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Title:
COMPACT, RECONFIGURABLE LOAD MOVING DEVICE, PNEUMATICALLY OR BATTERY POWERED
Document Type and Number:
WIPO Patent Application WO/2005/092746
Kind Code:
A1
Abstract:
A compact, reconfigurable device that allows its operator to move large and/or heavy loads, consisting of a modular base frame (1) fitted with a roller (2) which is driven by an electric or pneumatic motor and gearbox (3) attached to and residing primarily inside of said drive roller (2), a rear axle and maneuvering wheels (4) that is able to freely rotate forwards and backwards within the base frame (1) and to which is attached various types of handle shafts such as a straight (5) or “L-shaped” (6) handle shaft. Such handle shafts (6) include a controller throttle in the handle grip (7) that with the two axes of motion (pivoting rear axle forward/back and rotating handle shaft in the rear axle (4) provides the operator greater versatility in maneuvering the device. Further accessories such as brackets provide additional functionality, such as pushing and rolling with bracket (8). In the case of battery-powered models, the battery packs (9) can be quick-changed to a quick-charger (10) allowing offline charging of a battery pack while the device is in operation, avoiding the requirement for the machine to carry lager batteries or be inoperable while said batteries aye being recharged.

Inventors:
NEWELL GREGORY JAMES (AU)
Application Number:
PCT/AU2005/000407
Publication Date:
October 06, 2005
Filing Date:
March 23, 2005
Export Citation:
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Assignee:
NEWELL GREGORY JAMES (AU)
International Classes:
B61J3/12; B62D51/04; B65G7/10; (IPC1-7): B65G7/10
Foreign References:
US2432156A1947-12-09
US4125029A1978-11-14
US4582154A1986-04-15
Other References:
DATABASE WPI Week 199708, Derwent World Patents Index; Class X12, AN 1997-083017, XP008110486
DATABASE WPI Week 199747, Derwent World Patents Index; Class Q35, AN 1997-508494, XP008110487
DATABASE WPI Week 199644, Derwent World Patents Index; Class Q35, AN 1996-439042, XP008110488
See also references of EP 1732830A4
Download PDF:
Claims:
CLAIMS
1. A materials handling device, comprising: a) a chassis; b) an elongated handle shaft mounted to said chassis for use in maneuvering said device; c) at least one roller, being the drive roller, rotatjonally mounted to said chassis at one end and open atthe other end; d) a motor mount extending inside the open end of said drive roller from its attached end at the said chassis; e) a drive unit such as, but not necessarily limited to, an electric, pneumatic or hydraulic motor, connected to a reductive gearbox that is attached to said motor mount such that said drive unit's output shaft, when energized, rotates said drive roller;.
2. The device, of Claim 1, wherein said handle shaft is connected to said chassis via another connecting shaft, tube or other mechanical linkage that is itself capable of rotating in a secondary plane that is perpendicular to said handle shaft and parallel with the direction of travel of said device, such that said handle shaft is therefore able to be rotated, within a mechanically restricted range of motion, forwards and backwards, • relative to said chassis, with such motion enabling new and different positions for said handle shaft relative to said chassis.
3. The device of Claim 2 wherein the said connecting shaft, tube or other mechanical linkage that is itself capable of rotating also serves as the rear axle tubing for the rear wheels of the device.
4. The device of Claim 1 , wherein the geometry of the components, and the chassis in particular, is such that said handle shaft (or said handle shaft along with said connecting shaft, tube or other mechanical linkage of Claim 2) can be disconnected from said, chassis and said chassis then inverted (ie rotated 180 degrees) and said components then reassembled to create a functionally useful but different device with the drive roller that was in its previous configuration disposed on one side of said chassis now being disposed on the opposite side of said chassis.
5. The device of Claim 4 wherein the bracket so affixed allows the unit to become a pushing (and in the case where the. motor is reversibly operable) a pulling device, as opposed to a rolling device as in its previous configuration that has (typically) two active rollers, one driven and one in direct circumferential contact with the driven roller such that one roller will engage with the ground, advancing the unit forwards, while the other roller will engage with the circumferential surface of a cylindrical load (or wheel) and simultaneously rotate such element forwards with the device.
6. A materials handling device, comprising: a) a chassis; b) an elongated handle shaft mounted to said chassis for use in maneuvering said device; c) at least one roller, being the drive roller, rotationally mounted to said chassis; d) an electrically powered drive unit connected to a reductive gearbox that is attached to said chassis and which, when energized, rotates said drive roller;.
7. The device of Claim 6, wherein said handle shaft is connected to said chassis via another connecting shaft, tube or other mechanical linkage that is itself capable of rotating in a secondary plane that is perpendicular to said handle shaft and parallel with the direction of travel of said device, such that said handle shaft is therefore able to be rotated, within a mechanically restricted range of motion, forwards and backwards, relative to said chassis, with such motion enabling new and different positions for said handle shaft relative to said chassis.
8. The device of Claim 6, wherein the geometry of the components, and the chassis in particular, is such that said handle shaft (or said handle shaft along with said connecting shaft, tube or other mechanical linkage of Claim 7) can be disconnected from said chassis and said chassis then inverted (ie rotated 180 degrees) and said components then reassembled to create a functionally useful but different device with the drive roller . that was in its previous configuration disposed on one side of said chassis now being disposed on the opposite side of said chassis.
9. The device of Claim 8 wherein the bracket so affixed allows the unit to become a pushing (and in the case where the motor is reversibly operable) a pulling device, as opposed to a rolling device as in its previous configuration that has (typically) two active rollers, one driven and one in direct circumferential contact with the driven roller such that one roller will engage with the ground, advancing the unit forwards, while the other roller will engage with the circumferential surface of a cylindrical load (or wheel) and simultaneously rotate such element forwards with the device.
10. The device of Claim 6, wherein the motor is electrically driven and the device comprises: a) a controller attached to or within said handle shaft that receives its instructions from an operator's throttle input and accordingly draws the required electrical energy from said battery pack(s), in turn releasing said electrical energy to said electric motor; b) at least one, relatively compact, rechargeable battery pack(s) supported on, around or contained within said handle shaft; c) said rechargeable battery pack(s) being able to be quickly and easily disconnected and removed from said handle shaft; d) at least one Recharging Unit that receives electrical energy from (typically though not necessarily) a "mains" electricity supply and converts such power to match the recharging requirements of said battery pack(s). e) Said Recharging Unit(ε) that can receive and electrically connect with said battery pack(s) once they have become fully or partially electrically discharged and removed from the device, while at least one (or more) other already recharged battery pack(s) are connected to the device and being used (i.e. discharged).
11. The device of Claim 6, wherein the motor is electrically driven and the device comprises: ■ a) a controller attached to or within said chassis that receives its instructions from an operator's throttle input and accordingly draws the required electrical energy from said battery pack(s), in turn releasing said electrical energy to said electric motor; b) at least one, relatively compact, rechargeable battery pack(s) supported on, around or contained within said handle shaft; c) said rechargeable battery pack(s) being able to be quickly and easily disconnected and removed from said handle shaft; d) at least one Recharging Unit that receives electrical energy from (typically though not necessarily) mains electricity supply and converts it to match the recharging requirements of said battery pack(s). e) Said Recharging Unit(s) that can receive and electrically connect with said battery pack(s) once they have become fully or partially electrically discharged and removed from the device, while at least one (or more) other already recharged battery pack(s) are connected to the device and being used (i.e. discharged).
12. The device of Claims 1 and 6 wherein said handle shaft is the conduit for the transfer of power' be it electric, pneumatic or hydraulic, to said motor, with the handle shaft being internally hollow for the purpose of containing the compressed air, compressed airline tubing, hydraulic fluid line or electrical cabling (all being generically referred to as the power line) and with such power, line that is connecting the bottom outlet end of said handle shaft and the inlet of the motor being of sufficient length and flexibility so as to allow the axial rotation of the said handle shaft (along with the said connecting shaft, tube or other rotating mechanical linkage as described in Claims 2, 3 and 6 if applicable) without interrupting the connection of said power line or therefore the flow of power through the handle shaft to the motor.
13. A materials handling device, comprising: a) a chassis; b) an elongated handle shaft mounted to said chassis for use in maneuvering said device; c) at least one roller, being the drive roller, rdtationally mounted to said chassis and driven in a given direction; d) a drive unit such as, but not necessarily limited to, an electric, pneumatic or hydraulic motor, connected to a reductive gearbox that is attached to said motor mount such that said drive unit's output shaft, when energized, rotates said drive roller; e) a secondary roller, also being rotationally mounted to said chassis and being parallel to and in direct circumferential contact with said drive roller, that is rotated by said drive roller during machine operation in the opposite direction to said drive roller and so arranged as to create a means of driving the device along the ground with one a given roller, while the second roller is simultaneously engaging with and rotating a cylindrical load that is being driven forwards by the device; f) a bracket or other fixture designed to be able to pivot, slide or otherwise be in connection with said chassis to disengage one of said rollers from its role of engaging with and rotating a cylindrical load while instead providing a nonrotating mounting point to which a hitch or other connecting point can make direct contact with a noncylindrical, nonrotating load such as one that is trolley or cart mounted.
Description:
COMPACT, RECONFIGURABLE LOAD MOVING DEVICE, PNEUMATICALLY OR BATTERY POWERED

FIELD OF THE INVENTION: This invention relates to an electrically or pneumatically powered device capable of manipulating heavy loads which is compact, multi-functional, of a modular design that allows it to be reconfigured into different "models" that perform different combinations of functions, that uses either compressed air or battery as its power source, that is aesthetically pleasing and that comprises a minimal number of component parts for reduced complexity and improved reliability.

BACKGROUND OF THE INVENTION: Over the last few decades there has been a growing emphasis placed on employee safety and lost productivity due to injuries in the workplace. In nearly every major corporation, programs and tools are employed to minimize injuries due to poor use of body mechanics that could otherwise result in muscle strains, joint injuries, injured ligaments/tendons etc.

Exacerbating this goal of improving worker safety has been the trend in both manufacturing and distribution to increase productivity and reduce unit cost through the processing of larger amounts (volume and weight) of product in shorter spans of time, while also reducing the run length of orders (more "nimble", flexible production). Higher volume production but with shorter production runs (for exampled as is needed for 'Just- in-Time' production) means not only more flexible production processes being required, but also more frequent raw material input changes of larger and heavier raw material stock. This trend has taken place across most manufacturing sectors, but as an example relevant to this invention, the trend can be seen in industries such paper and wire/cable manufacturing where machines such as this can be broadly employed.

To illustrate an example in greater detail, the corrugated packaging industry employs machines that process large rolls of paper into corrugated sheet. A few decades ago, these machines took 1 to VA ton paper rolls which could (with some effort) be hand rolled and pushed up onto dollies that convey them laterally into the corrugator and then transform that paper into corrugated board. Years ago, these machines would typically run until those rolls were empty (i.e. they only did long runs) and at relatively slow speeds that meant new paper rolls might only need to be pushed into the machine once every hour or two. However the need for higher volume production of significantly shorter runs has resulted in the development of modern, high speed, quick change corrugators that are significantly wider and run significantly faster than earlier machines. These machines use wider, larger diameter paper rolls that can weigh up to 3V- tons and that are being changed far more frequently. So while 20 years ago a corrugator may have run only 3 to 6 orders per shift, a modern corrugator may run as. many as 300 orders per shift.

The result has been substantially more paper roll changes being required, with these rolls being significantly heavier. So while previously operators could manually push these rolls along the ground and up onto the dollies, now they are faced with heavier rolls that need to be loaded and ' unloaded more quickly, many more times each day. Further, while traditionally the rolls only had to be rolled "into" the machine, they now frequently need to be also rolled "out' of the machine, which requires a pulling direction of travel rather than only a pushing direction of travel.

In plants where they have not adopted tools to address this changed state of manufacturing (or where they have adopted tools that are inadequate, inconvenient or unreliable and manual loading sometimes still occurs), soft-tissue injuries have been very common-place. The physical toll that this laborious and repetitive procedure takes upon the operators' bodies frequently results in injury.

In the case of the corrugating machines described above, the nature of the process (rolls needed at a precise time to keep the machine running continuously), the lack of available room in the area in which they are required compared to the size of the rolls and the "flexible manufacturing" nature of the process which requires the process be rapidly responsive to changes in the production mix mean that traditional methods such as forklift "grab-trucks" or other mechanized methods (such as conveyor lines or hydraulically operated push-arms recessed into the concrete floor) have proven to be impractical, inefficient or even dangerous.

Without describing all of the details of other industries, the same basic trends have occurred in many other fields of manufacturing and in various forms the same need for a compact, powerful, easy-to- use and maneuver device exists - to improve both manufacturing flexibility and productivity and also to ensure worker's health and safety. Many other industries make use of drums or rolls (of paper, steel, fabric, foil, plastic, cable etc) that need to be moved short distances into or out of unwind/rewind stands or other secondary processing stages with similar confined space, production flexibility, worker safety issues existing.

So while in the past it was considered acceptable for a worker to use their body strength, i.e., "brute force", to manipulate an object into a new location, the more developed countries are now trying to implement tools and methods to eliminate such acts, and the tendency for the weights requiring movement to become larger/heavier and cycle times to get shorter has further accelerated this need.

Within the last one to two decades sufficiently compact powered devices have become available that have sufficient mechanical advantage (i.e. torque output) to manipulate multi-ton objects in the workplace. U.S. Patent 4,582,154 discloses a drive device for manipulating large multi-ton cylindrical objects such as large rolls of paper material/stock or large reels of electrical cable. The drive device is produced under the trade name "EasyMover" and comprises a plurality of rolling elements in combination with a drive roller which, by contacting the cylindrical surface of the object and the floor beneath, causes the object to rotate and move in the desired direction. More specifically, and referring to Fig. 1a, the drive device'200 includes a front support roller 202, rear support roller 204 and aft wheels 206 which are mounted to a chassis 208. The rolling elements 202, 204 and 206 are, furthermore, spaced-apart and essentially co-planar. A drive roller 210 is disposed above and between the support rollers 202 and 204 to define an acute angle or "wedge- shaped" nose end. Additionally, a pneumatically powered, high torque motor and inline gearbox 212 is disposed aft of the drive roller 210 and in a substantially horizontal plane relative thereto. Torque is transferred from the motor 212 to the drive roller 210 by means of a power transmission chain 230 which engages sprockets 216 disposed on the output drive shaft of the motor 212 and input drive shaft of the drive roller 210. Furthermore, a passageway is provided for delivering pressurized air to the motor 212 via tube segments and fittings 234 which are in fluid communication with a tubular handle shaft 236 that extends up to within reach of the operator's hand.

To maintain its compact size, the EasyMover device described above requires that its energy source be external to the machine as maintaining a compact design envelope is essential to its functionality. However, the requirement for an external energy source necessitates that the unit be "tethered" in the sense that a compressed air line must remain connected to the device (entering at the non-machine end of the operator's handle grip and valve).

In operation, the device 200 is wedged under a cylindrically-shaped object 240, i.e., between the cylindrical surface thereof and the floor beneath. When positioned in this manner, the drive roller 210 makes circumferential contact with the support roller 202 to drive the unit and, therefore, the object/load in a forward direction. Prior to such positioning, pre-positioning of the device 200 is necessary. Pre-positioning can be achieved by rolling the unit on the rear support roller 204 which is disengaged from the drive roller 210 by the placement of a leaf spring 205 at the axle ends that support the support roller 204. This leaf spring pushes the axle of the support roller 204 downwards and out of engagement with the drive roller 210 during maneuvering, but upon engagement and driving under a load, this spring is compressed such that it is pushed up against the drive roller.

However in many cases, the operator will use the small aft wheels 206 for maneuvering the device 200, pushing down on the handle to slightly raise the support roller 202 to permit free-wheeling of the device while pre-positioning. It will be appreciated that inasmuch as the support roller 202 is in frictional engagement with the drive roller 210 (which does not rotate when not in. a powered condition), the support roller 202 must be raised slightly to allow the device 200 to roll freely.

Yet another feature of the device 200, and referring to Figs. 1b - 1d, includes a circumferential seal 250 disposed between the handle shaft 236 and the chassis 208 for permitting rotation about a substantially vertical axis VA (shown in Fig. 1c). Furthermore, the handle shaft 236 contains an approximately 90 degree bend so as to position the shaft 236 on either side of the chassis 208 or center the shaft 236 relative thereto (as seen in Fig. 1d, but only when maneuvering the unpowered unit into position). This_ feature permits operation of the drive device 200 from either the right or left hand side of the device. While the device 200 incorporates many features which continue to be used today, i.e., pneumatically driven motor, relatively compact design envelope etc., the device has several shortcomings and disadvantages.

Firstly, the device is entirely dependent on a continuous supply of compressed air to operate. This requirement limits its use to locations and applications that have the required compressor available. Further, the associated requirement that the device is always tethered by an air line can severely limit its use in locations/applications where free maneuverability is required, or where the device's area of operation is not confined to a small area. For example if it is necessary to move a load over a long distance, the airline becomes too cumbersome to manipulate and for many applications, particularly where there is stock, structure or other impediments to clear travel of the airline, it becomes too unwieldy forthe operator to work with.

• Further, the volume of compressed air that can be supplied through an air line decreases as the length of the line increases. Accordingly it is generally not feasible to operate the device through more than 30 to 50 feet of airline due to the reduced volume of airthat is supplied.

• Further, to achieve their compact size, such devices utilize a very compact but also very inefficient rotary vane style of pneumatic motor, having only approx 30% efficiency. That is, for every 100 units of energy input to such a rotary vane motor, only 30% of that energy is output while 70% is wasted, transferred to the ), that results in a high consumption of compressed air. This high volume consumption precludes any possibility of moving the energy store to the unit itself (such as connecting refillable or quick-change compressed air cylinders to the device) as they would need to be impractically large to provide anything more than about 30 seconds of continuous operation. In addition there is the obvious energy cost of operating at this level of inefficiency (please see attached efficiency table). (This compares to a rechargeable battery system where the efficiency is in the high nineties).

• Further, to achieve the high power output required of this motor, a very large diameter airline (to supply the required volume of air at the required pressure) is required, which exacerbates the previously described shortcomings of working with airlines to a machine (that due to the fact that it is moving loads, is constantly on the move).

Secondly, due to the spatial positioning and number of elements, e.g., forward roller, drive roller, motor etc. the drive device is longer and heavier than would be ideally preferred. Indeed, there are a number of applications in various industries where the machine needs to be maneuvered into a very small space to move a load, and while this device is much smaller than conventional battery- operated materials handling devices, it is still too large for a number of such applications. Exacerbating this lack of maneuverability is the use of the intermediate roller 204 in combination with the aft wheels 206 to preposition the device. That is, the cylindrical configuration of the intermediate roller 204 requires that the operator slide or drag the device to change direction, e.g., turn right to left, into a desired position. Moreover, the device cannot be easily maneuvered on these aft wheels 206 due to their small diameter in combination with the length of the unit. One. may analogize the manipulation of the device to parallel parking a multi-axle tractor trailer into a confined space. Furthermore, the length and weight of the device effects a forward center of gravity (generates a large moment arm) which therefore requires some force to lift it.

Thirdly, the device comprises a multiplicity of components which increases the complexity of the unit; while also decreasing its reliability. These components include the chain-link drive transfer which is subject to external impacting and failure and requires periodic maintenance and the rotating air fitting (connecting the handle shaft 250 to the air inlet shaft 208 in the frame (ref Fig's 1b - 1d). As the rotating air fitting is typically loaded during lifting/prepositioning, and further loaded by the operator as he jiggles the device to remove it back out from under a load once moved, its is very prone to failure (as the component used was not designed for such a loaded application and therefore is a source of ongoing component failure).

Fourthly, the device is designed for only one function, rolling a load forwards, while many flexible manufacturing applications require more flexible load manipulating capability. Following are two examples:-

• A paper roll can be rolled along the ground and then up onto a dollie that can then move that roll laterally into the machine. However in some cases the dollie is not motorized, or is motorized but breaks down or is unable to move tie load, and then the operator needs to push the dollie with the weight of the paper roll on top into the machine.

More generally, any cylindrical load that is to be rolled onto a trolley and then the trolley . needs to be maneuvered has such a need, and in many flexible manufacturing environments, such a requirement is not uncommon. EasyMover offers models that can roll and it offers different models that can push, but there is no device offered that can instantly switch from rolling to pushing (using just one machine).

• A cable drum may be rolled into an unwind stand, partially unwound (or even fully unwound) and then needs to be pulled back out of the stand. The weight of the drums (even empty can be upwards of 300 lbs / 140kg) means the unloading can be a laborious task. In the reverse situation, an empty spool may be being filled with cable, and so the empty drum rolled in and a full drum rolled out. In either case, the EasyMover described cannot roll a load backwards towards the operator (ie pull it out of a stand). A major shortcoming of the prior art design .is that it does not address the need that has evolved to roll loads backwards. The EasyMover device only rolls loads forwards and while the manufacturer also offers a device with a handle shaft that can be removed (by the operator reaching down to disconnect the handle remove it from the machine, then reconnect it on a different side of the machine), this process is relatively difficult and time consuming and as it is required to be repeated each cycle (Le. a product is typically rolled into a machine or bay, then rolled out again, then a new one rolled in, etc, etc), repeating this process continually becomes impractical and operator's will not typically choose to leave the device in one direction (pushing or pulling) and then move the product in the other direction by hand.

Alternatively, substantially less compact materials handling devices are available which are battery powered and thus are not tethered. Representative of these materials handling devices are the ones marketed under the brand names MasterMover, Nustar/PowerPusher and Electrodrive.

Fig. 1e illustrates scaled plan and side views of a pusher model of the present invention next to a popular model of conventional battery-powered mover called the "PowerPusher". The PowerPusher (and others) have substantially similar designs that typically utilize an electric motor, a high reduction (typically worm style) gearbox and one or more 12-volt deep discharge sealed lead acid (SLA) batteries as their power source. While such battery powered devices have the benefit of being untethered, providing a greater degree of mobility and range of operation than the pneumatic powered devices, while still being capable of generating significant amounts of torque, they lose the key benefits of the pneumatic powered devices in thatthe battery powered devices: (1) are significantly larger and heavier than the pneumatic devices which reduces the ease of use, maneuverability, etc., of the battery powered devices; (2) in being significantly larger, typically are not locatable under the load being moved and so oftentimes require an auxiliary downward force or cumbersome geometry to provide the necessary downward force on the drive rollers (to provide the roller traction) to move the load; and (3) typically require downtime for recharging of the onboard batteries which can limit their functionality in high duty cycle applications.

BRIEF SUMMARY OF THE INVENTION: Consequently, a need therefore exists lor an innovative handling device which avoids the aforementioned problems in the prior art with respect to pneumatic and battery powered high torque devices without introducing any new problems in place thereof. More specifically, there is a need for a device that is more compact in size, easier to maneuver, more reliable / heavy-duty, that is able to operate with compressed air (where appropriate) but alternatively by battery-power when a tethered implementation is not desirable, that has the additional functionality of being able to roll a load forwards AND backwards, or roll a load forwards AND push a load forwards and backwards with virtually instant, tool-less reconfiguring by the operator to achieve these extra functions. OBJECT OF THE INVENTION: It is an object of the present invention to provide a power handling device for manipulating heavy loads which is more compact than the present machine and more maneuverable.

It is another object of the present invention to provide a power handling device which is reconfigurable for rolling cylindrical objects "forwardly"' (away from the operator)' and additionally, with negligible or no reconfiguration time, also "rearwardly" (towards the operator), from either the right or left hand side of the cylindrical object.

It is another object of the present invention to provide a power handling device which is reconfigurable for "rolling" cylindrical objects forwardly while additionally being able to be reconfigured with negligible or no reconfiguration time to also "push" and/or "pull" a (typically trolley- mounted) load.

It is another object of the present invention to provide a power handling device which is self-powered and able to produce the same or even more massive amounte of torque (required to propel substantial loads) while still maintaining an equivalent or more compact design envelope.

It is still another object of the present invention to provide such a power handling device which is modular in design to allow assembly of multiple machine "models" from a limited number of machine sub-assemblies.

It is yet a further object of the invention to provide such a power handling device with comprises a minimum of component parts for improved reliability and decreased inventory requirements.

It is yet another object of the present invention to provide a power handling device which is aesthetically pleasing for improved appeal in the marketplace.

These and other objectives are achieved by a power handling device that (at its most basic level) comprises a chassis supporting one or more rolling elements (at least one of which is "driven"), a rear axle assembly mounted, coupled or otherwise integrated with the said chassis, a handle shaft mounting to the rear axle assembly, a motor for driving at least one of said rolling elements and (optionally depending on the configuration) a power supply for energizing the said motor.

In another embodiment of the invention, the power handling device is portable and self-powered by the introduction of a removable, rechargeable power supply substantially supported by or integrated into the handle shaft of the device and separate to the chassis (thereby allowing the base machine to remain similarly compact). Furthermore, the power handling device employs a method of supplying this power thatforthe materials handling industry is very novel. In yet another embodiment of the invention, the power handling device comprises two modular, separable sections, i.e., a propulsion and load-interfacing section and an aft multi-axis-pivoting power-transfer section which between them facilitate reconfiguration and permit interchangeability of sub-assemblies, allowing customers or distributors the option of configuring multiple machine models or achieving multiple functions without actually requiring multiple machines. DETAILED DESCRIPTION OF THE INVENTION: The machine of the present invention is actually an assembly of a number of sub-assemblies, with the choice and orientation of said sub-assemblies determining the final configuration (Le. "model") that results. Each model has certain capabilities according to the tasks that it is required to perform, as such, the modularity of the design allows a broad range of machine models, using a large number of common components and therefore reducing the amount of stock required to be kept to support such a broad product range.

In Fig. 2, the components of the machines are illustrated in a perspective, exploded-view format According to the combination of components or sub-assemblies used, different models can be built.

The central core of the machine, common to every model that is built, consists of the base machine -comprising the main chassis sub-assembly 1 1 and the pivoting rear axle sub-assembly 10.

• The main chassis sub-assembly 11 consists of the welded steel plate chassis itself, a drive roller that includes an oil-impregnated bronze bushing internal of it and a bearing mount attached to the side frame that has pressed into it a roller bearing 'which together support the journal end of said drive roller.

• The pivoting rear axle sub-assembly 10 consists of a central solid steel axle with large diameter rear wheels connected at each end of the shaft and a hollow steel tube that is able to freely rotate about said axle shaft and between the Iwo said rear wheels, with three major incursions into said tubing:

1. The first (center-top) incursion being for the insertion of the handle shaft;

2. The second (front left) incursion being for the egress of the power line from the handle shaft through the axle tubing to the motor on roller models (ie models with the chassis oriented as shown);

3. The third (front right) incursion being for the egress of the power line from the handle shaft through the axle tubing to the motor on pusher models (ie models with the chassis inverted to the position as shown).

• A further unique aspect of the rear axle is that the end plates of the rear axle tube have a . protrusion that extends away from the rear axle at the point where the recesses (described above) reach their highest point. When the rear axle is assembled into the main chassis, these protrusions are inside the chassis and when the axle shaft (and handle shaft connected into it) are pivoted backwards, they will only pivot until these protrusions rise up and make contact with the under side of the top x-tie (37 in Fig. 4 for a roller model, or 38 for a pusher model in which event the chassis has been inverted 180 degrees). In each case, the chassis has been so designed that the handle shaft stops in the exact same position (being deemed the ideal operating position) in each case.

• A unique characteristic of the design of the main chassis 11 and its connection with the pivoting rear axle 10 is the geometry of each sub-assembly as it fits with the other, as it was designed to provide maximum modularity and reconfigurability. To illustrate further, if the main chassis 11 were resting on the ground (the ground making a tangent line between the support roller and the rear wheels) with the handle shaft being at the predetermined most suitable angle relative to the ground, then the main chassis 11 was separated from the pivoting rear axle 10, inverted (rotated 180 degrees) so that the drive roller would now be on the ground, and then reattached to the pivoting rear axle 10, the handle shaft would remain at exactly the same angle.

• Further, the rear axle does not require hardware (bolts, screws etc) to be installed into the main chassis's front portion. The axle shaft rod that runs down the center of the axle tubing, serves to not only provide a pivoting axis for the tubing, but also as locating and connecting means between the two sub-assemblies plus as a mounting forthe fitting of the rear wheels.

• This feature allows a common main chassis 11 and rear axle 10 to be used for two different versions of machines (roller machines and pusher machines) without the need to produce different sub-assemblies. This feature is illustrated in Fig. 9. in which MO roller models are lined . up with a pusher model (at right), with all three being moved into their "parked" positions.

o The base of the pusher model is the same as the base of the roller model, but with the frame inverted 180 degrees and the support roller replaced with a pusher mounting bracket 19 (see Figs. 10 - 11 for further views of this configuration of machine in operation) where it is clearly apparent that the main chassis when reversed maintains the same exact angle on the axle and handle shaft.

o Similarly, the base of the roller model is the same as the base of the pusher model, but with the frame in its normal orientation and a support roller 20 installed where the pusher bracket would have otherwise been.

• As an alternative to either a dedicated pusher model or a dedicated roller model, the other option available with this design of machine is the fitting of a hybrid pushing bracket 12 over the chassis 11 which makes the resulting machine capable of either rolling (when this bracket 12 is pivoted up out of the way), or pushing and pulling (when this bracket is pivoted down onto the machine chassis and the device is tilted forward to that the forks from the bracket are under the load and the rear wheels are lifted out of contact with the ground). This operation is illustrated in Figs. 12 - 14. • Into the pivoting rear axle sub-assembly 10 is inserted a handle shaft 4, 5, 6 or 9. These handle shafts have at their base, where they connect with the pivoting axle tubing, a bronze . ' bushing pressed on, with a tapped hole for the- installation of a bolt, perpendicular to the handle shaft's center axis.

There are four handle shafts illustrated in Fig. 2 that can be chosen to be inserted into the rear axle shaft. These are:-

1. The center, pneumatic handle shaft sub-assembly 4 is a predominantly straight steel piece of tubing, with a linkage assembly at its base that bolts to the upper cross-tie of the main chassis assembly. This linkage provides a strong support when the operator pulls back on the handle shaft, while also defining the maximum stroke forward for the handle shaft (ie pushing the handle shaft forward, in turn rotating the axle tubing forward around the axle shaft). Additionally, this linkage prevents the handle shaft from rotating axially within the axle tube.

2. The swiveling, pneumatic handle shaft sub-assembly 5 is an "L" shaped handle shaft that is not prevented from swiveling inside of its connection point to the rear axle tubing. This allows the handle shaft to be swiveled from the left side to the right side of the main chassis, while the pivoting axle tube also allows the handle to be moved forwards and backwards whichever side of the chassis it is on (see Figs. 7 - 8).

3. The center, battery handle shaft sub-assembly 6 is functionally the same as item 4, except that it has a receptacle built into its shaft so that one or more battery packs can be quickly and easily connected for the supply of electric power.

4. The swiveling, battery handle shaft sub-assembly 9 is functionally the same as item 5, except that it too has a receptacle built into its shaft so that one or more battery packs can be quickly and easily connected for the supply of electric power.

• If a battery powered device is being assembled, battery pack(s) 7 are required. One (or more) on the handle shaft, and an equivalent number on a charger so that once the battery packs on the machine are depleted, they can be replaced with fully charged battery pack(s).

• The battery packs 7 actually deliver their power to the controller 8 which receives its instructions from the operator depressing the throttle. The controller board in turn delivers power to the motor. Without this controller, as soon as the batteries were connected to the ■ motor, the motor would pull as many amps as the batteries could deliver. The controller is an integral part of the assembly. • Inserted into (ie telescoping inside of) the handle shafts 4, 5, 6 or 9 is an upper handle shaft 3 - common to all lower handles. This upper handle shaft can be released from the tower handle shaft sub-assemblies by releasing the clamp at the top of lower handle assembly and then repositioning the upper handle shaft (either longitudinally up/down to match the height of the operator, or axially to adjust the orientation of the handle grip on the machine)

• If a battery powered device is being assembled, then a battery handle grip 2 will be bolted to the upper handle shaft 3. This handle grip has a throttle built into the grip to allow the operator to determine the amount of speed/torque that the electric motor should be transmitting and (if the controller board 8 is set for bi-directional control) also the direction (forward and reverse).

• If a pneumatically powered device is being assembled, then a pneumatic handle grip 1 will be bolted to the upper handle shaft 3. This grip has a valve fitted into its body that allows the operator to restrict the flow of compressed air through the handle into the handle shaft; adjusting it variably from "no air" to "full unrestricted flow".

To further explain the main chassis of the device, which is common to all models, explanation is herewith provided of the drive mechanism.

Fig. 3 is an enlarged fragmentary perspective view of the device, with portions of the device cut¬ away and longitudinally sectioned to show a driving unitof the device in the form of an electric motor and gearbox mounted in one of the rollers of the device. In this particular view, the section of the controller is shown inside the chassis, below the drive roller, however in other embodiments (and as illustrated in Fig.4, this controller is not located in or on the handle shaft, to better isolate it from the shocks associated with it being in the main chassis and also the potential ingress of moisture, oil and other contaminants that are on the floors on which it operates. (The drive roller and support roller can, in unclean environments, pick up contaminants from the ground and/or product being rotated and then transfer them into the chassis and potentially onto the controller board).

The drive mechanism remains essentially the same whether the unit is driven by an electric motor (battery-powered) or pneumatic motor (air-powered) and in the present invention, either motor can ■directly drive the same inline multi-stage planetary gearbox that is illustrated.

As seen diagrammatically in Fig. 3, the controller 28 is electrically connected between the battery pack 20 and the electric motor 23 such that it can supply the required amount of electrical power to the electric motor 23 which is transmitted to the gearbox 24, rotating the gearboxes output shaft 25 which is directly coupled to the journal end 17 of the drive roller 16, thus rotating said drive roller 16. In the roller configuration illustrated in Fig. 4, the rotary driving output of the drive roller 16 is transferred to the support roller 18 through the friction contact of the two, under load from the weight of whatever load is being moved by said device. The result is that while the support roller rotates clockwise (in Fig. 4) moving the device forwards along the ground, the drive roller rotates counter-clockwise to rotate the cylindrical load being moved, and in the process continually "wedging" itself in underneath the load.

The device further includes a cylindrical motor mount support 42 affixed to and supported by side-plate 32 on one side and notdirectly supported on its other side. The dual purpose of this motor mount 42 is to a) provide a non-rotating affixing point for the motor-gearbox 24 and b) provide a supporting surface at its attached side for the drive roller 16 that encompasses said motor mount 24.

The unattached end of the motor mount 42 is circular with a bolt pattern for the affixing of the motor- gearbox 24, and with a hole central to this bolt pattern that is sufficient diameter to allow the motor- gearboxes output shaft to pass outside of the . As the motor-gearbox output shaft 25 is supported in the bearing 46 of bearing mount 44 and said motor-gearbox is bolted to the unattached end of the motor mount -42 , then this non-attached end of the motor mount is indirectly supported by the motor- gearbox output shaft 25.

The drive roller 16 has one open end with an oil impregnated bronze bushing pressed into its internal , open end. This open end slides over the motor mount 42 on which that open end of the drive roller is rotatably supported. The opposing end of drive roller 16 necks down to a open-ended journal-end that is of just sufficient diameter for the penetration and fixing of the output shaft 25 of the motor-gearbox 24. The outside (working) diameter of the drive roller 16 has polyurethane, rubber or some other high friction, long-wearing material bonded or otherwise attached to it

The electric motor 23 and gearbox multi-stage planetary gearbox 24 are disposed inside the cylindrical motor mount support 42, which is in turn inside the drive roller 16, with all elements on the same center- line through.

The motor mount 42, motor 23 and gearbox 24 ail remain stationary while the device is energized, while the output shaft 25 of the gearbox 24 is drivingly coupled to the journal end of the drive roller 16 which in turn is supported by the bearing 46, in the bearing housing 44 which is attached to side-frame 34.

Figs. 4 - 5 do not show the controller mounted in the chassis, but illustrates a more generic model where the "power line" 45 is shown feeding power, whether it be controlled electrical power or compressed air, down through the handle shaft 14, through a fitting 44, through the pivoting rear axle 12 and through the chassis 13 to enter the in let of the motor 23 (which could be electric or pneumatic) .

The opposite side-plates 32, 34 are structurally interconnected by two or more cross members 36, 37 and 38. The device also has a pair of rear wheels 49 on bearings to a cross-axle 40 which supports both the pivoting rear axle 12 and the rear portion of the chassis 13, linking the two together. The pivoting rear axle 12 ph/ote smoothly on this cross shaft axle 40 due to the bushings 41 that are embedded into each end of the pivoting rear axle 12. The handle shaft 14 is inserted into tie pivoting rear axle 12 and retained in place in it by a bolt 39 which passes through the bushing 43 into the base of the handle shaft 14. Further, this bushing 43 is pressed onto the base of the handle shaft 14 so as to provide a smooth rotating surface for the rotating motion of the handle shaft in the rear axle 12. Further, the diameter and thickness of the components of this rotating connection are such that the fitting can withstand a significant amount of physical abuse without failing. Further, by installing the fitting atthe base of the handle shaft 14 and within the bushing 43, there is no requirement for this rotating connection point to be air tght (in the case of pneumatically operated models) as is the case for the Easymover design, where the light duty fitting serves the dual functions of providing both the rotation and the airline connection, Further, a recess in the upper portion of the base insert to the pivoting rear axle 12 scribes an approximately 180 degree channel around the back half ofthe base's circumference, so that the head of the bolt 39 which retains the handle shaft 14 in the pivoting rear axle 12 also then serves to limit the amount of rotation thatthe handle shaft can do (being the approximately required 180 degrees. This allows the "L-shaped" handle shaft 14 to be to the left orthe right of the main chassis, which when combined with the forward and backward mof on ofthe pivoting rear axle, provides a number of working positions for the handle shaft relative to the device.

A feature of this design is the use of flexible airline or electrical cabling that is able to adjust its position within the chassis to accommodate the pivoting of the rear axle. Therefore as the axle pivots forwards and backwards, the airline or power line flexes accordingly and still maintains its connection with the air motor or electric motor to which it is connected.

One of the benefits of mounting the motor and gearbox inside the drive roller is illustrated in Fig. 6, when comparing scale models of approximately equivalent torque device of the present invention (upper image) with the prior art same-scale model. Despite having significantly larger rear wheels to improve the maneuverability of the present invention, it is still substantially smaller in size.

The other benefit is the elimination of the chain and sprocket transfer system, which improves the reliability of the power transfer system. An inexpensive oil-impregnated bronze bushing is used between the motor mount (that supports the motor and gearbox) and the drive roller (that is sleeved over it and is rotating about it). This bushing requires no maintenance during the life of the urethane on the roller and is virtually impervious to external impact, being well inside of the machine. Being an inexpensive part, it is able to be made a permanent part of the drive roller and so each time the urethane is worn on the drive roller and the roller is replaced, a new bronze bushing comes into play.

Further on the subject of reliability, the rotating air-fitting that at the base of the handle shaft of the EasyMover regularly fails (as it is not designed to be load bearing, but ends up being so) is replaced in the present design by a substantially more robust bronze bushing that fits into machined steel tubing. The rotating fitting is then replaced by a simple straight fitting that is not subjected to any loads, being mounted inside of the more heavy duty connection. Fig. 7 illustrates the other benefit of this additional axis of motion in the present invention, being the pivoting rearaxle 12, which when combined with the rotating handle shaft (as also employed in the prior art version) provides for five handle shaft positions. Fig. 8 illustrates by way of example an application that would call for such versatility, also showing the 5th orientation for the handle shaft where it is moved to the center position so that the elbow of the handle shaft 14 rests on the drive roller 16, essentially resulting in the handle shaft rising vertically above the machine. This "parked" or non-operating position for the handle has two benefits in that it balances the weight of the handle (and in the case of the battery powered version, trie weight of the associated battery packs) above base unit, so that it does not have any tendency to fell over, while it also reduces the footprint of the machine, that is, the amount of floor space that the device occupies when it is not in use.

Fig's. 12 - 14 illustrate yet another feature of the present invention which is a moveable bracket that when attached to a configuration of machine designed for "rolling" a cylindrical load, it serves no purpose when in its "disengaged" position, but once engaged, whether by pivoting (as illustrated), sliding, or being separately attached, then covers over and essentially disengages one of the said rollers from its role of engaging with and rotating a cylindrical load, while instead providing a non- rotating mounting point to which a hitch or other connecting point can make then direct contact with a non-cylindrical, non-rotating load such as one that is trolley or cart mounted.

This bracket is illustrated in the unengaged position in Fig. 13 (rolling a cylindrical load) and in the engaged position in Fig. 14 (pushing a sliding or trolley mou nted load). Further, Fig. 12 illustrates a typical industry application for such dual rolling and pushing functionality, where a paper roll in a paper corrugating plant is required to be rolled up onto a floor or surface mounted trolley (in the example illustrated, this trolley being mounted into a recessed floor channel) and that trolley with the paper roll so mounted then being pushed laterally into the corrugating machine.

Fig. 15 illustrates alternative key components of two particular embodiments of the battery-powered configuration of the said device, which has been more extensively described in Continuation in Part 10/810,992 filed March 26, 2004. The purpose of Fig. 15 in this application is merely to illustrate a secondary embodiment of the battery-pack and controller design and placement, with the original being the clam-shell design of battery-pack illustrated in the right hand image (with corresponding battery pack charger) in which a battery-pack encompasses said handle shaft, making it more or less retrofittable to a device that may have originally been a pneumatically operated device. In contrast, the design illustrated on the left hand side of Fig. 15 makes use of battery-packs that are arranged into what is essentially a "rectangular prism", and so the handle shaft is specially designed to allow such battery-packs to insert into said handle shaft, as opposed to wrapping around them. The benefit of such alternative design is a more compact and densely packed battery pack (still comprising the same cylindrical battery cells to make up the same high voltage pack) and makes use of a more established battery pack engagement and connection design, as broadly used in the connection of hand power tool battery packs. As such, the battery-pack design as illustrated on the left hand side uses male and female connectors that are similar to those used on a cordless rechargeable electrical drill or other similar hand tool. Further, the battery recharging unit for this battery pack is illustrated in the top center Fig. 15.

Another noticeable diversion in the design of the left-hand embodiment compared to the right-hand embodiment is the relocating of the controller board 28 from the chassis of the device to the handle shaft, which better isolates itfrom the shocks and potential ingress of moisture and contaminants when it is located in the chassis. This relocation is more clearly identified in Fig. 16 in which it is shown in an enlarged oval, and further illustrated in this Fig. 16 is the optional single or double battery pack configurations, also described in U.S. application No. 10/810,992 filed March 26, 2004 and as pertaining to the clam shell design of battery-pack.