Abstract:
A watercraft storage system, a ‘wishbone’ or U-shaped cradle, liftable and rotatable by an overhead crane, comprises adjustable air filled hull supports to either side of a boat hull and a keel support toward the stem of the watercraft. The cradle central opening clears a cantilever storage rack support beam assembly allowing the watercraft to be lowered onto or raised from the cantilever storage rack support beam assembly by an overhead traveling crane. To substantially reduce any longitudinal swaying of the cradle and watercraft during raising and lowering, a system of diagonal anti-sway bracing cables that automatically retract and extend is employed. In the preferred embodiment, the cradle is lowered into a water-filled channel within the storage structure to re-float the watercraft. A watercraft to be stored can be brought into the channel which contains alignment means to accurately position the watercraft over the cradle.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    The field of the invention pertains to large-scale warehouse and boat storage facilities and, in particular, to the out-of-water storage of motor yachts. 
         [0002]    For storage and repair, motor yachts of about 30 to 80 feet in length are typically hauled from the water in slings suspended from wheeled gantry cranes or in cradles riding on marine railways. Larger yachts require marine railways or dry docks. Smaller yachts utilize trailers towable behind vehicles—usually trucks. 
         [0003]    Powerboats and yachts above about 25 feet in length typically are stored outdoors on trailers or cradles. On occasion, they are stored on wooden blocks and supports. Small boats below about 20 feet in length are now often stored in warehouses on racks. The small boats are placed in, or removed from, the racks with forklift trucks (“hi-lo&#39;s”). Such trucks are inadequate for larger boats and yachts for a variety of reasons. 
         [0004]    Since indoor warehousing of a wide variety of other objects up to and including the size of automobiles has become common, there has been some development of more convenient and safer warehousing for small boats. Illustrative of such warehousing is U.S. Pat. No. 6,007,288 wherein the warehouse is equipped with a traveling overhead crane having a specialized cradle to lift a boat. The boat racks comprise frame assemblies to support rack assemblies having cantilever beams to support the boats. While practical for small boats, such a warehousing system is not practical for large powerboats and yachts. 
         [0005]    U.S. Pat. No. 3,786,942 discloses an overhead traveling crane for carrying boats in suspended slings. The suspended slings descend from a first frame that is carried by a second frame in direct suspension from the traveling crane. The first frame is movable horizontally and remains with the stored boat in a rack. 
         [0006]    U.S. Pat. Pub. No. 2002/0176767 discloses a rotatable forklift that travels on rails into and out of the storage area to place boats in storage racks. This design allows relatively low warehouses with low doors to be used. 
         [0007]    Japanese Pat. Pub. No. 2-183055 and No. 2-241891 disclose a relatively low tower for lifting a boat from the water or a trailer and transferring the tower and boat to a second lift where the tower and boat are lifted to a storage location in a rack. The boat is supported on a frame that is moved into, or retrieved from, the storage location. 
         [0008]    French Pat. Pub. No. 2552411 discloses an overhead traveling crane with a telescopic retrieval device for lifting boats from underneath and depositing them in racks for storage. 
         [0009]    U.S. Pat. No. 4,190,013 discloses an overhead traveling crane with a rotator and a telescopic frame hanging therefrom to lift relatively small boats to storage locations. U.S. Pat. No. 6,162,003 discloses a honeycomb cell-like storage configuration that is particularly directed to sailing yachts with deep keels and substantial draft. The individual boats are supported on individual cradles that, in turn, slide or roll into individual cells. 
         [0010]    While suitable for small watercraft storage, the devices of the prior art are not practical for the storage and retrieval of large power yachts weighing many tons and worth hundreds of thousands, and sometimes millions, of dollars. 
       SUMMARY OF THE INVENTION 
       [0011]    This application discloses further improvements on the watercraft storage systems disclosed in U.S. Pat. No. 6,007,288 and International Publication No. WO 2005/073074 A2, which are incorporated herein by reference. In particular, the new improvements are directed to the storage of boats lying in size and weight between the boats contemplated in the patent, and publication just above but these improvements are not necessarily limited thereto. 
         [0012]    The new improvements comprise a new U-shaped or “wishbone” cradle that better supports a boat and allows easy placement and retrieval of a boat into and from a cantilever storage rack. The system as a whole is improved by a channel within the storage structure fitted with features for alignment of a boat therein to quickly facilitate placement of a boat on a cradle. The cradle provides full support of the keel adjacent the stern and full support of the hull to either side of the cradle central opening and well ahead of the boat center of gravity. 
         [0013]    Further new improvements comprise components of the anti-sway cable system that diagonally braces the suspended cradle and any boat thereon. The diagonal bracing cables suppress longitudinal sway which must be substantially prevented as the cradle is raised, lowered, translated horizontally, or rotated. Each of the diagonal bracing cables shorten or lengthen as the cradle is raised or lowered while maintaining proper tension to prevent sway. The proper tension is provided by a rotatable drum upon which the cables wind and unwind. The rotatable drum is preferably controlled by a dynamic brake and motor connected thereto. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]      FIG. 1  is a plan view of the boat storage facility showing a typical level of boat storage; 
           [0015]      FIG. 2  is a lateral elevation view of the boat storage facility; 
           [0016]      FIG. 3  is a longitudinal elevation view of the boat storage facility from within the gallery; 
           [0017]      FIG. 4  is a partial perspective view of the water channel extending within the boat storage facility; 
           [0018]      FIG. 5  is a plan view of the water channel of  FIG. 4 ; 
           [0019]      FIG. 6  is a perspective schematic view of the boat hoisting apparatus; 
           [0020]      FIG. 7  is a perspective view of the new boat cradle for the system; 
           [0021]      FIG. 8  is a plan view of the boat cradle of  FIG. 7 ; 
           [0022]      FIG. 9  is a bow end elevation of the boat cradle of  FIG. 7 ; 
           [0023]      FIG. 10  is a side elevation of the boat cradle of  FIG. 7 ; 
           [0024]      FIG. 11  is a plan view of the boat cradle in position to place or retrieve a boat from a storage location; 
           [0025]      FIG. 12  is a side elevation of the boat cradle in position just above the boat support of a storage location; 
           [0026]      FIG. 13  is a bow end elevation of the boat cradle in position just above the boat support of the storage location. 
           [0027]      FIG. 14  is a plan view showing the location of a boat on the cradle but in position for storage; 
           [0028]      FIG. 15  is a side elevation showing the location of a boat on the cradle but in position for storage; 
           [0029]      FIG. 16  is a stern end elevation showing the location of a boat on the cradle but in position for storage; 
           [0030]      FIG. 17  is a detail of the cradle cushion supports for the boat amidships; 
           [0031]      FIG. 18  is a perspective view of the anti-sway bracing system from above the traveling overhead crane; 
           [0032]      FIG. 19  is a perspective view of the anti-sway bracing system from below the traveling overhead crane; 
           [0033]      FIG. 20  is a close-up perspective view of the cable and pulley system from below the traveling overhead crane; 
           [0034]      FIG. 21  is an underneath schematic plan view of the drums, cables and pulleys at the top of the anti-sway bracing system; and 
           [0035]      FIG. 22  is an overhead perspective schematic view of the anti-sway bracing cables and pulley system. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0036]    Illustrated in  FIG. 1  is a plurality of racks  10  to either side of a central gallery  12  for storage of a plurality of boats  14  all inside a substantial structure  16 . The structure  16  is located adjacent a canal, stream or other body of water whereby a channel  18  can lead into the structure gallery  12 . There may be tie-up locations  20  on walkways  22  outside the structure. Beyond the channel  18  are a hull washing and drying station  24  and a cradle adjusting station  26  both in the gallery  12 . Within the channel  18  is a cradle and boat raising and lowering location  28  in which the boats&#39; position is variable depending on the length and center-of-gravity of the boat. 
         [0037]    Referring to  FIGS. 2 and 3 , there are four levels of boat storage racks  10  totaling  128  racks for boats; however, more or less total racks can be accommodated by changing the length or height of the structure  16 . Supported above the gallery  12  is a traveling overhead crane  30  movable the length of the structure above the gallery and racks  10 . Suspended on a plurality of cables  32  is a specially shaped boat cradle  34  and boat  36  that can be lowered into or raised from the channel  18  at location  28 . Once above the gallery  12  floor  38 , a rotator  40  on the traveling crane  30  allows the cradle  34  and boat  36  to be rotated 90° to either side for placement on a rack  10 . With the boat  36  and cradle  34  rotated 90°, the traveling crane  30  can move longitudinally and laterally to the position shown in dashed outline  42  and put the cradle and boat in position for placement on a rack  10 . 
         [0038]    In  FIGS. 4 and 5 , the channel  18  is equipped with several important features for moving a boat and positioning a boat properly in the cradle  34 . As a boat  36  is towed bow first into the channel  18  by a winch  44  and cable  45 , the boat keel engages a V-roller  46  and a second V-roller  48  mounted on shafts. The ends of the shafts are mounted in blocks that, in turn, allow the shafts to move vertically in tracks  50  on the channel sidewalls. The shafts are covered by floatation cylinders  52  which allow the V-rollers  46  to remain at the water surface when unengaged and to engage the boat keel from underneath when submerged. Thus, the boat automatically becomes properly aligned laterally in the channel  18 . The boat  36  can then be lifted by the cradle  34  from the channel  18 . 
         [0039]    When a boat  36  enters or is retrieved and is raised or lowered into the channel  18 , a movable catwalk  54  is lowered over the channel  18  in the manner of a draw-span and then moved on rails  56  to a location adjacent the stern of the boat. A pair of equal length lines  58  is attached to the stern and catwalk  54 , as shown, and the catwalk drawn back in the direction of arrow  60  to remove or insert the boat from or into the raising and lowering location  28 . 
         [0040]    The channel  18  also includes a cover  62  that may be drawn out to cover the channel when the structure  16  is otherwise completely closed, thereby sealing off the channel from the interior of the structure. The channel cover  62  drum may be as shown or down in the channel  18  to better clear winch cable  45  but above the high water level in the channel. 
         [0041]    In  FIG. 6 , a system of anti-sway cables is depicted. The anti-sway cables  64  diagonally brace the suspended cradle  34  longitudinally to prevent sway as the cradle is raised, lowered, translated horizontally, or rotated. As the vertical cables  32  shorten or lengthen as the cradle  34  is raised or lowered, the anti-sway cables  64  must also shorten or lengthen while providing adequate tension to prevent sway. The proper tension is provided by a rotatable drum  66  for winding the cables  64  and a dynamic brake and motor connected to the drum. The drum  68  for the lifting cables  32  is also illustrated in dashed outline. The anti-sway cable system is further explained below. 
         [0042]    Illustrated in  FIGS. 7 ,  8 ,  9  and  10  is the boat cradle  34  in detail. The sides  70  of the cradle  34  are of generally open truss work, and the base  72  is U-shaped of open truss work. At the stern end  74  are two lateral frame pieces  76  and  78  that connect the sides  70  together and support a keel block  80  shaped to engage and support the boat keel near the boat stern. Forward of the lateral frame pieces  76  and  78  are pairs of support beams  82  and  84  to provide outboard support to platforms  86  and  88 . The platforms  86  and  88  are also attached to the sides  70  of the cradle  34 . Slideable on top of each platform  86  and  88  are smaller platforms  90  and  92  hinged together which, in turn, support air cushioning means  94  for contact with the boat hull. As shown, the air cushioning means  94  comprises firehose tubes which have been found to be quite suitable. Inflatable tubes or other inflatable devices may also be used for cushioning. The smaller hinged platforms  90  and  92  can be simply wedged up or down and slid in or out to fit the individual boat hull shape. 
         [0043]      FIGS. 11 ,  12 , and  13  illustrate the positioning of the cradle  34  in relation to a rack  10 . Each rack  10  comprises a pair of horizontal beams  96  and  98  spanning between vertical post beams  100 , the latter forming a basic part of the overall structure  16 . Centrally located on and supported by the horizontal beams  96  and  98  is a cantilever beam assembly  102  comprising two parallel horizontal beams  104  and  106  and a plurality of V-shaped cross-members  108 . The cross-members  108  are formed or adjustable to match the keel and the hull shape of a particular boat and are preferably located beneath bulkheads of the boat. Thereby, the boat can be supported in the rack  10  for long periods of time without warpage or other damage to the hull. 
         [0044]    As shown in  FIG. 12 , the cradle  34  is positioned just above the horizontal beams  104  and  106  of the cantilever beam assembly  102 . The U-shape of the cradle  34  fits around the cantilever beam assembly  102  as best shown in  FIG. 11 . The cradle  34 , being suspended on the cables  32 , thus can be raised and lowered above and below the cantilever beam assembly  102  without contact between them. 
         [0045]    In  FIGS. 14 ,  15  and  16 , the outline of a boat  36  has been added to illustrate the position of the boat on the cradle  34  and just above the cantilever beam assembly  102 . The boat  36  bow extends well beyond the rack  10  and cradle  34 ; however, the boat beam and center of gravity is well within the cradle. Lowering the cradle  34  from the position shown rests the boat  36  on the V-shaped cross-members  108 , and the cradle can be backed out sternwise by the overhead crane  30 . 
         [0046]    For retrieval of a boat  36 , the cradle  34  is brought into the cantilever beam assembly  102  and raised, lifting the boat off the cross-members  108  and above the assembly to the position shown. The cradle  34  carrying the boat  36  can then be moved sternwise horizontally to retrieve the boat. 
         [0047]    The detail of  FIG. 17  illustrates the hinged platform  90  supporting the cushioning means  94  and boat  36  hull. The hinged platform  90  includes a hinge  110  along one side fastened to a horizontal platform  112  which, in turn, slides on platform  86 . Thus, cushioning means  94  can be moved horizontally and rotated upwardly to engage a boat hull as required. To retain the cushioning means  94  at the correct angle, wedges  114  are placed or driven into the position shown between platform  90  and platform  112 . Screw jacks or hydraulic lifts might also be used to raise and lower and to slide platforms  90  and  92 . 
         [0048]    In  FIG. 18 , the overhead traveling crane  30  movably supports a rotator carriage  120  which can translate in the direction of arrow  122  perpendicular to movement  124  of the crane. The rotator carriage  120  in turn supports the rotator  40  shown schematically. The rotator  40  includes descending vertical columns  126  which connect to a pulley frame  128 . All of these components are of very robust steel construction. 
         [0049]    The pulley frame  128  supports two separate descending cable systems as also illustrated in  FIG. 19 . Vertical lifting cables  32  perform the function of raising and lowering the cradle  34 . In  FIG. 6 , the vertical cables are shown as single cables  32  at the “four corners” of a square or rectangular horizontal pattern. In contrast, in  FIGS. 18 and 19 , the corner cables  32  pass through pulleys  130  attached to the cradle  34 . The anti-sway bracing cables  64 , however, are single cables also connected adjacent the “four corners” to the cradle  34 . Physically, the upper rails  132  of the cradle  34  provide locations for attachments  134  of the vertical cables  32  and attachments  136  of the diagonal bracing cables  64 . 
         [0050]    Thereabove, the pulley frame  128  supports a plurality of pulleys for both the vertical cables  32  and the bracing cables  64 . The pattern of pulleys attached to the pulley frame  128  are best shown in  FIGS. 20 to 22  wherein in  FIG. 20  the pulley frame replicates the “four corners” pattern as described for the cradle  34 . The vertical cables  32  at each corner of the pulley frame  128  attach at  138  and pass over pulleys  140 . Adjacent each corner are pulleys  142  over which pass the bracing cables  64 . Atop the rotator  40  are the drum  68  for the vertical lifting cables  32  and the drum  66  for the bracing cables  64 . 
         [0051]    Referring to  FIG. 21 , the four cables  32  are horizontally directed from pulleys  140  to pulleys  144  which, in turn, direct the cables upwardly to drum  68 . Drum  68  is preferably electric motor powered to raise and lower the cradle  34 . To provide smooth winding and unwinding of the cable  32 , pulleys  144  are movable parallel to the axis of the drum  68  as indicated by arrows  146 , and pulleys  140  are free to swivel as indicated by arrows  148 . 
         [0052]    Referring to  FIG. 22  wherein only the bracing cables  64  are shown in addition to  FIG. 21  where vertical lifting cables  32  are also shown, the bracing cables  64  pass horizontally from pulleys  142  around pulleys  150  and on to pulleys  152  directly below the drum  66 . The pulleys  152  direct cables  64  upwardly to drum  66  for winding and unwinding on the drum. Pulleys  152  are movable in a direction parallel to the axis of drum  66 , as indicated by arrows  154 , to provide smooth winding and unwinding under a tension load preferably provided by a dynamic electric brake and motor combination connected to the drum. Dynamic electric brake and motor combinations are well known in the elevator art, however, in this application the cables  64  act as structural diagonal bracing which changes length as required.