FIELD OF THE INVENTION

[0001 ] The present invention relates generally to stillages, and in particular to stillages for stowing and/or transporting elongate beam components. The invention is especially useful for transporting structural beam components for deployable aircraft maintenance and logistics shelters (DAMALSH) and it will be convenient to describe the invention in relation to that example application. It should however be understood that the invention is intended for broader application and use.

BACKGROUND TO THE INVENTION

[0002] DAMALSH structures are used by the military, and in particular the air force, such as the Royal Australian Air Force (RAAF). A requirement exists for the RAAF to safely transport DAMALSH structural beam components using a series of stillages.

[0003] DAMALSH structures can be quite large and structural beam components typically range in length from approximately 6ft (1829mm) to 8ft (2464mm) with a cross-sectional profile that varies from approximately rectangular to circular. A typical rectangular profile is approximately 275mm x 100mm and a beam component having these dimensions may have a weight in the range of 20 to 60 kg, or possibly more. The number of beam components within a complete DAMALSH structure could be in excess of 100.

[0004] Stillages are required to be suitable for safe transportation by marine, land or flight vehicles, either directly or whilst housed within International Standards Organisation (ISO) shipping containers or aircraft 'L pallets'. [0005] A RAAF requirement is that stillages must allow the DAMALSH structural beam components to be removed by no more than two personnel without the use of lifting aids.

[0006] From this RAAF requirement, the present inventor has recognised that it would be desirable for the stillages to be modular, such that the number of DAMALSH beam components stowed in a stillage may be varied, and hence the height of the stillage also varied so that use of space is maximised.

[0007] The height of a stillage is however restricted due to several factors including the safe working height that can be expected of two personnel to lift beam components out of the stillage, and the height limitations of the

transportation method utilised, eg shipping container height or aircraft cargo hold height limitations.

[0008] It is also desirable to ensure a stillage is no higher that is required to stow the desired number of beam components, thus allowing space above the stillage to be utilised for other DAMALSH components such as canvas, straps and other miscellaneous items.

[0009] With the forgoing in mind, there remains a need for an improved stillage for stowing and/or transporting beam components of the type which may be used in DAMALSH structures.

SUMMARY OF THE INVENTION

[0010] The present invention accordingly provides a stillage for stowing and/or transporting elongate beam components, the stillage comprising a base and at least one beam support assembly carried by the base, the beam support assembly comprising a plurality of modular cradles which are stackable one upon another in a multilevel configuration, each modular cradle comprising: at least one recess which is shaped and sized to support a beam component, such that in use a plurality of beam components can be carried one above the other by the plurality of stacked modular cradles;

self locating means to facilitate stacking of an upper cradle upon a lower cradle and to prevent subsequent horizontal movement between the cradles once stacked; and

a fastening mechanism enabling the upper cradle to be releasably secured to the lower cradle so as to prevent vertical separation of the cradles during transport.

[001 1 ] In one embodiment, the self locating means comprises mating cone formations, and may be in the form of truncated cones. For example, a truncated cone may project from a lower surface of the upper cradle and a corresponding cone shaped recess may be formed in an upper surface of the lower cradle. The mating cone shapes thereby enable the upper cone to nest within the lower recess and thereby prevent movement in the horizontal plane.

[0012] In one embodiment, the fastening mechanism comprises a quick release clasp. Such a clasp may be formed as an over center latch which may clamp the upper cradle to the lower cradle, thereby preventing movement in a vertical direction.

[0013] In a preferred embodiment, each modular cradle extends in a direction transverse to a longitudinal dimension of the elongate beam components. In this embodiment, the cradle may include a plurality of recesses arranged side-by-side to enable a corresponding plurality of beam components to be carried at each level of the beam support assembly. With this arrangement an array of beam components can be carried over several levels. For example, one embodiment of the stillage may be arranged to carry 12 beam components with 4 beams on each level and 3 levels being provided. Any alternative arrangement could also be created such as, for example, 16 beams, with 4 beams on each level and 4 levels being provided, or 20 beams, with 5 beams on each level and 4 levels again being provided. The preferred arrangement would naturally depend on the size of each beam and the available space in which the stillage is to be stored or transported..

[0014] In a particular embodiment, each recess is in the form of a U-shaped channel which has an inner profile shaped and sized to conform to an outer cross-sectional profile of a lower portion the beam components. Alternatively, or in addition, a lower edge of an upper modular cradle may include a U-shaped channel which has an inner profile shaped and sized to conform to an outer cross-sectional profile of an upper portion of the beam components. With this arrangement, the beam components may be securely held by the modular cradles with little possibility of movement during transport.

[0015] Although U-shaped channels are preferred, it will be appreciated that the recesses may take any alternative shape as may be applicable to the beam components being carried. For example, any depression, indentation or notch, of a shape corresponding to an outer profile of the beam components, could be used. And along similar lines, a 'U-Shape' channel could be square, rectangular, V-shaped, half-round, or some other shape corresponding to the outer profile of a relevant portion of the beam components.

[0016] In a preferred embodiment, the stillage includes a pair of beam support assemblies carried by the base. One assembly may be located at each end of the elongate beam components and each U-shaped channel may have an end stop which is arranged to extend at least partially into the channel so as to abut an end surface of the elongate beam component, and thereby prevent

longitudinal movement of the beam component within the channel and hence within the stillage.

[0017] In a particular embodiment, each modular cradle comprises a sandwich structure having the following sequence of components:

a first end plate, said end plate being arranged to prevent longitudinal movement of an elongate beam component; a protector plate, arranged to prevent damage to an end surface of the beam component;

a first U-shaped support plate, said U-shape having an inner profile configured to hold the beam component;

a spacer arrangement;

a second U-shaped support plate, held at a distance from the first U- shaped support plate by the spacer arrangement, and said U-shape of the second support plate also having an inner profile configured to hold the beam component; and

a second end plate, which together with the first end plate, provides rigidity to the sandwich structure.

[0018] In this embodiment, the first and second end plates may be made of metal, and the first and second U-shaped support plates may be made of a plastic material. The metal advantageously provides structural strength and provides a mounting surface for the plastic components. The plastic provides a non-abrasive bearing surface for the beam components and thereby prevents damage to those components. The protector plate may also be made of plastic material for similar reasons.

[0019] It will be appreciated that the modular cradles enable the beam components to be removed from the stillage, one layer at a time by two

personnel. For this purpose, each cradle is preferably manufactured to have a mass of no more than 40 kg. Once a layer of beam components has been removed, the cradle may be removed, which then enables the next layer of beam components to be removed, again using no more than two personnel.

[0020] The modular nature of the cradles also enables the height of the stillage to be quickly and easily configured by the user, without the need for tools, to any height required to stow the desired number of beam components. Any number of levels may be stacked one upon the other until the desired height, or height limit, is reached. [0021 ] Another embodiment of the stillage provides a beam stowage system that is able to be placed in an ISO shipping container in a longitudinal

configuration such that, with two stillages, a walk-way of approximately 380 mm exists between the two stillages within the ISO shipping container. This walk-way enables two personnel to utilise the manual unloading capability of the stillage. In one example, the stillage dimensions are approximately: height=1850mm, width=900mm, length=2700mm. An ISO shipping container has an internal width of approximately 2330mm.

[0022] In a further embodiment the stillage may include a top plate or cover configured to prevent rain and debris entering the stillage, and hence entering the spaces between the beam components. The cover may also then be used to carry other DAMALSH components, such as canvas, straps and other

miscellaneous items, within an ISO container.

[0023] In yet another embodiment, the stillage may include a base structure which enables the stillage to be lifted by a forklift. For this purpose the base may include appropriately sized/positioned channels or tunnels configured to receive the tines of the forklift.

[0024] The word comprises/comprising and grammatical variations thereof, when used in this specification, are to be taken to specify the presence of stated features, integers, steps or components or groups thereof, but do not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.

[0025] To assist the further understanding of the invention, reference is now made to the accompanying drawings which illustrate a preferred embodiment. Other embodiments of the invention are possible, and consequently the particularity of the accompanying drawings is not to be understood as

superseding the generality of the preceding description of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 shows a perspective view of a stillage in accordance with a preferred embodiment of the invention, with 8 of 12 beam components carried within the stillage.

[0027] Figure 2 shows a partial perspective view of a portion of the stillage shown in Figure 1 but with a modular cradle detached.

[0028] Figure 3 shows a schematic representation of a mating cone arrangement designed to facilitate stacking of an upper modular cradle upon a lower modular cradle.

[0029] Figure 4 shows a detailed perspective view of a modular cradle as used in the embodiment shown in Figures 1 and 2.

DESCRIPTION OF PREFERRED EMBODIMENT

[0030] Referring initially to Figures 1 and 2 of the drawings, there is shown a stillage 100 in accordance with a preferred embodiment of the invention. This stillage is designed to stow and/or transport twelve elongate beam components 102, with three layers of four beam components in each layer. However, any alternative arrangement could be created by varying the number of beam components 102 in each layer and/or varying the number of layers. In the embodiment shown in Figures 1 and 2, two layers of beam components have been placed in position and the third layer has been omitted for the sake of clarity. Thus, eight of the twelve intended beam components are shown.

[0031 ] The stillage 100 comprises a base 104 and a pair of beam support assemblies 106, 106'. Each beam support assembly 106, 106' comprises four modular cradles 108, 1 10, 1 12, 1 14 which are stackable one upon another in a multilevel configuration. In this regard, Figure 1 shows the modular cradles being in their "in use" position whereas Figure 2 shows an upper cradle 1 12 separated from a lower cradle 1 10.

[0032] The embodiment shown in Figure 1 also includes fork lifting capability in the form of a pair of hollow crossbeamsl 16, 1 16' which are sized and positioned to enable the tines of a forklift to be inserted so that the stillage can be easily lifted and moved.

[0033] Referring now to Figure 4, there is shown a close up view of a single cradle 1 10 as could be used at any of the intermediate levels within the stillage 100. For example, the cradle 1 12 shown in Figure 1 may be identical to the cradle 1 10 shown in Figure 4.

[0034] The cradle 1 10 includes a plurality of recesses (four in this instance) in the form of U-shaped channels 1 18 arranged side-by-side so as to support a corresponding plurality of beam components 102 at that level of the beam support assembly 106. The cradle 1 10 has an elongate configuration and, in use, extends in a direction transverse to the longitudinal dimension of the elongate beam components 102. Each of the U-shaped channels 1 18 is shaped and sized to support one of the beam components 102 such that, when the cradles are fixed in position as shown in Figure 1 , a plurality of beam components 102 (three in this instance) can be carried one above the other by the plurality of stacked cradles.

[0035] Each of the U-shaped channels 1 18 has an inner profile which is shaped and sized to conform to an outer cross-sectional profile of a lower portion of the beam components 102. Similarly, the lower edge of the cradle 1 10 also includes U-shaped channels 120 which have an inner profile shaped and sized to conform to an outer cross-sectional profile of an upper portion of the beam components 102. [0036] Each of the cradles 1 10 includes a self-locating arrangement in the form of mating truncated cone formations. In particular, an upper surface of the cradle 1 10 includes cone shaped recesses 122 and the lower surface of the cradle 1 10 includes projecting cones 124 (not seen in Figure 4 but visible in Figure 2). In use, the mating cone shapes facilitate stacking of an upper cradle 1 12 upon a lower cradle 1 10 and then prevent subsequent movement between the cradles in a horizontal plane.

[0037] While in the embodiment shown, the male cone shaped formations project from the lower surface of a cradle and the female cone shaped recesses are provided in the upper surface of the cradle (as seen in Figure 4), the reverse arrangement could instead be employed and would work in the same fashion.

[0038] Figure 3 shows a schematic representation of the mating cone shaped formations wherein each part is formed as a block which is incorporated into the structure of the modular cradles. It will be appreciated from the relative dimensions of the components shown in Figure 3 that the truncated cone formation 124 will nest within the truncated cone shaped recess 122.

[0039] Referring again to Figure 4, it can be seen that the modular cradle 1 10 in this embodiment is formed as a bolted "sandwich" structure comprising the following sequence of components:

1 . A first sheet metal end plate 126 which, in use, forms an end stop to prevent longitudinal movement of the elongate beam components 102. In particular, in the assembled stillage as shown in Figure 1 , the first end plates 126 form the outer sides of the beam support assemblies 106, 106' and hence form the end surfaces of the stillage 100.

2. A plastic protector plate 128 which provides a relatively soft surface for the beam components 102 to rest against, rather than the hard sheet metal surface of the end plate 126.

3. A first plastic U-shaped support plate 130 which has an inner profile shaped to hold the beam component 102 in the transverse and vertical direction. Preferably, a low friction plastic is utilised so as to reduce surface damage to the beam component 102 due to fretting etc. and does not require undue force for a user to remove the beam components 102 from the cradle 1 10. In addition, the plastic material should have sufficient strength to support the beams, and it should be weather resistance and not absorb water. For example, nylon might swell and make it difficult to remove the beam components.

4. A set of spacers132.

5. A second plastic U-shaped support plate 134, held at a distance from the first U-shaped support plate 130 by the spacers 132. The second U-shaped support plate 134 also has an inner profile shaped to hold the beam component 102 in the transverse and vertical direction.

6. A second sheet metal end plate 136 which, together with the first sheet metal end plate 126, provides rigidity to the sandwich structure.

[0040] This structure actually has two main properties: a) the layers of the sandwich perform different functions as described above and b) the layers function together, mainly due to friction between layers, to act as a composite beam structure - this provides the necessary stiffness.

[0041 ] Also seen in Figure 4 is a fastening mechanism used to enable an upper cradle to be releasably secured to a lower cradle so as to prevent vertical separation of the cradles during transport. The fastening mechanism includes a plurality of quick release clasps 138 incorporating over centre latches 140.

[0042] In the embodiment shown, the spacers 132 are used to separate the two plastic U-shaped support plates 130,134 so that the overall cradle depth (thickness) is sufficient to be stable when being stacked by a user, but not too heavy so as to not be considered a one man lift.

[0043] Additionally, the size of the cone formations 124 and recesses 122 of the self-locating arrangement are chosen to assist with stability as described above and to provide a sufficiently large sloped working surface such that the user is not required to be overly accurate in lining up the cradles when stacking them. Due to the cone geometry, any misalignment by the user will be corrected as the two mating cone surfaces meet and then nest together.

[0044] Whilst in the preferred embodiment each cradle is specifically designed for a particular DAMALSH beam profile, by altering the end plates and the profile of the U-shaped support plates, the same cradle design/construction

methodology may be used to accommodate different beam profiles, both rectangular and circular, or any other shape.

[0045] Although a preferred embodiment of the stillage is described herein in detail, it will be understood by those skilled in the art that variations may be made thereto without departing from the concepts embodied in the invention.

[0046] For example, the modular cradles may be designed differently whilst maintaining the same functionality. In this regard, each cradle could be constructed from one piece of plastic material with the "U" shapes being provided as machined or moulded recesses. In this embodiment, the recesses could then be integrally formed with end stops to abut the end surfaces of the beam components, rather than the end stops being formed as separate plates.

[0047] Similarly, the mating cone configuration could be integrally formed with the plastic material and may take alternative shapes, such as a simple pin and hole arrangement, although this would be less preferred.

[0048] Along similar lines, the fastening mechanism could take an alternative form, and could also potentially be integrally formed within a one-piece plastic cradle.

[0049] To add required strength and stiffness, metal beams could be bolted to the plastic cradle in appropriate locations, or the plastic moulding could include metal inserts within the moulding where required to maintain strength and stiffness. [0050] Other alternatives would be readily apparent to persons skilled in the art and those alternatives are also considered to fall within the spirit of the invention and the scope of the appended claims.