Patent ID: 12252167

DETAILED DESCRIPTION

The present disclosure relates to carts (e.g., industrial carts) for carrying large loads. In particular, the carts described in the present disclosure are double-decker carts having two (or more) levels where items (to be hauled) can be supported. More particularly, each level of the heavy-duty carts described in the present disclosure is configured to support a loaded pallet or crate, where the pallet or crate is of a common or known size. For example, common pallet sizes may include 40×48 (i.e., 40 inches wide by 48 inches long), 42×42, 48×48, etc., and some crates may also be configured with similar sizes with the pallet-type base arrangement for use with an electric forklift or manually-operated pallet jack. It should be understood that the dimensions of the pallets or carts described in the present disclosure are not limited by any specific dimensions or common sizes, but may include any suitable dimensions for supporting any type of container, crate, bin, pallet, platform, base, etc. that, in turn, may be configured to hold or support other (typically smaller) types of items.

For example, along an assembly line in a manufacturing plant (e.g., for manufacturing vehicles), a line worker may need to keep a large number of items near him or her for adding these items to the manufactured objects (e.g., vehicles) as they are passed down the line. In some cases, not only should a cart (e.g., large enough to carry multiple items) be able to be transported to the line worker's station, but also the line worker should be able to manually move the cart within a certain range to allow the line worker to complete his or her tasks for efficiently.

FIGS.2-4show images of an industrial cart30according to a first embodiment.FIG.2is an image showing a front view of the industrial cart. Also,FIGS.3and4are images showing a back view of the industrial cart30. As shown, the industrial cart30includes a lower frame32and an upper frame34, where each frame32,34is configured to support a loaded pallet or crate. It should be noted that the embodiments of the present disclosure do not necessarily include the crates, pallets, bins, etc. and/or the items stored therein or thereon, but instead may be configured to support any types of crates, pallets, bins having any known size, while the industrial cart30is in use.

Each frame of the lower frame32and upper frame34may include a rectangular shape, including, for example, at least a front metal beam, a back metal beam, a right side metal beam, and a left side metal beam. In some embodiments additional metal beams may be used in the frames32,34for additional strength. Also, according to some embodiments, each beam (not labelled in the drawings) may include one or two corresponding metal pieces. The beams (and/or half-beams) can be connected together by hardware elements (e.g., connectors, nuts, bults, etc.), by a welding process, or by other suitable means.

Furthermore, the industrial cart30includes a front hitch assembly36and a back hitch assembly38. The front hitch assembly36may be configured with suitable elements to enable the industrial cart30to be linked with another cart. In this respect, when multiple carts are linked together in a train, a warehouse utility vehicle may be used to pull this train from one area of a warehouse or manufacturing facility to another. Therefore, the front hitch assembly36may be used for connection to another cart which is in front of the industrial cart30in the train. The back hitch assembly38may be used for connection to another cart which is behind the industrial cart30in the train. Furthermore, the front hitch assembly36may include arms, links, handles, etc. used for connections to the forward-located cart or for manually pulling the industrial cart30by a human.

Also, the industrial cart30includes multiple (e.g., four) vertical posts used for supporting the upper frame34above the lower frame32. In some embodiments, these vertical posts may include a front left post40, a front right post42, a back right post44, and a back left post46. These posts40,42,44,46may also include steel or metal material and may be configured similar to the beams used for constructing the lower frame32and upper frame34. With this general construction, the industrial cart30may be configured to support a first crate48(e.g., on the lower frame32) and support a second crate50(e.g., on the upper frame34). Again, these crates48,50may include a common or known size. In this example, the crates48,50may be configured as 40″×48″ pallets and may be configured with walls for supporting any type of items (e.g., vehicle parts installed during manufacturing).

The industrial cart30also includes any suitable type of connection elements and/or hardware for connecting the posts40,42,44,46to the lower frame32and for connecting the upper frame34to the posts40,42,44,46. In particular, the industrial cart30may include a first set52of connectors and hardware for connecting the posts40,42,44,46to the lower frame32. Also, the industrial cart30may include a second set54of connectors and hardware for connecting the upper frame34to the posts40,42,44,46. For example, the first and second sets52,54of connectors and hardware may include plate brackets, corner brackets, angled brackets, etc., as well as mating fasteners, such as nuts, bolts, barrel bolts, etc.

It should be noted that the connectors and hardware may be removable to allow the upper frame34to be connected to the posts40,42,44,46at any suitable height above the lower frame32. Therefore, based on a known height of the lower crate48(and its contents), the upper frame34can be positioned to allow a forklift operator to lift the crate (or pallet) through a “window” formed by the frames32,34and posts40,42,44,46and place the crate or pallet onto the lower frame32. Therefore, the width between posts (e.g., between the back right post44and back left post46when the lower crate48is loaded from the back of the industrial cart10) is configured to be sufficient to allow enough clearance such that the forklift operator can fit the lower crate48between the posts. For example, assuming that the width of the crate48is 40″, the width between the posts44,46may be at least 42″. Also, the height of the upper frame34above the lower frame32may be adjusted, as needed, to allow enough headspace based on the height of the crate48and its contents to fit through the “window.” Furthermore, the four windows that are at the front side, right side, back side, and left side of the industrial cart30should also allow sufficient space such that the line worker is able to easily pull items out of the lower crate48when needed.

The industrial cart30may also be configured, in particular, to sufficiently support a certain sized rectangular objects (e.g., pallets, crates, containers, bins, etc.) on each of the lower frame32and upper frame34. Therefore, the industrial cart30may include a plurality of corner supports that specifically support each corner of the rectangular pallet-type objects. For example, four corner supports may be used for supporting each corner of the rectangular pallet-type objects. More particularly, the industrial cart30may include a first set56of corner supports connected to the lower frame32and a second set58of corner supports connected to the upper frame34. Each corner support of the first and second sets56,58may be arranged to receive the weight of the respective corner of the respective crate48,50. That is, a front right corner support of the first set56may be configured to support the weight of the front right corner of the crate48when the crate48is placed on the lower frame32, a front left corner support of the first set56may be configured to support the weight of the front left corner of the crate48when the crate48is placed on the lower frame32, and so on.

Therefore, according to one embodiment of the present disclosure, the industrial cart30may be configured to move along a substantially horizontal surface (e.g., any floor of a building, the floor of a warehouse, etc.). The industrial cart30may include the lower frame32, having sufficient dimensions so as to support the lower crate48, which may have a common size (e.g., 40″×48″). The industrial cart30may also include a plurality of wheels connected to an underside of the lower frame32to allow the industrial cart30to move. Also, the industrial cart30may include the upper frame34, having sufficient dimensions so as to support the upper crate50, which may also have a common size (e.g., 40″×48″). In this embodiment, the industrial cart30may also include a plurality of vertical posts40,42,44,46configured to support the upper frame34at any of a plurality of fixed heights above the lower frame.

According to additional embodiments, the industrial cart30may further include the front hitch assembly36connected to a front side of the lower frame32. The front hitch assembly36may be configured to enable removable attachment of the industrial cart30to a warehouse utility vehicle or to a forward-positioned cart in a train-type arrangement pulled by a warehouse utility vehicle. The industrial cart30may also include the back hitch assembly38connected to a back side of the lower frame32. The back hitch assembly38may be configured to enable removable attachment of a rearward-positioned cart to the industrial cart in the train-type arrangement. The industrial cart30may include an arm having a first end and a second end, whereby the first end of the arm may be connected to the front hitch assembly36and the second end of the arm configured for removable attachment to the warehouse utility vehicle or forward-positioned cart in the train-type arrangement. In some embodiments, a handle may be removably attached to the second end of the arm when the arm is disconnected from the warehouse utility vehicle or forward-positioned cart. The first end of the arm may be rotatably connected to the front hitch assembly36to adjust to any suitable angle for allow a user to pull the industrial cart30. In this way, the arm can rotate with respect to the front hitch assembly36in a pitch orientation to allow the user to manually pull the industrial cart30.

In some embodiments, the industrial cart30may further include the first set56of horizontally-arranged plates or corner supports attached near corners of the lower frame32. This first set56of plates or corner supports is configured to support the corners of the lower crate48when it is placed on the lower frame32. Also, the industrial cart30may include a second set58of horizontally-arranged plates or corner supports attached near corners of the upper frame34. The second set58of horizontal plates/supports is configured to support the corners of the upper crate50when it is placed on the upper frame34.

Each of the horizontal plates or corner supports of the first and second sets56,58may include two vertically-directed walls or flaps as described in more detail with respect toFIGS.7and8. For instance, the plates/supports for supporting the respective crate corners may include the horizontal portion that supports the weight (at that corner) as well as two perpendicularly bent edges that form a three-dimensional inside corner structure that is configured to limit the movement of the respective crate48,50in three different (perpendicular) directions. For example, one edge may be bent upward from the horizontal base of the plate/support to form a wall that limits the movement of the crate48,50in a sideways direction. Likewise, another edge of the plate/support may be bent upward from the horizontal base to form a wall that limits the movement of the crate in a forward or backward direction.

Each frame of the lower frame32and the upper frame34may include a rectangular shape having a forward left corner, a forward right corner, a back right corner, and a back left corner. The plurality of vertical posts40,42,44,46may include a first post, a second post, a third post, and a fourth post, whereby the first post40connects the forward left corner of the lower frame32to the forward left corner of the upper frame34, the second post42connects the forward right corner of the lower frame32to the forward right corner of the upper frame34, the third post44connects the back right corner of the lower frame32to the back right corner of the upper frame34, and the fourth post46connects the back left corner of the lower frame32to the back left corner of the upper frame34. The third post44and fourth post46(e.g., back posts) may be separated by a distance to create sufficient horizontal clearance to allow the lower crate48to move therebetween for receiving the lower crate48onto the lower frame32and/or for removing the lower crate48from the lower frame32.

The wheels of the industrial cart30may include a first wheel, a second wheel, a third wheel, and a fourth wheel. For example, the first wheel may be attached near the forward left corner of the lower frame32, the second wheel may be attached near the forward right corner of the lower frame32, the third wheel may be attached near the back right corner of the lower frame32, and the fourth wheel may be attached near the back left corner of the lower frame32. At least the first wheel and the second wheel, for example, may be caster-type wheels, which may allow the wheel to swivel and to allow easier steerability of the industrial cart30.

The lower frame32, upper frame34, and vertical posts40,42,44,46may include any suitable material having sufficient strength (e.g., metal, steel, alloys, etc.). The first set52of connection brackets and mating fasteners may be used for connecting the vertical posts40,42,44,46to the lower frame32. The second set54of connection brackets and mating fasteners may be used for connecting the upper frame34to the vertical posts40,42,44,46. The second set54of connection brackets and mating fasteners may be removable and reconnectable to enable the upper frame34to be supported by the vertical posts40,42,44,46at any of a plurality of fixed heights above the lower frame32.

FIGS.5and6show images of an industrial cart60according to a second embodiment.FIG.5is an image showing a back view of the industrial cart60.FIG.6shows connection features of an upper frame with respect to a vertical post of the industrial cart60. In this embodiment, the industrial cart60includes many similarities to the embodiment of the industrial cart30shown inFIGS.2-4.

In this embodiment, the industrial cart60includes the lower frame32, front hitch assembly36(not shown inFIG.5), back hitch assembly38, and first set52of connectors and hardware, which are similar to the industrial cart30. In addition, the industrial cart60includes a front left post62, a front right post64, a back right post66, and a back left post68. According to this embodiment, the posts62,64,66,68may have a predetermined height to create a large enough window, formed by the upper and lower frames and the particular pair of posts, such that the lower crate48(with its contents) can be placed on the lower frame32and such that the line operator will be able to easily remove the items from the lower crate48when needed.

The industrial cart60further includes an upper frame70which may be slightly different from the upper frame34shown inFIGS.2-4. For example, the upper frame70may include a front beam70athat sits on top of the posts62,64and a back beam70bthat sits on top of the posts66,68. A set72of connectors and hardware (e.g., brackets, mating hardware components, etc.) is used to connect the upper frame70to the posts62,64,66,68. The upper frame70may also include side beams70c,70dthat sit on top of the front and back beams70a,70band are attached thereto using the set72of connectors and hardware.

Furthermore, the lower frame32includes a first set74of corner supports (e.g., one corner support at each of the four corners), which may be used for supporting the lower crate48. A second set76of corner supports is connected to the upper frame70and may be used to support an upper crate (not shown inFIG.5). Each of the corner supports of the first and second sets74,76may have substantially the same shape and/or features as the types of corner supports used with respect to the embodiment of the industrial cart30ofFIGS.2-4.

FIG.7is an image showing a top view of an embodiment of a corner support and may represent any of the corner supports56,74connected to the lower frame32of the first or second industrial carts30,60described above. The corner support80in this embodiments may include a horizontal portion80a, which may be attached, using suitable hardware, to a horizontal support (e.g., beam) of the lower frame32. In this embodiment, the corner support80sits on top of an intermediate beam81of the lower frame32. Also, a wheel assembly82may be sandwiched by and connected to an outer beam83of the lower frame32and the intermediate beam81. The wheel assembly82may also be attached to a front or back beam of the lower frame32. The wheel assembly82may include an attachment base element, a wheel or caster (hidden from view), and hardware for attaching the wheel or caster to the attachment base element. The attachment base element may be used for attaching the wheel assembly82to the different beams of the lower frame32.

Furthermore, the bottom corner support80may also include an end wall80b, which may be a flange or a bended edge of a sheet of metal used for forming the corner support80, whereby the end edge if folded or bent upward (e.g., at about 90°) with respect to the horizontal portion80a. The corner support80also includes a side wall80c, which also may be a flange or a side edge that has been bent or folded upward. The end wall80bmay be used to limit the movement of a crate or pallet (placed on the lower frame32) in the forward direction (for a front side positioned corner support80) or in the backward direction (for a back side positioned corner support80). The side wall80cmay be configured to limit the movement of the crate or pallet (placed on the lower frame32) in a rightward direction (for a right side positioned corner support80) or in a leftward direction (for a left side positioned corner support80).

FIG.8is an image showing a top view of an embodiment of a corner support84and may represent any of the corner supports58,76connected to the upper frame34,70of the first or second industrial carts30,60. The corner support84may be the same as or similar to the corner support80described with respect toFIG.7. The corner support84, as shown in the embodiment ofFIG.8, includes a horizontal portion84a, an end wall84b, and a side wall84c. Again, the three planes formed by the horizontal portion84a, end wall84b, and side wall84cof the corner support84may be used to limit the movement of a crate or pallet (placed on the upper frame34,70in three different directions.

FIG.9is an image of an embodiment of the wheel assembly82shown inFIG.7. The wheel assembly82is configured to be attached to the lower frame32of the first or second industrial carts30,60. The wheel assembly82may include a wheel or caster87, an attachment base element (shown inFIG.7), and hardware (e.g., nuts, bolts, etc.) for attaching the wheel or caster87to the attachment base element and for attaching the attachment base element to the beams of the lower frame32. In some embodiments, the front wheels87may be configured to swivel about a vertical axle to enable the industrial cart30,60to steer more easily. In some embodiments, the back wheels87may also be capable of swiveling, or alternatively may be fixed with a front-to-back alignment.

FIG.10is an image showing the details of an embodiment of the upper set54of connection elements and hardware for connecting the upper frame34to a vertical post (e.g., one of the posts40,42,44,46) of the first industrial cart30shown inFIGS.2-4.

FIG.11is an image showing an embodiment of an arm92that may be connected to the front hitch assembly36of the first or second industrial carts30,60. In this embodiment, the arm92may be configured as a metal or steel rod or beam connected to an axle90on the front hitch assembly36. The axle90allow the arm92to rotate about the axis of the axle90. In the upper position, as shown inFIG.11, the arm92may be secured in order to keep it out of the way while the line worker is busy with other tasks.

FIG.12is an image of a coupling94attached to the arm32shown inFIG.11. When the arm92is in a horizontal position, the coupling94may be used for connection with another cart that is located in front of the industrial cart30,60in a train configuration. As such, a warehouse utility vehicle may be used for pulling the train of linked carts. In an intermediate position between the vertical and horizontal positions, the arm92(unlinked from the train) can be used in a manual mode, where a user can manually pull the industrial cart30,60, as needed. It may be noted, however, that because of the size and weight of the industrial cart30,60, particularly when loaded with two crates/pallets filled with assorted items, it may be somewhat difficult to pull the industrial cart30,60manually. Nevertheless, the person may be able to move the cart30,60within a certain work area. Also, in some embodiments, a handle (not shown) may be attached to the coupling94or arm92to enable the user to pull the cart30,60more easily.

Therefore, the embodiments described in the present disclosure provide certain advantages over conventional carts. For instance, the industrial carts30,60are configured as heavy-duty carts for hauling bulky and/or cumbersome loads. Although supporting and pulling a single pallet or crate on a cart may be fine in many cases, occasionally there is a need for pulling a greater load. Thus, the embodiments of the present disclosure are configured to carry two pallets/crates at once, which can minimize the amount of horizontal space occupied by the carts and allows a user to have access to a greater amount of materials or items that may be needed in a specific area, such as a vehicle manufacturing work area of an assembly line where a worker may need to assembly multiple vehicle parts, multiple types of parts for different types of vehicles, etc.

The carts30,60may be configured as two-level container dollies for hauling parts that can be used in line side production and logistics. The stacked design of the cart30,60may be create such that there will be enough space between the two levels of the two-level container dollies for the line production operator to pick parts from both levels. The configurations of the carts30,60may result in a lean manufacturing process and improvements with respect to innovation management, accounting for executives, and structural engineering for getting parts to the production line without taking up space horizontally. In some respects, two cart30,60may be brought to the production line, where one may be used on the left side of the assembly line and one may be used on the right side of the assembly line. Also, it may be noted that each cart30,60may include the same (or mirrored) parts for the left-hand and right-hand sides. The embodiments are configured to keep the cost of getting parts to the line at a minimum. Also, the carts30,60may be configured to reduce or eliminate the excessive cost of kitting (i.e., bundling items into a “kit” to be assembled later).

The embodiments of the carts30,60are configured to meet certain ergonomic specifications and safety specification. The carts30,60are configured for the support of a unit load, mobility, constructability, and functionality. Along with many other factors that can drive manufacturing cost upward, the embodiment of the carts30,60may help to reduce the costs associated with transporting items to the assembly lines, such as by allowing a greater amount of items to be delivered by an electric tractor, warehouse utility vehicle, etc., at a time. It may be noted that left and right hand sides can be paired more easily with bigger loads and may have the same take rate and replenishment rate.

According to one embodiment, the carts30,60may be built on top of a tugger container cart that is 1260 mm×1260 mm. Also, the carts30,60may include certain materials, such as about 43 nuts, about four hexagon head bolts (3.5 inch), about 28 flat head bolts (3.5 inch), about 16 half-size bolts (1 inch), about four metal bars (blue) (43⅝ length) for the top shelf, about 12 metal bars (blue) (46⅞″) also for the top shelf, about 16 bolt barrels (3.5 inch), about eight L-plates (white) (⅛″), about four additional L-plates (silver) ( 1/16″), and about eight crate plates (black)56,58,76,80,84. Of course, these specific details are not meant to limit any embodiments of the present disclosure, since changes to the types of elements and number of elements can be made without departing from the spirit and scope of the disclosed embodiments.

Although the present disclosure has been illustrated and described herein with reference to various embodiments and examples, it will be readily apparent to those of ordinary skill in the art that other embodiments and examples may perform similar functions, achieve like results, and/or provide other advantages. Modifications, additions, or omissions may be made to the systems, apparatuses, and methods described herein without departing from the spirit and scope of the present disclosure. All equivalent or alternative embodiments that fall within the spirit and scope of the present disclosure are contemplated thereby and are intended to be covered by the following claims.