This invention relates to a manipulator for use with a lift truck attachment which enables the attachment to access a load located on either widthwise side of the lift truck.
A lift truck is a self-propelled vehicle equipped with a movable, frame, referred to as a carriage, which can be raised and lowered along an upright mast. Various attachments, such as forks or clamps for supporting or grasping a load, can be mounted on the carriage so that the lift truck can raise and lower the load.
A typical lift truck is designed so that a load being supported, transported, or otherwise handled by the lift truck is disposed directly in front of the lift truck. However, in some situations, it is desirable for a lift truck to be able to grasp a load located to a widthwise side of the lift truck. For example, in factories and warehouses, merchandise is often stored on shelves or in rows of pallets separated by an aisle. If a lift truck situated in such an aisle is capable of grasping merchandise located on a widthwise side of the lift truck instead of the lift truck having to be turned within the aisle so as to directly face the merchandise, the lift truck can be operated in a narrow aisle only slightly wider than the width of the lift truck, thus enabling more merchandise to be accommodated in a given floor area.
The present invention provides a manipulator for use with a lift truck which can support a lift truck attachment so as to be able to grasp a load located on either widthwise side of the lift truck.
The present invention also provides a manipulator for use with a lift truck which can change the orientation of a load while operating within a narrow space.
The present invention also provides a lift truck equipped with such a manipulator.
The present invention additionally provides a method of operating a lift truck equipped with such a manipulator.
According to one form of the present invention, a manipulator for manipulating a lift truck attachment includes a guide assembly which can be mounted on a mast of a lift truck so as to extend in a widthwise direction of the lift truck. A carriage assembly is supported by the guide assembly for movement along the guide assembly, and an arm assembly has a first arm connected to the carriage assembly and a second arm connectable to an attachment for a lift truck and rotatably connected to the first arm. Preferably the second arm is capable of being rotated with respect to the first arm by at least approximately 180° to enable a load to be transferred between opposite widthwise sides of the lift truck.
Preferably the carriage assembly can move along the guide assembly by at least 40 inches to enable a load to be transferred between two standard pallets disposed side by side.
The manipulator is not restricted to any particular use, but typically is it mounted on a mast for a lift truck such that the manipulator can be raised and lowered along the mast. The manipulator can be used with a wide variety of lift truck attachments. In preferred embodiments, the manipulator is used to support a clamping apparatus for grasping a load from two or more sides.
According to another form of the present invention, a method of operating a lift truck includes moving a load held by a clamping apparatus between opposite widthwise sides of a lift truck using a manipulator according to the present invention.
According to still another form of the present invention, a method of moving a load includes transferring a load from a first pallet to a second pallet using a manipulator according to the present invention mounted on a lift truck without changing the location of the mast of the lift truck.
It is common for lift trucks to be equipped with a device referred to as a sideshifter for translating the forks of the lift truck from side to side in the widthwise direction of the lift truck. However, a sideshifter has a very limited range of movement, and is primarily intended for carrying out fine adjustment of the widthwise position of the forks of the lift truck, such as when aligning the forks with openings in a pallet, and it is not capable of performing any substantial movement of a load in the widthwise direction of the lift truck.
In contrast, a manipulator according to the present invention is capable of extensive movement of a load in the widthwise direction of a lift truck, enabling it to perform tasks such as transferring a load from one pallet to another or moving a load between opposite widthwise sides of the lift truck. Therefore, it provides a whole different range of uses not possible with a sideshifter.
An embodiment of a manipulator for a lift truck according to the present invention will be described while referring to the accompanying drawings.
The lift truck 10 may have any structure enabling it to support and transport a load. For example, it may be selected from a wide variety of commercially available lift trucks. The illustrated lift truck 10 includes a body 11 supported by a plurality of wheels 12 (four in the present embodiment). A mast 20 is mounted on the front of the body 11 in a conventional manner so that the mast 20 can be tilted forward and backward with respect to the body 11 to adjust the angle of the mast 20 with respect to the vertical, and a carriage 30 is supported by the mast 20 for vertical movement along the mast 20. The illustrated mast 20 is what is commonly referred to as a two-stage mast, but it may instead be a one-stage mast or a mast with three or more stages. The structure of the mast 20 may be conventional. As best shown in
The lift truck attachment which is supported by the arm assembly 80 may be any type of attachment adapted for mounting on a lift truck, such as an attachment for lifting, grasping, or otherwise manipulating a load. Some examples of attachments which can be employed are forks and various types of clamps. In the present embodiment, the attachment comprises a clamping apparatus 100 capable of grasping a load 106 from two or more sides. The structure of the illustrated clamping apparatus 100 is described in detail in U.S. patent application Ser. No. 10/689,848 entitled “Clamping Apparatus”, the disclosure of which is incorporated by reference, so it will be described only briefly here.
The clamping apparatus 100 includes a cross-shaped frame 101 having four legs 102 on which are mounted a plurality of clamping arms 103 capable of pivoting with respect to the frame 101 to grasp and release a load 106. At its lower end, each clamping arm 103 is equipped with a contact portion 104 for contacting the side of a load 106. The clamping arms 103 can be pivoted on the frame 101 by suitable actuators, such as hydraulic cylinders 105.
The guide assembly 50 supports the carriage assembly 60 for movement in the widthwise direction of the lift truck 10 while supporting the weight of the carriage assembly 60, the arm assembly 80, the clamping apparatus 100, and any load 106 grasped by the clamping apparatus 100. In the present embodiment, the guide assembly 50 includes a plurality of guide rails, and the carriage assembly 60 includes rollers which can roll along the guide rails of the guide assembly 50. However, the guide assembly 50 may support the carriage assembly 60 in a different manner, such as for sliding movement. As shown in
The guide assembly 50 is preferably capable of being raised and lowered by the lift truck 10 to adjust the height of a load 106 supported by the manipulator 40. The guide assembly 50 may be detachably mounted on the carriage 30 of the lift truck 10. For example, the upper and lower guide rails 51 and 52 may be equipped with fittings for detachable engagement with the horizontal mounting bars of a typical lift truck carriage. Alternatively, as in this embodiment, the guide assembly 50 may be integrated with the lift truck carriage 30 so as to form a single unit. As shown in
As shown in
The carriage assembly 60 also includes structure for supporting the arm assembly 80. In the present embodiment, the support structure comprises a mounting bracket including a pair of vertical side plates 67 mounted atop the front plate 61 of the carriage assembly 60 and a vertical end plate 68 extending between the side plates 67. As shown in
The carriage assembly 60 may be manually movable along the guide assembly 50 in the widthwise direction of the lift truck 10, or the manipulator 40 may include a powered drive mechanism for moving the carriage assembly 60 along the guide assembly 50. A drive mechanism may be mounted either on the guide assembly 50 or on the carriage assembly 60. The present embodiment includes a chain and sprocket drive mechanism mounted on the guide assembly 50. As best shown in
The arm assembly 80 holds the clamping apparatus 100 at a sufficient distance from the front of the lift truck 10 that the clamping apparatus 100 can pass in front of the lift truck 10 in the widthwise direction thereof between a position in which the clamping apparatus 100 does not overlap the guide assembly 50 in the widthwise direction of the lift truck 10 (such as the position shown in
In the present embodiment, the arm assembly 80 includes a first arm 81 having one end connected to the carriage assembly 60, a second arm 86 having one end connected to the clamping apparatus 100 or other attachment being supported by the manipulator 40, and a joint 90 rotatably connecting the other ends of the two arms 81 and 86 to each other to enable the second arm 86 to rotate by 180° about a substantially vertically axis with respect to the first arm 81. The illustrated first arm 81 comprises a tube having a rectangular cross section. A first end of the first arm 81 is pivotably mounted on the mounting bracket of the carriage assembly 60 by a pivot pin 82 which passes through a pair of aligned holes formed in the first arm 81 near its first end and through the pair of holes 69 in the side plates 67 of the mounting bracket. A plate 83 is secured to the first end of the first arm 81, and one or more bolts 84 are screwed into the plate 83 with the head of each bolt 84 opposing the end plate 68 of the mounting bracket. The weight of the arm assembly 80 exerts a moment on the first arm 81 about the pivot pin 82 to make the heads of the bolts 84 abut against the end plate 68 to limit the rotational movement of the first arm 81 about the pivot pin 82. The length by which the bolts 84 are screwed into plate 83 can be adjusted by screwing the bolts 84 into or out of plate 83 to vary the angle of the first arm 81 with respect to the horizontal when the first arm 81 is in the position shown in
The illustrated second arm 86 likewise comprises a tube with a rectangular cross section. The second arm 86 may be detachably connected to the clamping apparatus 100 to enable the manipulator 40 to be employed with different types of equipment. Alternatively, the second arm 86 may be permanently attached to the clamping apparatus 100. For example, in this embodiment, the second arm 86 is integral with one of the legs 102 of the clamping apparatus 100.
The joint 90 can have any structure which enables the first arm 81 to support the second arm 86 while enabling the second arm 86 to rotate, preferably by at least approximately 180°, with respect to the first arm 81 about a substantially vertical axis. As best shown in
The second arm 86 may be manually rotatable with respect to the first arm 81, or the manipulator 40 may include a drive mechanism to enable the operator of the lift truck 10 to rotate the second arm 86 about the first arm 81 by remote control. In the present embodiment, the arm assembly 80 includes a sprocket and chain drive mechanism including a drive sprocket 95 secured to the output shaft of a reversible motor 96 (which may be hydraulic or electric, for example) secured to the upper mounting plate 91 of the joint 90, a driven sprocket 97 secured to the pivot pin 92 for the second arm 86, and a chain 98 passing around both sprockets 95 and 97. The motor 96 can be controlled by the operator of the lift truck 10 to rotate the second arm 86 in either rotational direction with respect to the first arm 81. The motor 96 will typically be controlled by a controller on board the lift truck 10 where it can be readily operated by the operator of the lift truck 10.
The length of the first arm 81 is preferably such that the distance from the rotational center of the joint 90 (pivot pin 92) to the front surface of the guide assembly 50 is at least one-half the maximum outer dimensions of the clamping apparatus 100 measured in the fore-and-aft direction of the lift truck 10 so that when the second arm 86 is at right angles to the first arm 81 as shown in
The hydraulic cylinders 105 of the clamping apparatus 100 and motors 55 and 96 (when they are hydraulic motors) may be driven by an unillustrated hydraulic power supply on the lift truck 10 through unillustrated hydraulic lines supported by the manipulator 40. When electric motors are used, the motors may be powered by a battery or generator in a suitable location, such as on board the lift truck 10.
Each of the arms 81 and 86 in this embodiment has a constant length, but it is also possible for one or both arms to have a variable length. For example, either arm may be telescoping.
A situation in which a manipulator 40 according to the present invention can be used highly advantageously is for operation in a narrow aisle between rows of storage racks such as are frequently found in warehouses and distribution facilities.
In order to keep the lift truck 10 at a suitable distance from the sides of the aisle 110 without the operator having to steer the lift truck 10, the lift truck 10 may be equipped with a guide system. For example, guide rollers may be provided on the body 11 of the lift truck 10 for rolling engagement with a guide rail mounted on the floor of the aisle 110, as described in U.S. Pat. No. 6,477,964, entitled “Guide System for a Forklift”.
A manipulator according to the present invention can be employed in a manner similar to that described above on a lift truck operating alongside a row of pallets containing stacks or merchandise or in an aisle between two such rows of pallets. A clamping apparatus supported by the manipulator can be moved in a straight line in the widthwise direction of the lift truck to remove a load from or place a load onto one of the pallets in the row(s) without disturbing merchandise on adjoining pallets even when there is very little clearance between adjoining pallets. In addition, the clamping apparatus can be swung between opposite sides of an aisle to enable the clamping apparatus to access pallets on either side of the aisle.
Yet another situation in which a manipulator according to the present invention can be advantageously employed is to transfer a load from one pallet to another. Such a situation may occur when a manufacturer ships merchandise to a warehouse on pallets, and the manufacturer wishes to have his pallets returned to him rather than going into the distribution system from the warehouse. In this situation, the warehouse operator needs to transfer the merchandise from the pallets of the manufacturer to his own pallets. Transfer between two pallets can be carried out as follows. With two pallets placed side by side and the lift truck 10 positioned in front of the two pallets, the clamping apparatus 100 can be positioned by the manipulator 40 above a load on one of the pallets. The load can be grasped and lifted by the clamping apparatus 100, and the carriage assembly 60 of the manipulator 40 can be moved along the guide assembly 50 until the load is positioned above the second pallet. The clamping apparatus 100 can then be lowered until the load rests atop the second pallet, and the load can be released by the clamping apparatus 100. If the center-to-center distance between the two pallets is less than the maximum distance of which the carriage assembly 60 is capable of traveling along the guide assembly 50, the transfer of the load between the pallets can be accomplished while maintaining a constant angle between the arms 81 and 86 of the arm assembly 80. For example, the arms can be maintained at right angles to each other or aligned with each other during the transfer process.
A suitable range of movement of the carriage assembly 60 along the guide assembly 50 will vary with the application for which the manipulator 40 is employed. When the manipulator 40 is being used to transfer a load between two pallets in the manner just described, the range of movement of which the manipulator 40 needs to be capable is at least the center-to-center distance between the pallets. If two standard pallets, each measuring 40×48 inches, are placed side by side with no separation between them and with their longer sides (the 48-inch sides) opposing each other, the center-to-center distance between the pallets is 40 inches, so a suitable range of movement of the carriage assembly 60 in this situation is at least 40 inches. In order to allow some separation between adjoining pallets, a more suitable range of movement is somewhat larger than 40 inches, such as approximately 45 inches. If the two pallets are disposed with no separation between them and with their shorter sides (the 40-inch sides) opposing each other, the center-to-center distance between the pallets is 48 inches, so in this case a suitable range of movement of the carriage assembly 60 is at least 48 inches and preferably somewhat larger than this to permit some separation between the pallets.
When the manipulator 40 is being used to transfer a load to or from atop a shelf 114 on a rack 111 in the manner shown in
minimum range of movement=A+B
wherein
A is the distance from the edge of the rack adjoining the aisle to the center of the load disposed on the rack, and
B is the distance from the edge of the rack adjoining the aisle to the center of the clamping apparatus when the clamping apparatus is located inside the aisle and spaced from the edge of the rack by a sufficient clearance to enable the lift truck to travel along the aisle
When a load is disposed on a rack, the load will typically be sitting atop the center of a pallet. In this case, distance A is the distance from the edge of the rack to the center of the pallet. If the pallet is a standard pallet measuring 40×48 inches, distance A is 20 inches when one of the 48-inch sides of the pallet is flush with the edge of the rack.
Distance B will depend upon the design and the size of the clamping apparatus. For a clamping apparatus like that shown in
In this case, the minimum range of movement given by the above formula becomes 20+28=48 inches. In order to enable the edge of the pallet to be offset with respect to the rack 111 and to enable a larger clearance between the clamping apparatus 100 and the edge of the rack 111, a more suitable minimum range of travel is somewhat larger, such as approximately 50 inches. The minimum range of movement would be the same as this for the case in which a load measuring 40 inches wide is being placed onto or removed from a pallet in a row of pallets.
The values given by the above calculations are merely examples of a minimum range of movement for the carriage assembly 60 along the guide assembly 50, and the minimum range of movement can be larger or smaller than this value, depending upon the size of the load, the design of the clamping apparatus, the size of a pallet on which the load is sitting, how far the pallet is offset from the edge of a rack, and other factors. However, since a load measuring a maximum of 40 inches wide in the widthwise direction of a lift truck is fairly common, a minimum range of movement of approximately 50 inches enables the manipulator 40 to be widely employed for handling loads disposed on racks or on rows of pallets.
If the second arm 86 of the arm assembly 80 has an adjustable length, the carriage assembly 60 can be moved along the guide assembly 50 by a lesser distance than that given by the above formula, and the second arm 86 can be lengthened so that the total distance of travel of the clamping apparatus 100 due to the movement of the carriage assembly 60 along the guide assembly 50 and the lengthening of the second arm 86 equals the range of travel given by the above formula.
As can be seen from the above description, the ability of the carriage assembly 60 to be moved along the guide assembly 50 enables the clamping apparatus 100 to be moved along a straight line in the widthwise direction of the lift truck 10 and thereby enables the clamping apparatus 100 to be inserted into or withdrawn from a narrow space located to a widthwise side of the lift truck 10. In addition, the ability of the second arm 86 to rotate with respect to the first arm 81 combined with the ability of the carriage assembly 60 to be moved along the guide assembly 50 in the widthwise direction of the lift truck 10 enables the orientation of a load 106 to be changed within a very narrow space. These abilities give the manipulator 40 excellent versatility when operated in confined areas.
This application claims the priority of U.S. Provisional Application No. 60/699,379 filed on Jul. 15, 2005, the disclosure of which is incorporated by reference.
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Number | Date | Country | |
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Number | Date | Country | |
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60699379 | Jul 2005 | US |