Apparatus for handling heavy components on containers

Abstract

A machine for handling heavy components in a heavy equipment environment. In an example implementation, the machine includes a truck having at least two front wheels and at least one rear wheel. A outrigger portion extends forward from the truck. The front wheels are attached at a forward end of the outrigger portion. A mast extends vertically from a track extending forward from the truck on a base of the outrigger portion. The mast is movably extendable or retractable along the track. A carriage is mounted on the mast and configured to move vertically on the mast. A pair of forks are mounted on the carriage to move vertically when the carriage is controlled to move. A personnel platform is mounted on the carriage independent of the mounting of the forks on the carriage. A remote control panel is configured to override a cab control panel under operator control. The remote control panel includes a plurality of controls for moving the carriage and for extending or retracting the mast.

Claims

1. A method of attaching a generator set to a shipping container comprising: positioning a multi-loader in proximity to the generator set, where the multi-loader includes a cab supported by a base with at least three wheels, an outrigger portion extending from the cab, a mast movably mounted on the outrigger portion, and a carriage movably mounted on the mast, the carriage configured to support a pair of forks and a personnel platform; using a user interface device on a main control panel in the cab to move the mast forward and away from the cab to position the personnel platform against the generator set and the forks under the generator set; lifting the generator set by controlling the carriage to move upward on the mast using a user interface device configured to control movement of the carriage; driving the multi-loader to the shipping container in proximity to a genset position on the shipping container; raising the personnel platform using user interface devices on a remote control panel mounted on the personnel platform for controlling vertical movement of the carriage to a level even with the genset position on the shipping container; positioning the generator set using user interface devices on the remote control panel for moving the carriage laterally and vertically; attaching the generator set to the genset position on the shipping container; lowering the personnel platform and forks using user interface devices on the remote control panel; and entering the cab and driving the multi-loader away from the shipping container.

2. The method of claim 1 further comprising: inserting a key in the main control panel to enable operation of the main control panel; removing the key from the main control panel to disable operation of the main control panel; inserting the key in the remote control panel to enable operation of the remote control panel; and removing the key from the remote control panel to disable operation of the remote control panel.

3. The method of claim 1 wherein the step of driving the multi-loader includes mounting the personnel platform and controlling movement of the multi-loader using user interface devices on the remote control panel.

4. The method of claim 3 wherein the step of driving the multi-loader includes lowering the personnel platform to enable movement of the multi-loader.

5. The method of claim 1 wherein the step of lifting the generator set includes mounting the personnel platform and controlling movement of the carriage using user interface devices on the remote control panel.

6. A method of detaching a generator set from a shipping container comprising: positioning a multi-loader in proximity to the generator set on the shipping container, where the multi-loader includes a cab supported by a base with at least three wheels, an outrigger portion extending from the cab, a mast movably mounted on the outrigger portion, and a carriage movably mounted on the mast, the carriage configured to support a pair of forks and a personnel platform; using first user interface devices on a first control panel to move the mast forward and away from the cab to position the personnel platform against the generator set and the forks under the generator set; detaching the generator set from the shipping container; lowering the generator set by controlling the carriage to move downward on the mast using the first user interface devices configured to control movement of the carriage; driving the multi-loader to a storage location for the generator set; positioning the multi-loader to place the generator set in the storage location using second user interface devices on a second control panel remote from the first control panel for moving the carriage laterally and vertically; lowering the personnel platform and forks using the second user interface devices on the second control panel to place the generator set in the storage location; and driving the multi-loader away from the storage location.

7. The method of claim 6 wherein the step of driving the multi-loader includes lowering the personnel platform to enable movement of the multi-loader.

8. The method of claim 6 wherein the step of lowering the generator set includes mounting the personnel platform and controlling movement of the carriage using user interface devices on the first control panel.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is an isometric side view of a machine for handling generator sets.

(2) FIG. 2A is a front isometric view of the machine with the mast in a retracted position.

(3) FIG. 2B is a side view of the machine with the mast in a retracted position.

(4) FIG. 3A is a front isometric view of the machine with the mast in an extended position.

(5) FIG. 3B is a side view of the machine with the mast in an extended position.

(6) FIG. 4 is a top view of a personnel platform control panel.

(7) FIG. 5 shows a machine approaching a generator set mounted on a container.

(8) FIG. 6 shows an operator in the personnel platform while raised even with the generator set on the container.

(9) FIG. 7 shows the machine loaded with the generator set in a lowered, retracted position.

(10) FIG. 8 shows the machine next to the generator set, operator and container.

DETAILED DESCRIPTION

(11) Disclosed herein is an example machine for handling heavy components for attachment or detachment to or from a container. Example implementations described below are directed to a machine configured to handle a generator set for attachment to or detachment from a refrigeration unit on a shipping container. The description below is provided as an example use and is not intended to be limited to any particular application or for handling any particular components. The generator sets used to power the refrigeration units on shipping containers are typically gas-fueled motors configured to drive an electrical generator. The generator sets used in the industry have evolved into a large unit having a somewhat standard shape and can be quite heavy, particularly when filled with fuel. The generator set units are configured for attachment at an elevated position on an end of a rectangular container.

(12) The machine or mechanism for handling generator sets described below includes a base portion having an operator cab and an outrigger portion, which includes a mast, a carriage, a pair of forks, and a personnel platform. The operator cab provides a seat, steering unit, and cab control panel to allow an operator to drive the machine and to control the mast. The outrigger portion includes a hydraulic extender attached at one end to a frame of the base and at another end to a mast mount, which supports the mast. The hydraulic extender is controlled to extend or retract the mast, which is mounted to move on a track in the outrigger portion of the truck. The outrigger portion is supported at a distal end by two front wheels. The mast extends vertically from the mast mount and supports the carriage that is movable in an upward or downward direction using a drive system, such as for example, a hydraulic drive system. The carriage supports the pair of forks and the personnel platform, where the personnel platform and forks are attached independently of one another to the carriage.

(13) The operator is able to control the outrigger portion using controls in the cab, or using a removable control panel that the operator may carry to the personnel platform when the operator has positioned the machine for attachment or detachment of the generator set. The removable control panel may also be implemented as a remote control panel mounted on the personnel platform. The cab control panel is configured to perform all functions associated with moving the outrigger portion as well as controls for moving or driving the machine. The removable or remote control panel shall include controls for moving the lift, but shall not include controls for moving the truck as a safety feature. As used in this disclosure, the term remote control panel shall be understood to mean a removable or remotely mounted (on the personnel platform, for example) control panel that is secondary to the cab control panel, and is limited to controlling the lift and optionally, turning the power on or off to the machine, but shall not include controls for moving the machine.

(14) The machine may be used to attach or detach a generator set to or from a refrigeration unit on a shipping container by a single worker. In attaching the generator set, the operator drives the machine to a generator set and uses the forks on the machine to lift the generator set. The operator then drives the generator set to an end of the container on which the generator set is to be attached. As noted above, the outrigger portion includes a track on which the mast travels in response to commands to extend or retract. The operator then controls the mast to extend towards the container end. The operator may then enter the personnel platform and use the remote control panel to lift the generator set on the forks to the level of attachment on the container. The operator removes a key from the cab to operate the remote and vice versa, meaning the operation can only be controlled from only one position at a time. The remote control panel includes fine positioning controls for moving the generator set closer to the container or from side-to-side so that the generator set is aligned properly with the points of attachment on the container. The operator may then attach the generator set to the container. The operator may then use the remote control panel to retract the forks from under the now attached generator set, and to lower the personnel platform back to a low level to permit the operator to dismount. The operator may then re-enter the cab of the truck and use the key to transfer control back to the cab to position the forks to a drive position (such as by fully retracting the mast to the retracted position on the truck), to retract the outrigger portion on the front wheels, and to drive the machine back to the next task.

(15) The generator set may be detached by a single worker, the user, driving the machine to the end of the container on which the generator set is mounted. The operator may then mount the personnel platform and use the key or similar lock-out device to transfer control from the cab to the remote control panel so that the operator has exclusive control of the machine movements. The operator can fine tune the position of the personnel platform using the remote control panel so that the forks are under the generator set and the operator can detach the generator set from the container. Further fine tuning of the position using the remote control panel allows the user to ensure the generator set is supported by the forks before complete detachment is achieved. When the generator set is detached, the user controls the mast to retract along its base track and then to lower the generator set on the forks to a safe dismount level. Once lowered, the user dismounts the personnel platform and uses the key or similar lock out device to transfer control back to the cab control panel to drive the machine.

(16) In an example implementation, the machine is rated for a load of 12,000 lbs. at 24 load center, which is proper for handling the heaviest known generator sets based on 50% de-rating per OSHA standards ANSI/ITSD56.1. Standard ANSI/ITSD56.1 is incorporated by reference herein.

(17) FIG. 1 is an isometric front view of a machine 100 for handling a generator set 120. The machine 100 in FIG. 1 is in a lifted and extended position. The machine 100 in FIG. 1 includes a base 102 having an outrigger portion, which supports a mast 106. The mast 106 is mounted on a track in the outrigger portion 104 to permit motion of the mast 106 along the path indicated by the double arrow, M. The mast 106 supports a carriage, which holds a personnel platform 108, and a pair of forks (described with reference to FIGS. 2A-3B below). The personnel platform is configured to support an operator as shown in FIG. 1 in a space that allows the operator to work on the generator set attachment or detachment to a shipping container 130. The operator is able to control the position of the personnel platform and forks with the generator set load using a remote control panel 109.

(18) The base 102 includes a cab 112 having a full cab control panel to allow the operator to control the position of the mast 106 and forks as well as to drive the base 102. The base portion 102 of the truck is supported by two front wheels 110 and a rear wheel and/or a set of rear wheels (not visible in FIG. 1).

(19) FIG. 2A is a front isometric view of the machine 100 with the mast 106 in a retracted position. FIG. 2B is a side view of the machine 100 with the mast 106 in a retracted position. The machine 100 in FIGS. 2A and 2B is not loaded thereby exposing a pair of forks 114 on which the generator set is mounted during attachment. The machine 100 is typically driven with the mast 106 in the retracted position whether the forks 114 are loaded with a generator set or not. The carriage 116 is mounted on the mast 106 and configured to move up or down on the mast 106 in response to control signals triggered by the operator using the remote control panel or the cab control panel. The personnel platform 108 and the forks 114 are mounted on the carriage 116 by independent attachment to the carriage 116. That is, the personnel platform 108 supports the weight of the operator or any other load on the personnel platform 108, but does not support any of the load on the forks 114. The forks 114 support the load on the forks 114, such as a generator set that has been mounted on the forks 114, but does not support any of the load in the personnel platform 108. The personnel platform 108 includes a gate 118 to permit entry and exit to and from the personnel platform 108.

(20) The base 102 supports the cab 112 and includes two front wheels 110 and a single rear wheel 111 (shown in FIG. 2B). The base 102 may include more wheels, for example, two wheels may be attached to the rear portion of the base 102. The number of wheels used may depend on the desired manoeuvrability of the base 102 and the wheelbase desired for supporting the loads to be handled by the base 102.

(21) FIG. 3A is a front isometric view of the machine 100 with the mast 106 in an extended position. FIG. 3B is a side view of the machine 100 with the mast 106 in an extended position. The mast 106 may be mounted on a track 119 at the base of the outrigger portion 104 of the machine 100. The track 119 may be implemented, in one example implementation, as a pair of toothed rails configured to support a corresponding pair of toothed wheels, or gears connected by an axle configured to support the mast 106. The mast 106 may be further connected to a hydraulic drive configured to push or pull the mast 106 along the pair of rails. The pair of rails having wheels mounted thereon is one example of a track for extending and retracting the mast 106. The mast 106 may be moved along the base of the outrigger portion 104 using any other suitable system for moving heavy loads in a linear motion.

(22) It is noted that as the mast 106 is extended or retracted, the mast 106 remains between the front wheels 110 and the rear wheel 111 for most, or all, of the extent of travel of the mast 106. In one example implementation, the mast 106 may remain between the front wheels 110 and the rear wheel 111 for as much as 75% of the extent of travel of the mast 106 along its track. By remaining between the front wheels 110 and the rear wheel 111, the load on the mast 106 may be moved up and down without applying a leverage that converts the front wheels 110 to a fulcrum as is the case with forklifts. The base 102 need not be provided with a counterweight to balance the load on the mast 106 as the load is moved upward. Even when at its fullest extended position, the mast 106 may rely on the full extent of the wheelbase of the base 102 to counterbalance a load at its highest level as shown in FIG. 3B.

(23) As shown in FIGS. 2A, 2B, 3A, and 3B, the carriage 116 is attached to the mast 106 in a manner that permits an operator to move the carriage 116 up or down along the mast 106. The personnel platform 108 and the forks 114 are independently attached to the carriage 116 and move up and down with the carriage 116. The carriage 116 (and personnel platform 108 and forks 114) may be moved with the mast 106 when the mast 106 is extended (out towards the front wheels 110) or retracted (in towards the base 102). The remote control panel (described in more detail with reference to FIG. 4) and the cab control panel include controls, such as for example, lever switches or buttons or dial switches or other suitable switch mechanism configured to extend or retract the mast 106, and with it, the carriage 116, personnel platform 108 and forks 114 when actuated by the operator. The carriage 116 may also be mounted on the mast 106 with a mechanism for moving laterally (a function known as side shifting). A switch (such as for example, a lever switch or button or dial switch or other suitable switch mechanism) may be mounted on the remote control panel and the cab control panel to allow the user to move the carriage 116 to the right side or to the left side.

(24) When controlled to move sideways, right or left, the carriage 116 may be moved using a hydraulic cylinder in the indicated direction along a channel or a track extending across opposite sides of the mast 106. The carriage 116 may include a roller, wheel, or channel member suitably formed to fit within the channel allowing the carriage 116 to move in only a sideways (right or left) direction.

(25) As noted above, the personnel platform 108 is mounted and supported by the carriage 116 and configured to move up and down or side to side when the carriage 116 is controlled to move by the operator. The personnel platform 108 is mounted on the carriage 116 independent of the forks 114. It is noted that the personnel platform 108 in FIGS. 2A and 3A is formed to match a contour of a typical generator set on a front side 115, which is the side of the personnel platform 108 that receives the generator set when the operator is in position to perform tasks on the generator set. The form of the front side 115 is generally curved to substantially match a curve around the generator set allowing an installer in the personnel platform 108 to more easily reach any part of the generator set. As noted above, examples of implementations of the machine 100 may be configured to handle other types of heavy components in other environments and the shape of the opening 115 of the personnel platform 108 is one modification that can be made for other applications.

(26) The forks 114 may be mounted on one or two channels, or tracks, affixed to the carriage 116 in a forward and backward direction. A hydraulic drive may be controlled by one or more switches on the cab control panel or the remote control panel to move the forks 114 in or out, or forward or backward.

(27) FIG. 4 is a top view of a remote control panel 140. The remote control panel 140 in FIG. 4 includes the following control elements:

(28) 1. Take Control Button 149

(29) 2. Start Engine Button 148

(30) 3. Emergency stop 143

(31) 4. Lift up/down 144

(32) 5. Extend/Retract 146

(33) 6. Forks in/out 150

(34) 7. Side shift left/right 152

(35) As noted above, the remote control panel 140 may be affixed to a part of the personnel platform. When the operator has moved to the personnel platform from the cab, the operator may actuate the Take Control Button 149 to disable the control panel in the cab and transfer control to the remote control panel 140. The remote control panel 140 provides the operator with functions for raising the load on the forks, or raising the forks to position the forks at the load. The remote control panel 140 includes functions that would allow the operator to adjust the position of the forks relative to the container without having to be in the cab. Whether the generator set is being attached or detached, the operator is able to perform any task at the generator set from the personnel platform without the assistance of any other workers on ladders or on the ground below the generator set.

(36) It is noted that the remote control panel 140 need not include any controls for driving the truck from the personnel platform. In one example implementation, at a minimum, all drive functions are disabled when the carriage is at an elevated position for safety reasons. In another example implementation, the remote control panel 140 includes user interface devices for driving the multi-loader. In another example implementation, the functions for driving the multi-loader using the remote control panel 140 are enabled only when the personnel platform is in a fully-lowered position.

(37) Example implementations of a machine for handling heavy components, such as a generator set, advantageously allows a single operator to drive the machine with or without a load, and to control the positioning of the forks allowing the operator to perform tasks on the generator set in position for attachment or detachment from the personnel platform, without the need of assistance from any other worker. FIGS. 5-8 illustrate steps for detaching a generator set 120 from a container 130 by a single worker, employee O. FIG. 5 shows an operator O driving the machine 100 and approaching the generator set 120 mounted on the container 130. The operator is approaching the container 130 with the mast 106 in retracted position. The operator may approach the container 130 and stop so that, for example, the front wheels 110 directly underneath the personnel platform 108 in retracted position are just behind the generator set.

(38) FIG. 6 shows the personnel platform 108 raised to a level even with the generator set 120 with the operator in the personnel platform 108. The operator in the personnel platform 108 is at the remote control panel, which is not visible in FIG. 6, and is able to first actuate the control on the remote control panel to take control of the lift. In taking control of the lift, the cab control panel may be disabled completely. The operator may then actuate a control on the remote control panel to raise the personnel platform and generator set.

(39) The position of the operator and the remote control panel provides the operator with a vantage point from which the operator is able to view the position of the personnel platform 108, and therefore, the forks 114 relative to the generator set 120. The operator is also able to use the controls on the remote control panel to extend and shift the forks 114 toward the generator set 120 to ensure the center of gravity of the generator set 120 is above and between the forks 114. When the operator has properly positioned the forks 114 to support the weight of the generator set 120 when it is detached, the operator may leave the remote control panel to perform the tasks of detaching the generator set 120 from the container 130. Typically, the generator sets 120 are attached using multiple bolts, all of which will be accessible to the operator from the personnel platform 120.

(40) FIG. 7 shows the machine 100 detached from the container 130 and the generator set 120 loaded on the forks of the machine with the mast 106 in a retracted position. The operator is able to control the personnel platform 108 and forks 114 using the remote control panel. First, the operator lowers the forks 114 and personnel platform 108. Then, the operator retracts the mast 106 using the controls on the remote control panel. The operator may then dismount from the personnel platform 108.

(41) The operator may then re-enter the cab 112 of the base 102 to take control from the remote control panel and reset the control back to the cab control panel. From the cab, the operator may operate the machine 100 in a manner similar to a forklift to set the generator set 120 down, preferably in a place of storage. FIG. 8 shows the machine 100, the detached generator set 120, the operator and the container 130 after performing an operation by a single worker.

(42) The process of attaching the generator set 120 would be a reverse of the process described with reference to FIGS. 5-8 for detaching the generator set 120.

(43) The use of the terms a and an and the and similar references in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., such as) provided herein, is intended merely to better illuminate the disclosure and does not pose a limitation on the scope of the disclosure unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the disclosure. Numerous modifications to the present disclosure will be apparent to those skilled in the art in view of the foregoing description. It should be understood that the illustrated embodiments are exemplary only, and should not be taken as limiting the scope of the disclosure.