Patent Publication Number: US-6220462-B1

Title: Flexible parts transporting system

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to a parts transporting system. More specifically the present invention relates to a modular flexible parts transporting system ideal for parts sequencing procedures involving varying part sizes. 
     It is frequently necessary to pack articles for shipment to a location where the articles are unpacked for assembly with other parts. An important aspect of a parts transporting system is its flexibility to accommodate parts of different sizes while still maintaining simple loading and unloading methods and a stackable shape. Various systems have been developed for parts storage and transportation which disclose a parts loading system using a compartmental scheme. These systems utilize moving rods and shelves to vary the size of their storage compartments. These systems are effective in maintaining a flexible configuration of the size and number of compartments. However, these systems do not utilize a sequenced, pivoting, multi-level, compartmentalized system which decreases the difficulty in loading and helps to protect parts. Loading and unloading these previous systems is done by placing each part in a compartment and then securing the part. The present invention reduces these two actions into one thereby reducing the time needed to load and unload parts. A system of lids and shelf assemblies are used in the present invention to protect, store, and secure parts. The lid and shelf assemblies are sequenced so that as each shelf assembly is emptied it is lifted and this action will lift the lid below, exposing the next layer of parts to be removed. The reverse action of loading is also sequenced so that as each shelf assembly is loaded the lid is closed, securing the loaded parts and opening the shelf assembly above. Another previous storage system discloses a two level storage layout which incorporates a pivoting upper deck that serves the dual purpose as a second level of storage and a lid for the bottom storage level. However, this system does not utilize a compartmentalized storage scheme that sequences, protects, and insures the cleanliness of the stored parts. 
     SUMMARY OF THE INVENTION 
     The present invention possesses shelf assemblies and a compartmental system that are easily modified into many different configurations to accommodate parts of differing size. The shelf assemblies are sequenced so that when parts are removed from each separate shelf assembly, that shelf assembly is raised to an elevated pivoted position, thus exposing parts in the next lower shelf assembly. An object of the present invention is to maintain simple loading and unloading methods no matter what configuration is chosen. By creating the sequenced shelf assemblies, the ease of loading and unloading parts from the system has been improved. 
     A further object of the invention is to maintain the safety and the cleanliness of the parts stored in the invention. Often parts are finely finished and require special handling to prevent marring or damage during transport. This invention protects such vulnerable parts by creating sealed flexible storage compartments. 
     Further objects, features, and advantages of the invention will become apparent from a consideration of the following description and the appended claims when taken in connection with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of one embodiment of the present invention; 
     FIG. 2 is a perspective view of the framework of the flexible transportation system in accordance with one embodiment of the present invention; 
     FIG. 3 is a perspective view of a second embodiment of the framework of the present invention; 
     FIG. 4 is a perspective view of the universal shelf supports coupled to the uprights; 
     FIG. 5 is a perspective view of a shelf assembly with a single sling; 
     FIG. 6 is a perspective view of the shelf assembly with a twin sling; 
     FIG. 7 is a perspective view of the shelf assembly with a center hung sling; 
     FIG. 8 is a perspective view of one embodiment of the present invention; 
     FIG. 9 is a side elevation view of one embodiment of the present invention demonstrating the shelf assembly sequencing; 
     FIG. 10 is a view of one embodiment of the lid positioning device; and 
     FIG. 11A-11F illustrates permutations of shelving configurations for the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     FIG. 1 is a perspective view of one embodiment of the present invention. The flexible parts transportation system is generally shown as  3  and is constructed from a rigid rack frame  7 , uprights  19 , and shelf assemblies  21 . The uprights  19  are mounted on the rigid rack frame  7  and the shelf assemblies  21  are operably coupled to the uprights  19  by universal shelf supports  23 . 
     FIG. 2 is a perspective view of the framework  5  of the flexible parts transportation system  3  in accordance with one embodiment of the present invention. The framework  5  has a rigid rack frame  7  which constitutes the base and determines the footprint of the flexible parts transporting system  3 . The rigid rack frame  7  is generally rectangular in shape and formed in a segmented mold allowing flexible sizing and configuration. In one embodiment the mold comprises modular segments allowing any dimensional configuration of the rigid rack frame  7  which is a multiple of the segment size. The rigid rack frame  7  is preferably formed from sheet molded compound although other formable materials including plastics, metals, woods, and resins shaped by stamping, molding, carving or cutting can be used with equivalent results. The rigid rack frame  7  has recesses  9  for forklift entry and receptacles  11  for casters or stacking pins. The rigid rack frame  7  is designed so that the flexible parts transporting system  3  can be moved by an operator rolling it on installed casters, or lifting the system with a forklift, handjack or other movement means. In one embodiment of the present invention the receptacles  11  are cylindrical holes which will accept a caster mounted on a metal pin. In another embodiment the receptacles  11  may be used to accept pins  12  located on the topside of another flexible parts transporting system  3  (not shown). The penetration of these pins  12  into the receptacles  11  will insure a stable arrangement when multiple flexible parts transporting systems  3  are stacked for shipment. 
     The rigid rack frame  7  includes segments  13  whose edges define cavities  17 . In one embodiment of the present invention there are eight segments  13  that are located at each comer of the rigid rack frame  7  and in the center of each side of the rigid rack frame  7 . Uprights  19  are placed snugly into cavities  17  in a generally perpendicular manner with respect to the rigid rack frame  7  and are securely anchored by a fastening means. The uprights  19  add structural strength to allow for the stacking of several flexible parts transporting systems  3  and provide the basic vertical shape of the flexible parts transporting system  3 . The uprights  19  of the preferred embodiment have a C shaped channel  18  running their entire length which provides a surface on which to mount additional components. In one embodiment the uprights  19  have an element  20  for securing the flexible parts transporting system  3  in a locked down position. The element  20  could be a metal loop affixed to uprights  19  for use with a portable lock or other suitable means. 
     FIG. 3 is a perspective view of a second embodiment of the framework  5  of the flexible transportation system  3 . The rigid rack frame  7  is constructed from two sheets,  91  and  93 , of corrugated sheet molded compound or suitable formable materials that have been shaped to the desired dimensions. The bottom corrugated sheet  91  is rotated ninety degrees with reference to the top corrugated sheet  93  so that the corrugations of sheets  91  and  93  are generally perpendicular to each other. The sheets  91  and  93  are then permanently coupled in this position to provide the basic structure of the rigid rack frame  7 . Brackets  87  are then coupled to each corner of the rigid rack frame  7 . In one embodiment sheet  93  has elevated corrugations  97  on its two ends and sheet  91  extends slightly outward from underneath sheet  93  in a direction parallel to the corrugations  97  of sheet  93  to create lips  95 . Lips  95  extend slightly outward from the sides of the rigid rack frame  7  which are perpendicular to the corrugations  97 . The brackets  87  are coupled directly onto the elevated corrugations  97  of the corrugated sheet  93  and rest on lips  95 . In another embodiment the brackets  87  have flanges  88  that overlap the sides of the elevated corrugations  97  and are fastened to the elevated corrugations  97 . Brackets  89  are coupled to the center of the sides of the rigid rack frame  7 . In one embodiment sheet  93  has a depressed corrugation  98  in the center of its shortest side. Brackets  89  are coupled to the interior walls of the depressed corrugation  98  by flanges  99  that overlap the surface of the elevated corrugations  96  which adjoin the depressed corrugation  98 . Uprights  19  are then coupled to the brackets  87  and  89 . 
     Selected uprights  19  coupled to the rigid rack frame  7  provide a mounting surface for the universal shelf supports  23  as shown in FIG.  4 . Universal shelf supports  23  have spring loaded rods  83  and bolts  24  which couple to the offset pivot hinges  35  of later added shelf assemblies  21 . In one embodiment the universal shelf supports  23  are attached to the root surface  26  within the C shaped channels  18  in uprights  19 , but it would also be obvious to one skilled in the art to attach the supports  23  to the sides  528  of the channels  18 . The uprights  19  which are equipped with shelf supports  23  will be determined by the shelf configuration of the flexible parts transporting system  3 . 
     FIG. 5 is a perspective view of a shelf assembly  21  with a single open sling. Each shelf assembly  21  includes a shelf frame  37  and a sling assembly  39  which is chemically or mechanically connected to the shelf frame  37  and hangs downward from the shelf frame  37 . The shelf frame  37  provides support and form for the sling assembly  39  and includes shelf frame supports  36  which rest on the shelf assembly  21  immediately below It. The shelf frame is also coupled to an offset pivot hinge  35  used to later mount the shelf assembly  21  to universal shelf supports  23 . The sling assembly  39  is preferably made of a flexible material  43  to allow for shock absorption during transport. In one embodiment the flexible material  43  has a moistureproof coating to seal and protect the parts. Further materials can be used which protect the parts from dust or other contaminants commonly experienced during shipping and storage at manufacturing plants. Also, if the parts require air circulation during storage, a mesh can be used as the flexible material. 
     The sling assembly  39  can be configured into a single compartment  45  or multiple compartments. A permanent or removable dunnage  47  may be used to further subdivide the compartment  45  and provide a mechanical means to help secure parts. The sling assembly  39  may be coupled to the shelf frame  37  by mechanical or chemical means as mentioned above. In one embodiment the sling assembly  39  is attached to the shelf frame  37  on all exterior sides by a J clip. The J clip allows the removal of the sling in a fast and nondamaging manner. 
     A lid and strut assembly  41  is operably coupled to the shelf frame  37  and includes a lid  51 , a lid attachment point  52 , a linkage  53 , and a strut anchor  38 . In one embodiment the lid and strut assembly  41  is hinged to the shelf frame  37  to allow rotation of the lid and strut assembly  41  in an upward manner. The strut anchor  38  is an elevated bracket that is mounted onto the edge of the lid  51 . When in the closed position the shelf frame support  36  of each shelf assembly  21  rests upon the strut anchor  38  immediately beneath it, providing a stable foundation. The lid  51  completely covers the sling assembly  39  during transport and storage. A seal  55  is affixed to the perimeter of the lid  51  providing a dirt and moisture seal. The sling assembly  39  in combination with the seal  55  provides a clean and safe method for the transport of fragile parts. In one embodiment of the present invention each compartment  45  of the sling assembly  39  may be equipped with a valve  57  to allow easy flushing of residue from each compartment  45 . In another embodiment of the present invention the sling assembly  39  is equipped with a transparent window  59  or aperture so that stored parts may be viewed when the lid  51  is in a closed position. 
     FIG. 6 is a perspective view of the shelf assembly  21  with twin slings. This embodiment has subdivided the sling assembly  39  into two compartments  61  by the addition of a shelf sling support  63 . In one embodiment the shelf sling support  63  is a rod that snaps into the center of the shelf frame  37 . The compartments  61  are formed when the flexible material  43  of the sling assembly  39  is draped over the shelf sling support  63 . 
     FIG. 7 is a perspective view of the shelf assembly  21  with a center hung sling  65 . The flexible material  43  is pliant so that when the adjustable shelf sling supports  63  are slid in a perpendicular manner along the shelf support frame  37  the compartment  67  of the center hung sling  65  may be varied in size. Varying the compartment  67  size will allow a secure fit for parts of various sizes. 
     The flexible parts transporting system  3  is realized when the universal shelf supports  23 , mounted on uprights  19 , are operably coupled to shelf assemblies  21 . Shelf assemblies  21  are joined to the supports  23  by offset pivot hinges  35  which are coupled to bolts  24 . The universal shelf supports  23  allow the shelf assemblies  21  to swing open at an angle relative to the rigid rack frame  7 . In a first embodiment of the present invention show in FIG. 8, the base has been formed with two short sides  25 A and  25 B and two long sides  27 A and  27 B. Brackets  89  are located in the center of the two short sides  25  and brackets  87  are located at each corner of the rigid rack frame  7 . Uprights  19  having equal vertical dimensions are coupled to brackets  87  and  89 . Universal shelf supports  23  are mounted to the uprights  19  coupled to brackets  89 . Shelf assemblies  21  are then operably coupled to the universal shelf supports  23 . This configuration produces twin shelf assemblies  21 A and  21 B that swing open widthwise in opposite directions A and A′. This twin shelf configuration is then repeated with consecutive twin shelf assemblies placed on top of each other until the desired or absolute number of shelf assemblies is reached. Since the universal shelf supports  23  can be coupled to any upright  19  there are numerous shelving configurations which can be created. 
     The sequencing advantage of this invention is provided by the interaction of the shelf assemblies  21  and the lid and strut assemblies  41  as shown in FIG.  9 . The lid attachment point  52  attaches to the lid  51  and shelf assembly  21  above it using linkage  53 . In one embodiment of the present invention linkage  53  comprises a mechanical connection or chord. As each shelf assembly  21  is emptied, it is lifted and this action will lift the lid  51  below, exposing the next layer of parts to be removed. Loading is the reverse process, starting with all shelf assemblies  21  open and loading from the bottom. As each shelf assembly  21  is loaded, its lid  51  is closed and this action will open the shelf assembly  21  directly above the lid  51 . This sequencing greatly decreases the time needed to load and unload parts because it reduces two actions, moving the shelf assembly and moving the lid, into a single action. 
     The lid and strut assemblies  41  and shelf assemblies  21  can be locked open, closed or in an intermediate position with a lid positioning device  73 . FIG. 10 is a view of one embodiment of the lid positioning device  73  used to hold the lid  51  and shelf assemblies  21  open or closed. The offset pivot hinge  35  is operably coupled to the lid positioning device  73 . The lid positioning device  73  includes a rod assembly  81  and a cam  75  whose edges define a first indentation  77  and a second indentation  79 . The rod assembly  81  is coupled to the universal shelf support  23  and is composed of a rod  83  and spring  85  applying a force to the rod  83 . When the offset pivot hinge  35  rotates, the cam  75  will rotate and the spring  85  will force the rod  83  along the edge of the cam  75  until the rod  83  engages the first indentation  77  or the second indentation  79 . If the rod  83  engages the first indentation  77 , the lid  51  will be locked open, whereas if the rod  83  engages the second indention  79 , the lid  51  will be locked closed. 
     FIG. 11A illustrates a flexible parts transporting system  3  with a longer latitudinal side  102  and a shorter longitudinal side  104 . Shelf assemblies  21 A and  21 B are of equal size and bisect side  104 , dividing the flexible parts transporting system  3  into two equal sections and forming hinge line  103 . Sequential shelf assemblies  21  are stacked underneath shelf assemblies  21 A and  21 B and are configured in the same manner. A person of ordinary skill in the art would recognize that the shelf assemblies  21 A and  21  B may be of differing dimensions and may divide the flexible parts transporting system  3  into unequal sections shifting the hinge line  103 . The shelf assemblies  21 A and  21 B are configured to swing open about the hinge line  103  in a longitudinal direction with respect to the flexible parts transporting system  3  and in opposite directions with respect to each other as indicated by arrows B and C. 
     FIG. 11B illustrates a flexible parts transporting system  3  with a longer latitudinal side  106  and a shorter longitudinal side  108 . Shelf assembly  21  is the lone shelf assembly visible in this plan view, but sequential shelf assemblies  21  configured in the same manner are stacked underneath the visible shelf assembly  21 . The shelf assembly  21  is configured to swing open about hinge line  107  and in a latitudinal direction with respect to the flexible parts transporting system  3  indicated by arrow D. 
     FIG. 11C illustrates a flexible parts transporting system  3  with a longer latitudinal side  112  and a shorter longitudinal side  114 . Shelf assembly  21  is the lone shelf assembly visible in this plan view, but sequential shelf assemblies  21  configured in the same manner are stacked underneath the visible shelf assembly  21 . The shelf assembly  21  is configured to swing open about hinge line  113  and in a longitudinal direction with respect to the flexible parts transporting system  3  indicated by arrow E. 
     FIG. 11D illustrates a flexible parts transporting system  3  with a longer latitudinal side  116  and a shorter longitudinal side  118 . Shelf assembly  21  is the lone shelf assembly visible in this plan view, but sequential shelf assemblies  21  configured in the same manner are stacked underneath the visible shelf assembly  21 . The shelf assembly  21  is configured to swing open about hinge line  117  and in a latitudinal direction with respect to the flexible parts transporting system  3  indicated by arrow F. 
     FIG. 11E illustrates a flexible parts transporting system  3  with a longer latitudinal side  122  and a shorter longitudinal side  124 . Shelf assembly  21  is the lone shelf assembly visible in this plan view, but sequential shelf assemblies  21  configured in the same manner are stacked underneath the visible shelf assembly  21 . The shelf assembly  21  is configured to swing open about hinge line  123  and in a longitudinal direction with respect to the flexible parts transporting system  3  indicated by arrow G. 
     FIG. 11F illustrates a flexible parts transporting system  3  with a longer latitudinal side  126  and a shorter longitudinal side  128 . Shelf assemblies  21 C and  21 D are of equal size and bisect side  126 , dividing the flexible parts transporting system  3  into two equal sections and forming hinge line  127 . Sequential shelf assemblies  21  are stacked underneath shelf assemblies  21 C and  21 D and are configured in the same manner. A person of ordinary skill in the art would recognize that the shelf assemblies  21 C and  21 D may be of differing dimensions and may divide the flexible parts transporting system  3  into unequal sections shifting the hinge line  127 . The shelf assemblies  21 C and  21 D are configured to swing open about hinge line  127 , in a latitudinal direction with respect to the flexible parts transporting system  3 , and in opposite directions with respect to each other as indicated by arrows H and I. 
     It is to be understood that the invention is not limited to the exact construction illustrated and described above, but that various changes and modifications may be made without departing from the spirit and scope of the invention as defined in the following claims.