Box loader

Abstract

A loader includes a sling for supporting a one or more items. The sling is secured on opposite sides of a loading chamber. The loader also includes a lowering mechanism. The lowering mechanism can lower the sling. The loader includes a release mechanism that secures one or both sides of the sling. After the sling is lowered by the lowering mechanism an adequate distance to place the one or more items close to the receptacle, the release mechanism releases one or both sides of the sling, which places the one or more items in or on a receptacle. The loader includes a take-up mechanism attached to one side of the sling. The take-up mechanism takes up the sling when the opposite side of the sling is released by the release mechanism. The loader is capable of inserting close fitting items into receptacles, such as a stack of trays of produce.

1 . A. loader, comprising: (a) a sling; (b) a lowering mechanism in contact with the sling that can lower the sling; (c) a release mechanism that secures at least one side of the sling; and (d) a take-up mechanism attached to the sling on the side opposite from the release mechanism. 
   
   
       2 . The loader of  claim 1 , wherein the sling is formed from a strap, one end of the strap is clamped, the strap passes over a first and a second set of stationary rollers, each set having a first and a second roller, and the lowering mechanism creates a loop between each first and second roller of each set of stationary rollers. 
   
   
       3 . The loader of  claim 1 , wherein the sling is formed from a strap that spans a loading chamber, the strap is secured on both sides of the loading chamber, the strap passes over a first and a second set of stationary rollers, each set having a first and a second roller, and a moving roller engages the strap between the first and the second stationary roller of each set. 
   
   
       4 . The loader of  claim 1 , wherein the lowering mechanism comprises a frame having vertical corner beams, wherein a moving roller is connected at the lower end of each vertical corner beam. 
   
   
       5 . The loader of  claim 1 , wherein the take-up mechanism comprises a take-up reel connected to a driver, wherein the sling is attached to the take-up reel. 
   
   
       6 . The loader of  claim 1 , wherein the loader further comprises an infeed conveyor comprising a series of bands which can be actuated to rise above the level of slats, and the slats can be translated linearly to deliver an item to the sling. 
   
   
       7 . The loader of  claim 1 , wherein the loader further comprises a box conveyor comprising a set of front and rear box stoppers which act in unison to remove a loaded box and locate an empty box at a loading location. 
   
   
       8 . The loader of  claim 1 , further comprising a first and a second flap, wherein the flaps are actuatable from the horizontal position to a vertical position to place an item on the sling. 
   
   
       9 . The loader of  claim 1 , wherein the sling spans across a loading chamber, and the sling is secured on opposite sides of the loading chamber. 
   
   
       10 . The loader of  claim 1 , further comprising a set of flippers that are actuatable from a horizontal position to a vertical position. 
   
   
       11 . The loader of  claim 1 , further comprising a home setting mechanism that locates one end of the sling at a reliable location before securing the end with the release mechanism. 
   
   
       12 . The loader of  claim 1 , further comprising a computer system having software modules for: (a) locating the end of a strap at a predetermined location; (b) grasping the end of the strap with the release mechanism; (c) pulling the strap to pay out the strap from the take-up mechanism, and carry the strap across a first and a second set of stationary rollers, wherein each set of stationary rollers includes a first and a second roller; (d) lowering the lowering mechanism while paying out the strap from the take-up mechanism to pass a moving roller between the first and second roller of each set of stationary rollers to create a first and a second loop in the strap; and (e) securing both sides of the strap ahead and behind of the first and the second set of stationary rollers to form the sling. 
   
   
       13 . The loader of  claim 12 , wherein the method further comprises, carrying an item to a loading chamber, raising a set of flippers, and placing the item on a first and a second flap. 
   
   
       14 . The loader of  claim 13 , wherein the method further comprises, moving the first and the second flap to a vertical position to place the item on the sling. 
   
   
       15 . The loader of  claim 14 , wherein the method further comprises, raising the lowering mechanism to shorten the first and the second loops and lowering the sling. 
   
   
       16 . The loader of  claim 15 , wherein the method further comprises, placing an item on top of a previous item, followed by raising the lowering mechanism to lower the sling. 
   
   
       17 . The loader of  claim 16 , wherein the method further comprises, releasing one side of the sling, taking up the sling from the opposite side to place the items into or onto a receptacle. 
   
   
       18 . The loader of  claim 1 , wherein the loader comprises a second sling that is parallel with the first sling. 
   
   
       19 . The loader of  claim 1 , wherein the sling comprises at least one loop in the sling that can be shortened to lower the sling. 
   
   
       20 . A method for loading an item, comprising: (a) forming a sling; (b) placing one or more items on the sling; (c) lowering the sling with the one or more items; (d) releasing one side of the sling; and (e) taking up the sling from the side opposite to the side that is released thereby loading the one or more items. 
   
   
       21 . The method of  claim 20 , further comprising locating an end of the sling at a predetermined location to enable securing the end of the sling with a release mechanism to pay out a length of sling from a take-up reel. 
   
   
       22 . The method of  claim 20 , further comprising securing one end of the sling, paying out a length of sling from a take-up reel, passing the sling over a first and a second set of stationary rollers, each set having a first and a second stationary roller, forming loops in the sling between the first and the second stationary roller of each set by lowering a moving roller between each first and second roller of each set, and securing the sling at or adjacent to the take-up reel. 
   
   
       23 . The method of  claim 20 , further comprising delivering an item to a loading chamber via a carrying platform, raising a set of flippers to the vertical position and retracting the platform while the set of flippers prevents the item from being retracted with the platform to leave the item in or on the loading chamber. 
   
   
       24 . The method of  claim 20 , further comprising placing an item on a first and a second flap that are disposed horizontally and above the sling, and then placing the item on the sling by articulating the flaps to a downward, vertical position. 
   
   
       25 . The method of  claim 20 , further comprising lowering the sling before placing an item on a stack of items carried by the sling. 
   
   
       26 . The method of  claim 20 , further comprising lowering the sling by reducing the size of a first loop in a first side of the sling and a second loop in a second side of the sling, so that the additional sling length results in lowering of the sling between the loops. 
   
   
       27 . The method of  claim 20 , wherein a first side of the sling is secured on a first side of a loading chamber and a second side of the sling is secured on a second side of the loading chamber, and releasing both sides of the sling, and taking up the sling to place the one or more items into or onto a receptacle positioned at or adjacent to the loading chamber. 
   
   
       28 . The method of  claim 20 , further comprising loading the one or more items into or onto a receptacle, and replacing the loaded receptacle with an empty receptacle. 
   
   
       29 . The method of  claim 20 , wherein the sling is passed over a first and a second set of stationary rollers, wherein each set of stationary rollers includes a first and a second stationary roller, and a moving roller is engaged between the first and the second roller of each set of stationary rollers, and the sling is lowered by raising the moving rollers. 
   
   
       30 . The method of  claim 20 , further comprising forming a second sling that is parallel to the first sling. 
   
   
       31 . A loader, comprising: (a) a take-up mechanism including a reel with a strap wound on the reel; (b) a release mechanism that can secure one end of the strap; and (c) a computer having a computer readable medium with executable instructions for: (c)(i) locating the end of the strap before being secured by the release mechanism; (c)(ii) unwinding the strap across a loading chamber; and (c)(iii) lowering a lowering mechanism to form a first loop on one side of the strap and a second loop on a second side of the strap. 
   
   
       32 . A loader, comprising: (a) a sling that spans a loading chamber; (b) a release mechanism that secures one side of the sling; and (c) a computer having a computer readable medium with executable instructions for: (c)(i) releasing the sling from the release mechanism; (c)(ii) withdrawing the sling from across the loading chamber; and (c)(iii) returning the sling to a take-up mechanism. 
   
   
       33 . A loader, comprising: (a) a sling that spans a loading chamber; (b) a lowering mechanism that is engaged with the sling; and (c) a computer having a computer readable medium with executable instructions for: (c)(i) delivering one or more items to the sling; (c)(ii) lowering the sling via the lowering mechanism; (c)(iii) determining when the sling is full; and (c)(iv) withdrawing the sling from across the one or more items to place the items into or onto a receptacle at or adjacent to the loading chamber. 
   
   
       34 . A loader, comprising: (a) a loading chamber; (b) a first flap and a second flap at the loading chamber to receive an item; (c) a carrying platform that delivers one or more items to the first flap and the second flap; and (d) a set of flippers that is at or adjacent to the side of the loading chamber; (e) an infeed conveyor that delivers an item to the platform; and (f) a computer having a computer readable medium with executable instructions for: (c)(i) delivering an item to the platform; (c)(ii) determining when the loading chamber is clear to deliver an item to the loading chamber; (c)(iii) delivering an item to the first flap and the second flap at the loading chamber; (c)(iv) raising the set of flippers and retracting the platform so that the set of flippers prevents the item from being carried out of the loading chamber. 
   
   
       35 . A loader, comprising: (a) a sling; (b) means for lowering the sling; (c) a release mechanism that secures at least one side of the sling; and (d) a take-up mechanism attached to the sling on the side opposite from the release mechanism. 
   
   
       36 . The loader of  claim 35 , wherein the means for lowering the sling include a frame comprising vertical corner beams having a moving roller at the bottom of the vertical corner beams, and a lead screw that engages the frame. 
   
   
       37 . The loader of  claim 35 , wherein the means for lowering the sling include a means that pays out length of sling to lower the part of the sling being weighted down by one or more items being carried by the sling. 
   
   
       38 . The loader of  claim 35 , wherein the means for lowering the sling comprises a first loop formed on a first side of the sling and a second loop formed on a second side of the sling. 
   
   
       39 . The loader of  claim 35 , wherein the means for lowering the sling comprises a first loop formed on a first side of the sling between a first and a second stationary roller and a second loop formed on a second side of the sling between a first and a second stationary roller, and a moving roller engaged with the sling at the bottom of the first loop and the second loop.