Abstract:
An indexing parts rack for supporting a plurality of objects includes an elongated track having a longitudinal axis and at least one hanger assembly mounted on the track. The hanger assembly is movable along the track in a direction of the longitudinal axis and is rotatable about the longitudinal axis. The indexing parts rack also includes a stop positioned adjacent the track whereby when no object is supported from the hanger assembly, the hanger assembly assumes a first position relative to the longitudinal axis to enable the hanger assembly to move along the track past the stop. When an object is supported from the hanger assembly, the hanger assembly rotates relative to the longitudinal axis to a second position to engage the stop and prevent the hanger assembly from moving past the stop along the track.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    The present invention relates generally to storage racks and, in particular, to an indexing parts rack.  
           [0002]    Storage racks having indexing properties are well known. Places such as commercial cleaners have cleaned items that hang from hooks attached to a chain where the chain indexes mechanically. Meat factories and trucks hang large slabs of meat from hooks attached to a frame. Other prior art racks exist that include a rack that indexes forward but includes electronic controls and a motor to advance the hanging parts, which makes the rack disadvantageously expensive and requires considerable maintenance.  
           [0003]    It is also common to store large parts, such as modular automotive headliners, in a vertical orientation because higher part density can be achieved than in a horizontal orientation for the same size container. These parts must be shipped either separated from each other or with some type of physical protector between adjacent parts. The conventional prior art way to ship modular headliners vertically is in pouches that hang from the upper bars of a shipping rack. As the parts increase in weight and size, however, two people are required to remove the headliner from the pouch, which becomes an ergonomic issue for the operator and also requires a longer cycle time. There are alternative racks for horizontal shipping in which the parts rest in rolling tubes but they have lower part density for the same size rack and they are difficult to use with an assist tool, such as a forklift modified to lift headliners.  
           [0004]    It is desirable, therefore, to provide an improved and cost-effective means for supporting a plurality of objects having indexing properties for moving the objects. It is desirable to provide a means for hanging objects that also provides frontal access to the hanging objects for easy removal with an assist tool. It is also desirable to provide a rack for hanging vehicle headliners and having frontal access to the hanging headliner for easy removal with or without an assist tool.  
         SUMMARY OF THE INVENTION  
         [0005]    The present invention concerns an indexing parts rack for supporting a plurality of objects. The indexing parts rack includes an elongated track having a longitudinal axis and at least one hanger assembly mounted on the track. The hanger assembly is movable along the track in a direction of the longitudinal axis and is also rotatable about the longitudinal axis. The parts rack also includes a stop positioned adjacent the track whereby when no object is supported from the hanger assembly, the hanger assembly assumes a first radial position relative to the longitudinal axis to enable the hanger assembly to move along the track past the stop. When an object is supported from the hanger assembly, the hanger assembly rotates relative to the longitudinal axis to a second radial position to engage the stop and prevent the hanger assembly from moving past the stop along the track.  
           [0006]    The indexing parts rack is preferably adapted to be attached to a frame disposed within a shipping container. The rack is designed to fit inside current production shipping containers.  
           [0007]    The parts rack according to the present invention is preferably two rows of hooks (one row per side of a shipping container) from which the parts are hung. The weight of the part combined with the tension generated by the angle of the hooks holds the part in place when the part is attached. Each hook is attached to a separate hanger assembly. Each hanger assembly includes an upper roller and a lower roller with concave radiuses, which rollers are rotatably mounted to a housing and positioned on opposite sides of an elongated tube. The concave shape of the rollers conforms to an outer surface of the tube, permits movement along the tube and perpendicular swivel relative to a longitudinal axis of the tube. Alternatively, the outer surfaces of the rollers have a V-shaped groove that conforms to the outer surface of the tube, permits movement along the tube and perpendicular swivel relative to a longitudinal axis of the tube. The tubes from which the hooks hang are positioned parallel and spaced apart wider than the width of the parts. Thus, when the parts hang from one of the hooks on each of the tubes, the hooks and the hanger assemblies are rotated at an angle inclining towards the centerline of the container. The distance separating adjacent ones of the parts is dictated by the thickness of the housing which covers each hanger assembly. Each of the tubes forms a continuous track with a generally horizontal upper portion, a lower portion inclined downwardly from front to rear of the container, and a pair of curved portions connected to corresponding ends of the upper and lower portions.  
           [0008]    In operation, at the point of part installation, the container is tipped forward a few degrees, which allows the hanger assemblies to move to the front under the influence of gravity to push the parts forward. When the hooks are at an angle, the housing of the first hanger assembly rests against the stop member in the front of the container, which stops further travel until the part is removed. When the first part is removed from the container by lifting it from the hooks, the weight of the hooks makes the hanger assemblies move to an almost vertical, unengaged position. In that position the housing no longer contacts the stop member and the hanger assemblies are free to roll forward and around the front curved portions of the tubes. The empty hanger assemblies advantageously collect in the lower portion of the tube for future reuse.  
           [0009]    The parts are preferably loaded into the container through the rear and are removed from the front. Because the present invention allows direct frontal access to the part, an operator can easily remove the part by lifting it just enough to release the hooks (approximately one inch). If the part is too large or heavy for a single operator to manually remove, an assist tool especially designed for this type of rack can be used. In the case that some parts have a large width, a set of empty hooks can be placed in between the parts, which doubles the space between the large-width parts. The height of the tubes and the length of the hooks are adjustable. In this way, the parts rack can be easily and advantageously modified for numerous programs.  
           [0010]    The present invention advantageously eliminates damage to the parts during shipping, and increases part density in the container compared to the prior art pouch or horizontal shipping racks. In the case of a headliner, it allows easier access for operators to manually remove the headliners with or without an assist tool, which causes a reduction in plant cycle time, reduces ergonomic stressors and, if combined with a load assist tool, can result in a labor savings as well.  
       
    
    
     DESCRIPTION OF THE DRAWINGS  
       [0011]    The above, as well as other advantages of the present invention, will become readily apparent to those skilled in the art from the following detailed description of a preferred embodiment when considered in the light of the accompanying drawings in which:  
         [0012]    [0012]FIG. 1 is a front view of an indexing storage rack in accordance with the present invention shown with a hanger assembly in an engaged position in partial cross-section;  
         [0013]    [0013]FIG. 2 is a front view of the indexing storage rack in FIG. 1 shown with the hanger assembly in an unengaged position in partial cross-section;  
         [0014]    [0014]FIG. 3 is a partial cross-sectional side view of the indexing storage rack hanger assembly shown in FIG. 1;  
         [0015]    [0015]FIG. 4 is a side elevation view of the indexing storage rack shown in FIG. 1 mounted in a shipping container; and  
         [0016]    [0016]FIG. 5 is a front elevation view of the indexing storage rack and container of FIG. 4. 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0017]    In FIG. 1, a hanger assembly in accordance with the present invention is indicated generally at  10 . The hanger assembly  10  includes an upper roller  12  and a lower roller  14  disposed in and rotatably attached to a hanger assembly housing  16 . The rollers  12  and  14  are preferably attached to the hanger assembly housing  16  by an associated ball bearing and axle assembly  17  or similar rotatable attachment means, such as a roller bearing or the like. The hanger assembly housing  16  includes a plate  18  and a pair of shrouds  20 . The plate  18  extends in a generally vertical plane and has the assemblies  17  mounted on a first surface thereof. The shrouds  20  are semicircular with each extending about a portion of the associated one of the rollers  12  and  14  and being attached to the plate  18 . A hook bracket  22  is rotatably attached to a second surface of the plate  18  of the hanger assembly housing  16  by a ball bearing and axle assembly  19  or similar rotatable attachment means, such as a roller bearing or the like. A hook member  24  attaches to a lower surface of the hook bracket  22  and extends downwardly therefrom. Preferably, a shank of the hook member  24  is received in an aperture  23  in the lower surface of the hook bracket  22  and may be attached at a number of different points in the aperture, such as by a threaded connection or by set screws (not shown), in order to vary the vertical position of the hook member  24 . The hook member  24  is operable to attach to a part (not shown), such as an automotive headliner, that is to be supported by the hanger assembly  10 .  
         [0018]    The rollers  12  and  14  each have a concave outer surface  13  and  15  respectively to cooperate with an outer surface of an elongated tube  26  and are preferably constructed of steel, hard plastic, or similar material. Alternatively, the rollers  12  and  14  each have an outer surface having a V-shaped groove (not shown) that conforms to the outer surface of the tube  26 . The spacing between the two bearing and axle assemblies  17  and the width of the surfaces  13  and  15  ensures that the rollers  12  and  14  remain engaged with the tube  26 . The rollers  12  and  14  allow the hanger assembly  10  to be moveable along a longitudinal axis (see FIG. 3) of the tube  26 . The tube  26  is attached to a mounting member  28  extending outwardly from a surface  30 , such as an interior wall of a shipping container. The mounting member  28  is preferably an angle iron or similar shape and is attached to the surface  30  by a plurality of fasteners  32 . A stop member  34  is attached to the surface  30  adjacent the mounting member  28  and extends outwardly from the surface  30  towards the hanger assembly  10 . The hanger assembly  10 , the stop member  34 , and the tube  26 , together form an indexing storage rack according to the present invention, indicated generally at  11 .  
         [0019]    The hanger assembly  10  is shown in FIG. 1 in an engaged position that the hanger assembly  10  assumes when the part is hung from the hook  24 . The hanger assembly  10  is rotatable about a central axis  27  of the tube  26 . When the part is hung from the hook  24 , the hanger assembly  10  rotates about the central axis  27  of the tube  26  in an engaging direction indicated by an arrow  36  to the engaged position as shown. When in the engaged position, a portion  38  of the hanger assembly housing  16 , such as the upper shroud  20 , contacts the stop member  34 , which prevents any further movement of the hanger assembly  10  along the longitudinal axis of the tube  26 .  
         [0020]    Referring now to FIG. 2, the hanger assembly  10  of FIG. I is shown in an unengaged position, which is the position that the hanger assembly  10  assumes when the part is not hung from the hook  24 . Because no part is attached to the hook  24 , the weight of the hanger assembly  10  allows the hanger assembly  10  to move in an unengaging direction indicated by an arrow  40 , in FIG. 1, to the generally vertical orientation of the unengaged position. In the unengaged position, the portion  38  of the hanger assembly housing  16  does not contact the stop member  34 , which allows movement of the hanger assembly  10  along the longitudinal axis of the tube  26  since the mounting member  28  can pass between the shrouds  20 .  
         [0021]    Referring now to FIG. 3, a side view of the hanger assembly  10  is shown. The rollers  12  and  14  are operable to allow the hanger assembly  10  to move in a first direction, indicated by an arrow  42 , and a second direction, indicated by an arrow  44 , along a longitudinal axis  46  of the tube  26 . The hook bracket  22  is rotatably attached to the first surface of the plate  18  of the hanger assembly housing  16 .  
         [0022]    Referring now to FIG. 4, the indexing storage rack  11  is shown attached to the surface  30  that forms a side wall of a shipping container  48  having a plurality of frame members  31  with the front of the container shown on the right in the drawing. Alternatively, the indexing storage rack  11  is attached to respective interior surfaces of a plurality of vertical frame members (not shown) that form the frame of a shipping container (not shown). The tube  26  is formed with a generally horizontal upper portion  50 , a lower portion  52  inclined downwardly toward a rear of the shipping container, a front curved portion  54  connecting front ends of the portions  50  and  52 , and a rear curved portion  56  connecting rear ends of the portions  50  and  52  to define a continuous track having the longitudinal axis  46 . The upper roller  12  and the lower roller  14  of a first hanger assembly  10  and a second hanger assembly  10 ′ are shown movably attached to the tube  26 . The track tube  26  is attached to the surface  30  by a plurality of the mounting members  28 . The surface  30  includes a plurality of attachment points  58  formed thereon. The attachment points  58  allow the tube  26  and mounting members  28  to be attached at various vertical points along the surface  30 , allowing the indexing storage rack  11  to be utilized for parts of varying size. The stop member  34  is preferably located adjacent a junction of the front curved portion  54  and the upper portion  50  of the tube  26 . Another stop member (not shown), similar to the stop member  34  of FIGS. 1 and 2, is preferably located at a point  60  adjacent a junction of the rear curved portion  56  and the upper portion  50  of the tube  26 , to prevent the hanger assemblies  10  and  10 ′ from rolling from the upper portion  50  and along the rear portion  56  down to the lower portion  52  of the tube  26 .  
         [0023]    Referring now to FIG. 5, the shipping container  48  is viewed from an open front side showing the indexing storage rack  11  attached to the side wall surface  30  and a similar indexing storage rack  11 ′ attached to an opposite side wall  62 . The first hanger assembly  10  is shown in an engaged position with the hook member  24  attached to a part  64 , such as an automotive headliner, adjacent one upper corner of the part. When the hook member  24  is under tension, and the hanger assembly  10  is in the engaged position, the hanger assembly housing  16  contacts the stop member  34 , preventing any movement of the hanger assembly  10  toward the front of the container  48 . The second indexing storage rack  11 ′ has a hook member  24 ″ attached to the part  64  near another upper comer opposite from the hook member  24 .  
         [0024]    In operation, a part, such as the part  64  of FIG. 5, is attached to the hook members  24  and  24 ″. The weight of the part  64  causes the hanger assemblies  10  and  10 ″ to rotate about the longitudinal axis  46  of each of the track tubes  26  in the engaging direction  36  until the hanger assemblies  10  and  10 ″ reach the engaged position of FIG. 1. Preferably, the container  48  is tilted at the point of use, such as during loading of the parts  64  in the container  48 , by raising the rear of the container  48  enough for the hanger assemblies  10  and  10 ″ to move from the rear of the container  48  where the parts  64  are loaded to the front of the container  48  under the influence of gravity. During storage and shipping, the container  48  is level. When ready for use, such as during unloading of the parts  64  from the container  48 , the rear of the container  48  is again raised enough for the hanger assemblies  10  and  10 ″ to move towards the front of the container  48  and the part  64  is removed from the hook  24  or hooks  24  and  24 ″. After the part  64  is removed from the hook  24 , gravity allows the hanger assembly  10  to return to the unengaged position of FIG. 2, where the portion  38  of the hanger assembly housing  16  no longer contacts the stop member  34 . Because the portion  38  no longer contacts the stop member  34 , the hanger assembly  10  is free to move along the longitudinal axis  46  of the tube  26  from the upper portion  50 , around the front curved portion  54  and onto the lower portion  52  to move under the influence of gravity toward the rear portion  56  of the tube  26 . During this movement the hook member  24  points downwardly because the hook member  24  rotates about the ball bearing and axle assembly  19 . The hanger assembly  10  travels along the lower portion  52  of the tube  26  until the hanger assembly  10  reaches the junction of the lower portion  52  and the rear portion  56  of the tube  26 , which acts as a natural stop and allows for a plurality of hanger assemblies  10  to be collected at the junction of the lower portion  52  and the rear portion  56  of the tube  26  for future reuse. Preferably, more than one hanger assembly  10  is installed on the tube  26 , allowing more than one part  64  to be stored on the indexing storage rack  11 . If the part  64  is too large, multiple hanger assemblies  10  are installed and the parts  64  are attached to every other hanger assembly  10  or every third hanger assembly  10  in order to achieve proper spacing between the parts  64 .  
         [0025]    In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiment. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope. For example, while the present invention has been described utilizing two hanger assemblies, those skilled in the art will recognize that one, two, or three or more hanger assemblies may be utilized while remaining within the scope of the present invention.