Patent Application
20210102351
This invention relates to a barrier with a cable system.
Warehouses, distributions centers, factories, and similar facilities often have large stock handling equipment such as fork trucks which frequently move stock into, out of, and around the facility. In some examples, the stock is stored on shelving (e.g., pallet racks) and stock handling equipment must navigate through the shelving to move stock to and from the shelving. Some facilities may have other obstacles (e.g., support columns, walls, pedestrian walkways) which the stock handling equipment must navigate around as it travels through the facility.
As an operator navigates stock handling equipment through a facility, it is possible for the operator to inadvertently cause the stock handling equipment to collide with obstacles such as shelving, support columns, or walls or to encroach on pedestrian walkways. When stock handling equipment collides with an obstacle, both the obstacle and the stock handling equipment can become damaged. In the case of shelving, a strong enough collision can cause the shelving to collapse. In the case of an encroachment on a pedestrian walkway, a pedestrian can be seriously injured.
Because of the dangers associated with stock handling equipment, barriers are often installed to protect obstacles and walkways in facilities from interactions with stock handling equipment.
Conventional barriers are often associated with a maximum load rating. If that maximum load rating is exceeded, conventional barriers fail. In the case of a catastrophic failure, parts of conventional barriers may break or separate in such a way that they are dangerously propelled into stock or pedestrians. Aspects described herein are directed to a cable system that prevents and mitigates catastrophic failure of barriers.
In a general aspect, a protective barrier includes a first end piece configured to be anchored and secured to a surface, a second end piece configured to be anchored and secured to the surface, a rail extending between the first end piece and the second end piece, the rail having a first end mechanically coupled to the first end piece and a second end mechanically coupled to the second end piece, a cable extending through the rail and having a first end attached to the end piece and a second end attached to the second end piece.
Aspects may include one or more of the following features.
The first end piece includes a first opening and the second end piece includes a second opening, the cable extending through the first opening and the second opening. The first end piece includes a first anchoring member and the second end piece includes a second anchoring member, the first anchoring member and the second anchoring member configured to be anchored and secured to the surface opening.
The cable includes a first fastener at the first end and a second fastener at the second end, the first fastener being coupled to the first anchoring member and the second fastener being coupled to the second anchoring member.
The first end of the cable may include a first hook for fastening the first end of the cable to the first fastener and the second end of the cable may include a second hook for fastening the second end of the cable to the second fastener. The first anchoring member may be a shock absorbing anchoring member and the second anchoring member may be a shock absorbing anchoring member. The first fastener may form a part of the first anchoring member and the second fastener may form a part of the second anchoring member. The cable may be a braided steel cable. The cable may be a nylon cable.
The rail may be formed from a plastic material. The rail may have a cavity running along its length. The cable may extend through the cavity running along the length of the rail. The first end of the cable may be fastened to the first fastener by welding and the second end of the cable may be fastened to the second fastener by welding.
The first anchoring member and the first fastener may be disposed inside of the first end piece and the second anchoring member and the second fastener may be disposed inside of the second end piece.
The first end of the cable may include a first attachment member coupled to the first fastener and the second end of the cable may include a second attachment member coupled to the second fastener. The protective barrier may include a first pin coupling the first attachment member to the first fastener and a second pin coupling the second attachment member to the second fastener. The first fastener may include a first eye hook, the second fastener may include a second eye hook, the first attachment member may include a first loop of cable, and the second attachment member may include a second loop of cable. The first pin may extend through the first eye hook and the first loop of cable and the second pin may extend through the second eye hook and the second loop of cable.
Aspects may have one or more of the following advantages.
Aspects prevent and/or mitigate catastrophic failure of barriers and therefore prevent damage to stock and/or injury to pedestrians or other workers nearby the barrier. Upon failure of the barrier, parts of the barrier are prevented from being propelled in an uncontrolled manner from the barrier's location.
Aspects limit a maximum deflection of the plastic bumper rail, making the barrier design well suited to meet or exceed a number of industry standards.
Aspects are capable of sustaining a greater force of impact than some conventional barriers due to the use of a cable system to bolster the strength of the barrier. Aspects are able to absorb impact and return to their original state.
Aspects are capable of minimizing catastrophic damage in the event that the force of an impact is greater than that which would otherwise be withstood by conventional barriers due to the use of a cable system to bolster the strength of the barrier.
Some aspects advantageously include a pin-based cable system that couples the rails of the protective barriers and the posts of the protective barriers to ensure that any load due to unintentional collisions is distributed throughout the entire protective barrier.
Other features and advantages of the invention are apparent from the following description, and from the claims.
Referring to
As seen in detail in
In some examples, the plastic bumper rail 102 is a hollow part formed by extruding high density polyethylene (HDPE). The plastic bumper rail 102 includes ribs 114 which increase the amount of plastic material present in the wall of the plastic bumper rail 102, thereby increasing the rigidity and collision absorption capability of the plastic bumper rail 102.
Regarding the rounded metallic end caps 104, each rounded metallic end cap 104 is a substantially cuboid-shaped metallic member with a rounded outer wall 124 opposite the opening 122, and a rounded top wall 123. The outer wall 124 includes a rounded protrusion 116 which is intended to receive and deflect the force of any object colliding with the metallic end cap 104. Each of the rounded metallic end caps 104 includes an anchoring mechanism access opening 113 which has a cover 112 placed thereon. The cover 112 covers the anchoring mechanism access opening 113 to hide the anchoring mechanism from view and prevent debris from entering the anchoring mechanism.
In some examples, each of the brackets 254a, 254b is a metallic member with a substantially ‘s-shaped’ profile. Each bracket has a body 258 with a first flange 260 extending from the body in a first direction perpendicular to the body and a second flange 262 extending from the body 258 in a second direction, opposite the first direction, perpendicular to the body 258.
The first flange 260 includes two anchoring openings 261 configured to receive members of the anchoring mechanism. In some examples, the cable 252 is a braided steel cable (sometimes referred to as ‘wire rope’) with fasteners 256 (e.g., hooks) attached to its ends. In those examples, the second flange 262 includes a hook-receiving opening 263 configured to receive the hooks 256 that are attached to the ends of the cable 252. It is noted that other suitable fastening methodologies (e.g., welding, nuts and bolts, etc.) can be used to fasten the cable to the brackets instead of the hook-based system described herein.
The first bracket 254a and second bracket 254b are installed in their respective rounded metallic end caps 104 (as is described in greater detail below). Opposite ends of the cable 252 are fastened to the brackets 254a, 254b. In some embodiments, the opposite ends of the cable 252 are fastened via hooks 256 attached to the ends of the cable 252. The hooks 256 interact with hook-receiving openings 263 in the brackets 254a, 254b to attach the cable 252 to the brackets 254a, 254b. The cable 252 extends from the first bracket 254a through a cavity 258 extending along a length of the plastic bumper rail 102.
Referring now to
Referring to
Further referring to
Referring generally now to
Referring to
In some examples, the openings 474 in the bottom wall 476 of the rounded metallic end cap 104 and/or the anchoring openings 261 in the first flange 260 of the bracket 254 have an inner diameter that is larger than an outer diameter of the anchoring fastener 366. This difference in diameters allows the bracket 254 and/or the rounded metallic end cap 104 to pivot about the shock absorbing mechanism 362 when sufficient force is applied to the cable system 250 and/or the plastic bumper rail 102.
In some examples, the body 258 of each of the brackets 254 rests against an internal rib 580 extending between two sidewalls of the rounded metallic end cap 104, providing additional support for the cable system 250.
Referring to
The protective barrier 600 includes a first rounded end post 604a and second rounded end post 604b, each of which is anchored into the ground using a corresponding anchoring assembly 643. The first rounded end post 604a and the second rounded end post 604b are mirror images of each other. The rounded end posts 604a-b are interconnected by plastic bumper rails 602, 603.
When the protective barrier 600 is assembled, an upper portion 608a of the first rounded end post 604a is connected to an upper portion 608b of the second rounded end post 604b by an upper plastic bumper rail 602. The upper plastic bumper rail 602 has a first end 612a inserted into an upper opening 614a of the first rounded end post 604a and a second end 612b inserted into an upper opening 614b of the second rounded end post 604b.
A lower portion 610a of the first rounded end post 604a is connected to a lower portion 610b of the second rounded end post 604b by a lower plastic bumper rail 603. The lower plastic bumper rail 603 has a first end 616a inserted into a lower opening 618a of the first rounded end post 604a and second end 616b inserted into a lower opening 618b of the second rounded end post 604b.
A cable system 695 is disposed inside a hollow interior of the lower plastic bumper rail 603 and extends between the first and second rounded end posts 604a-b. The cable system 695 includes a first eye hook 681a, a second eye hook 681b, and a cable 696.
The first eye hook 681a is installed in a through hole 683a in a sidewall of the inner core 650a of the first rounded end post 604a and the second eye hook 681b is installed in a through hole 683b in a sidewall of the inner core 650b of the second rounded end post 604b. In some examples, the eye hooks 681a-b are secured by a nut on an inside of the inner cores 650a-b, while in other examples, the through holes 683a-b in the sidewalls of the inner cores 650a-b are threaded and threaded eye hooks are screwed into the through holes.
The cable 696 includes a first loop 697a at a first end 699a of the cable and a second loop 697b at a second end 699b of the cable. The “eyes” of the eye hooks 681a-b and the loops 697a-b of the cable 696 are both dimensioned to accommodate lower pins 644a-b (respectively), as is described in greater detail below.
When assembled (as described below), the cable system 695 securely couples the inner cores 650a-b of the rounded end posts 604a-b to each other and to the lower plastic bumper rail 603 via the lower pins 644a-b.
The first rounded end post 604a is an assembly including a cap 638a, a first upper pin 636a, an outer shell 642a, a first lower pin 644a, and an anchoring assembly 643a. The anchoring assembly includes an inner core 650a and a first lower pin-receiving socket 682a. Similarly, the second rounded end post 604b is an assembly including a cap 638b, a second upper pin 636b, an outer shell 642b, a second lower pin 644b, and an anchoring assembly 643b. The anchoring assembly includes an inner core 650b and a second lower pin-receiving socket 682b.
The anchoring assemblies 643a-b include several other features that are described in U.S. patent application Ser. No. 15/940,281 (and will not be repeated herein for the sake of brevity), and are configured to securely attach the rounded end posts 604a-b and the ends 616a-b of the lower plastic bumper rail 603 to a mounting surface 624.
The first end 616a of the lower plastic bumper rail 603 includes a through hole 694a. When the protective barrier 600 is assembled, the through hole 694a of the first end 616a of the lower plastic bumper rail 603 is aligned with the first lower pin-receiving socket 682a and the first lower pin 644a is positioned through the through hole 694a with a distal end of the first lower pin 644a received in the first lower pin-receiving socket 682a.
Similarly, the second end 616b of the lower plastic bumper rail 603 includes a through hole 694b. The through hole 694b of the second end 616b of the lower plastic bumper rail 603 is aligned with the second lower pin-receiving socket 682b and the second lower pin 644b is positioned through the through hole 694b with a distal end of the second lower pin 644b received in the second lower pin-receiving socket 682b.
When installed as described above, the first lower pin 644a also extends through the first eye hook 681a and through the first loop 697a of the cable 696, thereby coupling the first end 699a of the cable 696 to the first eye hook 681a via the first lower pin 644a. Similarly, the second lower pin 644b extends through the second eye hook 681b and through the second loop 697b of the cable 696, thereby coupling the second end 699b of the cable 696 to the second eye hook 681b via the second lower pin 644b. The cable 696 extends from the first lower pin 644a to the second lower pin 644b and through the hollow interior of the lower plastic bumper rail 603. In general, the cable 696 is held substantially taut between the first lower pin 644a to the second lower pin 644b.
The remaining assembly of the protective barrier 600 proceeds as described in U.S. patent application Ser. No. 15/940,281 and is not repeated herein for the sake of brevity.
Referring to
The protective barrier 700 includes a corner post 704a, an end post 704b, and an intermediate post 704c, each of which is round in shape and each anchored into the ground using a corresponding anchoring assembly 743a, 743b, 743c. Corner post 704a is interconnected to intermediate post 704c by a pair of plastic bumper rails 702a, 703a. Similarly, end post 704b is interconnected to intermediate post 704c by a pair of plastic bumper rails 702b, 703b. Corner post 704a is connected to another portion of the protective barrier having an end post and bumper rails that are positioned at a substantially right angle to the portion of the barriers shown in
When the protective barrier 700 is assembled, an upper portion 708a of the corner post 704a is connected to an upper portion 708c of the intermediate post 704c by the upper plastic bumper rail 702a. Specifically, the upper plastic bumper rail 702a has a first end 712a inserted into an upper opening 714a of the corner post 704a and a second end 712b inserted into an upper opening 714b of the intermediate post 704c.
A lower portion 710a of the corner post 704a is connected to a lower portion 710b of the intermediate post 704c by the lower plastic bumper rail 703a. The lower plastic bumper rail 703a has a first end 716a extends to a lower portion 718a of the corner post 704a and second end 716b extending to a lower portion 718b of the intermediate post 704c.
A cable system 795a is disposed inside a hollow interior of the lower plastic bumper rail 703a and extends between the corner post 704a and intermediate post 704c. A similar cable system 795b extends between intermediate post 704c and end post 704b. Cable systems 795a, 795b both include a nylon strap 796 having looped ends 797 that are mechanically secured to corner post 704a and intermediate post 704c as well as between intermediate post 704c and end post 704b. Nylon straps 796 are secured so as to be taut.
Referring to
When assembled (as described below), the cable system 795a, 795b securely couples the inner cores 750 of the posts 704a, 704b, 704c to each other and to the lower plastic bumper rails 703a, 703b via U-shaped holder 730 and pins 734.
Each of corner post 704a, intermediate post 704c, and end post 704b are assemblies including a cap 770, an outer shell 760, and an anchoring assembly 773. The anchoring assembly includes the inner core 750 and a corresponding anchoring plate 743a, 743b, 743c.
The anchoring assemblies 743a, 743b, 743c are similar to those described in conjunction with protective barrier 600 shown in
Referring to
In some examples, protective barriers 600, 700, as described above, provide two levels of impact absorption. A first level of impact absorption is provided for less forceful impacts on the lower rail (e.g., a fork truck bumping into the rail), where the lower rail flexes to absorb the impact without the cable system being engaged and then returns to its original state after the impact. A second level of impact absorption is provided for impacts of greater force on the lower rail (e.g., a fork truck driving at full speed into the lower rail), where the lower rail flexes to absorb the impact and then makes contact with the cable system. The cable systems for each protective barrier provide additional strength to receive the impact without allowing a breach of the barrier.
In some examples, the bracket is an integral part of the rounded metallic end cap (e.g., the bracket and end cap are sand cast as a single integral part).
In some examples, the cable system limits a maximum deflection of the plastic bumper rail. In such examples, the rounded metallic end caps may be configured to retain the ends of the plastic bumper rail in their openings when the maximum deflection is reached (i.e., the plastic bumper rail does not ‘pop out’ of the rounded metallic end caps).
The cable system described above includes a braided steel cable. It is noted, however that other types of cables such as nylon cables, elastomer cables, solid steel (or other metal) cables, plastic cables, or any other suitable cable material can be used.
The plastic bumper rail described above includes ribs. It is noted, however that other embodiments of the plastic bumper rail do not include ribs.
In some examples, the pins describe herein are metallic pins. In other examples, the pins are plastic pins.
In some examples, the opposite ends of the cable are fastened to the brackets using “shackles” such as the shackle 856 shown in
The cable system is described above in the context of one exemplary barrier. But the same cable system can be used to improve any number of barriers, including but not limited to the barriers and other protective apparatuses described in U.S. Pat. Nos. 9,103,163, 10,060,154, 9,644,393, 9,732,485, and U.S. patent application Ser. No. 15/940,281, the contents of which are incorporated herein in their entirety.
It is to be understood that the foregoing description is intended to illustrate and not to limit the scope of the invention, which is defined by the scope of the appended claims. Other embodiments are within the scope of the following claims.
This application claims priority to U.S. Provisional Application No. 62/910,189, filed Oct. 3, 2019, the contents of which are hereby incorporated by reference in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62910189 | Oct 2019 | US |
