TENDON BUNDLE

SCOPE OF THE INVENTION

The present invention relates to an apparatus for use in disentangling elongated tendons such as metal bars, pipes and semi-rigid tubes from a tendon bundle, and more particularly an apparatus which is operable to sort and separate selected tendons from the bundle without requiring the exertion of manual labour.

BACKGROUND OF THE INVENTION

In the fabrication of metal bolts, anchor rods, elongated rebar and other fastening and anchor systems, raw steel stock in the form of elongated tubular steel bars, strand cables, woven steel bars, and other elongated metal tendons are shipped and delivered to end users and fabricators in bundle form. Typically stock steel bars or tendons when initially delivered have an overall length of from about 3 metres to more than 10 metres, depending on the fabricator's needs. Furthermore, depending upon the intended use for the bar or tendon stock and its diameter and length, each tendon bundle may consist of between about 50 to 400 individual tendons.

As a result of their elongated length, during bundling and transport, the tendons tend to twist about their axial length, shifting and intertwining within the bundle. Heretofore, upon delivery it has been necessary for the fabricator to manually disentangle and separate individual tendons from a remainder of the bundle. In addition to increased labour costs, the necessity of manually sorting and removing individual tendons frequently weighting in excess of 100 lbs, increases the likelihood of employee injury, resulting in productivity loss and higher disability claims. SUMMARY OF THE INVENTION

To at least partially overcome at least some of the difficulties associated with the prior art, the present invention provides an apparatus which is operable for the mechanized disentanglement and/or separation of individual elongated tendons from a tendon bundle. Typically, each of the tendons are provided as metal bar stock having an axial length of between about 3 and 20 metres, and a diameter of between 1 and 4 cm, and more typically 1 and 2 cm. In this regard, the apparatus includes a cradle which has a cradle bed sized to generally support the tendon bundle in general alignment thereon. The cradle bed is provided with one or more conveyor assemblies which are selectively actuable to move at least part of the bundle laterally to assist in repositioning and moving the tendons in co-alignment.

Preferably, the cradle conveyor assemblies are operable to convey a selected disentangled tendon from the cradle and onto an outfeed table for further manufacturing and/or transport to a location remote from the cradle.

One object of the invention is to provide an apparatus for use in the mechanized sorting and separation of one or more selected tendons from a tendon bundle, without requiring significant physical exertion by the operator.

Another object of the invention is to provide an apparatus for the mechanical sorting and removal of tendons from a tendon bundle, and which is formed from modular

components to allow for simplified modification and/or customization for use in and sorting of tendons having a variety of different lengths.

Yet another object of the invention is to provide an apparatus which allows the user to disentangle and remove a selected tendon from a tendon bundle consisting of fifty or more individual metal tendons which are more than 3 metres in length, and which in operation repositions the separated tendon to a sorting table for simplified processing.

Another object of the invention is to provide an apparatus for the simplified disentanglement of a variety of different types of longitudinally elongated tendons from a shipping bundle and which may include without restriction, solid cylindrical bar stock, metal angle bar, tubular steel, woven steel cable, strand bar stock, and metal and/or plastic pipe or tubing.

In a simplified construction, the apparatus includes a cradle which has a cradle bed configured to at least partially support the tendon bundle thereon. The cradle is most preferably formed having a number of longitudinally spaced cradle or sling support segments. Although not essential, in one possible construction the sling support segments are provided in the form of interchangeable or modular cradle units. The modular cradle units are configured for coupling in a generally longitudinally aligned orientation, to enable

customization of the cradle bed length having regard to the axial length of the tendons to be sorted.

The cradle or sling support segments are provided with a conveyor belt or drive of which at least part is arranged in a generally laterally extending orientation, and which defines a portion of the cradle bed. The conveyor belt may be in the form of a rubber or nylon belt, a screw conveyor, a metal or synthetic link chain, a cloth belt, a flexible cable, a rope, or other suitable drive. Most preferably, however, the conveyor belt is provided as a metal toothed chain belt which has a tooth size and lateral spacing selected to mechanically engage a selected tendon when resting directly thereon. Preferably, the conveyor belts are each moveably supported along at least laterally forward and rearward portions of the cradle, whereby the actuation of the conveyor belts roll and/or partially laterally move any tendons supported thereon. In a most preferred mode of operation, the conveyor belts are configured so as to be reciprocally movable, to assist in the sorting and alignment of the tendons in an orientation substantially parallel to a longitudinal axis of the cradle bed.

The applicant has appreciated that by reciprocally rolling and moving the bundle, the disentanglement of individual selected tendons along the lateral sides of the bundle is simplified. Once a selected tendon is disentangled from a remainder or the tendon bundle, its mechanical engagement with the conveyor belt furthermore permits its lateral movement and conveyance therewith for removal from the cradle bed for further working as part of a manufacture or fabrication process.

One or more drives are provided which are operable to actuate the conveyor belts in lateral movement to effect at least partial sliding and/or rotational movement of the tendon bundle thereon. The drives may be adapted for either concurrent or individual operation of the conveyor belts to effect movement of the part of the bundle which is supported thereby. Optionally, the apparatus may also be provided with a vibrator, such as an eccentric drive to assist in tendon repositioning or realignment of the tendon bundle in general alignment with a longitudinal axis of the cradle bundle.

In a preferred construction, each conveyor belt has a length chosen such that the portion of the belt between the forward and rearward portions of the cradle extends as a sling having downwardly extending bight portion. Preferably, the bight portion has a size and width configured to partial receive and support the tendon bundle thereon. The bight portions preferably have a size selected to retain therein at least the lower portion of the tendon bundle, with the conveyor belt providing at least one cascading surface which inclines downwardly at an angle towards a mid-portion of the bight. The cascading surface is oriented to effect at least partial sliding and/or rotational movement of any tendons therealong which are not directly engaged by the conveyor belt teeth. The inclined cascading surface thus orients so that any tendons which are not mechanically engaged by the conveyor belt surface tend to slide, roll or otherwise move therealong towards the apex of the bight. Although not essential, a tensioner may be provided which allows for either the automatic or user selected adjustment in the conveyor belt tension between forward and rearward belt supports. Adjustment in the conveyor belt tension may advantageously vary the angle of inclination of the cascading surface, depending upon the size of the bundle or the number of tendons remaining therein.

Accordingly, in one aspect the present invention resides in an apparatus for use in disentangling tendons from a tendon bundle, the apparatus including, an elongated cradle assembly extending longitudinally in an axial direction and having a size selected to substantially support the tendon bundle thereon, the cradle assembly including longitudinally spaced sling supports segments each sling support segments comprising, a first rotatable sprocket; a second rotatable sprocket spaced laterally from the first sprocket; and an associated conveyor chain movably engaging said first and second sprockets, the portion of the conveyor chain intermediate the first and second sprockets defining an upwardly open bight for at least partially supporting part of said tendon bundle thereon, a drive selectively actuable to move said conveyor chains laterally in forward and reverse directions to effect lateral movement of at least partial rotation of said tendon bundle, an outfeed table assembly disposed proximate to at least one of said sling support segments for receiving a selected tendon carried in movement over said first sprockets by said associated sling chain.

In another aspect the present invention resides in a tendon sorting apparatus for disentangling a selected tendon from a bundle of axially elongated tendons, the apparatus including, an elongated cradle assembly extending longitudinally in an axial direction, the cradle assembly for movably supporting the bundle with the tendons in generally axially alignment thereon and including a plurality of axially spaced cradle units, each cradle unit comprising, a forward belt support, a rearward belt support spaced laterally from the forward belt support, and an associated conveyor belt defining a bight positioned intermediate the forward and rearward belt supports for at least partially supporting part of said bundle thereon, a conveyor drive selectively actuable to move at least one of said associated conveyor belts laterally in forward and reverse directions, whereby the forward and rearward movement of said associated conveyor belt by said drive effects at least partial movement of said bundle thereon to assist in the repositioning of a generally forwardmost tendon in substantially direct engagement with said associated conveyor belts, and said associated conveyor belts being operable to convey said generally forwardmost tendon forwardly over said forward belt supports as a selected tendon, and an outfeed table assembly for receiving said selected tendon thereon over said forward belt support.

In a further aspect the present invention resides in a tendon untangling apparatus for separating selected tendons from a tendon bundle comprising a plurality of axially elongated tendons, the apparatus including, a longitudinally elongated cradle having an axially extending cradle bed for movably supporting the tendon bundle with the tendons in general axial alignment thereon, the cradle comprising a plurality of cradle segments, each segment having laterally spaced forward and rearward upper edge portions and an associated conveyor belt defining part of said conveyor bed, the associated conveyor belts being selectively positionable to define in part a cascading surface inclined at an angle and being selectively movable laterally to effect at least partial sliding and/or rotational movement of rotation of tendons thereon.

BRIEF DESCRIPTION OF THE DRAWINGS Reference may now be had to the following detailed description taken together with the accompanying drawings in which:

Figure 1 shows a perspective view of an apparatus used in disentanglement and separation of selected tendons from a tendon bundle in accordance with a preferred embodiment of the invention;

Figure 2 shows a perspective view showing a first end of a cradle assembly, outfeed table assembly and drive assembly used in the apparatus of Figure 1 ;

Figure 3 shows a partial sectional view of the apparatus shown in Figure 1 taken along line 3-3;

Figure 4 shows a partial top view of the apparatus shown in Figure 1 ;

Figure 5 shows a partial top view of the apparatus as shown in Figure 4, illustrating the positioning of a tendon bundle thereon in the sorting and disentanglement of selected tendons;

Figure 6 shows schematically a partial view of a cradle assembly conveyor chain in initial sorting and disentanglement of tendons from a tendon bundle;

Figure 7 shows schematically a partial view of the conveyor chain shown in Figure 6, re-positioned for final tendon sorting; and

Figure 8 illustrates an enlarged partial view of the conveyor chain shown in Figure 6, illustrating the orientation of part of the conveyor chain as a cascading surface.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Reference may be had to Figures 1 and 5 which illustrate an apparatus 10 which, as will be described, is operable for use in the sorting and successive separation of selected steel tendons 20',20"20'" from a tendon bundle 22 used in tendon shipping and delivery. Each tendon 20 typically consists of a 1 to 2.5 cm diameter solid steel bar, having an overall axial length of between about 4 and 20 metres and weighing between about 75 to 200 lbs. For manufacturing efficiencies, at the time of initial delivery, the tendon bundle 22 typically comprises between about 150 to 250 individual tendons 20.

The apparatus 10 is shown best in Figure 1 as having a cradle assembly 12, an outfeed table assembly 14 and a drive assembly 16. In a simplified construction, the drive assembly 16 includes an electric motor 24 which is operated by way of a controller 26 (Figure 4) to selectively and independently rotate drive shafts 30,32 which are respectively mechanically coupled to the cradle assembly 12 and outfeed table assembly 14. It is to be appreciated however, that the drive shafts 30,32 could also be actuated either by hydraulic or pneumatic motor drive. More preferably, the drive shaft 30 is coupled to a reversible clutch assembly 25 which is operable to rotate the drive shaft 30 in reciprocal movement.

As shown in Figure 1, both the cradle assembly 12 and outfeed table assembly 14 are longitudinally elongated in a direction of axis Ai-Aj. Most preferably the cradle assembly 12 and table assembly 14 are each provided an overall longitudinal length which is selected at least as long as the axial length of the tendons 20 to be sorted, allowing the bundle 22 to be fully positioned thereon.

The cradle assembly 12 is shown in Figures 1, 2 and 4, as including a number of conveyor support frame units 40a,40b,40c,40d,40e. The conveyor support frame units 40a,40b,40c,40d,40e,40f are each provided in a generally longitudinally aligned orientation. Although not essential, most preferably the support frame units 40 are formed having a modular construction, allowing a number of individual units 40 to be added or removed from the apparatus 10, depending on the axial length of the tendons 20 and tendon bundle 22.

Each support frame unit includes a conveyor belt or chain 42 which forms a segment of a longitudinally extending conveyor bed 44 (Figure 1). The conveyor chains 42 extend in a lateral direction and have a length sized to support an overlying portion of the tendon bundle 22 thereon. The conveyor chain 42 is most preferably formed as a metal link chain providing a series of 0.2 to 0.5 cm metal bosses or teeth 45 (Figure 8) at 1.5 to 2.5 cm spaced intervals. As will be described, the engagement of the teeth 45 with an individual tendon 20 advantageously provides a mechanical contact therebetween to assist in the conveyance of the tendons 20 in lateral direction, together with conveyor chain 42 movement. Most preferably, the teeth or bosses 45 are laterally spaced along the conveyor chains 42 of each support frame unit 40 with the same alignment and spacing, and which is selected to maintain a selected tendon 20 in general alignment with the apparatus axis A _\ -A _\ when engaged thereby.

As shown best in Figure 2, in addition to the conveyor chain 42, each support frame unit 40 further includes a steel frame 48, which is connectable to the frame 48 of a next adjacent support frame unit 40, a series of laterally aligned guide sprockets 50,52,54,56 which are rotatably mounted to the frame 48, a toothed drive sprocket 58 and a linkage 60.

The guide sprockets 50,52,54,56 are mounted to the frame 48 in an orientation to movably support the conveyor chain 42 in a general lateral alignment, so as to be reciprocally movable thereon in a lateral direction generally transverse to the axis Ai-Ai. The drive sprocket 58 engages a lower portion of the conveyor chain 42 to drive the conveyor chain 42 in forward and reverse movement. The linkage 60 is operable to translate rotational movement from the drive shaft 30 to the toothed drive sprocket 60 in response to control signals output from the controller 26.

As shown best in Figure 2, an uppermost forward sprocket 50 is disposed immediate adjacent to the outfeed table assembly 14, with the upper rearward sprocket 52 being positioned laterally rearwardly a distance therefrom. The spacing between the forward and rearward sprockets 50,52 is selected to enable the positioning of the tendon bundle 22 on the upper surface of the drive chain 42 which is suspended therebetween. The conveyor chain 42 has an overall length selected having regard to the lateral spacing between the sprockets 50,52, so to hang downwardly therebetween as a sling, defining a downwardly extending bight 80 (Figure 2). It is to be appreciated that the spacing between the forward and rearward sprockets 50,52 and the overall length of the conveyor chain 42 for each unit 40 are preferably equal and are selected to enable the positioning of a desired tendon bundle 22 on the cradle bed 44 generally aligned with the apparatus axis Ai-Ai so as to be supported in part by each support frame unit 40a,40b,40c,40d,40e,40f. The conveyor chain 42 thus is moveably disposed on the sprockets 50,52,54,56 so as to be selectively reciprocally moveable in a lateral direction, to move any tendons 20 thereon in a direction generally transverse to the apparatus axis Aj-Aj. The frame 48 is provided with a selectively movable pivot arm 68 which is movably secured to base rail 70 of the frame 48 by way of a pivot 72. Figure 2 shows best the rearward sprocket 52 and rear guide sprocket 54 as being rotatably mounted to respective upper and lower ends of the arm 68. As will be described, the pivot arm 68 is moveable in a lateral direction between a first proximal position, wherein the rearward sprocket 52 is moved a distance towards the forward sprocket 50 (as shown in Figure 6); and a second distal position (shown in Figure 7) where the sprocket 52 is displaced laterally rearwardly a distance therefrom. A hydraulic ram 74 is mounted at one end of the base rail 70 and includes a selectively operable piston 76 which engages an upper portion of the pivot arm 68. The activation of the hydraulic ram 74 and the extension and retraction of the piston 76 selectively pivots the arm 68 to move the rearward sprocket 52 between proximate and distal positions. Each hydraulic ram 74 may be provided for movement independent of each other. In a more simplified construction, however, the control panel 26 is operable to concurrently operate the hydraulic rams 74 of each support frame unit 40 in unified movement. It is to be appreciated that by reciprocally moving the piston 76, the pivot arm 68 may be moved to agitate the bundle 22 to assist in the repositioning tendons 20 on the conveyor chains 42. Further, by moving the sprocket 52 rearwardly, the tension on the conveyor chain 42 may be increased, reducing the size of the bight 80 and/or assisting in the repositioning of tendons 20 on the conveyor bed 44.

As will be described, as successive tendons 20',20",20'" are separated from the tendon bundle 22, the hydraulic ram 74 is actuable to reposition the pivot arm 68 to move the rearward sprocket 52 to the distal position, increasing the tension of the conveyor chain 42. It is to be appreciated that with the increase in chain tension, the chain bight 80 will reduce in size, resulting in the bight 80 moving upwardly in the direction of arrow 100. This upward movement further reduces the inclination of the chain angle a (Figure 8) adjacent the forward sprocket 50. Preferably, the movement of the rear sprocket 52 towards the distal position is selected to tighten the tension of the conveyor chain 42 and reduce the slope of a cascading surface of the chain 42 immediately adjacent the sprocket 50 to chain angle a between +5° to -30°, and preferably about 0 to -15° relative to horizontal, minimizing the likelihood of tendons 20 being unintentionally retained on the cradle bed 44. The outfeed table assembly 14 is illustrated best in Figures 2 and 3 as including a slide table magazine 90 and a sorting conveyor 92. The slide table magazine 90 includes a series of longitudinally spaced laterally aligned plates 98a,98b,98c. Each of the plates 98 are provided with an angled uppermost slide surface 102 which extends from an upper edge portion which is disposed immediately adjacent to an adjacent forward sprocket 50, to a lower edge spaced laterally forwardly therefrom.

The sorting conveyor 92 includes a plurality of toothed metal conveyor belts 106. Each of the conveyor belts 106 are mounted for concurrent movement in a lateral direction. The conveyor belts 106 are movably mounted at each end on a respective pair of rotatable roller sprockets 108a, 108b. The upper surface of the toothed conveyor belts 106 extend horizontally parallel to each other from a rearward end 1 10 laterally adjacent to the lower edge of the slide surface 102, to a forward end 1 12. A drive linkage 1 14 rotatably couples each conveyor belt roller sprocket 108b to the drive shaft 32 for activation by the motor 24.

The apparatus 10 is operable for use in the disentanglement, sorting and sequential separation and conveyance of selected steel tendons 20',20",20"' from the tendon bundle 22. In use, the tendon bundle 22, consisting of between about 50 and 150 tendons 20 is initially placed on the cradle assembly 12. The bundle 22 is positioned on the cradle bed 44 with the longitudinal length of the tendons 20 in general alignment with the apparatus axis Ai-Aj, resting in the bight 80 of the conveyor chain 42 of each support frame

40a,40b,40c,40d,40e,40f.

As shown best in Figure 6, at the time of initial placement of the tendon bundle 22 on the apparatus 10, the hydraulic rams 74 are actuated to extend the pistons 76 and reposition the pivot arms 68 to move the sprockets 54 to the proximal position spaced towards the forward sprocket 50. The repositioning of the rearward sprocket 52 to the proximal position shown in Figure 6, reduces the tension on the conveyor chains 42, increasing both the size of the bight 80, as well as the angle a of the upper surface of the conveyor chain 42 adjacent the forward sprocket 50. The increased size of the bight 80 is preferably selected to

accommodate the tendon bundle 22 resting at least partially therein, while maintaining its position in general alignment on the cradle bed 44. Most preferably, the angle of the conveyor chain 42 adjacent to the sprocket 50 is initially provided at an angle a of between about -10° to -30° relative to horizontal, to define an inclined cascading surface which angles downwardly and rearwardly towards the centre of the bight 80.

Once the bundle 22 is positioned in a most simplified mode of operation, the drive assembly 16 is operated by the manual use of the controller 26 providing power to the drive shafts 30,32 by way of motor 24. The drive shafts 30,32 in turn, via the linkages 60 and 114, translate the rotational movement respectively to the drive sprocket 58 of each support frame unit 40 and the roller sprocket 108b, so as to actuate movement of the conveyor chains 42 and each conveyor belt 106 concurrently.

In initial sorting, the controller 26 is used to actuate the motor 24, and initially drive the shaft 30 and drive sprockets 58 in reciprocal movement to partially rotate the bundle 22. Optionally, the hydraulic pistons 76 may be reciprocally moved to effect a vibratory movement on the associated conveyor chains 42. The reciprocal and/or vibratory movement of the conveyor chains 42 produces a sifting-type movement of the tendons 20 within the bundle 22. As a result, the tendons 20 along the laterally forward and rearward edges of the bundle 22 tend to move into direct engaging contact with the conveyor chain teeth 45, disentangling and aligning with the apparatus axis Ai-Aj . In particular, as tendons 20 move with the conveyor belt 42 upwardly away from the centre of the bight 80 and towards the sprockets 50,52 along the inclined cascading chain surfaces, the tendons 20 which are not directly mechanically engaged by the conveyor belt teeth 45 tend to roll and/or slide under gravity back downwardly towards the centre portion of the bight 80. The result is that along the edge portions of the bundle 22, only individual tendons 20 which are substantially directly engaged by the conveyor belt teeth 45 and which are aligned with the axis Ai-Aj continue to be carried upwardly and over the sprocket 50.

As an individually selected tendons 20a is separated from the remainder of the bundle 22, the operator may use the controller 26 to actuate the conveyor chain 42 forwardly, and convey the separated tendon 20a off of the conveyor bed 44. As the separated tendon 20a moves forwardly with the conveyor chains 42 past the forward sprocket 50, it is deposited onto the slide table magazine 90. On the slide table magazine 90, the selected tendon 20 engages the slide surface 102 and moves downwardly therealong under gravity, sliding downwardly onto the toothed conveyor belts 106. Once resting on the toothed conveyor belts 106, each selected tendon 20',20"20"' is conveyed horizontally thereby to a pickup station 120 for removal either manually or mechanically for further working, fabrication, or the like.

As tendons 20',20"20"' are successively removed from the conveyor bed 44 and the bundle 22 decreases in size, the rams 74 are activated to gradually move the sprocket 52 rearwardly towards the displaced position, decreasing the size of the bight 80. Preferably, as the last tendons 20 remain on the conveyor bed 44, the chain 42 is tensioned to reposition the cascading surface immediately adjacent the forward sprocket 50 at an angle a selected at between about +5° to -10° relative to horizontal, to assist in final tendon 20 movement to the outfeed table assembly 14.

Although a simplified mode of operation is described in which selected tendons 20 are being moved forwardly over and past the forward sprocket 50, the invention is not so limited. In an alternate embodiment, the conveyor chains 42 may be reciprocally moved to sort and laterally move selected tendons 20 in both forward and rearward lateral directions, over and past both forward and rearward sprockets 50,52.

Similarly, while the detailed description describes the support frame units 40 as including guide sprockets 50,52,54,56 used to engage and guide the conveyor chains 42 in lateral movement, it is to be appreciated that other types of conveyor belt guide structures could also be used. Suitable guides could possibly include without restriction, live bearings, fixed guides, slide surfaces, bushings and the like.

While the detailed description describes the conveyor chains 42 as toothed metal link chains, the invention is not so limited. Other types of conveyor belts and conveyor apparatus including mechanical drives, ropes, flexible cables, rubber belts, synthetic belts, toothed belts, mesh belts may also be used, without departing from the spirit and scope of the invention.

Although the detailed description describes the tendon bundle 22 as consisting of between about 50 and 150 solid steel tendons 20, the apparatus 10 is equally suitable for use in sorting and separating a variety of different types of tendons which are packaged and shipped in smaller or larger bundle form. Such tendons could possibly include strand cables, steel or metal rods, woven metal cables and rods, metal and /or plastic pipes or tubes, as well as other raw stock and finished goods which are provided or constructed with an elongated length.

The detailed description describes an apparatus 10 as advantageously including modular support frame units 40 which allow the cradle bed 44 to be customized with either shorter or longer lengths, depending on the length of the tendons 22 to be sorted. In a more simplified construction, however, the cradle assembly 12 could be provided with a series of laterally extending conveyor chains 42 which are mounted on a single unitary support frame.

Although the detailed description describes a hydraulic ram 74 as used in the repositioning of the rear sprocket 52, other apparatus used to tension the conveyor chains 42 may also be used, including without restriction pneumatic cylinders, and electric motors. Similarly, although the use of pivot arm 68 and hydraulic ram 74 provides a simplified tensioning mechanism, other mechanisms to effect selective conveyor chain tensioning may also be used.

While the detailed description describes the cradle assembly 12 and outfeed table assembly 14 as having an overall longitudinal length of between about 4 and 10 metres, it is to be appreciated that where shorter or longer tendons are to be sorted, corresponding adjustments are to be made in the longitudinal length of the cradle assembly 12.

Although the disclosure describes and illustrates various preferred embodiments, the invention is not so limited. Many modifications and variations will now occur to persons skilled in the art. For a definition of the invention, reference may be had to the appended claims.