Note: Descriptions are shown in the official language in which they were submitted.
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DYNAMIC SENSOR SYSTEM AND METHOD
CROSS-REFERENCE TO RELATED APPLICATIONS
1_0001] This patent application is a continuation of U.S. Patent
Application Serial No.
14/073,431, filed November 6, 2013, which is a continuation-in-part of U.S.
Patent Application
Serial No. 13/801,109, filed on March 13, 2013, which is hereby incorporated
in its entirety,
FIELD OF THE :INVENTION
[0002] This invention relates to a dynamic sensor system for use in the
transferring of a
container.
BACKG.ROUND OF TUE INVENTION
[0003] The shipment of goods is a complex and costly process with many
actors, including
shippers, manufacturers, wholesalers, and retailers. Currently, goods are
placed in containers
of various lengths, e.g., 20', 40', 45', 48,' and 53', for transport. The
containers may be
transported via a ship to a shipyard or via a train to a rail yard. From the
shipyard or rail yard,
the containers may then be transferred to a chassis of a tractor trailer for
further shipment or
distribution. Different sized chassis are available to accommodate the
different sized
containers,
[0004] The transfer of a container onto a chassis is presentl:,,,,
cumbersome and .time
consuming. The transfer of the container requires an operator of a crane or
side loader or other
personnel to be present when the. tractor trailer with an empty chassis
arrives. If the crane
operator or the driver of the tractor trailer is delayed, the driver of the
tractor trailer will have to
wait until the crane operator is available to load the container onto the
chassis. Once the
container is loaded onto the chassis, the container is transported to its next
location by the
tractor trailer. The next destination may be another ship yard or rail yard, a
distribution center,
or it may be a warehouse or retail store where the goods in the container are
unloaded. In any
ease, the container will eventually be removed from the chassis. Again, as
with loading the
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container onto the chassis, removing the chassis is also cumbersome and time
consuming
requiring both the presence of the crane operator or dock personnel and the
driver of the tractor
trailer.
[0005] Several systems attempt to solve the inefficiencies noted above. For
example, U.S.
Patent No. 7,231,065 (Peach et al.) discloses a method and apparatus for
controlling cameras
and performing Optical Character Recognition of a container code and chassis
code that
processes containers and chassis into and out of a facility. A camera is used
to determine when
a truck is present within a specific gate lane in the facility. The camera is
also used to
determine if the truck is a Bob-tail (i.e., the tractor trailer is without a
chassis or container); a
bare chassis or a chassis having a container. In the latter case, the camera
takes various images
to determine the container's size. The container's size, along with other
information, is then
used to process the trucks into or out of the facility. However, the method
and apparatus
disclosed in Peach et al. do not provide an automated way to remove the
container from the
chassis or place a container onto the chassis, nor is a signaling system
provided to assist the
driver in positioning the chassis into the gate lane. Further, the system uses
cameras to
determine the size of the container, which can be costly.
[0006] U.S. Patent No. 5,142,658 (McMon-an et al.) discloses a container
chassis
positioning system. In this system, a light signal and camera are used to
assist a driver to
position the chassis at a preprogrammed stop point in a loading or unloading
lane. This
system, however, requires the use of a crane to unload or load a container on
the chassis. Thus,
a driver must still wait until a crane is free before he can drive the tractor
trailer to the next
location. Further, a camera is required for the positioning of the chassis,
which can be
expensive.
[0007] U.S. Publication No. 2008/0219827 (Lanigan et al.) discloses an
inline terminal
system. The system includes a buffer that includes four side latch cylinders
that engage the
bottom comer castings of a container. The buffer can be used to unload a
container from a
chassis without the assistance of a crane. However, the system does not
provide a buffer that
can be used with different sized containers, nor is a light signal provided
that assists a driver
position a chassis or container at a proper stopping position within the
buffer.
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[0008] U.S. Publication 2008/0219827 (Lanigan, Sr. et al.) discloses a
distribution system
that includes a buffer. The buffer includes movable shelves having a retracted
and extended
position. The system also has a chassis having a support structure that can be
raised or lowered
using a lift control. The support structure is used to raise a container
resting on the support
structure so that the container can be transferred to the buffer after the
chassis and container
have been positioned in the buffer. Further, the buffer includes at least one
wheel guide to aid
in aligning the chassis in the buffer. Although this system allows a driver to
load or unload a
container without the assistance of crane, it requires a chassis that is
specially fitted with an
elevating structure to raise and/or lower the container. Therefore, the system
cannot be used
with a standard chassis.
[0009] For these reasons, a system that can economically load and unload
varying sized
containers from a standard chassis without requiring the use of crane would be
an important
improvement in the art.
SUMMARY OF THE INVENTION
[0010] In one embodiment of the present invention, a sensor system is
disclosed. The
sensor system includes a mounting member, an actuator disposed adjacent the
mounting
member, and a sensor connected to the actuator for sensing movement of an
object using a
signal. The actuator moves the sensor from a first sensing position to a
second sensing position
if the sensor is unable to read the signal.
[0011] In another embodiment of the present invention, a method of
transferring a
container to a buffer using a sensor system that has a distance sensor is
disclosed. The method
includes the steps of sensing movement of the container carried by a chassis
into the buffer
using a plurality of sensors including a thru beam sensor and the distance
sensor, sending a
signal from the distance sensor to the container, and determining 'a distance
from the distance
sensor to the container using the signal generated by the distance sensor. The
method also
includes the steps of moving the distance sensor if the distance sensor cannot
obtain a readable
signal, determining a length of the container based on data received from the
plurality of
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sensors, and guiding an operator via a light signal to position the chassis
into the buffer based
on the length of the container.
[0012] In a further embodiment of the present invention, a positioning
system for use in
transferring a container to a butler is disclosed. The positioning system
includes a light signal
disposed adjacent the buffer for guiding an operator to position a chassis
into the buffer and a
program logic controller associated with the positioning system. The
positioning system also
includes a thru beam sensor that senses movement of the container into the
buffer and outputs
data to the program logic controller. The sensor system has a distance sensor
that determines
the distance from the distance sensor to the container via a signal. The
distance sensor is
moved from a first sensing position to a second sensing position if a readable
signal is not
obtained. The distance sensor outputs data to the program logic controller.
The program logic
controller determines a length of the container based on the data received
from the thru beam
sensor and the distance sensor and provides an output signal to the light
signal based on the
length of the container and the data received from the distance sensor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is an isometric view of one embodiment of the light
positioning system;
[0014] FIG. 2 is a top plan view of the light positioning system of FIG. 1;
[0015] FIG. 3 is a left side elevational view of the light positioning
system of FIG. 1;
[0016] FIG. 4 is a =front elevational view of the light positioning system
of FIG. 1;
[0017] FIG. 5 is a rear elevational view of the light positioning system of
FIG. 1;
[0018] FIG. 6 is a enlarge view of a support pad as shown in FIG. 1;
[0019] FIG. 7 is a enlarged view of a signal light as shown in FIG. 1;
[0020] FIG. 8 is a diagram showing final stopping distances associated with
various sized
containers;
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[0021] FIG. 9 is a flow chart of one embodiment of a method of transferring
a container
using the light position system of FIG. 1;
[0022] FIG. 10 is a flow chart of another embodiment of a method of
transferring a
container using the light positioning system of FIG. 1;
[0023] FIG. 11 is a flow chart of a further embodiment of a method of
transferring a
container using the light position system of FIG. 1;
[0024] FIG. 12 is a flow chart of a still further embodiment of a method of
transferring a
container using the light position system of FIG. 1;
[0025] FIG. 13 is an isometric view of one embodiment of a dynamic laser
system;
[0026] FIG. 14 is an isometric view of another embodiment of a dynamic
laser system; and
[0027] FIG. 15 is a flow chart of a method of transferring a container to a
buffer using the
dynamic laser system of FIG. 13 or FIG. 14.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] Disclosed is a light positioning system 20 for use in the
transferring of a container.
FIGS. 1-8 show one embodiment of the light positioning system 20, which is
used to
conjunction with a buffer 21, and FIGS. 9-12 show various embodiments of
methods for
transferring a container to or from the buffer 21 using the light positioning
system 20. In
general, the buffer 21 is used to temporarily store a container. The light
positioning system 20
enables the container to be transferred from a chassis of a tractor trailer to
the buffer 21 by an
operator of the tractor trailer without the assistance of a third party. Once
stored in the buffer
21, the container may then be later picked-up by a tractor trailer with a
chassis that is empty.
Again, the light positioning system 20 enables the operator of the tractor
trailer to remove the
container from the buffer 21 without the need for a third party. The container
may then by
transported by the tractor trailer to a destination, e.g., a warehouse.
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[0029] The term "container' as used herein has its common and ordinary
meaning, and can
include any type of container such as an ISO container, domestic container,
semi-trailer,
enclosure, and the like. In addition, the terms "tractor, truck, and tractor
trailer" have their
generally accepted meanings and are used interchangeably. These vehicles are
used to pull,
carry, and/or haul containers. Further, the term "buffer" as used herein
refers to a temporary
storage apparatus or device.
[0030] Turning to FIG. 1, the buffer 21 includes a first frame member 22
and a second
frame member 24. Together, the first frame member 22 and the second frame
member 24
define a channel 25. In addition, on one end of the buffer 21, is an entry 26
and at the opposite
end is a rear frame 28.
[0031] The first frame member 22 includes a first vertical support 30 and a
second vertical
support 32. Disposed between the first and second vertical supports 30, 32 is
a first lift beam
34. In one embodiment, the first lift beam 34 is attached to the first
vertical support 30 and the
second vertical support 32 via mounting brackets 36A and 36B, respectively.
The mounting
brackets 36A, 36B are movably attached to the first and second vertical
supports 30, 32 so that
they may slide along the vertical supports in a vertical direction. The
movement of the
mounting brackets 36A, 36B along the respective first vertical support 30 and
the second
vertical support 32 are controlled by vertical actuators 38A and 38B,
respectively. In one
embodiment, power is provided to the vertical actuators 38A, 38B by motors 40
that are
mechanically connected to each of the vertical actuators 38A, 38B. The motors
40 may be
electric motors or other type of motors such as hydraulic. A pneumatic motor
may also be
used without violating the scope and spirit of the invention.
[0032] The structure of the second frame member 24 is similar to the first
frame member
22 and includes a first vertical support 42 and a second vertical support 44.
Vertical supports
30, 32, 42, 44 may be secured to the ground in any fashion known in the art
such as anchor
bolts or similar device. A second lift beam 46, which is a mirror image of the
first lift beam
34, is disposed between the first and second vertical supports 42, 44 of the
second frame
member 24 and is substantially parallel 10 the first lift beam 34. Mounting
brackets 48A and
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48B are movably attached to the first vertical support 42 and the second
vertical support 44,
respectively. Mounting brackets 48A, 48B are mechanically connected to
vertical actuators
50A (not shown) and 50B (see FIG. 5), and can move vertically along the first
and second
vertical supports 42, 44 via the vertical actuators 50A and 50B. In one
embodiment, power is
provided to the vertical actuators 50A, 50B by motors 40 that are mechanically
connected to
each of the vertical actuators 50A, 50B. In another embodiment, a single motor
is utilized that
provides power to the vertical actuators 38a, 38B and 50A, 50B. The vertical
actuators 38A,
38B arid 50A, 50B may be motorized screws, hydraulic cylinders or any other
similar device
known in the art. In the case of a motorized screw, the motor may be electric,
hydraulic, or
pneumatic.
[0033] The motors 40 are electronically connected to the program logic
controller ("PLC")
52. The PLC 52, which is discussed in further detail below, controls the
movement of the first
lift beam 34 and the second lift beams 46 along the vertical supports 30, 32,
and 42, 44. More
specifically, the PLC 52 controls via the motors 40 the vertical actuators
38A, 38B and 50A,
50B, which move the mounting brackets 36A, 36B of the first lift beam 34 and
the mounting
brackets 48A, 48B of the second lift beam 46. In one embodiment, the PLC 52 is
disposed
adjacent the rear frame 28. The vertical actuators 38A, 38B and 50A, 50B are
directed by the
PLC 52 to raise the first and second lift beams 34 and 46 via the mounting
brackets 36A, 36B
and 48A, 48B, respectively, when a chassis carrying a container reaches its
final stopping
distance as described in the discussion of FIG. 8 below. Likewise, when an
empty chassis
enters the buffer 21 to pick up a container, the PLC 52 directs the vertical
actuators 38A, 38B
and 50A, 50B to lower the first and second lift beams 34 and 46 via the
mounting brackets
36A, 36B and 48A, 48B, respectively.
[0034] As best shown in FIG. 2, the buffer 21 includes two guide tracks 54A
and 54B. The
guide tracks 54A, 54B are disposed between the first frame member 22 and the
second frame
member 24 and are substantially parallel to each other. Guide tracks 54A, 54B
are provided to
guide the wheels of a chassis into the buffer 21. Guide tracks 54A, 54B may be
secured to the
ground in any manner known in the art such as anchor bolts or similar device
and may be
welded to the base plates of the first frame member 22 and the second frame
member 24.
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[0035] As shown in FIGS. 1-3, four support pads 56A, 56B, 56C, and 56D are
spaced
apart and movably attached to the first lift beam 34. In addition, four
support pads 58A, 58B,
58C, and 58D are spaced apart and movably attached to the second lift beam 46.
Each of the
support pads 56A¨D corresponds to one of the support pads 58A¨D. For example,
the support
pad 56A is located across from the support pad 58A and both support pads 56A
and 58A are
located at the substantially same point along the first lift beam 34 and the
second lift beam 46,
respectively (see FIGS. 2 and 3). Further, six of the eight support pads
(56A¨C and 58A¨C)
are located substantially proximate the first vertical supports 30 and 42 of
the first and second
frame members 22 and 24, respectively, and the remaining two support pads (56D
and 58D)
are located proximate the second vertical supports 32 and 44 of the first and
second frame
members 22 and 24, respectively.
[0036] Attached to each of the support pads 56A, 56B, 56C, and 56D and the
first lift beam
34 are support pad actuators 60A, 60B, 60C, 60D, respectively. Similarly,
attached to each of
the support pads 58A, 58B, 58C, 58D and the second lift beam 46 are support
pad actuators
62A, 62B, 62C, 62D, respectively. Although eight support pads are shown in
total, any
number of support pads 56 and 58 and corresponding support pad actuators 60
and 62,
respectively, may be included as long as enough pads are provided to
adequately support
containers of various sizes. In one embodiment, as shown in Table 1 below, the
number of
support pads 56, 58 used for a 20' container is four, and the number of
support pads 56, 58
used for a 40'-53' container is six. Table 1 also identifies the specific
support pads used to
support a container of a particular size in this embodiment.
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TABLE 1
IContainer Size Number of Support Pads Specific Support Pads
20' ................... 4 support pads 56A, 56C and 58A, 58C
40' 6 supportpads 56B, 56C, 561) and 58B, 58C, 58D
45' 6 support pads 56B, 56C, 56D and 58B, 58C, 58D
48' 6 support pads 56B, 56C, 56D and 58B, 58C, 58D
53'i 6 support pads 56B, 56C, 56D and 58B, 58C, 58D
[0037] The support pad actuators 60A¨D and 62A¨D are electronically
connected to the
PLC 52. The PLC 52 controls the horizontal movement of the support pads 56A¨D
and 58A¨
D via the support pad actuators 60A¨D and 62A¨D, respectively. The support
pads 56A¨D
and 58A¨D may be moved from a first position 64 to a second position 66. In
one
embodiment, the first position 64 may be a retracted position as shown in
=FIG. 4 and the
second position 66 may be an extended position as shown in FIG. 5. In another
embodiment,
the first position 64 may be the extended position (see FIG. 5) and the second
position 66 may
be the retracted position (see FIG. 4).
[0038] When in the extended position 66, the support pads 56 and 58 are
positioned under
the underside of the container. The support pads 56A¨D are moved from the
retracted position
64 to the extended position 66 when a container is positioned in the buffer 21
for storage. The
support pads 56A¨D are moved from the first position 64 (extended position) to
the second
position (retracted position) 66 when a container has been placed on an empty
chassis for
transport. Corresponding supports pads may be moved separately or in groups.
For example,
in one embodiment, the support pads 56A and 58A may be moved from the first
position 64 to
the second position 66 simultaneously along with any of 56B and 58B, 56C and
58C, and 56D
and 58D. However, in this embodiment the support pads are typically moved in
groups of
opposing pairs such as shown in Table 1. in this manner, all containers of the
typical container
lengths shown in Table 1 can be handled by the buffer 21
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[0039] FIG. 6 shows an enlarged view of the support pad 58D and support pad
actuator
62D in a default retracted position. All of the support pads 56A¨D, 58A¨D and
support pad
actuators 60A¨D, 62A¨D contain the same components with the only difference
being the side
upon which the actuator is positioned relative to the support pad.
Accordingly, detail will only
be provided with regard to support pad 58D and support pad actuator 62D. In
one
embodiment, the support pad actuator 621) comprises an electric linear
actuator 68 and a
linkage assembly 70. The linkage assembly 70 is attached to the support pad
58D via a
protrusion 72. The support pad 58D comprises a lower portion 74, a first upper
portion 76, and
a second upper portion 78. In one embodiment, the lower portion 74 and the
second upper
portion 78 each comprise a steel plate, and the first upper portion 76
includes a slip pad 80.
The slip pad 80 contacts the underside surface of the container to prevent
slipping of the
container when the container is being transferred to or from a tractor
trailer. The slip pad 80
may be made of urethane or arty similar material. The support pad 58D is
bordered on its left
side, rear, and right side by a support pad frame 82. In one embodiment, the
support pad frame
82 contains four support bars 84A, 84B, 84C and 84D, which are fixedly
attached to the second
lift beam 46, in this example. The support pad frame 82 also includes four
movable rollers
86A, 86B, 86C, and 86D, which are attached to the support bars 84A, 84B, 84C,
and 841),
respectively, with fasteners 88. The underside of the lower portion 74 of the
support pad 58D
rests upon the rollers 86A¨I) and engages the rollers 86A¨I) when the support
pad 581) is
moved from the first position 64 to the second position 66 and vice versa.
[0040] Near the entry 26 of the buffer 21 adjacent the first vertical
support 30 of the first
frame member 22, is a light signal 90 of the light positioning system 20 (see
FIGS. 1, 2, and 7).
The light signal 90 is attached to a light post 92 and electrically connected
to the PLC 52. The
light signal 90 guides the operator of a tractor trailer into the buffer 21 by
providing a visual
indication of the chassis' position within the buffer 21. As best shown in
FIGS. 4, 5, and 7, the
light signal 90 comprises a light bar 94. The light bar 94 contains multiple
rows of lights 96 A,
B, ... N. In one embodiment, a display (not shown) may be provided adjacent
the light bar 94
that includes text that explains the light coloring system. In one embodiment,
LED lights are
used. However, any type of illumination device known in the art may be used
such as
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incandescent light bulbs. The light bar 94 is comprised of a first set of
lights 98, a second set
of lights 100, and a third set of lights 102. The first set of lights 98 is
comprised of green
LEDs. The second set of lights 100 is comprised of yellow LEDs, and the third
set of lights
102 is comprised of red LEDs. The second set of lights 100 further includes
light subsets
104A, B, N. The light subsets 104A, B, N
are each comprised of at least one row of
yellow LEDs. The use of green, yellow, and red LEDs is preferred because these
specified
colors are generally understood by all vehicle operators to mean "go" or
"maintain speed,"
"slow-down" or "reduce speed," and "stop," respectively.
[0041]
Disposed on the top of the light post 92, is a warning light 106. In one
embodiment, the warning light 106 emits a blinking red light. The warning
light 106 can be of
any size, but should be large enough to be easily seen by the operator of the
tractor trailer in
the side and/or the rear view mirrors of the tractor trailer. In addition,
disposed on the lower
portion of the light post 92, below the light bar 94 is an emergency stop
button 107. The
emergency stop button 107 can be pressed by an operator to immediately stop
the light
positioning system 20 at any point in time.
[0042]
The light position system 20 also includes a chassis sensor 108 and a film
beam
sensor 110. The chassis sensor 108 and the thru beam sensor 110 are also
located near the
entry 26 of the buffer 21. The chassis sensor 108 senses movement of an
object, i.e., a chassis,
into the buffer 21. Similarly, the thru beam sensor 110 senses movement of an
object, i.e., a
container, into the buffer 21 and is used to determine the length L of the
container.
[0043]
The chassis sensor 108 may be an ultrasonic sensor. The thru beam sensor 110
is
comprised of separate receiver and emitter portions. In one embodiment, a thru
beam sensor
receiver 112 is attached to the light post 92. As best shown in FIG. 7, the
thru beam sensor
receiver is attached to the light post 92 behind the light bar 94.
Substantially aligned with the
light post 92 and disposed adjacent the first vertical support 42 of the
second frame member 24
is an emitter post 116. Attached to the emitter post 116 is a thru beam sensor
emitter 120. The
thru beam receiver 112 and the thru beam sensor emitter 120 together form the
thru beam
sensor 110 and are located at a height on the light post 92 and the emitter
post 116,
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respectively, that enables the thm beam sensor 110 to sense a container of any
length that is
entering the buffer 21. Further, the thm beam 110 may be a through-beam laser
or a photo
electric sensor or other emitter and receiver device.
[0044] The rear frame 28 of the light positioning system 20, as shown in
FIGS. 1, 4, and 5,
includes a cross bar member 122 and rear support members 124. Located at a
distance from
the rear frame 28 is a distance sensor post 126. Attached to the distance
sensor post 126 are a
container distance sensor 128 and chassis distance sensors 130A and 130B. The
distance
sensor post 126 is shown disposed at a point that is substantially centered
between the first
frame member 22 and the second frame member 24. Although a centered position
is preferred,
the distance sensor post 126 may be disposed at any point between the first
and second frame
members 22 and 24 that enables an unobstructed viewpoint from the container
distance sensor
128 or the chassis distance sensors 130A, 130B to a container or chassis.
[0045] The container distance sensor 128 measures the distance from the
container distance
sensor 128 to a container. The chassis distance sensor 130A is used to measure
the distance
from the chassis distance sensor 130A to a chassis that is 20' in length. The
chassis distance
sensor 130B is used to measure the distance from the chassis distance sensor
130B to a chassis
that is 40', 45', 48', or 53' in length. All the distance sensors 128 and
130A, 130B are
electronically connected as inputs to the PLC 52.
[0046] The container distance sensor 128 and the chassis distance sensors
130A, 130B
comprise a single unit and include both emitter and receiver portions. For
example, in one
einbodiment, the container distance sensor 128 and the chassis distance
sensors 130A, 130B
may comprise a laser system such as a DT series distance sensor that is
commercially available
under the trademark SICKTM. The container distance sensor and the chassis
distance sensor
may also be other suitable proportional distance sensing devices. In use, the
container distance
sensor 128 and the chassis distance sensors 130A, 130B of the light
positioning system 20
measure the time it takes for an emitted beam to reflect off an object (e.g.,
a container or a
chassis) and return to the receiver portion of the distance sensor. The time
measurement is
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then converted into a distance measurement signal that is proportional to the
distance from the
distance sensor to the object. This distance measurement signal is then sent
to the PLC 52.
[0047] Power can be provided to the electrical components of the light
positioning system
20 including the motors 40, the vertical actuators 38A, 38B and 50A, 50B, the
PLC 52, the
support pad actuators 60A¨I), 62A¨I), the light signal 90, the light bar 94,
the various lights
98, 100, 102, and 106, and the multiple sensors 108, 110, 128, and 130,
through a standard
power grid or with a stand alone engine driven electric generator. Wires 132
may run along
the outer portion of the first lift beam 34 and the second lift beam 46 to
connect the
aforementioned components to the power source.
[0048] Also disclosed are methods for transferring a container using the
light positioning
system 20. As shown in FIG. 9, one embodiment of a method of transferring a
container
includes the steps of backing a chassis with a container into a buffer 200;
sensing a rear edge of
the container 202; sensing a front edge of the container 204; determining a
length of the
container 206; determining a final stopping distance of the container 208;
storing the final
stopping distance in the PLC 210; sensing the longitudinal position of the
container 212;
actuating a light bar based on the position of container in relation to the
final stopping distance
214; and indicating on the light bar that the final stopping distance has been
reached 216.
[0049] As shown in FIG. 10, another embodiment of a method of transferring
a container
includes the steps of sensing movement of the container carried by a chassis
into the buffer
using a plurality of sensors 230; determining a length of the container based
on data received
from the plurality of sensors 232; guiding an operator via a light signal to
position the chassis
into the buffer based on the length of the container 234; extending a
plurality of support pads
associated with the buffer to an underside of the container 236; raising the
support pads so as to
support the container 238; and withdrawing the chassis from the buffer 240.
[0050] FIG. 11 discloses a further embodiment of a method of transferring a
container
including the steps of backing an empty chassis into a storage buffer to
retrieve a stored
container 250; sensing the longitudinal position of the chassis 252;
retrieving a previously
stored final stopping distance 254; actuating a light bar based on position of
chassis in relation
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to the previously stored final stopping distance 256; indicating on the light
bar that the chassis
has reached final stopping distance 258.
[0051] A still further embodiment of a method of transferring a container
is shown in FIG.
12 and is comprised of the steps of providing a buffer in which the container
is positioned on a
plurality of support pads associated with the buffer 270; sensing movement of
the chassis into
the buffer using a plurality of sensors 272; retrieving stored data relating
to the container,
wherein the stored data includes the container's length 274; guiding an
operator via a light
signal to position the chassis beneath the container, wherein the light signal
illuminates in a
specific color to guide the operator based on the stored data and data
received from the
plurality of sensors 276; lowering the plurality of support pads such that the
container rests
upon the chassis 278; retracting the plurality of support pads from under the
container to a
retracted position 280; and withdrawing the chassis carrying the container
from the buffer 282.
[0052] In operation, when a container 134 is to be transferred from a
chassis 136 to the
buffer 21, the operator of a tractor trailer unfastens the container 134 from
the chassis 136
before entering the buffer 21 so that the container 134 can be freely removed
from the chassis
136 by the buffer 21. Because the chassis 136 will be moving at a slow speed
(i.e., <5mph)
into the buffer 21, there is little risk of the container 134 shifting to an
improper position on the
chassis 136 or falling off the chassis. Once the container 134 is unfastened,
the operator begins
to back the tractor trailer into the buffer 21. 'The wheels of the chassis
engage the guide tracks
54A and 54B near the entry 26. The guide tracks 54A, 54B guide the chassis 136
into the
buffer 21 in a relatively straight line thereby preventing the chassis 136
from moving into the
buffer 21 at an improper angle.
[0053] When the chassis sensor 108 senses an object (e.g., a chassis)
entering the bay, the
container distance sensor 128 is activated and a data signal, which includes a
measurement of
the distance from the container distance sensor 128 to the container, is sent
to PLC 52. When
the rear edge of the container 134 breaks the through-beam laser of the thru
beam sensor 110,
the data signal from the container distance sensor 128 is interrupted at the
PLC 52. When the
front edge of the container 134 passes the thru beam sensor 110 at point A
(see FIG. 8), the
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distance measurement from the container distance sensor 128 to the container
134 is
reestablished at the PLC 52.
[0054] Each container of a particular length L has a corresponding final
stopping distance
138B. The final stopping distance 138B of each container length L is stored in
the PLC 52
prior to use. As shown in FIG. 8, for example, the final stopping distance
138B for a 20'
container is 414.4 inches, the final stopping distance 138B for a 40'
container is 174.5 inches,
the final stopping distance 138B for a 45' container is 126 inches, the final
stopping distance
138B for a 48'container is 90 inches, and the final stopping distance 138B for
a 53' container
is 30 inches.
[0055] Also shown in FIG. 8 is the point at which the through-beam laser of
the thru beam
sensor 110 is reestablished. The through-beam laser of the thru beam sensor
110 is
reestablished at a point A for all the different container lengths L. At the
point A, each of the
containers 134 is a particular distance 138A from the container distance
sensor 128. For
example, in an embodiment, at the point A, the 20' container is a distance of
455.5 inches from
the container distance sensor 128, the 40' container is 214 inches from the
container distance
sensor 128, the 45' container is 154 feet from the container distance sensor
128, the 48'
container is 118 inches from the distance sensor 128, and the 53' container is
58 inches from
the container distance sensor 128. These distances 138A are stored in the PLC
52 prior to use.
Therefore, once the container distance sensor 128 is activated by the
reestablishment of the
through-beam laser of the thru beam sensor 110 at point A, the distance
measured from the
container distance sensor 128 to the container 134 when the container is at
Point A is used by
the program logic of the PLC 52 to determine the length L of the container,
which is recorded
and stored in the PLC 52. The light positioning system 20 via the PLC 52 then
uses the
container length measurement along with the corresponding final stopping
distance 138B to
guide the operator of the chassis 136 into the buffer 21.
[0056] The data the PLC 52 receives from the container distance sensor 128
is used to
direct the light signal 90 to illuminate a particular set of LEDS. More
specifically, when the
container 134 initially enters the buffer 21 the light signal 90 is activated
by the PLC 52 and
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illuminates the first set of lights 98 (i.e., green LEDs) on the light bar 94.
Once the container
length L and the final stopping distance 138B are determined, illumination of
the light bar 94
progresses to the second set of lights 100 (i.e., yellow LEDS). The container
distance sensor
128 continues to send data regarding the distance measurements to the PLC 52
as the container
134 moves from point A, the point in which the through-beam laser of the thru
beam sensor
110 is reestablished, to a position deeper within the buffer 21 (i.e., a point
closer to the rear
frame 28). Thus, based on continued input from the container distance sensor
128, the PLC 52
directs the light signal 90 to illuminate the light subsets 104A, B, N
of the second set of
lights 100. The light subsets 104A, B, N illuminate in a progressive manner up
the light bar
94 (see FIG. 7). This illumination progression will continue until the
container reaches its final
stopping distance 138B. When the final stopping distance 138B is reached based
on
measurements obtained from the container distance sensor 128, the PLC 52
instructs the light
signal 90 to illuminate the third set of lights 102 (e.g., red LEDs). The
third set of lights 102
on the light bar 94 emits a steady red light. If the operator continues to
back the chassis into
the buffer 21 so that the final stopping distance 138B is surpassed, the red
LEDs 102 will flash,
thereby signaling to the operator that the chassis has gone too far. By
illuminating different sets
and subsets of lights along the light bar 94, the light signal 90 of the light
positioning system
20 guides the operator of the tractor trailer to position a container within
the buffer 21.
[0057]
Once the final stopping distance I38B is reached and the container 134 carried
by
the chassis 136 is no longer moving, the PLC 52 instructs specific support
pads 56 and 58 to
move from the default retracted position (first position) 64 to the extended
position (second
position) 66. As shown in Table 1, in one embodiment, support pads 56A, 56C
and 58A, 58C
will be moved from the retracted position 64 to the extended position 66 if,
for example, a 20'
container is in the buffer 21. Once the appropriate selection of support pads
56 and 58 are in
the extended position 66, the PLC 52 instructs the motors 40 to raise the
first and second lift
beams 34 and 46, respectively, from a default starting position, which is
lower than any chassis
or chassis/container combination, to a pre-programmed height that is
appropriate for the
container's size. Further, the first and second lift beams 34 and 46,
respectively, will raise the
container 134 to a height that is higher than that of the chassis 136, to
enable the chassis 136 to
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be easily withdrawn from the buffer 21 and prevent the chassis 136 from coming
into contact
with the underside of the container 134 as the chassis 136 is moved out of the
buffer 21. Once
the container 134 has been lifted off of the chassis 136, the empty chassis
136 is withdrawn
from the buffer 21 by the operator.
[0058] As shown in FIGS. 11 and 12, when the container 134 is to be
transferred from the
buffer 21 to an empty chassis, the light positioning system 20 works in
substantially the same
mariner. The wheels of the chassis 136 engage the guide tracks 54 as the
tractor trailer is
backed into the buffer 21 by the operator. As noted above, the length L of the
container 134,
which was previously transferred to the buffer 21, was recorded and stored in
the PLC 52. The
stored container length L and the corresponding final stopping distance 138B
provides the
necessary data for the light positioning system 20 to guide an operator of the
tractor trailer into
the buffer 21 to pick-up the container 134.
[0059] When the empty chassis 136 passes through the entry 26, the light
signal 90 and the
chassis sensor 108 are activated. In this configuration, the thru beam sensor
110 is not used
because the container length L is already known. In addition, the container
distance sensor 128
is not used. Rather, one of the chassis distance sensor 130A and the chassis
distance sensor
130B is used to provide data relating to the movement of the chassis 136 into
the buffer 21 to
the PLC 52, which in turn provides a signal to the light signal 90. As noted
above, the chassis
distance sensor 130A is used for a container having a length of 20', and the
chassis distance
sensor 130B is used for a container having length of 40', 45', 48'; or 53'.
Two chassis distance
sensors 130A and 130B are required because the 20' chassis are generally
higher off the
ground than chassis for 40'-53' containers. The PLC 52 instructs either the
chassis distance
sensor 130A or the chassis distance sensor 130B to be activated based on the
stored container
length L. Similar to when the container 134 is being transferred to the buffer
21, when a
chassis 136 is being positioned in the buffer 21 to pick up the container 134,
the light signal 90
guides the operator. Based on the measured distance of the chassis 136 from
its current
position to its final stopping position 138B, the PLC 52 will instruct the
light signal 90 to
illuminate the first, second, or third set of lights 98, 100, 102,
respectively, and the light
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subsets 104A, B, N in the same manner as discussed above with regard to the
transferring of
the container 134 from the chassis 136 to the buffer 21.
[0060] When the final stopping distance 138B is reached, the PLC 52 directs
the motors 40
to lower the first and second lift beams 34 and 46, respectively, to a default
height that is
sufficiently low to clear the chassis 136. As the container 134 is lowered
onto the chassis 136,
the motors 40 continue to lower the first and second lift beams 34 and 46,
respectively, until
the default starting position is reached. When the default starting position
of the first and
second lift beams 34 and 46, respectively, is reached, the PLC 52 directs the
support pads 56
and 58 that were previously extended to move from the extended position 66 to
the default
retracted position 64. After the support pads 56 and 58 have been retracted,
the operator may
then withdraw the chassis carrying the container from the buffer 21. The
operator must secure
the chassis 136 to the container 134 for transport after withdrawing the
chassis 136 and the
container 134 from the buffer 21.
[0061] The above light positioning system 20 can also be used in
conjunction with an
overhead crane. In this embodiment, an overhead crane places a container onto
the buffer 21.
The first and second lift beams 34 and 46 are in a raised position and the
proper support pads
56A¨D and 58A¨D, which are determined based on the container's length, are in
an extended
position to accept the container. A guidance system on the overhead crane
positions the
container into the correct position on the lift beams 34 and 46 so that the
container can be
lowered properly onto an empty chassis as described above.
[0062] Because chassis and container surfaces are not uniform from one
manufacturer to
another, a stationary distance sensor such as the container and chassis
distance sensors 130A,
130B, described above, may not always be able to obtain a readable or accurate
signal to send
to the PLC 52. For example, the chassis or container surfaces may have
different colors,
reflective labels, latches, decals, signs, etc. that are located in various
positions on the chassis
or container, which interrupt the distance sensor signal. Such inconsistencies
in the chassis and
container surfaces may also prevent a stationary distance sensor from
obtaining accurate
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distance data of a container or chassis, even if the signal produced by the
stationary distance
sensor is readable.
[0063] To address these issues, in another embodiment of the light
positioning system 20, a
dynamic sensor system 300 is provided. As shown in FIG. 13, the dynamic sensor
system 300
includes a mounting member 302, a distance sensor 312, and a distance sensor
actuator 304 to
which the distance sensor 312 is connected. The distance sensor actuator 304
may be disposed
on or adjacent to the mounting member 302 and is electronically connected to
and driven by a
motor 306. The motor 306 may be disposed on or adjacent to the mounting member
302 and
may be a servo type motor or other suitable electronically controlled motor.
The motor 306
optionally includes a motor cover 308 to protect the motor 306 from a user,
the sun, rain, wind,
and other external elements. A motor control box 310 may also be disposed on
the mounting
member 302. The motor control box 310 provides the necessary electronics to
connect the
motor 306, which powers the actuator 304, to the PLC 52 so that data or
instruction signals can
be sent to and received from the PLC 52. Other control arrangements, which
control the motor
306 directly by means of a CAN bus, may also be used.
[0064] The distance sensor actuator 304 vertically raises and lowers the
distance sensor
312 at various heights along the mounting member 302. In this embodiment, a
single distance
sensor 312 measures the distance to a container, a 20 foot chassis, or a
chassis having a length
of 40-53 feet. The distance sensor 312 includes both emitter and receiver
portions (not shown),
so that it may send and receive a signal. The distance sensor 312 may be a
laser system or the
like. The distance sensor 312 provides the signal it receives to the PLC 52.
The PLC 52 then
uses the signal received by the distance sensor 312 to send a separate signal
to the light signal
90. Although not shown in the drawings, it is contemplated that the distance
sensor 312 could
be moved in a horizontal, diagonal, or circular direction. The distance sensor
312 may include
a sensor cover 314 to protect the distance sensor 312 from damage caused by
users and
external elements such as the wind, sun, and rain.
[0065] A container height sensor 316, a 20 foot chassis height sensor 318A,
and a 40-50
foot chassis height sensor 318B may also be disposed on or adjacent to the
mounting member
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302. The container height sensor 316 is located approximately 70 inches from
the ground.
The 20 foot chassis height sensor 318A is located approximately 54 inches from
the ground,
and the 40-50 foot chassis height sensor 319A, it is located approximately 48
inches from the
ground. The container height sensor 316, the 20 foot chassis height sensor
318A, and the 40-
50 foot chassis height sensor 318B may be a proximity switch or other similar
device.
[0066] The container height sensor 316 and the chassis height sensors 318A
and 318B are
activated by the PLC 52 and are used to signal to the PLC 52 that the distance
sensor 312 has
reached the location or height of the particular sensor. For example, the
container height
sensor 316 will generate a signal to the PLC 52 when the distance sensor 312
has reached the
height of the container height sensor 316, which is the default sensing
height. At that point,
the PLC 52 may signal the distance sensor actuator 304 to stop movement of the
distance
sensor 312. Similarly, when the container sensor 312 reaches the 20 or 40-53
foot chassis
height sensors 318A and 318B, the chassis height sensor 318A or 318B sends a
signal to the
PLC 52. The PLC 52 may then instruct the distance sensor actuator 304 to stop
movement of
the distance sensor 312.
[0067] In operation, when a container 134 on a chassis 136 has entered the
buffer 21,
reestablishment of the through-beam laser of the thru beam sensor 110 begins
the distance
sensor's 312 distance measurement to the container 134. The distance sensor
312 sends a
signal, which strikes the container at the default sensing height for
approximately 0.1 seconds
to obtain a readable signal. If a readable signal is obtained, the data is
sent to the PLC 52,
which determines the container length L and the final stopping distance 214 in
the same
manner as discussed above. This information is then used by the light signal
90 to guide the
operator.
[0068] If the distance sensor 312 for any reason does not receive a
readable signal, the
distance sensor 312 via the sensor actuator 304 is lowered from the default or
first position
322A to a second position 322B that is approximately 0.20 inches below the
first position. The
distance sensor 312 will again send a signal, which will strike the container
for approximately
0.1 seconds, and if a readable signal is not obtained, the distance sensor 312
will be moved by
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the sensor actuator 304 to a third position 322C that is approx 0.20 inches
below the second
position. The distance sensor 312 will continue to send signals, which will
strike the container
at each position, and will be lowered in 0.20 inch increments until a readable
distance
measurement is obtained. However, if a readable signal is not obtained and the
distance sensor
reaches the 40-53 foot chassis sensor 318B, then an error message will be
generated and sent to
the PLC 52. At this point, the light signal 90 will stop working and the
operator can either start
the process over or manually back the chassis 136 and container 134 into the
buffer 21.
[0069] Assuming a readable signal is obtained, the chassis 136 and
container 134 continue
to move into the buffer 21. When the distance sensor 312 has established that
the container 134
is at its final stopping distance 138B, the light signal 90 illuminates a set
of red lights on the
light bar 94. The container 134 is then lifted off the chassis 136 via the
support pads 56, 58 and
lift beams 34, 46 as discussed above.
[0070] When the container 134 has been raised by the support pads 56, 58
and lift beams
34, 46 to its appropriate transfer height, the empty chassis is withdrawn. The
distance sensor
actuator 304 then automatically lowers the distance sensor 312 to the proper
chassis sensing
height based on the container length L information stored in the PLC 52. The
chassis height
sensors 318A, 318B are used to signal to the PLC 52 that the appropriate
chassis sensing height
has been reached. For example, if a 20 foot container is in the buffer, then
the 20 foot chassis
height sensor 318A will be activated and will notify the PLC 52 when the
distance laser 312
has reached the chassis sensing height.
[0071] The known length L of the container 134 having been previously
established by the
PLC 52 provides the input position command to the distance sensor actuator 304
so that the
distance sensor 312 may be positioned at the proper height to generate a
signal for an empty 20
foot chassis or a 40-53 foot chassis that is backing into the buffer 21 to
retrieve the stored
container. Again, if for any reason the distance sensor 312 does not produce a
readable
distance measurement of the chassis 136, while it is being backed into the
buffer 21 to retrieve
the stored container, the distance sensor actuator 304 will automatically
lower the distance
sensor 312 in approximately 0.20 inch increments until a readable distance
measurement is
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obtained. If the distance sensor 312 reaches a point B and no readable signal
is obtained, then
the light signal 90 stops working and the operator can either start the
process over or manually
back the chassis 136 and container 134 into the buffer 21.
[0072] FIG. 14 shows another embodiment of the dynamic sensor system 300.
In this
embodiment, the dynamic sensor system 300 includes a filter system 400. The
filter system
400 is used when the distance sensor 312 is overloaded with signals due to the
presence of
reflective material on the container 134 or chassis 136.
[0073] The filter system 400 includes a filter actuator 402, an arm member
404, a filter
positioning mechanism 406, and a filter 408. The filter 408 may be a film or
lens such as
LAMIN-xTm film or other suitable optical filter material. The filter actuator
402 is connected
to the mounting member 302 and the arm member 404 and can move the arm member
404 in a
vertical direction. The arm member 404 is connected on one end to the filter
actuator 402 and
projects horizontally away from the mounting member 302. The arm member 404 is
connected
via a second end to the filter positioning mechanism 406. The filter
positioning mechanism
406 includes an extension member 410. The filter positioning mechanism 406
also includes
the electronics (not shown) needed to communicate with the PLC 52 and to move
the filter 408
from a stored position 412 to an engaged position 414.
10074J The default position of the filter 408 is the stored position 412.
In the stored
position 412, the filter 408 is position away from the distance sensor 312 so
that the filter does
not interfere with the signal 416 of the distance sensor 312. The stored
position may be a
vertical or upright position. When the filter 408 is to be used, the filter
positioning mechanism
406 via extension member 410 moves the filter 408 from the stored position 412
to the
engaged position 414. In the engaged position 414, the filter 408 is located
in front of the
distance sensor 312 such that the distance sensor's signal 416 passes through
the filter 408.
[0075] When in use, the distance sensor 312 begins sending a signal that
strikes the
designated target of the container or chassis at a starting height. The
starting height of the
distance sensor 312 may be the container sensing height, the 20 foot chassis
sensing height, or
the 40-53 foot chassis sensing height depending on whether a chassis 136
carrying a container
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134 is entering the buffer 21 or if an empty chassis is entering the buffer 21
to retrieve a stored
container as discussed above. If a readable signal is not received by the
distance sensor 312 at
the starting height, the filter 408 is moved by the filter position mechanism
406 to the engaged
position 414 so that the signal 416 of the distance sensor 312 passes through
the filter 408. If a
readable distance measurement is obtained, the data is sent to the PLC 52,
which determines
the container length L and the final stopping distance 214. This information
is then used by the
light signal 90 to guide the operator.
[0076]
However, if no readable signal is obtained, then the distance sensor 312 and
the
filter 408, which is in the engaged position 414, are lowered by the distance
sensor actuator
304 and the filter actuator 402, respectively, to a height that is
approximately 0.2 inches below
the starting height. The distance sensor 312 will again send a signal through
the engaged filter,
which will strike the container or chassis, and if no readable signal is
obtained, the distance
sensor 312 and filter 408 will be lowered again in an increment of
approximately 0.2 inches.
This will continue until a readable signal is obtained or an error message is
generated as
discussed above.
[0077] In
a further embodiment a method of transferring a container using a sensor
system
having a distance sensor is shown in FIG. 15. The method is comprised of at
least the steps of
sensing movement of the container carried by a chassis into the buffer using a
plurality of
sensors including a thru beam sensor and the distance sensor 500; sending a
signal from the
distance sensor to the container 502; and determining a distance from the
distance sensor to the
container using a signal generated by the distance sensor 504. The method also
comprises the
steps of moving the distance sensor if the distance sensor cannot obtain a
readable signal 506;
determining a length of the container based on data received from the
plurality of sensors 508;
and guiding an operator via a light signal to position the chassis into the
buffer based on the
length of the container 510. The method may further include the step of moving
a filter
associated with the distance sensor from a stored position to an engaged
position if the distance
sensor cannot obtain a readable signal.
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INDUSTRIAL APPLICABILITY
[0078] Numerous modifications to the present invention. will be apparent to
those skilled in
the art in view of the foregoing description. Accordingly, this description is
to be construed as
illustrative only and is presented for the purpose of enabling those skilled
in the art to inake
and use the invention and to teach the best mode of carrying out same. The
exclusive rights to
all modifications which come within the scope of the appended claims are
reserved.
