Patent Application
20070217892
This invention relates to power handling devices for manipulating heavy loads, and, more particularly, to a new and useful handling device which is, inter alia, compact, versatile, reconfigurable/modular, aesthetically pleasing, and comprises a minimum number of component parts for reduced complexity and improved reliability.
In the past two decades greater emphasis has been placed on employee safety and lost productivity due to injuries in the workplace. In nearly every Fortune 500 Corporation, programs and special tools are employed to minimize injuries due to poor use of body mechanics resulting in muscle strains, joint injuries, torn ligaments and tendons etc. Oftentimes, equipment, machinery and tools are analyzed and modified for improved ergonomics, i.e., designed to cooperate/complement the natural strengths, leverage points and movements of the human body.
Another trend tending to conflict with the above safety issues are the packaging and production of larger, heavier raw materials/material containers which require special handling. That is, manufacturers of such goods as paper, wire and cable, deliver such materials in bulk for economy of warehouse/stocking space and, of course, greater revenues. For example, a roll of raw paper material which may have previously been delivered in one ton rolls may now be sold in significantly larger quantities, e.g., three ton rolls, to lower the cost to consumers while improving margins for the manufacturer.
The size and weight of such packaged goods/products presents challenges for those responsible for their shipment, storage and use, especially when operating in confined work/warehouse environments. While gross movement and handling of such heavy, multi-ton goods/products is readily achieved by conventional lifting/towing devices, e.g., forklifts, grabbers etc., there are commonly areas of the workplace that require movement or more precise manipulation of these goods/products without the assistance of conventional materials handling devices. For example, where drums or rolls need to be moved short distances into or out of unwind stands, rewind stands or other secondary processing stages, confined work areas renders automated methods inappropriate.
In the past, it was considered acceptable for a worker or workmen to use their body strength, i.e., “brute force”, to manipulate the object into its storage space or dispensing position. At the current time, however, employees are urged to use caution and/or directed not to use body strength to manipulate heavy objects, but to seek other methods and/or use other tools to move/position such objects. This is especially true due to the increasing tendency for the weights requiring movement being larger/heavier and cycle times increasing in line with increased productivity pressures.
Only recently, i.e., within the past 10-15 years, have sufficiently compact, powered devices become available with sufficient mechanical advantage (i.e. power) to manipulate multi-ton objects in the workplace. U.S. Pat. No. 4,582,154 discloses a drive device for manipulating large multi-ton cylindrical objects such as large rolls of paper material/stock or large reels of electrical cable. The drive device is produced under the trade name “EasyMover” and comprises a plurality of rolling elements in combination with a drive roller which, by contacting the cylindrical surface of the object and the floor beneath, causes the object to rotate and move in a desired direction. More specifically, and referring to
Referring again to
Additionally, the EasyMover device described above requires external power to maintain a compact design envelop. However, the requirement for an external energy source requires that the unit be “tethered” in the sense that a compressed air line must remain connected to the device while in operation. In operation, the device 200 is wedged under a cylindrically-shaped object 240, i.e., between the cylindrical surface thereof and the floor beneath. When positioned in this manner, the drive roller 210 makes circumferential contact with the support roller 202 to drive the unit and, therefore, the object/load in a forward direction.
Prior to such positioning, prepositioning of the device 200 is necessary. Prepositioning is achieved by rolling the unit on the intermediate roller 204 and/or the aft wheels 206 with the support roller 202 being slightly raised to permit free-wheeling of the device while prepositioning. It will be appreciated that inasmuch as the support roller 202 is in frictional engagement with the drive roller 210 (which does not rotate in an unpowered condition), the support roller 202 must be raised slightly to allow the device 200 to roll freely.
Yet another feature of the device 200, and referring to
While the device 200 incorporates many features which continue to be used today, i.e., pneumatically driven motor, compact design envelope, etc., the device has several shortcomings and disadvantages.
Firstly, due to the spatial positioning and number of elements, e.g., forward roller, drive roller, motor etc., the drive device is longer and heavier than would be ideally preferred. Exacerbating the lack of maneuverability is the use of the intermediate roller 204 in combination with the aft wheels 206 to preposition the device. That is, the cylindrical configuration of the intermediate roller 204 requires that the operator slide or drag the device to change direction, e.g., turn right to left, into a desired position. Moreover, the device cannot be tilted upward about its aft wheels 206 to facilitate mobility due to the small diameter of the aft wheels in combination with the length of the unit. One may analogize the manipulation of the device to parallel parking a multi-axle tractor trailer into a confined space. Furthermore, the length and weight of the device effects a forward center of gravity (generates a large moment arm) which cannot be easily lifted.
Secondly, the device comprises a multiplicity of components which increases complexity and manufacturing costs, and more importantly, decreases the reliability of the device. These components include the chain-link drive which is subject to failure and requires periodic maintenance, and a rotating air fitting which is typically loaded during lifting/prepositioning, but is not intended for such application. Finally, the device is essentially uni-directional and has limited application, i.e., can only function to push an object. Other functions such as pulling an object or changing direction, require other or additional dedicated devices.
A need therefore exists for a handling device which is compact in size, possesses fewer component parts, provides enhanced reliability, and is reconfigurable/modular for improved functionality/use.
It is an object of the present invention to provide a power handling device for manipulating heavy loads which is compact and versatile for use in various industrial applications.
It is another object of the present invention to provide such a power handling device which is reconfigurable for rolling cylindrical objects, forwardly and rearwardly, while additionally being able to push/pull objects having a variety of shapes/sizes.
It is yet another object of the present invention to provide a power handling device which may be used in a variety of orientations, i.e., right-hand, left-hand etc., to permit manipulation from either side of a load.
It is still another object of the present invention to provide such a power handling device which is modular in design to allow substitution of other component parts for permitting commonality of parts thereby decreasing costs.
It is yet another object of the present invention to provide a power handling device which is aesthetically pleasing for improved appeal in the marketplace.
These and other objects are achieved by a power handling device having a chassis supporting at least two rolling elements, a handle shaft mounting to the chassis, a motor for driving at least one of said rolling elements, and a power supply for energizing the motor. In the broadest embodiment of the invention, the power handling device is characterized by a Non-Interference Envelope (NIE) defined by straight lines intersecting outermost points of tangency on at least two of the rolling elements. To enable reconfiguration and reorientation of the power handling device, the motor and other propulsion related components are disposed internally of the NIE.
In another embodiment of the invention, at least three rolling elements are arranged to define a substantially triangular profile and a means is provided for reconfiguring the chassis to enable support by at least two pairs of rolling elements. In yet another embodiment of the invention, the power handling device includes a pivotable fitting to enable use in two operational modes, one to roll an object and another to push/pull an object.
In yet another embodiment of the invention, the power handling device comprises two separable sections, i.e., a forward propulsion section and an aft handling section, to facilitate reconfiguration and/or permit interchangeability of components. More specifically, to perform the aforementioned operations, in addition to yet others, it will be necessary to vary the position, e.g., angular orientation, of the handle shaft relative to the chassis. The forward propulsion and aft handling sections are detachably mounted via a pair of identically configured lap joints capable of reversibly mounting the units to achieve the desired handle shaft orientation or configuration. Alternatively, the mounting arrangement also facilitates the interchangeability of units having different or additional functionality.
A more complete understanding of the present invention and the attendant features and advantages thereof may be had by reference to the following detailed description of the invention when considered in conjunction with the following drawings wherein:
a is a profile view of a prior art drive device for manipulating a heavy cylindrical object.
b is the same profile view of the drive device illustrated in
c depicts a view of the prior art drive device taken along line 1c-1c of
d and 1e depict the same view of the prior art drive device as that shown in
a is a front view of the power handling device (excluding the handle and handle shaft thereof) according to the present invention in a common operating configuration and orientation.
b is a profile view of the power handling device according to the present invention in the operating configuration shown in
a-10k depict various orientations/configurations which may be employed to manipulate loads in a variety of applications.
The invention described herein is best illustrated by reference to a particularly relevant application which best demonstrates its utility and advantages. More specifically, the power handling device of the present invention will be described in the context of the movement and manipulation of large, multi-ton cylindrical objects/raw materials such as those used in the paper or wire cable industries. However, it will readily be appreciated that the power handling device may be employed in any application wherein the movement/manipulation of heavy objects is required. The power handling device of the present invention will first be described in the context of a pneumatic power source and briefly described in the context of an electrical power source. With respect to the latter, the electrical power source is integral with the device thereby enabling portable, self-powered operation.
In
In the preferred embodiment, and referring to
The aft handling section 12AH, on the other hand, does not employ substitutable components for performing different functions nor does it require routine replacement of parts, for maintenance purposes. Although, many different embodiments of the aft handling section 12AH, are envisioned, (e.g., fixed handle or handle accommodating pneumatic or electric power delivery etc.) as will be described in greater detail below.
In one of the preferred embodiments, the chassis 12 is adapted to support three rolling elements 30 comprising a forward support roller 32 (sometimes referred to as simply the “forward roller” when not shown in an embodiment requiring “support”), a pair of aft wheels 34, and a drive roller 36 interposed between the forward support roller 32 and aft wheels 34. In the context used herein, the term “rolling element” means any object having a circular cross-section in at least one plane orthogonal to its rotational axis. Consequently, cylindrical rollers, wheels or other functional equivalents are intended to fall within the meaning of the term rolling element. Furthermore, in one of the primary configurations or applications of the power-handling device 10, the drive roller 36 is elevated relative to the other rolling elements 32, 34 to define a triangular profile geometry. As such, the drive roller 36 is disposed at the apex of the triangle. Moreover, the rotational axes 32A, 34A and 36A (referenced in
The chassis 12 also includes several detachable elements which provide structural support for the rolling elements yet may be removed to facilitate assembly/disassembly. More specifically, the chassis 12 also includes a cylindrical support 40 mounted to one of the sideplates 16a and an end cap 42 (shown only in
Referring to
The drive roller 36 comprises a cylindrical body 54 which is disposed over and supported by the cylindrical support 40 at one end thereof and is supported at the other end by a journal bearing 56. The journal bearing 56 accepts a stub axle 58 of the cylindrical body 54 and is supported within the chassis-mounted end cap 42. In the preferred embodiment, an oil impregnated brass sleeve 60 is disposed between the drive roller 36 and the cylindrical support 40 to provide a low friction bearing interface therebetween.
More specifically, the cylindrical body 54 of the drive roller 36 defines a first end 62 which is open for accepting the cylindrical support 40 and a second end 64 which is configured (e.g., necked-down) to form the stub axle 58 as an integral element of the cylindrical body 54. Additionally, the second end 64 is adapted for receiving the output drive shaft 52 of the motor 50 and for transferring torque from the motor 50 to the drive roller 36. In the preferred embodiment, a keyway (not shown) is formed internally of the stub axle 58 for receiving a key 68 formed on the exterior of the output drive shaft 52. While the embodiment shown describes a keyed connection for transferring torque, it will be appreciated that the invention envisions any of a variety of means for transferring torque from the output drive shaft 52 to the drive roller 36.
The drive roller 36, therefore, circumscribes or envelops the output drive shaft 52 of the motor 50 in addition to a significant portion of the motor itself. Furthermore, the drive roller 36 is coaxial with the output drive shaft 52 and driven directly thereby. Finally, the stub axle 58 of the drive roller 36 dually serves to support the drive roller 36 and output drive shaft 52 within the journal bearing 56.
In the preferred embodiment, and still referring to
Referring again to
The forward support roller 32 is mounted to the chassis 12 and adjacent to the drive roller 36 such that the exterior surfaces of the rollers 32, 36 are contiguous. Consequently, in operation, the forward roller 32 is driven by the drive roller 36 through frictional engagement of the rollers 32, 36. Similar to the drive roller 36, the forward roller 32 preferably employs a high friction surface for improving the efficacy of the friction drive. Moreover, inasmuch as the forward support roller 32, in the most frequently used configuration, propels and supports the power-handling device 10 along the floor, a herringbone tread is formed on the surface of the roller 32. Finally, to ensure that the rollers 32, 36 remain in contact during operation and, over time, as wear may alter the diameter dimensions of the rollers 32, 36, the apertures 76 (see
As described hereinbefore, the motor 50 is disposed internally of the drive roller 36 and affixed to the chassis 12 by the cylindrical support 40. While the motor 50 is mounted to the cylindrical support 40 at a forward location (i.e., at the output shaft end 50e thereof) any one of a variety of means may be employed for reacting motor torque and/or preventing motor rotation. For example, the motor housing may be polygonally-shaped for engaging a similarly shaped aperture of the chassis thereby effecting mechanical interlock for anti-rotation.
In the preferred embodiment, the motor 50 delivers high torque to the drive roller 36 and may be powered by any of a variety of known power sources. In the described embodiment, the motor 50 is pneumatically powered driven and is of the type produced by Atlas Copco, a US Manufacturer. The motor is capable of delivering high torque when supplied with a working pressure of 600 to 700 kPA.
Still referring to
A pair of conventional wheels 34 are journally mounted to stub axles 82 projecting outwardly of each sideplate 16a, 16b. Furthermore, the cross member 18c disposed between the sideplates 16a, 16b defines an internal passageway which is in fluid communication with the tubing 80 for supplying pressurized air to the motor 50. More specifically, the handle shaft 90 is disposed in combination with the cross member 18c and provides a conduit for pressurized air to be delivered to an internal chamber 84 of the cross member 18c. In one embodiment of the invention, the cross member 18c defines an inlet aperture 18I and an outlet fitting 18E. The handle shaft 90 is rigidly affixed, e.g., welded to the cross member 18c, and aligned with the inlet aperture 18I such that pressurized air PA may flow from the tubular shaft 90 to the internal chamber 84 of the cross member 18c. Furthermore, the outlet fitting 18E is coupled to the tubing 80 to complete the air supply line from the handle shaft 90 to the motor 50.
As previously mentioned, the chassis 12 is preferably bifurcated by means of a separation or split in each of the sideplates 16a, 16b between the drive roller 36 and the pair of aft wheels 34. More specifically, the sideplates 16a, 16b are configured to define lap joints 100a, 100b which are substantially symmetric. Furthermore, the lap joints 100a, 100b and the outlet fitting 18E are designed to facilitate ease of assembly and disassembly. For example, the lap joints 100a, 100b are readily assembled by means of a wrench or ratchet (not shown) and the outlet fitting 18E may employ a quick disconnect coupling (also not shown).
Before discussing yet other embodiments of the invention, it will be useful to discuss the scope of several teachings of the invention in addition to various structural and functional advantages of the specific embodiment(s) described above.
The power handling device 10 of the present invention is uniquely packaged and arranged to provide optimum versatility and maximum utility. To best appreciate the scope and utility of the invention, it is useful to examine certain geometric characteristics of the power handling device 10. In
The invention requires that all elements in connection with the propulsion of the power handling device 10, e.g., the motor 50, tubing 80, torque reaction means, and cylindrical motor mount 40 etc., lie within the boundaries established by the NE. In accordance with this teaching, the drive roller 36 circumscribes the motor 50 and the tubing 80 is disposed internally of the chassis 12, thereby mounting these components within the NIE.
When employing this teaching, the power handling device 10 may be reversed, re-oriented and/or reconfigured to operate on at least two pairs of rolling elements 30. Referring collectively to
In a second orientation (most appropriately illustrated in
It will also be appreciated that the handle shaft 90 must be reconfigured to function in both modes of operation. To maintain the substantially upright position and attitude of the handle shaft 90, the aft handling section 12AH is detached from the forward propulsion section 12FP and rotated 180 degrees relative to a forwardly-facing horizontal axis LA (see
In view of the foregoing, the power handling device 10 of the present invention may be supported by at least two pairs of the rolling elements 30, (e.g., the forward support roller 32 in combination with the aft wheels 34, and the aft wheels 34 in combination with the drive roller 36) without interfering with other components or requiring use thereof in an ergonomically incorrect position. By way of comparison, the prior art drive device 200 shown in
Furthermore, location of the motor 50 within the drive roller 36 permits a direct torque drive from the output drive shaft 52 of the motor 50 and the drive roller 36. As such, high maintenance components such as the chain link drive 230 of the prior art may be eliminated. Consequently, the maintenance requirements of the power handling device 10 are reduced while improving reliability.
The power handling device 10 is, furthermore, capable of being pivoted about the aft rotational axis 34A to raise the forward propulsion section 12FP out of contact with the underlying floor in a manner similar to a hand-cart. Here again, the compact design of the power handling device 10 effects a short or small moment arm between the chassis center of gravity (C.G.) and the rotational axis 34A, thus minimizing the handle torque and torsional stresses at the point of handle-chassis connection. This pivoting capability greatly improves the maneuverability of the power handling device 10.
Additionally, bifurcation of the power handling device into forward propulsion and aft handling sections 12FP, 12AH permits extensive reconfiguration and modularity of the device 10. For example, a forward propulsion section having greater power output, larger drive and forward support rollers, or other geometric modifications may be employed while using the same aft handling section 12AH. Furthermore, by designing identical and symmetrical lap joints 100a, 100b, the aft handling section 12AH may be rotated to change the position of the handle shaft 90 relative to the chassis 12 and with respect to the subject object or article being move/manipulated.
In another embodiment of the invention and referring to
The spool fitting 102 includes a first cylindrical end 102E-1 which engages an end cap 90e of the handle shaft 90 and a second cylindrical end 102E-2 for engaging a double J-shaped locking plate of the locking mechanism 120. Furthermore, the spool fitting 102 includes ring seals 104a, 104b disposed about the periphery of the spool fitting 102, which ring seals 104a, 104b provide an airtight seal against the internal surface of the stub axle 82. Furthermore, the seals 104a, 104b permit rotation of the spool 102 about the rotational axis 34A. The spool fitting 102 also defines a central aperture 106 (best seen in
The locking mechanism 120 comprises a kick-plate 122 disposed externally of the rear cross member 18c, a double J-shaped locking plate 124 for engaging the spool fitting 102 of the pivot mount 100 and spring bias means 126 for causing the locking plate 124 to engage and disengage the spool fitting 102 in response to radial motion of the handle shaft 90. More specifically, the locking plate 124 is disposed substantially horizontally (in the orientation shown) and extends across the diameter of the cylindrically shaped cross member 18c. The locking plate 124 furthermore, includes an upper stem 124s for mounting to the kick-plate 122 (i.e., extending through a wall of the cylindrical cross member), a base portion 124b extending through and supported by a longitudinal slot 18s of the cross member 18c, and a pair of J-hooks 124h which engage longitudinal slots 102s of the spool fitting 102. Finally, the locking plate 124 is disposed in combination with the spring bias means 126 for biasing the J-hooks 124h into engagement with the slots 102s of the spool fitting 102e. The spring bias means 126 may be any of a variety of known devices, although the present invention employs a coil spring 130 disposed about and supported by a guided plunger 132 which is affixed to the stem 124s of the locking plate 124.
In operation, the kick-plate 122 is urged inwardly against a counteracting force provided by the spring bias means 126. The locking plate 102 and, more specifically, the J-hooks thereof, is displaced causing the J-hooks 102h to disengage the longitudinal slots 102s of the spool fitting 102. As such, the handle shaft 90 is released and may be repositioned by rotating the shaft 90 through a predetermined angle. When the shaft 90 rotates through an angle which causes the J-hooks to once again align with the longitudinal slots 102s, the spring bias means 126 will again cause the locking plate 102 and the J-hooks 102h thereof to engage the slots 102s. Consequently, the handle shaft 90 is caused to rotate 180 degrees from its initial position and locked. While only two angular positions are depicted in the described embodiment, it will be appreciated that the spool fitting 102 may contain multiple slots 102s disposed about its circumference, thereby enabling the handle shaft 90 to assume a multiplicity of angular positions.
To improve the ergonomic position of the handle 90H, the handle shaft 90 may comprise upper and lower shaft segments 90U and 90L, respectively. These segments 90U, 90L are joined by a coupling PM90 which enables relative rotation about the longitudinal axis of the 90L of the handle shaft 90. Moreover, the coupling PM90 may also permit the segments to telescope. As such, the handle 90H may be rotated or telescoped to the correct ergonomic position and/or height. The telescoping feature may also facilitate storage in confined areas or shipping in small containers.
In another embodiment of the invention shown in
In another embodiment, the power-handling device 10 need not be reversed or reconfigured. In this embodiment, shown in
In yet another embodiment of the invention, the power handling device 10 may be portable and includes a dedicated power supply which is disposed internally of the chassis. More specifically, the power handling device 10 may include a rechargeable energy source (not shown), e.g., a rechargeable battery, and a means for recharging the energy source, e.g., a docking station (also not shown). The battery may be disposed in combination with either the forward propulsion or aft handling sections 12FP, 12AH. When being mounted in combination with the forward propulsion section 12FP, the battery will necessarily lie with the bounds of the Non-Interference Envelope NIE (similar to the teaching involving the motor and other propulsion system components). When mounted in combination with the aft handling section 12AH, the battery will mount to the chassis 12 forward of the aft wheels 34. In this configuration, rearward propulsion of an object is not possible, hence the power handling device 10 will necessarily be dedicated to “forward propulsion”.
Furthermore, the weight of the battery should lie proximal to the rotational axis 34A about which the power handling device 50 is pivoted for prepositioning. As such, a short moment arm is effected between the battery the Center of Gravity (C.G.) and the axis 34A, and the force required to pivot the device 10 is minimized.
The docking station interfaces with and recharges the power handling device 10 via the aft handling section 12AH, but may interface by any of a variety of means. In the preferred embodiment, the handle shaft 90 is repositioned to assume a substantially vertical orientation for space efficiency and to minimize any likelihood (albeit small) that the power handling device 10 will cause an accident or injury.
The features described in connection with the pneumatically powered handling device are essentially identical for the electrically powered device, although certain structure such as the cross members may be modified to accommodate the size and/or weight of the power source.
In
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Although the invention has been described in terms of its various embodiments, one will appreciate that the teachings of the invention provide for various other embodiments which fall within the spirit and scope of the invention.
