METHOD FOR MANUFACTURE OF A COUNTERWEIGHT APPARATUS CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority of United States Provisional Patent Application Serial No. 60/813,480 filed June 14, 2006. STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

REFERENCE TO A MICROFISHE APPENDIX Not applicable.

BACKGROUND OF THE INVENTION Field of the Invention

The invention relates to methods for manufacture of counterweight apparatus for use in devices requiring balancing functions and, more particularly, methods for manufacture of counterweights composed of concrete materials. Background Art When rotatable elements are utilized with various types of products or devices, one problem which may exist is the capability of achieving a balanced condition throughout a range of rotational speed and/or uneven distribution of variable loads carried by the rotatable members. In this regard, various types of balancing schemes are known within the prior art. Where rotatable objects are not in "perfect" balance, no n- symmetrical or uneven mass distribution will create out-of-balance forces, as a result of the centrifugal forces generated from rotation of the object. Although rotatable objects can be found in many different types of applications, two particular applications are the rotating drums associated with washing machines and dryers.

For example, Yapes, U.S. Patent No. 3,304,032 issued February 14, 1967 describes a self-balancing support mechanism. The mechanism includes a cabinet design to receive a washing machine. One side of the cabinet is provided with a strap member extending across the lower end of the cabinet, and includes a pair of spaced apart upwardly diverging slots. A mounting leg is provided for attachment of the strap. The mounting leg includes a generally horizontal central portion, with one of a pair of downwardly extending support feet formed at each end thereof. The leg includes a pair of spaced, threaded holes and an attachment stud securely threaded into each of the holes and extending through a cooperating one of the slots. When the machine is mounted on a base surface, the weight of the machine causes the studs to slide within the slots, until the machine assumes a position in which the weight distribution among the various support contact members or feet is balanced.

Severance, et al., U.S. Patent No. 3,275,146 issued September 27, 1966 describes washing machines and dryers utilizing a different type of balancing mechanism. The washing machines and dryers are of the horizontal axis drum type, where it is desirable to have the rotatable cylinder rotate at a speed as high as possible, during extraction of liquid from clothing. In such a situation, and as well known in the industry, any unbalanced condition in the load within the drum during such rotation will cause serious vibration conditions. The mechanism disclosed by Severance, et al. includes an application control device which is connected between the rotatable drum mounting configuration and support means of the machine. The support means includes a relatively thin leaf spring member which is alternately placed in tension and compression, so as to control water balancing and clutch control functions.

Elgersma, et al., U.S. Patent No. 5,561,993 issued October 8, 1996 describes a general self balancing rotatable apparatus. The apparatus includes devices for measuring forces

and motion of a rotatable member, by means of measurement of accelerations at various locations physically positioned around the rotatable member. Forces and moments are balanced through the use of matrix manipulation, so as to determine appropriate counter balance forces located at two axial position of the rotatable member. Accordingly, the system accounts for possible accelerations of a machine (such as a washing machine), which allegedly could not otherwise be accomplished if the motion of the machine was not measured. The system is described as being particularly adapted for use in conjunction with machines that are not rigidly attached to immovable objects. The algorithm used with the balancing configuration permits the counterbalance forces to be calculated, notwithstanding that the washing machine or other device is located on a moveable floor structure, which may be combined with carpet padding and carpets between the washing machine and a rigid support structure.

Kim, et al., U.S. Patent No. 5,850,748 issued December 22, 1998 discloses a front loading clothes washing machine having a spin basket which is rotatably driven about a horizontal axis. The front and rear sides of the spin basket are axially spaced, and are formed by panels. Located on each of the front and rear panels is a dynamic balancing mechanism. The mechanism includes an annular chamber which is arranged coaxially with an axis of rotation. The chamber includes a liquid and a series of balls which are freely movable within the liquid. At least one side of the spin basket includes a first annular groove which is formed within the panel. A plate member is mounted in opposing relationship to the panel, so that a second annular groove formed in the plate member is axially aligned with the first groove, thereby forming the annular chamber therewith.

Jonsson, U.S. Patent No. 6,578,225 discloses a horizontally oriented laundry washing machine. Automatic balancers are operated at a speed below the stick speed for the

laundry load, for purposes of redistributing portions of the load in the wash basket. By monitoring properties of the machine which are indicative of the balance level of the load, and selectively accelerating and decelerating the wash basket at about the stick speed, the load can be redistributed so that the load imbalance is sufficiently low so as to speed up the wash basket through its natural resonant frequencies.

Hafstrom, U.S. Patent No. 4,022,147 issued May 10, 1977 discloses a signal device which signals cycle changes in a dryer. Signaling is produced by sounding a bell assembly upon acceleration and/or deceleration of the motor shaft of the dryer. When rotational speed of the flywheel is synchronized with the rotational speed of the motor shaft, there is no striking contact between the bell assembly and the clapper of the flywheel assembly. To provide this structure, a one-way spring clutch is employed to limit the signaling to either acceleration or deceleration of the motor shaft. As an alternative embodiment, the signal device may also be constructed in a reverse manner. In this manner, the bell acts as a flywheel journaled on the shaft. The clapper assembly is then rotatable with the motor shaft. In general, the Hafstrom patent relates to improvements in home appliances, where a device is provided for audibly indicating selectively the beginning, the end or both the beginning and the end of a cycle by automatically signaling acceleration and/or deceleration of the drive mechanism. The Hafstrom patent cites other references showing various devices for bringing a clapper and a bell into contact within one another, including a screw thread on a motor shaft, a tuned wire oscillated by a cam, and a counter- weighted, spring-biased arm.

Haberl, et al., U.S. Patent No. 5,862,553 issued January 26, 1999 describes a dynamic balancing mechanism for a washing machine. More specifically, a clothes washing machine is provided with an oscillating washing assembly. The assembly includes a rotating

drum capable of being driven at various rotating speeds, and provided with a series of annular hollow bodies secured to the drum. A series of moving masses are capable of freely moving within the hollow bodies. Before at least one spin-extraction phase, the drum is driven to rotate in a continuous manner at a variable, relatively low speed. The speed is lower than the resonance frequency of the oscillating washing assembly, but is adequate to cause the wash load in the drum to keep adhering against the inner peripheral surface of the drum. As soon as the moving masses distribute themselves in such a matter that their center of gravity locates itself in a position that is substantially opposite to the unbalanced condition of the wash load, the drum has started to rotate at the desired spin extraction rate. In general, this patent is directed to problems associated with balancing of the drum holding the wash load during the spin-extraction phases that are carried out for purposes of extracting rinse water quickly from the same wash load. These problems are particularly evident when the wash load in the drum is not evenly distributed, i.e. is unbalanced. This causes undesired and unacceptable oscillations of the drum. These oscillations are then passed on to the tub of the machine. From the tub, these oscillations can be passed on to the entire outer casing.

Kawaguchi, et al., U.S. Patent No. 6,029,300 issued February 29, 2000 is directed to a spin extractor. The extractor includes a speed controller which applies a constant voltage to a motor, for purposes of starting the rotation of a drum. Since the torque is constant, the drum rotates at a low speed when the laundry is in a form of a large mass, and the load on the drum is, accordingly, large. Any time that part or all of the laundry falls between the baffles provided on the inner peripheral wall of the drum, the laundry is loosened and scattered, so that the load on the drum decreases. When the laundry is scattered adequately, the motor torque overcomes the laundry load, and the drum speed will rapidly rise. When the speed exceeds the equilibrium

speed where the centrifugal force acting on the laundry is equal to gravity, the scattered laundry will start to rotate in the state of being pressed on the inner peripheral wall of the drum. When the drum speed reaches a preset speed, higher than the equilibrium speed, the speed controller changes the speed control method to a phase control method for maintaining the drum speed at an object speed. While the drum is rotating at the opposite speed, the eccentric load detector detects the magnitude of the eccentric load based on the period change in the motor torque. A central controller will then determine whether the laundry is distributed evenly on the inner peripheral wall of the drum.

Gougoulas, U.S. Patent No. 5,454,136 issued October 3, 1995 describes a forced air vehicle dryer, with a proximity control system for the dryer. The dryer is for vehicle laundering operations, where nozzles move rectilinearly relative to the vehicle surfaces, and under the control of a sonar transducer. The sonar transducer detects the vehicle surface and measures the distance between the surface and the outlets of the air nozzles. The control system is applied to both vertical and horizontal nozzles. The position control system is in the form of a scissors mechanism, which is activated through a hydraulic cylinder. The top nozzle is divided into a series of hollow tubular sections, so as to permit the passage of vehicle mirrors and other apparatus. The side nozzle can be divided and arranged for progressive actuation, so as to accommodate vehicles of varying height.

Jeon, et al., U.S. Patent No. 6,401,284 issued June 11, 2002 is directed to a method for controlling washing during spinning in tilt-type washing machines. The purpose of the method is to attenuate vibrations. The method includes a main rotation step for exerting a centrifugal force to the laundry gathered to a center of the inner tube, for spreading the laundry to an inside wall of the inner tube before the water discharging step. A laundry disentangle

alternately rotating step in then performed, for alternately rotating the inner tube for a preset time, so as to disentangle the laundry spread to the inside wall of the inner tube. A supplemental rotating step is then provided, for rotating the inner tube at a preset RPM, so as to keep the laundry in the tilted inner tube spread evenly during the water discharge step. The method can also include, as an alterative, a rotating step for alternately rotating the inner tube so as to eliminate eccentricity of the laundry and inner tube before the water discharge step. A determining step can be used either for carrying out a control pattern to eliminate the laundry eccentricity after the rotating step is greater than a preset value, or for proceeding to the water discharging step if the eccentricity of the laundry is smaller than the preset value. In this manner, the vibration can be attenuated to a minimum.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described with reference to the drawings, in which: FIG. 1 is a direct, elevation view of a first embodiment of a counterweight assembly which may be manufactured through methods in accordance with the invention; FIG. 2 is a second embodiment of a counterweight assembly which may be manufactured through methods in accordance with the invention;

FIG. 3 is a third embodiment of a counterweight assembly which may be manufactured through methods in accordance with the invention;

FIG. 4 is a partially schematic and partially diagrammatic illustration of a conveyor system which may be utilized in accordance with the invention for manufacture of the counterweight assemblies;

FIG. 5 is a diagrammatic illustration of a set of five conveyors which may be utilized with pallets in the manufacturing methods in accordance with the invention;

FIG. 6 is a diagrammatic view of a portion of a feed conveyor and a pair of vibrating tables which may be utilized in accordance with the invention;

FIG. 7 is a perspective illustration of the relative positioning of a water meter within the equipment utilized with manufacturing methods in accordance with the invention; FIG. 8 is a photograph of a cement batcher which may be utilized with manufacturing methods in accordance with the invention;

FIG. 9 is a device characterized as a silo over- fill alarm which may be utilized with manufacturing methods in accordance with the invention;

FIG. 10 is a photograph showing a weigh belt which may be utilized with manufacturing methods in accordance with the invention;

FIG. 11 is a photograph showing the relative positioning of an additive dispensing system which may be utilized with manufacturing methods in accordance with the invention; and FIG. 12 is a close up view of the water meter illustrated in FIG. 7.

SUMMARY OF THE INVENTION In accordance with the invention, a method is provided for manufacturing a counterweight assembly. The method includes the mixing of concrete with a metallic material, so as to form the counterweight assembly. The concrete and the metallic material are placed in curing molds. At least one cure accelerant is added to the mixture while in the mold. The counterweight assembly is then cured. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The principles of the invention, which is directed towards methods of manufacture of counterweight assemblies, will now be described. Example counterweight assemblies which may be manufactured in accordance with the invention are illustrated in FIGS.

1, 2 and 3. Methods for manufacture of counterweight assemblies in accordance with the invention may be used for various types of washers, dryers and similar appliances. However, it should be emphasized that methods for manufacture of counterweight assemblies in accordance with the invention may be used in other applications, including tumblers, mixers, vibration machines and tables, tractors, cranes and concrete reinforcements.

In this regard, known concrete and cast iron assemblies are used within many industries to act as counterweights. Washer and dryer appliances use counterweights to provide balance for wet laundry during washing and drying cycles. As an example of such use, wet laundry in relatively modern washer and dryer drums is subjected to extremely rapid revolutions. Counterweights are used to help keep the appliances in place during use. These known washers and dryers use known concrete or cast iron counterweights to provide balance. Such counterweights can vary in size and shape, and may use metal stampings to provide fastening capabilities.

Example counterweight assemblies which may be manufactured through methods in accordance with the invention are illustrated in the photographs of FIGS. 1, 2 and 3. FIG. 1 illustrates a counterweight assembly 100, while FIG. 2 illustrates a counterweight assembly 102, having somewhat of an alternative shape and configuration. Still further, FIG. 3 also illustrates an alternative counterweight assembly 104. Counterweight assembly 104 shows a still further differing shape and configuration from the counterweight assemblies 100, 102. As will be described in greater detail herein, counterweight assemblies manufactured through processes in accordance with the invention will utilize metal materials and concrete, so as to provide for a counterweight assembly which is relatively less expensive to manufacture and provides relatively greater density. In certain methods for preparing a

counterweight assembly in accordance with the invention, the concrete is mixed with the metallic material, so as to form the counterweight assembly. With the metallic material used as a filler material, counterweight assemblies manufactured in accordance with the invention are relatively less expensive to manufacture than known counterweight assemblies. An example embodiment of a manufacturing method in accordance with the invention for manufacture of counterweight assemblies will now be described. Certain example equipment which may be utilized for this manufacturing process is illustrated in FIGS. 4 - 12.

The raw materials which are utilized in this embodiment of a manufacturing process in accordance with the invention are described below: 1. Sand. Preferably, the sand should be 1% to 80% by weight. Also, in a preferred embodiment, the granular size should be within the range of 0.0020 inches to 0.3 inches.

2. Metallic materials such as magnetite. Preferably, the materials should be up to 80% by weight. The granular size of the magnetite can range from 0.0020 inches to 0.4 inches. Such magnetite is readily commercially available and, for example, such a product is sold under the trade name "Minelco."

3. The cement utilized should preferably be 2% to 30% by weight. One exemplary type of cement which may be utilized is known as Cemex CPO 40R Hydrolic cement.

4. The water utilized should preferably be from 0.04% to 15% by weight.

5. A chemical additive which may preferably be utilized in the manufacturing process is known as "Naphthalene Sulphonic Acid Derivative." Such an additive is sold under the trade name "Rheobulid 1000." 6. On an optional basis, the raw material ingredients can include fiberglass within a range of 0% to 2% by weight. Such fiberglass is chemically known as polypropylene. One type of fiberglass which is sold as loose fibers in pellet form is available under the name "Fibercon." In a physical embodiment having apparatus for performing manufacturing processes in accordance with the invention, storage bins can be utilized which house materials such as the sand and the magnetite to be used in the manufacturing process. In addition, a silo or similar type of storage facility can be used to house cement. Under the storage bins, an automated weigh belt conveyor system may be utilized to carry bulk sand and magnetite into a building where the primary functions associated with the manufacturing process will be performed. Such a weigh belt system is illustrated as weigh belt system 106 in FIG. 10. The weigh belt conveyor system 106 can be utilized to carry the bulk sand and magnetite into what could be characterized as a holding hopper. An additional holding hopper (preferably located in the upper part of the building where the manufacturing process occurs) may be fed from the cement silo. A computerized programmable logic control (PLC) mechanism can be utilized to control various features associated with the manufacturing process. For example, the PLC mechanism may be utilized to automatically control:

1. The weighing and release of raw material (by means of, for example, outside release gates on the storage bins and silo).

2. Water metering. An example water meter is illustrated in FIGS. 7 and 12 as water meter 108. 3. The metering of the addition of the chemical additive.

4. The mix time.

5. The release of the upper hoppers holding the sand, magnetite and cement into an automated concrete mixture.

6. The release of the concrete mixture to a lower hopper. 7. A sensor located on what could be characterized as a "last" holding hopper, which signals when it is time to initiate the mixing of a new batch of concrete.

Certain portions of a physical realization of the equipment associated with the manufacturing process in accordance with the invention are illustrated in several of the drawings. For example, FIG. 9 illustrates a silo over-fill alarm 110. The over-fill alarm will indicate critical situations where the silo has been overfilled with cement. FIG. 8 illustrates a cement batcher 112. Correspondingly, FIG. 11 illustrates an additive dispensing system 114 for dispensing the chemical additive.

Still further in accordance with the physical realization of the practice of the manufacturing process in accordance with the invention, it was found that the amount of time required to fill the two upper hoppers holding the sand and magnetite was in a range of 30 seconds to 4 minutes. Again, it should be emphasized that control of all of this equipment is under the PLC mechanism. The two holding hoppers release and feed the sand and magnetite

into the automated concrete mixer or batcher 112. A water pump is connected to the automated concrete mixer 112, and will feed water into the mixture as needed. The water metering is provided by the water meter 108 shown in FIGS. 7 and 12. Correspondingly, the chemical additive and the fiberglass also are put into the concrete mixer as required. The automated concrete mixer is then utilized to mix the sand, magnetite, chemical additive, cement, water and fiberglass. Again, in a physically realized system, the concrete mixing cycle time ranged from 1 to 10 minutes, depending on the amount of concrete being mixed. It has been found that a typical concrete mix batch size may range from 1,200 to 1,800 pounds. However, the exact weight may vary dependent upon counterweight demand, counterweight product size and the like. The PLC mechanism may be utilized such that it can be adjusted so to control the batch size, and correspondingly modify the input size of material ingredients. When mixing is complete, the concrete can be released in to a third and final holding hopper located underneath the automated concrete mixer.

After the resultant concrete mixture is placed into the third and final holding hopper (or, what could be referred to as the lower holding hopper), a hollow pallet plate carrying molds, mold carriers and a mold pan can be positioned below the third hopper on a conveyor system, for purposes of filling the molds with concrete. FIG. 4 illustrates an embodiment of a conveyor system 16 which may be utilized to practice the manufacturing process in accordance with the invention. The mold carrier can be a support and strapping mechanism which facilitates holding the molds together. The mold carrier can also assist in transporting the molds during the manufacturing process. The mold pan preferably fits on top of the molds, for purposes of directing cement into the molds during a release from the third holding hopper. Accordingly, the mold pan facilitates the speed of the mold filling process.

The conveyor underneath the third holding hopper may include, for example, two shaker or vibration tables. Such vibration tables are illustrated in FIG. 4 as vibration tables 118. The PLC mechanism can control activation of the vibration tables 118, when a pallet comes into the fill position on the conveyor. While the molds are being filled with concrete (through gravity feed from the holding hopper), the hollow pallet plate carrying the molds may be positioned on the vibration tables 118 through the use of the conveyor. The purpose of the vibration tables 118 is to shake the pallets containing the molds, so as to ensure that the molds are completely filled with concrete. Correspondingly, this shaking function eliminates air gaps or empty spaces which may exist within the molds. Preferably, each hollow pallet plate can carry multiple molds, and the number of molds can vary depending upon the size and shape of the desired concrete counterweight product. After the molds are completely filled with the concrete mixture, the mold pan can be removed, and the pallet of molds can continue on the conveyor toward the cure chamber. Such a cure chamber is illustrated in FIG. 4 as a pair of two cure chambers 120.

In a physically realized embodiment of the process in accordance with the invention, each hollow pallet plate included an identification tag tracked by the PLC mechanism through use of radio frequency identification (RFID), as the pallet moved toward and into the cure chambers 120. The identification tracking system essentially ensures that the concrete filled molds spend the necessary amount of time required in the cure chambers 120 for purposes of curing. In addition, this tracking system also improves traceability and quality assurance. The cure chambers 120 themselves preferably include an automated conveyor control system for controlling conveyors (shown as conveyors 122 in FIG. 4) for slowing moving the pallets of concrete filled molds through the cure chambers 120 for purposes of curing. An example pallet is illustrated as pallet 124 in FIG. 4. The conveyor system within the

cure chambers preferably includes multiple conveyors 122, so as to allow for staging of a number of pallets 124 for curing simultaneously. The cure chambers 120 should preferably be in the form of an environmentally controlled space, with temperature and humidity levels monitored so as to create an optimum curing environment. An example environment which has been found by the inventors to be preferable is one where the operating temperature is within the range of 105° to 150° Fahrenheit. Correspondingly, ideal humidity levels are in the range of 8% to 100%. In one example embodiment, the temperature and humidity may be controlled by means of a direct fire, steam generator. Such a generator directs steam by means of a central pipe which runs through the length of the cure chambers 120. Fans within the cure chambers 120 assist in circulating the steam and thereby stabilizing the temperature, so as to create a relatively optimum curing environment. It is believed by the inventors that a direct fire steam generator is preferable, in that it provides finished concrete counterweights with a relatively more consistent cure and relatively more consistent color. It has further been found that the ideal cure time is in the range of 3 to 6 hours. This is a substantial improvement over traditional counterweight curing methods, which are believed to be approximately 24 hours.

As previously described, the pallets 124 are preferably staged and monitored by means of identification tags as they pass through the cure chamber, for purpose of facilitating proper curing. When the pallets 124 reach the end of the conveyor lanes, they may be transferred out of the cure chambers 120 and directly onto a single lane conveyor system located outside of the cure chambers 120. Such a single lane conveyor system is illustrated as conveyor system 126 in FIG. 4.

The single lane conveyor system 126 carries the pallets containing the cured concrete counterweights to a staging area 128 (FIG. 4). It is within the staging area 128 that the

cured concrete counterweights are removed from the molds and packaged in preparation for shipment. The staging area 128 is essentially the first location where any manual handling of the counterweights occurs. That is, all manufacturing process steps prior to the staging area are automatically controlled with the PLC mechanism. However, it should be mentioned that if desired, certain of the process steps may be performed on a manual basis. For example, the concept of filling the molds with concrete by means of a gravity feed mechanism was previously described herein. However, if desired, the molds can be filled manually with buckets containing the material mixture. Also, reference was earlier made to the concept that the fiberglass could be automatically added to the concrete mixture as needed. However, the addition of the fiberglass to the concrete mixture can also occur on a manual basis.

It is at the staging area where demolding will occur. During the demolding process, the molds are manually emptied, and prepared to again be run through the entirety of the system. The mold carriers are released, and the molds are taken apart. In one embodiment of equipment used in the process in accordance with the invention, the molds may consist of two halves, and constructed of polyurethane. Another part of the processes which occur within the staging area may include not only the removal of the counterweight from the mold, but also the weighing of the counterweight, by manual or automated means. This function is to ensure that the correct weight has been achieved for the counterweight.

Following these processes, the empty molds are then preferably cleaned with brushes and a mold release agent is then applied to the molds, so as to help aid removal of the counterweight from the mold during the next demolding cycle. When such type of mold release agent which may be utilized and is commercially available is referred to as Petroleum Distillate, Hydrotreated Heavy Naphthenic. This release agent is sold under the brand name "Cast Off" by

Degussa. Following the cleaning of the molds and the application of the release agent, the molds are then put back together and secured by means of the mold carrier on the pallet plate. The pallet plate is then ready to be placed on the conveyor system, for purposes of again going through the manufacturing processes for the counterweights in accordance with the invention. The methods in accordance with the invention can also include other features, in accordance with certain novel concepts of the invention. For example, the PLC mechanism can include sensors which signal when a new batch of concrete needs to be mixed. The PLC mechanism can automatically control operations all the way from bringing in materials by means of the automated weigh belt conveyor, to releasing the concrete from the automated concrete mixture. Correspondingly, the RFID system can control the movement of the pallets from entry into the cure chambers 120 to the staging area 128.

The transfer of pallets can occur through a "pop up" process. This pop up transfer process can be used to change direction on the automated conveyor system by means of sensors or other electronic instruments. Still further, it should be emphasized that the use of the fiberglass is believed to minimize cracking within the counterweight assemblies. Also, it is believed that certain novel concepts associated with processes in accordance with the invention include the use of the hollow pallet plate, mold pan, mold carrier and mold transfer system. Still further, with respect to the cure chambers 120, it may be preferable to insulate the cure chambers with foam panels, for purposes of holding the curing temperature relatively steady, and for purposes of conserving energy.

The manufacturing process in accordance with the invention for manufacture of the concrete counterweights includes several advantages, a number of which have been

previously described herein. Because the metal material magnetite (or other metal material which may be utilized) has a density substantially greater than that of concrete, the use of the metallic material and concrete in a combination reduces the amount of concrete traditionally used in known concrete counterweight assemblies. Correspondingly, greater space utilization is realized, and the same amount of weight is provided as exists in known counterweight assemblies, where the weight is achieved within a smaller combined space. Also, in view of the greater space utilization, relatively more efficient freight and handling can be realized for the counterweight assemblies. That is, traditional concrete and cast iron counterweight assemblies may result in more difficulty in shipping and handling, in addition to relatively more costs. Also, because the metal is used as a filler material, manufacturing processes in accordance with the invention are relatively less expensive than processes for manufacturing known counterweight assemblies.

It will be apparent to those skilled in the arts that other embodiments of manufacturing processes for counterweight assemblies in accordance with the invention may be designed. That is, the principles of processes as described herein are not limited to the specific embodiments described herein. Accordingly, it will be apparent to those skilled in the art that modifications and other variations of the above-described illustrative embodiments of the invention may be effected without departing from the spirit and scope of the novel concepts of the invention.