Abstract:
A method and apparatus is described for disassembling a wooden pallet by mechanically and automatically removing a pre-selected damaged board from the pallet, comprising a frame intended to be arranged in close proximity with a conveyor and a bi-directional rotating ram assembly mounted within the frame and carrying spikes thereupon. The invention is configured such that the ram assembly is moved into a board-engaging position to enable the spike to puncture and fasten to a predetermined (damaged) board of the pallet, and to thereafter be moved up and away from the pallet in order to remove and separate the board from the pallet.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 61/798,571, filed Mar. 13, 2013, for IMPROVED AUTOMATED PALLET REFURBISHING APPARATUS AND METHOD, incorporated herein by reference. This application also claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 61/677,789, filed Jul. 31, 2012, for AUTOMATED PALLET REFURBISHING APPARATUS AND METHOD, incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    (a) Field of the Invention 
         [0003]    The present disclosure relates to machinery and processes for refurbishing pallets. More specifically, the present disclosure relates to an automated process and apparatus for removing broken or damaged slats or boards from a pallet to facilitate the easy replacement of the damaged slat or board, thereby refurbishing and prolonging the useful life of the pallet. 
         [0004]    (b) Description of the Prior Art 
         [0005]    Pallets are flat transport structures, typically made of wood, used to support goods. A common pallet is typically constructed in layers—a bottom layer, a top layer, a middle layer connecting the top and bottom layers in a spaced apart relationship, and, optionally, an intermediate layer. The bottom layer and top layers will commonly comprise a number of deck boards that typically run parallel with one another with some or no spacing between each board, although some bottom deck boards can run perpendicular to other bottom deck boards to allow for spacing therebetween. The top deck boards provide a deck or flat platform for goods to be placed on the top deck. 
         [0006]    Pallets are not gently used and often sustain damage. Pallets are typically lifted by forklifts, pallet jacks, front loaders, or other jacking devices. Operator error can result in jacking devices colliding with pallets, which may result in damaged or broken deck boards. Unloaded pallets are often lifted and, although inadvisable, thrown or dropped by operators. Rough usage can damage pallets, which then become safety risks. When parts of a pallet break, a load supported by the pallet may become destabilized. Furthermore, breakage of a deck board may expose nails or sharp edges. 
         [0007]    Traditionally, damaged pallets are either discarded or manually repaired. An operator removes a damaged or broken deck board using a crowbar or similar tool, then nails or otherwise fastens a replacement deck board to the pallet. This manual repair process is time consuming and physically wearing on operators. 
       SUMMARY 
       [0008]    The present disclosure relates to an automated apparatus for refurbishing a pallet by removing a damaged board therefrom. The present disclosure also relates to a method for refurbishing a pallet by removing a damaged board therefrom. 
         [0009]    One aspect of the present invention pertains to an automated board-removing apparatus comprising: a ram assembly carrying spikes; and a spacer assembly configured to secure a pallet with a predetermined board of the pallet at an operable position; where the ram assembly is configured to move into a board-engaging position to enable said spikes to engage the predetermined board, and to thereafter move away from the pallet to remove the predetermined board from the pallet. 
         [0010]    In some embodiments of this aspect, the ram assembly is suspended from a ram frame. In further embodiments, a drive cylinder connected to the ram frame and the ram assembly is operable to move the ram assembly between a start position, the board-engaging position, and an end position. In certain embodiments, movement of the ram assembly between the start position, the board-engaging position, and the end position defines an arc, the board-engaging position being the lowest position of the arc. In some embodiments of this aspect, the apparatus includes means for rotating the ram assembly, such as, for example, an electric motor or a hydraulic or pneumatic cylinder. 
         [0011]    In certain embodiments, the spacer assembly includes a spacer frame and at least one spacer extending therefrom. In further embodiments, the spacer is sized to extend within said pallet and configured to reversibly expand to press against an interior of the pallet. In some embodiments, the spacer includes two parallel rail members and an expandable bladder positioned between the rail members. In further embodiments, the apparatus includes springs connecting the rail members, the springs biased to draw the rail members together. In some embodiments, the spacer includes a plurality of pads, the pads configured to transition from a retracted state to an expanded state. In certain embodiments, each pad is connected to the support frame by an actuating cylinder, whereby actuation of the cylinders transitions the pads from the retracted state to the expanded state. 
         [0012]    In some embodiments, the ram assembly further comprises a push plate, the spikes extending through the push plate. In further embodiments, the spikes are carried on a first side of the ram assembly and a rake is carried on a second side of the ram assembly. In certain embodiments, the spikes are carried on a first side and a second side of the ram assembly. 
         [0013]    Another aspect of the present invention pertains to a method of removing a board from a pallet, comprising the steps of: (a) providing a pallet; (b) providing a ram assembly movable relative to the pallet; (c) identifying the position of a board to be removed from the pallet; (d) translating the ram assembly to a position to engage the board; (e) engaging the board with the ram assembly; and (f) translating the ram assembly away from the pallet to remove the board from the pallet. 
         [0014]    In some embodiments, the ram assembly includes spikes configured to engage the predetermined board. In further embodiments, step (e) includes puncturing the predetermined board with the spikes. 
         [0015]    In some embodiments, the method includes (g) ejecting the predetermined board from the ram assembly. In further embodiments, (g) includes initially rotating the ram assembly prior to ejecting the predetermined board from the ram assembly. In certain embodiments, the spikes are attached to a first side of the ram assembly and a rake is attached to a second side of the ram assembly. In further embodiments, the method includes (h) translating the ram assembly to move the rake across the pallet. In some embodiments, the spikes are attached to a first side and a second side of the ram assembly. 
         [0016]    In further embodiments, the method includes (h) identifying the position of a second board to be removed from the pallet; (i) rotating the ram assembly to orient the second side in the direction of the pallet; (j) translating the ram assembly to a position to engage the second board; (k) engaging the second board with spikes on the second side of the ram assembly; and (I) translating the ram assembly away from the pallet to remove the second board from the pallet. 
         [0017]    In some embodiments, (g) includes ejecting the board onto a conveyor configured to translate the board away from the ram assembly. In further embodiments, (c) further comprises securing the pallet in position relative to the ram assembly. In certain embodiments, securing the pallet includes inserting a spacer into the pallet then reversibly expanding the spacer to press against the pallet. In some embodiments, expanding the spacer includes laterally expanding the spacer by inflating a bladder within the spacer. In certain embodiments, the spacer includes a plurality of pads and wherein expanding the spacer includes translating the pads relative to each other to increase their width. 
         [0018]    In certain embodiments, the translating in (d) is translating the ram assembly parallel to a longitudinal axis of the board. In further embodiments, the translating in (d) is translating the ram assembly perpendicular to a longitudinal axis of the board. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0019]      FIG. 1A  is a perspective view of a first embodiment of an apparatus for refurbishing pallets positioned in conjunction with a pallet conveyor system. 
           [0020]      FIG. 1B  is a perspective view of a pallet. 
           [0021]      FIG. 2  is a perspective view of the first embodiment shown in  FIG. 1A  with the pallet in an operable position. 
           [0022]      FIG. 3  is a perspective view of the ram support frame and the spacer support frame of the first embodiment in combination without a pallet, the board-engaging surface of the board-removal assembly carried by the ram disposed in a downward orientation and the spacers in a retracted position. 
           [0023]      FIG. 4  is a perspective view of the board-removal assembly carried by the ram shown in isolation without a pallet, with the board-engaging surface of the assembly disposed in the vertical position. 
           [0024]      FIG. 5  is a perspective view of the first embodiment showing the ram that supports and carries the board-removal assembly shown in combination with a pallet, wherein the ram is in a first start position. 
           [0025]      FIG. 6  is a perspective view of the ram support frame, with the ram in the third position after having engaged and removed a board from the pallet, the ram being rotated 90 degrees to orient the removed board toward the front of the apparatus. 
           [0026]      FIG. 7A  is a perspective view showing the spacer support frame with spacers in an expanded state.  FIG. 7B  is a perspective view showing the spacer in isolation, the spacer being in a retracted state.  FIG. 7C  is a perspective view showing the spacer in isolation, the spacer being in an expanded state. 
           [0027]      FIG. 8  is an enlarged isolated perspective view of the ram, actuating cylinders, and ram pivot arms of the invention as shown in  FIG. 6 , with the board omitted. 
           [0028]      FIG. 9  is an enlarged isolated perspective view of the board-removal assembly carried by the ram of the invention, showing the manner in which the tips of the spikes extend through slots provided in the board push plate. 
           [0029]      FIGS. 10  is a perspective view of the push plate. 
           [0030]      FIG. 11A  shows a perspective view of the ram in isolation carrying spike plates and rake plates.  FIG. 11B  shows a second side view of the ram of  FIG. 11A .  FIG. 11C  shows a first side view of the ram of  FIG. 11A . 
           [0031]      FIG. 12  is a perspective view of an individual spike plate in isolation. 
           [0032]      FIG. 13  is a perspective view of an optional rake plate in isolation. 
           [0033]      FIG. 14  is a perspective view of the ram support frame, the ram having returned back to the first position after the optional rake plates have passed across the surface of the pallet (not shown). 
           [0034]      FIGS. 15A and 15B  are perspective views of the first embodiment including a laser positioning means,  FIG. 15B  being an enlarged view of the apparatus shown in  FIG. 15A . 
           [0035]      FIG. 16  is a perspective view of the first embodiment of the apparatus shown in combination with a conveyor belt and a control system. 
           [0036]      FIG. 17A  is a front perspective view of a second embodiment of the apparatus.  FIG. 17B  is a rear perspective view of the second embodiment.  FIG. 17C  is a top plan view of the second embodiment. 
           [0037]      FIG. 18  is a top plan view of the spacer support frame of the second embodiment with the spacers in a retracted position. 
           [0038]      FIG. 19  is a perspective view of the spacer support frame with the pads removed from one spacer to show the spacer cylinders. 
           [0039]      FIGS. 20A and 20B  are perspective views of the pads of the spacer means of the second embodiment shown in isolation.  FIG. 20A  shows the pads arranged side-by-side in their retracted state and  FIG. 20B  shows the pads in a displaced arrangement in their extended or expanded state. 
           [0040]      FIG. 21  is a perspective view of the pads of the spacer means of this embodiment shown in combination with their respective drive cylinders in a retracted state. 
           [0041]      FIG. 22  is a perspective view of the spacer support frame of this embodiment with the spacers in an expanded or extended state. 
           [0042]      FIG. 23  is a perspective view of the pads of the spacer means of this embodiment shown in isolation in combination with their respective drive cylinders in an expanded state. 
           [0043]      FIGS. 24A and 24B  are partial front elevation and front perspective views, respectively, of the second embodiment showing the ram that supports and carries the board-removal assembly, wherein the ram is in the fully extended third position during a forward stroke. 
           [0044]      FIG. 25  is a partial front perspective view of the second embodiment showing the board-removal assembly in the third position during a forward stroke with the spikes facing the front of the assembly. Pads are removed from one spacer to show the spacer cylinders. 
           [0045]      FIGS. 26A and 26B  are partial front elevation and front left perspective views, respectively, of the invention showing the ram that supports and carries the board-removal assembly, wherein the board-removal assembly is in a fully retracted position after a reverse stroke. 
           [0046]      FIG. 27  is a partial front perspective view of the second embodiment showing the ram that supports and carries the board-removal assembly, wherein the board-removal assembly is in a fully retracted position during a return stroke with the ram assembly disposed in the vertical position after having engaged and removed a damaged board from the pallet and thereafter rotated 90 degrees to vertical. 
           [0047]      FIG. 28  is an partial perspective view of the mechanism coupling the ram to the drive cylinder of this invention. 
           [0048]      FIG. 29  is a perspective view of the second embodiment of the invention showing the ram assembly in the first position. 
           [0049]      FIG. 30  is a flow chart reciting a method of removing a board from a pallet using the apparatus of the first embodiment. 
           [0050]      FIG. 31  is a flow chart reciting a method of removing a board from a pallet using the apparatus of the second embodiment. 
       
    
    
     DESCRIPTION OF THE INVENTION 
       [0051]    For the purpose of promoting an understanding of the principles of the invention, reference will now be made to certain embodiments illustrated in the disclosure, and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. 
         [0052]    While the inventions have been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that the preferred embodiment has been shown and described and that changes and modifications that come within the spirit of the invention are desired to be protected. 
         [0053]    Referring now to  FIGS. 1-16 , a first embodiment of an automated apparatus  10  for refurbishing or recycling a pallet  16  is shown. As best shown in  FIG. 1B , a common pallet  16  is typically constructed in layers—a bottom layer, a top layer, a middle layer and an intermediate layer. The bottom layer  16   d  will commonly comprise a number of bottom deck boards that can either run parallel with one another with some or no spacing between each board, or some bottom deck boards can run perpendicular to other bottom deck boards to allow for spacing therebetween. The top layer  16   e  also preferably comprises a number of deck boards that typically likewise run parallel with one another. Their purpose is to provide a deck or flat platform for goods to be placed on the top deck. The top deck boards, while running parallel with one another, can likewise be arranged with some or no spacing between them. 
         [0054]    The middle layer  16   c  of the pallet is used to provide a supporting connection of the bottom deck boards  16   d  to the top deck boards  16   e , as well as vertical spacing between the top and bottom of the pallet, thereby defining open areas  16   a  and  16   b  which can accommodate the tines of a fork lift or hand truck device for transporting the pallet. The middle layer  16   c  can be composed of various types of components to join the bottom deck  16   d  to the top deck  16   e . Typically, blocks of material are used interspersed throughout the middle layer. When such blocks are used to define the middle layer, the bottom deck boards are typically fastened directly to the blocks to secure the bottom layer  16   d  to the bottom side of the middle layer  16   c . In addition, when the middle layer has such blocks, there will commonly be an additional intermediate layer  16   i  arranged between the top layer  16   e  and the middle layer  16   c . This intermediate layer  16   i  allows for the top deck boards to connect to the middle layer blocks via the intermediate layer. These intermediate boards  16   i , commonly referred to as “runners” or “stringers,” will typically run perpendicular to the top deck boards  16   e.    
         [0055]    A preferred pallet suitable for use with this invention may be wood or non-wood, and selected from the group consisting of a block pallet, a double-face pallet, a double-wing pallet, a flush pallet, a four-way stringer, a non-reversible pallet, a reversible pallet, a single-face pallet, a single wing pallet, a skid pallet, a solid deck pallet, and two-way and four-way stringer pallets. 
         [0056]    Referring now to apparatus  10 , the apparatus  10  preferably includes a support frame  12 , a bi-directional rotating ram  18  mounted on the frame  12  and driven by a drive cylinder  15 , and a spacer support frame  26 . Drive cylinder  15  may be pneumatic or hydraulic, but, in some embodiments, is preferably hydraulic. Spacer support frame  26  supports one or more spacers  28 , within which are located spacer cams or blocks  30  (see  FIGS. 7A-C  for greater detail). Apparatus  10  is usually arranged closely adjacent a conveyor  14 , which is configured for moving a pallet  16  into position in the direction of reference arrow “a” in  FIG. 1A  to receive the spacers  28  for proper alignment for the purpose of removing a damaged board or slat (for example, board  16   e ′) from the pallet. 
         [0057]    Upon the pallet  16  coming into alignment with the spacers  28 , that is, when the spacers  28  extend into the interior of the pallet shown as open areas  16   a  and  16   b  (see  FIG. 2 ), the board removal process is then initiated whereupon the spacers  28  extend or expand laterally to press or bear against the inside of the middle layer  16   c , specifically, the blocks, of pallet  16  to secure and stabilize pallet  16  and prevent its movement during the board removal process. After the spacers  28  finish their lateral expansion, spacer cams  30  lock or secure the spacers  28  in place (as will be discussed in greater detail below) in order to secure and stabilize the pallet  16 . Pallet  16  can also be secured in position and prevented from moving when engaged by ram  18  by lateral bracket  19  as best shown in  FIG. 6 . While automated apparatus  10  removes a damaged top board  16   e ′ from pallet  16 , spacers  28  secure and stabilize boards  16   d  and  16   e  and blocks  16   c  adjacent to the top board  16   e ′ being removed, thereby inhibiting adjacent boards from splitting or shifting. Lateral bracket  19  also inhibits pallet  16  from moving out of alignment with spacers  28  during the board removal process. 
         [0058]    As shown in  FIGS. 7A-7C , each spacer  28  is supported by spacer support frame  26  and comprises one or more spacer cams  30 , each comprising a fixed cam block  30   a , one or more sliding cam blocks  30   b , one or more expandable bladders  31 , one or more expandable cam bladders  33 , a series of tension springs  37  arranged adjacent the air bladders  31 , and cam springs  39  coupled to each sliding cam block  30   b . All of the aforementioned components are arranged between lateral rail members  28   a  and  28   b .  FIG. 7B  depicts a single spacer  28  in a static or retracted state, while  FIGS. 7A and 7C  depicted the spacers in an expanded state. Once the retracted spacers are properly positioned within the open spaces  16   a  and  16   b  of the pallet  16  as noted above, spacers  28  are expanded to an expanded state as shown in  FIGS. 7A and 7C  by the following process: (1) air bladders  31  are inflated, pushing lateral rail members  28   a  and  28   b  apart; (2) substantially simultaneously cam air bladders  33  are inflated to drive the sliding cam blocks  30   b  toward each other as shown by the reference arrows “b” in  FIG. 7C  in order to form a cam- or wedge-type locking engagement against fixed cam block  30   a , thereby locking the lateral members  28   a  and  28   b  in abutting engagement against the interior blocks or braces of the middle layer  16   c  of the pallet  16  to prevent its movement during the board removal process. Such a locking engagement of cam blocks  30   a  and  30   b  can be enhanced by providing a serrated surface to one of both of the cams blocks as shown in the figures to increase their frictional engagement. 
         [0059]    The spacer  28  returns from its expanded state to its retracted state by deflation of the bladders  31  and cam air bladders  33 . The tension springs  37  are biased to draw the rail members  28   a  and  28   b  together and the cam springs  39  are biased to draw the sliding cam blocks  30   b  away from the fixed cam block  30   a . Once the opposing force of the inflated bladders  31  and  33  is removed, the springs  37  and  39  return the spacer to its retracted state. 
         [0060]    Upon the control system detecting there is no further movement in the sliding cam blocks  30   b , thereby indicating the spacer is displaced at its maximum point of expansion and is locked or fully engaged with the pallet, the control system then activates the ram  18  to initiate the board removal process. Upon activation, ram  18  moves from its first or ready position shown in  FIGS. 1A ,  2 ,  3 , and  5 , and begins a forward stroke or movement to engage a pre-selected pallet board  16   e ′ with the board removal assembly  20  carried by ram  18 . 
         [0061]    Board removal assembly  20  preferably includes a push plate  21  (see  FIGS. 9 and 10 ), air bags or bladders  23 , and a plurality of spikes  22  shown here as fixed on one or more spike plates (see  FIGS. 11A-C  and  12 ). Optionally, a rake  34 , shown here as fixed on one or more rake plates, can also be employed as shown in  FIGS. 11A-C  and  13  to be carried upon assembly  20 . The spikes comprise a plurality of angled teeth or spikes configured to removably engage a single slat or board  16   e ′ of the pallet as described herein during a first stroke of the ram  18 . Referring again to  FIGS. 9 and 10 , the spikes  22  extend through slots  27  in the push plate  21 . The air bags  23  are configured to fit between the push plate  21  and the ram  18 , on the same side of the ram as the spikes  22 . Inflation of the air bags  23  forces the push plate  21  outward and away from the ram  18 , effectively retracting the spikes  22  through the slots  27  provided in the push plate  21 . Springs  25  are attached to the push plate  21  and are biased to return the push plate  21  to its original state upon deflation of the air bags  23 . 
         [0062]    After the ram  18  has completed its forward stroke to a point of maximum displacement, ram  18  can be rotated by cylinder  24  (see  FIG. 8 ) to position the optional rake plates  34  facing downwardly, in the direction of the pallet, whereupon the rakes  34  then pass back over the pallet surface to remove any remaining fasteners (nails, staples, etc.) during the ram&#39;s reverse return stroke to its first ready or home position. 
         [0063]    Ram  18  is configured to translate from a first or ready position as shown in  FIGS. 1A ,  2 ,  3 , and  5  laterally (and slightly downwardly in an arc-like path due to the pendulum-like pivoting action of ram pivot arms  18   a  and  18   b ) to a second, board-engaging position to engage the slat or board  16   e ′ with the assembly  20 . After the completion of the forward stroke by ram  18  (see  FIG. 6 ), ram  18  is rotated 90 degrees by rotation means  24 , in this embodiment, a pneumatic or hydraulic cylinder configured to rotate the ram  18 , so that the spike plates  22  and the board push plate  21  are facing towards the front of the apparatus  10 , as shown in  FIG. 6 . Board push plate  21  is then activated by air being introduced into airbags  23  carried by assembly  20  to eject the damaged board from the assembly  20 . Before the rotating ram  18  begins to reverse its original path, sensors facing towards the board push plate confirm that the damaged board is in fact ejected cleanly from the assembly  20  and generate a signal to the control system that the ram  18  can proceed in a reverse path. 
         [0064]    During the reverse stroke of ram  18 , optional rake plates  34  carried by assembly  20  can scrape across the open surface of the pallet where the removed board had been located in order to remove any free standing fasteners, such as nails or screws. When the ram  18  return stroke has been completed, as shown in  FIG. 14 , the cylinder  24  will then reverse the 90-degree rotation that it previously performed at the end of the ram&#39;s forward stroke, which will reset the ram  18  back into its first or ready home position with spike plates  22  facing downwardly. 
         [0065]    In operation, once the board  16   e ′ is engaged, the ram  18  is configured to be driven by drive cylinder  15  from the second board-engaging position shown in  FIG. 16  (where ram supporting arms  18   a  and  18   b  are substantially vertical) to a third removal position shown in  FIG. 6 , wherein ram  18  has moved further laterally away from its home or ready position but also slightly upwardly as shown due to the pendulum—like pivoting action of ram supporting arms  18   a  and  18   b , in order to completely remove and separate the board  16   e ′ from the pallet  16  by spike plates  22  physically puncturing and engaging the board  16   e ′ and then disengaging the board  16   e ′ from the pallet by a mechanical shearing or pulling action acting on the board  16   e ′, which is now firmly secured or affixed to spike plates  22 , caused by the lateral and upward movement of ram  18  away from the pallet  16 . 
         [0066]    Once the ram  18  has removed and separated the board from the pallet, the ram  18  is rotated 90 degrees by the rotation cylinder  24  to a vertical position as shown in  FIG. 6 . At that point the removed board is disengaged or ejected from the assembly  20  of ram  18  by the inflation of airbags  23 , which acts to push the push plate  21  outwardly, which in turn pushes and ejects the board from the spikes  22  that extend through the push plate  21 . In some embodiments, the ejected board then drops onto a conveyor belt  40 , as shown in  FIG. 16 , to be carried away from the apparatus. 
         [0067]    In some embodiments, a laser  48  is mounted to the frame  12  as shown in  FIGS. 15A and 15B . The laser  48  is configured to identify when the pallet and the selected board to be removed is located in the proper position, at which point the board removal process is initiated and the pallet is secured by spacers  28  and bracket  19 , and ram  18  is activated by the control system to initiate the board removal process. In some embodiments, the laser  48  emits a visible beam aligned with the direction of travel of the ram  18 , and an operator positions the pallet  16  onto the spacers  28  such that the beam generally falls on the midline of the board  16   e ′ to be removed. 
         [0068]    In some embodiments, the apparatus  10  includes a sensor for detecting when the ram has completed a forward or a reverse stroke. For example, contact sensors may be positioned on the frame  12  such that the ram  18  contacts the sensors when disposed in the first and third positions. Activation of the contact sensors indicates to the control system that no further extension or retraction of the drive cylinder  15  is necessary. 
         [0069]    A second embodiment of an automated apparatus  110  for refurbishing or recycling a pallet  16  is shown and described hereinafter in connection with  FIGS. 17-29 . More particularly,  FIGS. 17A ,  17 B, and  17 C show left front perspective, left rear perspective, and top plan views, respectively, of the apparatus  110 . Apparatus  110  includes a support frame  112  intended to be arranged closely adjacent with a conveyor (not shown in  FIG. 17  for clarity) in a fashion substantially similar to apparatus  10  shown and described in connection with  FIGS. 1-16  above. Apparatus  110  further comprises a bi-directional rotating ram  118  mounted on frame  112  and a spacer support frame  126 . Ram  118  is rotatingly driven by a motor  124 , and is laterally driven to and fro by drive cylinder  115  coupled to frame  112 . Drive cylinder  115  can be pneumatic or hydraulic. Motor  124  is optionally an electric motor. Spacer support frame  126  supports one or more spacer means  128 . 
         [0070]    As discussed above in connection with  FIGS. 1-16 , in operation a conveyor is preferably configured for moving the pallet to be worked upon into position by feeding the pallet onto the spacers  128  for proper alignment for the purpose of removing a damaged board or slat from the pallet. Upon the pallet coming into alignment with the spacers  128 , whereupon the spacers extend into the interior of the pallet (open areas  16   a  and  16   b  in  FIG. 1B ), the spacers  128  extend or expand laterally to press or bear against the inside portions of the pallet in order to secure and prevent movement of the pallet during the board removal process. 
         [0071]    Each spacer  128  may include a pair of cam-shaped pads or blocks  130   a ,  130   b , each of which is coupled to a respective spacer cylinder  132   a ,  132   b  for moving each pad  130  to and fro. Cylinders  132   a ,  132   b  may be pneumatic or hydraulic cylinders. In a first home or steady position as shown in  FIGS. 18 ,  19 ,  20 A and  27 , pads  130   a ,  130   b  are retracted and arranged immediately side-by-side to define a narrow retracted state for spacer means  128  in order to receive the pallet. For illustration purposes,  FIG. 19  shows a pair of spacer means  128  with one pair including pads  130   a ,  130   b  and the other such pair not including pads  130  in order to readily depict the manner in which each cylinder  132  is connected to a respective pad  130  on one end and to the support frame  126  at its opposite end. All of the aforementioned components are arranged and supported upon lateral rail members  126   a  and  126   b  of support frame  126 . 
         [0072]    More particularly,  FIG. 21  shows in isolation a pair of pads  130   a ,  130   b  in a retracted state coupled to their respective spacer cylinders  132   a ,  132   b . Each cylinder  132  may be attached at its first end  132   c  to either rail member  126   a  or  126   b  of support frame  126  (as shown in  FIG. 18 ) and at its second (opposing) end  132   d  to anchor post  131  of a pad  130 . Each pad  130   a ,  130   b  has at least one angled lateral side  130   a ′,  130   b ′ (as best shown in  FIG. 20B ), such that when each pad is in proper position and connected to its respective spacer cylinder  132 , the angled lateral sides  130   a ′,  130   b ′ face each other in an opposing manner. In operation, referring now to  FIG. 22 , when pad  130   a  is driven in the direction of reference arrow a in  FIG. 22  and pad  130   b  is driven in the opposite direction of reference arrow b in  FIG. 22  by their respective cylinders  132   a ,  132   b , the angled sides  130   a ′ and  130   b ′ slidingly engage and bear against each other and, due to their angled shape, act in a camming fashion to push outwardly the wider end of each pad  130   a ,  130   b  in the direction of reference arrows a′ and b′, respectively. This slight swing-out action of the wide end of each pad causes the pads to increasingly engage the interior portions of the pallet to releasably secure the pallet in position. 
         [0073]    As shown in  FIGS. 20A ,  20 B,  21 , and  23 , in order to keep each pad  130   a  in proper sliding alignment with each opposing pad  130   b , one pad is provided with a slot  133  in its angled lateral side  130   a ′,  130   b ′ and the opposing pad is equipped with a side post-and-tab  135  that extends from its angled lateral side through slot  133  and travels to and fro within slot  133 . 
         [0074]    Once the pallet has been properly positioned within apparatus  110 , cylinders  132  are activated by the control system to drive pads  130   a ,  130   b  in opposing directions, as shown in  FIGS. 20B ,  22  and  23 , in order to widen spacers  128  to engage, secure and stabilize the pallet within apparatus  110 . The pallet can further be secured in position and prevented from moving when engaged by ram  118  by lateral brackets  119  as shown best in  FIG. 17A . Lateral brackets  119  also inhibit the pallet  16  from moving out of alignment with spacers  128  during operation. Once spacers  128  secure the pallet in position, the control system then activates the ram  118  and board removal assembly  120  to initiate the board removal process. 
         [0075]    For purposes of the following discussion, reference may at times be made to the mode of operation of apparatus  10  as described above in connection with  FIGS. 1-16  as the mode of operation of apparatus  110  is similar. It will be pointed out throughout the discussion, however, where the operation or structure of apparatus  110  differs from that of apparatus  10 . 
         [0076]    Once the pallet is secured in position, the ram  118  is activated by the control system to move from a first or ready position, as shown in  FIG. 29 , and begin a forward stroke or movement to engage a pre-selected board on the pallet via board removal assembly  120  carried by ram  118 . The primary differences between assembly  20  discussed above and  120  discussed herein is that assembly  120  does not include rake plates  34 , and that assembly  120  is equipped with spike plates  122  on opposing first and second sides of the assembly whereas assembly  20  has spike plates  22  on only a first side and a rake  34  on a second side perpendicular to the first side. Because it carries spike plates  122  on opposing sides, assembly  120  further carries a second push plate and air bladders disposed on that opposing side of assembly  120  as well in order to eject the removed board from that side of the assembly as needed. More particularly, board removal assembly  120  can include a pair of push plates  121   a  and  121   b , air bladders or bags  123   a  and  123   b , and spike plates  122   a  and  122   b  carried on opposing sides of assembly  120 . 
         [0077]    The spike plates  122  carried by assembly  120  are configured to removably engage a single slat or board of the pallet as described herein during a first forward stroke of the ram  118 . One may discern that the ram  118  has just finished its forward stroke in the direction of reference arrow a in  FIG. 24A  by the direction in which the angled teeth or spikes of the lower spike plates  122   a  are facing. More specifically, if the spikes are angled or pointing in the right direction, such as they are in  FIGS. 24A and 24B , then the ram is poised to move, is moving, or has moved to the right in a forward stroke. Conversely, if the angled spikes of the lower spike plates nearest the pallet are pointing to the left, then ram  118  is poised to move, is moving, or has moved in its second reverse stroke returning to its ready first position (as shown in  FIGS. 26A and 26B ). While automated apparatus  110  removes a damaged top board from the pallet, spacers  128  secure and stabilize boards  16   d  and  16   e  and blocks  16   c  (see  FIG. 1B ) adjacent to the top board  16   e ′ being removed, thereby inhibiting the pallet&#39;s adjacent boards from splitting or shifting. 
         [0078]    As shown in  FIGS. 24A and 24B , after ram  118  and assembly  120  have completed a forward stroke to a point of maximum displacement, ram  118  and assembly  120  are positioned at a point of maximum distance away from cylinder  115  carrying abuttingly against its lower side a removed pallet board (not shown in  FIGS. 24A ,  24 B, or  25  for clarity). At this point ram  118  an assembly  120  can be rotated 90 degrees by motor  124  as shown in  FIG. 25  to position the damaged board forward-facing in order for the removed board to be ejected from the ram  118  in the same manner as described in connection with ram  18  and  FIGS. 1-16  above, that is, air bladders  123   a  carried within assembly  120  are pressurized, which in turn push or urge push plate  121   a  outwardly. Plate  121   a  in turn urges the pallet board outwardly as well, thereby increasingly dislodging and disconnecting the board from the teeth of the spike plates  122   a . Optionally, the removed board may thereafter be dropped onto a conveyor, such as conveyor  40  shown in  FIG. 16 , in order to be carried away from apparatus  110 . 
         [0079]    Once the removed board is ejected from the ram  118 , the ram may be rotated another 90 degrees so that the opposite-facing spike plates  122   b  are now facing downwardly and spike plates  122   a  are now facing upwardly, each set of plates now being oriented 180 degrees from their previous position during the first forward stroke. In this instance, the teeth of the lower spike plates  122   b  are now pointing to the left in  FIGS. 26A and 26B . The ram  118  is then activated to proceed in a reverse return stroke to engage and remove another board from the same or another pallet as it returns to its first ready or home position as shown in  FIG. 29 . 
         [0080]    Referring now to  FIGS. 26A and 26B , after ram  118  and assembly  120  have completed a return stroke by the retraction of cylinder  115  to a point of minimum displacement, ram  118  and assembly  120  are positioned at a point closest to cylinder  115  carrying abuttingly against its lower side a removed pallet board (not shown in  FIGS. 26A  or  26 B for clarity). At this point ram  118  an assembly  120  can again be rotated 90 degrees, as shown in  FIG. 27 , by motor  124  to position the damaged board forward-facing (see  FIG. 14A  for example) in order for the removed board to be ejected from the ram  118  in the same manner as described above, that is, air bladders  123   b  carried within assembly  120  are pressurized, which in turn push or urge push plate  121   b  outwardly. Plate  122   b  in turn urges the pallet board outwardly as well, thereby increasingly dislodging and disconnecting the board from the teeth of the spike plates  122   b . Again, the removed board may thereafter optionally be dropped onto a conveyor, such as conveyor belt  40  shown in  FIG. 16 , in order to be carried away from apparatus  110 . 
         [0081]    Once the removed board is ejected from the ram  118 , the ram may be rotated another 90 degrees (or alternatively 270 degrees in the opposite direction in order to avoid tangling or causing undue stress on any pneumatic or hydraulic line(s) that lead to any drive cylinder or air bladder) so that the opposite-facing spike plates  122   a  are again facing downwardly and spike plates  122   b  are again facing upwardly, each set of spike plates oriented 180 degrees from their previous position during the second return stroke. In this instance, the teeth of the lower spike plates  122   a  are be pointing to the right as shown in  FIGS. 24A and 24B . The ram  118  can then activated to proceed in another forward stroke to engage and remove another board from the same or another pallet in the same manner as described above. 
         [0082]    As noted above with respect to ram  18 , ram  118  is configured to translate from a first or start position to a second board-engaging position in the direction laterally (and slightly downwardly along an arc-like path due to the pendulum-like pivoting action of ram pivot arms  118   a  and  118   b ) as shown in  FIG. 17A  in order to engage the pallet slat or board to be removed with the removal assembly  120 . Once the pallet board is engaged, the ram  118  is configured to be driven by drive cylinder  115  from the second board-engaging position, where ram pivot arms  118   a  and  118   b  are substantially vertical, to a third, fully extended position shown in  FIGS. 24A and 24B , wherein the ram  118  has moved further laterally away from its ready position but also slightly upwardly as shown due to the pendulum—like pivoting action of ram support arms  118   a  and  118   b . The assembly  120  moves back-and-forth in a generally pendulum fashion, defining an arc, in order to remove and separate the board from the pallet by the spike plates  122  physically puncturing and engaging the pallet board being removed. 
         [0083]    As noted above, the pallet board is disengaged from the pallet by a mechanical shearing or pulling action acting on the board, which is now secured or affixed to the spike plates  122  carried by assembly  120 , caused by the lateral and upward movement of the ram  118 . 
         [0084]    Before the ram  118  begins to reverse its path in either a return stroke or another forward stroke, sensors facing towards the board push plate  121  will observe whether the removed boarded has in fact been ejected from the removal assembly  120 , and then indicate to the control system that ram  118  can proceed. By effecting the removal of a board in each of its forward and reverse strokes, as compared to the embodiment of apparatus  10  shown and described in connection with  FIGS. 1-16  above, which removes a board only during the forward stroke of ram  18  of apparatus  10 , the cycle time of apparatus  110  is generally shorter than that of apparatus  10 . 
         [0085]    The first embodiment suspends the ram  18  from the frame  12  using single pivot arms  18   a  and  18   b  attached at either end of the assembly  20 , as shown most clearly in  FIG. 8 . In contrast, the second embodiment suspends the ram  118  using a pair of pivot arms  118   a  and  118   b  attached at either end of the ram  118 , as shown most clearly in in  FIG. 17A . Use of a pair of pivot arms  118   a  and  118   b  at either end of the ram  118  provides greater torsional support to the entire structure of apparatus  110  and the support of ram  118 , as compared to the single ram pivoting support arms  18   a  and  18   b  used in the first embodiment. 
         [0086]      FIG. 28  is an enlarged isolated view of the first end coupling by which ram  118  is coupled to drive cylinder  115  (not shown) via a drive piston  115   a  extending from the drive cylinder  115 . The pair of pivoting support arms  118   a  are hingedly connected at their upper ends to the upper vertical cross member  112   a  of support frame  112 , as shown in other figures, and likewise hingedly coupled to block member  131  at  118   c  at their lower end. Clearly observable in  FIG. 28  is one of the plurality of tension springs  125  that connect opposing push plates  121   a  and  121   b  of assembly  120  to each other and bias the push plates  121   a  and  121   b  together. Block member  131  also rotatingly secures a drive axle  123  coupled to ram  118 , the drive axle  123  also coupled to motor  124  (not shown in this figure). Block member  131  is also hingedly coupled to the distal end of piston  115   a  at  114 . 
         [0087]    In some embodiments, the apparatus  10 ,  110  is automatically controlled by a programmable logic controller through a control input  50 ,  150 . In other embodiments, the apparatus is automatically controlled by a general purpose computer loaded with appropriate programming and in electronic communication with the apparatus. 
         [0088]    In some embodiments, this invention pertains to a method of automatically removing a damaged board or slat from a pallet, including the steps of: 
         [0089]    (a) providing a pallet; 
         [0090]    (b) providing a ram assembly movable relative to the pallet, the ram assembly connected to a frame; 
         [0091]    (c) identifying the position of a board to be removed from the pallet; 
         [0092]    (d) translating the ram assembly to a position to engage the board; 
         [0093]    (e) engaging the board with the ram assembly; and 
         [0094]    (f) translating the ram assembly away from the pallet to remove the board from the pallet. 
         [0095]    The method can further comprise (g) ejecting the predetermined board from the ram assembly. Step (g) may include initially rotating the ram assembly prior to ejecting the predetermined board from the ram assembly. Step (g) may include ejecting the board onto an optional conveyor configured to translate the board away from the ram assembly. 
         [0096]    In certain embodiments, such as the disclosed first embodiment, the spikes are attached to a first side of the ram assembly and a rake is attached to a second side of the ram assembly. When the method is used with the first embodiment or similar embodiments of the apparatus, the method may include step (h), translating the ram assembly to move the rake across the pallet. 
         [0097]    In certain embodiments, such as the disclosed second embodiment, the spikes are attached to a first side and a second side of the ram assembly. 
         [0098]    When the method is used with the second embodiment or similar embodiments of the apparatus, the method may include (h) identifying the position of a second board to be removed from the pallet; (i) rotating the ram assembly to orient the second side in the direction of the pallet, in other words, downwards; (j) translating the ram assembly to a position to engage the second board; (k) engaging the second board with spikes on the second side of the ram assembly; and (I) translating the ram assembly away from the pallet to remove the second board from the pallet. 
         [0099]    In some embodiments, step (c) includes securing the pallet in position relative to the ram assembly. In some embodiments, such as the disclosed first and second embodiments, securing the pallet includes inserting a spacer into the pallet then reversibly expanding the spacer to press against the pallet. In some embodiments, such as the first embodiment, expanding the spacer includes laterally expanding the spacer by inflating a bladder within the spacer. In certain embodiments, such as the second embodiment, the spacer includes a plurality of pads and wherein expanding the spacer includes translating the pads relative to each other to increase their width. 
         [0100]    The translating of the ram in step (d) is translating the ram assembly parallel to a longitudinal axis of the board in the disclosed first and second embodiments. In other embodiments, the translating in (d) is translating the ram assembly perpendicular to a longitudinal axis of the board. 
         [0101]      FIG. 30  describes a method of removing a board from a pallet in further detail using the apparatus  10  of the first embodiment, the method including: 
         [0102]      200 —loading the pallet  16  onto the spacers  28 , where initially the ram  18  is at the first position, the spacers  28  are closed or retracted, cam blocks  30   a  and  30   b  are disengaged, drive cylinder  15  is retracted, rotation cylinder  24  is retracted, ram  18  is positioned with the spikes  22  facing downwardly, and all air bladders  31  and  33  and air bags  23  are deflated; 
         [0103]      202 —securing the pallet in position by expanding the spacers  28  by inflating the bladder  31  and cam bladder  33 , thereby reversibly locking the spacers  28  into their extended state by engaging the cam blocks  30   a  and  30   b;    
         [0104]      204 —translating the ram  18  from the first position, through the second position, to the third position by extending the drive cylinder  15 , the ram  18  engaging the board  16   e ′ to be removed with the carried spikes  22  in the second position and removing the board  16   e ′ in translating to the third position; 
         [0105]      206 —rotating the ram  18  90 degrees to orient the spikes  22  toward the front of the apparatus  10  and orient the rake  34  toward the pallet  16 , the ram  18  being rotated by operation of the rotation cylinder  24 ; 
         [0106]      208 —ejecting the board  16   e ′ by inflating the air bags  23  to operate the push plate  21  (the board  16   e ′ is ejected onto the conveyor belt  40 , if the optional conveyor belt is present). 
         [0107]    Optional additional steps of this method include: 
         [0108]      210 —retracting the push plate  21  by deflating the air bags  23 , whereupon springs  30  facilitate retraction of the push plate  21 ; 
         [0109]      212 —translating the ram  18  from the third position, through the second position, to the first position by retracting the drive cylinder  15 , the ram  18  moving the rake  34  across the pallet  16  while transitioning through the second position; 
         [0110]      214 —rotating the ram  18  90 degrees to orient the spikes  22  downward, the ram  18  being rotated by operation of the rotation cylinder  24 ; 
         [0111]      216 —retracting the spacers  28  by deflating the bladder  31  and cam bladder  33 , the tension springs  37  drawing the rail members  28   a  and  28   b  together and the cam springs  39  disengaging and separating the cam blocks  30   a  and  30   b  (this step may occur after or substantially simultaneously to step  214 ); 
         [0112]      218 —restarting at step  200  by selecting a second board for removal from pallet  16  or by removing the pallet  16  and providing a new pallet with a board for removal, or, alternatively, ending the process. 
         [0113]      FIG. 31  describes a method of removing a board from a pallet in further detail using the apparatus  110  of the second embodiment, the method including: 
         [0114]      300 —loading the pallet  16  onto the spacers  128 , where initially the ram  18  is at the first position, the spacers  128  are closed or retracted, drive cylinder  115  is retracted, ram  118  is positioned with the spikes  122   a  facing downwardly, and air bags  123  are deflated; 
         [0115]      302 —securing the pallet  16  in position by expanding the spacers  128  by extending spacer cylinders  132 , thereby sliding pads  130  into their extended state; 
         [0116]      304 —translating the ram  118  from the first position, through the second position, to the third position by extending the drive cylinder  115 , the ram  118  engaging the board  16   e ′ to be removed with the carried spikes  122   a  in the second position and removing the board  16   e ′ in translating to the third position; 
         [0117]      306 —rotating the ram  118  90 degrees to orient the spikes  122   a  toward the front of the apparatus  110 , the ram  118  being rotated by operation of the motor  124 ; 
         [0118]      308 —retracting the spacers  128  by retracting spacer cylinders  132 , thereby sliding pads  130  into their retracted state (this step may occur after or substantially simultaneously with step  306 ); 
         [0119]      310 —ejecting the board  16   e ′ by inflating the air bags  123  to operate the push plate  121   a  (the board  16   e ′ is ejected onto a conveyor, if the optional conveyor is present). 
         [0120]    Optional additional steps of this method include: 
         [0121]      312 —retracting the push plate  121   a  by deflating the air bags  123   a , whereupon springs  125  facilitate retraction of the push plate  121   a;    
         [0122]      314 —rotating the ram  118  90 degrees to orient the spikes  122   b  downward, the ram  118  being rotated by operation of the motor  124 ; 
         [0123]      316 —positioning a second board to be removed by either repositioning the pallet  16  on the spacers  128  or removing the pallet  16  and loading a new pallet on the spacers  128 , the repositioned pallet  16  or new pallet collectively referred to as the current pallet; 
         [0124]      318 —securing the current pallet in position by expanding the spacers  128  by extending spacer cylinders  132 , thereby sliding pads  130  into their extended state; 
         [0125]      320 —translating the ram  118  from the third position, through the second position, to the first position by retracting the drive cylinder  115 , the ram  118  engaging the board to be removed from the current pallet with the carried spikes  122   b  in the second position and removing the board in translating to the third position; 
         [0126]      322 —rotating the ram  118  90 degrees to orient the spikes  122   b  toward the front of the apparatus  110 , the ram  118  being rotated by operation of the motor  124 ; 
         [0127]      324 —retracting the spacers  128  by retracting spacer cylinders  132 , thereby sliding pads  130  into their retracted state (this step may occur after or substantially simultaneously with step  322 ); 
         [0128]      326 —ejecting the board by inflating the air bags  123   b  to operate the push plate  121   b  (the board is ejected onto the conveyor, if the optional conveyor is present); 
         [0129]      328 —retracting the push plate  121   b  by deflating the air bags  123   b , whereupon springs  125  facilitate retraction of the push plate  121   b;    
         [0130]      330 —rotating the ram  118  90 degrees to orient the spikes  122   a  downward, the ram  118  being rotated by operation of the motor  124 ; 
         [0131]      332 —restarting at step  300  by selecting an additional board for removal from the current pallet or by removing the current pallet and providing a new pallet with a board for removal, or, alternatively, ending the process. 
         [0132]    In some embodiments, the apparatus  10 ,  110  includes optional safety features to protect users from accidental contact with the moving parts of the apparatus or from splinters from pallets. In certain embodiments, the safety features includes guards, covers, mesh screens, gratings, or other structures configured to prevent contact between the user and the moving parts of the apparatus. In further embodiments, the frame includes a hinged plexiglass cover attached to the frame. The user may open the hinged cover to access the ram  18 ,  118 , for example, to pick splinters off of the spike plates  122 . Preferably, a kill switch is connected to the hinged cover such that opening the cover automatically terminates all movement of the apparatus  10 ,  100 . In some embodiments, the control system includes two buttons which must be simultaneously depressed by the operator while the apparatus  10 ,  110  is in operation. By requiring that the operator&#39;s hands be on the buttons, the operator is prevented from reaching into the apparatus  10 ,  110 . 
         [0133]    While illustrated examples, representative embodiments and specific forms of the invention have been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive or limiting. The description of particular features in one embodiment does not imply that those particular features are necessarily limited to that one embodiment. Features of one embodiment may be used in combination with features of other embodiments as would be understood by one of ordinary skill in the art, whether or not explicitly described as such. Exemplary embodiments have been shown and described, and all changes and modifications that come within the spirit of the invention are desired to be protected.