AU2008200441B2

AU2008200441B2 - Lead board adjustment apparatus for a pallet and associated methods

Info

Publication number: AU2008200441B2
Application number: AU2008200441A
Authority: AU
Inventors: Christopher Bertram Anderson; Steve Townsend
Original assignee: Chep Technology Pty Ltd
Current assignee: Chep Technology Pty Ltd
Priority date: 2008-01-29
Filing date: 2008-01-29
Publication date: 2011-03-31
Anticipated expiration: 2028-01-29
Also published as: AU2008200441A1; AU2008200441B8

Description

S&F Ref: 844816 AUSTRALIA PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT Name and Address CHEP Technology Pty Limited, of Level 40, Gateway, 1 of Applicant: Macquarie Place, Sydney, New South Wales, 2000, Australia Actual Inventor(s): Steve Townsend, Christopher Bertram Anderson Address for Service: Spruson & Ferguson St Martins Tower Level 35 31 Market Street Sydney NSW 2000 (CCN 3710000177) Invention Title: Lead board adjustment apparatus for a pallet and associated methods The following statement is a full description of this invention, including the best method of performing it known to me/us: 5845c(1 108717_1) LEAD BOARD ADJUSTMENT APPARATUS FOR A PALLET AND ASSOCIATED METHODS Field of the Invention 5 [0001] The present invention relates to pallet inspection and repair systems, and more particularly, to a pallet repair apparatus. Background of the Invention 10 [0002] Wooden pallets are used to transport a variety of bulk goods and equipment as required in manufacturing and warehousing operations. In high volume industries, pallet pools provide a lower total industry cost than one-way pallets. The current 15 assignee of the present invention recognizes the benefits of pooled pallets, and currently has over several hundred million pallets that are pooled each year. [0003] After the bulk goods and equipment are off 20 loaded from the pooled pallets, the pallets are returned to pallet inspection and repair facilities for inspection, and if necessary, repair, before the pallets are returned to service. (0004] As one might expect, wooden pallets are 25 subject to damage in use that occurs from handling with forklifts or other like equipment. Since wooden pallets are in wide use, a large number of damaged and unusable pallets need to be repaired or discarded daily [0005] during the pallet inspection and repair process. Repair of damaged pallets has become an increasingly sound alternative to disposal due to the sheer volume of pallets that require repair each day. 5 [0006] Pallet inspection and repair traditionally requires manual handling and inspection by an operator, with mechanized systems available for moving pallets to and from the human operator who completes the repair of the pallets. An automated pallet inspection and repair 10 system is advantageous because it does not rely on a human operator to perform the inspection and all of the repairs. [0007] U.S. published patent application no. 2006/0242820 discloses an automated pallet inspection 15 and repair system, which is assigned to the current assignee of the present invention and is incorporated herein by reference in its entirety. The automated pallet inspection and repair system discloses an automatic pallet inspection cell comprising multi-axis 20 robot arms that terminate in either internal or exterior pallet grippers. A robot may be used to transport a gripped pallet through an automated pallet inspection station that generates a three-dimensional data map of a pallet surface. A processor interprets 25 the map and generates a corresponding repair recipe. [0008] One or more repair stations may conduct pallet repair operations that are specified by the repair recipe. While the '820 published patent application makes a general reference to adjusting lead 30 boards, there is still a need to improve such a process. 2 3 Object of the Invention It is the object of the present invention to substantially overcome or ameliorate one or more of the disadvantages of the prior art. s Summary of the Invention The present invention provides a lead board adjustment apparatus for a pallet, said apparatus comprising: a frame; a pallet receiving area associated with said frame for receiving the pallet, the io pallet comprising spaced apart lead board areas on a first surface of the pallet and spaced apart lead board areas on a second surface of the pallet opposite the first surface, said lead board areas having at least one lead board coupled thereto needing adjustment; an adjust stop assembly carried by said frame and for holding the pallet in a stationary position; Is a pair of spaced apart upper adjust beam assemblies carried by said frame, each upper adjust beam assembly comprising an upper adjust beam for contacting a respective lead board area on the first surface of the pallet, and a plurality of upper board grip fingers having an extended position and a retracted position; a pair of spaced apart lower adjust beam assemblies carried by said frame, each 20 lower adjust beam assembly comprising a lower adjust beam for contacting a respective lead board area on the second surface of the pallet, and a plurality of lower board grip fingers having an extended position and a retracted position; and a controller coupled to said pairs of upper and lower adjust beam assemblies for selectively placing said plurality of upper and lower board grip fingers 25 in the extended position corresponding to the at least one lead board needing adjustment, and selectively moving said upper and lower adjust beams corresponding to the at least one lead board needing adjustment, with the at least one lead board being moved until said adjust stop assembly is contacted. 30 The present invention also provides a lead board adjustment apparatus for a pallet comprising spaced apart lead board areas on a first surface of the pallet and spaced apart lead board areas on a second surface of the pallet opposite the first surface, the lead board areas having at least one lead board coupled thereto needing adjustment, the lead board adjustment apparatus comprising: 35 a frame; 3a an adjust stop assembly carried by said frame and for holding the pallet in a stationary position; a pair of spaced apart upper adjust beam assemblies carried by said frame, each upper adjust beam assembly comprising an upper adjust beam for contacting a respective s lead board area on the first surface of the pallet, and a plurality of upper board grip fingers having an extended position and a retracted position; a pair of spaced apart lower adjust beam assemblies carried by said frame, each lower adjust beam assembly comprising a lower adjust beam for contacting a respective lead board area on the second surface of the pallet, and a plurality of lower board grip 10 fingers having an extended position and a retracted position; and a controller coupled to said pairs of upper and lower adjust beam assemblies for selectively placing said plurality of upper and lower board grip fingers in the extended position corresponding to the at least one lead board needing adjustment, and is selectively moving said upper and lower adjust beams corresponding to the at least one lead board needing adjustment, with the at least one lead board being moved until said adjust stop assembly is contacted.

5 The lead board adjustment apparatus advantageously allows one, two, three or four of the lead boards on the pallet to be adjusted without having to flip or reposition the pallet within the frame. The amount of time to adjust the lead boards on the pallet 10 may thus be reduced. Moreover, since the controller selectively places the board grip fingers in the extended position, the lead board adjustment apparatus is operational even if the pallet is missing one or more lead boards. 15 The adjust stop assembly may comprise a fixed adjust stop and a moveable adjust stop. The fixed adjust stop may be coupled to the frame, and preferably extends in a same direction as the lead board areas on the pallet. The moveable adjust stop also preferably 20 extends in a same direction as the lead board areas on the pallet. The moveable adjust stop may hold the pallet in the stationary position by contacting and moving the lead board areas on one side of the pallet until the lead board areas on an opposite side of the 25 pallet contact the fixed adjust stop. The upper and lower adjust beams may be selectively moved so that the at least one lead board needing adjustment butts up against an edge of at least one of the moveable adjust stop and the fixed adjust 30 stop. Each upper adjust beam assembly may comprise a plurality of upper actuators coupled between the frame and the upper adjust beam. Similarly, each lower adjust beam assembly may comprise a plurality of lower actuators coupled between the frame and the lower 4 5 adjust beam. Each of the plurality of upper and lower actuators may comprise a hydraulic actuator for moving the respective upper and lower adjust beams, for example. Each upper adjust beam assembly may comprise a plurality of upper grip finger actuators coupled to the plurality of upper board grip fingers for positioning thereof. s Similarly, each lower adjust beam assembly may comprise a plurality of lower grip finger actuators coupled to the plurality of lower board grip fingers for positioning thereof. Each grip finger actuator may comprise a pneumatic actuator, for example. Each lower adjust beam assembly may comprise a plurality of lifting actuators coupled between the frame and the lower adjust beam. The controller may control the 1o plurality of lifting actuators for lifting the pallet off of the pallet receiving area until the upper adjust beams contact the respective lead board areas on the first surface of the pallet. The controller may further control the lifting actuators for further lifting the pallet for applying additional pressure on the respective lead board areas after adjustment of the at least one lead board so that the at least one adjusted lead board remains in its adjusted is position when the pallet is returned to the pallet receiving area. The present invention further provides a method for adjusting lead boards on a pallet using a lead board adjustment apparatus comprising a frame; an adjust stop assembly carried by the frame; a pair of spaced apart upper adjust beam assemblies carried by the frame, each upper adjust beam assembly comprising an upper adjust beam 20 for contacting a respective lead board area on a first surface of the pallet, and a plurality of upper board grip fingers having an extended position and a retracted position; and a pair of spaced apart lower adjust beam assemblies carried by the frame, each lower adjust beam assembly comprising a lower adjust beam for contacting a respective lead board area on a second surface of the pallet, and a plurality of lower board grip fingers having 25 an extended position and a retracted position, the method comprising: contacting the respective lead board areas on the second surface of the pallet with the lower adjust beams; contacting the respective lead board areas on the first surface of the pallet with the upper adjust beams; 30 holding the pallet in a stationary position using the adjust stop assembly; selectively placing the plurality of upper and lower board grip fingers in the extended position corresponding to the at least one lead board needing adjustment; and selectively moving the upper and lower adjust beams corresponding to the at least one lead board needing adjustment, with the at least one lead board being moved 35 until the adjust stop assembly is contacted.

6 Brief Description of the Drawings A preferred embodiment of the present invention will now be described, by way of an example only, with reference to the accompanying drawings wherein: FIG. 1 is a top-level block diagram of a pallet inspection and repair system in 5 accordance with the present invention. FIG. 2 illustrates a forklift removing pallets from a truck prior to inspection in accordance with the present invention. FIG. 3 is a schematic diagram of the stack in-feed illustrated in FIG. 1. FIG. 4 is a schematic diagram of the tipper/accumulator illustrated in FIG. 1. 1o FIGS. 6 and 7 are schematic diagrams of the automated digital inspection (ADI) station illustrated in FIG. 1. FIGS. 8 and 9 respectively illustrate a pallet repair summary table and an element repair summary table generated by the ADI station in accordance with the present invention. is FIGS. 10, 11 and 12 respectively illustrate different configurations of the top deck boards of a pallet as well as element ID and indexing of the boards in accordance with the present invention.

[0026] FIG. 13 illustrates the bottom deck baseboards of a pallet as well as element ID and indexing of the boards in accordance with the present invention. 5 [0027] FIG. 14 illustrates the stringers of a pallet as well as element ID and indexing of the boards in accordance with the present invention. [0028] FIG. 15 is a schematic diagram of the classification divert line illustrated in FIG. 1. 10 [0029] FIG. 16 is a more detailed block diagram of the different repair machines/repair devices associated with the repair line illustrated in FIG. 1. [0030] FIG. 17 is a side view of a lead board adjustment apparatus without a pallet positioned 15 therein in accordance with the present invention. [0031] FIG. 18 is a side view of the lead board adjustment apparatus illustrated in FIG. 17 with a pallet positioned therein. [0032] FIG. 19 is a top view of the lead board 20 adjustment apparatus illustrated in FIG. 17 without the adjust stop assembly included therein. [0033] FIG. 20 is a flow diagram for adjusting lead boards on a pallet in accordance with the present invention. 25 Detailed Description of the Preferred Embodiments [0034] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments 30 of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, 7 and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout. [0035] A top-level overview of the pallet inspection 5 and repair system 40 will initially be discussed with reference to FIG. 1. Pooled pallets 50 from different customers are returned to a pallet pooling company for inspection, and if necessary, repair, before the pallets are returned to service 51. As the pallets 50 10 are received, customer data is collected and recorded. Customer data includes the customer providing the pallets, along with how many pallets are being returned. Customer data may also include other pertinent information about the customer, as readily 15 appreciated by those skilled in the art. [0036] Prior to inspection, the pallets 50 are provided to a stack in-feed 52. As the pallets 50 are placed in the stack in-feed 52, customer data 70 associated with the pallets are provided to at least 20 one processor, referred to herein as a factory management system (FMS) server 56. As each pallet 50 is individually tracked through the pallet inspection and repair system 40 by an automated controller 60, the FMS server 56 keeps track of the corresponding customer 25 data 70 to be associated therewith. [0037] The stack in-feed 52 squares each stack of pallets before being passed to a tipper/accumulator 62. The tipper/accumulator 62 provides a steady stream of spaced apart pallets 50 for inspection by the automated 30 digital inspection (ADI) station 66. As the pallets 50 leave the tipper/accumulator 62, they pass through a preparation screening line 64. [0038] In the preparation screening line 64, each pallet 50 is visually inspected by a human operator to 8 remove any loose debris or trash that may affect the ADI station 66. If necessary, the human operator will also make minor repairs. Each pallet 50 is individually tracked through the preparation screening line 64 by 5 the automated controller 60. In some cases, a pallet 50 may be discarded during the preparation screening line 64 if it is damaged too badly, as indicated by block 65. [0039] From the preparation screening line 64, each 10 pallet 50 is inspected by the ADI station 66. The ADI station 66 may be configured as one or two inspection booths. As part of the inspection, image data 72 is generated for the pallet 50. The ADI station 66 compares the generated image data 72 to an expected 15 profile 74. The generated image data 72 may also be referred to as measurement data, and the expected profile 74 may also be referred to as pallet classification. Based on the comparison, a damage report 76 is generated. As will be discussed in 20 greater detail below, the damage report 76 comprises a pallet repair summary and an element repair summary. [0040] The damage report 76 is sent to the FMS server 56. The FMS server 56 generates a repair recipe 78 for the inspected pallet 50 based on the damage 25 report 76. During the pallet inspection and repair process, the information in the FMS server 56 (i.e., repair recipes 78) is queried. The inspected pallet 50 travels from the ADI station 66 to a classification divert line 68. 30 [0041] The classification divert line 68 may also be referred to as a sort line, and queries the FMS server 56 to determine if the inspected pallet is good or bad. If the inspected pallet 50 is bad, this means that the pallet requires repair (via repair line 80) or is to be 9 discarded (via discard line 84). If the inspected pallet 50 is good, then the pallet 50 is sent to the paint booth 82 prior to being returned to service 51. [0042] Prior to being sent to the repair line 80, 5 the classification divert line 68 may position which way the pallets are to face for the repairs to be made. The repair line 80 includes a series of processor controlled repair machines/repair devices available for repairing each pallet 50 based on the corresponding 10 repair recipe 78, as will be discussed in greater detail below. Depending on how extensive the pallet 50 is damaged, the number of repair machines/repair devices involved in the repair can vary from one to more than one. In addition, certain repairs may be 15 manually made by a human, as readily appreciated by those skilled in the art. [0043] As illustrated in FIG. 1, the automated controller 60 controls the tipper/accumulator 62, the preparation screening line 64, the ADI station 66 and 20 the classification divert line 68. In this portion of the pallet inspection and repair system 40, the pallets 50 are moved on a conveyor system, for example. A series of detectors, such as photocells, for example, are positioned along the conveyor system for tracking 25 position and movement of each pallet. The automated controller 60 is a computer-based controller that tracks the position and movement of each pallet 50 via the sensors, and coordinates with the ADI system 66 on when the image data 72 of each pallet 50 is to be 30 generated. [0044] For each pallet 50, the corresponding customer data 70 and repair recipe 78 are provided from the FMS server 56 to another processor, which is referred to herein a data analysis server 58. The data 10 analysis server 58 is illustrated as being separate from the FMS server 56. Alternatively, the FMS server 56 and the data analysis server 58 could be configured as a single server or processing system, as readily 5 appreciated by those skilled in the art. [0045] The data analysis server 58 performs post analysis processing for the inspected pallets 50. This involves comparing the repair recipes 78 to determine performance repair parameters 90 for the pallets 50. 10 The performance repair parameters 90 correspond to the different types of repairs to be made to the pallets. [0046] As a result of analyzing the types of repairs being made to the pallets 50, statistical data can be collected including how many pallets are being 15 repaired, how much time and lumber is being consumed or is expected to be consumed in repairing the pallets, as well as tracking what repairs are being made. This advantageously allows the throughput of the pallet inspection and repair system 40 to be monitored so that 20 lumber and personnel can be accurately forecasted. [0047] By determining certain repair trends, changes may be made to the pallet inspection and repair system 40 to more efficiently make the repairs. This may involve modifying one or more of the processor 25 controlled repair devices, or even the addition of a processor-controlled repair device if the repair was initially being manually made by a human operator. [0048] Moreover, the repair trends may cause an examination of the inspection tolerances associated 30 with the ADI station 66, for example. If one or more of the inspection tolerances are set to stringent, this may cause unnecessary repairs to be made to the pallets 50. By relaxing the inspection tolerances, less 11 repairs would be made with the pallets 50 still meeting customer demands. [0049] The performance repair parameters 90 may also be tracked with the customer data so that feedback can 5 advantageously be provided to the customer. The feedback would allow corrective action to be taken by the customer to reduce certain types of repairs being made to the pallets provided by that customer. [0050] By analyzing the types of repairs being made 10 to the pallets for a particular customer, certain trends may be noted. For example, the customer may be damaging the supports blocks on the pallets more often than other customers, or the top deck boards are being replaced more often than other customers. Corrective 15 action may be for the customer to instruct their forklift operators to reduce impacting the forklift tines with the support blocks, and to not stack loaded pallets too high on top of one another, for example. If the customer ignores the feedback, then the customer 20 may be charged a higher rate on their pooled pallets. [0051] The pallet inspection and repair system 40 will now be discussed in greater detail. Referring now to FIG. 2, a forklift 100 is used to unload wooden pallets 50 from a tractor-trailer truck 102. A standard 25 tractor-trailer truck 102 holds about 500 pallets 50, for example. As the pallets 50 are unloaded, a vehicle mount terminal (VMT) 104 on the forklift 100 records the customer data 70. The customer data 70 includes the truck number, the customer providing the pallets 30 50, and how many pallets are being unloaded for inspection. The customer data 70 is entered into the VMT 104 by the operator of the forklift 100. This process is repeated each time pallets 50 are unloaded from a truck 102 or any other delivery vehicle. 12 [0052] At the stack in-feed 52, the forklift 100 places the wooden pallets 50 against a backboard 124, as illustrated in FIG. 3. As the pallets 50 are stacked, the VMT 104 communicates with the FMS server 5 56. The FMS server 56 may also be referred to as a logistics database, for example. [0053] The stack in-feed 52 comprises a series of conveyors 110, 112, 114 and 116, which are controlled by electrical motors 119. The illustrated arrow 107 10 indicates the flow direction of the pallets 50. Each conveyor has one or more detectors 120 for determining the position of a stack of pallets 122 as it moves along the conveyors 110, 112, 114 and 116. The detectors 120 may be photoelectric sensors, or 15 photoeyes, for example. A photoelectric sensor is used to detect the presence of a stack of pallets 122 by using a light transmitter, often infrared, and a photoelectric receiver. Other types and forms of detectors 120 may be used, as readily appreciated by 20 those skilled in the art. [0054] The pallets 50 are initially stacked on a conveyor 110 against the backboard 124 to form a stack of pallets 122. Each illustrated stack of pallets 122 is 20 pallets high. After a stack of pallets 122 has 25 been formed, the stack moves from conveyor 110 to a stack squarer 126 via conveyor 112. The stack squarer 126 squares each stack of pallets 122. After being squared, the conveyor 114 associated with the stack squarer 126 moves the stack of pallets 122 to an 30 adjacent conveyor 116. This conveyor 116 then moves the stack of pallets 122 toward the tipper/accumulator 62. [0055] The tipper/accumulator 62 comprises a tipper 130 and an accumulator 140, as the name implies, as illustrated in FIG. 4. The illustrated arrow 107 13 indicates the flow direction of the pallets 50. The tipper 130 includes an L-shaped member that is tilted from a first position in which the long side 132 of the L-shaped member is upright and the short side 134 is 5 horizontal, to a second position in which the long side 132 is near horizontal and the short side 134 is near vertical (as in FIG. 4). When the short side 134 of the L-shaped member is in the horizontal. position, the stack of pallets 122 is loaded onto the tipper 140. 10 After loading, the tipper 140 moves the L-shaped member to the second position in which the long side 132 of the tipper is nearly horizontally disposed so that the pallets 50 held on the L-shaped member can be moved off the tipper 130 to the accumulator 140. 15 [0056] The accumulator 140 provides an intermediate stage between the stack of pallets 122 and the preparation screening line 64. The tipper 130 delivers and transfers the stack of pallets 122 to the accumulator 140 which then holds and delivers the 20 pallets 50 one at a time to the preparation screening line 64. This is while the tipper 130 returns to receive another stack of pallets 122. [0057] At the output of the accumulator 140, the pallets 50 are passed to another series of conveyors 25 150, 152, 154, 156, 158 and 160 defining the preparation screening line 64, as illustrated in FIG. 5. The illustrated preparation screening line 64 is one example, and others variations are readily applicable. The illustrated arrow 107 indicates the flow direction 30 of the pallets 50. Detectors 120 are spaced along the conveyors 150-160 for tracking the position of each pallet 50. The pallets 50 from the accumulator 140 are placed with the top deck facing up on conveyor 150. The top deck of each pallet 50 is visually inspected by 14 a human operator to insure that any loose debris or trash is removed from the pallet 50 before reaching the ADI station 66. Also, any loose boards on the top deck that can be easily repaired may also be nailed down at 5 this time. If the human operator determines that the pallet 50 is too damaged to be repaired, then the pallet is discarded at this point. [0058] The pallets 50 travel along conveyor 152 and are then flipped because of the transition with 10 conveyor 154 so that the bottom deck is now facing up. Likewise, the bottom deck of each pallet 50 is visually inspected by a human operator to insure that any loose debris or trash is removed from the pallets before reaching the ADI station 66. As with the top deck, any 15 loose boards on the bottom deck that can be easily repaired may also be nailed down at this time. Again, if the human operator determines that the pallet 50 is too damaged to be repaired, then the pallet is discarded at this point. 20 [0059] The pallets 50 travel along conveyor 156 and are then flipped over at conveyor 158 so that the top deck is again facing up. This is so the ADI station 66 first inspects the top deck of each pallet 50. The pallets 50 continue moving on conveyor 160 toward the 25 ADI station 66. [0060] The next step in the pallet inspection and repair system 40 is to inspect the pallets 50, as illustrated in FIGS. 6 and 7. The illustrated embodiment for the ADI station 66 shown in FIG. 1 30 comprises a pair of ADI inspection stations 180, 182. The illustrated arrow 107 indicates the flow direction of the pallets 50. [0061] During the inspection process, the top and bottom decks of each pallet 50 are inspected in 15 separate ADI inspection stations 180, 182. Conveyor 170 receives a pallet 50 from conveyor 160 in the preparation screening line 64. The top deck of the pallet 50 is inspected in ADI inspection station 180. 5 Detectors 120 are used to track movement of the pallet 50 prior to entering the ADI station 180, as well as tracking movement within the ADI station. [0062] The ADI station 180 inspects the top deck of the pallet 50 using pallet feature sensing heads 190 10 placed above the pallet. Each pallet feature sensing head 190 may comprise a series of sensors in a line (linear array) to detect the presence or absence of timber (or other pallet material), as discussed in the above-referenced patent application that is 15 incorporated herein by reference. This type of sensing head is positioned adjacent to the moving pallet 50 so that it scans the pallet surface passing near it for generating an image 72 of the pallet. [0063] In another embodiment, the pallet feature 20 sensing head 190 may comprise a laser and camera system to capture individual profiles (cross-sections) of the pallet 50 (i.e., the camera records the location of a projected laser line and triangulates its position to give height and coordinate data). The laser beam that 25 is projected onto the pallet 50 may be fan shaped, or it may be scanned across the pallet surface using, for example, moving mirrors. Such a system will generate a three-dimensional digital data map on the pallet 50 and can be used for detecting gaps or protrusions such as 30 nails, hanging wood, etc. [0064] Alternatively, similar three-dimensional maps of pallet features, dimensions and topography may be created using a system of cameras, which may be stereoscopic or monocular in location and action. These 16 can be mathematically manipulated to give data on each element that can then be analyzed for damage as in other pallet feature sensing head arrangements. [0065] The ADI station 180 has at least one 5 computing system 194 cooperating with the pallet feature sensing heads 190 for generating an image of the top deck of the pallet 50 being inspected. Likewise, the other ADI station 182 has at least one computing system 194 cooperating with the pallet 10 feature sensing heads 190 for generating an image of the bottom deck of the pallet 50. [0066] Between the ADI stations 180 and 182, conveyor 172 moves the pallet 50 to conveyor 174, wherein the transition between the two conveyors causes 15 the pallet to flip over so that the bottom deck is facing up. The pallet 50 then moves on conveyors 176 and 178 to the ADI station 182 for inspecting the upper facing bottom deck. [0067] Although not illustrated, the two computing 20 systems 194 and 204 are coupled together for generating a damage report 76 on the pallet 50. The computing system 194 compares the generated image data 72 for the top and bottom decks of the pallet 50 with expected profiles 74 for generating the damage report 76. 25 [0068] The damage report 76 comprises a pallet repair summary and an element repair summary. The pallet repair summary and the element repair summary may be configured as tables, as illustrated in FIGS. 8 and 9. The element repair summary corresponds to the 30 elements making up the pallet 50. For example, the top deck of the pallet 50 could be formed with 5, 6 or 7 boards as illustrated in FIGS. 10, 11 and 12. Accordingly, when a pallet 50 is to be inspected, the pallet needs to be classified as a 5, 6 or 7 board 17 pallet. The corresponding element ID 206 and element index 208 for each type of pallet are also provided. [0069] Once the pallet 50 has been classified, then the expected profile can be selected by the computing 5 systems 194, 204. Similarly, the elements making up the bottom deck of the pallet 50, and the elements making up the stringer boards of the pallets are illustrated in FIGS. 13 and 14. The corresponding element ID 206 and element index 208 for the pallet are 10 also provided. [0070] As an alternative to separate ADI stations 180 and 182, a single ADI station may be used when pallet feature sensing heads 190 are positioned below the conveyor. In this embodiment, the pallet 50 does 15 not have to be flipped over so that the bottom deck is facing up during inspection. In addition, a single computing system 194 may be used. [0071] As illustrated in FIG. 1, the damage report is provided to the FMS server 56. Since the damage 20 report 76 includes the pallet repair summary table and the element repair summary table as illustrated in FIGS. 8 and 9, the FMS server 56 generates a repair recipe 78 for the pallet 50. [0072] The repair recipe 78 determines how the 25 pallet 50 is to be repaired if it is damaged. The repair recipe 78 takes into account the inspection results, the complexity of the repair and the repair machines available and the paths available (with respect to the repair machines) in the pallet 30 inspection and repair system 40. The repair recipe 78 also takes into consideration what repair operations get priority if multiple repairs have to be made to the pallet 50. The FMS server 56 thus creates a relational database scheme for handling the very large number of 18 repair variables that are possible when repairing pallets 50. [0073] Conveyor 180 moves the pallet 50 from the second ADI station 182 to the classification divert 5 line 68, as illustrated in FIG. 15. The classification divert line 68 includes a conveyor 185 for receiving the pallet 50 from the second ADI station 182. Conveyor 210 operates as a control gate for directing the pallet 50 to conveyor 212 or to conveyor 208. 10 Conveyor 212 provides the pallet 50 to conveyor 214 which directs the pallet to the repair line 80. Conveyor 208 provides the pallet 50 to the paint booth 82. Although not illustrated, the classification divert line 68 also directs the pallet to the discard 15 line 84 if the pallet 50 is too damaged to be repaired. The classification divert line 68 thus operates based on the repair recipe 78. [0074] In the repair line 80, a number of different processor-controlled repair devices and repair machines 20 are available to support a complete repair of a pallet 50. The repair line 80 includes the following: a de stubbing device 240, a lead board adjustment apparatus or machine 242, a nailing machine 244 for the lead board adjustment machine, an any board removal 25 apparatus or machine 246, a board placing/nailing machine 248, a lead board removal machine 250 and a nail presser for proud nails 252. In addition, some repairs may be manually made by a human, either directly or with the human operating a repair machine, 30 as indicated by reference 254. The order in which a pallet 50 is repaired in the repair line 80 is based on the generated repair recipe 78. [0075] The repair recipe 78 may be provided to the repair line 80 in a number of different ways. For 19 example, the position of each pallet 50 is still being tracked so that the repair recipe 78 "travels" with each pallet. Alternatively, each pallet 50 may be physically marked with their repair recipe 78 before 5 leaving the classification divert line 68. This may be in the form of a bar code, or as a set of written instructions. Once the pallet 50 arrives at the repair line 80, the repair recipe 78 is read. The repair recipe 78 may be read by a processor or by a human 10 operator. [0076] As part of the repair line 80, one or more robot cells may be used to position each pallet 50 among the different repair devices/machines based on the repair recipe 78. Alternatively, conveyors with 15 switch gates may be used for providing the pallets 50 to the appropriate repair devices/machines based on the repair recipe 78. [0077] After a pallet 50 has been repaired, or for a pallet that did not need repair, the pallet may be sent 20 to the paint booth 82 before being returned to service. In one embodiment, several pallets 50 are placed in the paint booth 82 at one time. The paint booth 82 is enclosed, and the pallets 50 spin as edges or sides of the pallets are sprayed with paint. Next, a stencil 25 may be used to mark the pallets with indicia, such as the company logo. In one embodiment, a robot is used for dipping its paint guns into a pit of paint for marking at least two pallets at a time. An alternative design is to use an inkjet type paint sprayer to spray 30 in a dot matrix format the indicia. [0078] In the discard line 84, the pallets 50 are dismantled. A robot, for example, may be programmed to dismantle the pallets 50. 20 [0079] Referring now to FIGS. 17, 18 and 19, the lead board adjustment machine 242 comprises a rigid frame 300 and a pallet transport mechanism 302 associated therewith for positioning a pallet 50 5 between the frame. The illustrated pallet transport mechanism 50 is a conveyor. Alternatively, other methods for positioning the pallet 50 between the frame 300 may be used, such as a programmed robot arm, for example. The pallet 50 may even be manually placed 10 between the frame 300. [0080] The pallet 50 has spaced apart lead board areas on a first surface of the pallet, and spaced apart lead board areas on a second surface of the pallet opposite the first surface. The lead board 15 areas have at least one lead board 53, 55 coupled thereto needing adjustment. The lead board adjustment machine 242 advantageously allows one, two, three or four of the lead boards 53, 55 on the pallet 50 to be adjusted without having to flip or reposition the 20 pallet within the frame 300. The lead boards 53, 55 on the pallet 50 may even be adjusted if the pallet is missing one or more lead boards. For discussion purposes, all four lead boards 53, 55 are on the illustrated pallet 50. 25 [0081] The lead board adjustment machine 242 includes a pair of lower adjust beam assemblies 304. Each lower adjust beam assembly 304 is pivotally attached to the frame 300, and comprises a pair of lower adjust beam lifting actuators 306 and a lower 30 adjust beam or bar 308 coupled thereto. The lower adjust beams 308 contact the lead boards 53 or the lead board areas on one side of the pallet 50. The length of each lower adjust beam 308 is substantially the same as the length of the lead boards 53. As illustrated, 21 the pallet 50 may be positioned on the conveyor 302 so that the top side of the pallet faces downward. Alternatively, the pallet 50 may be positioned so that the bottom side faces downward. 5 [0082] Movement of each lower adjust beam assembly 304 in a vertical direction is controlled by the illustrated pair of lower adjust beam lifting actuators 306. The lower adjust beam lifting actuators 306 are hydraulically controlled. The fixed end of each lower 10 adjust beam lifting actuator 306 is coupled to a cross member 301 on the frame 300. The use of hydraulics for controlling the lower adjust beam lifting actuators 306 allows for a more precise control of the lower adjust beams 308. Alternatively, the lower adjust beam 15 lifting actuators 306 could be controlled by other methods, such as pneumatics, for example. [0083] The lower adjust beam assemblies 304 initially raise the pallet 50 off of the conveyor 302 prior to adjusting the lead boards 53 and 55, and then 20 lowers the pallet back on the conveyor after the lead boards have been adjusted. Illustration of the pallet 50 lifted off of the conveyor 302 is shown in FIG. 18. Low pressure is sufficient for raising the pallet 50 off of the conveyor 302. When the pallet 50 is raised 25 off of the conveyor 302, the lead boards 55 on the other side of the pallet 50 contact a pair of upper adjust beams or bars 310. [0084] Coupled to each upper adjust beam 310 is a pair of upper lead board adjust actuators 312, which is 30 also hydraulically controlled for adjusting one of the lead boards 55 of the pallet 50. The fixed ends of the upper lead board adjust actuators 312 are pivotally coupled to the frame 300. 22 [0085] Movement of the upper adjust beams 310 in the horizontal direction is guided by a pair of upper adjust beam rails 350. The pair of upper adjust beam rails 350 is attached to the frame 300 at a midsection 5 303 thereof, and back where the upper adjust beams 310 are in a resting position. In addition, the upper adjust beams 310 are support by cam followers mounted on the pair of upper adjust beam rails 350 for allowing horizontal movement of the upper adjust beams. The 10 pair of upper adjust beam rails 350 also receive or resist the vertical pressure from the lower adjust beam lifting actuators 306 when pushing the pallet 50 against the upper adjust beams 310. [0086] Likewise, coupled to each lower adjust beam 15 308 is a lower lead board adjust actuator 322, which is also hydraulically controlled for adjusting one of the lead boards 53 on the other side of the pallet 50. The fixed end of the lower lead board adjust actuator 322 is pivotally coupled to the frame 300. 20 [0087] After the lower adjust beam assemblies 304 have lifted the pallet 50 off of the conveyor 302, an adjust stop assembly carried by the frame 300 holds the pallet in a stationary position. The adjust stop assembly includes a fixed adjust stop 316 and a 25 moveable adjust stop 314. The fixed ad-just stop 316 is coupled to the frame 300 and extends in a same direction as the lead board areas on the pallet 50. The moveable adjust stop 314 also extends in a same direction as the lead board areas on the pallet. The 30 moveable adjust stop 314 is for holding the pallet 50 in the stationary position by contacting and moving the lead board areas on one side of the pallet until the lead board areas on an opposite side of the pallet contact the fixed adjust stop 316. Movement of the 23 moveable adjust stop 314 between an extended and retracted position is via a pair of hydraulic adjust stop actuators 318 coupled thereto. [0088] As will now be discussed in greater detail, 5 each lower adjust beam 308 and each upper adjust beam 310 has a plurality of respective board grip fingers or hooks 326, 328 associated therewith. In the illustrated embodiment, each adjust beam 308, 310 has three spaced apart board grip fingers 326, 328. The 10 number of board grip fingers 326, 328 can vary, as will be appreciated by those skilled in the art. Each board grip finger 326, 328 is controlled by a respective actuator 327, 329. The actuators 327, 329 for the board grip fingers 326, 328 are pneumatically 15 controlled. Alternatively, hydraulics or springs may be used instead pneumatics. [0089] After the pallet 50 is firmly held in place by the moveable adjust stop 314 against the fixed adjust stop 316, the respective lower board grip 20 fingers 326 and the respective upper board grip fingers 328 can be selectively operated depending on how many of the lead boards 53, 55 need to be adjusted. Each board grip finger 326, 328 has an extended position and a retracted position. When extended, each board grip 25 finger 326, 328 extends between the gap between the lead board 53, 55 to be adjusted and an adjacent board. [0090] Operation of the lead board adjustment apparatus 242 is based on a controller 330, which includes a hydraulics controller section 332 and a 30 pneumatics controller section 334. For purposes of simplifying the drawings, interfaces between the controller sections 332, 334 and the corresponding hydraulic and pneumatic actuators 306, 318, 322, 327 24 and 329 are not shown, but will be readily understood by those skilled in the art. [0091] The controller 330 may operate based on a processor for controlling the hydraulics controller 5 section 332 and the pneumatics controller section 334. The processor operates in response to the repair recipe 78 generated by the FMS server 56 for the pallet 50. Alternatively, the controller 330 may be operated independently from the repair recipe 78 for adjusting 10 the lead boards 53, 55 on the pallet 50, as will be appreciated by those skilled in the art. [0092] Once the lower and upper board grip fingers 326, 328 are extended, the corresponding lower and upper lead board adjust actuators 322 and 312 are 15 retracted for pulling the lead boards against either the edge of the fixed adjust stop 316 or the edge of the moveable adjust stop 314. In other words, the lead boards 53, 55 on one-half of the pallet 50 are adjusted against the edge of the fixed adjust stop 316, whereas 20 the lead boards on the other half of the pallet are adjusted against the edge of the moveable adjust stop 314. All four lead boards 53, 55 are being adjusted in the illustrated example even though the apparatus 242 can be operated for adjusting a single lead board. 25 (0093] Once the adjusted lead boards 53, 55 are in place, the lower adjust beam assemblies 304 operate under high pressure via the lower adjust beam lifting actuators 306 so as to put enough pressure on the lead boards so that they are held in their adjusted place by 30 their existing nails. This allows the adjusted lead boards 53, 55 to be held in place when the moveable adjust stop 314 is retracted and the lower adjust beam lifting actuators 306 return the pallet 50 to the conveyor 302. The pallet 50 with the adjusted lead 25 boards 53, 55 is then moved via the conveyor 302 to a nailing machine 244 for nailing the adjusted lead boards in place. [0094] A method for adjusting lead boards 53, 55 on 5 a pallet 50 using a lead board adjustment apparatus 242 is provided. As noted above, the lead board adjustment apparatus 242 comprises a frame 300, and an adjust stop assembly carried by the frame. A pair of spaced apart upper adjust beam assemblies is carried by the frame. 10 Each upper adjust beam assembly may comprise an upper adjust beam 310 for contacting a respective lead board area 55 on a first surface of the pallet 50, and a plurality of upper board grip fingers 328 having an extended position and a retracted position. A pair of 15 spaced apart lower adjust beam assemblies 304 is carried by the frame 300. Each lower adjust beam assembly may comprise a lower adjust beam 308 for contacting a respective lead board area 53 on a second surface of the pallet 50, and a plurality of lower 20 board grip fingers 326 having an extended position and a retracted position. [0095] Referring now to the flow diagram in FIG. 20, from the start (Block 400), the method comprises positioning the pallet 50 in a pallet receiving area at 25 Block 402. The pallet 50 is lifted so that the respective lead board areas on the second surface of the pallet contact the lower adjust beams 308 at Block 404, and the respective lead board areas on the first surface of the pallet contact the upper adjust beams 30 310 at Block 406. The pallet 50 may then be held in a stationary position using the adjust stop assembly at Block 408. The method may further comprise selectively placing the plurality of upper and lower board grip fingers 328, 326 in the extended position corresponding 26 to the at least one lead board 53, 55 needing adjustment (Block 410), and selectively moving the upper and lower adjust beams 310, 308 corresponding to the at least one lead board needing adjustment, with 5 the at least one lead board 53, 55 being moved until the adjust stop assembly is contacted (Block 412). The method ends at Block 414. [0096] Many modifications and other embodiments of the invention will come to the mind of one skilled in 10 the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and 15 embodiments are intended to be included as readily appreciated by those skilled in the art. 27

Claims

1. A lead board adjustment apparatus for a pallet, said apparatus comprising: 5 a frame; a pallet receiving area associated with said frame for receiving the pallet, the pallet comprising spaced apart lead board areas on a first surface of the pallet and spaced apart lead board areas on a second 10 surface of the pallet opposite the first surface, said lead board areas having at least one lead board coupled thereto needing adjustment; an adjust stop assembly carried by said frame and for holding the pallet in a stationary position; 15 a pair of spaced apart upper adjust beam assemblies carried by said frame, each upper adjust beam assembly comprising an upper adjust beam for contacting a respective lead board area on the first surface of the pallet, and a plurality of upper board 20 grip fingers having an extended position and a retracted position; a pair of spaced apart lower adjust beam assemblies carried by said frame, each lower adjust beam assembly comprising a lower adjust beam for 25 contacting a respective lead board area on the second surface of the pallet, and a plurality of lower board grip fingers having an extended position and a retracted position; and a controller coupled to said pairs of upper 30 and lower adjust beam assemblies for selectively placing said plurality of upper and lower board grip fingers in the extended position corresponding to the at least one lead board needing adjustment, and 28 selectively moving said upper and lower adjust beams corresponding to the at least one lead board needing adjustment, with the at least one lead board being moved until 5 said adjust stop assembly is contacted.

2. The lead board adjustment apparatus according to Claim 1 wherein said adjust stop assembly comprises: 10 a fixed adjust stop coupled to said frame and extending in a same direction as the lead board areas on the pallet; and a moveable adjust stop extending in a same direction as the lead board areas on the pallet, said 15 moveable adjust stop holding the pallet in the stationary position by contacting and moving the lead board areas on one side of the pallet until the lead board areas on an opposite side of the pallet contact said fixed adjust stop. 20

3. The lead board adjustment apparatus according to Claim 2 wherein said upper and lower adjust beams are selectively moved so that the at least one lead board needing adjustment butts up against an 25 edge of at least one of said moveable adjust stop and said fixed adjust stop.

4. The lead board adjustment apparatus according to Claim 1 wherein each upper adjust beam 30 assembly comprises a plurality of upper actuators coupled between said frame and said upper adjust beam; and wherein each lower adjust beam assembly comprises a plurality of lower actuators coupled between said frame and said lower adjust beam. 29 30

5. The lead board adjustment apparatus according to Claim 1, wherein each upper adjust beam assembly comprises a plurality of upper grip finger actuators coupled to said plurality of upper board grip fingers for positioning thereof; and wherein each lower adjust beam assembly comprises a plurality of lower grip finger actuators s coupled to said plurality of lower board grip fingers for positioning thereof.

6. The lead board adjustment apparatus according to Claim 1, wherein each lower adjust beam assembly comprises a lifting actuator coupled between said frame and said lower adjust beam; and wherein said controller controls said lifting actuators for lifting the pallet off of said pallet receiving area until said upper adjust beams contact the 1o respective lead board areas on the first surface of the pallet.

7. The lead board adjustment apparatus according to Claim 6, wherein said controller further controls said lifting actuators for further lifting the pallet for applying additional pressure on the respective lead board areas after adjustment of the at least one lead board so that the at least one adjusted lead board remains in its adjusted position is when the pallet is returned to said pallet receiving area.

8. A lead board adjustment apparatus for a pallet comprising spaced apart lead board areas on a first surface of the pallet and spaced apart lead board areas on a second surface of the pallet opposite the first surface, the lead board areas having at least one lead board coupled thereto needing adjustment, the lead board adjustment apparatus 20 comprising: a frame; an adjust stop assembly carried by said frame and for holding the pallet in a stationary position; a pair of spaced apart upper adjust beam assemblies carried by said frame, each 25 upper adjust beam assembly comprising an upper adjust beam for contacting a respective lead board area on the first surface of the pallet, and a plurality of upper board grip fingers having an extended position and a retracted position; a pair of spaced apart lower adjust beam assemblies carried by said frame, each lower adjust beam assembly comprising a lower adjust beam for contacting a respective 30 lead board area on the second surface of the pallet, and a plurality of lower board grip fingers having an extended position and a retracted position; and a controller coupled to said pairs of upper and lower adjust beam assemblies for selectively placing said plurality of upper and lower board grip fingers in the extended position corresponding to the at least one lead board needing adjustment, 35 and 31 selectively moving said upper and lower adjust beams corresponding to the at least one lead board needing adjustment, with the at least one lead board being moved until said adjust stop assembly is contacted.

9. The lead board adjustment apparatus according to Claim 8, wherein said s adjust stop assembly comprises: a fixed adjust stop coupled to said frame and extending in a same direction as the lead board areas on the pallet; and a moveable adjust stop extending in a same direction as the lead board areas on the pallet, said moveable adjust stop for holding the pallet in the stationary position by i contacting and moving the lead board areas on one side of the pallet until the lead board areas on an opposite side of the pallet contact said fixed adjust stop.

10. The lead board adjustment apparatus according to Claim 9, wherein said upper and lower adjust beams are selectively moved so that the at least one lead board needing adjustment butts up against an edge of at least one of said moveable adjust stop is and said fixed adjust stop.

11. The lead board adjustment apparatus according to Claim 8, wherein each upper adjust beam assembly comprises a plurality of upper actuators coupled between said frame and said upper adjust beam; and wherein each lower adjust beam assembly comprises a plurality of lower actuators coupled between said frame and said 20 lower adjust beam.

12. The lead board adjustment apparatus according to Claim 8, wherein each upper adjust beam assembly comprises a plurality of upper grip finger actuators coupled to said plurality of upper board grip fingers for positioning thereof; and wherein each lower adjust beam assembly comprises a plurality of lower grip finger actuators 25 coupled to said plurality of lower board grip fingers for positioning thereof.

13. The lead board adjustment apparatus according to Claim 8, further comprising a pallet receiving area associated with said frame for receiving the pallet; wherein each lower adjust beam assembly comprises a lifting actuator coupled between said frame and said lower adjust beam; and wherein said controller controls said lifting 30 actuators for lifting the pallet off of said pallet receiving area until said upper adjust beams contact the respective lead board areas on the first surface of the pallet.

14. The lead board adjustment apparatus according to Claim 13, wherein said controller further controls said lifting actuators for further lifting the pallet for applying additional pressure on the respective lead board areas after adjustment of the at 32 least one lead board so that the at least one adjusted lead board remains in its adjusted position when the pallet is returned to said pallet receiving area.

15. A method for adjusting lead boards on a pallet using a lead board adjustment apparatus comprising a frame; an adjust stop assembly carried by the frame; a s pair of spaced apart upper adjust beam assemblies carried by the frame, each upper adjust beam assembly comprising an upper adjust beam for contacting a respective lead board area on a first surface of the pallet, and a plurality of upper board grip fingers having an extended position and a retracted position; and a pair of spaced apart lower adjust beam assemblies carried by the frame, each lower adjust beam assembly comprising a lower 1o adjust beam for contacting a respective lead board area on a second surface of the pallet, and a plurality of lower board grip fingers having an extended position and a retracted position, the method comprising: contacting the respective lead board areas on the second surface of the pallet with the lower adjust beams; is contacting the respective lead board areas on the first surface of the pallet with the upper adjust beams; holding the pallet in a stationary position using the adjust stop assembly; selectively placing the plurality of upper and lower board grip fingers in the extended position corresponding to the at least one lead board needing adjustment; and 20 selectively moving the upper and lower adjust beams corresponding to the at least one lead board needing adjustment, with the at least one lead board being moved until the adjust stop assembly is contacted.

16. The method according to Claim 15, wherein the adjust stop assembly comprises a fixed adjust stop coupled to the frame and extending in a same direction as 25 the lead board areas on the pallet; and a moveable adjust stop extending in a same direction as the lead board areas on the pallet, the moveable adjust stop for holding the pallet in the stationary position by contacting and moving the lead board areas on one side of the pallet until the lead board areas on an opposite side of the pallet contact the fixed adjust stop. 30

17. The method according to Claim 16, wherein the upper and lower adjust beams are selectively moved so that edges of the at least one lead board needing adjustment butts up against an edge of at least one of the moveable adjust stop and the fixed adjust stop.

18. The method according to Claim 15, wherein each upper adjust beam 35 assembly comprises a plurality of upper actuators coupled between the frame and the 33 upper adjust beam; and wherein each lower adjust beam assembly comprises a plurality of lower actuators coupled between the frame and the lower adjust beam.

19. The method according to Claim 15, wherein each upper adjust beam assembly comprises a plurality of upper grip finger actuators coupled to the plurality of 5 upper board grip fingers for positioning thereof; and wherein each lower adjust beam assembly comprises a plurality of lower grip finger actuators coupled to the plurality of lower board grip fingers for positioning thereof.

20. The method according to Claim 15, further comprising placing the pallet in a pallet receiving area associated with the frame; wherein each lower adjust 1o beam assembly comprises a lifting actuator coupled between the frame and the lower adjust beam; and wherein a controller controls the lifting actuators for lifting the pallet off of the pallet receiving area until the upper adjust beams contact the respective lead board areas on the first surface of the pallet.

21. The method according to Claim 20, wherein the controller further is controls the lifting actuators for further lifting the pallet for applying additional pressure on the respective lead board areas after adjustment of the at least on lead board so that the at least one adjusted lead board remains in its adjusted position when the pallet is returned to the pallet receiving area.

22. A lead board adjustment apparatus for a pallet, said lead board 20 adjustment apparatus substantially as hereinbefore described with reference to the accompanying drawings.

23. A method for adjusting lead boards on a pallet, said method substantially as hereinbefore described with reference to the accompanying drawings. 25 Dated 11 February 2011 CHEP Technology Pty Limited Patent Attorneys for the Applicant/Nominated Person SPRUSON & FERGUSON