The following disclosure is directed generally to lighting systems for use with loading docks.
Conventional loading docks typically include an elevated door (e.g., an overhead door) on a side of a warehouse or other building. To load or unload a trailer or other transport vehicle, the doors on the back of the vehicle are opened and the vehicle is backed up to the loading dock door. A vehicle restraint (e.g., a barrier, hook, wheel chocks, etc.) is typically employed to hold the vehicle in position in front of the loading dock door. The loading dock door can then be raised or otherwise opened and a dock leveler extended between the floor of the warehouse and the open end of the transport vehicle. Conventional dock levelers typically include a deck that rotates upwardly and away from the floor, and then downwardly as a lip on the front edge of the deck rotates outwardly. As the deck descends, the lip comes to rest on the bed of the transport vehicle. Once the dock leveler has been properly positioned, forklifts, workers, etc. can move back and forth over the dock leveler to load and/or unload the vehicle.
Conventional loading docks typically include lights for illuminating the interior of transport vehicles during loading and unloading operations. A typical dock light includes an incandescent light or light-emitting diode (LED) to provide white or near white light that is projected into the open end of a trailer or truck. The dock light is typically mounted to one side of the loading dock opening on an extensible arm that allows it to be moved into a desired position for use and out of the way when not in use. The light can be manually turned on with a conventional switch, or automatically turned on by means of an inter-connect that is operably coupled to another piece of dock equipment, such as a loading dock door, vehicle restraint, or dock leveler.
A typical shipping trailer can be up to 60 feet in length. In addition, the ambient noise level in a typical warehouse environment can be very high. These factors can make it difficult to inform or warn a person working deep in a trailer that the status of a piece of dock equipment may have changed. For example, it may be difficult to communicate to a person moving cargo at the forward end of a trailer that the vehicle restraint has inadvertently disengaged. Accordingly, it would be advantageous to provide a system for communicating information, such as dock equipment status information, to persons working in shipping vehicles at loading docks.
The present disclosure describes various embodiments of loading dock lighting systems that can include one or more features for communicating information, such as equipment status information to dock operators and/or other personnel. In one embodiment, for example, a lighting system for illuminating the interior of a transport vehicle during loading/unloading can include a lighting feature that visually communicates information to a person or persons working in the vehicle. The lighting feature can include, for example, various colors of light and/or flashing lights. Activation of the lighting feature can provide a visual signal to a person or persons working inside the vehicle that, for example, the status of a piece of dock equipment, such as a vehicle restraint, has changed.
Certain details are set forth in the following description and in
Many of the details, dimensions, angles and other features shown in the Figures are merely illustrative of particular embodiments of the disclosure. Accordingly, other embodiments can add other details, dimensions, angles and features without departing from the spirit or scope of the present invention. In addition, those of ordinary skill in the art will appreciate that further embodiments of the invention can be practiced without several of the details described below.
The loading dock 100 can further include a dock shelter and/or dock seal 35. In the illustrated embodiment, the dock seal 35 includes compressible side members 36 extending vertically along each side of the opening 102, and a compressible head member 37 extending horizontally across the top of the opening 102. When a truck or trailer backs into the loading dock 100, the aft end of the truck or trailer compresses the side members 36 and the head member 37, and forms an environmental seal between the truck or trailer and the dock wall.
The loading dock 100 can include a dock leveler 10 (e.g., a hydraulic dock leveler) positioned adjacent to the opening 102. The dock leveler 10 includes a movable deck 11 having an aft edge portion pivotally attached to a frame 12. The frame 12 is mounted in a pit 4 formed in a floor 3 of the building 101. A lip 15 is pivotally attached to a forward edge portion of the deck 11 via one or more hinges 13. In the stored position shown, the distal or outer edge portion of the lip 15 is supported by keepers 14 mounted toward the front of the frame 12.
In operation, the deck 11 rotates upwardly and then downwardly as the lip 15 rotates outward and eventually comes to rest on the bed of an open truck, trailer or other shipping vehicle (not shown). The deck 11 and extended lip 15 thereby provide a ramp from the warehouse floor 3 to the truck or trailer, so that one or more persons, a fork lift, etc. can move back and forth over the deck 11 and lip 15 to load and/or unload the trailer.
A signal assembly 23 can be mounted adjacent to the opening 102 for providing signals to the vehicle driver. For example, the signal assembly 23 can include a red light 24 and a green light 25. When the green light 25 is illuminated, the driver can back up to or pull away from the loading dock 100. Conversely, when the red light 24 is illuminated, the driver should not pull away from the loading dock 100. These instructions can be posted on a nearby sign 26. The sign 26 can include reversed lettering so that the driver can read the sign 26 in a truck mirror.
The lighting system 110 can include a dock light 28 movably mounted proximate one side of the opening 102 to illuminate the interior of a trailer during loading and/or unloading operations. In one aspect of this embodiment, the dock light 28 can include one or more signal lights 120. As described in greater detail below, the signal light or lights 120 can be configured to inform and/or warn the dock operator and/or other personnel working in or around the vehicle of a change in status of an associated piece of dock equipment, such as the dock leveler 10, the vehicle restraint 20, etc. Such changes in status can include, for example, partial or total disengagement of the vehicle restraint 20, partial closure of the door 18, partial or total closure of the barrier gate 30, and/or retraction of the lip 15 away from the vehicle bed, etc.
Referring to
Once the truck or trailer has been sufficiently restrained by either the vehicle restraint 20 or chocks, the operator can depress the Door Open button 61 on the door control panel 60 to raise the door 18. The operator can then turn to the dock leveler control panel 40 and press the Raise button 41 to raise the deck 11 and extend the lip 15. The operator releases the Raise button 41 to lower the deck 11 onto the truck or trailer bed. Pressing the Lip Extend button 42 can allow faster deck operation by causing the lip 15 to extend before the deck 11 is fully raised. Pressing the Emergency Stop button 43 causes the dock leveler 10 to stop so that it will not descend on top of, for example, any misplaced cargo.
In some embodiments, the dock light 28 can be automatically turned on when the door 18 is raised. In other embodiments, the dock light 28 can include a manual On/Off switch that the operator turns on to illuminate the interior of the truck or trailer for loading and/or unloading. When the loading/unloading operation is finished, the operating sequence can be reversed, or at least generally reversed. For example, the operator can press the dock leveler Raise button 41 to raise the deck 11 and retract the lip 15, and then release the Raise button 41 to lower the deck 11 to the stored position. The operator can also press the Door Close button 63 to lower the door 18, and press the Release button 53 to lower the vehicle restraint barrier 21 and release the trailer. As the barrier 21 starts to lower, the interior red light 55 can be illuminated to indicate that the dock is not ready for use. When the barrier 21 is fully lowered, the exterior green light 25 can be illuminated to indicate that the truck driver may leave.
Although
The design, manufacture, and use of PLCs and associated electrical circuits, program statements, etc. are well known in the loading dock industry and, accordingly, are not set forth in detail herein to avoid unnecessarily obscuring the description of the various embodiments of the disclosure. Moreover, as those of ordinary skill in the art will appreciate, the various apparatuses, systems, and methods described above with reference to
As shown in
The colored LEDs 328b can include, for example, an array of red LEDs that illuminate (and/or flash) only when there is a change in status of an associated piece of dock equipment that a dock operator and/or other persons loading/unloading the vehicle may have an interest in. For example, in one embodiment the colored LED array 328b could illuminate when the vehicle restraint 20 changes status from locked to unlocked. In another embodiment, the colored LED array 328b could illuminate or flash when the dock leveler lip 15 changes status from extended to retracted, when the barrier gate 30 changes status from raised to lowered or at least partially lowered, and/or when the door 18 changes status from fully opened to at least partially closed. Both the first and second arrays of LEDs can receive facility power via a suitable power cord 332. The LED arrays can also receive power from other suitable sources, a battery, etc.
In operation, the first array of white LEDs 328a in the dock light 28 would illuminate the interior of the transport vehicle so that it could be loaded and/or unloaded in a conventional manner. In the event that the status of a piece of dock equipment changed, the signal light 120 could be illuminated to warn the dock operator of this occurrence. The immediate change in the ambient light color from white to, for example, red, will alert the dock operator of the change in equipment status.
In other embodiments, other colored light signals can be used (e.g., green, blue, amber, etc.) in place of, or in addition to, the red LEDs 328b. For example, in another embodiment the signal light 120 can include an array of blue LED's (not shown) in addition to the red LEDs 328b. In this embodiment, illumination of the red LEDs 328b could signal a change in status of a first piece of dock equipment (e.g., the vehicle restraint 20), and illumination of the blue LEDs could signal a change in status of another piece of dock equipment (e.g., the dock leveler 10). In yet another embodiment, one or more of the LED arrays associated with the signal light 120 can be pulsed or flashed to attract the attention of the operator. In a further embodiment, the first array of white LEDs 328a can automatically turn off to remove the normal white light so that only the, e.g., red light from second array of colored LEDs 328b is visible in the event of a status change.
Although in the illustrated embodiment the signal light 120 is integrated with and/or otherwise carried within a housing or cover 324 of the dock light 28, in other embodiments the colored signal light or lights can be contained in a secondary housing and/or mounted independently of the dock light 28. In a further embodiment, the colored signal light array can be omitted, and equipment status can be communicated to the dock operator by pulsing or flashing the existing dock light 28. In yet other embodiments, directional strobe lights can be utilized to warn the dock operator or communicate a change in vehicle or equipment status.
In the embodiment described above, the various dock lights and/or signal lights can be LED light sources. In other embodiments, however, virtually any type of visible light source can be used to communicate information to the dock operator and/or individuals working in or around the transport vehicle. For example, in other embodiments all or some of the colored LEDs described above can be replaced with one or more incandescent, florescent, halogen, and/or other suitable light sources having, e.g., suitably colored lenses. Similarly, in other embodiments all or some of the white LEDs described above can be replaced with incandescent, florescent, halogen, and/or other suitable light sources. In some embodiments, it is contemplated that one or more tunable light sources, or an array of tunable light sources (e.g., an array of tunable LEDs) can be used to emit both white or near white light for normal loading/unloading operations, and colored light for signaling a change in equipment status. Moreover, in further embodiments the signal light 120 and associated systems can be retrofitted to an existing loading dock lighting system and/or integrated with existing loading dock equipment.
In yet another embodiment, the loading dock 100 can further include an audio device, such as a speaker 370 or an alarm 371, for providing an audible warning to the dock operator in conjunction with the visual light signals, or even exclusive of the light signals under certain circumstances. Suitable alarms can include, for example, a Model FS 255 alarm from Preco Incorporated of Boise, Id. 83704. The audio device can provide an additional layer of communication by focusing or directing the audible signals so that they are effective at transport vehicle distances, and/or are only audible to those personnel working at the affected dock station. Moreover, the audio device can be mounted to the dock light housing 324, to a dock light mounting bracket 373, or other structure so that the audio device moves in conjunction with the dock light 28 and is directed in the same general direction (e.g., into the shipping vehicle) as the dock light 28.
In one embodiment, the controller 470 can be positioned in a box associated with one or more of the control panels. In another embodiment, the controller 470 can be incorporated into the dock light housing 324 (
Upon receiving information indicating a change in equipment status, the controller 470 transmits corresponding signals to the signal light 120 and/or the speaker 370. For example, when the dock operator presses a button or switch on the restraint control panel 50 to engage the vehicle restraint 20 with a trailer RIG, the control panel 50 transmits a signal to the controller 470 indicating that the vehicle restraint 20 should be in the “engaged” position. Similarly, the vehicle restraint 20 can send a corresponding signal to the controller 470 when the barrier 21 is properly engaged with the vehicle RIG. In the event that the vehicle barrier 21 is prematurely and/or inadvertently disengaged from the vehicle, the restraint 20 can send a corresponding signal to the controller 470 causing the controller 470 to in turn illuminate the colored LED array 328b (
As described above, in one embodiment the signal light 120 can convey the change in status of the vehicle barrier 20 to the operator by means of a bright red light. In another embodiment, the controller 470 can illuminate an array of blue lights on the signal light 120 to notify the operator of a change in status of a different piece of dock equipment, such as the dock leveler 10. Moreover, the controller 470 can cause the signal light 120 to display yet another color of light, such as amber, in the event that the barrier gate 30 inadvertently closes, the over-head door 18 inadvertently closes, or some other event takes place to change the status of a particular piece of dock equipment that a person working in or around a trailer at the loading dock 100 may wish to know about. Other combinations of light colors, flashing sequences, audible signals, etc. can be used to communicate other types of information.
In other embodiments, the signal light 120 (and/or the audio device 370, 371) can be used to convey other types of information to persons working in and around a shipping vehicle parked at the loading dock 100. For example, the signal light 120 can be configured to project colored light, flashing light, or some other visible signal in case of a fire, a natural disaster (earthquake, tornado, etc.), or some other event. The signal light 120 can also be configured to project a particular type of visible signal if, for example, a dock supervisor or other person wishes to summon the person or persons working inside the vehicle, the person working in the vehicle has a phone call, or a shift has ended. Accordingly, in one embodiment the signal light 120 can be configured to project a first color of light (e.g., blue, amber, etc.) to convey general information, and a second color of light (e.g., flashing red light) to signal persons to get out of the vehicle.
The signal light 120 can also be used as a tool to communicate to persons working both in and out of the vehicle how long a particular loading or unloading process is taking. For example, if a particular unloading process has taken longer than an allotted amount of time (e.g., 1 hour), then the signal light 20 can change to a first color to so indicate. If the process continues beyond a second amount of time (e.g. 2 hours), then the signal light 120 can change to a second color to so indicate. Moreover, in any of the embodiments described herein an additional signal light (e.g., a signal light at least generally similar to the signal light 120) can be positioned proximate the signal light 120, but rather than facing into the shipping vehicle the additional light can face away from the vehicle (e.g., into the building 101). In the foregoing manner, persons positioned outside the vehicle (e.g. a dock supervisor) in the vicinity of the loading dock 100 can immediately ascertain various types of information relating to the loading/unloading process, such as elapsed time.
In some embodiments, the signal light 120 (and/or the audio device 370/371) can display or project the various signals described above in response to inputs received from the dock management system 480. For example, in one embodiment the dock management system 480 can transmit an input signal to the signal light 120 causing the signal light 120 to project an appropriate visible signal when an unloading process has taken longer than an allotted time. The dock management system 480 can generate the input signal automatically in response to an elapsed time clock, or in response to, for example, manual input from a dock supervisor.
The foregoing embodiments described above illustrate only some of the ways that the colored lights of the signal light 120 can be utilized to warn and/or communicate equipment status information to the dock operator or personnel working within a truck or other transport vehicle. Accordingly, in other embodiments, different lights and/or different combinations of colors and/or audible signals can be used to communicate this information without departing from the spirit or scope of the present disclosure.
From the foregoing, it will be appreciated that specific embodiments of the invention have been described herein for purposes of illustration, but that various modifications may be made without deviating from the spirit and scope of the various embodiments of the invention. Further, while various advantages associated with certain embodiments of the invention have been described above in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments need necessarily exhibit such advantages to fall within the scope of the invention. Accordingly, the invention is not limited, except as by the appended claims.
The present application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application No. 61/306,867, filed Feb. 22, 2010, and entitled “LOADING DOCK LIGHTING SYSTEMS HAVING WARNING FEATURES,” which is incorporated herein in its entirety by reference. The disclosure of U.S. Pat. No. 7,274,300 is incorporated herein in its entirety by reference.
Number | Date | Country | |
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61306867 | Feb 2010 | US |