Automatic bundle loading apparatus and method

Abstract

In an automatic loading system and method wheeled carts receive five or six layers of newspaper bundles of four to six bundles per layer. A waist-high conveyor and an inclined ramp conveyor move bundles to a roller platform of independently operated roller sections selectively halted upon receipt of a bundle. When the desired number of bundles have been delivered to the roller platform, a pusher laterally moves the bundles to a split roller platform. A second group of bundles are delivered to the roller platform and the split roller platform. The sections of the split roller platform are then abruptly pulled apart causing the bundles to drop upon a fork-like platform extending into one side of a cart receiving the bundles. The pusher is retracted to the start position and the fork-like platform is lowered to receive the next layer of bundles in a like manner. Once the cart is filled with the desired number of layers, the fork-like platform is withdrawn from the cart, the cart is advanced to a take-off location and the next cart is indexed to the receiving location, being guided thereto along guide rails. Each cart comprises a platform rolling upon casters and having an open top defined by four sides which form a cage-like structure. One side has lockable double doors to facilitate bundle removal. Cart sizes are desired to make efficient use of the truck cargo space receiving the carts.

What is claimed is: 
     
       1. Apparatus for automatically loading a cart comprised of a platform surrounded by sidewalls and having an open top, at least one of said sidewalls having a plurality of vertically aligned elongated clearance slots; said apparatus comprising:   a loading station for receiving and positioning said cart;   means for receiving bundles to be loaded into said cart;   conveyor means adjacent said receiving means for conveying the bundles received from said receiving means to a location a .[.predetermiend.]. .Iadd.predetermined .Iaddend.height above an open end of said cart at said loading station;   a platform assembly for receiving bundles from said conveyor means;   said platform assembly being comprised of a plurality of sections;   means for selectively advancing bundles along said sections including means to halt the advancing of bundles on each section responsive to detection of a bundle on said section;   pusher means responsive to the presence of bundles upon .[.predetermiend.]. .Iadd.predetermined .Iaddend.ones of said sections for pushing said bundles in a transverse direction onto a split platform means;   said split platform means comprising first and second platform sections movable between a closed position wherein adjacent edges of said platform sections are in close proximity and an open position wherein said sections are moved apart to define a gap region between said split platform sections;   said gap region being positioned immediately above the open end of said cart; and   means responsive to delivery of bundles by said pusher means upon said split platform assembly for moving said split platform sections apart whereupon the bundles resting thereon are dropped through said gap region toward said cart.   
     
     
       2. The apparatus of claim 1 wherein said split platform means has a supporting surface area large enough to receive a plurality of groups of bundles from said platform assembly wherein each group of bundles comprises a predetermined number of bundles collected upon said platform assembly; said pusher means pushing a first group of said bundles to a first position on said split platform furthest removed from said platform assembly; and   said pusher means moving a next group of bundles delivered to said platform assembly to a location upon the surface of said split platform means located between said platform assembly and the first group of bundles delivered to said split platform means.   
     
     
       3. The apparatus of claim 2 further comprising: means for operating said split platform means comprising a pair of air cylinders each having a piston movable therein responsive to pressurized fluid applied to said cylinder;   each piston means including rod means with a first end extending into said cylinder for coupling with said piston and a second end pivotally coupled to an associated one of said split platform sections for reciprocating said split platform sections.   
     
     
       4. The apparatus of claim 1 wherein the number of sections provided is greater than a number of bundles pushed onto said split platform means by said pusher means. 
     
     
       5. The apparatus of claim 4 wherein the number of sections is twice the number of bundles pushed onto said split platform means from said platform assembly by said pusher means. 
     
     
       6. The apparatus of claim 1 further comprising: movably mounted platform means having a plurality of spaced substantially parallel tines cooperatively forming a fork-like platform;   means for reciprocating said fork-like platform in a substantially horizontal plane from a first position wherein said fork-like platform is inserted into the sidewall of a cart provided with said vertically oriented insertion slots, and a second position wherein said fork-like platform is totally withdrawn from said cart;   means for reciprocating said fork-like platform in a vertical direction between an upper and a lower position; and   means for moving said fork-like platform in a downward direction after the bundles delivered by the split platform means are dropped upon said fork-like platform responsive to opening of said split platform sections.   
     
     
       7. The apparatus of claim 6 further comprising: means for moving the cart from the loading station and moving a cart adjacent to the loading station into the loading station responsive to removal of said fork-like platform from the cart in the loading station.   
     
     
       8. The apparatus of claim 6 further comprising: means for reciprocating said fork-like platform in a vertical direction including bidirectional, two-speed motor means; and   means responsive to an output of said motor means for moving said fork-like platform.   
     
     
       9. The apparatus of claim 8 further comprising control means for said motor means for moving said motor means at a first, higher speed and for operating said motor means at a second lower speed when said fork-like platform has travelled a predetermined distance from a desired location. 
     
     
       10. The apparatus of claim 8 wherein said motor means is a qualified brake motor means including brake means which is engaged when power is removed from said motor means. 
     
     
       11. The apparatus of claim 8 wherein said means for horizontally reciprocating said fork-like platform comprises: a rodless cylinder means having an output member coupled between said platform means and piston mounted within said cylinder;   said cylinder having an elongated axially aligned slot said coupling means moving along said slot;   said slot being sealed to prevent an escape of pressurized fluid introduced into said cylinder; and   said cylinder being provided with control ports for controlling a direction of movement of said piston according to the pressurized fluid selectively introduced into said ports.   
     
     
       12. The apparatus of claim 6 wherein said means for reciprocating the fork-like platform in a substantially horizontal plane comprises: motor means;   means responsive to the operation of said motor means for rotating a drive gear;   a freely rotatable driven gear;   a pulley entrained about said drive and driven gears; and   means for coupling a first run of said pulley to said movably mounted platform means.   
     
     
       13. The apparatus of claim 6 further comprising: means for reciprocating said fork-like platform in a horizontal direction including bidirectional, variable speed motor means; and   means responsive to an output of said motor means for moving said fork-like platform.   
     
     
       14. The apparatus of claim 13 further comprising "fail-safe" brake means for selectively braking said variable speed motor means. 
     
     
       15. The apparatus of claim 1 wherein said pusher means comprises: a pusher member;   elongated guide members;   a housing slidable along said elongated guide members;   means extending from said housing for mounting said pusher member;   motor means; and   means coupled to motor means for moving said pusher means from a start position adjacent one side of said roller platform assembly toward said split platform means.   
     
     
       16. The apparatus of claim 15 wherein said means for coupling drive from said motor means and said pusher means further comprises: means responsive to the operation of said motor means for rotating a drive gear;   a freely rotatable driven gear;   a pulley entrained about said drive and driven gears; and   means for coupling a first run of said pulley to said housing.   
     
     
       17. The apparatus of claim 16 wherein said motor means is a bidirectional motor. 
     
     
       18. The apparatus of claim 1 where said carts are comprised of at least one releasably lockable door hingedly coupled to said cart along one side thereof and swingable between an open and a closed position; and locking means for selectively locking said door in said closed position.   
     
     
       19. The apparatus of claim 18 wherein said door comprises the sidewall provided with said elongated .[.inserting.]. .Iadd.clearance .Iaddend.slots. 
     
     
       20. The apparatus of claim 19 wherein said elongated insertion slots are defined by a rectangular-shaped door frame having a plurality of rigid elongated spaced parallel members secured to an upper and a lower side of said door frame wherein regions between adjacent members and between vertical sides of said door frame and said members comprise said insertion slots. 
     
     
       21. The apparatus of claim 1 wherein at least one sidewall of said carts comprises: first and second swingably mounted doors movable between a closed position and an open position; and   means for selectively locking said doors in the closed position.   
     
     
       22. The apparatus of claim 1 wherein each of said carts is provided with identification means; reading means for reading said identification means on said cart means and means for associating the identification means with contents of the cart and the destination for said contents; and   remote reading means coupled to said central reading means for obtaining information from said central reading means for identifying the cart for a particular destination and including reading means for reading said carts to determine an identity of the cart and data associated with said destination.   
     
     
       23. The apparatus of claim 1 further comprising: guide means for guiding said cart toward a loading position;   means for automatically advancing the carts in said guide means toward said loading position responsive to completion of loading of a cart in the loading position.   
     
     
       24. The apparatus of claim 23 wherein said cart advancing means comprises: a drive means;   a drive chain entrained about a first gear coupled to said drive means and a second free-wheeling gear;   pusher members coupled to said chain at spaced intervals therealong for moving a said cart engaged by said pusher means.   
     
     
       25. The apparatus of claim 24 wherein said pusher means comprises: means for enabling each pusher means to swing downwardly when moved by a cart in a cart advancing direction to provide clearance for pushing the cart onto said guide means and bias means for automatically moving said pusher means to an upright position when said pusher means clears the cart; and   means preventing each pusher means from rotating in a second direction when in the upright position, thus assuring each pusher means pushes a cart in a forward indexrag direction when the indexing drive motor means is energized.   
     
     
       26. The apparatus of claim 1 wherein said bundles are packages. 
     
     
       27. The apparatus of claim 1 wherein said bundles are each comprised of newspapers wrapped to form a bundle. 
     
     
       28. The apparatus of claim 1 wherein the conveyor means lifts the bundles toward a location above the cart. 
     
     
       29. The apparatus of claim 1 wherein the conveyor means lowers the bundles toward a location above the cart. 
     
     
       30. The apparatus of claim 1 wherein said platform assembly is a roller platform assembly and said sections comprise roller sections. 
     
     
       31. The apparatus of claim 30 wherein said means for selectively advancing bundles along said sections further comprises means for selectively rotating the rollers of said roller sections. 
     
     
       32. Carts for use in a system for automatically loading said carts including a platform arranged above a loading position for receiving a cart therebeneath; said platform having a delivery opening whereby a cart in the loading position has an upper end thereof aligned with said openings;   split platform means comprising first and second platform sections movable between a first position closing said opening for receiving the bundles thereon and a second position for unsealing said opening;   stop means on opposite parallel sides of said opening for limiting movement of objects on said platform sections as they are moved to said second position whereby objects on said platform sections are caused to fall downwardly through said openings;   means for delivering and arranging bundles upon said platform sections when in said first position;   said cart being comprised of a platform;   caster assemblies mounted upon the underside of said platform for rollingly moving said platform upon a supporting surface;   a plurality of said walls extending upwardly from said platform for enclosing said platform;   said cart having an open upper end defined by the upper ends of said sidewalls;   at least one of said sidewalls being provided with a plurality of elongated spaced vertically aligned insertion slots adapted to receive a fork-like platform having a plurality of spaced parallel tines and being movable between a first position wherein said tines are inserted into respective ones of said insertion slots and a second position wherein said tines are withdrawn from said cart; and   means for moving said platform downwardly through a predetermined distance responsive to bundles being dropped upon said fork-like platform through said delivery opening.   
     
     
       33. The apparatus of claim 32 wherein at least one of the sidewalls of said cart comprises a hingedly mounted door to facilitate unloading of bundles therefrom. 
     
     
       34. The apparatus of claim 32 wherein at least one of the sidewalls of said cart comprises a pair of hingedly mounted doors to facilitate unloading of bundles therefrom. 
     
     
       35. The apparatus of claim 34 further comprising releasable locking means for selectively retaining the hingedly mounted doors in a locked position. 
     
     
       36. The apparatus of claim 34 wherein said insertion slots are provided in said doors. 
     
     
       37. The apparatus of claim 32 further comprising means for hingedly mounting said platform and at least two opposing sidewalls thereof to facilitate collapsing of said cart. 
     
     
       38. The apparatus of claim 32 further comprising horizontal reinforcing means for reinforcing all of said sidewalls except the sidewall having said insertion slots to enhance structural strength of said cart. 
     
     
       39. Apparatus for automatically loading a cart comprised of a platform surrounded by sidewalls and having an open top, at least one of said sidewalls having a plurality of vertically aligned elongated clearance slots; said apparatus comprising:   a loading station for receiving and positioning said cart;   means for receiving bundles to be loaded into said cart;   conveyor means adjacent said receiving means for conveying the bundles received from said receiving means to a location a .[.predetermiend.]. .Iadd.predetermined .Iaddend.height above an open end of said cart at said loading station;   a platform assembly for receiving bundles from said conveyor means;   said platform assembly being comprised of a plurality of sections;   means for selectively advancing bundles along said sections including means to halt advancing of bundles on each section responsive to detection of a bundle on said section;   pusher means responsive to a presence of bundles upon predetermined ones of said sections for pushing said bundles in a transverse direction onto a split platform means;   said split platform means comprising first and second platform sections movable between a closed position wherein adjacent edges of said platform sections are in close proximity and an open position wherein said sections are moved apart to define a gap region between said split platform sections;   said gap region being positioned immediately above the open end of said cart; and   means responsive to delivery of bundles by said pusher means upon said split platform assembly for moving said split platform sections apart whereupon the bundles resting thereon are dropped through said gap region toward said cart;   said cart being comprised of:   caster assemblies mounted upon an underside of said platform for rollingly moving said platform upon a supporting surface;   a plurality of sidewalls extending upwardly from said platform for enclosing said platform;   said cart having an open upper end defined by the upper ends of said sidewalls;   at least one of said sidewalls being provided with a plurality of elongated spaced vertically aligned insertion slots adapted to receive a fork-like platform having a plurality of spaced parallel tines and being movable between a first position wherein said tines are inserted into respective ones of said insertion slots and a second position wherein said tines are withdrawn from said cart; and   means for moving said platform downwardly through a predetermined distance responsive to bundles being dropped upon said fork-like platform through said delivery opening. .Iadd.   
     
     
       40.  Apparatus for automatically loading a wheeled cart comprised of a floor, sidewalls and an open top, said apparatus comprising: a cart loading station at which a cart may be positioned for loading;   platform means arranged above said cart loading station and having a supporting surface of a size sufficient to receive a plurality of groups of bundles;   said platform means comprising at least one movable platform member for supporting bundles delivered to said platform means, and being movable between a closed position and an open position to define a gap region in said platform means;   said gap region being positioned immediately above an open top of a cart at said loading station;   conveying means for receiving bundles and delivering received bundles to a location adjacent to said platform means;   pusher means for pushing a first group of said bundles from said conveying means onto said platform;   said pusher means moving a second group of bundles delivered to said platform means onto said platform means, said first and second groups of bundles being positioned upon said gap region; and   means responsive to delivery of bundles by said pusher means upon said platform means gap region for moving the movable platform member to the open position whereupon bundles located in the gap region are dropped through said gap region toward said loading station. .Iaddend..Iadd.   
     
     
       41.  Apparatus for automatically loading a wheeled cart comprised of a floor, sidewalls and an open top, at least one of said sidewalls having an opening, said apparatus comprising: a cart loading station for receiving a cart to be loaded;   first platform means arranged above the cart loading station for dropping bundles on said first platform means toward an open top of a cart at said cart loading station;   second platform means being arranged beneath said first platform means for supporting at least one bundle dropped by said first platform means;   first means for selectively moving said second platform means in substantially horizontal direction between a first position wherein said second platform means is inserted into a cart at said loading station and a second position wherein said second platform means is withdrawn from a cart at said loading station;   said first platform means including movable support means to provide a gap region in said first platform means for dropping at least one bundle on said gap region through said gap region and toward an open top of a cart at said loading station and upon said second platform means; and   second means for moving said second platform means in a downward direction after a bundle is dropped upon said second platform means. .Iaddend..Iadd.   
     
     
       42.  The apparatus of claim 41 further comprising: said second means for moving including means to move said second platform means in a downward vertical direction a distance substantially equal to a height of a bundle responsive to a bundle being dropped onto said second platform means. .Iaddend..Iadd.43. The apparatus of claim 42 wherein said cart at the loading station is provided with means for retaining bundles in said cart when said second platform means is moved to said second position. .Iaddend..Iadd.44. The apparatus of claim 41 wherein said second means further comprises means for moving said second platform means at a first, lower speed when lowering said second platform means and for moving said second platform means at a second higher speed when raising said second platform means. .Iaddend..Iadd.45. Apparatus for automatically loading a cart comprised of a platform having a floor, sidewalls and an open top, said apparatus comprising:   loading station for receiving and positioning a cart;   platform assembly above said loading section for delivering bundles to a cart at said loading station;   conveyor means for conveying the bundles received from a receiving means to a location adjacent said platform assembly;   pusher means responsive to a presence of bundles upon said conveyor means for pushing said bundles onto said platform assembly;   said platform assembly comprising at least one movable platform section movable between a closed position and an open position to define a gap region in said platform assembly;   said gap region being positioned immediately above an open end of a cart at said loading station; and   means responsive to delivery of bundles by said pusher means upon said platform assembly for moving said movable platform section to said open position whereupon bundles resting thereon are dropped through said gap   
     
     
        region toward said cart. .Iaddend..Iadd.46.  The apparatus of claim 45 wherein said platform assembly further comprises a second movable platform section cooperating with said one movable platform section and movable, together with said one movable section, between a closed position where edges of said first and second sections are adjacent to one another and an open position where said edges are spaced apart to define said gap region. .Iaddend.