Patent Publication Number: US-7909562-B2

Title: Material handling apparatus

Description:
CROSS-REFERENCE TO RELATED ACTIONS 
     This application claims the benefit of U.S. Provisional Application No. 60/821,786 filed Aug. 8, 2006, which is incorporated by reference herein in its entirety. 
    
    
     BACKGROUND 
     Today, many forms of goods are transported through the supply chain from manufacturers and growers to distributors and retailers. The manufacturers and suppliers typically use material handling devices, such as pallets and slip sheets, to move the products through the supply chain. Material handling devices are typically moved about using material handling vehicles, such as forklifts, pallet jacks, orderpickers, robots, etc. The material handling vehicles typically place the material handling devices, along with the product, into a conventional warehouse racking system. Employees and/or consumers can retrieve the products from the racking system. 
     SUMMARY 
     In general, in an aspect, the invention provides a material handling apparatus for use with a material carrier board including an aperture, the material handling apparatus being configured to couple to a lifting portion of a lift truck that includes forks, the material handling apparatus including a mount configured to be coupled to the lifting portion of the lift truck, a backrest having a bottom edge and a front face, a scissor structure coupled to the mount and to the backrest, the scissor structure being configured to operate between extended and retracted states, wherein when the scissor structure is operated from the retracted state to the extended state, the backrest is extended from a proximal end of the forks towards a distal end of the forks, a stop plate including horizontal and vertical planar portions, the stop plate being attached to the bottom edge of the backrest, the stop plate being attached to the backrest such that the horizontal planar portion is substantially perpendicular to the front face of the backrest, the vertical planar portion is substantially parallel to and offset from the front face of the backrest, the horizontal planar portion of the stop plate forming an aperture, a first actuator coupled to the mount and the scissor structure being configured to actuate the scissor structure between the extended and retracted states, a second actuator coupled to the backrest, a stud coupled to the second actuator and configured to operate between extended and retracted states along an axis that is substantially parallel to the front face of the backrest, the stud being configured to extend through the aperture formed in the stop plate and through the aperture formed in the carrier board when the stud is actuated from the retracted to the extended state, wherein the material handling apparatus is configured to pull the carrier board onto the forks by, when the stud is in the extended state, actuating the scissor portion from an extended state to a retracted state. 
     Embodiments of the invention may provide one or more of the following features. The horizontal and vertical planar portions are configured in an L-shape. The stud includes a tapered portion that is positioned on a distal end of the stud, wherein the tapered portion is configured to aid alignment of the stud and the aperture in the carrier board. The actuation of the scissor portion is controlled by a three-way control. The actuation of the stud is controlled by a three-way control. The actuation of the scissor portion and the stud are controlled by a single three-way control. The apparatus further includes a plurality of guide blocks coupled to the stop and configured to align the stud with the aperture formed in the horizontal portion of the stop. 
     In general, in another aspect, the invention provides a method for handling a load disposed on a carrier board using a lift truck including a lifting portion that includes forks, the method including approaching the carrier board at a first location with the lift truck, positioning the lifting portion to a height such that a top surface of the forks is lower than a bottom of the carrier board, extending a backrest portion towards a distal end of the forks, the backrest portion including a stud configured to be received by an aperture in the carrier board, actuating the stud such that the stud extends at least partially through the aperture in the carrier board, retracting the backrest portion towards a proximal end of the forks such that the carrier board is pulled onto the forks by the stud, wherein the carrier board is supported by the forks, relocating the carrier board to a second location, positioning the lifting portion such that the top surface of the forks is at least as high as a surface of interest onto which the carrier board will be placed, and extending the backrest portion towards the distal ends of the forks such that a stop portion of the backrest pushes the carrier board onto the surface of interest. 
     Embodiments of the invention may also provide one or more of the following features. The method further includes retracting the stud from the aperture. Extending the backrest portion towards the distal ends of the forks such that a stop portion of the backrest drives the carrier board onto the surface of interest includes driving the carrier board into a racking system. The method further includes controlling the operation of the lift truck using hand operator controls. The method further includes controlling the operation of the lift truck using an automated controller. The method further includes controlling the operation of the backrest using a three-way control. The method further includes controlling the operation of the stud using a three-way control. The method further includes controlling the operation of the backrest and the stud using a single three-way control. 
     Various aspects of the invention may provide one or more of the following capabilities. A load of material can be handled without an ordinary pallet. Individual tiers of material can be handled using carrier boards. Load handling efficiency can be increased. A push-pull assembly can be used to handle a load of material disposed on a carrier board. Ordinary pallets and carrier boards can be handled by a single lift truck. 
     These and other capabilities of the invention, along with the invention itself, will be more fully understood after a review of the following figures, detailed description, and claims. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1  is a diagram of a portion of a material handling apparatus. 
         FIG. 2  is a diagram of the material handling apparatus shown in  FIG. 1  with a push-pull assembly extended. 
         FIG. 3  is a diagram of the material handling apparatus shown in  FIG. 1  with the push-pull assembly extended. 
         FIG. 4  is a diagram of the material handling apparatus shown in  FIG. 1  with the push-pull assembly and a stud extended. 
         FIG. 5  is a diagram of the material handling apparatus shown in  FIG. 1  with the stud extended. 
         FIG. 6  is a diagram of the material handling apparatus shown in  FIG. 1  with the push-pull assembly retracted. 
         FIG. 7  is a diagram of the material handling apparatus shown in  FIG. 1  with the stud retracted. 
         FIG. 8  is a diagram of the push-pull assembly shown in  FIG. 1 . 
         FIG. 9  is a diagram of the stud in an extended position. 
         FIG. 10  is a diagram of the stud in a retracted position. 
         FIG. 11  is a diagram of the stud shown in  FIG. 10 . 
         FIG. 12  is a diagram of the stud shown in  FIG. 10 . 
         FIG. 13  is a diagram of a process for retrieving and unloading a carrier board. 
         FIGS. 14A-14C  are diagrams of a carrier board for use with the material handling apparatus shown in  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments of the invention provide techniques for providing an apparatus that is configured to handle material carrier boards used in material handling systems. The apparatus is an attachment that is configured to be used with a standard forklift truck or automated material handling system. The handling apparatus is further configured to be used with a carrier board that includes gripping apertures. The handling apparatus includes a backrest portion, an actuating portion, and a scissor portion. The actuating portion includes a stud that that is configured to be actuated in first and second positions such that in the second position the stud extends through the gripping aperture in the carrier board. The scissor portion can be actuated to extended and retracted positions such that when the stud is extended, and the scissor portion is actuated from the extended position to the retracted position, the stud is configured to pull the carrier board onto the forks of the forklift. Other embodiments are within the scope of the invention. 
     Referring to  FIGS. 1-8 , a carrier board handling system  1  includes an extendable push-pull assembly  5 , forks  10 , and a lift truck  12 . The lift truck  12  is, for example, a forklift, a slipsheet machine, an order picker, a tractor, or a reach truck. The lift truck  12  includes a lifting portion  13 . The lifting portion  13  extends vertically and is configured to lift the forks  10  and the push-pull assembly  5  to a desired height (e.g., the height of a bay in a racking system). The push-pull assembly  5  is configured to attach to the lift truck  12  either removably or permanently. For example, the push-pull assembly  5  can be attached to the lift truck  12  using hooks, fasteners (e.g., bolts), can be welded to the lift truck  12 , or can be coupled to the lift truck  12  using a “quick connect” system. The push-pull assembly  5  is configured to be actuated in outward and inward directions (relative to the front of the lift truck  12 ), although other directions are possible. For example, the push-pull assembly  5  is extended away from the front of the lift truck  12  towards a distal end of the forks  10  by actuating the push-pull assembly  5  in the outward direction. The push-pull assembly  5  is retracted towards the lift truck  12  by actuating the push-pull assembly in the inward direction. The push-pull assembly  5  is configured to be controlled by an operator of the lift truck  12  using, for example, a hand controller. 
     The push-pull assembly  5  includes a stop  15 , an extendable stud  20  (not visible in  FIG. 1 ), a scissor portion  25 , and a backrest  30 . The push-pull assembly  5  is configured to be operable using hydraulic, pneumatic, electrical, and/or electromechanical power provided by the attached lift truck and/or can be self powered. The scissor portion  25  is, for example, a pantograph device. The backrest  30  can vary in size (e.g., a few inches tall to a few feet tall). The stop  15  and the stud  20  are supported by the push-pull assembly  5 . The stop  15  is preferably about the same width as the backrest  30 , although other configurations are possible (e.g., the stop  15  can be split into two sections). To retrieve a carrier board  35 , the push-pull assembly  5  is preferably configured to extend at least about as far as the end of the forks  10  (e.g., as shown in  FIGS. 2-3 ) and is configured to extend the stud  20  into and/or through an aperture  40  provided by the carrier board  35  to “attach” the carrier board  35  to the push-pull assembly  5  (e.g., as shown in  FIGS. 4-5 ). The push-pull assembly  5  is configured to retract, with the stud  20  extended, to pull the attached carrier board  35  onto the support members  10  (e.g., as shown in  FIG. 6 ). The system  1  is configured to securely grip the attached supported carrier board  35  such that the lift truck can move about without the attached supported carrier board  35  becoming separated from the system  1 . 
     The push-pull assembly  5  is also configured to unload a carrier board  35  that is supported by the forks  10 . The push-pull assembly  5  is configured to (e.g., using the stop  15 ) push the carrier board  35  off of the forks  10  onto, for example, a racking system. Upon placing the carrier board  35  onto a racking system, the operator can disengage the stud  20  from the aperture  40  of the carrier board  35  (e.g., as shown in  FIG. 7 ) and retract the push-pull assembly  5 , leaving the carrier board  35  on the racking system. The stud  20 , however, can be retracted at other times as well. 
     The push-pull assembly  5  is configured to be operated using several methods. The operation of the push-pull assembly  5  and the stud  20  can be controlled by respective hand and/or foot controls. For example, one three-way switch (e.g., extend, stop, and retract) can control the operation of the push-pull assembly  5 , and another three-way switch can control the operation of the stud  20 . Likewise, a single three-position can be used to control the operation of the push-pull assembly  5  and the stud  20  jointly. For example, the operator can extend the push-pull assembly  5  by moving the switch to the extend position. Once the push-pull assembly  5  is fully extended, the operator can maintain the switch in the extend position to extend the stud  20 . Other control configurations are possible. 
     Referring to  FIGS. 8-12 , the stud  20  is disposed on the backrest  30  and is configured to actuate between retracted and extended positions using an actuator  50  that is coupled to a plate  55 . The actuator  50  is preferably hydraulic, although other types of actuators can be used. The plate  55  is disposed on the backrest  30  and is configured to attach to the actuator  50 . Guides  60  are disposed on the stop  15  and the backrest  30  and are configured to position the stud  20  relative to an aperture  65  in the stop  15 . The aperture  15  is sized such that the stud  20  can pass therethrough when actuated by the actuator  50 . The guides  60  include channels  70  that are sized to receive the peripheral edges of the stud  20  and are configured to align the stud  20  relative to the aperture  65 . The actuator  50  and the guides  60  are configured such that when the actuator  50  actuates the stud  20  between the retracted and extended positions, the stud  20  moves in a substantially vertical direction (e.g., arrow  75 ) that is parallel to the backrest  30  (e.g., perpendicular relative to the direction of travel of the push-pull assembly  5 ). 
     The push-pull assembly  5  is configured to facilitate alignment of the stud  20  with a carrier board  35  which is to be handled by the system  1 . The stud  20  is configured to be adjustable in multiple directions and is configured to compensate for a misaligned carrier board  35  relative to the stud  20 . The stud  20  includes rounded portions  21  and is tapered to facilitate alignment and insertion of the stud  20  into the aperture  40 . For example, the channels  70  can be “loose-fit” to the stud  20  (e.g. represented by the dashed lines in  FIG. 10 ) such that as the stud  20  is extended towards the aperture  40  of the carrier board  35 , the rounded portions  21  are configured to cause the stud  20  to self-align with the aperture  40 . 
     Additional hydraulic actuators can also be used to align the stud  20  relative to the aperture  40  of the carrier board  35 . For example, the guide blocks  60  can be coupled to hydraulic actuators such that the stud  20  can move in a direction perpendicular to the backing plate  30  (e.g., in the same direction as the direction of travel of the push-pull assembly  5 ). Furthermore, hydraulic actuators can also be configured to actuate the guide blocks  60  such the stud  20  can move in a direction parallel to the backing plate (e.g., side-to-side as shown by arrow  80 ). The additional actuators can be configured to be controlled by an operator of the lift truck  12  using a hand-control. 
     The push-pull assembly  5  is configured to be stowed (e.g., in the retracted position) such that the lift truck  12  can function normally (e.g., the push-pull assembly  5  can remain attached to the lift truck  12  while the lift truck  12  handles ordinary pallets). For example, a manufacturer could supply a pallet of goods that includes multiple levels of carrier boards (e.g., every tier of product on the pallet is on a separate carrier board). A single unit could unload the pallet of carrier boards from a truck, and place the carrier boards in the racking system without having to use a separate lift truck, or change lift truck attachments. 
     In operation, referring to  FIG. 13 , with further reference to  FIGS. 1-12 , a process  100  for retrieving and unloading a carrier board using the system  1  includes the stages shown. The process  100 , however, is exemplary only and not limiting. The process  100  may be altered, e.g., by having stages added, removed, or rearranged. The process  100  is configured to be used with carrier boards such as the carrier board  35  shown in  FIGS. 14A-14B , although other carrier boards can be used. 
     At stage  105 , the lift truck  12  driven by an operator approaches a carrier board  35 . The operator generally aligns the lift truck  12  with the carrier board  35 . The carrier board  35  can be located in a racking system, or in a stack (e.g., a carrier board layer, a material layer, a carrier board layer, a material layer, etc.), although other configurations are possible. The remainder of the description pertaining to the process  100  assumes that the carrier board  35  is located in a racking system. 
     At stage  110 , the operator retrieves the carrier board  35  from the racking system. Preferably, the operator adjusts the lift truck  12  such that the distal ends of the forks  10  are close (e.g., within a few inches) of the carrier board  35  and such that the top of the forks  10  are positioned slightly below the bottom of the carrier board  35 . The operator extends the push-pull assembly  5  to at least about the end of the forks  10  such that one edge of the carrier board  35  is preferably in contact with the stop  15 . The operator extends the stud  20  through the aperture  40  of the carrier board  35 . The operator retracts the push-pull assembly  5  such that the carrier board  35  is pulled onto the forks  10  by the stud  20 . Preferably, the operator retracts the push-pull assembly  5  such that the carrier board is fully supported by the forks  10 . 
     At stage  115 , the operator relocates the carrier board to a desired location using the lift truck  12 . While relocating the carrier board  35  to the desired location, the stud  20  is preferably extended thereby reducing the likelihood that the carrier board  35  will become displaced from the forks  10 . 
     At stage  120 , the operator unloads the carrier board  35  from the lift truck. Preferably, the operator adjusts the lift truck  12  such that the distal ends of the forks  10  are slightly above the surface upon which the carrier board  35  will be supported on once unloaded from the lift truck  12 . The operator extends the push-pull assembly  5  such that the stop  15  pushes the carrier board  35  away from the lift truck  12  into the desired location (e.g., in a bay of a racking system). The operator retracts the stud  20  from the aperture  40  of the carrier board  35  and retracts the push-pull assembly  5 . 
     Other embodiments are within the scope and spirit of the invention. For example, due to the nature of software, functions described above can be implemented using software, hardware, firmware, hardwiring, or combinations of any of these. Features implementing functions may also be physically located at various positions, including being distributed such that portions of functions are implemented at different physical locations. 
     While “forks”  10  have been described herein, other configurations are possible. For example, the forks can be other support means capable of supporting the weight of a load placed thereupon (e.g., slip sheet forks or an extendable table). 
     While the push-pull assembly  5  is described herein as being attached to forklift truck  12 , other configurations are possible. For example, the push-pull assembly  5  can be configured to attach to a lift truck such as an automated material handling system (e.g., a robotic material handling system). 
     Further, while the description above refers to the invention, the description may include more than one invention.