CA2575236A1 - Pivotal and translational dock leveler lip - Google Patents

Abstract

A dock leveler, for bridging the gap between a loading dock platform and a vehicle at the dock, includes an adjustably overlapping lip and ramp that provide a traffic surface of variable length to accommodate situations where there is only a limited amount of space for the lip to rest on the rear of the vehicle. The lip pivots and translates from a stored, pendant orientation to an operative orientation with a range of extended positions. In the stored position, one edge of the lip protrudes above the deck to inhibit material handling equipment from accidentally driving over the edge of the deck when a vehicle is not parked adjacent the dock leveler.

Description

PIVOTAL AND TRANSLATIONAL DOCK LEVELER LIP
Background Of The Invention Field Of The Invention The subject invention generally relates to dock levelers, and more specifically, to dock levelers having a lip extension.
Descri~~tion Of Related Art Dock levelers are used to compensate for height differences between a loading dock platform and an adjacent bed of a truck or trailer. A typical dock leveler includes a deck, also known as a ramp or dockboard, which is pivotally hinged along its back edge to vary the height of its front edge. An extension plate, or lip, extends outward from the deck's front edge to span the gap between the rear of the truck bed and the front edge of the deck. The lip is usually moveable between a retracted, stored position (i.e., clear of the truck) to an extended, operative position.
In the extended, operative position, the lip extends from the deck's front edge and rests upon the truck bed to form a bridge between the two. This allows personnel and material handling equipment to readily move on and off the vehicle during loading and unloading operations.
With some dock levelers, the lip moves linearly, as disclosed in U. S. Patent 6,081,954 and German Patent DE2800128A1. The linear movement allows varying the extent to which the front edge of the lip overlaps the vehicle bed. A
variable overlap can be useful when cargo rests particularly near the rear edge of the vehicle bed, and thus limits the bed's available floor space upon which the front edge of the lip may rest. In such cases, the operator may move the lip linearly up against the cargo. But this could create dangerously insufficient overlap between the lip and the truck bed;
as such an approach relies on the operator's judgment. Too small of an overlap could result in loss of contact between the lip and the bed - potentially allowing the deck to fall. Another dock leveler, disclosed in German Patent DE19612135A1, has a lip fixed relative to its deck with side bumpers that move along a plane. However, all of these devices in their stored positions (also known as a cross-traffic position where an upper surface of the deck is flush with the adjacent floor) provide no significant obstruction to a forklift or other material handling equipment that might accidentally drive off the front edge of the deck when a vehicle is not present at the dock.
However, some dock levelers include a pivotal lip with a rear edge that protrudes above the deck when the deck is in its cross-traffic position, thereby providing an obstruction to material-handling equipment. During loading or unloading operations, a front edge of the tip pivots out over the rear edge of the truck bed, while the rear edge of the lip pivots down to overlap the deck, thus bridging the gap between the deck and the truck bed while removing the obstruction to material-handling equipment. But the extension of the lip is generally fixed, so the lip is unable to adjust to situations where there is limited floor space at the rear of a vehicle bed.
Another dock leveler, disclosed in U. S. Patent 4,920,598, provides a pivoting lip with some sliding movement when the tip hangs generally pendant. In the stored, cross-traffic position, the sliding movement allows the lip to protrude above the deck.
The protruding portion of the lip thus creates an obstruction that helps inhibit equipment from accidentally driving off the front edge of the deck. When the deck is raised from the cross-traffic position, the sliding movement allows the lip 30 to translate relative to the deck to a position where the rear or top edge of the lip no longer forms an obstruction. The lip can then be extended to a position where the rear edge of the lip abuts the front edge of the deck, thus preventing the lip from sliding back. Thus, cargo at the very back of the truck bed may interfere with a fully extended lip. So in such cases, the lip is moved to a substantially pendant position below the deck, and the deck is either moved to its cross-traffic position or to a below-dock position. In the cross-traffic position the deck is generally flush with the adjacent floor of the dock platform, and in the below-dock position, the deck is below the adjacent floor. In either case, the lip does not rest on the bed of the truck nor does it protrude above the deck. This allows some material-handling equipment, such as fork lift trucks, to drive onto the deck and reach out with their forks to place or remove loads from the very rear of the truck bed without interference from the lip. However, the gap between the deck and the truck bed (due to the lip being pendant) is generally not meant to be driven across. Thus, the gap inhibits some material handling equipment, such as pallet jacks, from loading or unloading cargo from the very rear of the vehicle bed.
Summary Of The Invention In order to provide a dock leveler with a traffic surface of variable length, a dock leveler includes a lip that pivots and translates from a stored, pendant position to various operative, extended positions.
In some embodiments, a dock leveler includes a lip moveably coupled to a deck, such that when the deck is in a cross-traffic position, the lip protrudes above the deck to obstruct material handling equipment from accidentally driving over the edge of the deck when a vehicle is not parked adjacent the dock leveler.
In some embodiments a dock leveler includes a deck and a lip that together provide a traffic surface of variable length by having a variable overlap between the lip and the deck.
In some embodiments, a dock leveler includes a deck and a lip with the lip being pivotal relative to the deck about a substantially horizontal axis and being further rotatable about a second axis generally perpendicular to the horizontal axis, whereby a forward edge of the lip can lie at various angles relative to the horizontal axis.
In some embodiments, a dock leveler includes a manually operated switch installed a significant distance away from a lip of the dock leveler to help encourage an operator to stay off the leveler while the lip moves from a pendant position to an extended position.
in some embodiments, a dock leveler includes a deck with a recess in which a lip may lie to help align an upper surface of the lip to an upper surface of the deck.
Therefore, in accordance with the present invention, there is provided a dock leveler adapted to engage a vehicle that can have one of several different operational circumstances. The dock leveler comprises a ramp and a lip pivotally coupled to the ramp about a substantially horizontal axis, the axis being fixed relative to the ramp, the lip being moveable relative to the ramp such that the lip and the ramp overlap a variable amount to create a traffic surface of variable length to accommodate the different operational circumstances.
Also in accordance with the present invention, there is provided a dock leveler adapted to engage a vehicle. The dock leveler comprises a ramp having a forward edge and a rear edge and a lip adjacent to the forward edge and being pivotally coupled to the ramp about a substantially horizontal axis, the axis being fixed relative to the forward edge, wherein the lip is moveable to place a distal edge of the lip upon the vehicle while creating a traffic surface of variable length extending from the distal edge to the rear edge.
Further in accordance with the present invention, there is provided a dock leveler adapted to engage a vehicle. The dock leveler comprises a ramp pivotal about a first axis and a lip pivotal relative to the ramp about a second axis, wherein the lip is pivotal from a pendant orientation to an operative orientation and is also selectively moveable to a fully extended position and a partially extended position, wherein the lip includes a distal edge adapted to engage the vehicle with a distance between the distal edge and the second axis being greater when the lip is in the operative orientation while in the fully extended position than when the lip is in the operative orientation while in the partially extended position.
Still further in accordance with the present invention, there is provided a method of operating a dock leveler that includes a ramp rotatable about a first axis with a lip coupled to the ramp and being adapted to engage a vehicle, the lip having a width substantially the same as a width of the ramp. The method comprises pivoting the lip about a substantially horizontal axis and simultaneously providing relative translation between the lip and the ramp.
Still further in accordance with the present invention, there is provided a dock leveler adapted to engage a vehicle. The dock leveler comprises a ramp, a lip having a front edge and a rear edge with the front edge being adapted to engage the vehicle and the lip being pivotally coupled to the ramp to render the lip moveable between a pendant orientation and an operative orientation, wherein the rear edge of the lip protrudes above the ramp in the pendant orientation and overlays the ramp in the operative orientation and a switch disposed at a remote location relative to the lip, wherein the switch being manually unattended inhibits the lip from moving completely from the pendant orientation to the operative orientation.

5 Still further in accordance with the present invention, there is provided a dock leveler adapted to engage a vehicle that can have one of several different operational circumstances. The dock leveler comprises a ramp, a iip pivotally coupled to the ramp about a substantially horizontal axis and slidably coupled to the ramp and being moveable relative to the ramp such that the lip and the ramp overlap a variable amount to create a traffic surface of variable length to accommodate the different operational circumstances and a means for rotating the lip about the horizontal axis.
Brief Description Of The Drawings Figure 1 is a side view of one exemplary embodiment of a dock lever in its standby position with its lip in a stored, pendant position.
Figure 2 shows the dock leveler of Figure 1 with its ramp having risen above the bed of a vehicle while the leveler's lip hangs in a pendant orientation relative to the ramp.
Figure 3 is the same as Figure 2, but with the lip pivoted outward to an intermediate orientation.
Figure 4 is the dock leveler of Figure 1 touching its lip to a vehicle.
Figure 5 shows the dock leveler of Figure 1 simultaneously resting a portion of the lip upon the vehicle, pivoting the ramp downward about an axis, and moving another portion of the lip toward the axis.
Figure 6 shows the dock leveler of Figure 1 with its lip at an operative orientation and a partially extended position.
Figure 7 shows the dock leveler of Figure 1 with its lip at an operative orientation and a fully extended position.
Figure 8 is a top view of Figure 6 with the lip having rotated about an axis perpendicular to a horizontal axis.
Figure 9 is a hydraulic schematic used in operating the dock leveler of Figure 1.
Figure 10 is an electrical schematic associated with the hydraulic schematic of Figure 9.
Figure 11 shows the dock leveler of Figure 1 with its lip pivotally fixed to force sliding motion between the lip and the deck as the deck descends.
Description of the Preferred Embodiment To compensate for height differences between a loading dock platform 10 and the bed of a vehicle 12 (e.g., truck, trailer, etc.) and to form a bridge between the two, a dock leveler 14 includes a pivotal ramp 16 with a moveable lip extension 18, as shown in Figures 1 - 8. Along a rear edge 20 of ramp 16, a hinge 22 allows ramp 16 to pivot about a generally horizontal axis 24 to adjust the height of a front edge 26 of ramp 16. A ramp actuator 28 (e.g., fluid cylinder, diaphragm, bellows, spring, motor-driven actuator, etc.) can then move front edge 26 to the same general elevation as a rear edge 30 of vehicle 12.
To bridge the gap between rear edge 30 of vehicle 12 and front edge 26 of ramp 76, lip 18 is moveably coupled to front edge 26. Lip 18 is interconnected to the front edge 26 to provide a variety of positions and types of motion relative to the ramp. For example, lip 18 is pivotable relative to the ramp 16 between a stored, or pendant, orientation (as in Fig. 1 ) wherein the lip 18 is disposed generally perpendicular to ramp 16; and an operative orientation wherein lip 18 is pivoted so as to form a generally co-planar extension of the ramp 16. It is in the operative orientation that lip 18 forms a bridge between the ramp 16 and the rear edge 30 of the vehicle 12. Movement of the lip 18 to the operative orientation thus creates a traffic surface 32 (Figures 6 and 7) extending from a front edge 34 of lip 18 to rear edge 20, which allows personnel and material handling equipment to readily move on and off the vehicle during loading and unloading operations.
According to one aspect of the invention, the length of traffic surface 32 can vary. That is, with lip 18 in the operative orientation, the amount of overlap between the rear portion of the lip 18 and the front portion of the ramp 16 may be different for different operational circumstances. Indeed, the nature of the interconnection between lip 18 and ramp 16 is adapted to provide this adjustability of the length of traffic surface 32 based on the operational circumstances, as will be discussed in detail below.
In some embodiments, lip 18 is coupled to ramp 16 by way of a sliding connection that includes a series of studs 40 extending through a corresponding series of slots 42 in lip 18. Studs 40 are screwed into or otherwise fastened to a hinge plate 44 of a hinge 39. Hinge plate 44 can be one continuous plate or a series of individual plate segments, with each segment carrying one of studs 40. A slip-fit between studs 40 and slots 42 allows the relative sliding motion, while the heads on studs 40 prevent lip 18 and hinge plate 44 from separating. Hinge 39, in turn, pivotally couples plate 44 to ramp 16 to provide lip 18 with pivotal motion about a substantially horizontal axis 48 for certain operational circumstances, and to provide lip 18 with a fixed reference point for a more complex translating/rotational motion for other operational circumstances, as discussed below.
When the lip 18 is in the pendant orientation of Figures 1 and 2, the sliding connection allows the iip 18 to slide relative to the ramp 16 between a stored, pendant position (in which the lip 18 extends above the ramp 16 to form an obstruction to material handling equipment that might otherwise accidentally drive of the front edge of the ramp 16) as in Figure 1, and a retracted, pendant position in which the rear edge of the lip 18 does not extend above the upper surface of the ramp 16, as in Figure 2. According to the embodiment, movement of lip 16 from the stored, pendant position to the retracted, pendant position is caused by relative movement between the ramp 16 and lip 18. That is, lip 18 remains substantially fixed as ramp 16 is raised to the Figure 2 position. The sliding connection between the lip 18 and ramp 16 facilitates this movement. In this regard, the sliding connection between lip 18 and ramp 16 is similar to the one disclosed in U.S. Patent 4,920,598.
In distinction to the '598 patent, however, the sliding connection according to this embodiment also provides for a sliding translation of the lip 18 relative to the ramp 16 for the full range of lip orientations between the pendant orientation and the operative orientation. For example, in the operative orientation according to this embodiment, rotation of the lip about axis 54 allows lip 18 to adjust to situations where vehicle 12 andlor load 36 are disposed at a slight angle to dock face 10, as shown in Fig. 8. Such movement does not appear to be possible in the context of the '598 patent as the rear edge of the lip abuts a vertical surface on the ramp when the lip is in the operative orientation (Fig. 3 of '598). Perhaps more importantly, the interconnection between the lip 18 and ramp 16 in this embodiment is also distinct from that shown in the '598 patent, as the interconnection here provides for sliding movement of the lip relative to the ramp 16 at intermediate orientations between the pendant and operative orientations. It is this movement that allows the amount of overlap between the rear portion of lip 18 and the front portion of deck 16 to be different for varying operational circumstances, and thus to adjust the length of the traffic surface 32 depending on those circumstances. To provide this enhanced functionality relative to the '598 patent, the position of slots 42 in lip 18 and the height of hinge 39 relative to traffic surface 32 are different to allow lip 18 to slide relative to ramp 16 throughout the range of lip orientations. More specifically, slots 42 are shifted further away from a rear edge 62 of lip 18 and hinge 39 is raised to be closer to traffic surface 32.
The operational advantages provided by this structure will now be discussed in greater detail, particularly in regard to the ability of the length traffic surface 32 to be adjusted depending on operational circumstances. In one operational circumstance, the vehicle being unloaded has ample floor space at the rear to receive the lip 18. In this instance, the leveler according to this embodiment would be operated conventionally. Ramp 16 would be raised until studs 40 engaged the tops of slots 42 and raised lip 18 out of lip keepers 60. Once the front edge of lip were high enough for front edge 34 to clear the bed of the vehicle, the lip would be rotated fully to the operative orientation. To pivot lip 18 about axis 48, a lip actuator 50 (e.g., fluid cylinder, diaphragm, bellows, spring, motor-driven actuator, etc.) is coupled to a lug 52 that rigidly extends from hinge plate 44. As actuator 50 extends, lip 18 pivots outward. When the lip is fully rotated to the operative orientation, the ramp 16 and now generally co-planar lip 18 can be lowered onto the bed of vehicle 12, to facilitate the unloading or loading process. In this circumstance, the length 38 of traffic surface 32 is at its maximum, as the lip in the operative orientation has its most minimal overlap with ramp 16 (see Fig. 7). That is, lip 18 is in an extended position in its operative orientation.
A hydraulic circuit 64 of Figure 9 and an electrical circuit 66 of Figure 10 can control the operation of dock leveler 14. A typical operating sequence would begin with dock leveler 14 in its standby position of Figure 1. In this position, ramp 16 is in its cross-traffic position where an upper surface 58 of ramp 16 is generally flush with the adjacent floor of dock 10. Lip 18 is stored in a generally pendant orientation with front edge 34 of lip 18 supported by lip keepers 60 and with a rear edge 62 of lip 18 ramp 16, as ramp 16 descends from its position of Figure 4 to that of Figure 5. To do this, load 36, being an obstruction to further extension of lip 18, forces rear edge 62 of lip 18 to overlap ramp 16 as ramp 16 descends. Varying the amount of overlap adjusts length 38 of traffic surface 32 or the distance between axis 24 and the rear of load 36. In some embodiments, the movement between lip 18 and ramp 16 is, in part, a sliding motion guided by studs 40 sliding within slots 42. While rear edge 62 of lip 18 moves toward axis 24, lip 18 continues rotational movement.
Once lip 18 moves upward (relative to ramp 16) beyond its position shown in Figure 5 and into the operative orientation of Figure 6 (either by powered movement or because of deck descent), ramp descent switch 124 can be released. To sense the pivoted positions of lip 18, an arm 130 carrying cams 102, 132 and 134 has one end fixed to a rod end 136 of lip actuator 50 while an elongated portion of arm 130 slides within a guide 138 fixed relative to the cylinder of actuator 50. As rod end extends and retracts, arm 130 moves cams i02 and 132 across limit switch 96 and moves cam 134 across a roller arm actuator 142 of a limit switch 140. As lip moves from its position of Figure 5 to that of Figure 6, cam 132 actuates limit switch 96. Cam 132 closing limit switch 96 keeps solenoid valve 92 open (regardless of switch 124) by energizing solenoid 90 through the closed contacts 94 of limit switch 96 and the normally closed contacts 98 of lip switch 100. With cam 132 holding the contacts of limit switch 96 closed, solenoid valve 92 remains open while dock leveler 14 is in the position shown in Figure 6. Solenoid valve 92 being open allows ramp 16 to "float" with the incidental up and down movement of vehicle 12, as vehicle 12 is being loaded or unloaded of its cargo.
To minimize any impedance to material handling equipment traveling between lip 18 and ramp 16, in some embodiments, ramp 16 includes a pocket or 5 recess 144 into which lip 18 lies when in the operative orientation. In other embodiments; however, lip 18 simply overlays surface 58 of ramp 16 without a recess.
After completing the loading or unloading of vehicle 12 and vehicle 12 departs the dock area, ramp 16 descends under its own weight, as cam 132 actuating limit 10 switch 96 keeps solenoid valve 92 open. Once ramp 16 bottoms out (e.g., ramp 16 abuts some mechanical stop), the pressure in line 112 drops virtually to zero, as actuator 28 no longer supports the weight of ramp 16. The absence of significant pressure in line 112 allows the hydraulic fluid in line 122 (which is pressurized by the weight of lip 18 pushing against lip actuator 50) to release through a pressure relief valve 146, thereby pivoting lip 18 downward by the weight of lip 18 and/or by a biasing force of compression spring 125 in cylinder 50. Although slight downward movement of lip 18 causes cam 132 to release limit switch 96, cam 134 trips limit switch 140 just before cam 132 disengages limit switch 96. Cam 134 closing the contacts of limit switch 140 restarts pump 82 and keeps solenoid valve 92 open.
Thus, ramp 16 begins rising due to pressurized hydraulic fluid entering ramp actuator 28 upon flowing in series through fluid line 88, line 110, solenoid valve 92, line 112 and velocity fuse 114.
Meanwhile, lip 18 continues pivoting downward by way of hydraulic fluid draining from lip actuator 50 to tank 84 upon flowing in series through normally open valve 123, line 122, a pilot-operated check valve 150 (held open by a pilot line 152 being pressurized by line 88), and a flow restrictor 154. The upward movement of ramp 16 and the relative downward movement of lip 18 continue until lip 18 achieves the pendant orientation.
At that point, cam 134 releases limit switch 140 just after cam 102 trips limit switch 96. This turns pump 82 off as the contacts of limit switch 140 and pump switch 70 are open. Yet, cam 102 tripping limit switch 96 continues to energize solenoid 90 of valve 92 through closed contacts 98 of lip switch 100 and the closed contacts 94 of limit switch 96. Thus, ramp 16 descends to its standby position of Figure 1, as hydraulic fluid escapes from ramp actuator 28 by flowing in series through velocity fuse 114, line 112, open solenoid valve 92, and flow restriction 128 of shuttle valve 104.
When wanting to place the last load on the end of vehicle 12, lip 18 may need to be slid back without the aid of a load already in place to help push lip 18 back. To do this, ramp 16 and lip 18 are first moved to the position of Figure 3. From there, dock leveler 14 can be lowered to the position of Figure 11 by actuating ramp descent switch 124 and a lip-lock switch 127 at the same time. Lip-lock switch 127 energizes a solenoid 129 to close valve 123, which helps prevent lip 18 from pivoting in either direction. Thus, as ramp 16 descends due to switch 124 opening solenoid valve 92, lip 18 is forced to slide back as front edge 34 abuts vehicle 12. Once lip 18 is slid back, lip-lock switch 127 can be released, so that further downward movement of ramp 16 can force rear edge 62 of lip 18 to pivot downward until dock leveler 14 is in the position of Figure 6 (but without load 36 already in place).
Although the invention is described with respect to a preferred embodiment, modifications thereto will be apparent to those skilled in the art. For example, a pressure relief valve 156, as shown in Figure 9, can be added to line 110 to limit the maximum pressure in the hydraulic system. Therefore, the scope of the invention is to be determined by reference to the claims that follow.

Claims (11)

1. A dock leveler adapted to engage a vehicle, comprising:
a ramp pivotal about a first axis; and a lip pivotal relative to the ramp about a second axis, wherein the lip is pivotal from a pendant orientation to an operative orientation and is also selectively moveable to a fully extended position and a partially extended position, wherein the lip includes a distal edge adapted to engage the vehicle with a distance between the distal edge and the second axis being greater when the lip is in the operative orientation while in the fully extended position than when the lip is in the operative orientation while in the partially extended position.

2. The dock leveler of claim 1, wherein the lip moves from the fully extended position to the partially extended position as the ramp pivots downward.

3. The dock leveler of claim 1, further comprising a hinge plate pivotally attached to the ramp with the lip being slidingly attached to the hinge plate.

4. The dock leveler of claim 1, wherein the lip is selectively moveable to a stored pendant position with an appreciable portion of the lip extending above the ramp to form an obstruction and a receded pendant position with the lip being substantially non-obstructing

5. The dock leveler of claim 1, wherein the lip is further pivotal about an axis perpendicular to the second axis.

6. The dock leveler of claim 1, wherein the ramp includes an upper surface that defines a recess, wherein one edge of the lip ties in the recess when the lip is in the operative orientation.

7. The dock leveler of claim 1, wherein the lip and the ramp overlap when the lip is in the operative orientation.

8. A method of operating a dock leveler that includes a ramp rotatable about a first axis with a lip coupled to the ramp and being adapted to engage a vehicle, the lip having a width substantially the same as a width of the ramp, the method comprising:
pivoting the lip about a substantially horizontal axis; and simultaneously providing relative translation between the lip and the ramp.

9. The method of claim 8, further comprising raising a portion of the lip above an upper surface of the ramp.

10. The method of claim 8, wherein the lip and the ramp create a traffic surface of variable length.

11. A dock leveler adapted to engage a vehicle that can have one of several different operational circumstances, comprising:
a ramp;
a lip pivotally coupled to the ramp about a substantially horizontal axis and slidably coupled to the ramp and being moveable relative to the ramp such that the lip and the ramp overlap a variable amount to create a traffic surface of variable length to accommodate the different operational circumstances; and a means for rotating the lip about the horizontal axis.