Source: http://www.google.com/patents/USRE35555?ie=ISO-8859-1&dq=7253017
Timestamp: 2015-04-01 22:59:26
Document Index: 83336737

Matched Legal Cases: ['art. 2', 'art 70', 'art 70', 'art 70', 'art 70', 'art 70', 'arts 70', 'arts 70', 'art 70', 'art 70', 'art 70']

Patent USRE35555 - Automatic bundle loading apparatus and method - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inAdvanced Patent SearchPatentsIn an automatic loading system and method wheeled carts receive five or six layers of newspaper bundles of four to six bundles per layer. A waist-high conveyor and an inclined ramp conveyor move bundles to a roller platform of independently operated roller sections selectively halted upon receipt of...http://www.google.com/patents/USRE35555?utm_source=gb-gplus-sharePatent USRE35555 - Automatic bundle loading apparatus and methodAdvanced Patent SearchPublication numberUSRE35555 EPublication typeGrantApplication numberUS 08/369,879Publication dateJul 8, 1997Filing dateJan 9, 1995Priority dateMar 27, 1991Fee statusPaidAlso published asCA2063898A1, CA2063898C, DE69228056D1, DE69228056T2, EP0577765A1, EP0577765A4, EP0577765B1, EP0867382A2, EP0867382A3, US5181820, WO1992017391A1Publication number08369879, 369879, US RE35555 E, US RE35555E, US-E-RE35555, USRE35555 E, USRE35555EInventorsChrister A. Sjogren, Kevin CoteOriginal AssigneeQuipp Systems, Inc.Export CitationBiBTeX, EndNote, RefManPatent Citations (14), Referenced by (5), Classifications (16), Legal Events (2) External Links: USPTO, USPTO Assignment, EspacenetAutomatic bundle loading apparatus and method
US RE35555 EAbstract
In an automatic loading system and method wheeled carts receive five or six layers of newspaper bundles of four to six bundles per layer. A waist-high conveyor and an inclined ramp conveyor move bundles to a roller platform of independently operated roller sections selectively halted upon receipt of a bundle. When the desired number of bundles have been delivered to the roller platform, a pusher laterally moves the bundles to a split roller platform. A second group of bundles are delivered to the roller platform and the split roller platform. The sections of the split roller platform are then abruptly pulled apart causing the bundles to drop upon a fork-like platform extending into one side of a cart receiving the bundles. The pusher is retracted to the start position and the fork-like platform is lowered to receive the next layer of bundles in a like manner. Once the cart is filled with the desired number of layers, the fork-like platform is withdrawn from the cart, the cart is advanced to a take-off location and the next cart is indexed to the receiving location, being guided thereto along guide rails. Each cart comprises a platform rolling upon casters and having an open top defined by four sides which form a cage-like structure. One side has lockable double doors to facilitate bundle removal. Cart sizes are desired to make efficient use of the truck cargo space receiving the carts.
1. Apparatus for automatically loading a cart comprised of a platform surrounded by sidewalls and having an open top, at least one of said sidewalls having a plurality of vertically aligned elongated clearance slots;said apparatus comprising: a loading station for receiving and positioning said cart; means for receiving bundles to be loaded into said cart; conveyor means adjacent said receiving means for conveying the bundles received from said receiving means to a location a .[.predetermiend.]. .Iadd.predetermined .Iaddend.height above an open end of said cart at said loading station; a platform assembly for receiving bundles from said conveyor means; said platform assembly being comprised of a plurality of sections; means for selectively advancing bundles along said sections including means to halt the advancing of bundles on each section responsive to detection of a bundle on said section; pusher means responsive to the presence of bundles upon .[.predetermiend.]. .Iadd.predetermined .Iaddend.ones of said sections for pushing said bundles in a transverse direction onto a split platform means; said split platform means comprising first and second platform sections movable between a closed position wherein adjacent edges of said platform sections are in close proximity and an open position wherein said sections are moved apart to define a gap region between said split platform sections; said gap region being positioned immediately above the open end of said cart; and means responsive to delivery of bundles by said pusher means upon said split platform assembly for moving said split platform sections apart whereupon the bundles resting thereon are dropped through said gap region toward said cart. 2. The apparatus of claim 1 wherein said split platform means has a supporting surface area large enough to receive a plurality of groups of bundles from said platform assembly wherein each group of bundles comprises a predetermined number of bundles collected upon said platform assembly;said pusher means pushing a first group of said bundles to a first position on said split platform furthest removed from said platform assembly; and said pusher means moving a next group of bundles delivered to said platform assembly to a location upon the surface of said split platform means located between said platform assembly and the first group of bundles delivered to said split platform means. 3. The apparatus of claim 2 further comprising:means for operating said split platform means comprising a pair of air cylinders each having a piston movable therein responsive to pressurized fluid applied to said cylinder; each piston means including rod means with a first end extending into said cylinder for coupling with said piston and a second end pivotally coupled to an associated one of said split platform sections for reciprocating said split platform sections. 4. The apparatus of claim 1 wherein the number of sections provided is greater than a number of bundles pushed onto said split platform means by said pusher means.
6. The apparatus of claim 1 further comprising:movably mounted platform means having a plurality of spaced substantially parallel tines cooperatively forming a fork-like platform; means for reciprocating said fork-like platform in a substantially horizontal plane from a first position wherein said fork-like platform is inserted into the sidewall of a cart provided with said vertically oriented insertion slots, and a second position wherein said fork-like platform is totally withdrawn from said cart; means for reciprocating said fork-like platform in a vertical direction between an upper and a lower position; and means for moving said fork-like platform in a downward direction after the bundles delivered by the split platform means are dropped upon said fork-like platform responsive to opening of said split platform sections. 7. The apparatus of claim 6 further comprising:means for moving the cart from the loading station and moving a cart adjacent to the loading station into the loading station responsive to removal of said fork-like platform from the cart in the loading station. 8. The apparatus of claim 6 further comprising:means for reciprocating said fork-like platform in a vertical direction including bidirectional, two-speed motor means; and means responsive to an output of said motor means for moving said fork-like platform. 9. The apparatus of claim 8 further comprising control means for said motor means for moving said motor means at a first, higher speed and for operating said motor means at a second lower speed when said fork-like platform has travelled a predetermined distance from a desired location.
18. The apparatus of claim 1 where said carts are comprised of at least one releasably lockable door hingedly coupled to said cart along one side thereof and swingable between an open and a closed position; andlocking means for selectively locking said door in said closed position. 19. The apparatus of claim 18 wherein said door comprises the sidewall provided with said elongated .[.inserting.]. .Iadd.clearance .Iaddend.slots.
21. The apparatus of claim 1 wherein at least one sidewall of said carts comprises:first and second swingably mounted doors movable between a closed position and an open position; and means for selectively locking said doors in the closed position. 22. The apparatus of claim 1 wherein each of said carts is provided with identification means;reading means for reading said identification means on said cart means and means for associating the identification means with contents of the cart and the destination for said contents; and remote reading means coupled to said central reading means for obtaining information from said central reading means for identifying the cart for a particular destination and including reading means for reading said carts to determine an identity of the cart and data associated with said destination. 23. The apparatus of claim 1 further comprising:guide means for guiding said cart toward a loading position; means for automatically advancing the carts in said guide means toward said loading position responsive to completion of loading of a cart in the loading position. 24. The apparatus of claim 23 wherein said cart advancing means comprises:a drive means; a drive chain entrained about a first gear coupled to said drive means and a second free-wheeling gear; pusher members coupled to said chain at spaced intervals therealong for moving a said cart engaged by said pusher means. 25. The apparatus of claim 24 wherein said pusher means comprises:means for enabling each pusher means to swing downwardly when moved by a cart in a cart advancing direction to provide clearance for pushing the cart onto said guide means and bias means for automatically moving said pusher means to an upright position when said pusher means clears the cart; and means preventing each pusher means from rotating in a second direction when in the upright position, thus assuring each pusher means pushes a cart in a forward indexrag direction when the indexing drive motor means is energized. 26. The apparatus of claim 1 wherein said bundles are packages.
32. Carts for use in a system for automatically loading said carts including a platform arranged above a loading position for receiving a cart therebeneath;said platform having a delivery opening whereby a cart in the loading position has an upper end thereof aligned with said openings; split platform means comprising first and second platform sections movable between a first position closing said opening for receiving the bundles thereon and a second position for unsealing said opening; stop means on opposite parallel sides of said opening for limiting movement of objects on said platform sections as they are moved to said second position whereby objects on said platform sections are caused to fall downwardly through said openings; means for delivering and arranging bundles upon said platform sections when in said first position; said cart being comprised of a platform; caster assemblies mounted upon the underside of said platform for rollingly moving said platform upon a supporting surface; a plurality of said walls extending upwardly from said platform for enclosing said platform; said cart having an open upper end defined by the upper ends of said sidewalls; at least one of said sidewalls being provided with a plurality of elongated spaced vertically aligned insertion slots adapted to receive a fork-like platform having a plurality of spaced parallel tines and being movable between a first position wherein said tines are inserted into respective ones of said insertion slots and a second position wherein said tines are withdrawn from said cart; and means for moving said platform downwardly through a predetermined distance responsive to bundles being dropped upon said fork-like platform through said delivery opening. 33. The apparatus of claim 32 wherein at least one of the sidewalls of said cart comprises a hingedly mounted door to facilitate unloading of bundles therefrom.
39. Apparatus for automatically loading a cart comprised of a platform surrounded by sidewalls and having an open top, at least one of said sidewalls having a plurality of vertically aligned elongated clearance slots;said apparatus comprising: a loading station for receiving and positioning said cart; means for receiving bundles to be loaded into said cart; conveyor means adjacent said receiving means for conveying the bundles received from said receiving means to a location a .[.predetermiend.]. .Iadd.predetermined .Iaddend.height above an open end of said cart at said loading station; a platform assembly for receiving bundles from said conveyor means; said platform assembly being comprised of a plurality of sections; means for selectively advancing bundles along said sections including means to halt advancing of bundles on each section responsive to detection of a bundle on said section; pusher means responsive to a presence of bundles upon predetermined ones of said sections for pushing said bundles in a transverse direction onto a split platform means; said split platform means comprising first and second platform sections movable between a closed position wherein adjacent edges of said platform sections are in close proximity and an open position wherein said sections are moved apart to define a gap region between said split platform sections; said gap region being positioned immediately above the open end of said cart; and means responsive to delivery of bundles by said pusher means upon said split platform assembly for moving said split platform sections apart whereupon the bundles resting thereon are dropped through said gap region toward said cart; said cart being comprised of: caster assemblies mounted upon an underside of said platform for rollingly moving said platform upon a supporting surface; a plurality of sidewalls extending upwardly from said platform for enclosing said platform; said cart having an open upper end defined by the upper ends of said sidewalls; at least one of said sidewalls being provided with a plurality of elongated spaced vertically aligned insertion slots adapted to receive a fork-like platform having a plurality of spaced parallel tines and being movable between a first position wherein said tines are inserted into respective ones of said insertion slots and a second position wherein said tines are withdrawn from said cart; and means for moving said platform downwardly through a predetermined distance responsive to bundles being dropped upon said fork-like platform through said delivery opening. .Iadd. 40. Apparatus for automatically loading a wheeled cart comprised of a floor, sidewalls and an open top, said apparatus comprising:a cart loading station at which a cart may be positioned for loading; platform means arranged above said cart loading station and having a supporting surface of a size sufficient to receive a plurality of groups of bundles; said platform means comprising at least one movable platform member for supporting bundles delivered to said platform means, and being movable between a closed position and an open position to define a gap region in said platform means; said gap region being positioned immediately above an open top of a cart at said loading station; conveying means for receiving bundles and delivering received bundles to a location adjacent to said platform means; pusher means for pushing a first group of said bundles from said conveying means onto said platform; said pusher means moving a second group of bundles delivered to said platform means onto said platform means, said first and second groups of bundles being positioned upon said gap region; and means responsive to delivery of bundles by said pusher means upon said platform means gap region for moving the movable platform member to the open position whereupon bundles located in the gap region are dropped through said gap region toward said loading station. .Iaddend..Iadd. 41. Apparatus for automatically loading a wheeled cart comprised of a floor, sidewalls and an open top, at least one of said sidewalls having an opening, said apparatus comprising:a cart loading station for receiving a cart to be loaded; first platform means arranged above the cart loading station for dropping bundles on said first platform means toward an open top of a cart at said cart loading station; second platform means being arranged beneath said first platform means for supporting at least one bundle dropped by said first platform means; first means for selectively moving said second platform means in substantially horizontal direction between a first position wherein said second platform means is inserted into a cart at said loading station and a second position wherein said second platform means is withdrawn from a cart at said loading station; said first platform means including movable support means to provide a gap region in said first platform means for dropping at least one bundle on said gap region through said gap region and toward an open top of a cart at said loading station and upon said second platform means; and second means for moving said second platform means in a downward direction after a bundle is dropped upon said second platform means. .Iaddend..Iadd. 42. The apparatus of claim 41 further comprising:said second means for moving including means to move said second platform means in a downward vertical direction a distance substantially equal to a height of a bundle responsive to a bundle being dropped onto said second platform means. .Iaddend..Iadd.43. The apparatus of claim 42 wherein said cart at the loading station is provided with means for retaining bundles in said cart when said second platform means is moved to said second position. .Iaddend..Iadd.44. The apparatus of claim 41 wherein said second means further comprises means for moving said second platform means at a first, lower speed when lowering said second platform means and for moving said second platform means at a second higher speed when raising said second platform means. .Iaddend..Iadd.45. Apparatus for automatically loading a cart comprised of a platform having a floor, sidewalls and an open top, said apparatus comprising: loading station for receiving and positioning a cart; platform assembly above said loading section for delivering bundles to a cart at said loading station; conveyor means for conveying the bundles received from a receiving means to a location adjacent said platform assembly; pusher means responsive to a presence of bundles upon said conveyor means for pushing said bundles onto said platform assembly; said platform assembly comprising at least one movable platform section movable between a closed position and an open position to define a gap region in said platform assembly; said gap region being positioned immediately above an open end of a cart at said loading station; and means responsive to delivery of bundles by said pusher means upon said platform assembly for moving said movable platform section to said open position whereupon bundles resting thereon are dropped through said gap region toward said cart. .Iaddend..Iadd.46. The apparatus of claim 45 wherein said platform assembly further comprises a second movable platform section cooperating with said one movable platform section and movable, together with said one movable section, between a closed position where edges of said first and second sections are adjacent to one another and an open position where said edges are spaced apart to define said gap region. .Iaddend.
Completed bundles delivered from the mailroom facility into the circulation phase in which bundles are typically delivered from the mailroom into trucks by a conveyor, the bundles typically being removed manually from the conveyor and loaded into the truck cargo space.
Inserts, such as, for example, advertising insets are typically placed in each newspaper. This is quite often the case for weekend newspapers and especially Sunday newspapers. The number of inserts is very often quite large and the size of the inserts typically vary and also deviate from the size of the newspaper. In addition, the insets are often placed into the newspaper in a haphazard manner with the result that the major side surfaces of the newspaper assume a bulging shape which significantly deviates from a desirable pair of flat, substantially parallel surfaces. Bundles of a plurality of such signatures, when wrapped or tied together assume a shape which significantly deviates from a rectangular parallelepiped shape and, in fact, take on a shape somewhat similar to that of a watermelon, such wrapped bundles of newspapers containing numerous insets typically being referred to as "watermelons". The insets are usually placed into the newspapers at the request of local merchants or retailers to concentrate their advertising in those areas within a reasonable distance from their locations. Thus, a newspaper intended for distribution over a large area may contain different inserts according to its final destination within its distribution area.
Techniques which have been developed to reduce the circulation phase operating costs include the development of loading carts each of which are comprised of cage-like sidewalls mounted upon a platform provided with casters for enhancing portability. At least one side surface of the cart is provided with a hingedly mounted door which is unlocked and opened for the purpose of receiving bundles. When the cart is loaded, the door is swung closed and locked enabling the cart to be loaded (i.e. pushed) into the cargo space. The carts are dimensioned so as to make the most economic use of the total cargo space volume. The carts are preferably of a boxlike shape and are capable of receiving a plurality of layers of newspaper bundles, each layer comprising a plurality of bundles. In one example the cart is designed to receive a layer of four bundles arranged in two-by-two fashion (i.e. two rows of two bundles per row), for example, or six bundles arranged in three-by-two fashion (i.e. three rows of two bundles per row or two rows of three bundles per row), the cart having a height capable of accommodating of the order of five or six such layers.
Alternatively, the system control, by way of a software routine, may index each layer of bundles with the vertically movable fork-like platform to its lowest position (just above the previous layer) and then retract the tines carrying the layer or bundles to be "dropped" on top of the platform of the cart, or the previous layer, as the case may be.
When the desired number of layers have been deposited in the cart, the fork-like platform is withdrawn from the cage-like cart, the bars of the cage sidewall cooperating to provide a "scraping" action, the bars serving to remove or "scrape" the layers of bundles stacked upon the fork-like platform from the platform as it is withdrawn from the cart the layers of bundles removed from the platform being retained within the cart and being stacked in substantially neat fashion. Even assuming the bundles being stacked are "watermelon-shaped" the cart nevertheless serves to retain stacks of signature bundles contained therein in a substantially neat and compartmentalized manner, which is especially important for delivery groupings wherein the contents of each cart may be of a particular bundle count and are scheduled for delivery to different destinations.
When the loading of the cart is completed, drive means moves the loaded cart from the loading position towards the next station, which is typically the truck loading dock. Simultaneously therewith the next empty cart is advanced and indexed to the cart loading position The carts are moved along guide tracks to facilitate alignment in one direction. Sensor means are provided to accurately align the cart at the loading position whereupon the initial operating steps are repeated namely, the fork-like platform is reinserted into the cart located at the loading position and positioned near the top, open end of the cart, bundles are advanced along the delivery and ramp conveyors to the forwardmost roller sections (if they have not already been delivered thereto), and a row of bundles is then pushed onto the split platform, these steps being repeated for the present and each subsequent cart to be loaded.
FIG. 1d is a simplified elevational view of the elevator mechanism of FIG. 1 showing an alternative embodiment;
FIGS. 2c, 2d and 2e show top plan views of carts which are useful in describing the various cart sizes and the manner in which a layer of bundles are arranged thereto;
It should further be understood that the conveyors 12 and 16 may be of a variety of different lengths in order to accommodate the existing installations of mailrooms and circulation facilities. In the preferred embodiment, the bundles are delivered from a conveyor 12 of a height of the order of three or so feet above the ground along the ramp conveyor 18 to a height or about six feet.
The bundles are delivered from the ramp conveyor 18 to the roller platform assembly 20 which, in turn, is comprised of a plurality of individual selectively powered roller assemblies 22, 24, 26 and 28 shown in greater detail in FIG. 1c. Each assembly is comprised of a power unit 22a through 28a or powering those rollers R associated with the roller section, power being selectively controlled by CPU 32 applying the control signals to control inputs 22c through 28c for automatically and independently controlling each roller section.
The pusher assembly 36 comprises a pusher plate 38 mounted to a pair of downwardly depending arms 39a, 39b secured to a housing 40. A pair of elongated rods 41a, 41b are mounted in spaced parallel fashion and have their ends secured to a pair of support plates 42a, 42b secured to the system famework F. Rods 41a, 41b extend through openings in housing 40 which is adapted to be freely slidable along rods 41a and 41b. It should be understood that suitable bearings and/or bushings B shown in dotted fashion are provided in the housing to render housing 40 freely slidable along rods 41a and 41b.
FIGS. 2a and 2b show two different perspective views of a cart 70 utilized in the automatic loading system 10 and comprised of a floor or platform P supported by a plurality of rugged, durable casters 72 provided at each corner of the underside of platform P. The casters are mounted for rotation about a vertical axis 73 as shown by arrow A4, in FIG. 2b.
Cart 70 has three fixed sides 74, 76 and 78, each having a substantially rectangular-shaped frame 74a, 76a, 78a provided with intermediary, integral cross pieces 74b-74c, 76b-76c and 78b-78c. A plurality of vertically aligned, spaced, parallel bars 74d, 76d and 78d are secured to the upper horizontal member of the frames 74a, 76a and 78a and the horizontal members 74b, 76b and 78b respectively. Similar groups of vertically oriented, spaced, parallel bars 74e, 76e, 78e and 74f, 76f, 78f are similarly secured to associated horizontal members of each sidewall, yielding an open, cage-like cart and yet one having sufficient inherent structural strength to provide a rugged cart capable of withstanding heavyduty use. If desired, the vertical bars may be one-piece members extending between the upper and lower horizontal members of each sidewall frame and extending through the reinforcing members 74b, 76b, etc.
The fourth sidewall 80 is comprised of a pair of hingedly mounted doors 82, 84 each having a rectangular-shaped frame 82a, 84a, each provided with hinges, such as the hinges H for swingably moving the doors between a closed (solid line) position and any one of a variety of open positions shown in dotted line fashion as 82', 82" and 82'" and 84', 84" and 84'". Each door is provided with vertically oriented, spaced, parallel uprights 82b and 84b respectively secured to the upper and lower horizontally aligned portions of frames 82a and 82b. The doors may be retained in the locked position by a pair of locking means 86 and 88 each having a locking bolt 86a, 88a arranged on frame 84a into an associated receiving housing 86b, 88b for receiving its associated sliding bolt. Any other suitable type of releasable locking means may be utilized. In addition, or as an alternative to the locking means described hereinabove, similar sliding bolt, may be provided at the lower inside portion of each frame and comprising a sliding bolt for slidable movement into an opening provided in platform P Note, for example, FIG. 2b showing a locking means 96 provided on the inside frame 84a of swingable door 84 and provided with a sliding bolt 90a movable into an opening O in platform P. Although not shown for purposes of simplicity, similar locking means may be provided along the lower interior side of door 82.
FIG. 2k shows another self-locking arrangement wherein each door frame, such as frame 84a is provided with an opening for receiving a latch pin 91. A cover plate 93 is mounted upon the surface 84a-1 of frame 84a and is secured thereto by fasteners F. Plate 93 has an opening aligned with the opening in frame 84a. Platform P also has an opening aligned with the pin 91, extending through plate 93 and frame 84a, when the door is in the closed position. Pin 91 has an enlarged head portion 91a and an annular shoulder 91b. A helical bias spring SP engages plate 93 and shoulder 91b. urging pin 91 downwardly toward the locked position. The pin is removed from (or returned to) the locking hole in platform P simply by gripping head 91a and lifting pin 91 upwardly against the force of bias spring SP.
The structure of the doors 82 and 84, differs from the remaining sidewalls 74-78 of the cart in that horizontal reinforcing members have been omitted from the doors to enable insertion and unimpeded vertical sliding movement of the fork-like platform within the cart, as will be described hereinbelow in greater detail.
The cart may further be modified by replacing the pair of double doors with a single door or alternatively, with upper and lower single doors or two pair of double doors to facilitate a variety of options for facilitating unloading of the carts. As was mentioned hereinabove, the carts may handle four bundles or six bundles per layer (respectively arranged two-by-two or two-by-three) or even nine bundles per layer (arranged three-by-three). The double doors permit removal of the contents of half of the layers at one time. One typical cart has a height of the order of five foot two inches and is capable of receiving five to seven layers per cart. The carts are preferably rated for twelve hundred pound loads. Assuming six two-by-three layers for a total of thirty-six bundles with a weight of twenty-six pounds per bundle, the total/weight of the load is less than one thousand pounds, well within the rating of the cart.
System 10 is provided with a pair of elongated, channel-shaped cart guides 92 and 94 having outwardly tapered sides 92a, 94a which facilitate guiding of the cart casters 72 into the channel guides. The guides 92, 94 are shown as being filled to capacity with four carts, 70, 70', 70" and 70'". A cart 70"", shown in dotted fashion, is pushed up against the last cart 70 to enter into the guides in readiness for automatic advancement. A drive motor 96 is provided with a sprocket 98 having a chain 100 entrained around drive sprocket 98 and a driven sprocket 102 rotatably mounted upon a support bracket 104 by shaft 106. Motor 96 drives chain 100 in the direction so that its upper run moves in the direction of arrow A4. A plurality of pusher members 108 are arranged in spaced intervals along the length of chain 100 (note also FIGS. 1a and 1b) and have a forward surface 108a for engaging the lower frame portion of frame 74a forming sidewalls 74. The pushers 108 are arranged at spaced intervals each interval, being greater than the width W of a cart measured along the sidewall of the cart carrying the door. When a cart has been filled by the loading system 10, motor 96 is operated to advance each pusher along the upper run of chain 100 a distance equal to approximately one cart length to advance the cart (70") in the loading position to the position occupied by cart 70'". Carts 70 and 70' are likewise advanced to occupy the positions shown by carts 70" and 70' thus allowing space for one additional cart to be pushed onto the guides 92, 94. The cart 70"" may now be manually pushed into the guides to occupy the position shown by cart 70. The pushers 108 are hingedly coupled to chain 100 by angle bracket 109 and a coupling pin 111 enabling the pushers to swing in the counterclockwise direction (see FIGS. 1a and 1b) to be swung downwardly and out of the way of the cart 70"" being pushed onto the guides 92, 94. Recess 108b in pusher 108 receives the chain 100 enabling the pusher 108 to move downwardly and out of the path of a cart. As soon as the cart is clear of the pusher 108, the spring loading mechanism provided therein comprising a torsion spring 113 having an arm 113a resting against the rear end of pusher 108 and an arm 113b coupled to the horizontal portion of angle bracket 109 permits the pusher to swing counterclockwise and snaps the pusher to the upright position when the pusher clears the bottom of a cart. The upright portion 109a of bracket 109 is engaged by the rearward end of pusher 108 preventing pusher from rotating clockwise when in the upright position.
Any other mechanisms utitized for swingably moving the pushers in a first direction, snapping them upwardly and preventing the pushers from rotating counterclockwise when in the upright position may be utilized and details therefor have been omitted herein for purposes of simplicity.
Initially, let it be assumed that the fork-like platform 112 is located at the uppermost position approximately four inches below the split platform assembly 50 with the fork-like platform extending into the cart. A layer of bundles is dropped from the split platform onto the fork platform and, after a predetermined delay, the program jumps over to the loading elevator routine shown in FIG. 2j. Initially, assuming the platform 112 be located at its upper extreme position, approximately four inches below the split platform 50, delay D3 is selected to be sufficient to assure that the bundles of the present layer have dropped upon the platform 112 whereupon motor 118 is operated at its high speed. A sensor 150a is activated and a counter is examined. If the counter has not reached the predetermined count, after a predetermined delay, the counter is incremented by one count. The program continues to loop therearound until the count C2 is reached at which time motor 118 is changed to low speed and sensor 150a is examined. When sensor 150a detects The presence of the platform 112, power to the motor is turned off, automatically braking the motor and the routine then returns to the main program,
When the next layer of bundles is deposited upon be layer of bundles previously loaded upon platform 112, the downward movement described hereinabove is repeated utilizing the next sensor 150b. Similar sensors are positioned at set intervals along the left-hand side of frame 114, for example, with the lowermost sensor 150n being shown in FIG. 4.
The two parallel sides 152a, 152b of the frame structure 152 are hollow, channel-shaped members for slidably receiving a housing 166 from which the fork-like tines 112a extend and to which the lines are integrally joined. The rectangular parallelepiped-shaped housing 166 is provided with two pairs of wheels arranged on opposite parallel sides thereof. A first pair of outer wheels 168a rollingly engage the top and bottom horizontally aligned surfaces of the channel-shaped frame portion 152b. A second pair of wheels 168b arranged to route about vertically oriented axes which are perpendicular to the horizontally oriented axes about which rollers 168 rotate, rollingly engage the interior surface of the vertical side of the channel-shaped portion 152b. These two pairs of wheels prevent relative movement of the housing 166 in both the horizontal and vertical direction relative to frame 152. Similar pairs of wheels 168a and 168b are provided along the left-hand side of housing 166 and function in a manner substantially identical to the pairs of wheels arranged along the right-hand side of housing 166.
The motor 176 may be any suitable motor and may be abruptly halted when a predetermined element 166a, such as a magnet, is sensed by proximity sensors 188 and 190 to respectively indicate when the housing 166 and hence tines 112a have been moved to the fully-inserted (112a') and fully-withdrawn (112a) position relative to a cart being loaded. If desired, a similar arrangement may be provided on frame 152 and frame 114 wherein sensors 150-150n may be proximity switches for sensing a magnet or ferromagnetic member arranged on frame 152.
As soon as the platform 112 reaches the fully-withdrawn position, element 166a (see FIG. 4a) is detected by sensor 190 whereupon motor 176 is halted and motor 118 is operated at high speed to return the platform to the uppermost position. A predetermined number of counts are accumulated as motor 118 is operating at high speed to lift the platform 112. When the predetermined number of counts has been detected, motor 118 is controlled to operate at the low speed. This position is typically in close proximity to the uppermost sensor 150, for example, whereupon when sensor 150 is detected, motor 118 is deenergized and abruptly brakes to a stop. When the next cart has been indexed into the loading position, motor 176 is activated to move platform 112c into the cart to support the first layer of bundles delivered to the cart. The platform 112 is lowered as each layer of bundles is deposited thereon until the platform is lowered to the lowermost position or any other appropriate position (in the case where a cart is programmed to receive less than the maximum number of bundles) whereupon the platform 112 is delivered to the bottommost position and the platform 112 is withdrawn from the cart by motor 176 and is returned to the uppermost position in readiness for loading another cart under the control or motor 118.
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