Provisional Application No. 60/287,022 filed April 30,2001, in the name of Carl SMITH, and titled ADVANCED BULK AUTOMATED CONTAINER UNLOADING SYSTEM, the entire contents of which are fully incorporated herein by reference.

Technical Field [002] This invention relates generally to the automated processing of large containers of bulk material.

Background [003] In industry today, production, manufacturing, and distribution facilities for any business utilize automated services to quickly and efficiently handle bulk materials. These bulk materials may include anything from products sold by a company to bulk mail sent and received by businesses and other organizations. In the case of bulk mail, many businesses and organizations specializing in mail delivery have bulk mail facilities, which process and sort mail according to certain user defined criteria (e. g., recipient's name, ZIP code, street address, etc.). These facilities can exist for any type of business. The purpose of having a facility designed for processing materials in bulk is to improve the entire assembly line process of getting materials to and from the business or organization efficiently so that the consumer may realize a cost savings or receive a higher quality product or service. Handling materials in bulk is more efficient and cost effective than handling materials individually, and businesses and other organizations constantly seek to improve the steps in existing methods and systems to make the entire process more efficient and cost-effective.

[004] One step in processing bulk materials, for example, is the initial step of receiving the incoming materials at the bulk material processing facility.

Current methods of transporting bulk materials, for example unloading the contents of a truck onto a loading dock, may be slow and require too much human exertion to be cost effective and efficient. Furthermore, increased human intervention, even in automated processes, in handling bulk materials increases the risk of harm to employees or workers of the bulk material processing facility.

Current methods of automated transporting of bulk materials are not user friendly, may cause delays in the entire production, manufacturing, or distribution process, and may have a high risk of harm to workers when manual attention is needed.

[005] It is therefore desirable to provide systems and methods to allow for the safe, efficient, cost effective, and automated transportation of bulk materials to the facilities engaged in processing those bulk materials.

SUMMARY [006] There is provided a system for automatically processing contents of a first container, comprising a system for automatically processing contents of containers, comprising a tow assembly for advancing a first container to a first predetermined position; a grasping mechanism for securely clasping the first container at the first predetermined position; a lifting mechanism, coupled to the grasping mechanism, for moving the first container between the first predetermined position and a second predetermined position, and to begin rotating the container, at the second predetermined position, to a third predetermined position; and a lid mechanism for covering the contents of the first container at the first predetermined position and moving apart to allow the contents to be released from the container at the third predetermined position.

[007] There is also provided A method for automatically processing contents of containers; comprising advancing a first container, in an upright position, along a path with a tow assembly mechanism; grasping the first container at a first predetermined position; lifting the container to a second predetermined position, while the contents are secured inside the first container by a lid ; rotating the first container to a third predetermined position and moving the lid sufficiently to allow the contents to exit from the first container; returning the first container, in the upright position, to the first predetermined position; and advancing the first container along the path so that a second container may be processed.

[008] Additional features and advantages will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the claims. The advantages will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims.

[009] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS [010] FIG. 1 is a flowchart of a method of processing a bulk container, consistent with the present invention; [011] FIG. 2 is a front view of a system for processing a bulk container ; [012] FIG. 3 is a cross sectional view of FIG. 2; [013] FIG. 4 is a front view of FIG. 2, showing a step involved in processing bulk containers; [014] FIG. 5 is a front view of FIG. 2, showing a step involved in processing bulk containers; [015] FIG. 6 is a front view of FIG. 2, showing a step involved in processing bulk containers; and [016] FIG. 7 is a front view of FIG. 2, showing a step involved in processing bulk containers.

DETAILED DESCRIPTION [017] Referring now to the drawings, in which the same reference numbers will be used throughout the drawings to refer to the same or like parts, Fig. 1 is a flowchart of a method for automatically processing bulk. materials, for example, unloading a large and heavy container of packages. A method for processing bulk materials in a container begins at Stage 102, where a user places a container full of packages, using the example from above, in a position accessible to a tow assembly, so that the tow assembly advances the container to a predetermined first position. The tow assembly may be a chain in the floor which attaches to the container and pulls the container along a track. The container may include a securing component, such as a net or lid, to prevent the contents from spilling from the container.

[018] The predetermined first position is a user defined station where the container is placed in order to fulfill the other stages within the method of processing materials in a bulk container. The first predetermined position can be inside a system or machine designed to implement the stages described herein.

[019] Once the container is at the first predetermined position, a grasping mechanism, such as a set of arms, securely grip the container at Stage 104, so that the container is securely fastened within the mechanism. The arms can be made of high pressured vulcanized rubber or another suitable material to hold and handle the container.

[020] Once the arms have securely gripped the container, the container is lifted, at Stage 106, to a second predetermined position. The second predetermined position may be directly above the first predetermined position, so that the container is suspended at a height suitable for rotation about a horizontal axis.

[021] At Stage 108, the lid is opened and the container is rotated about a horizontal axis to an angle to allow the contents of the container. A suitable angle for this purpose may be approximately 155 degrees from the initial orientation of the container at the second predetermined position. A guide may be used to ensure that the contents are safely removed from the container without damage. In addition, the container may be jostled or shaken, to allow trapped contents to unfasten and fall from the container.

[022] Once the contents have been discharged from the container, the container is rotated back to an upright position and returned to the first predetermined position at Stage 110. At Stage 112, the container is advanced further along the track by the tow assembly and the method is repeated for other containers that need to be processed in this manner.

[023] FIG. 2 is a front view of a system 200 for processing bulk containers, using, for example, the method outlined in FIG. 1. System 200 may include a support structure 202 mounted on a platform 204, a lifting mechanism 206, a track 208, pusher 210, container 212, and a repository 218. Container 212 may further include wheels 214 and a pin 216. The contents of container 212 may constitute anything that needs processing under the method of FIG. 1, including bulk mail packages.

[024] Lifting mechanism 206 may further include a guide 219, a lid 220, and clamps 222. FIG. 2 shows lifting mechanism 206 in an up position, as lifting mechanism 206 waits for container 212 to advance to the first predetermined position, which may be a position directly underneath lifting mechanism 206 on platform 204. Lifting mechanism 206 is described in further detail below.

[025] Container 212, using wheels 214, is moved onto platform 204 along track 208. As container 212 advances to the first predetermined position, pin 216, which may be located on the bottom side of container 212, engages a pusher 210, so that container 212 may be secured to follow track 208.

[026] System 200 may also include structures to guard against an overflow of containers from entering. There may be a situation where other containers to be processed precede container 212 in a process queue.

Container 212 may not be processed until all preceding containers are processed. This may be implemented by using an overflow limit switch in track 208 to prevent system 200 from accepting container 212 if another container is already being processed.

[027] FIG. 3 shows system 200 in greater detail. In FIG. 3, container 212 is inside system 200 and on top of platform 204. Pin 216, attached to the bottom of container 212 engages pusher 210, so that container 212 is secured to track 208. Pusher 210 advances container 212 to proceed along track 208. A towline assembly may also be included in track 208. The towline assembly may include a chain attached to pusher 210 that pulls container 212 into system 200 after pin 216 engages pusher 210, but may include anything capable or suitable to pull container 212.

[028] FIGs. 4 through 7, front views of previously described system 200, show in greater detail the method outlined in FIG. 1. FIG. 4 is a front view of system 200 using, for example, the method outlined in FIG. 1. FIG. 4 shows system 200 lowered over container 212 at the first predetermined position. After container 212 enters system 200, pin 216 engages pusher 210, lifting mechanism 206 lowers over container 212 and lid 220 closes (or remains closed) to secure the contents of container 212. The contents of container 212 may be packaged bulk mail, which is being transported to a conveyor belt or a storage bin.

[029] Next, referring to FIG. 5, clamps 222 securely grasp container 212 in preparation of lifting container 212. The position of container 212, when still on platform 204, may be a user defined first predetermined position, as previously described.

[030] Referring to FIG. 6, pusher 210 disengages pin 216 and lifting mechanism 206 lifts container 212 to a user defined second predetermined position. The second predetermined position can be above the first predetermined position to allow lifting mechanism 206 and container 212 to rotate.

[031] Next, in FIG. 7, lifting mechanism 206 rotates about an axis perpendicular to the plane of FIG. 7, in order to empty container 212. The lifting mechanism may rotate either way, but should rotate to angle that allows the contents to safely fall from container 212. Once lifting mechanism 206 and container 212 have reached that angle, lid 220 is opened and the contents of container 212 fall into repository 218. Also, guide 219 may be used in guiding the contents of container 212 into repository 218, to ensure all the contents reach repository 218 without damaging the contents. Repository 218 may be any suitable device used in conjunction with transporting bulk materials (e. g., a bin, a loading truck, or a conveyor belt). Lifting mechanism 206 may also have sensors located on either side of the opening to container 212. This allows system 200 to sense whether the contents have all been removed from container 212. Lifting mechanism 206 may also jostle or shake container 212 to loosen trapped contents. Once all the contents have been removed from container 212, lifting mechanism rotates back into the second predetermined position and then subsequently lowered to the first predetermined position (see FIG. 5). If sensors are used, lifting mechanism 206 can return to the first predetermined position after the sensors indicate that the flow of materials exiting container 212 has ended. At the second predetermined position, clamps 222 disengage from container 212 (FIG. 4) and lifting mechanism 206 raises to its up position (see FIG. 3), leaving processed container 212 on platform 204. Pin 216 engages pusher 210 and container 212 is advanced out along track 208.

[032] Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the appended claims disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit being indicated by the following claims.