Technical field of the invention

The present invention relates to an apparatus for removing elongate members from a bundle of elongate members.

Background of the invention

Distribution facilities within the construction sector serve to facilitate transfer of building materials from manufacturers to contractors and construction markets. The standard situation for store level replenishment orders is the case when contractors and construction markets will order by the number, and not by the pallet/bundle. Homogenous bundles (with only one type of product) of elongate members, such as profiles and reinforcement rods, needs to be de-bundled (de-palletized), sorted by replenishment order, and then re-palletized. Hence, in high-volume distribution facilities, it is important to handle orders for store level replenishment as lean as possible. Currently, this process is performed manually. A specific problem when handling bundles of reinforcement rods is that the rods tend to become entangled within the bundle. Hence, a worker needs to detangle the reinforcement rod during picking of the order. This may be performed by whiplash movements of the heavy weight rods, which is physically demanding for the worker.

Summary of the invention

It is an object of the present invention to provide assistive technology to the process of removing elongate members from a bundle of elongate members. One aspect relates to an apparatus for removing one or more elongate members from a bundle of elongate members, the apparatus comprising:

- a roller;

- drive means adapted for rotating the roller; and

- positioning means adapted for positioning a bundle of elongate members such that the internal angle between a vertical first plane containing the midline longitudinal axis of the bundle of elongate members and a second vertical plane containing the midline longitudinal axis of the roller is within the range of 0-45 degrees;

wherein the roller comprises:

- a body part with a high-friction coating/layer, and/or

- a body part with protrusions extending radially outward from the body part. Another aspect relates to an apparatus for removing one or more elongate members from a bundle of elongate members, the apparatus comprising:

- a roller;

- drive means adapted for rotating the roller; and

- positioning means adapted for positioning a bundle of elongate members in close proximity to the roller;

wherein the roller comprises:

- a body part with a high-friction coating/layer, and/or

- a body part with protrusions extending radially outward from the body part. In the present context the term "internal angle" is to be understood as the smallest angle of the two angles formed between two intersecting vertical planes - one vertical plane containing the midline longitudinal axis of the bundle of elongate members, and the other vertical plane containing the midline longitudinal axis of the roller. The sum of the internal angle and the other angle (the external angle) will always be 180 degrees. In the present context the term "midline longitudinal axis of the bundle of elongate members" is to be understood as the longitudinal axis dividing the bundle of elongate members into two equal sized pieces. In the present context the term "midline longitudinal axis of the roller" is to be understood as the longitudinal axis dividing the roller into two equal sized pieces.

In one or more embodiments, the positioning means is adapted for positioning a bundle of elongate members such that the internal angle between a vertical first plane containing the midline longitudinal axis of the bundle of elongate members and a second vertical plane containing the midline longitudinal axis of the roller is within the range of 0-45 degrees, such as within the range of 1 -40 degrees, e.g. within the range of 2-35 degrees, such as within the range of 3-30 degrees, e.g. within the range of 4-25 degrees, such as within the range of 5-20 degrees, preferably within the range of 0-15 degrees.

In one or more embodiments, the positioning means is a storage rack. Hence, the storage rack is positioned in relation to the roller such that when a bundle of elongate members are positioned therein, the internal angle between a vertical first plane containing the midline longitudinal axis of the bundle of elongate members and a second vertical plane containing the midline longitudinal axis of the roller is within the range of 0-45 degrees, such as within the range of 1 -40 degrees, e.g. within the range of 2-35 degrees, such as within the range of 3-30 degrees, e.g. within the range of 4-25 degrees, such as within the range of 5-20 degrees, preferably within the range of 0-15 degrees. The drive means is adapted for rotating the roller. In one or more embodiments, the drive means comprises a motor operatively connected to the roller. A drive shaft may be positioned in-between the roller and the motor. In one or more embodiments, the drive means is operatively connected to a first end of the roller. In one or more embodiments, the drive means further comprises a controller configured for reversing and/or deactivating the motor when the torque required to turn the roller at a given speed exceed a preset threshold. This is important to avoid that the elongate members are bent in a situation where they have not been properly released from the bundle. The controller may be configured to stop in such a situation, and a worker needs to remove the elongate members manually. The controller may also be configured to aid the worker in removing the elongate members from the roller by reversing the direction of motor, and hence reversing the rolling direction of the roller.

The roller is the core element of the apparatus, and functions to release an elongate member from the bundle and to move it over the roller and into a picking rack or the like. The roller is adapted for rotating around its longitudinal center axis. In order to perform such an operation, the roller needs to passively hold on to the elongate member. Hence, the roller comprises a body part with a high-friction coating/layer, and/or a body part with protrusions extending radially outward from the body part. In one or more embodiments, the protrusions comprises a high-friction coating/layer. In the present context, the term "high-friction coating" means a coating of e.g. an organic material provided on an outer surface of the roller and/or protrusions. The high-friction coating has anti-skid properties and thus lowers the slipperiness of the roller and/or protrusions and increases the coefficient of friction between the coated roller and/or protrusions and the elongate members, compared to the coefficient of friction of the roller and/or protrusions without said coating. Any type of a high-friction coating/layer may be used, such as an acrylic resin or rubber, such as an acrylic acid ester copolymer, a nitrile resin or rubber, a vinylacetate copolymer, a polystyrene resin, an acrylate-styrene copolymer, a styrene-butadiene resin, a SIS (styrene/isoprene/styrene) block copolymer, a latex, an EPDM (ethylene/propylene/diene monomer), an ABS (acrylonitrile/butadiene/styrene), a PP (polypropylene) or PE (polyethylene) film, and combinations thereof. Inorganic materials such as silica particles, alumina particles, clay particles, abrasive particles etc. can also be used as high friction coatings. Good results can be achieved using combinations of organic and inorganic high friction coating materials such as blends of the above materials, and specifically copolymers of acrylic acid esters.

In one or more embodiments, the roller comprises a body part with protrusions extending radially outward from the body part, and wherein the protrusions are positioned on the body part in a pattern configured to induce a vibrational motion along the length of an elongate member being in contact therewith. This effect mimics the whiplash movement that the worker uses to release an elongate member from a bundle.

In one or more embodiments, the roller comprises a body part with protrusions extending radially outward from the body part, and wherein the protrusions are scalene triangular shaped plates. The inventors have shown that this particular shape is better than a squared, tube, spiral, or round shape.

In one or more embodiments, the drive means is operatively connected to a first end of the roller; wherein the roller comprises a body part with protrusions extending radially outward from the body part, and wherein the protrusions are scalene triangular shaped plates. The scalene triangular shaped plates comprises two side faces, a base edge face, and two leg edge faces. The base edge face is connected to the body part. The longest of the two leg edge faces is facing towards the first end of the roller. If the shortest of the two leg edge faces is facing towards the first end of the roller, the elongate members will become stuck between the protrusions. In one or more embodiments, the roller comprises a first and a second roller section, each configured for rotating around its longitudinal center axis. In one or more embodiments, an angle is formed between the first and the second roller section, and wherein the internal angle between the first and the second roller section is within the range of 90-179 degrees. Such a roller is useful when the middle segment of an elongate member, rather than one of the ends, is initially brought into contact with the roller. This process could e.g. be performed by the use of lifting means comprising an electromagnet. In the present context the term "internal angle" is to be understood as the smallest angle of the two angles formed between two connecting roller sections. The sum of the internal angle and the other angle (the external angle) will always be 360 degrees. In one or more embodiments, the internal angle between the first and the second roller section within the range of 90-179 degrees, such as within the range of 95-175 degrees, e.g. within the range of 100-170 degrees, such as within the range of 105-165 degrees, e.g. within the range of 1 10-160 degrees, such as within the range of 1 15-155 degrees, e.g. within the range of 120-150 degrees, such as within the range of 125-145 degrees preferably within the range of 140-160 degrees.

In one or more embodiments, each first and second roller section comprises a body part with protrusions extending radially outward from the body part, and wherein the protrusions are scalene triangular shaped plates; wherein the scalene triangular shaped plates comprises two side faces, a base edge face, and two leg edge faces; and wherein the shortest of the two leg edge faces is facing towards an angular connection point, such as an angular shaft coupling. In one or more embodiments, the apparatus further comprises means for catching the one or more elongate members as they pass over the roller. In one or more embodiments, means for catching the one or more elongate members as they pass over the roller are a plurality of brackets positioned alongside the roller. In one or more embodiments, the means for catching the one or more elongate members (e.g. the brackets) may be adapted for holding a plurality of elongate members.

In one or more embodiments, the means for catching the one or more elongate members as they pass over the roller are positioned alongside both sides of the roller. This enables the worker to use the apparatus for removing one or more elongate members from a bundle of elongate members positioned on each side of the roller. In such a situation, the drive means is adapted for rotating the roller in a forward and a backward direction. In one or more embodiments, the means for catching the one or more elongate members are configured to be in an active state when the roller is rotating towards it; and configured to be in an inactive state when the roller is rotating away from it.

In one or more embodiments, the apparatus further comprises means for positioning the end section or the middle segment of one or more elongate members into contact with the roller.

In one or more embodiments, the positioning means is adapted for positioning the bundle of elongate members at a level below the roller. In this way, the weight of the elongate member is used to obtain better contact with the roller. Furthermore, the level difference prevents the roller from dragging, in an uncontrolled manner, several elongate members from the bundle at the time.

In one or more embodiments, one or more roller sections are configured for lateral/sideways movement relative to the positioning means.

In one or more embodiments, one or more roller sections are configured for pivotable movement. In one or more embodiments, the apparatus further comprises lifting means for lifting the end section or the middle segment of one or more elongate members, and wherein the roller, or a roller section, is configured for lateral/sideways movement relative to the positioning means. The lifting means may e.g. comprise an electro magnet, and/or means for counting the amount of elongate members being lifted.

In one or more embodiments, the apparatus further comprises a sensor system for controlling the release of an elongated member from the bundle. In one or more embodiments, the sensor system is configured for reversing and/or deactivating the drive means if the release does not occur within a preset time period.

A third aspect relates to the use of an apparatus according to the present invention for removing one or more elongate members from a bundle of elongate members.

A fourth aspect relates to a system comprising a plurality of apparatuses according to the present invention, wherein a first apparatus is positioned above, but laterally displaced, in relation to a second apparatus. In one or more embodiments, the system further comprises a receiving station (such as a conveyor) adapted for receiving elongate members from both the first and the second apparatus.

In one or more embodiments the system further comprises a chute for directing the elongate members from both the first and the second apparatus towards the receiving station.

It should be noted that embodiments and features described in the context of one of the aspects of the present invention also apply to the other aspects of the invention.

Brief description of the figures

Figure 1 A shows a perspective view of an apparatus for removing one or more elongate members from a bundle of elongate members in accordance with various embodiments of the invention;

Figure 1 B shows an enlarged view of a part of Figure 1 A;

Figure 2A shows a perspective view of the apparatus in Figure 1 A, but at a later stage in the process of drawing the end section of an elongate member towards the other side of the roller;

Figure 2B shows an enlarged view of a part of Figure 2A; Figure 3A shows a top view of an apparatus for removing one or more elongate members from a bundle of elongate members, where the roller comprises a first and a second roller section;

Figure 3B shows an enlarged view of a part of Figure 3A; Figure 4A shows a top view of the apparatus in Figure 3A, but at a later stage in the process of drawing the middle section of an elongate member towards the other side of the roller; Figure 4B shows an enlarged view of a part of Figure 4A;

Figure 5A shows a top view of an apparatus comprising a roller with a plurality of roller sections. The last roller section is configured for pivotable movement; and

Figure 5B shows an enlarged view of a part of Figure 5A.

Detailed description of the invention

Referring to Figure 1A, the general scheme of the invention is shown in perspective view.

Figure 1A shows an apparatus 100 for removing one or more elongate members 10 from a bundle 20 of elongate members. The elongate members are here exemplified as reinforcement rods. The apparatus 100 comprises a roller 200, drive means 300 adapted for rotating the roller, and positioning means 400 adapted for positioning a bundle 20 of elongate members in close proximity of the roller 200. The positioning means 400 may be adapted for positioning a bundle 20 of elongate members such that the internal angle between a vertical first plane containing the midline longitudinal axis of the bundle of elongate members and a second vertical plane containing the midline longitudinal axis of the roller is within the range of 0-45 degrees. In Figure 1 A, the internal angle is 0-5 degrees - the bundle 20 positioned approximately parallel to the roller 200.

The roller is the core element of the apparatus, and functions to release an elongate member from the bundle and to move it over the roller and into a picking rack or the like. In order to perform such an operation, the roller needs to passively hold on to the elongate member. Figure 1 B is an enlarged view of a part of the apparatus 100. The roller 200 is shown comprising a body part 210 with protrusions 212 extending radially outward from the body part 210.

The protrusions 212 are positioned on the body part 210 in a pattern (rows of uniform protrusions) configured to induce a vibrational motion along the length of an elongate member being in contact therewith. This effect mimics the whiplash movement that the worker uses to release an elongate member from a bundle.

The shown protrusions 212 are scalene triangular shaped plates attached to the body part 210. The inventors have shown that this particular shape is better than a squared, tube, spiral, or round shape.

The drive means 300 is operatively connected to a first end 201 of the roller 200 (Figure 1 A). The scalene triangular shaped plates comprises two side faces, a base edge face, and two leg edge faces. The base edge face is connected to the body part 210. The longest of the two leg edge faces is facing towards the first end 201 of the roller 200. If shortest of the two leg edge faces were to face towards the first end of the roller, the elongate members would become stuck between the protrusions.

The apparatus also comprises means 500 for catching/receiving the one or more elongate members 10 as they pass over the roller 200. The catching means 500 are here shown as a plurality of brackets positioned alongside the roller. The means 500 for catching the one or more elongate members (e.g. the brackets) are adapted for holding a plurality of elongate members. The apparatus also comprises means 600 for positioning the end section Figure 1 B, the end section 12 is positioned within the means 600. In a rotational movement, the means 600 then draws the end section 12 towards the other side of the roller 200 - thereby bringing the elongate member 10 into contact with the roller 200 (Figure 2A). The roller 200 then pulls the entire rod 10 towards the other side of the roller 200. Figure 2B-C are an enlarged view of a part of the apparatus 100.

The placement of the one or more elongate members into contact with the roller may simply be performed manually by placing an end section of one or more reinforcement rods from the bundle into contact with the roller.

In Figure 3A, the apparatus 100 is shown comprising roller 200 with a first 220A and a second 220B roller section, each configured for rotating around its longitudinal center axis. An angle is formed between the first and the second roller section, and the internal angle between the two roller sections is about 172 degrees. The angle is made possible by an angular connection point 222, positioned in-between the two roller sections. Such a roller is useful when the middle segment of an elongate member, rather than one of the ends, is initially brought into contact with the roller. This process is shown performed by the use of lifting means comprising an electromagnet 700. The positioning means 400 is adapted for positioning the bundle of elongate members at a level below the roller. Figure 3B is an enlarged view of a part of the apparatus 100. The apparatus 100 also comprises a sensor system 800 adapted for controlling the release of an elongated member from the bundle. If the release does not occur within a preset time, the sensor system 800 is configured for reversing and/or deactivating the drive means.

The roller sections 220 are configured for lateral/sideways movement relative to the positioning means 400. In Figure 4A, the roller sections have been positioned beneath the middle segment of a couple of elongate members lifted from the bundle by the electromagnet 700. Figure 4B is an enlarged view of a part of the apparatus 100.

In Figure 5, the apparatus 100 is shown comprising roller 200 with a plurality of roller sections, each configured for rotating around its

longitudinal center axis. The last roller section 220B is configured for pivotable movement. This embodiment is suitable to avoid flexion of the end section of an elongate member in order to bring it into contact with the roller. Rather, the end section of the elongate member only needs to be lifted upwards by a worker/means adapted for lifting the end section. Figure 5B is an enlarged view of a part of the apparatus 100.

References

10 Elongate member/Reinforcement rod

12 End section

14 Middle segment

20 Bundle

100 Apparatus

200 Roller

210 Body part

212 Protrusion

213 Side fase

214 Base edge face

215 Leg edge face

220 Roller section

222 Angular connection point

300 Drive means

400 Positioning means

500 Means for catching/receiving elongate members

600 Means for positioning the end section/middle segment of an elongate member into contact with the roller

700 Electromagnet

800 Sensor system