AU2004213060A1 - Transport module - Google Patents

Description

WO 2004/074136 PCT/AU2004/000188 TRANSPORT MODULE 5 Field of the Invention This invention relates to a transport module and methods of operating using transport modules. It relates particularly but not exclusively to transport modules suitable for use with trucks and trains. 10 Background of the Invention The mass transport of goods by road involves careful scheduling of trucks so that they can enter and leave loading and unloading facilities one at a time. When the 15 trucks arrive and leave in accordance with their scheduled times, such systems work well. However, as is inevitable with any enterprise that relies upon road transport, delays often occur through a combination of factors such as heavy traffic, breakdowns, road works and other forms of diversions. 20 When the trucks miss their scheduled loading or unloading time, they may often be left idle for hours until an opportunity arises to slot them into an alternative time. Clearly, the cost of such delays can be quite significant as it not only involves lost working time by the truck driver but there is also loss associated with an expensive capital item such as a truck laying idle. Additionally, in these days of "just in time" 25 manufacturing, a delay of several hours can have disastrous flow-on effects for a manufacturing plant. Thus, there is a need to develop an approach which does not require trucks or other forms of transport to lay idle whilst they wait to be loaded or unloaded. 30 WO 2004/074136 PCT/AU2004/000188 2 Disclosure of the Invention The invention provides in one aspect a transportable module comprising, a floor member, and 5 a plurality of leg supports each leg support being moveable between a retracted configuration in which the floor member is supported by directly resting on a base support surface and a support configuration in which the floor member is supported by the plurality of leg supports resting on a leg support surface, the support members extending clear of the floor member when in the support configuration such 10 that there is a clear region defined between, and bounded by the perimeter of bottom of the floor member and the leg support surface directly thereunder, wherein the leg supports comprise uplift means for raising and lowering the floor member with respect to the level of the base support. 15 The leg supports may be attached to the floor member. They may be attached by an intermediate part of the module such as via the walls. The floor member may be a generally horizontally extending planar construction. It may be provided with sides. It may be provided with a roof. The sides may comprise rigid walls. Alternatively, they may comprise flexible walls such as tied down sheets of flexible canvas or 20 plastic. They may comprise a mixture of rigid and flexible walls. One or more sides may include a doorway. The floor may be constructed so that it includes a support portion which raises the level of the floor above a bearing surface on which it rests. In this way, it may 25 include side clearance into which the rocker supports may be folded when not in use. Thus, the floor may include longitudinally extending beams to raise the floor in this manner. The longitudinally extending beams may be I-beams of metal such as steel. The floor may also include a perimeter frame. It may also include a plurality of cross 30 beams.

WO 2004/074136 PCT/AU2004/000188 3 Recesses for receiving the tynes of fork lift trucks may be provided on the floor member. Where the floor member has a square or rectangular shape, the recesses for the tynes may be provided on one to four of the sides of the floor member. 5 The leg supports may be moveable from the retracted configuration to an operational configuration in which they are held clear of the perimeter of the floor member. When in the operational configuration the uplift means may be actuated to raise the floor member and bring it into the support configuration. 10 The uplift means may comprise a wheel mounted on a leg and a rocker member attached to the leg. The rocker member may be constructed such that pivoting of each leg support towards the support configuration initially brings the rocker member into contact with the leg support surface whereby to raise the floor member with respect to the leg support surface. It then brings the wheel into supporting contact 15 with the leg support surface when the support position is reached. Each leg may be attached to the floor member by a swivel. The swivel may be constructed so as to allow the leg to be pivoted so that it can move from a substantially horizontal configuration to a substantially vertical configuration. 20 Suitably, it should allow the leg to pivot in a vertical plane to the vertical configuration. The swivel may also be constructed so as to allow the leg to rotate along its axis so as to allow the leg to be folded into the clearance at the side of the floor member. 25 Locking means may also be provided in association with each leg support. The locking means may be constructed so as to lock the leg in the vertical configuration. The locking means may be integrally formed with the swivel. Alternatively or additional, the locking means may comprise a component separate from the swivel. 30 WO 2004/074136 PCT/AU2004/000188 4 Brake means may be provided in association with one or more of the wheels. The brake means may be constructed so as to automatically brake rotation of the wheels when the leg support is in the support position. 5 Brake release means may also be provided to release the brake means to allow the wheel to rotate. The brake release means may be arranged so that they are actuated by the entry of a tyne into one of the tyne recesses. The rocker member may comprise an arcuate member. It may be provided next to the 10 wheel. It may be attached to a rocker member support which in turn is attached to the leg. In a typical loading and unloading operation, the transportable module may initially be loaded with the leg supports in the support configuration. Following loading, the 15 tray of a truck may be backed underneath the floor member with the tray of the truck lying between legs on either side of the floor member. The legs may then be moved to their folded position to lower the transport module onto the truck tray and hence load the truck. Means may be provided to control the rate of lowering eg. one or more hydraulic cylinders. The operation can be reversed at an unloading station so 20 that the loaded transport module can be raised from the truck tray when the leg supports are moved to their support position and the truck driven out from underneath the transport module. A fork lift may then roll the loaded transport module to an unloading station as and when required. 25 In an alternative construction the uplift means may comprise a hydraulic cylinder. Each of the uplift means may be moveable from a recess in the floor member or a recess in a wall of the module. A motor or hydraulic cylinder may be used to move the leg supports between the various configurations. 30 In another aspect the invention provides, a method of transporting a module comprising, WO 2004/074136 PCT/AU2004/000188 5 placing the module with retracted leg supports on a base support surface of a conveyance, moving the conveyance to a desired location, extending the leg supports to contact a leg support surface whereby to raise 5 the module with respect to the base support surface, moving the conveyance from underneath the module so as to leave it freestanding on the leg support surface. In another aspect the invention provides a method of transporting goods by a plurality 10 of modules comprising, loading the modules onto a plurality of transport vehicles, driving the transport vehicles to a leg support surface comprising a holding station adjacent a railway line, removing the modules from the transport vehicles and leaving them 15 freestanding on leg supports at the holding station, and lifting the modules such as by forklift and transferring them onto railway carriages after the leg supports have been retracted. Preferred aspects of the invention will now be described with reference to the 20 accompanying drawings, Brief Description of the Drawings Figure 1 shows a plan view of a transport module according to the invention not 25 including roof and walls with the rocker supports folded in for transport; Figure 2 shows an elevation of the transport module of Figure 1 including roof and walls loaded onto a lorry; Figure 3 shows a plan view of the rocker supports partially unfolded; Figure 4 shows a plan view of the rocker supports after rotation prior to 30 engagement; Figure 5 shows an elevation corresponding to Figure 4; WO 2004/074136 PCT/AU2004/000188 6 Figure 6 shows an intermediate step in unloading the transport module from the lorry of Figure 2; Figure 7 shows the lorry backing and moving out of a transport module; Figure 8 shows two transport modules loaded on a railway wagon platform; 5 Figure 9 shows a conceptual isometric view of elements of an alternative transport module construction according to the invention; Figure 10 shows an enlarged fragmentary cut away plan view of the floor and motorized mounts of the module of Figure 9; Figure 11 shows an enlarged elevational view of the leg support of Figure 9; 10 Figure 12 shows an enlarged view of a motor and gearbox for altering the configuration of the leg support; Figure 13 shows a plan view of elements of the floor of another alternative transport module construction with leg supports retracted; Figure 14 shows a plan view of the transport module floor of Figure 13 with the 15 leg supports in an operational configuration; Figure 15 shows a plan view of the transport module floor of Figure 13 with the leg supports in a support configuration; and Figure 16 is an elevational view of the complete transport module in the configuration shown in Figure 15. 20 Detailed Description of the Preferred Embodiment The various elements identified by numerals in the drawings are listed in the following integer list. 25 Integer List 1 Lorry 3 Transport module 30 5 Tray 7 Floor 9 Side WO 2004/074136 PCT/AU2004/000188 7 11 Tie down straps 13 Roof 15 I-beam 17 Cross beam 5 19 Perimeter frame 23 Tyne recess 25 Tyne recess 27 Rear coupling 29 Forward coupler 10 31 Rocker support 32 Leg 33 Swivel joint 34 Extension assembly 35 Castor wheel 15 36 Adjustment assembly 37 Rocker member 39 Strut 41 Brake release 43 Railway wagon platform 20 50 Transport module 52 Floor 53 Reinforcing beam 54 Doorway 55 Wall 25 56 Roof 58 Hydraulic cylinder 59 Retractable leg 60 Hinge mount 62 Motorised mount 30 64 Hydraulic fluid tank 65 Hydraulic fluid lines 67 Motor WO 2004/074136 PCT/AU2004/000188 8 68 Recess 69 Control means 70 Transport module 72 Floor 5 74 Hydraulic cylinder 75 Double sided hydraulic cylinder 76 Extended leg Referring to Figures 1 to 7 of the accompanying drawings, there is shown a lorry 1 in 10 various stages of loading and unloading a transport module 3 according to the invention. The lorry includes a tray 5 on which the transport module can be loaded and unloaded. 15 The transport module itself comprises a floor 7 having a generally planar rectangular configuration. Sides 9 are suitably formed of a light weight material such as reinforced plastic or canvas and are tied down by the tie down straps 11 as is known in the art. 20 The transport module suitably includes a roof 13 to provide a completely enclosed container area. Whilst the module illustrated in the drawings includes a roof and walls, it is to be appreciated that a simple flat top module without either is equally possible depending upon the requirements of the user. 25 The floor of the module is strengthened and supported by two deep I-beams 15 running longitudinally down the central portion of the module. These I-beams are arranged so that the module rests on them thereby creating a side clearance down both sides of the module between the floor and the support surface in the form of the 30 tray of a lorry.

WO 2004/074136 PCT/AU2004/000188 9 A number of cross beams 17 extend perpendicular to the I-beam and join with the perimeter frame 19 to give added strength. Tyne recesses 23 and 25 are provided at the sides and forward and rear ends of the module respectively. These are provided so as to give access to the tynes of a fork lift truck either for the purpose of lifting the 5 modules as is the case with the larger tyne recesses 23 provided at the sides of the module or for pushing the module, as is the case with the smaller tyne recesses 25 provided at the front and the rear of the module. The front of the module includes a forward coupling 29 which may be used to secure 10 the forward end of the module to a lorry. Similarly, the rear of the transport module may incorporate a rear coupling 27 which can be used to couple the module to a fork lift or other vehicle when the module is being manoeuvred by that vehicle. The transport module is provided with uplift means in the form of a number of rocker 15 supports 31 connected to the floor by swivel joints 33. In the illustrated embodiment three such rocker supports are provided on each side of the transport module. However, it is to be appreciated that more or fewer rocker supports may be used depending on the length of the transport module. 20 The swivel joint is constructed so as to allow the rocker support to be folded into a side clearance and to be subsequently moved out and pivoted in a vertical frame to the upright support position illustrated in Figure 7. The rocker support is attached to the swivel joint which is in turn connected to the floor by an extension assembly 34. The extension assembly allows the rocker support to be telescopically moved into and 25 out of the side clearance. Furthermore the swivel joint should allow rotation of the rocker support 31 about the longitudinal axis of the leg 32 of the rocker support and also pivoting in a vertical plane. As the rocker support needs to be locked into the support configuration shown in Figure 7, it is preferred that the swivel joint includes means to lock the rocker support in this position, although alternative or additional 30 means may be used. For example, the leg 32 of the rocker support may incorporate a mechanism associated with the side of the floor which locks it into place in the support configuration. It is noted that this alternative is not shown in the drawing.

WO 2004/074136 PCT/AU2004/000188 10 The leg 32 of the rocker support may also include an adjustment assembly 36 which allows the length of the rocker support to be adjusted to compensate for variations in ground level. This may be achieved by any suitable means such as a mechanical 5 arrangement, hydraulics, counter balancing springs or air means, or any combination. Hydraulic pressure equalisation may be provided to each wheel via the leg or other part of the rocker support. Castor wheels 35 are attached to the rocker support as are the arcuate rocker members 10 37 which are attached to the legs 32 via the struts 39. The castor wheels include braking means which prevent rotation of the castor wheels when the rocker supports are in the support position shown in Figure 4. 15 A brake release 41 is provided in both of the tyne recesses 25. It is constructed so that it may be actuated by the tynes of a forklift truck entering the tyne recess when it is desired to push the transport module from one location to another. In a typical unloading operation, taking Figures 3 to 7 in sequence, the rocker 20 supports 31 may be telescoped out of the side clearance and swivelled and rotated so that the rocker members 37 extend in the direction of a vertical plane clear of the perimeter of the floor 7 as is illustrated in Figures 4 and 5. The rocker members are then pivoted in the vertical plane in a clockwise or counter 25 clockwise direction so as to assume the configuration in Figure 6 ie. the rocker members contact the ground and as a truck reverses, the rocker supports raise the level of the transport module above the level of the tray of the truck so as to assume the configuration shown in Figure 7. In this support configuration, the rocker supports are locked in place and the castor wheels 35 are braked automatically. 30 Furthermore the adjustment assemblies may automatically adjust the length of the legs 32 and hence rocker supports to compensate for variations in ground level.

WO 2004/074136 PCT/AU2004/000188 11 The lorry then moves away leaving the module ready to be pushed to a loading/unloading station as the need may be by a fork lift. The whole operation is then reversed to reload the transport module onto another lorry after it has been loaded and/or unloaded. 5 As can be seen from Figure 8, two or more modules may be loaded on railway wagon platforms 43 should there be a need to transport the modules by means other than road transport. 10 Referring to Figures 9 to 12, the alternative form of transport module 50 shown therein may typically have the dimensions of a standard shipping container. It includes a floor 52 having a number of longitudinal reinforcing beams 53, a doorway 54 at the rear of the container, walls 55 and a roof 56.. The walls and roof 15 may be of rigid material such as is normally found in standard shipping containers or they may comprise flexible sheet material suspended on a frame as is known in the art. The four corners of the transport module are each provided with leg supports which 20 each comprise a hydraulic cylinder 58 having a retractable leg 59. Each of the hydraulic cylinders are mounted at the corners by the hinge mount 60 at the top of the hydraulic cylinder and a motorized mount 62 provided at floor level of the module. The motorized mount 62 in each case incorporates a motor 67 located in the floor 25 between the reinforcing beams. The motor may be electrically or hydraulically driven and it operates to move the hydraulic cylinder 58 in and out of a recess 68 provided at each of the four corners. The motor moves the hydraulic cylinders through an arc so that they assume the position shown in Figure 9. 30 A hydraulic fluid tank 64 connected by hydraulic fluid lines 65 supplies hydraulic fluid to advance and retract the retractable legs 59 as and when required. The motor may also be hydraulically operated. Obviously, the legs will be retracted when the WO 2004/074136 PCT/AU2004/000188 12 hydraulic cylinder is retained within the recess 68. They remain retracted as the motors swing each hydraulic cylinder to the operational configuration at which time the legs can be advanced to raise the transport module. 5 As for the hydraulic fluid lines, they may be associated with control means 69 which are arranged to control the rate of hydraulic fluid flow to and from the various hydraulic cylinders. This is to ensure that the transport module can be raised and lowered in a controlled manner, especially in a manner in which the floor of the module is controlled to remain horizontal. Thus, the control means may include 10 chokes or valves for regulating the flow of hydraulic fluid as well as means for sensing the inclination of the transport module. The chokes or valves may be responsive to the inclination sensing means to ensure that the rate of retraction or advance of the legs 59 is controlled so as to keep the transport module level. Thus, the construction is such that it should be able to accommodate variations in ground 15 level. Referring to Figures 13 to 16, the alternative transport module 70 shown therein comprises a floor 72 which includes recesses for receiving the four hydraulic cylinders 74 at each of the corners. In this example, -the hydraulic cylinders are 20 retained in recesses within the floor in a horizontal configuration as compared with the vertically directed recesses described with respect to Figures 9 to 12. Double sided hydraulic cylinders 75 are also provided within the floor, and are arranged to move the hydraulic cylinder 74 out of the recesses so that they extend 25 beyond the perimeter of the floor 72. The hydraulic cylinders 74 may be arranged to rotate as they clear the perimeter of the floor or they may reach the end of the travel of the double hydraulic cylinders 75 before they are rotated to the vertical configuration. 30 When in the vertical configuration the extended legs 76 are advanced to assume the configuration shown in Figure 16.

WO 2004/074136 PCT/AU2004/000188 13 In a typical sequence of operations for transporting goods by rail and road using a number of trucks and modules as well as a train, the following steps may be involved: 5 (i) A number of modules at a loading depot are loaded with goods. (ii) The loaded modules are lifted onto trucks for transport by forklifts. Alternatively the modules may be lifted by their leg supports after which trucks may reverse underneath them and the leg supports retracted to leave the modules loaded on the truck. 10 (iii) The trucks deliver the loaded modules to a dispatch area of a railway station. (iv) The leg supports are raised allowing the trucks to drive off leaving the modules at the dispatch station. (v) The modules at the dispatch station are picked up by forklift trucks 15 and loaded onto a train as the legs are retracted. (vi) After travel by train, the modules are unloaded by forklift truck and loaded directly onto trucks or allowed to wait in a dispatch station where they can be picked up by trucks later on. They may be loaded onto the trucks by the forklifts. Alternatively the legs of the modules 20 may be extended to raise them. This allows the trucks to back their trailers beneath the modules after which the legs are retracted to load the modules onto the trailers. Whilst the above description includes the preferred embodiments of the invention, it 25 is to be understood that many variations, alterations, modifications and/or additions may be introduced into the constructions and arrangements of parts previously described without departing from the essential features or the spirit or ambit of the invention. 30 It will be also understood that where the word "comprise", and variations such as "comprises" and "comprising", are used in this specification, unless the context WO 2004/074136 PCT/AU2004/000188 14 requires otherwise such use is intended to imply the inclusion of a stated feature or features but is not to be taken as excluding the presence of other feature or features. The reference to any prior art in this specification is not, and should not be taken as, 5 an acknowledgment or any form of suggestion that such prior art fonns part of the common general knowledge in Australia.

Claims (18)

1. A transportable module comprising, a floor member, and 5 a plurality of leg supports each leg support being moveable between a retracted configuration in which the floor member is supported by directly resting on a base support surface and a support configuration in which the floor member is supported by the plurality of leg supports resting on a leg support surface, the support members extending clear of the floor member when in the support configuration such 10 that there is a clear region defined between, and bounded by the perimeter of bottom of the floor member and the leg support surface directly thereunder, wherein the leg supports comprise uplift means for raising and lowering the floor member with respect to the level of the base support. 15

2. A transportable module according to claim 1 wherein the floor member comprises a generally horizontally extending planar construction.

3. A transportable module according to claims I or claim 2 comprising walls and a doorway mounted on the floor member and a roof atop the walls and doorway. 20

4. A transportable module according to any one of the preceding claims wherein the floor member comprises, a rectangular perimeter frame, a plurality of cross beams, and 25 a plurality of longitudinally extending beams.

5. A transportable module according to any one of the preceding claims wherein the floor member comprises a plurality of tyne recesses for receiving the tynes of fork lift trucks. 30

6. A transportable module according to any one of the preceding claims wherein the floor member comprises a generally horizontally extending square or rectangular WO 2004/074136 PCT/AU2004/000188 16 construction with the leg supports provided at or near the corners of the floor member.

7. A transportable module according to anyone of the preceding claims 5 comprising leg support recesses in the floor member for receiving the leg supports when they assume the retracted configuration.

8. A transportable module according to any one of the preceding claims wherein the uplift means comprise a wheel mounted on a leg and a rocker member attached to 10 the leg, the rocker member being constructed such that pivoting of each leg support towards the support configuration initially brings the rocker member into contact with the leg support surface whereby to raise the floor member with respect to the leg support surface and then brings the wheel into supporting contact with the leg support surface when the support position is reached. 15

9. A transportable module according to any one of claims 1 to 7 wherein the uplift means comprise hydraulic cylinders.

10 A transportable module according to claim 9 when appended to claim 7 20 comprising placement means extending within the floor member for moving the leg supports between the retracted configuration and an operational configuration in which the uplift means extend clear of the perimeter of the floor member.

11. A transportable module according to claim 10 wherein the placement means 25 comprise double sided hydraulic cylinders for simultaneously moving pairs of leg supports.

12. A transportable module according to claim 9 when appended to claim 3 comprising a plurality of vertically extending recesses in the walls for housing the 30 uplift means when the leg supports are in the retracted configuration. WO 2004/074136 PCT/AU2004/000188 17

13. A transportable module according to claim 12 wherein the leg supports comprise motor means for moving the uplift means through an are between the retracted configuration and an operational configuration in which the uplift means extend clear of the perimeter of the floor member. 5

14. A method of transporting a module comprising, placing the module with retracted leg supports on a base support surface of a conveyance, moving the conveyance to a desired location, 10 extending the leg supports to contact a leg support surface whereby to raise the module with respect to the base support surface, moving the conveyance from underneath the module so as to leave it freestanding on the leg support surface.

15 15. A method of transporting goods by a plurality of modules according to claim 14 comprising, loading the modules onto a plurality of transport vehicles, driving the transport vehicles to a leg support surface comprising a holding station adjacent a railway line, 20 removing the modules from the transport vehicles and leaving them freestanding on leg supports at the holding station, and lifting the modules by forklift and transferring them onto railway carriages after the leg supports have been retracted. 25

16. A method according to claim 14 or claim 15 wherein the modules comprise transportable modules as defined in any one of claims I to 13.

17. A transportable module according to claim 1 substantially as hereinbefore described. 30

18. A method transporting modules according to claim 14 substantially as hereinbefore described.