Note: Descriptions are shown in the official language in which they were submitted.
CANADA
TITLE: CART LOADER/UNLOADER AND A SWITCHER SYSTEM
FIELD OF THE INVENTION
[0001] The present invention relates to industrial cart systems, and
more
particularly, to industrial cart loading/unloading and a cart switching
system.
BACKGROUND OF THE INVENTION
[0002] In the art, forklifts are typically used to deliver or move
materials, for
example, palletized loads, or loads contained in bins, in a factory or other
industrial
plant.
[0003] For mass manufacturing, the industry typically utilizes an
assembly line
configuration wherein a product, for example, an automobile, is assembled or
built in a
sequence of operations performed at stations configured along the assembly
line. To
support the continuous operation of the assembly line, parts or components
must be
replenished continuously and in a timely manner. Since there are space
restrictions for
the stations along the assembly line, the parts or components cannot be stock
piled
and must be restocked in near real-time and prior to demand. It will be
appreciated that
this places a high premium on logistical control and movement of parts within
the
manufacturing facility and bottlenecks in the supply of fresh parts or
components can
arise.
[0004] Accordingly, there remains a need for improvements in the art.
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BRIEF SUMMARY OF THE INVENTION
[0005] The present invention is directed to an industrial cart
loading/unloading and
a switcher system.
[0006] According to an embodiment, the present invention comprises a
cart
switcher system comprising: a base member having a loading end and an operator
end;
a first carriage for carrying a bin, said first carriage being operatively
coupled to said
base member and configured to move between said loading end and said operator
end;
a second carriage for carrying another bin; a bypass mechanism configured to
support
said second carriage and said other bin; said bypass mechanism being
operatively
coupled to said base member and configured to move between said loading end
and
said operator end; and said bypass mechanism being further configured to
operate in a
bypass mode, and in said bypass mode said bypass mechanism being operable to
permit movement of said first carriage and said bin between said loading end
and said
operator end.
[0007] According to another embodiment, the present invention
comprises a rack
loader/unloader and switcher system comprising: a base having a loading end
and an
operator side end, and said base including a first track and a second track; a
first
carriage configured for carrying a rack, said first carriage being operatively
coupled to
move on said first track; a controller; a first drive mechanism operatively
coupled to
said first carriage for moving said first carriage between said loading end
and said
operator side end, and said first drive mechanism being responsive to one or
more
control signals from said controller for controlling movement of said first
carriage
between said loading end and said operator end; a second carriage configured
for
carrying another rack; a travel lift mechanism configured to support said
second
carriage and said other rack, said travel lift mechanism being operatively
coupled to
move on said second track; a second drive mechanism operatively coupled to
said
travel lift mechanism for moving said travel lift mechanism between said
loading end
and said operator side end, and said second drive mechanism being responsive
to one
or more control signals from said controller for controlling movement of said
travel lift
mechanism between said loading end and said operator end; said travel lift
mechanism
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further including a lift drive mechanism operatively coupled to said second
carriage,
said lift drive mechanism being responsive to one or more control signals from
said
controller for controlling movement of said second carriage between a lowered
position
and a raised position; and wherein in said raised position, said travel lift
mechanism is
configured to allow movement of said first carriage on said first track under
said second
carriage and between said loading end and said operator side end.
[0008] Other aspects and features of the present invention will become
apparent to
those ordinarily skilled in the art upon review of the following description
of
embodiments of the invention and/or the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Reference will now be made to the accompanying drawings which
show, by
way of example, embodiments of the present invention, and in which:
[00010] Fig. 1 shows in diagrammatic form a cart or rack loader/unloader and
switcher system according to an embodiment of the present invention with a
rack or bin
ready for loading at a forklift loading stage or side;
[00011] Fig. 2 shows the cart or rack loader/unloader and switcher of Fig. 1
with a
rack or bin loaded or positioned on the first transfer carriage of the
switcher;
[00012] Fig. 3 shows the cart or rack loader/unloader and switcher of Fig. 2
with the
second transfer carriage and the travel lift mechanism in an extended or
raised position
or condition at the operator line side;
[00013] Fig. 4 shows the cart or rack loader/unloader and switcher of Fig. 3
in with
the first transfer carriage and the loaded rack moved to the operator line
side and the
second transfer carriage maintained in a raised or elevated position at the
operator line
side;
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[00014] Fig. 5 shows the cart or rack loader/unloader and switcher of Fig. 4
with the
second transfer carriage moved to the forklift loading side and maintained in
a raised or
elevated position by the travel lift mechanism;
[00015] Fig. 6 shows the cart or rack loader/unloader and switcher system of
Fig. 5
with the second transfer carriage lowered by the travel lift mechanism to a
lower
position for unloading an empty rack on the carriage at the forklift
loading/unloading
side or station;
[00016] Fig. 7 shows the cart or rack loader/unloader and switcher system of
Fig. 6
with a new or full rack ready for loading onto the second transfer carriage at
the forklift
loading/unloading side or station;
[00017] Fig. 8 shows the cart or rack loader/unloader and switcher system of
Fig. 7
with the new rack (full) loaded onto the second transfer carriage at the
forklift
loading/unloading side;
[00018] Fig. 9 shows the cart or rack loader/unloader and switcher system of
Fig. 8
with second transfer carriage and loaded rack raised to elevated or vertical
position by
the travel lift mechanism;
[00019] Fig. 10 shows the cart or rack loader/unloader and switcher system of
Fig. 9
with the first transfer carriage moved to the forklift loading/unloading side
and in a
position below the travel lift mechanism to allow unloading of the rack
(empty) from the
first transfer carriage;
[00020] Fig. 11 shows the cart or rack loader/unloader and switcher system of
Fig.
with second transfer carriage and loaded rack moved by the travel lift
mechanism to
the operator line side;
[00021] Fig. 12 shows the cart or rack loader/unloader and switcher of Fig. 11
with
the second transfer carriage lowered by the travel lift mechanism to a lower
position to
provide access to the rack for an operator at the operator line side or
station;
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[00022] Fig. 13A shows an exemplary sequence of operations for the rack
loading
and switcher system with a first loaded rack in "Position 1";
[00023] Fig. 13B shows the exemplary sequence of operations for the rack
loading
and switcher system with the first rack moved to "Position 2";
[00024] Fig. 13C shows the exemplary sequence of operations for the rack
loading
and switcher system with a loaded second rack moved or loaded into "Position
1";
[00025] Fig. 13D shows the exemplary sequence of operations for the rack
loading
and switcher system with the loaded second rack moved to "Position 2";
[00026] Fig. 13E shows the exemplary sequence of operations for the rack
loading
and switcher system with the empty first rack being moved back to "Position 1"
and the
loaded second rack being moved to a "Position 3" in the switcher system;
[00027] Fig. 13F shows the exemplary sequence of operations for the rack
loading
and switcher system with the empty first rack moved back to "Position 1" and
the
loaded second rack being moved from Position 3 to Position 2;
[00028] Fig. 13G shows the exemplary sequence of operations for the rack
loading
and switcher system with the empty first rack removed or unloaded from
"Position 1"
and the loaded second rack moved to Position 2 and ready for unloading or
access at
the line side operator;
[00029] Fig. 13H shows the exemplary sequence of operations for the rack
loading
and switcher system with the empty second rack being moved back to "Position
3" and
the loaded second rack being moved from Position 1 to Position 2;
[00030] Fig. 131 shows the exemplary sequence of operations for the rack
loading
and switcher system with the empty rack raised and moved to "Position-3" and
the
second full rack moved from Position-1 to Position-2 and located underneath
the empty
rack in Position-3;
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[00031] Fig. 13J shows the exemplary sequence of operations for the rack
loading
and switcher system with the empty second rack being moved back, i.e. lowered,
to
"Position 1" from "Position 4" and the loaded first rack moved from Position 2
and
ready for unloading or access at the line side operator; and
[00032] Fig. 14 shows in block diagram form an exemplary configuration for a
controller or control module for the switcher system suitable for implementing
the
functional and operational control of the system according to embodiments of
the
present invention.
[00033] In the drawings, like reference numerals indicated like components or
elements.
DETAILED DESCRIPTION OF THE EMBODIMENTS OF THE INVENTION
[00034] Reference is first made to Fig. 1, which shows a rack or bin cart
loader/unloader and switcher system according to an embodiment of the present
invention and indicated generally by reference 100. According to an
embodiment, the
rack loader/unloader and switcher system 100 comprises a support base or
member
102, a first transfer carriage 110, a second transfer carriage 120, and a lift
mechanism
130. The second transfer carriage is coupled to and carried by the lift
mechanism 130.
In an exemplary implementation, the support base includes one or more rails or
tracks
140, indicated individually by references 142a and 142b, for a dual rail or
track
arrangement, configured to support and/or guide the first transfer carriage
110 between
a loading/unloading position or stage indicated generally by reference 101 and
an
operator side or line position or stage indicated generally by reference 103,
in Fig. 1.
The support base includes one or more rails or tracks 144, indicated
individually by
references by 144a and 144b configured to support and guide the lift mechanism
130
back and forth between the loading/unloading stage 101 and the operator side
or line
position 103, for example, in a generally horizontal plane as will be
described in more
detail below.
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[00035] Referring still to Fig. 1, the switcher system 100 includes a drive
mechanism
for the first transfer carriage 110 indicated generally by reference 150.
According to an
exemplary implementation, the drive mechanism 150 comprises a hydraulic
actuator, or
a belt drive, configured to move the first transfer carriage 110 on the rails
142 back and
forth between the loading/unloading position 101 and the operator side
position 103.
The drive mechanism 150 may be implemented using other types of drive motors
or
actuators, for example, a motor and a worm-gear drive. Similarly, the switcher
system
100 includes a drive mechanism for the lift mechanism 130 and indicated
generally by
reference 152. The drive mechanism is configured to move the second transfer
carriage
110 on the rails 142 and in an elevated position back and forth between the
loading/unloading position 101 and the operator side position 103. The drive
mechanism 152 may be implemented using other types of drive motors or
actuators, for
example, a hydraulic based system, a belt and motor drive, a motor and a worm-
gear
drive. In the context of the present description, the travel lift mechanism
comprises the
second transfer carriage 120 and the lift mechanism 130.
[00036] As also shown in Fig. 1, the rack loader/unloader and switcher system
100
includes a controller indicated generally by reference 160. The controller 160
comprises
a programmable logic device, or a microprocessor-based device programmed to
operate under stored-program control, to provide the functionality and
operational
control of the switcher system 100 as described herein. The controller 160 may
be
implemented with a configuration as shown in Fig. 14. According to another
embodiment, or implementation, the controller comprises a relay logic system,
e.g. a
relay logic controller and/or relay logic board, coupled to the relay
(switches and/or
sensors or other compatible input devices) devices as described above the
particular
hardware implementation details, and/or software programming, and/or logic or
relay
logic function details, will be within the understanding of those skilled in
the electronic
hardware, logic control circuits, relay logic control, and programming arts.
[00037] As shown in Fig. 1, the loader/unloader and switcher system 100 may
also
include with a protection plate indicated by reference 104 at the end of the
base 102 on
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the loading/unloading side 101. The base 102 may further include forklift
guides 106,
indicated individually by references 106a and 106b.
[00038] Reference is next made to Fig. 2, which shows the rack loader/unloader
and
switcher system 100 with a rack or bin 10 loaded or positioned on the first
transfer
carriage 110. The bin(s) 10 (11) may comprise a bin or a rack loaded with
parts or
components, or a cart loaded with parts or components. In the context of the
present
description, the rack 10 is loaded with parts or components utilized on an
assembly line
in an automobile manufacturing facility or application. As also shown, the
lift
mechanism 130 is in a lowered or retracted position which provides an
operator, e.g. an
assembly line worker, access to the rack or bin loaded on the second transfer
carriage
120 which located on the operator or line side 102 of the switcher 100.
[00039] Reference is made to Fig. 3, which shows the loader/unloader and
switcher
system 100 with a travel lift mechanism 130 in an extended or raised position
or
condition, at the operator line side 102, as indicated by arrow 3-3. With the
second
transfer carriage 120 in a raised position at the operator line side 102, the
first transfer
carriage 110 with a loaded rack or a new rack can be moved into position at
the
operator line side 101 as shown in Fig. 4, and indicated by arrow 4-4. It will
be
appreciated that the configuration of the switcher 100 according to this
embodiment
provides the capability to move or manipulate two racks, or two bins, in the
same
footprint between the loading/unloading side 101 and the operator line side
102. For
instance, by effectively utilizing the available vertical or height clearance
normally
available at the assembly line station. It will be further appreciated that
since floor
space alongside an assembly line or automated manufacturing facility is
typically
limited, the capability to handle two containers simultaneously or
sequentially is
advantageous, and can serve to prevent bottlenecks arising from delayed
delivery of
parts or components.
[00040] Reference is next made to Fig. 5, which shows the rack loader/unloader
and
switcher 100 with the travel lift mechanism 130 moved to the loading/unloading
side
101, as indicated by arrow 5-5, and the second transfer carriage 120 in a
raised or
elevated position with the lift mechanism 130 in an extended or raised
position. The
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second transfer carriage 120 is then lowered by the lift mechanism 130 at the
loading/unloading side 101, as indicated by arrow 6-6 in Fig. 6. With the
second
transfer carriage 120 in a lowered position, an empty bin or rack can be
unloaded, for
example, using a forklift, and/or a loaded rack 11 (e.g. a bin, a rack or a
cart) can be
positioned for loading shown in Fig. 7 and indicated by arrow 7-7, and then
loaded onto
the second transfer carriage 120 as shown in Fig. 8, as indicated by arrow 8-
8. The lift
mechanism 130 is then actuated (for example, under the control of the
controller 160 as
described in more detail below), to raise the second transfer carriage 120
with the
newly loaded rack or bin 11 to an elevated position as indicated by arrow 9-9
in Fig. 9.
In the elevated position, the second transfer carriage 120 can be moved by the
travel lift
mechanism 130 over the rack or bin 10 loaded on the first transfer carriage
110, and/or
the first transfer carriage 110 with the rack 10 can be moved under the
elevated second
transfer carriage 120, either substantially simultaneously or in sequence. As
shown in
Fig. 10, the first transfer carriage 110 with an empty rack 10 is moved from
the operator
line 102 to a position underneath the second transfer carriage 120 at the
loading/unloading side 101, as indicated by arrow 10-10.
[00041] As also shown in Fig. 5, the lift mechanism 130 comprises a pair of
scissor
lift mechanisms indicated individually by references 170 and 172. Each scissor
lift
mechanism 170 and 172 has a base indicated by references 174 and 176,
respectively,
and an upper shelf or support section, indicated by references 178 and 179,
respectively. The base 174 of the first scissor lift mechanism 170 is
configured to
couple to and ride the rail(s) 144a, and may comprise one or more rollers 175,
indicated
individually by references 175a, 175b. Similarly, the base 176 of the second
scissor lift
mechanism 172 is configured to couple to and ride the rail(s) 144b, and may
comprise
one or more rollers 177, indicated individually by references 177a, 177b. Each
of the
upper support sections 178, 179 is configured to support and attach a
respective side
or section of the second transfer carriage 120 as also shown in Fig. 5. The
drive
mechanism 152 is operatively coupled to the base 174 and/or the base 176 and
configured to move the second transfer carriage 120 and the lift mechanism
130, i.e.
the travel lift mechanism, back and forth between the loading/unloading
station 101 and
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the operator side station 102 under the control of the controller 160 as
described in
more detail below.
[00042] According to an exemplary implementation, each scissor lift mechanism
170,
172 comprises two scissor lift mechanisms in a vertical or stacked
configuration. As
shown in Fig. 5, the scissor lift mechanism 170 comprises a lower scissor lift
mechanism indicated by reference 180 and an upper scissor lift mechanism
indicated
by reference 181. The configuration of the two scissor lift mechanisms 180,
181
provides the lift mechanism with a greater range of vertical movement within a
narrower
horizontal footprint or template. The lower scissor lift mechanism 180
comprises the
base 174 which is coupled to the rail(s) 144a as described above. The upper
scissor lift
mechanism 181 comprises the upper shelf or support section 178 which is
connected
to the second transfer carriage 120. The scissor lift mechanisms 180 and 181
are
coupled together and are configured with individual drive lift mechanisms or a
single
drive mechanism for the scissor lift mechanism 170. The drive lift mechanism
may
comprise a hydraulic actuator configured to open/close, i.e. extend and
retract, the
scissor lift mechanism 170 to raise and lower the second transfer carriage 120
under
the control of the controller 160 as described in more detail herein.
Similarly, the scissor
lift mechanism 172 comprises a lower scissor lift mechanism indicated by
reference 182
and an upper scissor lift mechanism indicated by reference 183. The lower
scissor lift
mechanism 181 comprises the base 176 which is coupled to the rail(s) 144b as
described above. The upper scissor lift mechanism 183 comprises the upper
shelf or
support section 179 which is connected to the second transfer carriage 120.
The
scissor lift mechanisms 182 and 183 are coupled together and are configured
with
individual drive lift mechanisms or a single drive lift mechanism for the
scissor lift
mechanism 172 in a manner similar to the scissor lift mechanism 172. Then as
shown in
Fig. 11, the elevated second transfer carriage 120 and loaded rack 11 is moved
by the
travel lift mechanism 130 to the operator side 102, as indicated by arrow 11-
11. As
shown in Fig. 12 and indicated by arrow 12-12, the second transfer carriage
120 is
lowered by the lift mechanism 130, and the loaded rack 11 is accessed at the
operator
side 102 by an assembly line worker.
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[00043] Reference is next made to Figs. 13A to 13J which shows a sequence of
operations for a rack loader/unloader and switcher system according to an
embodiment
of the invention and indicated generally by reference 1300. The rack
loader/unloader
and switcher system 1300 may be implemented in a manner similar to the rack
loader/unloader and switcher system 100 described above and comprises a first
transfer carriage indicated by reference 1310 and a second transfer carriage
1320 with
a lift mechanism indicated by reference 1322.
[00044] As shown in Fig.13A, the rack loader/unloader and switcher 1300
comprises
a loading station or side indicated by reference 101 and an operator or line
side
indicated by reference 102. The loading station or side 101 is configured for
loading
and unloading a rack 1312, comprising, for example, a bin, rack, or pallet,
loaded with
materials, parts or other components, required at the operator side, e.g. an
assembly
worker at a station on an automobile assembly. The cart(s) are loaded/unloaded
at the
loading station 101 using a forklift, other lifting and transport mechanism or
machine.
[00045] As shown in Fig. 13A, the rack loader/unloader and switcher system
1300 is
configured to operate in four positions or states comprising "Position 1"
indicated by
reference 1301, "Position 2" indicated by reference 1302, "Position 3"
indicated by
reference 1303, and "Position 4" indicated by reference 1304. The first
transfer carriage
1310 is configured to move between Position 1 and Position 2, for example,
along a
pair of rails or tracks with an actuator, e.g. a motor and/or drive shaft, or
a hydraulic
drive shaft, similar to the implementation described above. The switcher
system 1300
includes a controller, e.g. the controller 160 comprising a programmable
device (or
relay logic controller or board), configured to control and monitor the
components and
elements in the operation of the system as described herein. The particular
implementation details the controller 160 are described in more detail below
and also
will be readily within the understanding of those skilled in the art.
[00046] Referring again to Fig. 13A, the rack loader/unloader and switcher
system
1300 may further include one or more safety sensors or devices or relay logic
sensor
and/or output devices According to an exemplary, the rack loader/unloader and
switcher 1300 comprises a loading side safety sensor indicated by reference
1305 and
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an operator side safety sensor indicated by reference 1306. The loading side
safety
sensor 1305 is implemented as a "light curtain", for instance, comprising an
LED and
photosensor array configured with circuitry or logic control to generate an
alarm.
Similarly, the operator or line side safety sensor 1306 is also implemented as
a light
curtain configured to generate an alarm. According to an exemplary
implementation
and embodiment, the loading side safety sensor 1305 is configured to generate
an
alarm and a cycle-stop condition if the light curtain 1305 is breached during
any
movement of the first transfer carriage 1310, and/or the second transfer
carriage 1320,
and/or the lift mechanism 1322. Similarly, the operator side safety sensor
1306 is
configured to generate an alarm and a cycle-stop condition if the light
curtain 1306 is
breached during any movement of the first transfer carriage 1310, and/or the
second
transfer carriage 1320, and/or the lift mechanism 1322. According to another
aspect,
the rack loader/unloader and switcher system 1300 includes a safety light
indicator
1307, for example, a fork light beacon, which is mounted in a visible location
at the
loading station or side 101. According to an exemplary implementation, the
safety light
indicator 1307 is configured to illuminate green for a "Clear to Enter" state
when it is
safe for a fork lift operator to load/unload a cart or rack from the switcher
1300; and to
illuminate red for "Not Clear to Enter" state to indicate that it is not safe
for a fork lift
driver to load/unload a cart or rack. According to another aspect, the safety
light
indicator is configured to flash green and red to indicate that the loading
side, i.e. the
fork-lift side, light curtain 1305 has been breached (for instance as
described above).
According to another aspect, the safety light indicator 1307 is configured to
illuminate
white to indicate a "Rack Loaded Correctly" state when the cart or rack is
properly
loaded on the transfer carriage 1310 or 1320.
[00047] An exemplary sequence of operations a load and unload cycle is now
described with reference to Figs. 13A to 13J.
[00048] As shown in Fig. 13A, the safety light or beacon 1307 is configured to
show
Green indicating "Clear to Enter" condition for the fork-lift operator. The
first transfer
carriage 1310 is located at "Position-1" indicated by reference 1301. The fork-
lift (or
other loading machine or mechanism) loads a bin or rack (full of parts or
components)
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on the first transfer carriage 1310 located at "Position-1" 1301. The switcher
system
1300 may include a "Position-1" detect or proximity sensor, or relay logic
sensor,
indicated by reference 1331 configured to detect when the transfer carriage
1310 or
1320 is properly positioned or seated in Position-1 in the switcher 1300. As
shown, the
second transfer carriage 1320 and the lift mechanism 1322 are positioned or
moved to
Position-4 as indicated by reference 1304. In Position-4, the lift mechanism
1322 is
extended to position the second transfer carriage 1320 above the first
transfer carriage
1310, which as will be described in more detail below allows the first
transfer carriage
1310 to effectively move from Position-1 1301 to Position-2 1302 under the
second
transfer carriage 1320. The switcher system 1300 may include a Position-3
detect
sensor (or using a relay logic sensor) indicated by reference 1333 configured
to detect
when the second transfer carriage 1320 is properly positioned or seated in
Position-3 in
the switcher 1300.
[00049] Referring still to Fig. 13A, the switcher 1300 may include a Position-
4 detect
or proximity sensor (or relay logic sensor or output device) indicated by
reference 1334
configured to detect when the transfer carriage 1310 or 1320 is properly
positioned or
seated in "Position-4" 1304. The switcher 1300 may further include "slow-down"
sensors (or relay logic sensors or output devices) comprising a Position-1
slow-down
sensor 1341, a Position-2 slow-down sensor 1342, a Position-3 slow-down sensor
1343 and/or a Position-4 slow-down sensor 1344. The slow-down sensors 1341-
1344
are configured to sense the moving speed of the respective transfer carriage
1310,
1320 as the respective transfer carriage 1310 or 1320 moves from one operating
position to another operating position in the switcher 1300 and provide or
generate
associated output signals or data for the controller. If the moving speed
exceeds a pre-
determined threshold, the controller is configured to control the drive or
motor to
appropriately reduce the speed to a safe speed or range of speeds.
[00050] As shown in Fig. 13B, the first transfer carriage 1310 and the loaded
bin or
rack 1312 are moved by the motor or drive mechanism from "Position-1" 1301 to
"Position-2" 1302 at the operator or line side 102 of the switcher system
1300, as
further indicated by arrow 1-2. According to an exemplary implementation, the
switcher
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system 1300 comprises a loading side control panel 1351 configured with a
"Reset
Load Light Curtain" button 1353, which is pressed by the fork-lift operator to
initiate
movement of the transfer carriage 1310 by the drive mechanism. The Position-2
detect
or proximity sensor (an electronic sensor or a relay logic sensor or output
device) 1332
detects when the transfer carriage 1310 and the full rack 1312 are properly
positioned,
and disable the line side safety or light curtain 1306 to allow the operator,
e.g. assembly
line worker, to access, e.g. pick parts off, the rack or bin 1312 on the
transfer carriage
1310. The switcher 1300 may include a slow-down sensor 1345 (an electronic
sensor
device or a relay logic device) which is configured to monitor the moving
speed of the
transfer carriage 1310, 1320 between "Position-1" 1301 and "Position-2" 1302
as
indicated by arrow 1-2, and reduce speed if a pre-determined threshold is
exceeded, in
a manner similar to that described above.
[00051] Referring next to Fig. 13C, which shows the second transfer carriage
1320
lowered by the travel lift 1322 from "Position-4" 1304 to "Position-1" 1301 as
indicated
by arrow 4-1 for loading with a full or loaded rack or bin, indicated by
reference 1321.
The safety beacon 1307 is illuminated under the control of the controller 160
to
indicated the "Clear to Enter" condition or state for the forklift
truck/driver. The forklift
driver loads the second full rack or bin 1321 on the second transfer carriage
1320 as
shown. The switcher system 1300 may include additional loading or proximity
sensor(s)
(e.g. electronic sensor devices or relay logic sensor or output devices) to
generate an
output, e.g. signal, for the controller 160 indicating that the rack or bin
1321 (and bin
1312) is properly loaded or positioned on the second transfer carriage 1320
(or the first
transfer carriage 1310). In the response, the controller 160 activates the
safety beacon
1307 to indicate the "Rack Loaded Correctly" state for the forklift driver or
other
operator. The movement and position of the second transfer carriage 1320 is
monitored
by the sensors 1341 and 1344.
[00052] Reference is next made to Fig. 13D, which shows the switcher system
1300
moving the second transfer carriage 1320 with the full or loaded bin 1322
after being
loaded from "Position-1" 1301 to "Position-4" 1304. With the safety beacon
1307
showing the "Rack Loaded Correctly" state (Fig. 13C), the forklift driver or
another
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operator presses "Reset Load Light Curtain" 1355 on the loading side control
panel
1351, and the controller operates or actuates the travel lift mechanism 1322
to move
the second transfer carriage 1320 with the loaded bin 1323 to "Position-4"
1304 as
indicated by arrow 1-4 in Fig. 13D.
[00053] Reference is next made to Fig. 13E, which depict the sequential
movement,
or substantially simultaneous movement, of the first transfer carriage 1310
from
"Position-2" 1302 back to "Position-1" 1301 and the second transfer carriage
1320
from "Position-4" 1304 to "Position-3" 1303, and then from "Position-3" 1303
to
"Position-2" 1302 as depicted in Fig. 13F. As shown, the switcher system 1300
is
configured with a first or lower drive mechanism unit indicated generally by
reference
1360 and a second or upper drive mechanism or unit indicated generally by
reference
1362. The lower drive unit 1360 is configured to move the first transfer
carriage 1310
back and forth between "Postion-1" 1301 and "Position-2" 1302 as indicated by
arrows
1-2, 2-1. Similarly, the upper drive unit 1362 is configured to move the
second transfer
carriage 1320 and the travel lift mechanism 1322 back and forth between
"Postion-3"
1303 and "Position-4" 1304 as indicated by arrows 3-4, 4-3. The drive units
1360, 1362
may be implemented in known manner, for instance, utilizing a hydraulic
mechanism or
actuator, or a belt drive and motor unit, or a motor and worm-gear drive unit.
[00054] Referring still to Fig. 13E, the lineside operator clears the Lineside
Operator
Light Curtain 1306 and then presses an "Operator Light Curtain Tripped" button
1354
on the lineside operator panel 1352 and then a "Cycle Start Button" 1356 on
the
lineside operator panel 1352. In response to signal(s) or data inputs from the
lineside
operator panel 1352, the controller 160 is configured to control the lower
drive unit
1360 to move the first transfer carriage 1310 with an empty rack or bin
indicated by
reference 1311' from "Position-2" 1302 back to "Position-1" 1301 as indicated
by arrow
2-1, i.e. a reverse direction. Similarly, the controller 160 is configured to
control the
upper drive unit 1362 to move the second transfer carriage 1320 with a full
rack or bin
indicated by reference 1324 from "Position-4" 1304 to "Position-3" 1303 as
indicated
by arrow 4-3, i.e. a forward direction. The controller 160 can be configured
to move the
first transfer carriage 1310 and the second transfer carriage 1320
substantially
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simultaneously, or in the alternative, sequentially. As further shown in Fig.
13F, once the
controller 160 detects that the second transfer carriage 1320 is properly
located or
situated in "Position-3" 1303, i.e. via an output signal or data from the
Position-3
location sensor 1333 (and the first transfer carriage 1310 has been moved from
Position-2 1302, i.e. via an appropriate output signal from the location
sensor 1332), the
controller 160 actuates the transfer lift mechanism 1322 to lower the second
transfer
carriage 1320 with the full rack or bin 1324 from "Position-3" 1303 to
"Position-2" 1302
as indicated by arrow 3-2 in Fig. 13F. On the Load/Unload side 102, the first
transfer
carriage 1310 with the empty bin or rack 1312' is in position for unloading,
and the
controller 160 activates the safety beacon 1307 to indicate the "Clear to
Enter" state for
example by illuminating a green light. The forklift driver or operator is free
to remove the
empty rack 1312' from the first transfer carriage 1310.
[00055] Reference is next made to Fig. 13G. With the second transfer carriage
1320
and new full rack or bin 1324 located at "Position-2" 1302, the lineside
operator is free
to pick or pull the full rack 1324 on the transfer carriage 1320. As shown in
Fig. 13H, a
new full rack or bin 1312 is loaded onto the first transfer carriage 1310 in
"Position-1"
1301 by the forklift driver or operator, and the driver or an operator presses
the "Reset
Load Light Curtain" button 1353 on the panel 1351 at the "load side" 101.
[00056] Referring still to Fig. 13H, the lineside operator initiates a new
cycle, e.g.
calling for a new rack or bin, by pressing the "Reset Load Light Curtain"
button 1354
and then the "Operator Cycle Start" button 1356 on the lineside operator panel
1352. In
response to the output signal(s) from operator panel 1352, the controller 160
actuates
the travel lift mechanism 1322 to raise the second transfer carriage 1320 and
the empty
rack indicated by reference 1324' from "Position-2" 1302 to "Position-3" 1303
as
shown in Fig. 13H and indicated by arrow 2-3. Once the second transfer
carriage 1320
and the empty rack 1324' are moved to "Position-3" 1303 as determined or
verified by
an output signal from the position location sensor 1333, the controller 160
actuates the
upper drive unit 1362 to move (i.e. in reverse) the second transfer carriage
1320 with
the empty rack 1324' (and the travel lift mechanism 1322) from "Position-3"
1303 to
"Position-4" 1304 as indicated by arrow 3-4 in Fig. 131. Simultaneously, or
sequentially
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(as described above), the controller 160 actuates the first drive mechanism or
lower
drive unit 1360 to move the first transfer carriage 1310 with the new loaded
rack 1312
from "Position-1" 1301 to "Position-2" 1301 as indicated by arrow 1-2 in Fig.
131. As
further shown in Fig. 13J, once the second transfer carriage 1320 with the
empty rack
1324' is positioned or located in "Position-4", for instance as verified by
the position
location sensor 1334, the controller 160 actuates the travel lift mechanism
1322 to
lower the second transfer carriage 1320 and the empty rack 1324' from
"Position-4"
1304 to "Position-1" 1301 as indicated by arrow 4-1 in Fig. 13J, for
subsequent
unloading and then reloading a new rack as described above.
[00057] According to another aspect and embodiment, the cart loader/unloader
and
switcher system 1300 may be configured to operate in a bypass lift mode, for
example,
implemented in a control module or logic circuit in the controller 160, e.g. a
microcontroller or processor, operating under stored program control, or a
logic circuit,
or other type of programmable control device or circuit, or a relay logic
controller or
system. According to an exemplary implementation, the bypass lift mode is
triggered if
the operator side safety sensor 1306, i.e. light curtain, is breached. In
bypass lift mode,
the switcher system 1300 is configured to allow the transfer lift mechanism
1322 to
move between "Position 1" 1301 and "Position 4" 1304 if the first transfer
carriage 1310
is located at the operator side 102 and the lift mechanism 1322 is located or
positioned
at the forklift loading/unloading side 101.
[00058] Reference is next made to Fig. 14, which shows an exemplary
implementation for the controller 160 and indicated generally by reference
1400. The
controller 1400 is implemented and configured to execute and/or control the
functionality and features of the embodiments of the switcher system 100, 1300
as
described herein. The controller 1400 is implemented in a hardware-based
configuration and comprises a processor 1401, a main memory 1402, a read only
memory or ROM 1404, a storage device 1406, an input device interface 1420, and
an
output device interface 1430. According to an exemplary implementation as
described
above, the controller 1400 also includes a device interface 1440 for the
safety light or
bean 1307 (Fig. 13A). The controller 1400 may also include a communication
interface
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for interfacing to a central plant computer or control system. The hardware
components
may be coupled utilizing a bus and/or an input/output port configuration.
[00059] According to the embodiments of the switcher system 100, 1300 as
described above, the input device interface 1420 comprises an interface
configured to
couple to the proximity or location sensors (e.g. electronic sensors and/or
relay logic
devices), i.e. "Position-1" detect sensor 1331 (Fig. 13A), "Position-2" detect
sensor
1332 (Fig. 13A), "Position-3" detect sensor 1333 (Fig. 13A), and "Position-4"
detect
sensor 1334 (Fig. 13A), and the slow-down sensors, comprising the "Position-1"
slow-
down sensor 1341 (Fig. 13A), "Position-2" slow-down sensor 1342 (Fig. 13A),
"Position-
3" slow-down sensor 1343 (Fig. 13A), "Position-4" slow-down sensor 1344 (Fig.
13A),
and the horizontal slow-down sensors comprising the "Position-1" slow-down
sensor
1345 (Fig. 13A) and "Position-4" slow-down sensor 1346 (Fig. 13A). The input
device
interface 1420 also includes an interface configured to couple to the load
side 1305 and
the operator side 1306 safety or light curtains (Fig. 13A) and the loading
side control
panel 1351 (Fig. 13A) and the lineside operator control panel 1352 (Fig. 13A).
The
controller 1400 is configured to receive and process output signals from these
sensors
and control the speed and/or positional movement of the first transfer
carriage 1310,
and/or the second transfer carriage 1320 and the travel lift mechanism 1322.
[00060] According to the embodiments of the switcher system 100, 1300 as
described above, the output device interface 1430 comprises an interface
configured to
couple and control the drive mechanism for the first transfer carriage 150
(Fig. 1), the
drive mechanism for the travel lift mechanism 152 (Fig. 1), and the lift drive
mechanism(s) for the scissor lift mechanisms 170, 172 (Fig. 5).
[00061] According to the embodiment of the switch system 1300, the output
device
interface 1430 couples the controller 1400 to the safety light or beacon 1307
(Fig. 13A).
The controller 1400 is configured to control the illumination states of the
safety light
1307.
[00062] As will readily understood by those skilled in the art, the processor
1401 may
comprise a computer, a microprocessor, a microcontroller or other type of
hardware-
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based processing device or logic board or circuit board or programmable logic
array
that is configured to interpret inputs and data and/or execute instructions to
perform
the functional operations, the control functions, the monitoring operations
and other
functions associated with the operation of the switcher system as described
herein. The
main memory 1402 may comprise a random access memory (RAM) or other types of
dynamic storage device that is configured to store information and/or
instructions for
execution by the processor 1401. The ROM 1404 may comprise a conventional ROM
device or another type of static or non-volatile storage device configured to
store static
information and/or instructions for use by the processor 1401. The storage
device 1406
may comprise a mass storage device for storing or archiving operational data
and other
information.
[00063] The particular implementation details associated with the hardware
and/or
software components comprising the controller 1400 will readily be within the
understanding of those skilled in the art of digital and/or analog hardware
design, logic
and logic relay design, and computer programming in high level programming
languages and/or firmware design.
[00064] The present invention may be embodied in other specific forms without
departing from the spirit or essential characteristics thereof. Certain
adaptations and
modifications of the invention will be obvious to those skilled in the art.
Therefore, the
presently discussed embodiments are considered to be illustrative and not
restrictive,
the scope of the invention being indicated by the appended claims rather than
the
foregoing description, and all changes which come within the meaning and range
of
equivalency of the claims are therefore intended to be embraced therein.
Date recue/Received Date 2020-04-06
