Patent Publication Number: US-2011058921-A1

Title: Mounting kit

Description:
INTRODUCTION 
     This invention relates to a mounting kit for a carrying vehicle chassis. More specifically, this invention relates to a mounting kit for fitting to a carrying vehicle chassis so that a number of different types of piggyback forklift truck may be mounted on the rear of that carrying vehicle chassis. 
     Piggyback forklift trucks are lightweight forklift trucks that are mounted on the rear of a carrying vehicle&#39;s chassis during transit to and from a customer&#39;s premises. Once at the customer&#39;s premises, the piggyback forklift truck is dismounted from the rear of the carrying vehicle and used to load goods onto or unload goods from the carrying vehicle&#39;s chassis. When the goods have been loaded or unloaded as appropriate, the piggyback forklift truck is mounted onto the rear of the carrying vehicle&#39;s chassis once more ready for onward transit. The mounting kit is provided to adapt the carrying vehicle&#39;s chassis so that the piggyback forklift truck may be securely fastened to the rear of the carrying vehicle during transportation. 
     One such type of mounting kit is that described in the applicants own U.S. Pat. No. 5,749,695. U.S. Pat. No. 5,749,695 discloses a mounting kit that may be mounted on carrying vehicle chassis&#39; of varying sizes. There are however a number of problems with the existing mounting kits. Piggyback forklift trucks come in a range of shapes, sizes and weights. Furthermore, piggyback forklift trucks come with a variety of different load handling units, for example vertical masts and pivoting telescopic booms. Heretofore, each model of piggyback forklift truck requires a dedicated mounting kit dimensioned to receive that particular type of forklift. Typically, a mounting kit for one design of piggyback forklift will be totally unsuitable for another design of piggyback forklift. Therefore, if an operator wishes to upgrade their piggyback forklift, extensive modifications will almost certainly also be necessary to the chassis of their carrying vehicle. These modifications are time consuming and expensive to carry out. 
     Furthermore, in situations where an operator has a number of piggyback forklift trucks of different shapes, sizes, weights and load handling arrangements at their disposal, they have had to provide a separate carrying vehicle for each piggyback forklift truck with a mounting kit that suits that type of forklift. Not only is this expensive for the operator to provide, this also places limitations on the operator and prevents the operator obtaining the full benefit and flexibility of the fleet of piggyback forklifts and carrying vehicles that are at their disposal. 
     It is an object therefore of the present invention to provide a mounting kit for a carrying vehicle that overcomes at least some of these problems and provides a useful choice. 
     STATEMENTS OF INVENTION 
     According to the invention, there is provided a mounting kit for fitting on the rear of a carrying vehicle chassis to receive a piggyback forklift truck having a pair of front wheels and a pair of height adjustable, forwardly projecting, load engaging tines, the mounting kit comprising:
         a mounting frame having a pair of tine receiving sockets;   means to secure the mounting kit to the chassis;   a pair of forklift support receiving brackets; and   a pair of adjustable wheel abutment plates, one on each side of the tine receiving sockets, moveable forwards and backwards parallel to the longitudinal axis of the carrier vehicle.       

     By having such a mounting kit, the mounting kit may be used with a wide range of piggyback forklift trucks. The adjustable wheel abutment plates may be positioned appropriately to suit a particular wheel base of forklift truck. Furthermore, by providing a pair of forklift support receiving brackets, the operator may use the mounting kit with a number of different piggyback forklift truck mounting equipment, including tabs, mounting hooks and chains. 
     In one embodiment of the invention, there is provided a mounting kit in which the wheel abutment plates each comprise a fixed track, an abutment frame moveable relative the track and a releasable fixing member to releasably secure the abutment frame in position relative the track. 
     In one embodiment of the invention, there is provided a mounting kit in which the abutment frame is slidably mounted on the track. 
     In one embodiment of the invention, there is provided a mounting kit in which the abutment frame further comprises an inclined plate for bearing against the front wheel of the forklift truck. 
     In one embodiment of the invention, there is provided a mounting kit in which the pair of forklift support receiving brackets each comprise at least two jaws, each jaw defining a mounting pin receiving aperture, and a mounting pin slidably mounted in the mounting pin receiving apertures of the jaws. 
     In one embodiment of the invention, there is provided a mounting kit in which there are provided a pair of retractable wheel rest plates, moveable to and from a retracted stored position and an extended in use position, mounted on the mounting frame. This is seen as particularly advantageous. Depending on the model of piggyback forklift truck and the chosen mounting arrangement for that piggyback forklift truck, wheel rest plates may or may not be required. The retractable wheel rest plates allow the operator to use the wheel rest plates when necessary and stow the wheel rests out of the way when they are not required. 
     In one embodiment of the invention, there is provided a mounting kit in which the wheel rest plates are pivotally mounted on the mounting frame, pivotable to and from a retracted stored position and an extended in use position. 
     In one embodiment of the invention, there is provided a mounting kit in which the mounting frame comprises a foldable crash bar, the crash bar comprising a central portion and a pair of extension arms, one at each end of the central portion, the extension arms being foldable to and from a stored position and an extended in use position. 
     In one embodiment of the invention, there is provided a mounting kit in which the extension arms are pivotally mounted on the central portion, pivotable to and from a stored position and an extended in use position. 
     In one embodiment of the invention, there is provided a mounting kit in which the mounting frame further comprises a forward section and a rear section,
         the forward section comprising a horizontal spacer bar and a pair of forward vertical spacer bars, one at each end of the horizontal spacer bar and projecting upwardly therefrom;   the rear section comprising a horizontal upper transverse crash bar, a lower transverse crash bar below the upper transverse crash bar and connected thereto by way of a pair of rear vertical spacer bars; and   the front section being connected to the rear section by way of the pair of tine receiving sockets being mounted adjacent their rearmost end on the lower transverse crash bar and mounted adjacent their front ends on the forward horizontal spacer bar.       

     In one embodiment of the invention, there is provided a mounting kit in which the mounting frame further comprises a pair of hanger plates connecting the front and rear sections, each hanger plate being connected to a forward vertical spacer bar and a rear vertical spacer bar. 
     In one embodiment of the invention, there is provided a mounting kit in which the mounting frame further comprises a pair of intermediate vertical spacer bars located between the pair of front vertical spacer bars and the pair of rear vertical spacer bars, and a horizontal structural bar connected to each of the intermediate spacer bars at their lowermost ends. 
     In one embodiment of the invention, there is provided in combination:
         a piggyback forklift truck comprising:
           a chassis having a pair of front wheels and at least one steerable rear wheel;   a drive unit mounted on the chassis for driving at least one of the wheels;   a steering unit mounted on the chassis for steering the at least one steerable rear wheel;   a load handling unit mounted on the chassis carrying a pair of height adjustable, forwardly projecting, load engaging tines;   means to raise and lower the tines relative the chassis;   means to extend the tines forwardly and retract the tines rearward relative the chassis;   a forklift support mounted on the chassis; and   
           a carrier vehicle comprising:
           a carrier vehicle chassis having mounted thereon a mounting kit for the piggyback forklift truck, the carrier vehicle chassis mounting kit comprising:   a mounting frame having a pair of tine receiving sockets;   means to secure the mounting kit to the chassis;   a pair of forklift support receiving brackets; and   a pair of adjustable wheel abutment plates, one on each side of the tine receiving sockets, moveable forwards and backwards parallel to the longitudinal axis of the carrier vehicle.   
               

    
    
     
       DETAILED DESCRIPTION OF THE INVENTION 
       The invention will now be more clearly understood from the following description of some embodiments thereof, given by way of example only, with reference to the accompany drawings, in which:— 
         FIG. 1  is a perspective view of a first embodiment of a mounting kit according to the invention mounted on a carrying vehicle chassis; 
         FIG. 2  is a perspective view of the mounting kit shown in  FIG. 1  free of the chassis; 
         FIG. 3  is a perspective view of another embodiment of mounting kit; 
         FIG. 4  is a perspective view of the mounting kit of  FIG. 3  with the retractable wheel rests in a stowed configuration; 
         FIG. 5  is a perspective view of the retractable wheel rest of the mounting kit in an operating configuration; 
         FIG. 6  is a perspective view of the retractable wheel rest of the mounting kit in a stowed configuration; 
         FIG. 7  is a perspective view of the adjustable wheel abutment plate of the mounting kit; 
         FIG. 8  is an exploded view of the of the adjustable wheel abutment plate of  FIG. 7 ; 
         FIG. 9  is a perspective view of the forklift support receiving bracket of the mounting kit; 
         FIG. 10  is a side elevational view showing the rear end of a carrier vehicle with the mounting frame attached; and 
         FIG. 11  is a side elevational view showing the rear end of a carrier vehicle with the mounting frame in use carrying a forklift. 
     
    
    
     Referring initially to  FIGS. 1 and 2 , there is shown a mounting kit, indicated generally by the reference numeral  1 , mounted on a chassis of a carrying vehicle. The chassis comprises a pair of longitudinal structural members  3 ,  5 . It will be understood that various parts of the chassis of the carrying vehicle have been omitted for clarity so that the parts of the mounting kit may be shown more clearly. The mounting kit  1  comprises a mounting frame  6  having a pair of tine receiving sockets  35 ,  37 , a pair of forklift support receiving brackets  15 ,  17  and a pair of adjustable wheel abutment plates  19 ,  21 . 
     The forklift support receiving brackets  15 ,  17  ( FIG. 9 ) each comprise three jaws  23  welded to an upper transverse crash bar  7 . Each of the jaws has a through bore  24  for reception of a horizontal mounting pin  25  and the horizontal mounting pin  25  is slidably mounted in the through bores of the jaws  23 . A locking mechanism  26  is provided to releasably secure the horizontal mounting pin in position relative the jaws. 
     The adjustable wheel abutment plates  19 ,  21  ( FIGS. 7 &amp; 8 ) each comprise an elongate fixed track  27  and an abutment frame  29  movable relative the track  27 . The abutment frame is moveable relative the track in a direction parallel to the longitudinal axis of the carrying vehicle chassis. The abutment frame  29  comprises an inclined plate  31  for bearing against the wheel of a forklift (not shown). The abutment frame  29  is slidably mounted on the longitudinal track  27  and means, in this case nut  32  and bolt  30 , are provided to releasably secure the frame in position relative the longitudinal track. The means to secure the abutment frame in position relative the track could be provided by way of a number of nuts and bolts, a locking pin arrangement, a spring loaded locking pin or other such device. The abutment frame  29  has a plurality of apertures  344  for reception of a locking member therein to secure the frame  29  in position relative the track. The fixed track may be bolted onto the chassis of the vehicle or may be mounted on the chassis using other suitable means, for example by welding the track onto the chassis. Indeed, the fixed track may be fixed in position relative the chassis by being affixed in a similar manner to the mounting frame which in turn is secured in position relative the chassis. 
     Referring again to  FIGS. 1 and 2 , the mounting frame  6  comprises a forward section and a rear section, the forward section comprising a horizontal spacer bar  39  and a pair of forward vertical spacer bars  14 , one at each end of the horizontal spacer bar  39  and projecting upwardly therefrom. The rear section comprises the horizontal upper transverse crash bar  7 , a lower transverse crash bar  9  below the upper transverse crash bar  7  and connected thereto by way of a pair of rear vertical spacer bars  11 ,  13 . The front section of the mounting frame is connected to the rear section by way of the pair of tine receiving sockets  35 ,  37  which are mounted adjacent their rearmost end on the lower transverse crash bar  9  and mounted adjacent their front ends on the forward horizontal spacer bar  39 . The mounting frame  6  further comprises a pair of hanger plates  16  connecting the front and rear sections, each hanger plate  16  being connected to a forward vertical spacer bar  11 ,  13  and a rear vertical spacer bar  14 . 
     The mounting frame  6  is connected to the longitudinal structural members  3 ,  5  of the chassis through the upper transverse crash bar  7  and the forward horizontal spacer bar  39  which are welded in position to the longitudinal structural members. Other parts of the mounting frame may also be welded in position to the chassis. As an alternative to welding, the mounting frame or individual parts thereof may be bolted to the chassis. Indeed, certain parts of the mounting frame, for example the upper transverse crash bar  7 , may be integral with the carrying vehicle chassis and the remainder of the mounting kit is connected onto that part that is integral with the chassis. 
     The mounting kit  1  further comprises a pair of retractable crash-bar extension arms  33 , one of which is mounted at either end of the lower transverse crash bar. One of the retractable crash-bar extension arms  33  is shown in an extended in use position substantially parallel to the central portion of the lower transverse crash bar and the other of the retractable crash-bar extension arms is shown in a stored position substantially perpendicular to the central portion of the lower transverse crash bar. The extension arm  33  is pivotable to and from the extended in use position and the stowed configuration substantially parallel to the longitudinal structural members  3 ,  5 . When the extension arms  33  are in an extended in use position, they operate as a crash bar providing protection to the carrying vehicle and when the extension arms are in the stowed configuration, they will allow a forklift to be mounted on the carrying vehicle chassis. 
     In use, the operator of the piggyback forklift adjusts the wheel abutment plates by releasing any locking members  30 ,  32  and moving the abutment frame  29  relative the longitudinal track  27  so that the inclined plate  31  is at the desired position to accommodate the wheel base of the piggyback forklift (not shown). The locking members are then used to secure the abutment frame  29  in position relative the longitudinal track. Furthermore, the horizontal mounting bars  25  of the forklift support receiving brackets  15 ,  17  may be inserted through all of the through bores of the jaws  23  and fixed in place or may be left free of an adjacent pair of jaws until such a time as a tab of a forklift is in position between the jaws, or a chain has been placed between the jaws, ready to be engaged by the horizontal mounting bar. Once the tab or chain is in position, the horizontal mounting bar may be slid between the jaws engaging the tab or chain and then locked in position. Other forklift support arrangements, for example hooks and chains with suitable connectors, may allow the mounting pin to be locked in position before it is engaged by the hooks or suitable connectors on the chains. 
     Referring to  FIGS. 3 and 4  of the drawings, there is shown an alternative embodiment of mounting kit  51  where like parts have been given the same reference numerals as before. The mounting kit  51  further comprises a pair of retractable wheel rest plates  53 ,  55 . The retractable wheel rest plates  53 ,  55  each comprise a wheel receiving plate  57  mounted on an arm  59  which in turn is pivotally mounted on an intermediate vertical spacer bar  61 . The intermediate vertical spacer bars  61  are located between the pair of front vertical spacer bars  14  and the pair of rear vertical spacer bars  11 ,  13 , and a horizontal structural bar  63  is connected to each of the intermediate spacer bars  61  at their lowermost ends. 
     Depending on the construction of piggyback forklift to be mounted on the rear of the carrying vehicle, the retractable wheel rest plates  53 ,  55  may be required. If required, the wheel rest plates  53 ,  55  may be pivoted from a stowed configuration where they rest up against the intermediate vertical spacer bar  61  ( FIG. 4 ) to a substantially horizontal operating configuration perpendicular to the intermediate vertical spacer bar  61  ( FIG. 3 ). The intermediate vertical spacer bars  61  and retractable wheel rests are positioned on the chassis forward of the lower transverse crash-bar  9  and in a position that ensures that they do not interfere with the operation of the retractable crash-bar extension arm  33 . The intermediate vertical spacer bars are so positioned that the retractable crash bar extension arm is able to pivot rearwards to a stored position substantially perpendicular to the central portion of the lower transverse crash bar and substantially parallel to the longitudinal structural members  3 ,  5 . 
     Referring to  FIGS. 5 and 6  of the drawings, there are shown perspective views of the retractable wheel rest plate  53  of the mounting kit  51 . The arm  59  is pivotally mounted about a pivot pin  65  on vertical spacer bar  61  so that it pivots to and from an operating configuration, as shown in  FIG. 5  and a stowed configuration, as shown in  FIG. 6 . Preferably, the operating arm  59  is dimensioned so that it abuts against an end  67  of the horizontal structural bar  63  when in an operating configuration, thereby limiting further downward movement of the arm  59  and wheel receiving plate  57 . 
     Referring to  FIGS. 10 and 11 , there are shown views of the mounting kit  51  secured to a carrying vehicle chassis  70  and the mounting kit in use mounting a forklift  71  on the chassis. The mounting and dismounting procedure is well understood by those skilled in the art. In brief, in those forklift mounting arrangements that do not require the wheel rest plates, the extendable arms  33  of the transverse crash bar and the wheel rest plates are pivoted to a stored configuration and the tines  73  of the forklift may be offered up to the tine receiving sockets  35 . The load handling unit  75  may be fully retracted or almost fully retracted on the forklift chassis  77  before the tines  73  are engaged in the tine receiving sockets. Once the tines are engaged in the tine receiving sockets, the tines  73  are lowered thereby raising the forklift  71  off the ground. The position of the tines on the mast  75  is manipulated until the forklift supports, in this case tab  79 , mounted on the chassis are aligned with the forklift support receiving brackets  15 ,  17  on the carrying vehicle chassis  70 . Once the forklift supports  79  have engaged the forklift support receiving brackets  15 ,  17 , the locking pins  25  are inserted and secured in position in the jaws  25  and the pressure in the hydraulics of the load handling unit can be released so that the forklift is carried by the forklift supports with the wheels of the forklift abutting against the abutment frame  29 . 
     For those mounting arrangements that require wheel rest plates, the wheel rest plates are lowered from a stored position to an extended in use position and the extendable arms of the lower transverse crash bar are pivoted into a stored configuration. The tines  73  of the forklift truck are extended by moving the load handling unit, in this case a vertical mast  75 , otherwise referred to in the art as a static mast, forward on the forklift chassis  77  and the tines  73  are offered up to the tine receiving sockets  35 ,  37  at the rear of the carrying vehicle. The tines are engaged fully in the tine receiving sockets and the tines are lowered on the vertical mast. By lowering the tines on the mast  75 , this has the effect of raising the forklift off the ground. When the wheels of the forklift are above the wheel rest plates, the mast may be retracted further on the forklift chassis thereby bringing the front wheels of the forklift under the carrying vehicle chassis and above the wheel rest plates. Forklift supports comprising one or more of tabs  79 , hooks and chains  81  are attached to the forklift support receiving brackets and secured in place and the pressure in the hydraulics of the load handling unit can be released so that the forklift is carried on the wheel rest plates and by the forklift supports. 
     In the embodiment shown, the forklift truck is a piggyback forklift truck having a u-shaped chassis with a pair of front wheels and at least one steerable rear wheel. The u-shaped chassis has a rear cross bar and a pair of forwardly projecting side bars. The forklift truck further comprises a drive unit, a driver&#39;s station and a load handling unit, comprising a vertical mast, all of which are mounted on the chassis. Forklift support means, in this case tabs  79  and chains  81  are provided but could be hooks similar in construction to the tabs  79  shown but with an open mouth to allow engagement of a horizontal bar  25  mounted in the forklift support receiving brackets on the carrying vehicle chassis. Furthermore, tabs, hooks or chains could be provided as the sole forklift support for engagement of the forklift support receiving brackets if desired. Other load handling units such as a pivoting boom arrangement could be used instead of the upright mast on the forklift without departing from the scope of the invention. 
     It will be understood that various modifications could be made to the present invention, without departing from the scope of the invention. For example, two jaws  23  could be provided instead of three for each of the forklift support receiving brackets and the horizontal mounting pin may be permanently mounted between the jaws for engagement of certain types of mounting kits of piggyback forklifts. However, it is envisaged that the horizontal mounting bar being slidably mounted in through bores in the jaws is preferable as this will accommodate numerous different types of mounting kits, including those using hooks, tabs or chains. Locking means such as split pins and other shaped pins could be provided to prevent inadvertent movement of the horizontal mounting pin from the through bores. 
     Similarly, various locking pins or locking mechanisms could be provided to maintain the retractable crash-bar extension arm  33  in an operating configuration and/or a stowed configuration and similarly, various locking pins or locking mechanisms could be provided to maintain the retractable wheel rests in an operating configuration and/or a stowed configuration. Furthermore, the longitudinal tracks  27  could be bolted onto the vehicle chassis or alternatively, could be welded onto the vehicle chassis, if desired. In another alternative, the longitudinal tracks could be bolted or welded to the mounting frame which in turn would be connected to the chassis. The longitudinal track could be provided with a plurality of holes for reception of a locking member mounted on the frame  29  or vice versa. Alternatively, one or more holes could be provided on both the track and the abutment frame and a nut and bolt or other locking member could be used to engage one or more holes on each of the track and the abutment frame. 
     The means to mount the mounting kit to the chassis could therefore comprise any suitable connection means including but not limited to nuts and bolts, welding joints and in some instances the means to mount the mounting kit to the chassis could include one or more structural members including one or more parts of the mounting kit that are welded to or bolted to the carrying vehicle chassis and suitable bolt receiving apertures in the mounting kit. The structural bar  63 , transverse crash bars  7 ,  9 , tine receiving sockets  35 ,  37 , vertical spacer bars  11 ,  13 ,  14  and  61 , hanger plates  16  and horizontal structural bar  63  could be welded or bolted directly or indirectly to the vehicle chassis and/or each other, if desired. Indeed, it may be advisable to provide a mixture of the two fixing methods to aid assembly. Similarly, various parts, such as the upper transverse crash bar  7  and vertical spacer bars  11 , could already form part of the vehicle chassis assembly. 
     Another alternative construction incorporates pivotally mounted forklift support receiving brackets. In some instances, the rear brackets protrude from the rear of the truck/trailer significantly and in some cases can cause over length issues with no forklift on board. Therefore, the jaws  23  and mounting pin  25  may be mounted on an assembly which is in turn pivotally connected to the rear cross member  7  on the kit. This assembly has a pivot point underneath item the transverse crash bar  7  and when in the lowered/unused state will not protrude beyond the rear of the kit. Alternatively, the jaws could be pivotally mounted directly onto the transverse crash bar and locking members could be provided to keep them in a desired position protruding from the rear of the chassis or underneath the chassis. 
     Furthermore, in an alternative embodiment, it is not necessary to mount the forklift machine using forks/tines. In some cases the forklift is mounted using the fork carriage itself and therefore neglecting the forks. This is preferred in certain circumstances as during the mounting process, the forks can take the entire load of the machine and in some cases are not rated to do so. Instead of mounting the forklift using the forks, fork boards are provided (fork carrying rails) to mount the machine usually by fitting hooks that engage the fork carriage of the lifting assembly. 
     In this specification, the terms “comprise”, “comprises”, “comprised” and “comprising” and the terms “include”, “includes”, “included” and “including” are deemed totally interchangeable and should be afforded the widest possible interpretation. 
     The invention is in no way limited to the embodiment hereinbefore described but may be varied in both construction and detail.