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Title:
IMPROVED CONTAINER LOADER
Document Type and Number:
WIPO Patent Application WO/2016/153361
Kind Code:
A1
Abstract:
One embodiment of the invention relates to a material loader for loading material into a freight container borne by a vehicle, the material loader comprising a bin having an open or openable discharge end, the bin, in use, being able to be positioned such that the discharge end extends into the freight container, a pusher having at least a part thereof operable to move along the inside of the bin from a first position inside the bin towards the discharge end, and first and second actuators configured and arranged to move the pusher along the inside of the bin towards the discharge end. The first and second actuators are configured and arranged such that actuation of one of the first and second actuators moves the other of the first and second actuators towards the discharge end of the bin, and said movement of the pusher towards the discharge end of the bin causes material in the bin to be loaded into the freight container.

Inventors:
WARD SIMON (NZ)
Application Number:
PCT/NZ2016/050045
Publication Date:
September 29, 2016
Filing Date:
March 23, 2016
Export Citation:
Click for automatic bibliography generation   Help
Assignee:
A WARD LTD (NZ)
International Classes:
B65D88/54; B60P1/64; B65F9/00; B65G67/04; B65G67/20
Domestic Patent References:
WO2008109678A12008-09-12
Foreign References:
EP2559548A12013-02-20
US3621775A1971-11-23
US4576540A1986-03-18
DE3447814A11986-07-03
US7275906B12007-10-02
DE3734555A11989-04-27
US3734005A1973-05-22
US6146078A2000-11-14
US6138557A2000-10-31
Attorney, Agent or Firm:
LUCAS, Jonathan et al. (NZ)
Download PDF:
Claims:
Claims

A material loader for loading material into a freight container borne by a vehicle, the material loader comprising:

a bin having an open or openable discharge end, the bin, in use, being able to be positioned such that the discharge end extends into the freight container;

a pusher having at least a part thereof operable to move along the inside of the bin from a first position inside the bin towards the discharge end; and

first and second actuators configured and arranged to move the pusher along the inside of the bin towards the discharge end,

wherein the first and second actuators are configured and arranged such that actuation of one of the first and second actuators moves the other of the first and second actuators towards the discharge end of the bin, and

wherein said movement of the pusher towards the discharge end of the bin causes material in the bin to be loaded into the freight container.

A material loader as claimed in claim 1, wherein the first actuator is configured and arranged to move the pusher from the first position inside the bin towards the discharge end of the bin to an intermediate pusher position, the intermediate pusher position being between the first position and the discharge end of the bin, and the second actuator is configured and arranged to move the pusher from the intermediate pusher position towards the discharge end of the bin.

A material loader as claimed in any one of the preceding claims, wherein the first and second actuators are first and second fluid cylinders.

A material loader as claimed in claim 3, wherein the fluid cylinders are mounted substantially horizontally behind the pusher from the discharge end of the bin such that each fluid cylinder extends outwardly parallel to the direction in which the pusher is operable to move along the inside of the bin.

5. A material loader as claimed in claim 4, wherein the first and second fluid cylinders are arranged such that the piston rods of the respective fluid cylinders extend outwardly in opposite directions.

6. A material loader as claimed in any one of claims 4-5, wherein the first fluid cylinder comprises:

a piston rod connected to the pusher; and

a barrel mounted on a carriage, and

the second fluid cylinder comprises:

a barrel mounted on the carriage; and

a piston rod connected to a structure substantially fixed relative to the bin, wherein the carriage is configured to move relative to the substantially fixed structure in the pusher moving direction.

7. A material loader as claimed in claim 6, wherein the material loader comprises a support structure configured to support the bin, the piston rod of the second fluid cylinder being connected to the support structure.

8. A material loader as claimed in claim 7, wherein the support structure comprises a

cylinder support frame extending behind the pusher from the discharge end of the bin, the cylinder support frame comprising one or more slide paths along which the carriage is configured to move and a distal support member at a distal end of the slide paths, the piston rod of the second fluid cylinder being connected to the distal support member.

9. A material loader as claimed in any one of the preceding claims, wherein the pusher comprises a pusher plate mounted in front of the actuators.

10. A material loader as claimed in claim 9, wherein the pusher comprises a strengthening frame provided behind the pusher plate.

11. A material loader as claimed in any one of claims 9-10, wherein the pusher plate has a slope such that the bottom end of the pusher plate is positioned closer to the discharge end of the bin than the top end of the pusher plate. 12. A material loader as claimed in claim 11, wherein the pusher plate has a curved side profile steeper at the top end than the bottom end.

13. A material loader as claimed in any one of claims 11-12, wherein the pusher plate

comprises a plurality of curved plate sections provide one on top of another.

14. A material loader as claimed in any one of the preceding claims, wherein, in use,

movement of the pusher from the fi rst position inside the bin towards the discharge end of the bin to an intermediate pusher position causes material inside the bin to be compacted.

15. A material loader as claimed in claim 14, wherein the bin comprises a bin door or doors at the discharge end of the bin and, when the bin door or doors are not open, movement of the pusher towards the discharge end compacts material in the bin. 16. A material loader as claimed in claim 15, wherein the bin door or doors are configured to be not open when the first actuator moves the pusher from the first position inside the bin towards the discharge end of the bin to an intermediate pusher position and the bin door or doors are configured to be open when the second actuator moves the pusher from the intermediate pusher position towards the discharge end of the bin.

17. A material loader as claimed in any one of the preceding claims, wherein the material loader comprises means for controlling actuation of the first and second actuators.

18. A material loader as claimed in claim 17, wherein the means for controlling allows the order and/or timing of actuation of the first and second actuators to be controlled.

19. A method of loading material into a freight container borne by a vehicle, the method comprising:

positioning the freight container such that an open or openable discharge end of a fully or partially loaded bin extends into the freight container;

actuating first and second actuators to move a pusher along the inside of the bin towards the discharge end,

wherein the first and second actuators are configured and arranged such that actuation of one of the first and second actuators moves the other of the first and second actuators towards the discharge end of the bin, and

wherein said movement of the pusher towards the discharge end of the bin causes material in the bin to be loaded into the freight container.

20. A method as claimed in claim 19, wherein the method comprises:

actuating the first actuator to move a pusher along the inside of the bin from a first position inside the bin towards the discharge end of the bin to an intermediate pusher position, the intermediate pusher position being between the first position and the discharge end of the bin; and

actuating the second actuator to move the pusher along the inside of the bin from the intermediate pusher position towards the discharge end of the bin.

21. A method as claimed in any one of claims 19-20, wherein the steps of actuating the first and second actuators comprises actuating first and second fluid cylinders.

22. A method as claimed in claims 21, wherein the steps of actuating the first and second fluid cylinders comprise extending the piston rods of the respective fluid cylinders outwardly in opposite directions.

23. A method as claimed in any one of claims 21-22, wherein the step of actuating at least one of the first and second fluid cylinders causes movement of a carriage relative to a substantially fixed structure in the pusher moving direction, wherein the first fluid cylinder comprises:

a piston rod connected to the pusher; and

a barrel mounted on a carriage, and

the second fluid cylinder comprises:

a barrel mounted on the carriage; and

a piston rod connected to the structure substantially fixed relative to the bin.

24. A method as claimed in any one of claims 19-23, wherein the method comprises

compacting material in the bin prior to loading the material into the freight container.

25. A method as claimed in claim 24, wherein the step of compacting the material

comprises actuating at least one of the first and second actuators.

26. A method as claimed in claim 25, wherein the step of compacting the material

comprises actuating the first fluid cylinder.

27. A method as claimed in claim 26, wherein the discharge end of the bin is not open when the first actuator is being actuated such that the material in the bin is compacted and the discharge end of the bin is open when the second actuator is actuated such that the material in the bin is loaded into the freight container.

28. A method as claimed in any one of claims 19-27, wherein the method comprises

controlling actuation of the first and second actuators. 29. A method as claimed in claim 28, wherein the method comprises controlling the order and/or timing of actuation of the first and second actuators.

Description:
IMPROVED CONTAINER LOADER

Field of Invention The invention relates to a material loader. More particularly, the invention relates to an improved apparatus and method for loading material into a shipping container and the like.

Background to the Invention Containers are used to transport a vast range of materials and goods all around the world. Quick and efficient loading and unloading of containers is desirable as this translates into cost savings and increased profits for companies in the transportation and freighting business. One way efficiencies have been improved is through the standardisation of container sizes, which has reduced the costs associated with transporters and freight equipment since there are fewer different container sizes. Despite these improvements, there are still a number of different standards which must be catered for when providing container loading equipment, which increases costs.

A number of ways of speeding up the loading of a container have been used. Pallets are convenient for materials of certain sizes and dimensions, but typically they are not suitable for bulk material, such as scrap metal, because the pieces of bulk material may be too large for a pallet or the use of pallets may lead to the underutilisation of space within the container. As a result, bulk material is usually loaded loosely into a container. Recent developments in bulk material loading devices include the Acculoader by Body Equipment, Inc and the

Scrapperâ„¢ produced by Steco. These devices comprise bins that can fit inside a container and are mounted on a sliding mechanism for sliding forwards and backwards in and out of the container. The bins are top-loaded with bulk material and a hydraulic ram is used to push the material from the bin into the container. An example of a similar such device is disclosed in US 7,837,428 in the name of SA Recycling LLC. In this invention, a bin is top-loaded with material to be loaded into a container. The container is backed up to the bin so the bin fits within the container. A ram is then used to push the material from the bin into the container. The truck carrying the container needs to edge forwards at a similar speed as the speed of the hydraulic ram so that the bulk material load is distributed through the container. This may be difficult to achieve in practice.

Container loaders such as have been described are typically very large pieces of equipment that have a large footprint and are not very mobile. For example, the loader disclosed in US

7,837,428 has a footprint of approximately twice the length of a container because of the need to cantilever the loaded bin to prevent tipping. It would be advantageous to provide a loader with as small a footprint as possible to save space in loading yards.

Another container loader is disclosed in International Patent Application No.

PCT/NZ2012/000016 in the name of A Ward Attachments Limited, the contents of which are incorporated herein by reference. This document discloses a material loader for quickly and easily loading material, particularly bulk material, into a containment apparatus. Material to be loaded is placed inside a bin that is dimensioned to fit inside the containment apparatus. In use, the containment apparatus is positioned so that the bin is inside the containment apparatus and the containment apparatus or a vehicle bearing the containment apparatus is connected to a material transfer member inside the bin. Forward movement of the

containment apparatus/vehicle causes the material transfer member to hold against the material while the bin slides out of the containment apparatus from the point of view of the containment apparatus, leaving the material behind. In other words, the forward movement of the containment apparatus/vehicle causes the material transfer member to pull the material into the containment apparatus. The invention may also be used for unloading a containment apparatus.

One problem with this apparatus is that, for heavy loads, the force required to pull the material transfer member forward may be greater than the force able to be exerted by the pulling vehicle.

Object of the Invention It is an object of the invention to provide an improved material loader. Alternatively, it is an object to provide an improved method of loading material into a containment apparatus, such as a freight container. Alternatively, it is an object to address at least some of the foregoing disadvantage(s) associated with the prior art. Alternatively, it is an object of the invention to at least provide the public with a useful choice.

Summary of the Invention According to a first aspect of the invention, there is provided a material loader for loading material into a freight container borne by a vehicle, the material loader comprising:

a bin having an open or openable discharge end, the bin, in use, being able to be positioned such that the discharge end extends into the freight container;

a pusher having at least a part thereof operable to move along the inside of the bin from a first position inside the bin towards the discharge end; and

first and second actuators configured and arranged to move the pusher along the inside of the bin towards the discharge end,

wherein the first and second actuators are configured and arranged such that actuation of one of the first and second actuators moves the other of the first and second actuators towards the discharge end of the bin, and

wherein said movement of the pusher towards the discharge end of the bin causes material in the bin to be loaded into the freight container.

Preferably, the first actuator is configured and arranged to move the pusher from the first position inside the bin towards the discharge end of the bin to an intermediate pusher position, the intermediate pusher position being between the first position and the discharge end of the bin, and the second actuator is configured and arranged to move the pusher from the intermediate pusher position towards the discharge end of the bin. Preferably, the first and second actuators are first and second fluid cylinders. More preferably, the first and second actuators are hydraulic cylinders, which may also be known in the art as hydraulic rams. In such an embodiment, extension of the first fluid cylinder moves the pusher from the first position inside the bin towards the discharge end of the bin to the intermediate pusher position and extension of the second fluid cylinder moves the pusher from the intermediate pusher position towards the discharge end of the bin.

Preferably, the fluid cylinders are mounted substantially horizontally behind the pusher from the discharge end of the bin such that each fluid cylinder extends outwardly parallel to the direction in which the pusher is operable to move along the inside of the bin. In a preferred embodiment, the first and second fluid cylinders are arranged such that the piston rods of the respective fluid cylinders extend outwardly in opposite directions.

Preferably, the first fluid cylinder comprises:

a piston rod connected to the pusher; and

a barrel mounted on a carriage, and

the second fluid cylinder comprises:

a barrel mounted on the carriage; and

a piston rod connected to a structure substantially fixed relative to the bin, wherein the carriage is configured to move relative to the substantially fixed structure in the pusher moving direction.

Preferably, the material loader comprises a support structure configured to support the bin, the piston rod of the second fluid cylinder being connected to the support structure. More preferably, the support structure comprises a cylinder support frame extending behind the pusher from the discharge end of the bin, the cylinder support frame comprising one or more slide paths along which the carriage is configured to move and a distal support member at a distal end of the slide paths, the piston rod of the second fluid cylinder being connected to the distal support member. In preferred embodiments of the invention, the pusher comprises a pusher plate mounted in front of the actuators. More preferably the pusher comprises a strengthening frame provided behind the pusher plate.

Preferably, the pusher plate has a slope such that the bottom end of the pusher plate is positioned closer to the discharge end of the bin than the top end of the pusher plate. More preferably, the pusher plate has a curved side profile steeper at the top end than the bottom end. More preferably, the pusher plate comprises a plurality of curved plate sections provide one on top of another.

Preferably, in use, movement of the pusher from the first position inside the bin towards the discharge end of the bin to an intermediate pusher position causes material inside the bin to be compacted.

More preferably, the bin comprises a bin door or doors at the discharge end of the bin and, when the bin door or doors are not open, movement of the pusher towards the discharge end compacts material in the bin. More preferably, the bin door or doors are configured to be not open when the first actuator moves the pusher from the first position inside the bin towards the discharge end of the bin to an intermediate pusher position and the bin door or doors are configured to be open when the second actuator moves the pusher from the intermediate pusher position towards the discharge end of the bin.

Preferably, the material loader comprises means for controlling actuation of the first and second actuators. More preferably, the means for controlling allows the order and/or timing of actuation of the first and second actuators to be controlled.

According to a second aspect of the invention, there is provided a method of loading material into a freight container borne by a vehicle, the method comprising:

positioning the freight container such that an open or openable discharge end of a fully or partially loaded bin extends into the freight container; actuating first and second actuators to move a pusher along the inside of the bin towards the discharge end,

wherein the first and second actuators are configured and arranged such that actuation of one of the first and second actuators moves the other of the first and second actuators towards the discharge end of the bin, and

wherein said movement of the pusher towards the discharge end of the bin causes material in the bin to be loaded into the freight container.

Preferably, the method comprises:

actuating the first actuator to move a pusher along the inside of the bin from a first position inside the bin towards the discharge end of the bin to an intermediate pusher position, the intermediate pusher position being between the first position and the discharge end of the bin; and

actuating the second actuator to move the pusher along the inside of the bin from the intermediate pusher position towards the discharge end of the bin.

Preferably, the steps of actuating the first and second actuators comprises actuating first and second fluid cylinders. More preferably, the first and second actuators are hydraulic cylinders, which may also be known in the art as hydraulic rams.

In a preferred embodiment, the steps of actuating the first and second fluid cylinders comprise extending the piston rods of the respective fluid cylinders outwardly in opposite directions.

Preferably, the step of actuating at least one of the first and second fluid cylinders causes movement of a carriage relative to a substantially fixed structure in the pusher moving direction, wherein

the first fluid cylinder comprises:

a piston rod connected to the pusher; and

a barrel mounted on a carriage, and

the second fluid cylinder comprises:

a barrel mounted on the carriage; and a piston rod connected to the structure substantially fixed relative to the bin.

Preferably, the method comprises compacting material in the bin prior to loading the material into the freight container.

More preferably, the step of compacting the material comprises actuating at least one of the first and second actuators. More preferably, the step of compacting the material comprises actuating the first fluid cylinder. More preferably, the discharge end of the bin is not open when the first actuator is being actuated such that the material in the bin is compacted and the discharge end of the bin is open when the second actuator is actuated such that the material in the bin is loaded into the freight container. Preferably, the method comprises controlling actuation of the first and second actuators. More preferably, the method comprises controlling the order and/or timing of actuation of the first and second actuators.

Further aspects of the invention, which should be considered in all its novel aspects, will become apparent to those skilled in the art upon reading of the following description which provides at least one example of a practical application of the invention.

Brief Description of the Drawings One or more embodiments of the invention will be described below by way of example only, and without intending to be limiting, with reference to the following drawings, in which:

Figure 1 is a side cut-away view illustration of a material loader according to one

embodiment of the invention;

Figure 2 is a plan view illustration of the material loader shown in Figure 1; Figures 3, 4 are cross-sectional side view illustrations of the material loader shown in Figures 1 and 2 in different configurations;

Figures 5-8 are side view illustrations of the actuation mechanism and pusher of Figures 1-4 in different configurations without other parts of the material loader being shown; and

Figure 9 is a flow chart illustrating a method of loading a container according to an

embodiment of the invention.

Detailed Description of Preferred Embodiments of the Invention

Embodiments of the invention are particularly applicable to loading and unloading freight containers, sometimes referred to as intermodal, shipping or ISO containers. However, some embodiments are not limited as such and embodiments of the invention may be used to load or unload any kind of container or containment apparatus. For example, in some embodiments the invention is used to load a transport trailer, semi-trailer truck or the like. The term

"container" when used herein will be understood to mean any device capable of containing material. In contrast, the term "freight container" or "ISO container" is used to refer to standard intermodal or shipping containers.

Bin Figure 1 is a side cut-away view illustration of a material loader 10 according to one

embodiment of the invention. Figure 2 is a plan view illustration of material loader 10.

Container loader 10 comprises a bin 11 that, in the embodiment shown, is generally elongate and has a bottom wall, two side walls and two end walls. One of the end walls has been cut away so that Figure 1 illustrates the space inside bin 11. The upper side of bin 11 may be open or comprise a lid. In the embodiment shown, bin 11 comprises a lid 12 covering a forward portion of the top side the bin 11 with an opening 13 in a rear portion of the top side of the bin. Opening 13 may be large enough to enable material to be loaded into another container (e.g. a freight container) to be inserted into bin 11.

In one exemplary use, the material loader 10 is used to load rubbish into a container. In this instance, opening 13 may be large enough to receive or align with an opening of a rubbish feed device, such as a hopper. In another example, scrap material may be loaded by material loader 10. In general, the opening is large enough to receive the type of material to be loaded from a feeding device or mechanism. The side walls 22 of bin 11 are, in the embodiment shown in Figure 1, continuous (i.e. there are no gaps in the walls) so that even very granular forms of material can be contained therein. The inner side of the walls 22 is sufficiently smooth such that material can generally slide relative thereto without snagging. The outer side of the walls 22 may comprise vertical struts 23 to reinforce their strength.

The upper side of the bottom of bin 11 is also sufficiently smooth for material to slide easily along the bottom of the bin. The lower side of bottom may also comprise reinforcing struts similar to struts 23 in the side walls. First end 15 of bin 11 is open or openable. For example, in Figure 1 bin 11 comprises doors 24 at first end 15. Bin doors 24 may be closed for the purposes of loading or unloading bin 11, or compacting material inside bin 11, but opened for the purposes of moving material out of bin 11 and into a container. In the embodiment shown, bin doors 24 comprise a series of vertical portions such that the doors can be closed gradually as material is ejected from bin 11. A bin opening/closing mechanism may be provided.

Pusher

Container loader 10 further comprises pusher 25. In Figure 1, pusher 25 is shown in a retracted position, proximate rear end 21 of bin 11, and also in ghost lines (marked 25a) in an extended position proximate discharge end 15 of bin 11. In the embodiment shown, pusher 25 comprises a pusher plate 26 mounted at the front of a strengthening frame 27. Pusher plate 26 has a slope such that its bottom end is closer to the discharge end 15 of bin 11 than its top end. Pusher plate 26 has a two-stage curved side profile with each stage being steeper near the bottom end than the top end of the pusher. In other embodiments, a single curved profile or multiple curved profiles may be used. The curved profile of plate 26 helps to push material inside bin 11 forward by slightly lifting it off the bottom of the bin, reducing friction. In other embodiments, the pusher plate may be a substantially vertical plate, or may include other undulations, indentations or profile shapes, as may be determined to be suitable for assisting movement of the material inside bin 11.

In use, pusher 25 is operable to move along the length of bin 11 such that plate 26 moves along the inside of bin 11 and transfers any material in the bin in front of it towards first end 15. The shape of plate 26 is preferably complementary to the cross-sectional shape of the inside of bin 11 such that there is minimal space between the edges of the plate and the inside of the bin. This ensures that minimal material contained in bin 11 can slip past the plate and so substantially all the material is transferred out of bin 11 upon actuation of the plate.

Pusher plate 26 may be strengthened by a strengthening frame on its rear side to enable it to withstand reaction forces from material in the bin 11 being pushed. For example, strengthening frame 27 comprises a rearwards extending bottom member and a diagonal brace connecting the bottom member to the top of pusher plate 26. A strengthening frame or lattice may also be provided to the rear side of pusher plate 26. Other strengthening arrangements may be provided as will be apparent to those of skill in the art such that pusher 25 has sufficient strength for its purpose as described above.

Support structure

Bin 11 is mounted on a support structure, generally indicated 14 in Figure 1. Support structure 14 is configured to support bin 11 on the ground or support surface, preferably at a suitable height to load material into a receiving container. For example, support structure 14 may support bin 11 in a generally horizontal position at substantially the same height as a freight container borne by a truck, and in particular so that the truck can drive backwards so that the front or discharge end 15 of bin 11 extends into the freight container.

In the embodiment shown in Figure 1, support structure 14 comprises front support legs 16 positioned to support bin 11 off the ground. Support legs 16 are operable to fold up against the underside of bin 11 into a folded configuration in which they are adapted to allow movement of a freight container longitudinally relative to the bin, as will be explained in more detail below. The legs of support legs 16 are preferably positioned proximate the middle or front end of bin 11. In a preferred embodiment, the bin 11 may be supported by two or more sets of support legs 16 across its width to provide stability in the sideways direction. Each set of support legs 16 may each comprise two struts 17 and 18 and a foot member 19. Struts 17 and 18 are pivotably attached at a first end to the foot member 19 and pivotably attached at a second end to the underside of bin 11. Strut 18, the strut furthest from the discharge end of bin 11, is attached to bin 11 by means of a sliding portion (not shown in Figure 1). Each sliding portion is able to move longitudinally along the underside of bin 11 along a cavity, thereby enabling each set of legs 16 to fold up under bin 11. Although not shown in Figure 1, a hydraulic ram is preferably connected between each sliding portion and the underside of the bin and positioned longitudinally along the underside of the bin to actuate the folding up and down of legs 11. Support structure 14 may also comprise rear support structure 20, comprising a frame arranged to support a rear end 21 of bin 11 off the ground. In the embodiment of Figure 1, rear support structure 20 comprises orientation adjustment means for adjusting the orientation of bin 11 connected to the bottom of a second end 21 of bin 11. For example, rear support structure 20 may comprise hydraulic pistons mounted on framing, the pistons being connected to the rear bottom edge of bin 11. A pivot bar further connecting bin 11 to the framing may also be provided. It will be appreciated by those of skill in the art how the orientation of bin 11 may be adjusted using hydraulic pistons. For example, the pistons are selectively operable to alter the height of the back of bin 11 and therefore its degree of tilt. The pistons also allow the bin to lean from side to side and to rotate horizontally. Rear support structure 20 may be

advantageously fixed to the ground in the desired location for container loader 10. This prevents the loader moving during transfer of material into a container. It also prevents the loader from tipping over should a large amount of material be loaded into the bin proximate the discharge end.

Actuators

Material loader 10 comprises an actuator mechanism, generally labelled 30 in Figure 1, for moving pusher 25 along the inside of bin 11 from a retracted position (for example in the position near end 21 as shown in Figure 1) towards discharge end 15. In preferred embodiments of the invention, two actuators are provided. The first and second actuators are configured and arranged such that actuation or de-actuation of the first and/or second actuator moves pusher 24 forwards and backwards inside bin 11. Furthermore, the actuators may be configured such that actuation of one of the first and second actuators moves the other of the first and second actuators towards the discharge end of the bin. This allows the second actuator to act, when the first actuator is at least partly actuated, from a position further forward than the position of the second actuator when the first actuator is not actuated. Consequently, the two actuators act together to cause a greater length of travel of pusher 25 than could be achieved by either actuator acting alone. The order and timing of the actuation of the two actuators may be controlled by a user or control mechanism. In one exemplary manner of operating material loader 10 the first actuator is configured and arranged to be actuated first to move pusher 25 a first part-way along the inside of the bin 11, i.e. from the retracted position to an intermediate position in between the retracted position and extended position, and the second actuator is configured and arranged to be actuated second (i.e. after actuation of the first actuator) to move pusher 25 a further part of the way along the inside of the bin 11, i.e. from the intermediate position towards the discharge end 15.

In the exemplary embodiment of Figures 1 and 2, the material loader 10 comprises a first hydraulic cylinder or ram 31 and a second hydraulic cylinder or ram 32. In other embodiments, the actuators may comprise different types of fluid cylinders, for example pneumatic cylinders. Selective extension of one of the cylinders 31 or 32, or extension of both cylinders 31 and 32, enables the pusher plate to be selectively moved the first part-way along the inside of the bin 11 or the further part-way along the inside of the bin. As will become clear from the ensuing description, one of the cylinders 31 or 32, when actuated alone, can move the pusher the first part-way along the inside of the bin. Actuation of the other cylinder then moves the pusher the second part-way along the inside of the bin but, in the embodiments described below, this requires the first cylinder to be already in the extended position.

Cylinders 31 and 32 are mounted substantially horizontally behind pusher 25 (i.e. on the opposite side of pusher 25 from the discharge end 15 of bin 11). The cylinders are oriented so that extension of the cylinders causes the pusher 25 to move in the direction along the inside of bin 11 from end 21 to end 15, i.e. in the longitudinal direction. That is, the cylinders 31 and 32 are oriented substantially parallel to the longitudinal direction. In the preferred embodiment of Figures 1 and 2 the cylinders 31 and 32 are oriented the opposite way round from each other, i.e. so that the piston rods of the cylinders extend out from their respective barrels in opposite directions.

The cylinders of material loader 10 are arranged one on top of another and both being positioned generally centrally relative to the width of the material loader and pusher 25. The cylinders are supported by cylinder support frame, generally labelled 33 in Figures 1 and 2, that forms part of support structure 14 and extends generally under cylinders 31 and 32 and behind the rear end 21 of bin 11. Cylinder support frame 33 comprises rear-extending support arms 34 connecting at their distal ends, i.e. distal from bin 11, to distal support member 35. Cylinder support frame 33 also comprises, or is adapted to receive, a carriage or carriage frame 36 which is operable to move along cylinder support frame 33 in the longitudinal direction. Cylinder support frame 33 may comprise one or more slide paths along which carriage 36 is configured to slide. The slide paths may comprise smooth sliding surfaces that may be lubricated to assist with a smooth sliding action. Alternatively the slide paths may comprise rollers or other devices to assist the movement of the carriage therealong. As will become apparent, the slide paths of material loader 10 extend inside bin 11 to enable carriage 36 to move into and out of bin 11 through end 21.

The material loader may also comprise tubing or other elongate housing for containing the hose lines to the cylinders 31 and 32. The hose lines need to be supported and held in such a way to avoid tangling. In one embodiment, the elongate housing is formed from multiple discrete housing parts connected together in a line in a manner similar to caterpillar tracks. When connected together the housing parts form an elongate tube through which the cylinder hose lines pass. The material loader may comprise two such tubes. The support frame may comprise a channel or the like for supporting and guiding the position of the elongate tube during use.

In the embodiment of Figures 1 and 2, the end of the piston rod of top cylinder 31 is connected directly or indirectly to the pusher 25. The barrel of top cylinder 31 is mounted on carriage 36. The barrel of bottom cylinder 32 is mounted on carriage 36 and the piston rod of bottom cylinder 32 is connected to distal support member 35. In other embodiments the piston rod of the bottom cylinder is connected to any part of the support structure that is substantially fixed relative to the bin. The connections and mountings of the piston rods and barrels of the cylinders to other parts of the material loader may be achieved by any suitable connection mechanism. According to the configuration of the cylinders described, the top cylinder has a piston rod that extends outwardly in the direction of bin 11 and discharge end 15 while the bottom cylinder has a piston rod that extends outwardly in the opposite direction, i.e. away from bin 11. In other embodiments the cylinders may be arranged in another manner. For example, the piston rod of the top cylinder may connect to the distal support member and the piston rod of the bottom cylinder may connect to the pusher. In this case it would be the top cylinder that extends rearwardly and the bottom cylinder that extends in the forwards longitudinal direction (where forwards is towards the discharge end of the bin). Alternatively, the cylinders may be positioned side by side. The skilled addressee would appreciate how the cylinder support frame and cylinder connection mechanisms would need to be configured dependent on the orientation and positioning of the cylinders.

The use of two actuators compared to a single actuator may provide certain advantages. Two double-acting cylinders occupy a smaller length when retracted for a given extension length compared to a single actuator, thus reducing the size of the material loader needed for a given extension length (and therefore volume of material to be loaded) and saving space in the location of use of the loader. Furthermore, the two-stage extension step (described in more detail below) allows the loader to perform distinct material compaction and material loading steps.

The arrangement of cylinders described above enables the top cylinder to act from a position that is further forward (i.e. nearer discharge end 15) when the bottom cylinder has been at least partially extended. Top cylinder may have already been extended when bottom cylinder acts to move top cylinder forwards.

The cylinders (or, in other embodiments, other types of actuator) may be configured to be able to lock so that extension of one of the cylinders against a large resistive force (for example, heavy objects) does not result in the compression or retraction of the other cylinder. By locking the extended cylinder in either a partly or fully extended position, this enables the force of extension of the other cylinder to be exerted on the object or objects exerting the large resistive force (e.g. the friction of the material in bin 11 with the bottom of the bin).

Carriage 36 has a length approximately equal to one third to one half of the length of each of cylinders 31 or 32 and has carriage frame members at either end to which the cylinders are mounted. This provides stability to the carriage.

Operation of the Material Loader

The operation of the material loader 10 when used to load material into a freight container according to the embodiment shown in Figures 1 and 2 will now be described with reference to Figure 9, which is a flow chart illustrating a method 90 of loading a container according to an embodiment of the invention, and Figures 3-8, Figures 3 and 4 are cross-sectional side view illustrations of the material loader 10 shown in Figures 1 and 2 in different configurations. Figures 5-8 are side view illustrations of the actuation mechanism and pusher of Figures 1-4 in different configurations without other parts of the material loader being shown.

At step 91, bin 11 is loaded (fully or partially) with material to be loaded into a freight container. Material may be loaded into bin 11 in any appropriate manner, including being loaded into the top of the bin, for example through opening 13. Material may be loaded into the top of bin 11, for example using a grapple, claw, crane, digger or the like. The front doors 24 of bin 11 are preferably closed during this step to assist in containing the material within the bin.

At step 92, the freight container to be loaded is positioned for loading in relation to the loaded bin 11. For the purposes of the following discussion of the method of loading, it will be assumed that the container is mounted on a vehicle, for example a truck or lorry. However, such an arrangement is not limiting to the invention. For example, the container may be hanging from a crane or in any other arrangement such that it is moveable in relation to the container loader.

Pusher 25 is positioned before loading at a suitable position to allow material to be loaded into bin 11 in front of the pusher plate 26. If part of bin 11 is covered, the pusher is positioned far enough back to allow part of the inside of bin 11 in front of the pusher to be below the opening 13. If material in the bin is not to be compacted by the material loader before loading, the pusher 25 may be located such that the volume of bin 11 between pusher plate 26 and doors 24 corresponds approximately to the volume of material to be loaded into the container.

Pusher 25 can be moved backwards or forwards to alter the volume of bin 11 capable of receiving material to be loaded. In one example of positioning the container at step 92, the vehicle bearing the container reverses in the direction of bin 11. As it reverses, bin 11 is aligned with the container. If necessary, the orientation adjustment means of the container loader can be operated to adjust the height and/or orientation of bin 11 such that it is aligned with the reversing container. Alignment assistance may be provided to the driver of the vehicle, for example in the form of wheel guides on the ground to ensure the vehicle reverses towards the container loader in the desired direction, thus minimising the risk of an impact between the container or vehicle and the loader, which could cause damage to any of these. The vehicle continues reversing such that the container engulfs at least end 15 of the bin, which is then positioned inside the container. When the container has reversed along bin 11 such that it contacts foldable legs 16, it pushes against the forward strut 17 of legs 16, causing the legs to fold up onto the underside of bin 11. Alternatively, the legs may fold up by virtue of a leg folding mechanism that is activated automatically, e.g. when the container nears legs 16, or manually, e.g. when an operator activates an activation mechanism. The leg folding mechanism may be hydraulically powered or otherwise. As legs 16 are folded up, they are no longer in contact with the ground and therefore no longer support part of the weight of bin 11. Instead, the container and vehicle support at least part of the weight of bin 11.

The container continues being reversed, preferably until it substantially encloses all of the container surrounds bin 11, i.e. discharge end 15 of bin 11 is at or proximate to the inner end of the freight container.

At step 93, the actuation mechanism is actuated by actuation of the first actuator, i.e. top cylinder 31. Upon actuation, the piston rod of top cylinder 31 extends outwardly from the barrel towards bin 11, i.e. in the direction of discharge end 15. This causes pusher 25 to be pushed along the inside of the bin from its starting position proximate bin end 21 the first part of the way along the inside of the bin towards an intermediate position. The intermediate position may correspond to the point at which the piston rod of the top cylinder 31 is substantially fully extended. This position is shown in Figures 3 and 5. During this step of actuating the top cylinder 31, material in the bin 11 may be compacted. To effectively compact material in the bin 11, the doors 24 of bin 11 are closed. Furthermore, the presence of lid 12 assists in containing the material in the bin and enabling it to be compacted. For this reason, lid 12 may cover as large an area of bin 11 as possible where compacting is required. It may be useful to compact material before loading it into a freight container in order to increase the amount of material that can be loaded and to make the transfer of material into the freight container easier.

Alternatively, no compaction of material may be necessary prior to loading material into the freight container. In this case, doors 24 of material loader 10 are opened (if they were not previously open) prior to extending the piston rod of top cylinder 31. Clearly the bin must be positioned inside the container so that there is enough room to open the doors 24 without abutting the inner end of the container. As top cylinder 31 extends, material will be transferred into the freight container in the manner that will be described below in relation to the extension of the bottom cylinder.

At step 94, bin doors 24 are opened. The bin doors may be opened manually, for example using a suitable door opening mechanism that can be accessed by an operator without having to enter the bin or freight container, or automatically. An automatic door opening mechanism may comprise a trigger mechanism that is activated to open the doors when pusher 25 reaches a certain point along the length of the bin, or when the freight container passes a certain point, for example. An exemplary mechanism is described in PCT/NZ2012/000016, the contents of which are incorporated herein by reference. The bin doors may be opened by mechanical or electrical means.

At step 95, the second actuator is actuated. With reference to the embodiment of Figures 1-8, bottom cylinder 32 is actuated. Upon actuation, the piston rod of bottom cylinder 32 extends outwardly from the barrel away from bin 11. Since bottom cylinder 32 is mounted with the end of the piston rod connected to the fixed distal support member 35, the extension of the bottom cylinder causes carriage 36 to move along the slide path on the carriage support frame 33 towards discharge end 15 of bin 11 and away from the distal support member 35. Since top cylinder 31 is mounted on carriage 36, the extension of bottom cylinder 32 causes carriage 36, top cylinder 31 and pusher 25 to be moved forwards in the direction of discharge end 15. Pusher 25 moves from the intermediate position shown in Figures 3 and 5 to an extended position where it is at or proximate discharge end 15 of bin 11, such as shown in Figures 4 and 6.

In other embodiments of the invention, the bin doors may not be opened in between actuation of the first and second cylinders. As pusher 25 moves forward from the intermediate position towards the discharge end of bin 11 it may continue to compact material in bin 11 if bin doors 24 remain close. Alternatively, it may unload material into the freight container if the bin doors 24 have been opened. It will be appreciated that the timing of opening of bin doors 24 can be determined based on the degree of compaction (if any) that is required. Depending on the degree of compaction required, bin doors 24 may remain open the whole time pusher 25 is moving forward, bin doors 24 may be opened during actuation of the top cylinder (i.e. while the pusher 25 is between the starting and intermediate positions), while the pusher 25 is in the intermediate position or during actuation of the bottom cylinder (i.e. while the pusher 25 is between the intermediate position and discharge end of the bin).

When the bin doors are open and pusher 25 moves forward, material inside bin is pushed along inside the bin and, when it reaches the open discharge end, is discharged out of the bin. Since the freight container is positioned so that bin 11 is inside the freight container, the material is transferred from the bin into the container. The transfer of material into the container causes the container to move forwards due to the pushing force imparted by the pusher 25 and transmitted to the container through the material being pushed. It will be understood that the freight container should be borne or mounted on a vehicle so that the freight container can move forwards. For example, a truck carrying the freight container can be placed in neutral. Alternatively, the truck may need to move forwards at a speed similar to the speed at which the pusher moves forward. As the pusher 25 moves forward (and hence the freight container continues to move forward), more and more of the material in bin 11 is transferred into the container. The material drops into the container from a height corresponding to the height of the bottom of bin 11 above the bottom of the inside of the container, which is typically a small height. Furthermore, material is transferred into the container substantially without any material sliding along its bottom. This means that the inside of a container used with the loader is subject to only little impact or abrasion, which is advantageous as containers can be easily damaged.

Once the container moves forward past the foldable legs 16, the legs are free to fold down into the support position, ready to support the bin of the container loader when the container and vehicle are no longer positioned to do so.

The container is moved forward until pusher 25 reaches discharge end 15 of bin 11. This position is shown in Figures 4 and 6, as well as by the position of the pusher shown in ghost lines 25a in Figure 1. At step 96, the container is moved forward and transported to its destination. The doors of the container may be closed once the material has been transferred into it and the freight container has been moved sufficiently far forward that it is possible to do so.

After all the material has been discharged from the bin 11, the pusher 25 is moved back into position ready for the bin to accept more material for loading at step 97. Each of cylinders 31 and 32 is retracted one after the other to move pusher 25 backwards. Figure 7 illustrates components of material loader 10 when top cylinder 31 has been retracted to move pusher 25 back into the intermediate position. Figure 8 illustrates components of the material loader 10 when bottom cylinder 32 has been retracted to move pusher 25 back into its starting position.

In the description of method 90 above, the top cylinder 31 is actuated first (at step 93) to move the pusher 25 from the starting position to the intermediate position and the bottom cylinder 32 is actuated second to move the pusher 25 from the intermediate position to discharge end 15. Then (at step 97) the cylinders are de-actuated in the same order, i.e. with the top cylinder being de-actuated first, followed by the bottom cylinder. It will be apparent to those of skill in the art that, during the extension or actuation steps, i.e. when pusher 25 is moved forwards in bin 11 towards discharge end 15, the top and bottom cylinders may be actuated in either order. That is, the top cylinder may be actuated followed by the bottom cylinder, or the bottom cylinder may be actuated followed by the top cylinder. Similarly, during the retraction or de- actuation steps, i.e. when pusher 25 is moved backwards in bin 11 away from discharge end 15, the top and bottom cylinders may be actuated in either order. That is, the top cylinder may be de-actuated followed by the bottom cylinder, or the bottom cylinder may be de-actuated followed by the top cylinder.

In another embodiment of the invention, the actuators of the material loader are actuated simultaneously. For example, in the case of material loader 10, the top and bottom cylinders may be actuated at the same time. In some embodiments, the commencement and/or cessation of actuation of the top and bottom cylinders may be simultaneous. In other embodiments, the latterly actuated cylinder may commence actuation before cessation of actuation of the formerly actuated cylinder. Furthermore, the actuation sequence of the cylinders of material loader 10 may be able to be controlled by a user or by a controller (e.g. software running on a processor) dependent on the circumstances.

Unless the context clearly requires otherwise, throughout the description and the claims, the words "comprise", "comprising", and the like, are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense, that is to say, in the sense of "including, but not limited to".

The entire disclosures of all applications, patents and publications cited above and below, if any, are herein incorporated by reference.

Reference to any prior art in this specification is not, and should not be taken as, an

acknowledgement or any form of suggestion that that prior art forms part of the common general knowledge in the field of endeavour in any country in the world. The invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, in any or all combinations of two or more of said parts, elements or features. Where in the foregoing description reference has been made to integers or components having known equivalents thereof, those integers are herein incorporated as if individually set forth.

It should be noted that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the invention and without diminishing its attendant advantages. It is therefore intended that such changes and modifications be included within the present invention.