Abstract:
This invention is an oblique fork or channel parallel moving transfer system especially for lift or stacker vehicles for storage and retrieval of containers such as automobile parking pallets, racks, parts boxes, etc. on storage shelves, platforms or racks including those having a plurality of tiers for storing the containers. It can serve as a parking garage, warehouse or other storage-retrieval system. The lift vehicle has a lift or fork bed with one or more oblique channels or forks extended to engage a line of rollers or cooperating slide member on the container to move the container out from the tier and support it when the vehicle is engaged and moved parallel to the facing side of the tier. The vehicle lifts and lowers and rolls along an aisle for transfer to and from racks on either or both sides. Two cooperating lifts columns are at opposite corners farthest from the channel for transfer clearance to and from either side. End loading ramps extend over the end of the stacker for end loading of a pallet with vehicles. The lift bed or forks can be mounted on a lift truck supported from one or both ends along one side to transfer when operated parallel along an aisle.

Description:
RELATED APPLICATIONS  
       [0001]     This application claims priority of U.S. Provisional Patent Application Ser. No. 60/553,271 filed Mar. 15, 2004, which is incorporated herein by reference.  
         [0002]     This invention is a continuation-in-part of my pending U.S. application Ser. No. 10/663,293 and relates to my U.S. Pat. Nos. 6,652,214 issued Nov. 25, 2003 and 6,695,561 issued Feb. 24, 2004. 
     
    
     FIELD OF THE INVENTION  
       [0003]     This invention is an application of my drive-by transfer to lift trucks. This invention combines an oblique channel transfer platform with a stacker or lift truck especially suited for warehouse storage and retrieval of racks, pallets, parts boxes, or other containers. The result is a reduction of aisle space needed, since the drive-by transfer eliminates need for transverse travel of forks.  
       BACKGROUND OF THE INVENTION  
       [0004]     At present forks are extended from an aisle to a side to go under pallets to lift them and back out. My improvement eliminates this and reduces aisle width to the width of the container plus clearance by eliminating the need to turn a stacker in the aisle even while serving both sides of the aisle.  
         [0005]     While lift trucks are available with forks turned 90° to a side and that move out to that side and back to eliminate turning of the stacker to serve only one side of an aisle, that type is considered complex and requires stopping in alignment for operation of the fork. It is an object to eliminate that mechanism and simplify for similar applications and further to be able to transfer to either side of an aisle without turning around.  
         [0006]     The motion of my lift truck for transfer is straight along the aisle past a storage rack where a container is thereby transferred in or out according to the direction of travel.  
       SUMMARY OF THE INVENTION  
       [0007]     It is an object to provide fast transfer to or from storage by providing transfer while moving steadily in either direction.  
         [0008]     It is an object to reduce the width of warehouse aisles.  
         [0009]     It is an object to provide a lift truck with platform for this parallel transfer along either or both sides of the aisle without turning the vehicle to transfer along different sides of the aisle.  
         [0010]     It is a further object to have open access above the pallet on the stacker to use a crane to load the pallet on the stacker. An end lift elevator for each end of the lift platform, preferably at diagonally opposite corners of the platform, provides overhead clearance and all sides access.  
         [0011]     It is an object to provide loading-unloading vehicle ramps at each end of travel of the stacker for drive on-off loading of the pallet on the stacker.  
         [0012]     It is an object to provide a simplified, dependable, low cost stacker that does not need an attendant at the storage rack location for transfer.  
         [0013]     It is an object to provide latches that release the pallet when engaged by the lift platform for transfer from the rack. 
     
    
     BRIEF DESCRIPTION OF THE DRAWING  
       [0014]     These other and further objects should be evident to those skilled in the art by studying this specification with reference to the accompanying drawings wherein:  
         [0015]      FIGS. 1 and 2  are respectively plan and side views of a parking garage or warehouse aisle with storage racks along both sides of the aisle with the stacker therein between the storage racks and end drive on-off loading ramps at ends of the aisle.  
         [0016]      FIGS. 3 and 4  are plan and side views of the far edge of a pallet on the stacker moving to the right engaging a tab arm on the pallet with an empty rack to transfer the pallet to the rack.  
         [0017]      FIG. 5  is a perspective view of a pallet.  
         [0018]      FIG. 6  is an end elevation view of  FIGS. 3 and 4 .  
         [0019]      FIGS. 7 and 8  are respectively plan and side views of the stacker.  
         [0020]      FIGS. 9 and 10  are respectively plan and side views of the platform on the stacker moving to the left to transfer the container in  FIG. 9  onto the platform.  
         [0021]      FIG. 11  is an end view in the direction of arrow  11  in  FIG. 9  to larger scale.  
         [0022]      FIG. 12  is a side view of the end of the oblique channel extended on the stacker to transfer a container thereto at a larger scale.  
         [0023]      FIG. 13  is a section on line  13 - 13  of  FIG. 9  to larger scale.  
         [0024]      FIG. 14  is a plan view of a variation of the load platform moving to the left engaging a container for transfer thereto.  
         [0025]      FIG. 15  is an end elevation of the pallet on lines  15 - 15  of  FIG. 14  showing an extended fixed cam roller arm.  
         [0026]      FIG. 16  is a side view on line  16 - 16  of  FIG. 14 .  
         [0027]      FIG. 17  is a plan view of the end of the storage rack with container on the stacker being moved to the right to transfer thereto.  
         [0028]      FIG. 18  is a side elevation of  FIG. 17 .  
         [0029]      FIG. 19  is an elevation on line  19 - 19  of  FIG. 14 .  
         [0030]      FIGS. 20-22  are respectively plan, front, and side views of a variation of cam roller arm found in  FIG. 14  to larger scale.  
         [0031]      FIGS. 23 and 24  are respectively aligned plan and side views of a preferred rotary lifting latch on the pallet of  FIG. 14 .  
         [0032]      FIG. 25  is a partial bottom view of  FIG. 24 .  
         [0033]      FIGS. 26 and 27  are elevation views on lines  26 - 27  of  FIG. 23  with respectively the latch lifted and lowered.  
         [0034]      FIG. 28  is a section on line  28 - 28  of  FIG. 26  to larger scale.  
         [0035]      FIGS. 29 and 30  are respectively plan and front elevations of a variation of the cam transfer arm of  FIGS. 23-28 .  
         [0036]      FIG. 31  is a section on line  31 - 31  of  FIG. 29  with arm extended.  
         [0037]      FIGS. 32 and 33  are respectively side and bottom views of another variation of the transfer arm.  
         [0038]      FIGS. 34 and 35  are respectively plan and side views of an oblique fork on a lift truck moving to the left about to engage a container with the fork.  
         [0039]      FIG. 36  is an oblique view of the container of  FIGS. 34 and 35 .  
         [0040]      FIGS. 37 and 38  are partial end elevations of the container being engaged by the forks of  FIGS. 34 and 35  to larger scale.  
         [0041]      FIG. 39  is a plan view of a container with two oblique channel tunnel tubes.  
         [0042]      FIGS. 40, 41 , and  42  are respectively plan, side, and end views of a two-column loader with load fork with portion of the container of  FIG. 39  in phantom. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0043]     Referring to the drawings and in particular to  FIGS. 1-13 , containers or pallets  20  are stored on racks or shelves  22  that face along either or both sides of aisle  24  along which stacker  26  runs to place and retrieve the containers.  
         [0044]     The stacker has a drop center frame  28 ,  FIGS. 2 and 8 , generally rectangular in plan supported on wheels  30  to run along aisle  24 . A lift column  32  is secured extending up vertically from two diagonally opposite corners of its drop center. The arm  76  extended up to be turned down by a pallet on the rack. Lever  76  extends down below shaft  74  with weight  78  to normally hold the lever upright and the tab extended. When the pallet enters the rack from the aisle it turns lever  76  down rotating sprocket  72  to pull tongue  70  in so the stacker will not try to put a pallet in a loaded rack. Arm  64 ,  FIG. 19 , is lifted by cam  80  on the rack to swing up past vertical to stay up and remain up for retrieval so as not to reenter a rack until after the arm  64  is reset out.  
         [0045]     Referring to  FIGS. 9-13 , ends of oblique runner, I-beam  56 , extend out from pallet  20  engage channel  54  when extended on the lift platform from either side. Channel  54 ,  FIG. 13 , has a tubular rectangular inner channel  82  with top slotted open central to capture runner  56  to slide therein. Channel  82  is slip-fit between holding channels  84  and  85  and positioned along these holding channels by rack and pinion gearing  88  driven by gearmotor  89  to extend out either end of channel  54  to engage the oblique I-beam runner  56  on the bottom of pallet  20  to engage and pull the pallet out of the rack onto the platform when moving along the aisle at the correct height.  
         [0046]     Inner channel  82  has a scoop  90 ,  FIG. 12 , at each end to lift latch  57  before entering into channel  54  to unlatch the pallet from the rack before pulling it onto the stacker. The web of channel  82  at the scoop slopes down on the end to lift latch  57  and recesses into a pocket  91  in the platform when retracted by gearmotor  89 . The leading leg of channel  82  is bent around and extended down along the side of the stacker has a lift platform  34  which runs up and down on the vertical track on columns  32 . The two diametrically opposite corners of platform  34  at columns  32  have a vertical tracking member  36  secured to the platform with shoes or rollers  38  engaged to travel the vertical track of column  32 ,  FIGS. 9 and 10 . A chain or cable  40  is connected to the top of each member  36  and run up and over a sprocket  42  at the top of the vertical column and down to a lifting device  44  coordinated to lift and lower the platform level. The stacker is driven or moved along the aisle in either direction by any suitable means such as cable drive  46 . The platform is stopped and held at the correct levels for transfer by any suitable controls. The racks have angle slides or roller ways  50  turned bottom legs in to support the pallets to slide or roll in and out or slip fit between these angle supports which can have sliding faces with plastic wear strips or coating for low friction.  
         [0047]     The ground level tier of berths can be accessed for drive on-off vehicle loading of the pallets, or a ramp  52  at each end of the aisle can be provided for loading and unloading of a pallet when on the load platform. The ends of the stacker run under rams  52 , as shown for the left end in  FIGS. 1 and 2 , to bring a pallet on the stacker to the ramp.  
         [0048]     Platform  34  has one or more oblique transfer channels  54  secured on top and extended out beyond the sides of the platform each to engage and guide an oblique runner  56  secured across the bottom of pallet  20  at the oblique angle. Runners  56  are I-shaped in section with end latch sections  57  hinged on pins  58  to droop and latch over a catch  59  on the rack to hold the pallet in until lifted by the transfer channel  54 . The ends  57  of runners  56  are cut tapered parallel to the side of the pallet so the coupling overlap can be small to engage with channel  54  when extended a small amount. Transfer channels  54  are run at preferably 45-50° from the sides and in the direction toward the corners opposite the lift tracks  36  so the pallet can travel the oblique channel off and on from either side while remaining parallel to the platform. Parallel supporting rails  62 , also on the oblique angle, are secured on top of the platform to support the pallet to slide or roll thereon.  
         [0049]     The pallet has a transfer starter arm  64  with roller arm  66  near the two opposite comers farthest from the runners or runner  56 . Arms  64  are mounted on longitudinal pins  67  in pockets  68  to swing up as in  FIGS. 5 and 11  and down as in  FIGS. 3 and 6  to extend their rollers  66  below the pallet in line to engage the inner edge of the support track  50  on the rack for the pallet. Arms  64  are set back from diagonally opposite leading corners, those near columns  32 , to clear member  36  and columns  32  so the pallet can be transferred to or from either side without shortening the pallet or lengthening the stacker.  
         [0050]     Referring to  FIGS. 3, 4 , and  6 , arm  64  is pushed down before the pallet is sent to an empty rack. The rack has a tongue or tab  70  extended to engage roller  66  when the rack is empty to push the pallet back off from the platform and into the rack. Tab  70  slides out and in along a horizontal slot and is moved by a sprocket  72  having teeth engaging in holes along tab  70 . Sprocket  72  is secured on shaft  74  with a lever platform, and the rear leg of channel  82  extends straight to push tongue  57  after it is lifted by the slope web of the channel. The top and web of tongues  57  are cut back to increase clearance to clear under the horizontal entry tabs  70  on racks  22 .  
         [0051]     The platform  34  has latches  94 ,  FIGS. 9, 11 ,  16  and  17 , for catching on opposite ends of the pallet when centered on the platform to prevent the pallet from sliding off either side until an arm  64  is lowered for transfer and engaged with a tab  70  at an empty berth to push the pallet hard enough to depress the latch to let the pallet pass to the rack.  
       Operation  
       [0052]     An empty pallet on stacker  26  in  FIG. 1  is in position for receiving a load such as auto A driven up ramp  52  onto pallet  20  on stacker  26  until its end wheels drop into shallow pockets  96  to hold it. Arm  64  is lowered to the far side of the aisle for the rack to be put in an empty rack on that side of the aisle. The stacker is moved along the aisle and its platform set to a height to engage arm  64  with an empty rack (one with tab  70  extended). When arm  64  meets a tab  70  the pallet is held while the stacker continues to travel to the right pushing the pallet onto the aligned rack. To put the pallet in a near-side rack, the opposite arm  64  is lowered before leaving the loading ramp and the stacker driven to the right and then back to an empty berth where the arm&#39;s roller  66  engages a tab  70 . To retrieve a stored pallet, gearmotor  89  shifts channel  82  out to the side to engage the hinge tongue  57  on the pallet and the stacker driven to lift the tongue, unlatching it and entering it into channel  82 . Channel  82  pushes on runner  56  pulling out the pallet from the rack over end latch  94  and onto the platform until clear of the rack moving until stopped by the end latch  94  on the trailing end.  
       Variations  
       [0053]     Like parts are given the same number or suffixed where modified.  
         [0054]     Referring to  FIGS. 14-22 , the preferred pallet  20 A has bottom cleared of I-beam runner  56 . Pallet  20 A has two transfer arms  102  or  102 A hinged mounted along each transfer side. Arm  102 ,  FIG. 15 , and arm  102 A,  FIGS. 20-22 , are each mounted on a longitudinal pin  104  between pillow blocks  106  recessed into the top of the pallet to be lifted up to stay up past vertical or lowered to extend out for transfer. Each arm  102  or  102 A has a cam roller  108  on pin  109  depending from its outer end each to align in one of two spaced apart parallel oblique channels  54  which run across the top of lift platform  34 A in the same direction as and replacing the one on platform  34 . The arms when extended hold rollers  108  to align each in a channel  54  which runs to guide the pallet parallel in alignment on the platform. Arm  102 A has an integral latch  110  depending between pin  104  and roller  108  to engage a catch  59  on the front of the rack.  
         [0055]     Channels  54  are secured obliquely across the top of platform  20 A and have inner extendable or telescoping channels  82  with end ramps  90  aligning to engage and lift rollers  108  together to unlatch the pallet from the rack and pull rollers  108  into both channels  54  simultaneously. The stacker, racks, and pallets are otherwise as described in  FIGS. 1-3 . Operation is similar except the inner channels  82  lift both rollers  108  simultaneously instead of just one channel lifting one tongue  57 .  
         [0056]     Referring to  FIGS. 23-28  for details of the preferred transfer arm  102 A applied to pallet  20 A, the arm has a vertical integral pivot tube  114  with a steep internal spiral spline with a latch pin rod  115  with an external spline slip-fit in the internal spiral spline. Tube  114  extends slip-fit through a housing or pallet  20 A and has a threaded collar  116  supporting arm  102 B to revolve horizontally below the pallet. Latch rod  115  slides up and down through arm  102 B, tube  114 , and housing  117  secured to the top of the pallet. A vertical key slot in rod  115  is engaged by pin  118  through the housing  117  to limit vertical travel of and prevent rotation of rod  115 ,  FIGS. 26-28 . Arm  102 B is a slot runner pivoted on its threaded latch rod  115  to turn horizontally and extends to support a cam roller  108  on each end to engage in channel  54  coming at it from front or rear. The two rollers  108  hold alignment of the arm with channels  54  during transfer. When arm  102 B is engaged by a channel  54  it is turned out into alignment in the channel, lifting its latch pin to release the pallet for transfer. Pin  119  extends up from arm  102 B to engage the front of the pallet in retracted position of the arm.  
         [0057]     A variation of the arm  102 C, shown in  FIGS. 29-31 , is a runner to travel the open top slot in channel  54  and has a pivot latch pin  115 C extending therethrough. Pin  115 C has a steep external spiral spline extending up through housing  117 C with internal spline to slip fit with pin  115 C to turn with arm  102 C and lift both the latch and arm when engaged from front or rear by a channel  54 . Latch pin  115 C is supported on a ledge in housing  117 C and has a wide slot engaged by pin  118  secured in a hole in housing  117 C to limit vertical and angular movement of the arm. Arm  102 C is pivoted off center between end cam rollers  108 . The shorter length of arm extends back to enter a channel  54  coming from behind. Latch pin  115 C is the arm&#39;s pivot shaft secured to turn with the arm and rotates the arm as it drops to retracted position,  FIGS. 29 and 30 . Rotation of arm  102 C is limited by pin  118  to about 45° from the position in  FIG. 29  out from the pallet to align its rollers  108  to the oblique angle of channels  54 , lifting the arm and latch on its spline to enter a channel  54 .  
         [0058]     Referring to  FIGS. 32 and 33  for another variation of arm  102 , arm  102 D is longer to guide pallet  20  along a channel  54 . Arm  102 D partially extends into channel  54  to be a slot runner extended out from its pivot spiral lift post  115 D and extends above and beyond the runner part to the forward roller  108 . Arm  102 D has a second optional roller  108  on its pivot to align in channel  54 . The outer extension of arm  102 D runs above channel  54  so the arm can turn into alignment before its runner fully engages into the channel slot. Arm  102 D is a lift arm similar to arm  102 C and rotates by gravity to the position of  FIG. 33  after each transfer to latch its roller on its pivot behind a catch  59 .  
         [0059]     Referring to  FIGS. 34-35 , pallet  20 E has a rectangular top plate  120  and aligned bottom plate  121  connected by a diagonal rectangular tube  122  and an open space between corner supports  124 . A standard fork lift truck LT has an oblique fork  
         [0060]     Referring to  FIGS. 39-42 , stacker  26 F can have one or more lift columns  32  on one side and a fork platform  34 F with two parallel oblique forks  54 F each to enter a parallel oblique tube  122 F on pallet  20 F to enter and pull the container onto the forks. Lift platform  34 F has one or more vertical columns  36  each to run on a column  32  to be lifted and lowered in the usual way.  
         [0061]     If necessary these stackers can be stabilized from tipping sideways by retractable rail wheels  140  to support it on rails  144  along the aisle, and/or by gyroscope  146 , or by an overhead track  148 ,  FIGS. 1 and 2 . The force of pushing a pallet into a rack is in part countered by the load being moved off center on the platform, causing a force in the opposite direction. These stackers do not extend a load all the way lifted off to the side but rest the load on the rack during most of the transfer, all but when the pallet is nearly centered on the platform. The racks should be braced against sideways forces the stacker could offer.  
         [0062]     Having thus described some embodiments and applications of my invention these are not intended as a limitation on the scope of this invention which is intended to cover all variations, applications, and parts within its true spirit and scope.  34 E replacing its straight forks. Fork  34 E has a main tine  54 E positioned horizontally obliquely for guiding into tube  122  and a side fork  62 E parallel to the oblique fork on each side all run together on the near side forming a horizontal platform  34 E. Platform  34 E has vertical arms  36 E for fitting in the standard lift members of the fork truck with a standard lift arrangement. Pallet  20 E is supported on a low friction plastic extrusion  50 E secured to the rack or floor along each end to guide its in and out movements.  
         [0063]     To pick up the container  20 E with fork platform  34 E moving to the left in  FIGS. 34 and 35 , center tang  54 E enters tube  122 , lifting the pallet as in  FIGS. 37-38  to unlatch it before pushing against the far wall of tube  122 , pulling the pallet straight out onto fork  34 E. To place the container in its berth, fork  34 E is moved to the right at a height to catch the right-hand bottom edge of pallet  20 E on the strip  50 E, which holds it as the fork is pulled to the right lengthwise the berth, leaving the pallet as in  FIG. 24 . Fork trucks so equipped can load and return pallets  20 E from racks  22  along either side of the aisle according to the direction the fork truck is turned to run along the aisle.  
         [0064]     Referring to  FIG. 36  the pallet can be stackable with a frame  20 E′ to protect the load and be self stackable. Strips  50 E″ run straight across the bottom in from the ends and strips  50 E′ along the ends at the top all secured on frame  20 E′ to key the pallets together lengthwise. Pallet  20 E′ is otherwise like  20 E having tube  122  with an open entry for the engaging tang  54 E of fork  34 E to enter as in  FIGS. 37 and 38 .