AU2008215165A1

AU2008215165A1 - Block pack forming method and apparatus

Info

Publication number: AU2008215165A1
Application number: AU2008215165A
Authority: AU
Inventors: Beau Arthur Charles Davis; Martin Daniel Murphy
Original assignee: BEAU DAVIS
Current assignee: BEAU DAVIS
Priority date: 2007-02-14
Filing date: 2008-02-14
Publication date: 2008-08-21
Also published as: WO2008098294A1

Description

WO 2008/098294 PCT/AU2008/000184 TITLE BLOCK PACK FORMING METHOD AND APPARATUS FIELD OF THE INVENTION 5 The present invention relates to a Block Pack Forming Method and Apparatus. BACKGROUND TO THE INVENTION It is known in the art to stack blocks such as limestone blocks into packs for shipping. Preferably these packs are arranged such that a plurality of blocks are positioned at a first 10 orientation in a bottom layer. One or more upper layers of a plurality of blocks are then placed centrally on the bottom layer at a second orientation. When the blocks are assembled they are strapped together to form a pack. The packs are typically arranged so that the upper layer or layers overhang the bottom layer so that the packs can be readily lifted by a fork lift truck or the like in which the arms of the truck engages the pack at the 15 overhanging regions thereof. Commonly, the blocks used in these packs may be rectangular in nature. Previously these packs of blocks have been assembled manually. As such, the stacking of limestone blocks into packs for shipping has been labour intensive and inefficient. Quality control in assembly of the packs has also been a problem. 20 The present invention attempts to overcome at least in part the aforementioned disadvantages of previous block stacking methods. SUMMARY OF THE INVENTION In accordance with one aspect of the present invention there is provided a block pack 1 WO 2008/098294 PCT/AU2008/000184 forming method characterised by: a. placing a first group of rectangular blocks in a layer on a flat tray, the first group of blocks being laterally disposed; b. placing a second group of rectangular blocks in one or more layers on the blocks 5 from step (a), the second group of blocks being longitudinally disposed; and c. strapping blocks from the first and second groups together to form a pack and removing the pack from the flat tray wherein a lowermost row of each pack comprises at least one block less than the rows above it, such that at least one laterally orientated block remains on the tray. 10 a) In accordance with a further aspect of the present invention there is provided a block pack form apparatus, characterised in that it comprises a grabbing member arranged to lift a layer of rectangular blocks, and a tray for receiving blocks lifted by the grabbing member. 15 BRIEF DESCRIPTION OF THE DRAWINGS The present invention will now be described, by way of example, with reference to the accompanying drawings, in which: Figure 1 is a side perspective view of a Block Stacking Apparatus of the present invention; and 20 Figures 2a to 2n show schematically in sequence a method of the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENT(S) Referring to Figure 1, there is shown a block pack forming apparatus 8 comprising a lower frame 10 having a first longitudinal frame side 12, a second longitudinal frame side 2 WO 2008/098294 PCT/AU2008/000184 14 and a third transverse frame side 16. The second longitudinal frame side 14 is positioned substantially parallel to the first longitudinal frame side 12. The third transverse frame side 16 extends substantially perpendicular to the first longitudinal frame side 12 and the second longitudinal frame side 14. A first end of the third 5 transverse frame side 16 joins with a first end of the first longitudinal frame side 12 to form a first corner portion 18. A second end of the third transverse frame side 16 joins with a first end of the second longitudinal frame side 14 to form a second corner portion 20. The corner portions 18 and 20 are each provided with a wheel member 22, only one of which can be seen. Further, respective wheel members 22 are provided at a second end 10 of the first longitudinal frame side 12 and a second end of the second longitudinal frame side 14 as shown in Figure 1. In Figure 1 there is also provided a moveable plate comprising a tray 26. The tray 26 comprises a plurality of transverse indentations 27. The tray 26 engages with inner rails 36 (only one of which can be seen) of the adjacent longitudinal frame sides 12 and 14. 15 Upright members 38 are provided at both ends of the first longitudinal frame side 12 and the second longitudinal frame side 14. An upper frame 40 comprises a first upper frame side 42 extending substantially parallel to the first longitudinal frame side 12 ofthe lower frame 10, and a second upper frame side 44 extending substantially parallel to the second frame side 14 of the lower frame 10. A third upper frame transverse side 46 extends from 20 a first end of the first upper frame side 42 to a first end of the second upper frame side 44, as shown in Figure 1. In Figure 1, there is further provided a first standing member 48 extending from the first frame side 12 to the first upper frame side 42 and beyond. A second standing member 48 extends from the second frame side 14 to the second upper frame side 44 and beyond. A 3 WO 2008/098294 PCT/AU2008/000184 moveable arm 52 is positioned between the standing members 48 and the upright members 38. The movable arm 52 is engaged slidably with a plurality of vertical bars 53. The bars 53 extend upwardly from the longitudinal side frames 12 and 14 and upper side frames 55. The moveable arm 52 is able to move up and down as shown by arrow A by 5 means of a hydraulic system or similar. A pair of struts 23 interconnect the tray 26 and the side 42 and the tray 26 and the side 44 respectively. The struts 23 are pivotally connected at each end thereof. The struts 23 are arranged to pivot about connections to hydraulic frames 24 so as to move the tray 26 horizontally between a retracted position and an extended position. 10 Figure 1 also shows that the moveable arm 52 is further provided with a rotatable member 54. The rotatable member 54 extends downwards through the arm 52 to engage with a supporting portion 58 of a grabber 56. The rotatable member 54 can move in the directions shown by arrow B. The grabber 56 is attached to the rotatable member 54 such that the grabber 56 can be rotated in the directions shown by arrow B. The grabber 56 15 comprises the supporting portion 58 which extends parallel to the moveable arm 52. A plurality of arm members 60 extend downwardly from each end of the supporting portion 58. The arm members 60 are engaged with the supporting portion 58 such that they can move laterally in the directions shown by arrow C. A respective grabbing member 62 is 20 provided at a lower end of each arm member 60. The rotatable member 54 and the arm members 60 may be moved in their respective positions by means of a hydraulic system or similar. A pair of spaced mountings 64 are provided on the third frame side 16 of the lower frame 10, as shown in Figure 1. Respective bar members 66 are attached to each mounting 64 at 4 WO 2008/098294 PCT/AU2008/000184 first ends thereof The bar members 66 can be rotated in the directions shown by arrow D. Second ends of the bar members 66 are provided with a shunting member 68. An automatic strapping mechanism of known type (not shown) is provided at a position between the shunting member 68 and the grabber 56. The automatic strapping mechanism 5 is attached at either side to the first longitudinal frame side 12 and the second longitudinal frame side 14 respectively. Straps 70 from the strapping mechanism are inserted in the inter portion 27 as will be described. In use, groups of three longitudinally arranged rectangular blocks are placed in a row. The block pack forming apparatus 8 moves over the top of this row and, following the 10 sequence of steps described below, arranges and straps a plurality of these blocks into a specific configuration. In the Figures 2a to 2n, whenever the grabber 56 is required to engage a group of blocks 100 from the row, the block pack forming apparatus 8 moves to the left such that the grabber 56 is arranged above a group of three longitudinally arranged blocks 100. 15 Initially, the tray 26 is arranged in a retracted position and the block pack forming apparatus 8 moves over the row such that the grabber 56 is arranged above a group of three longitudinally arranged blocks 100. The grabber 56 engages a group of three adjacent blocks as shown in Figure 2a. The grabber 56 then moves upwards to allow the tray 26 to move to a position below the 20 grabber 56. Referringto Figure 2b, the grabber 56 effects a substantially 90 degree turn in a substantially horizontal plane. The grabber 56 then lowers the group of blocks 100 onto the tray 26 such that the blocks are laterally disposed and each of the centres of the two rightmost blocks in Figure 2b are substantially vertically aligned with the indentations 27. As shown in Figure 2c, the tray 26 retracts again and the grabber 56 returns to its original 5 WO 2008/098294 PCT/AU2008/000184 non-rotated position. The block pack forming apparatus 8 moves to the left so that the next group of three longitudinally arranged blocks 100 are below the grabber 56. The grabber 56 engages the group of three blocks 100 and lifts them upwards. The block pack forming apparatus 8 then moves to the left so that a further group of three longitudinally 5 arranged blocks 100 are below the grabber 56. The grabber 56 then lowers the already engaged group of three blocks 100 onto the further group of three blocks 100 such that there is now a group of six blocks arranged three blocks wide by two blocks high. The grabber 56 then engages this group of six blocks and lifts them upwards. The tray 26 then moves under the grabber 56 as shown in Figure 2d such that the centre of the two 10 rightmost blocks on the tray 26 in Figure 2d is substantially vertically aligned with the centre of the six blocks engaged by the grabber 56. The grabber 56 then lowers the group of six blocks onto the tray 26 such that the group of six blocks are longitudinally arranged. As shown in Figure 2e, the two lower blocks to the right of Figure 2e and the group of six 15 blocks above are strapped together by the strapping mechanism 70 to form a pack 102. The indentations 27 assist in getting straps underneath the lower row. As shown in Figure 2f, the pack 102 is then engaged by the grabber 56 and the tray 26 retracted so that the grabber 56 can be lowered to leave the newly formed pack 102 on the ground. A single laterally orientated block 104 is left on the tray 26. 2.0 The block pack forming apparatus 8 then moves to the left so that the grabber 56 is arranged above the next group of three longitudinally arranged blocks 100. As shown in Figure 2g, the grabber 56 engages the group of three blocks 100 and lifts them upwards. As shown in Figure 2h, the grabber 56 effects a substantially 90 degree turn in a substantially horizontal plane and initially lowers the blocks to a height just above an 6 WO 2008/098294 PCT/AU2008/000184 upper end of the tray 26, the tray 26 still being retracted. The tray 26 then moves towards the grabber 56. The single laterally orientated block 104 left on the tray 26 from the previous step is pushed leftwards relative to the tray 26 of Figure 2h such that four blocks are now laterally disposed adjacent one another on the tray 26 and the centres of each of 5 the two rightmost blocks are substantially vertically aligned with the indentations 27. The block pack forming apparatus 8 moves to the left such that the grabber 56 is above the next group of three longitudinally arranged blocks 100. The tray 26 is retracted and the grabber 56 engages the group of three blocks 100. The block pack forming apparatus 8 then moves to the left so that a further group of three longitudinally arranged blocks 10 100 are below the grabber 56. The grabber 56 then lowers the already engaged group of three blocks 100 onto the further group of three blocks 100 such that there is now a group of six blocks arranged three blocks wide by two blocks high. As shown in Figure 2i, the grabber 56 then engages this group of six blocks and lifts them upwards. The tray 26 then moves under the grabber 56 such that the centre of the two 15 laterally orientated rightmost blocks on the tray 26 in Figure 2j is substantially vertically aligned with the centre of the six longitudinally orientated blocks engaged by the grabber 56. The grabber 56 then lowers the group of six blocks onto the tray 26 such that the group of six blocks are longitudinally arranged as shown in Figure 2j. As shown in Figure 2k, the lower rightmost laterally orientated two blocks and the six 20 longitudinally orientated blocks above are then strapped by the strapping mechanism 70 to form a pack 102. The indentations 27 assist in getting straps beneath the lower row. As shown in Figure 21, the grabber 56 engages the newly formed pack 102 and lifts it upwards. The shunt member 68 is lowered and the tray 26 retracts. The grabber 56 lowers the pack 102 onto the ground. 7 WO 2008/098294 PCT/AU2008/000184 As shown in Figure 2m, the retraction of the tray 26 causes the lowered shunt member 68 to engage with the remaining two laterally orientated blocks on the tray 26. This action moves the blocks to the right relative to the tray 26 of Figure 2m such that the centres of each of the two blocks are substantially vertically aligned with the indentations 27. The 5 block pack forming apparatus 8 moves to the left such that the grabber 56 is above the next group of three longitudinally orientated blocks 100. The grabber 56 engages the group of three blocks 100. The block pack forming apparatus 8 then moves to the left so that a further group of three longitudinally arranged blocks 100 are below the grabber 56. The grabber 56 then lowers the already engaged group of three blocks onto the further 10 group of three blocks 100 such that there is now a group of six blocks arranged three blocks wide by two blocks high. As shown in Figure 2n, the grabber 56 engages the group of six blocks and moves upwards. The shunt member 68 moves back to its original raised position and the tray 26 moves under the grabber 56 such that the centre of the two remaining laterally orientated 15 blocks is substantially vertically aligned with the centre of the six blocks longitudinally orientated engaged by the grabber 56. The grabber 56 then lowers the group of six blocks onto the two blocks already arranged on the tray 26. The blocks are then strapped by the strapping mechanism 70 to form a pack. The indentations 27 assist in getting straps beneath the lower row. The grabber 56 then engages the newly formed pack 102and, after 20 the tray 26 retracts once more, the grabber 56 lowers the newly formed pack to the ground. The sequence of steps described hereinabove may then be repeated again to form further packs of blocks. Whilst the present invention has been described with particular reference to the 8 WO 2008/098294 PCT/AU2008/000184 manufacture of block packs containing eight blocks, it is to be understood that it is equally applicable to manufacture of block packs containing other numbers of blocks such as five, eleven or fourteen blocks. Modifications and variations as would be apparent to a skilled addressee are deemed to 5 be within the scope of the present invention. 9

Claims

1. A block pack forming method characterised by: a. placing a first group of rectangular blocks in a layer on a flat tray, the first 5 group of blocks being laterally disposed; b. placing a second group of rectangular blocks in one or more layers on the blocks from step (a), the second group of blocks being longitudinally disposed; and c. strapping blocks from the first and second groups together to form a pack 10 and removing the pack from the flat tray wherein a lowermost row of each pack comprises at least one block less than the rows above it, such that at least one laterally orientated block remains on the tray.

2. A block pack forming method according to claim 1, characterised in that the first group of blocks is initially longitudinally orientated and rotated through a right 15 angle so as to be laterally orientated before being placed on the flat tray.

3. A block pack forming method according to claim 1 or 2 characterised in that a center of the second group of rectangular longitudinally orientated blocks is placed so as to be substantially vertically aligned with a centre of certain laterally orientated blocks of the first group in the tray, the second group of rectangular 20 blocks being subsequently strapped to the certain blocks of the first group so as to form a block pack with overhang, and removing the formed block pack from the tray.

4. A block pack forming method according to claim 3, characterised in that subsequently a third group of longitudinally orientated rectangular blocks is 10 WO 2008/098294 PCT/AU2008/000184 rotated through a right angle so as to be laterally orientated and then placed on the tray adjacent the block or blocks remaining in the tray.

5. A block pack forming method according to claim 4, characterised in that a fourth group of longitudinally orientated blocks is placed on the blocks on the tray, a 5 centre of the fourth group of longitudinally orientated blocks is substantially vertically aligned with certain of the laterally disposed blocks on the tray, the fourth group of longitudinally extending blocks being strapped to the certain laterally disposed blocks to form a second block pack and removing the second block pack from the tray, the remaining laterally orientated blocks remaining on 10 the tray.

6. A block pack forming method according to claim 5, characterised in that the laterally orientated blocks remaining on the tray are moved laterally to the position occupied by the removed laterally orientated blocks, a fifth group of longitudinally orientated blocks then filing places on the blocks on the tray, the 15 blocks on the tray then being strapped together to form a third block pack, and remove the third block pack from the tray.

7. A block pack form apparatus, characterised in that it comprises a grabbing member arranged to lift a layer of rectangular blocks, and a tray for receiving blocks lifted by the grabbing member. 20

8. A block pack forming apparatus according to claim 7, characterised in that the grabbing member is arranged to rotate the lifted layer of rectangular blocks through a right angle in a horizontal plane. 11 WO 2008/098294 PCT/AU2008/000184

9. A block pack forming apparatus according to claim 7 or 8, characterised in that the tray is moveable horizontally between a retracted position and an extended position below the grabbing member.

10. A block pack forming apparatus according to any one of claims 7 to 9, 5 characterised in that there is provided a shunting member for moving rectangular blocks in the tray.

11. A block pack forming apparatus according to any one of claims 7 to 10, characterised in that the apparatus comprises a strapping member. 12