IE980897A1

IE980897A1 - Panels

Info

Publication number: IE980897A1
Application number: IE980897A
Authority: IE
Inventors: Patrick Mcdonald
Original assignee: Kingspan Res And Dev Ltd
Priority date: 1998-06-15
Filing date: 1998-10-30
Publication date: 1999-12-29
Also published as: IES80819B2; GB2338468A; GB2338468B; GB9824017D0; IES980898A2

Abstract

A composite panel 1 is led along an infeed panel conveyor 2, 3. The panel 1 is engaged by a turn-over apparatus 4 and turned over onto a holding bay 5. The panel is then lifted by one of two hoist means 8, 9 and placed an a pallet stack 6 at a pallet stacking station 7. On completion of the stack, the stack is delivered onto a pallet take-off conveyor 10. The turn-over apparatus 4 is used so that both faces of the panel can be checked for quality assurance. The apparatus 4 comprises lifting arms 30 fitted with pads 31 for engaging a lower face of a panel and panel gripping means comprising suction cups 40 mounted on a turn-over arms 43. The turn-over arm 43 is pivotally mounted about a pivot pin 44 for movement between an engaged and a panel turn-over position.

Description

The invention relates to a method and apparatus for manufacturing and handling panels. In particular, the invention relates to insulating panels of the type comprising a profiled external skin and an internal backing tray having an insulating core there between.

UK-A-2227712 all UK-A-2257086 describe methods and apparatus for manufacturing insulating panels. However, there is an increasing need to improve manufacturing and handling efficiency, to cut costs and maximise the production rates for such panels.

This invention is therefore directed towards providing an improved method and apparatus for efficient manufacturing and handling of such panels.

Statements of Invention According to the invention there is provided a method of stacking panel lengths comprising the steps of: (i) leading a panel length along on infeed panel conveyor; (ii) engaging the lower face of the panel and the top face of the panel; (iii) turning the engaged panel over onto a holding bay; (iv) lifting the panel from the holding bay; INT CL -2(v) placing the lifted panel on a pallet stack; repeating steps (i) to (v) for further panel lengths; and on completion of the stack, delivering the stack of panels for stack take-off.

In one embodiment of the invention the lower face of the panel is engaged by a panel lifting means and the upper face of the panel is engaged by a panel gripping means, and the method comprises the step of pushing the panel upwardly to engage the panel against the panel gripping means. Preferably the panel gripping means is mounted on a turnover arm and the method comprises the step of rotating the arm about a longitudal axis to turn the panel over onto the holding bay. Ideally the panel gripping means comprises suction cup means for engaging the panel.

In a preferred embodiment of the invention the panel is lifted from the holding bay and placed on a pallet stack by a hoist means. Preferably there are at least two hoist means and the method includes selecting one of the hoist means as determined by the panel length to be stacked.

In one embodiment of the invention at least two infeed conveyors are provided and the method includes the step of selecting a panel length to be received at the turn-over station from one of the infeed conveyors.

In another aspect the invention provides an apparatus for stacking panels comprising: an infeed panel conveyor; a holding bay; -3turn-over means for turning the panel over from the infeed conveyor to the holding bay; hoist means for lifting the panel onto a pallet stack at a stacking station; and a stack take-off means for leading the stack of panels away from the stacking station.

Preferably the turnover means comprises panel lifting means for engaging the lower face of a panel, panel gripping means for engaging the upper face of the panel, and turning means for turning the panel onto the panel holding bay.

In a prefened arrangement the turning means comprises a rotatable arm carrying the panel gripping means, the arm being rotatable about a longitudinal axis to turn the panel over.

Ideally the panel gripping means comprising suction cup means.

Most preferably, there are two panel hoist means for lifting different sized panels onto a pallet stack at the stacking station.

In a preferred embodiment of the invention the apparatus includes at least two panel infeed conveyors from which panels are selectively delivered to the turnover means.

Brief Description of Drawings The invention will be more clearly understood from the following description thereof given by way of example only in which :IE 980897 -4Fig. 1 is a plan view of panel stacking apparatus according to the invention; Fig. 2 is an end elevational, partially cross sectional view of the apparatus; ,5 Fig. 3 is a plan view of a panel turnover apparatus; Fig. 4 is another plan view of the panel turnover apparatus; io Fig. 5 is an end elevational, partially cross sectional view of the panel turnover apparatus; Fig. 6 is a cross sectional view of a detail of the panel turnover apparatus; Fig. 7 is a cross sectional view of a typical roof panel; and Fig. 8 is a cross sectional view of a joint between adjacent wall panels.

Detailed Description Referring to the drawings there is illustrated a method of handling insulated panels I, especially panels of the type having a profiled external skin, an internal backing tray and an insulating core between the external skin and backing tray.

A panel 1 is led along one of two infeed panel conveyors 2, 3. The separate infeed conveyors 2, 3 allow the output from two separate panel lines to be handled simultaneously. The panel is engaged by a tum-over apparatus 4 and turned over onto a holding bay 5. The panel is then lifted by one of two hoist means 8, 9 from the holding bay 5 and placed on a pallet stack 6 at a pallet stacking station 7. On completion of the stack, the stack is delivered onto a pallet take-off conveyor 10. -5The holding bay 5 comprises a plurality of spaced-apart support arms 20. The bay 5 may be used in handling a panel which extends the full length of the bay, or panels of any smaller lengths. The larger hoist 9 is used in handling the longer panel lengths. The smaller hoist 8 is used for handling shorter panel lengths in a ; 5 cost efficient way as the power costs are considerably reduced over those required for a universal large hoist 9. It will be noted that the support arms 20 are closer together at the end of the bay 5 in which the smaller hoist operates. This ensures that smaller panel lengths are fully supported in the holding bay and optimises handling efficiency. io The tum-over apparatus 4 is used to turn the panels 1 over so that both sides of the panel can be quality checked for any imperfections. This is particularly important for those panels which are formed with the outer face, in use, of the external skin lowermost.

Referring in particular to Figs 2 to 6 the tum-over apparatus 4 comprises panel lifting means formed by lifting arms 30 fitted with pads 31, the lifting arms 30 being operated on a ram and linkage system 35 for movement between a released lower position illustrated by full lines in Fig. 6, in which the pads 31 are spaced below the panel conveyor, to a lifted engaged position in which the pads 31 engage the panel as illustrated by interrupted lines in Fig. 6 and by full lines in Fig. 5.

The tum-over apparatus 4 also comprises panel gripping means for engaging the upper face of the panel when the lifting pads 31 engage the panel 1, and turning means for turning the panel onto the holding bay 5. The panel gripping means comprises suction cups 40 mounted on a tum-over arm 43 which is pivotally mounted about a pivot pin 44 for movement between a panel engaged position illustrated by full lines in Fig. 5 to a tum-over position illustrated by interrupted lines in Fig. 5. In the tum-over position the panel 1 is deposited on the support arms 20 of the holding bay 5. The hoist 8 is then moved into position over the -6holding bay 5 and the hoist is extended so that hoist suction cups 50 engage the upper face of the panel 1 in the holding bay 5. The hoist 8 lifts the panel 1 onto the stack at the stacking station 7. When the panel 1 is lifted from the holding/inspection bay 5 the tum-over arm 43 is turned back into a panel engaging position. The procedure is repeated and on completion of the stack at the stacking station 7, the stack is shifted onto the stack take-off conveyor 10.

The invention provides a highly efficient automated method and apparatus for handling panels which greatly assists in optimising the manufacturing process.

The panel stacking method and apparatus of the invention is used as part of a method for forming a panel such as a wall or roof panel in a substantially continuous manner. In this method a sheet of external skin material 50 is led from a reel, profiled and laid onto a flat bed with the outermost face of the external skin lowermost. The external skin may be pre-heated prior to application of liquid foam reactants.

A sheet of backing tray 51 material is led from a supply reel, profiled and preheated. The profiled backing tray is then continuously applied over the external skin and liquid foam reactants.

The backing tray is maintained in spaced-apart relationship from the external skin by appropriately sized spacer blocks. The liquid foam reactants are then allowed to expand to fill the space between the external skin and the backing tray by passing the assembly through an oven in which the reactants are heated and allowed to expand to the desired thickness of foam insulating core 52. The output from the oven is a continuous longitudinal sheet of insulating panel which is cut to a desired length. The cut lengths are then delivered to the infeed panel conveyor of the stacking apparatus. -7In the case of a wall panel 55, a seal or seals may be inserted in a side marginal edge of the panel and the profile of a joint between adjacent panels as illustrated in Fig. 8.

Alternatively, the panel may be a roof panel 56 as illustrated in Fig. 7 in which panels are over-lapped longitudinally and/or transversely. In this case the extemai skin may be cut in-line and overlapped using a jointing tape prior to application of the liquid foam reactants. At the joint between extemai skins the backing tray and foam core are cut through to the upper (internal) face of the extemai skin. The panel lengths are then separated for delivery to the infeed panel conveyor of the stacking apparatus.

The invention is not limited the embodiments hereinbefore described which may be varied in construction and detail.

Claims

1. A method of stacking panel lengths comprising the steps of: (i) leading a panel length along on infeed panel conveyor; (ii) engaging the lower face of the panel and the top face of the panel; (iii) turning the engaged panel over onto a holding bay; (iv) lifting the panel from the holding bay; (v) placing the lifted panel on a pallet stack; repeating steps (i) to (v) for further panel lengths; and on completion of the stack, delivering the stack of panels for stack take-off.

2. A method as claimed in claim 1 wherein the lower face of the panel is engaged by a panel lifting means and the upper face of the panel is engaged by a panel gripping means, and the method comprises the step of pushing the panel upwardly to engage the panel against the panel gripping means.

3. A method as claimed in claim 2 wherein the panel gripping means is mounted on a turnover arm and the method comprises the step of rotating the turnover arm about a longitudal axis to tum the panel over onto the holding bay. -94. A method as claimed in claim 2 or 3 wherein the panel gripping means comprises suction cup means for engaging the panel.

4. 5. A method as claimed in any preceding claim wherein the panel is lifted from the holding bay and placed on a pallet stack by a hoist means.

5. 6. A me±od as claimed in claim 5 wherein there are at least two hoist means and the method includes selecting one of the hoist means as determined by the panel length to be stacked.

6. 7. A method as claimed in any preceding claim wherein at least two infeed conveyors are provided and the method includes the step of selecting a panel length to be received at the turn-over station from one of the infeed conveyors.

7. 8. A method of stacking panel lengths substantially as hereinbefore described with reference to the accompanying drawings.

8. 9. Apparatus for stacking panels comprising: an infeed panel conveyor; a holding bay; turn-over means for turning the panel over from the infeed conveyor to the holding bay; hoist means for lifting the panel onto a pallet stack at a stacking station; and • ίοa stack take-off means for leading the stack of panels away from the stacking station.

9. 10. Apparatus as claimed in claim 9 wherein the turnover means comprises panel lifting means for engaging the lower face of a panel, panel gripping means for engaging the upper face of the panel, and turning means for turning the panel onto the panel holding bay.

10. 11. Apparatus as claimed in claim 10 wherein the turning means comprises a rotatable arm carrying the panel gripping means, the arm being rotatable about a longitudinal axis to turn the panel over.

11. 12. Apparatus as claimed in claim 10 or 11 wherein the panel gripping means comprising suction cup means.

12. 13. Apparatus as claimed in any of claims 9 to 12 wherein there are two panel hoist means for lifting different sized panels onto a pallet stack at the stacking station.

13. 14. Apparatus as claimed in any of claims 9 to 13 including at least two panel infeed conveyors from which panels are selectively delivered to the turnover means.

14. 15. Apparatus for stacking panels substantially as hereinbefore described with reference to the accompanying drawings.

15.

16. Panels whenever stacked by a method as claimed in any claims 1 to 8 or using an apparatus as claimed in any claims 9 to 15.