BUNDLE BUILDER AND LIFTER

Abstract

A bundle builder and lifter assembly has a pair of parallel cross beams, and an actuator assembly for actuating the builder and lifter assembly. A pair of lift arms are moved along the parallel cross beams and each has a vertical portion and a horizontal portion forming a finger. The lift arms are also raised and lowered. A conveyor roller assembly is positioned above the lift arms and cross beams, where stacks of material are moved on the rollers of the conveyor assembly. The stacks of material are placed in a stack by the lift arms forming a bundle, which is then removed from the conveyor roller assembly.

Claims

1. A bundle builder and lifter assembly, comprising; a pair of parallel cross beams which are raised and lowered; an actuator assembly for actuating said builder and lifter assembly and raising and lowering said pair of parallel cross beams; a pair of lift arms which are moved along a longitudinal axis of the parallel cross beams via said actuator assembly; said lift arms each comprises a vertical portion and a horizontal portion forming a finger or L-shape member; a conveyor assembly comprising rollers and positioned above said lift arms and cross beams; wherein an associated first stack of material is placed on and moved along said rollers of said conveyor assembly and; said lift arms and cross beams are actuated and move to raise said first stack off of conveyor roller assembly by aligning said fingers with said first stack to support and lift said first stack.

2. The bundle builder and lifter assembly of claim 1, wherein said actuator assembly comprises an AC motor and screw jack for actuation of said bundle builder and lifter assembly.

3. The bundle builder and lifter assembly of claim 2, further comprising a plurality of pairs of lift arms extending along a longitudinal axis of support beams connected to and extending between said cross beams.

4. The bundle builder and lift assembly, of claim 3, wherein said plurality of pairs of lift arms are lowered below said conveyor assembly and underneath said first stack of material.

5. The bundle builder and lifter assembly of claim 4, wherein said plurality of pairs of lift arms are actuated and raised by said actuator assembly to lift said first stack of material off of said conveyor assembly.

6. The bundle builder and lifter assembly of claim 5, wherein an associated second stack of material is rolled along said conveyor assembly directly below said first stack of material.

7. The bundle builder and lifter assembly of claim 6, wherein said second stack of material comprises at least one spacer located on an upper surface of said second stack of material.

8. The bundle builder and lifter assembly of claim 7, wherein said plurality of pairs of lift arms lower said first stack onto said second stack and then move out of engagement with said first stack.

9. The bundle builder and lifter assembly of claim 8, wherein said plurality of lift arms are positioned underneath said second stack and raise said first stack and said second stack off of said conveyor roller assembly.

10. The bundle builder and lifter assembly of claim 9, wherein an associated third stack of material is rolled along said conveyor roller assembly directly below said first stack and said second stack.

11. The bundle builder and lifter assembly of claim 10, wherein said third stack of material comprises at least one spacer positioned on an upper surface of said third stack of material.

12. The bundle builder and lifter assembly of claim 11, wherein said plurality pairs of lift arms lower said first stack and said second stack onto said third stack and then are moved out of contact with said second stack.

13. The bundle builder and lifter assembly of claim 12, wherein said first stack, said second stack and said third stack form a bundle.

14. The bundle builder and lifter assembly of claim 13, wherein a lift mechanism comprises a pair of lift members which are moved towards each other to engage said bundle, and lift said bundle off of said conveyor roller assembly.

15. A bundle builder and lifter assembly comprising: a conveyor assembly comprising a plurality of rollers; a pair of horizontal support members comprising a plurality of lift arms; a pair of cross beams, wherein said horizontal support members extend between said cross beams; an actuator for moving and raising and lowering said lift arms and cross beams and moving said horizontal support members and lift arms along a longitudinal axis of said cross beams; said lift arms comprises fingers which engage and raise and lower associated stacks of material which are positioned on said rollers of said conveyor assembly; said stacks of material are stacked together using said lift arms to form a bundle; and wherein a lift mechanism raises said bundle off of said conveyor assembly.

16. A method forming and lifting a bundle assembly, comprising: providing a pair of cross beams; providing a pair of support beams extending between said cross beams; providing a plurality of lift arms positioned along a length of each of said support beams; providing a actuator for raising and lowering said cross beams and moving said support beams and said lift arms; providing a conveyor assembly having rollers; moving a first stack of material along said rollers; moving said lift arms below said first stack and then raising said first stack off of said conveyor via said lift arms; moving a second stack of material on said rollers to a position below said first stack; lowering said first stack onto said second stack via said lift arms; and, moving said lift arms out of engagement with said first stack; thereby forming a bundle and using a lift mechanism to lift and remove said bundle off of said conveyor.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] FIG. 1 is a top plan view of the bundle builder arrangement in accordance with a preferred embodiment of the disclosure.

[0020] FIG. 2 is a side elevational view of the bundle builder of FIG. 1. illustrating the bundle builder arrangement in the direction of travel.

[0021] FIG. 3 is another side elevational view of the bundle builder in the direction of travel.

[0022] FIG. 4 is a perspective view of the bundle lift arm arrangement.

[0023] FIG. 5 is a top plan view of the bundle lift arm arrangement.

[0024] FIG. 6A is a side elevational view of the drive side jack and motor assembly.

[0025] FIG. 6B is a side elevational view of the drive side jack and motor assembly.

[0026] FIG. 7A is a side elevational view of the operation side lift arm.

[0027] FIG. 7B is a side elevational view of the drive side lift arm.

[0028] FIG. 8 is a perspective view showing the lift arm assemblies positioned on opposite sides of the bundle builder assembly.

[0029] FIG. 9 is a perspective view of the conveyor roller assembly and the bundle builder assembly.

[0030] FIG. 10 is a front elevational view of the conveyor roller assembly, with stack B on the rollers.

[0031] FIG. 11 is a side elevational view of the conveyor rollers with the lift arm holding the stack.

[0032] FIG. 12 is a front elevational view of the lift arms holding the stack.

[0033] FIG. 13 is a front perspective view of a second stack rolled underneath the first stack on the conveyor rollers.

[0034] FIG. 14 is a front perspective view of the lift arms moving away from the first stack.

[0035] FIG. 15 is a front perspective view of the arms being lowered below the second stack.

[0036] FIG. 16 is a front perspective view of the lift arms raised the second and first stacks.

[0037] FIG. 17 is a front perspective view of a third stack being rolled with the raised front and second stacks.

[0038] FIG. 18 is a front perspective view showing the third stack position underneath the first and second stacks.

[0039] FIG. 19 is a front perspective view showing the lift arms moving away from the stacks.

[0040] FIG. 20 is a front elevational view of the stacks and a view of lift arms.

[0041] FIG. 21 is a front elevational view of the lift arms engaging the stacks.

[0042] FIG. 22 is a side perspective view showing the lift away raising the stacks from the conveyor.

[0043] FIG. 23 is a front perspective view of the stacks and lift arms moved away from the conveyor rollers.

DETAILED DESCRIPTION OF THE DISCLOSURE

[0044] With reference now to FIGS. 1-23, an automated bundle building/bundle lifting system in accordance with a preferred embodiment of the disclosure is shown and described. Referring to FIG. 1, a bundle builder/lifter general arrangement A is shown.

[0045] FIGS. 2 and 3 are side elevational views of the arrangement A looking in the direction of travel.

[0046] FIG. 4 illustrates a perspective view of the bundle lift arm arrangement showing longitudinal and parallel cross beams 10, 12, operator side and drive side beams 14, 16, (which are perpendicularly positioned relative to cross beams 10,12) and an operator side lift arm assembly 18 with multiple lift fingers 20, and a drive side lift arm assembly 22 with multiple lift fingers 24. Lift arm assembly 18 is mounted to a movable support cross beam 19, while lift arm assembly 22 is mounted to movable support cross beam 21. Cross beams 19 and 21 are mounted perpendicular to cross beams 10,12 and move along the longitudinal axes of beams 10,12. In turn, lift arms 18, 22 also move along a longitudinal axes of support beams 10,12. The drive side beam 16 includes an actuator assembly 26. (FIG. 5). The actuator assembly 26 preferably includes AC motors and screw jacks to actuate the lift arm assemblies 18,22 and raises and lowers cross beams 10,12 (and the lift arms 18,22) and moves support beams 19,21 along a longitudinal axis of beams 10,12 and also moves the lift arms 18,22 along the length of beams 10, 12. Alternately, hydraulic cylinders, rack and pinions or other linear actuators can be used.

[0047] FIGS. 6A and 6B illustrate detailed side elevational views of the rear cross beam assembly 12 and the front cross beam assembly 10.

[0048] FIGS. 7A and 7B illustrate additional views of the stacker and lift arm assemblies 18, 22 and the mechanism to raise and lower and move the lift arms.

[0049] FIG. 8 is a perspective view illustrating the lift arm assemblies 18, 22 in a raised and outwardly positioned arrangement. Lift arms 18,22 have horizontally extending lift fingers 20,24 formed at outer edges of the arms.

[0050] FIGS. 9 and 10 are perspective views of a conveyor system 30 using a series of parallel rollers 32 which form a track for a pack B to travel on.

[0051] Referring now to FIGS. 10-23, the process of building bundles and lifting them from the stacker arrangement will be discussed.

[0052] Refer to FIG. 10, a stack or pack B of metal sheets, pieces, or other material is placed on the rollers 32 of conveyer 30 of the stacker assembly A. The pack B is rolled along the conveyor and lined up with the opposing lift arms 18, 22 (FIG. 11) which are initially below the conveyor, and arms 18,22 (and beams 19,21) are then moved underneath the pack B (along beams 10,12) and then are vertically raised via actuator assembly 26 (and via beams 10,12 which are raised) and positioned underneath stack B on the conveyer. Each lift arm 18,22 has a substantial L-shape including a vertical member 33,35 perpendicular to horizontal members or fingers 20,24 to create the vertical spacing for the dunnage or spacers and another stack of material and the horizontal members 20,24 hold each end of stack B while in the raised position.

[0053] Referring to FIGS. 11 and 12, the stack B is raised up by lift arms 18, 22 and supported on horizontal fingers 20, 24. Referring to FIG. 13, once the pack B is raised, another pack C, with spacers 34 (such as a wooden or plastic pieces or dunnage) positioned on top of the stack C, is rolled into position along the conveyor rollers 32 until aligned with and directly below the first stack B. Alternately, the spacers 34 may be added onto pack C after pack C is placed on the conveyor. The lift arms 18, 22 then lower pack B onto pack C (FIG. 14). Lift arms 18,22 are lowered along with cross beams 10,12. Then the lifting arms 18, 22 are moved away from packs B and C (by traveling with support beams 19,21 along the longitudinal axes of beams 10,12) and then lowered below the conveyor by lowering beams 10,12 (see FIGS. 14 and 15).

[0054] Then, referring to FIG. 16, the lifting arms 18, 22 are moved inwardly, (with support beams 19,21) then raised directly underneath stack C (with beams 10,12) to raise stack C (supported on horizontal fingers 20,24) so another stack D, with spacers dunnage 37 attached to a top surface of stack D, can be rolled into position directly under stack C (see FIGS. 17 and 18).

[0055] The arms 18, 22 are again lowered to place stack C directly onto stack D (FIG. 19). Then the arms 18,22 are again moved outwardly away from stack D on opposite sides of stack D then below conveyor rollers 32 (FIGS. 19 and 20). This process is repeated until a desired bundle E is created from stacks B, C and D (see FIG. 21).

[0056] The preferred embodiment illustrates three stacks or packs forming a bundle. However, a bundle may be formed by two stacks, four stacks or more, as desired.

[0057] Referring now to FIG. 21, the bundle E (including stacks B, C and D) is lifted off of the conveyer via lift arms 40, 42 connected to lift mechanism 44 of which engage the bundle E on opposite sides. Arms 40,42 are moved laterally outward then inward towards each other until in contact with bundle E. Refer to FIGS. 21-23, bundle E is then lifted off of the conveyor 30 via lift mechanism 44 and moved to a desired location and lowered away from the conveyor.

[0058] Each pack or stack has a predetermined count or number of pieces or sheets, and spacers, known as dunnage, are inserted to separate the counted pack from subsequent packs that will continue to be dropped on the pack.

[0059] Separating stacks of strips or pieces into counted piece packs has been previously accomplished by stopping the line and manually inserting the dunnage, or else the stack can continue to build higher than the required piece count. This large stack can be subsequently separated into counted packs after the stack is run out of the stacker area. Both of these approaches reduce productivity and require manual labor. The present disclosure automates the process.

[0060] The exemplary embodiment has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the exemplary embodiment be construed as including all such modifications and alterations insofar as they come within the scope of the detailed description and the appended claims or the equivalent thereof.