Patent Publication Number: US-2011049076-A1

Title: Method and Apparatus for Vertically Orienting Precast Concrete Wall Panels

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS/INCORPORATION BY REFERENCE 
     This application claims priority benefits from U.S. Provisional Patent Application Ser. No. 61/239,141 filed Sep. 2, 2009, entitled “Method And Apparatus For Vertically Orienting Precast Concrete Wall Panels”. This application also claims priority benefits from U.S. Provisional Patent Application Ser. No. 61/239,063 filed Sep. 2, 2009, entitled “Tilting Table With Telescoping Arms For Precast Vertical Wall Panels”. The &#39;141 and &#39;063 provisional applications are hereby incorporated by reference herein in their entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to precast building wall panels. In particular, the present invention relates to a technique for lifting precast building wall panels formed in a horizontal position into a vertical position for subsequent storage and transporting. 
     BACKGROUND OF THE INVENTION 
     In the manufacture of precast building wall panels, it is particularly problematic to orient the heavy panels, which are formed by casting in a horizontal position, to a vertical position in which they can be conveniently stored and transported. The present technique overcomes the problem using a lifting beam with a pair of pin drive assemblies for engaging holes formed in opposite sides of the wall panel. 
     The advantages of handling, storing and shipping wall panels in a vertical position include:
         (a) road transportation permits are not required for panels wider than 8.5 feet;   (b) panels up to 12 feet wide can be shipped vertically with no dimensional travel restrictions;   (c) panels can stacked and stored more densely in a vertical position than in a horizontal position;   (d) special horizontal wall panel lifters are not required.       

     The present lifting beam apparatus can be used to lift concrete panels directly, or it can also be attached to a vacuum lifting beam. When panels are cast horizontally, the vacuum beam can be employed to lift the panel off the casting frame and place it on a hydraulic tilting table. The tilting table can tilt the panel to a near-vertical position (up to about 80° from horizontal), where the panel can then be lifted vertically by the lifting beam. 
     SUMMARY OF THE INVENTION 
     Embodiments of the present technology provide methods and systems for orienting to a vertical position a precast wall panel formed in a horizontal position, the panel having holes formed in opposite sides thereof. 
     In an embodiment, a lifting beam assembly includes: (a) a lifting beam; (b) a pair of oppositely facing pin carriages mounted on said lifting beam, each of said pin carriages comprising a pin adapted to be received in a hole formed in opposing sides of a precast wall panel formed in a horizontal position; and (c) a motorized drive mechanism configured to displace said pin carriages toward and away from each other along the length of said lifting beam. 
     In an embodiment, the lifting beam is configured to be lifted by an overhead crane using a pair of hooks. 
     In an embodiment, the motorized drive mechanism is operatively connected to a drive shaft that is operatively connected to a pair of ball screws, each ball screw associated with one of the pin carriages in order to displace the associated pin carriage. 
     In an embodiment, rotation of the drive shaft in a first direction causes the pin carriages to move away from each other, and wherein rotation of the drive shaft in a second direction opposite the first direction causes the pin carriages to move toward each other. 
     In an embodiment, the lifting beam further includes a load cell pin configured to detect a weight of the lifting beam assembly and any item affixed thereto. 
     In an embodiment, the lifting beam further includes a scale display configured to display the weight detected by the load cell. 
     In an embodiment, the pin carriages remain equidistant from a center of the lifting beam when the pin carriages are displaced. 
     In an embodiment, a system for orienting to a vertical position a precast wall panel formed in a horizontal position, the panel having holes formed in opposite sides thereof, includes: (a) an overhead crane having a pair of suspended hooks; (b) a lifting beam suspended from said crane hooks, said lifting beam comprising: (i) a pair of oppositely facing pin carriages mounted on said lifting beam, each of said pin carriages comprising a pin adapted to be received in one of said panel holes; (ii) a motorized drive mechanism for displacing said pin carriages toward and away from each other along the length of said lifting beam. 
     In an embodiment, the motorized drive mechanism is operatively connected to a drive shaft that is operatively connected to a pair of ball screws, each ball screw associated with one of the pin carriages in order to displace the associated pin carriage. 
     In an embodiment, rotation of the drive shaft in a first direction causes the pin carriages to move away from each other, and wherein rotation of the drive shaft in a second direction opposite the first direction causes the pin carriages to move toward each other. 
     In an embodiment, the system further includes a load cell pin configured to detect a weight of the lifting beam assembly and any item affixed thereto. 
     In an embodiment, the system further includes a scale display configured to display the weight detected by the load cell. 
     In an embodiment, the pin carriages remain equidistant from a center of the lifting beam when the pin carriages are displaced. 
     In an embodiment, the system further includes vacuum lifting beam configured to use suction to lift a horizontally disposed wall panel. 
     In an embodiment, a method of orienting to a vertical position a precast wall panel formed in a horizontal position includes: aligning pins extending from a pair of oppositely facing pin carriages on a lifting beam with holes formed in opposite sides of a precast wall panel formed in a horizontal position; displacing the pin carriages toward each other along the length of said lifting beam such that said pins engage said holes; and rising the lifting beam, thereby orienting said wall panel in a vertical position. 
     In an embodiment, hooks suspended from an overhead crane are used to align the pins and raise the lifting beam. 
     In an embodiment, the method further includes using a vacuum lifting beam to lift the wall panel in a horizontal orientation and place the wall panel on a tilting table in the horizontal orientation. 
     In an embodiment, the method further includes using the tilting table to rotate the wall panel from the horizontal orientation to a near vertical orientation. 
     In an embodiment, the method further includes placing the vertically oriented wall panel in a trailer configured to transport vertically oriented wall panels. 
     In an embodiment, the method further includes continuously measuring and displaying a weight of the lifting beam and the wall panel. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front elevation view of a lifting beam assembly used in accordance with embodiments of the present technology. 
         FIG. 2  is a top-sectional view of the lifting beam assembly of  FIG. 1 . 
         FIG. 3  is a side elevation view of the lifting beam assembly of  FIG. 1 . 
         FIG. 4  is a side sectional view of the lifting beam assembly of  FIG. 1  taken in the direction of arrows  4 - 4 . 
         FIG. 5  is an exploded view of the right-hand ball screw assembly for displacing the right-hand pin carriage along the length of the lifting beam assembly of  FIG. 1 . 
         FIG. 6  is an exploded view of the left hand pin carriage in the lifting beam assembly illustrated in  FIG. 1 . 
         FIG. 7  is a magnified view of the torque bracket assembly in the lifting beam assembly of  FIG. 1 . 
         FIG. 8  is a magnified view of the motor assembly in the lifting beam assembly of  FIG. 1 . 
         FIG. 9  is a magnified view of the bearing assembly in the lifting beam assembly of  FIG. 1 . 
         FIG. 10  depicts an apparatus for orienting to a vertical position a precast wall panel formed in a horizontal position in accordance with embodiments of the present technology. The apparatus includes an overhead crane and the lifting beam assembly of  FIG. 1 . 
         FIG. 11  is a side elevation view of the apparatus of  FIG. 10  depositing a vertically-oriented building wall panel into a trailer for transporting multiple wall panels oriented in a vertical position. 
         FIG. 12  is a rear elevation view of the apparatus of  FIG. 10  depositing a vertically-oriented building wall panel into a trailer for transporting multiple wall panels oriented in a vertical position. 
         FIG. 13  is a front elevation view of the apparatus of  FIG. 10  from which a vacuum lifting beam is suspended. 
         FIG. 14  is a side elevation view of a precast wall panel on a hydraulic tilting table in the horizontal position. 
         FIG. 15  is a side elevation view of a precast wall panel on a hydraulic tilting table in a near-vertical position. 
         FIG. 16  is a perspective view of a precast wall panel on a hydraulic tilting table in a near-vertical position. 
         FIG. 17  is a perspective view of the apparatus of  FIG. 10  being aligned so that the pins projecting from the pin carriage can be inserted into and engage the holes formed in a precast wall panel mounted in a tilting table holding the wall panel in a near-vertical position. 
         FIG. 18  is a perspective view of the apparatus of  FIG. 10  being used to transport a precast wall panel after the wall panel has been lifted from a tilting table into a vertical position. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENT(S) 
     The present invention relates to precast building wall panels. In particular, the present invention relates to a technique for lifting precast building wall panels formed in a horizontal position into a vertical position for subsequent storage and transporting. Certain embodiments employ a lifting beam assembly with opposing pin carriages configured to be movable about the length of a beam. The pin carriages each comprise a pin, such that the opposing pins can be inserted into holes on opposite sides of a wall panel in order to lift the panel such that the panel can be transported and/or stored in a vertical position. Certain embodiments are described below in connection with the figures. In the figures, like elements have like identifiers. 
       FIG. 1  is front elevation view of a lifting beam assembly  100  used in accordance with embodiments of the present technology. Lifting beam assembly  100  includes beam  102 , left hand pin carriage  104  comprising pin  105 , right hand pin carriage  106  comprising pin  107 , motorized drive mechanism  108 , drive shaft  109 , scale display  110 , load cell pins  111 , shackles  112 , left hand ball screw  113 , left hand ball screw bearing  114 , right hand ball screw  115 , and right hand ball screw bearing  116 . 
     Shackles  112  are attached to the top of beam  102  in spaced apart relation. In certain embodiments, right and left shackles  112  are spaced apart about 15 feet, each shackle  112  being 7.5 feet from the center of beam  102 . Shackles  112  are configured to receive respective hooks of an overhead crane. Shackles  112  are attached to the top of beam  102  at load cell pins  111 . Load cell pins  111  are configured to detect the weight of the lifting beam assembly  100  and any item(s) being lifted by lifting beam assembly  100 . Scale display  110  is in operable communication with load cell pins  111  and is configured to display the weight detected by load cell pins  111 . Load cell pins  111  and scale display  110  can be used to help prevent overloading an overhead crane. 
     Motorized drive mechanism  108  is disposed inside beam  102  and positioned at the center of beam  102 . Motorized drive mechanism  108  is operably connected to drive shaft  109  such that activating motorized drive mechanism  108  can cause drive shaft  109  to rotate in a first direct and a second direction opposite the first direction. Drive shaft  109  is disposed inside beam  102  and is operably connected to left hand ball screw  113  and right hand ball screw  115  such that ball screws  113 ,  115  rotate when drive shaft  109  rotates. Left hand ball screw  113  is disposed inside beam  102  and is operably connected to left hand ball screw bearing  114  such that left hand ball screw bearing  114  translates horizontally about left hand ball screw  113  when left hand ball screw  113  rotates, thereby causing left hand pin carriage  104  and pin  105  to translate horizontally about the length of beam  102 . Right hand ball screw  115  is disposed inside beam  102  and is operably connected to right hand ball screw bearing  116  such that right hand ball screw bearing  116  translates horizontally about right hand ball screw  115  when right hand ball screw  115  rotates, thereby causing right hand pin carriage  106  and pin  107  to translate horizontally about the length of beam  102 . 
     In operation, motorized drive mechanism  108  can be activated, causing drive shaft  109  to rotate in a first direction such that pins  105  and  107  move toward the center of beam  102 . That is, when drive shaft  109  rotates in the first direction, left hand ball screw  113  rotates in the first direction forcing left hand ball screw bearing  114  to translate horizontally about left hand ball screw  113  toward the center of beam  102 . This causes left hand pin carriage  104  and pin  105  to move toward the center of beam  102 . Likewise, when drive shaft  109  rotates in the first direction, right hand ball screw  115  rotates in the first direction forcing right hand ball screw bearing  116  to translate horizontally about right hand ball screw  115  toward the center of beam  102 . This causes right hand pin carriage  106  and pin  107  to move toward the center of beam  102 . 
     Motorized drive mechanism  108  can also be operated in reverse, causing drive shaft  109  to rotate in a second direction opposite the first direction such that pins  105  and  107  move away from the center of beam  102  toward the ends  118 ,  120  of beam  102 . That is, when drive shaft  109  rotates in the second direction, left hand ball screw  113  rotates in the second direction forcing left hand ball screw bearing  114  to translate horizontally about left hand ball screw  113  away from the center of beam  102  toward the left end  118  of beam  102 . This causes left hand pin carriage  104  and pin  105  to move away from the center of beam  102  toward the left end  118  of beam  102 . Likewise, when drive shaft  109  rotates in the second direction, right hand ball screw  115  rotates in the second direction forcing right hand ball screw bearing  116  to translate horizontally about right hand ball screw  115  away from the center of beam  102  toward the right end  120  of beam  102 . This causes right hand pin carriage  106  and pin  107  to move away from the center of beam  102  toward the right end  120  of beam  102 . 
     In the embodiment depicted in  FIG. 1 , left hand ball screw bearing  114  can translate horizontally about left hand ball screw  113  between the left end  118  of beam  102  and a point  122  where left hand ball screw  113  is attached to drive shaft  109 . In certain embodiments, point  122  is positioned at the same place on beam  102  that the left shackle is positioned. Similarly, right hand ball screw bearing  116  can translate horizontally about right hand ball screw  115  between the right end  120  of beam  102  and a point  124  where right hand ball screw  115  is attached to drive shaft  109 . In certain embodiments, point  124  is positioned at the same place on beam  102  that the right shackle is positioned. In certain embodiments, left hand ball screw bearing  114  and right hand ball screw bearing  116  are maintained at equal distances from the center of beam  102  in order to maintain balance of lifting beam assembly  100  and any item(s) being transported using lifting beam assembly  100 . In certain embodiments, beam  102  can span about 44 feet and 7 inches. In certain embodiments, the maximum distance between pins  105 ,  107  is about 40 feet. In certain embodiments, the minimum distance between pins  105 ,  107  is about 14 feet and 10 inches. In certain embodiments, the maximum distance that each pin carriage  104 ,  106  can move laterally about the length of beam  102  is about twelve feet and 7 inches. 
       FIG. 2  is a top-sectional view of the lifting beam assembly  100 .  FIG. 3  is a side elevation view of the lifting beam assembly  100 .  FIG. 4  is a side sectional view of the lifting beam assembly  100  taken in the direction of arrows  4 - 4  (see  FIG. 1 ). 
       FIG. 5  is an exploded view of right-hand ball screw assembly  500  for displacing right-hand pin carriage  105  along the length of beam  102 . The left-hand ball screw assembly for displacing left-hand pin carriage  104  mirrors the illustrated right-hand ball screw assembly  500 , using the same motorized drive mechanism  108 . Right-hand ball screw assembly  500  includes motorized drive mechanism  108 , drive shaft  109 , right hand ball screw  115 , right hand ball screw bearing  116 , and endplate  502 . Drive shaft  109  includes two portions connected at bolt flange bearing  504  with keystocks  506  at rigid coupling  508 . Bolts/washers  510  and hex nuts  512  are used to attach bolt flange bearing  504  to rigid coupling  508 . Similar, items are used to connect right hand ball screw  115  to drive shaft  109 . Similar, items are also used to connect endplate  502 . 
       FIG. 6  is an exploded view of left hand pin carriage  104  from lifting beam assembly  100 . Right hand pin carriage  106  mirrors the left hand pin carriage  104 . Left hand pin carriage  104  includes pin bracket  602  with rollers  608 , pin  105 , left hand ball screw bearing  114 , ball screw bracket  604 , and ball screw guide  606  with rollers  610 . Ball screw bracket  604  is configured to receive left hand ball screw bearing  114  and maintain left hand ball screw bearing  114  therein. Ball screw bracket  604  is rigidly attached to pin bracket  602  at its bottom and ball screw guide  606  at its top. Pin bracket  602  includes rollers  608  configured to contact a lower interior surface  612  (depicted in  FIG. 1 ) of beam  102  in order to facilitate lateral displacement of pin carriage  104  about the length of beam  102 . Ball screw guide  606  includes rollers  610  configured to contact an upper interior surface  614  (depicted in  FIG. 1 ) of beam  102  in order to facilitate lateral displacement of pin carriage  104  about the length of beam  102 . 
       FIG. 7  is a magnified view of the torque bracket assembly  700  in the lifting beam assembly  100 . Torque bracket assembly  700  is configured to mount motorized drive mechanism  108  to the upper interior surface  614  of beam  102 , and includes mounting beam  702 , bar mount  704  and mounting screw/nut  706 . In certain embodiments, torque bracket assembly  700  can be used to mount motorized drive mechanism  108  at or near the center of beam  102 . 
       FIG. 8  is a magnified view of the motor assembly  800  in the lifting beam assembly  100 . Motor assembly  800  is disposed inside beam  102 , and can be provided behind window  802 , which can allow motor assembly  800  to be viewed from outside beam  102 . Window  802  can also be opened or removed in order to provide access to motor assembly  800 . Motor assembly  800  includes motorized drive mechanism  108 , drive shafts  109  and bolt flange bearings  504 , as also depicted and described in connection with  FIG. 5 . 
       FIG. 9  is a magnified view of the right hand bearing assembly  900  in the lifting beam assembly  100 . Bearing assembly  900  is disposed inside beam  102 , and can be provided behind window  902 , which can allow bearing assembly  900  to be viewed from outside beam  102 . Window  902  can also be opened or removed in order to provide access to bearing assembly  900 . Bearing assembly  900  includes drive shaft  109 , bolt flange bearings  504 , and right hand ball screw  115 , as also depicted and described in connection with  FIG. 5 . 
       FIGS. 10-18  depict lifting beam assembly  100  being used in connection with an overhead crane  1002 , a vacuum lifting beam  1302  and/or a tilting table  1401  in order to transport horizontally precast wall panels in a vertical orientation. 
       FIG. 10  depicts an apparatus for orienting to a vertical position a precast wall panel  1008  formed in a horizontal position in accordance with embodiments of the present technology. The apparatus includes overhead crane  1002  and lifting beam assembly  100 . Crane  1002  is configured to be supported by, and movable about, an overhead support system  1006 . Overhead crane  1002  includes hooks  1004  suspended from crane  1002 . Hooks  1004  are received by shackles  112  of lifting beam assembly  100  such that crane  1002  can be used to lift and transport lifting beam assembly  100  and any item(s) affixed thereto. Lifting beam assembly  100  can be affixed to precast wall panel  1008  by inserting pins  105 ,  107  into holes  1010 ,  1012  located on opposing sides of precast wall panel  1008 . The location of holes  1010 ,  1012  on opposing sides and toward an end of wall panel  1008  cause wall panel  1008  to become vertically oriented when lifted by pins  105 ,  107 . That is, wall panel  1008  will rotate on pins  105 ,  107  to a vertical orientation when lifted by pins  105 ,  107 . 
     As depicted in  FIG. 10 , crane  1002  can include two hooks  1004  and lifting beam assembly  100  can include two shackles  112  in spaced apart relation. In other embodiments, crane  1002  can include more hooks  1004  and lifting beam assembly  100  can include a corresponding number of shackles  112  in spaced apart relation. In certain embodiments, crane  1002  can have a capacity of about 60,000 pounds. In certain embodiments, lifting beam assembly  100  can weigh about 6200 pounds. 
     As depicted in  FIGS. 11-12 , crane  1002  and lifting beam assembly  100  can be used to deposit a vertically-oriented building wall panel  1008  into a trailer  1102  configured to transport wall panels oriented in a vertical position. 
     As depicted in  FIG. 13 , lifting beam assembly  100  can be affixed to a vacuum lifting beam  1302  configured to use vacuum suction to lift a horizontally disposed wall panel  1008  from a casting frame  1306 . Wall panel  1008  can then be transported in the horizontal position to a tilting table, where vacuum suction can be discontinued such that wall panel  1008  rests on the tilting table. In certain embodiments, vacuum lifting beam  1302  can weigh about 4800 pounds. 
       FIG. 14  depicts wall panel  1008  disposed horizontally on tilting table  1401 . Tilting table  1401  includes telescoping table  1402 , hydraulic arm  1404  and pivot  1406 . Telescoping table  1402  can be extended to accommodate a wall panel with a greater surface area and retracted to accommodate a wall panel with less surface area. Telescoping table  1402  can be rotated about pivot  1406  using hydraulic arm  1404  in order to move wall panel  1008  from the horizontal position to a near vertical position.  FIGS. 15-16  depict wall panel  1008  disposed nearly vertical on tilting table  1401 . 
     As depicted in  FIG. 17 , crane  1002  can be used to align pins  105 ,  107  of lifting beam assembly  100  with holes  1010 ,  1012  of wall panel  1008 . Once aligned, Motorized drive mechanism  108  can be actuated to cause pins  105 ,  107  to move toward the center of beam  102  until pins  105 ,  107  engage holes  1010 ,  1012 . Once engaged, crane  1002  and lifting beam assembly  100  can be used to transport wall panel  1008  in the vertical orientation. 
     In certain embodiments, operating the systems and/or applying the methods described herein can provide for improved transportation and storage of wall panels in a vertical orientation that were cast in a horizontal orientation. 
     While particular elements, embodiments and applications of the present invention have been shown and described, it will be understood that the invention is not limited thereto since modifications can be made by those skilled in the art without departing from the scope of the present disclosure, particularly in light of the foregoing teachings.