area  104 . If desired, rollers may be used instead of the wheels  116  depending on the anticipated load and the surface under the translation apparatus  108 . Likewise, guides may be used instead of tracks. In another embodiment, ball bearings may be disposed in the tracks  118  or on a lower surface of the support frame  121  to provide easy movement of the support frame  121  with respect to the tracks  118 . While helpful to provide fixed movement of the support frame  121  between the support table  106  and the working area  114 , the tracks  118  are not necessary in all uses. 
   In operation, one or more bar stock members  102  are first loaded onto the support table  106  for storage. The bar stock members  102  may be loaded using, for example, a forklift, the translation apparatus  108  (in a manner reverse to the use of the translation apparatus  108  described below) or in any other desired manner. At an appropriate time, such as when a bar stock member  102  is needed at the working area  104 , the translation apparatus  108  is used to lift a bar stock member  102  off of the support table  106  and to move the bar stock member  102  to the working area  104  so that the bar stock member  102  is aligned with the working tool. In particular, the translation apparatus  108  may be moved from a first position (such as that illustrated in  FIG. 1 ) generally beneath the support apparatus  106  to a second position (such as that illustrated in  FIG. 2 ) wherein the bar stock member  102  can be moved onto the machining station of the working area  104 . When in the first position illustrated in  FIG. 1 , the translation apparatus  108  is proximate to and may be disposed beneath the support apparatus  106 . To attain this position, the translation apparatus  108  may be moved along the tracks  118  in, for example, a manual manner, to a position in which one of the sets of arms  122  aligns with a bar stock member  102  to be used while the bar stock member  102  rests on the support table  106 . If needed, an operator may manually shift the bar stock member  102  on the support table  106  to align the bar stock member  102  with the set of arms  122 . If severly misaligned, one arm of the set of arms  122  may be used to lift one end of the bar stock member  102  to aid in shifting it into alignment. The lifting mechanism  123  may then be operated to cause the risers  130  of the set of arms  122  to move upward until the support members  132  engage either side of the bar stock member  102  and lift the bar stock member  102  off of the support surfaces  110 . 
   If desired, the bar stock member  102  may be lifted to be higher than the retaining members  128  or the retaining members  128  may be lowered or removed from the table  106  so that the retaining members  128  do not interfere with movement of the bar stock member  102  off of the end of the table  106 . Next, the translation apparatus  108  is moved along the tracks  118  to a second position, such as that illustrated in  FIG. 2 , in which the bar stock member  102  is aligned with the working tool at the working area  104 . The translation apparatus  108  may be moved manually, such as by being pushed by the operator, or may be articulated by a motor or winch (not depicted). The lifting mechanism  123  may be operated to vertically adjust the risers  130  to align the bar stock member  102  with the working tool at the working area  104 . In some cases, one or more adjustable height auxiliary rollers  126  may be used to aid in moving the elongate member  102  from the translation apparatus  108  to rollers  127  associated with the working tool at the working area  104 . As will be understood, the auxiliary roller  126  can be raised and lowered, generally by a screw-type mechanism, to an appropriate height with respect to the one or more rollers  127  associated with the working tool at the working area  104 . The auxiliary roller  127  does not generally need adjustment once set because the work area rollers  127  are usually fixed in height. 
   The elongate member  102  can then-be moved to the machining apparatus as required. For example, the elongate member  102  can 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 member  132  has rollers  133 , as discussed above. However, if the rollers  133  are not used, the lifting mechanism may be lowered so that the bar stock member  102  comes to rest on the auxiliary roller  126  and one or more of the rollers  127  associated with the machining or working tool at the working area  104 . In either case, the rollers  126 ,  127  and, if present,  132  allow the bar stock member  102  to be easily pushed into the working area in a manner in which the bar stock is properly aligned with the working tool. 
   Referring to  FIG. 3 , a loading device  300  similar to that of  FIGS. 1 and 2  is shown having the same general features of the loading apparatus  100 , except that the table  310  includes a flat top  312  disposed between the supports  114 . In this case, the tracks  118  are on the outside of the supports  114  so that bar stock members longer than width of the table top may be lifted off of the table using the first set of arms  122   a  disposed in the rear of the translation device  108  (as illustrated in the perspective view of  FIG. 3 ) and so that bars longer than or shorter than the table top  312  may be rolled onto the set of arms  122   b  disposed in the near part of the translation device  108  (as illustrated in the perspective view of  FIG. 3 ). The table  310  may 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 apparatus  108  from 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. 
   This disclosure is intended to explain how to fashion and use various embodiments in accordance with the invention rather than to limit the true, intended, and fair scope and spirit thereof. The foregoing description is not intended to be exhaustive or to limit the invention to the precise form disclosed. Modifications or variations are possible in light of the above teachings. The described embodiments were chosen and to provide the best illustration of the principles of the invention and its practical application, and to enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims and all equivalents thereof, when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.