U.S. patent application number 10/918799 was filed with the patent office on 2005-02-10 for loading dock traffic automation and inventory control system.
Invention is credited to Ancel, Thomas A..
Application Number | 20050028723 10/918799 |
Document ID | / |
Family ID | 34114824 |
Filed Date | 2005-02-10 |
United States Patent
Application |
20050028723 |
Kind Code |
A1 |
Ancel, Thomas A. |
February 10, 2005 |
Loading dock traffic automation and inventory control system
Abstract
The loading dock traffic automation and inventory control system
of the present invention automates the loading dock area by
controlling a truck control notification automation system, traffic
signal dock lights, loading dock spot light, loading dock fan and
dock leveler. The manually operated control panel is energized or
de-energized with full automation by the movement of the overhead
dock door. The device includes a control panel enclosure mounted on
the interior wall of the building next to the loading dock door.
One control panel enclosure can service one or two loading dock
doors.
Inventors: |
Ancel, Thomas A.; (St.
Louis, MO) |
Correspondence
Address: |
Henry W. Cummings
3313 W. Adams St.
St. Charles
MO
63301
US
|
Family ID: |
34114824 |
Appl. No.: |
10/918799 |
Filed: |
August 16, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10918799 |
Aug 16, 2004 |
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10023030 |
Feb 19, 2002 |
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6812849 |
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Current U.S.
Class: |
116/202 |
Current CPC
Class: |
G06Q 10/08 20130101;
G07C 9/20 20200101; G08B 13/2454 20130101; B65G 69/2882 20130101;
G07C 1/10 20130101 |
Class at
Publication: |
116/202 |
International
Class: |
F21S 010/00 |
Claims
What is claimed is:
1. A loading dock traffic automation and inventory control panel
system comprising: a truck control notification automation system;
sensing means; at least one traffic signal dock light; at least one
loading dock spot light; at least one loading dock fan; at least
one dock leveler; and an electrical control panel to be
electrically fed by at least one power source.
2. A loading dock traffic automation and inventory control panel
system according to claim 1 wherein the power source is selected
from 480 Volt, 3 phase; 208 Volt, 3 Phase; and 120 V, 1 phase
electricity.
3. A loading dock traffic automation and inventory control panel
system according to claim 1 wherein said sensing means comprises
sensing means selected from a limit switch, photo eye, magnetic
switch, and a laser.
4. A loading dock traffic automation and inventory control panel
system according to claim 3 including selector switches which are
energized or de-energized with full automation by the movement of
said overhead door.
5. A loading dock traffic automation and inventory control panel
system according to claim 1 wherein said electrical control panel
enclosure is mounted on the interior wall of the building next to
the loading dock door.
6. A loading dock traffic automation and inventory control panel
system according to claim 5 wherein said electrical control panel
enclosure 5 includes electrical means for servicing one or two
loading dock doors.
7. A loading dock traffic automation and inventory control panel
system according to claim 6 wherein said electrical control panel
enclosure includes nomenclature on a face panel on the outside
front for easy operating instructions.
8. A loading dock traffic automation and inventory control panel
system according to claim 7 wherein said electrical control panel
enclosure includes at least one a terminal strip for easy wire
hookup.
9. A loading dock traffic automation and inventory control panel
system according to claim 4 wherein said selector for the dock
leveler, loading dock fan and loading dock spot light are
inoperable when the loading dock door is in the down and closed
position.
10. A loading dock traffic automation and inventory control panel
system according to claim 3 wherein said sensing means are
triggered and activated by loading dock door motion and energizing
the selector switches located in said loading dock traffic
automation and inventory control panel system enclosure for the
dock leveler, loading dock fan and loading dock spot light.
11. A loading dock traffic automation and inventory control panel
system according to claim 1 which includes traffic signal dock
lights mounted inside and outside the loading dock doors.
12. A loading dock traffic automation and inventory control panel
system according to claim 11 wherein said inside traffic signal
dock lights automatically change from red to green and said outside
traffic signal dock lights automatically change from green to red
as the loading door is raised.
13. A loading dock traffic automation and inventory control panel
system according to claim 12 wherein inside traffic signal dock
lights automatically change from green to red and the outside
traffic signal dock lights automatically change from red to green
as the loading door is lowered.
14. A loading dock traffic automation and inventory control panel
system according to claim 13 wherein said inside traffic signal
dock light colors are always opposite from the outside traffic
signal dock lights.
15. A loading dock traffic automation and inventory control panel
system according to claim 3 wherein all selector switches in the
control panel are energized and operable only when the loading dock
door is raised.
16. A loading dock traffic automation and inventory control panel
system according to claim 10 wherein said dock leveler and loading
dock fan selector switch operates with one selector switch.
17. A loading dock traffic automation and inventory control panel
system according to claim 16 wherein said dock leveler operates by
turning the selector switch as a momentary contact to the left as
on and is spring center off, said loading dock fan operates as lock
on to the right and center off.
18. A loading dock traffic automation and inventory control panel
system according to claim 17 wherein said loading dock spot light
selector switch operates lock on to the right and lock off to the
left.
19. A loading dock traffic automation and inventory control panel
system according to claim 15 wherein as the loading dock door is
lowered with said selector switches are selected with the on
energized position, the dock leveler and loading dock fan selector
switch, the loading dock spot light selector switch all become
de-energized and inoperable.
20. A loading dock traffic automation and inventory control panel
system according to claim 19 wherein the dock leveler, loading dock
fan and loading dock spot light all turn off.
21. A loading dock traffic automation and inventory control panel
system according to claim 1 wherein said sensing means senses a
truck has entered a sensing zone in front of the loading dock and
electrically responds inside and outside the building.
22. A loading dock traffic automation and inventory control panel
system according to claim 1 wherein a computer database network and
dock attendants inside the building are notified when a truck has
backed up to the dock.
23. A loading dock traffic automation and inventory control panel
system according to claim 1 wherein said computer database network
includes movement of any truck in front of a specific dock.
24. A loading dock traffic automation and inventory control panel
system according to claim 1 including means for barcode reading the
truck for traffic control management, delivery time management,
inventory control and loss prevention.
25. A loading dock traffic automation and inventory control panel
system according to claim 1 wherein said sensing means activates
(RFID) radio frequency identification.
26. A loading dock traffic automation and inventory control panel
system according to claim 1 wherein said sensing means activates
(SAW) surface acoustic wave technology.
27. A loading dock traffic automation and inventory control panel
system according to claim 1 wherein said sensing means activates an
alarm if a truck prematurely pulls away from the dock before
loading or unloading is complete and dock door is not closed.
28. A loading dock traffic automation and inventory control panel
system according to claim 1 wherein said sensing means will signal
and alert the truck driver with one or more of the following
devices: a warning beacon strobe located in the cab of the truck; a
warning beacon strobe located on the truck; the truck horn is
activated; the transmission of the truck is locked; the brakes of
the truck are locked; an independent signal warning device in front
of the truck is activated; the truck driver is notified on his
truck radio, the truck driver is notified on his phone, pager,
radio or other communication devices; and/or an audio alarm inside
the cab of the truck is activated.
29. A loading dock traffic automation and inventory control panel
system according to claim 1 including sensing means which notifies
a dock attendant inside the truck trailer of unauthorized truck
movement by means of a safety alarm light inside the truck trailer,
and/or an audio alarm inside the truck trailer.
30. A loading dock traffic automation and inventory control panel
system according to claim 1 wherein said sensing means notifies a
forklift driver of unauthorized truck movement by means of a beacon
alarm; a strobe on a forklift; an audio alarm on the forklift;
and/or the phone, pager, radio or other communication devices.
31. A loading dock traffic automation and inventory control panel
system according to claim 1 wherein as the loading dock door is
lowered, the truck control notification automation system automates
a reverse signal and all alarm warning notices to the truck, truck
driver, loading dock worker and forklift driver are reversed.
32. A loading dock traffic automation and inventory control panel
system according to claim 1 wherein a traffic signal dock light
step down transformer is installed inside the loading dock traffic
automation and inventory control panel.
33. A loading dock traffic automation and inventory control panel
system according to claim 1 wherein the traffic signal dock light
flasher is installed inside the loading dock traffic automation and
inventory control panel, thus eliminating the inside traffic signal
dock light.
Description
I FIELD OF THE INVENTION
[0001] This invention relates to apparatus for automating loading
and dock traffic control.
II BACKGROUND OF THE INVENTION
[0002] Truck restraints are expensive capital equipment. They are
expensive to install and maintain (with parts and labor). Traffic
signal dock lights have been an economical alternative.
[0003] U.S. Pat. No. 4,010,571 discloses an automatic loading dock.
This concept comprises an automatic dock leveler and dock light,
but has no provisions for a ventilation fan, traffic control
lights, or an inventory control system. It relies on a plurality of
electro-mechanical relays and limit switches which may be prone to
failure.
[0004] U.S. Pat. No. 4,692,755 discloses a loading dock signal and
control system. This concept includes traffic control lights as the
sole means of communicating to personnel the status of a truck
being loaded or unloaded. In addition, this concept comprises a
releaseable locking device for preventing a truck from leaving the
dock prior to the completion of the loading or unloading activity.
Such a device is expensive to install and maintain. This invention
has no provisions for a ventilation fan or an inventory control
system.
[0005] U.S. Pat. No. 4,843,373 discloses a loading dock signal and
control system. This concept comprises traffic control lights,
sensing devices, and a releaseable locking device for preventing a
truck from leaving the dock prior to the completion of the loading
or unloading activity. Such a device is expensive to install and
maintain.
[0006] This invention concept also includes sophisticated
electronic means for programming the system for various modes of
operation.
[0007] U.S. Pat. No. 5,453,735 discloses a loading dock signal and
control system. This concept comprises traffic control lights,
sensing devices, and a releaseable locking device for preventing a
truck from leaving the dock prior to the completion of the loading
or unloading activity. Such a device is expensive to install and
maintain.
III SUMMARY OF THE INVENTION
A. OBJECTS OF THE INVENTION
[0008] One object of the present invention is to provide a means to
automate loading dock activities including spot lights, ventilation
fans, truck traffic control lights, and dock levelers.
[0009] Another object of the present invention is to provide means
to automate inventory control systems.
[0010] Other objects of the present invention will become apparent
from the following description and drawings.
B. SUMMARY
[0011] The present invention comprises a loading dock traffic and
inventory control system which includes a truck control
notification automation system. The truck control notification
automation system reads a sensor electrically in the terminal strip
located in the loading dock traffic and inventory control system
panel. This tracking and additional safety device accompanies the
traffic signal dock lights without the expense of a truck
restraint. The truck control notification automation system is
integrated and designed in the loading dock automatic and manual
control system circuitry. The device design allows for an automatic
signal to be read from the sensor as soon as the dock door is
opened. The device design also allows for the automatic signal to
be read from the sensor as soon as the dock door is closed. The
sensor located on the building will read when a truck has backed up
to the dock door and therefore signals to the truck control
notification automation system when a truck approaches within a
specific distance of sensing zone and electrically responds inside
and outside the building. Dock employees inside the building are
notified when a truck has back up to the dock by warning devices.
The truck control notification automation system will immediately
respond if the truck pre-maturely pulls away from the dock before
loading or unloading is complete and dock door is not closed. The
truck control notification automation system signals and alerts the
truck driver with a warning beacon strobe located in the cab of the
truck, warning beacon strobe located on the truck, the truck horn
is activated, the transmission of the truck is locked, the brakes
of the truck are locked, an independent signal warning device in
front of the truck is activated, the truck driver is notified on
his truck radio, the truck driver is notified on his phone, pager,
radio or other communication devices, the audio alarm inside the
cab of the truck is activated. The dock attendant inside the truck
trailer is notified by a safety alarm light inside the truck
trailer, audio alarm inside the truck trailer, beacon alarm strobe
on the forklift, audio alarm on the forklift, forklift driver is
notified on his phone, pager or radio or other communication
devices. As the loading dock door is lowered the truck control
notification automation system automatically changes to free to
depart alert and alarm signal. The computer central station that
controls the computer traffic database will notify the truck driver
when he or she is free to depart. The departure notification to the
truck driver will be received by truck driver on his or her radio,
phone, pager, palm pilot, laptop, beacon located in the cab of the
truck, signal light in front of the truck.
[0012] The loading dock traffic automation and inventory control
system of the present invention automates the loading dock area by
controlling a truck control notification automation system, traffic
signal dock lights, loading dock spot light, loading dock fan and
dock leveler. The manually operated control panel is energized or
de-energized with full automation by the movement of the overhead
dock door. The device includes a control panel enclosure mounted on
the interior wall of the building next to the loading dock door.
One control panel enclosure can service one or two loading dock
doors. The selector switches for the dock leveler, loading dock fan
and loading dock spot light are inoperable when the loading dock
door is in the down and closed position. As the loading dock door
is raised, a sensing means is triggered and activated, therefore
energizing the selector switches located in the control panel
enclosure for the dock leveler, loading dock fan and loading dock
spot light. As the loading dock door is raised the inside traffic
signal dock lights automatically change from red to green and the
outside traffic signal dock lights automatically change from green
to red. As the loading dock door is raised the truck control
notification automation system automatically updates the computer
traffic database, bar code scans the truck, activates (RFID) radio
frequency identification, activates (SAW) surface acoustic wave
technology while changing to alert and alarm not to depart. All
selector switches are operable when the loading dock door is
raised. If the loading dock door is lowered when the switches are
in the on energized position, all selector switches become
inoperable again and all components turn off that are associated
with each specific selector switch, thus saving energy. As the
loading dock door is lowered the inside traffic signal dock lights
automatically change from green to red and the outside traffic
signal dock lights automatically change from red to green. As the
loading dock door is lowered the truck control notification
automation system updates the computer traffic database, bar code
scans the truck, activates (RFID) radio frequency identification,
activates (SAW) surface acoustic wave technology while
automatically changing to free to depart alert and alarm
signal.
IV. THE DRAWINGS
[0013] FIG. 1 is a inside frontal view of the 480 Volt, 3 phase
loading dock traffic automation and inventory control panel system,
traffic signal dock lights, loading dock spot light, loading dock
fans mounting and wiring detail of the present invention.
[0014] FIG. 2 is an outside frontal view of the loading dock
traffic signal dock lights and traffic signal dock light bracket
mounted to the door jamb of the present invention. This figure is
common to all embodiments of the present invention.
[0015] FIG. 3A is a frontal view of the 480 Volt, 3 phase loading
dock traffic automation and inventory control panel system of the
present invention showing the front door closed.
[0016] FIG. 3B is a frontal view of the 480 Volt, 3 phase loading
dock traffic automation and inventory control panel system of the
present invention showing the front door open.
[0017] FIG. 3C is an illustration of the terminal strip installed
in the 480 Volt, 3 phase embodiment of the present invention.
[0018] FIG. 4 is a wiring schematic of the 480 Volt, 3 phase
loading dock traffic automation and inventory control system of the
present invention.
[0019] FIG. 5A is a frontal view of the 208 Volt, 3 phase loading
dock traffic automation and inventory control panel system of the
present invention showing the front door closed.
[0020] FIG. 5B is a frontal view of the 208 Volt, 3 phase loading
dock traffic automation and inventory control panel system of the
present invention showing the front door open.
[0021] FIG. 5C is a side view of the 208 Volt, 3 phase loading dock
traffic automation and inventory control panel system of the
present invention.
[0022] FIG. 5D is an illustration of the terminal strip installed
in the 208 Volt, 3 phase embodiment of the present invention.
[0023] FIG. 6 is a wiring schematic of the 208 Volt, 3 phase
loading dock traffic automation and inventory control system of the
present invention.
[0024] FIG. 7 is a inside frontal view of the loading dock 208
Volt, 3 phase traffic automation and inventory control panel
system, traffic signal dock lights, loading dock spot light,
loading dock fans mounting and wiring detail of the present
invention.
[0025] FIG. 8A is a frontal view of the 120 Volt, 1 phase loading
dock traffic automation and inventory control panel system of the
present invention showing the front door closed.
[0026] FIG. 8B is a side view of the 120 Volt, 1 phase loading dock
traffic automation and inventory control panel system of the
present invention.
[0027] FIG. 8C is a frontal view of the 120 Volt, 1 phase loading
dock traffic automation and inventory control panel system of the
present invention showing the front door open.
[0028] FIG. 8D is an illustration of the terminal strip installed
in the 120 Volt, 1 phase embodiment of the present invention.
[0029] FIG. 9 is a wiring schematic of the 120 Volt, 1 phase
loading dock traffic automation and inventory control system of the
present invention.
[0030] FIG. 10 is a inside frontal view of the 120 Volt, 1 phase
loading dock traffic automation and inventory control panel system,
traffic signal dock lights, loading dock spot light, loading dock
fans mounting and wiring detail of the present invention.
V. DESCRIPTION OF PREFERRED EMBODIMENTS
[0031] FIGS. 1 through 4 illustrate the 480 Volt, 3 Phase, 60 Hz
embodiment of the device of the present invention.
[0032] The standard loading dock control panel for electrical dock
levelers are usually one single control box system supplied with
each individual specific piece of dock leveler equipment.
Traditionally, control boxes are made to manually operate one
specific piece of equipment. Loading dock fans and loading dock
lights usually are supplied with a cord and plug for an electrical
outlet.
[0033] An advantage of the present invention is to operate loading
dock equipment, track shipments and track inventory simultaneously
through an automation state with or without a manual process. As a
safety feature and energy saver, the manual process must be
energized to function by way of the automation process.
[0034] The automation dock door equipment process is controlled by
a sensing means such as a limit switch, photo eye, motion detector,
magnetic switch, or laser. These devices are commercially available
and well known in the art. When the dock door is raised the loading
dock traffic automation and inventory control panel system is
energized and all selector switches are functional. When the dock
door is lowered the loading dock traffic and inventory control
panel system is de-energized. The selector switches and all
functions associated with the selector switches on the control
panel are de-energized. If the selector switches had not been
previously turned off, when the dock door is lowered the loading
dock spot light and loading dock fan are automatically
de-energized, thus saving energy.
[0035] When the dock door is lowered the dock leveler selector
switch is de-energized and is inoperable, preventing damage to the
dock door with an unexpected dock leveler operation attempt from an
dock worker employee. The device of the present invention automates
the loading dock area with a traffic and inventory control panel
system 10. The automation process includes an optional truck
control notification automation system 90, 91, inside traffic
signal dock lights 20, 21, outside traffic signal dock lights 22,
23, loading dock spot lights 30, 31, loading dock fans 40, 41 and
electric dock leveler 50, 51.
[0036] Supply voltage 80 is applied to loading dock traffic
automation and inventory control system 10 by means of common
wiring. Said voltage is applied to the circuitry inside loading
dock traffic automation and inventory control system 10 by main
disconnect switch 101. When the contacts of main disconnect switch
101 are closed, power is delivered to the open contacts 116, 117,
118, 119 of contactors 112, 113, 114, and 115, respectively. Power
fuse blocks 105 are provided in series with said supply voltage to
provide overcurrent protection. Supply voltage is further applied
to transformer 120 via fuses 103. Transformer 120 steps down the
voltage to that commonly used by the components served by loading
dock traffic automation and inventory control system 10.
[0037] Prior to opening overhead dock door 60, 61, switches 12/13,
14, 16/17, and 18 mounted to control panel face 11 are
de-energized. When a truck is present at the door opening and
overhead dock door 60, 61 is opened, sensing means 65, 66 sends a
signal to control relay 150, 151. Sensing means 65, 66 are
commercially available devices which signal motion. Examples are an
electric eye, motion detector, limit switch, or any common
device.
[0038] Control relay 150, 151 is energized, closing contacts 152,
153, 154, 155, 158, and 159, and opening contacts 156 and 157. The
closure of contacts 152, 153 provides electrical power to switches
12/13, 14, and 16/17, 18, respectively. An operator may now
manually actuate any or all of the switches.
[0039] Closing contacts 154, 155 and opening contacts 156, 157
causes inside traffic signal dock lights 20, 21 to change color
from red to green and outside traffic signal dock lights 22, 23 to
change color from green to red. Optionally, an internal transformer
and flasher 210, 212 may be provided, which reduces the supply
voltage to the inside traffic signal dock lights 20, 21 and outside
traffic signal dock lights 22, 23, eliminating the need for a
transformer and flasher inside those devices.
[0040] Closing contacts 158, 159 provides a power signal to
optional external devices 90, 91. For example, these devices could
be a truck bar code scanner system or a truck control device such
as means to override the truck's transmission, preventing it from
being moved while the loading dock door is still open.
[0041] Depending on how the loading dock area is configured, any
combination of electric or manual dock levelers may be present. In
this example, both doors are equipped with electric dock levelers
50, 51. Selector switches 12, 16 are specified as `Dock
leveler/Of/Fan`. Selector switches 12, 16 are three-position spring
return left to center momentary contact and lock to right switches.
To operate, turn selector switch 12, 16 to the left for a moment.
This energizes dock leveler contactors 113, 115. Contacts 117 of
dock leveler contactor 113 close, applying power to dock leveler
motor 107, tuning it on. Likewise, contacts 119 of dock leveler
contactor 115 close, applying power to dock leveler motor 106.
[0042] When released, the switches spring to center while the dock
leveler motors complete their operating duty cycles. In the event a
manual loading dock leveler is present at the loading dock, the
associated selector switch 12, 16 would not have a dock leveler
energize position. Instead, the associated selector switch 13, 17
is a two-position switch with an off position and a fan on position
only.
[0043] When switch 12, 16 or 13, 17 is turned to the right, fan
motor contactor 112, 114 is energized, closing contacts 116, 118,
energizing fan motor 109, 108. Selector switches 14, 18 are the
loading dock spot light selector switches, which are turned to the
right to energize loading dock spot lights 30, 31, respectively,
and turned to the left to de-energize loading dock spot lights 30,
31. The selector switches are classified as pilot devices, 30 mm
oil tight type, rugged industrial operator that are of a durable
one piece casting, silver contacts carry heavy duty ratings.
Selector switch has positive action indexing, attractive chrome
plating on the locknut and designed to provide long, trouble free
service in the most demanding industrial applications. When
overhead dock doors 60, 61 are closed, sensing means 65, 66 are
triggered, signalling control relays 150, 151. Control relays 150,
151 de-energize, opening contacts 152, 153, 154, 155, 158, and 159,
and closing contacts 156 and 157. The opening of contacts 152, 153
removes electrical power from switches 12/13, 14, and 16/17, 18,
respectively. This removes power from all devices associated with
these switches, and also prevents them from being inadvertently
activated, adding to safety and saving energy. Opening contacts
154, 155 and closing contacts 156, 157 causes inside traffic signal
dock lights 20, 21 to change color from green to red and outside
traffic signal dock lights 22, 23 to change color from red to
green.
[0044] If an optional inventory control and/or truck control device
90, 91 is installed, opening contacts 158, 159 sends a signal to
the optional inventory control and/or truck control device 90,
91.
[0045] Control panel enclosure 15 is mounted on the interior wall
of the building next to loading dock door 60. One control panel
enclosure 15 can service one or two loading dock door areas 70, 75.
The left two selector switches 12/13, 14 on control panel face 11
control the left dock door area equipment and the right two
selector switches 16/17, 18 on control panel face 11 control the
right dock door area equipment. Wall mount enclosure 15 includes
internal mounting panel 100 to support all enclosure
components.
[0046] Control panel 15 includes main disconnect 101 with external
operating handle 102 to interrupt power from the incoming 480 Volt,
3 phase power source. Transformer 120, for example 480/120V CPT, is
provided to lower supply voltage 80 to the operating voltage
associated with devices connected to the traffic and inventory
control panel system, such as contactors, relays, loading dock
spotlight, and traffic signal dock lights.
[0047] Power fuse blocks 105 include fuses in each fuse block to
provide a means of individual short circuit protection.
[0048] Contactors 116, 117, 118, 119 are rated to operate 480 Volt,
3 phase 60 Hz for {fraction (1/2)} horsepower motors 106, 107, 108,
and 109. Line terminals 110 are located at the tops of contactors
116, 117, 118, 119 and load terminals 112 at the bottom. Shading
coil on the magnet insures positive sealing of the armature. Arc
box is made of a glass filled thermoset material to prevent
tracking and prevents flashover. Contacts are made of silver
cadmium oxide. Fixed mount control relay 150, 151 is supplied to
operate the traffic signal dock lights, suitable for industrial
use, with high contact reliability.
[0049] The device of the present invention includes a surge
suppressor on the control relay coil designed to work in
conjunction with devices in this control panel.
[0050] Control panel 15 of this invention includes terminal block
200 to wire external devices, (sensing means 60, 65, loading dock
spotlight 30, 31, traffic signal dock light 20, 21, 22, 23, and
optional truck control devices 90, 91). Terminal block 200 is
designed to provide ease of wiring of all external devices to the
control panel. Molded material prevents tracking across terminals,
large surface area permits ease of screwdriver insertion. There is
a clear indication where field wires are installed; white marking
strip showing a number for each wire. Screw terminals exist for
ease of wiring, and there is a dedicated terminal for each external
wire.
[0051] FIGS. 2 and 5 through 7 illustrate the 208 Volt, 3 Phase, 60
Hz embodiment of the device of the present invention.
[0052] The standard loading dock control panel for electrical dock
levelers are usually one single control box system supplied with
each individual specific piece of dock leveler equipment.
Traditionally, control boxes are made to manually operate one
specific piece of equipment. Loading dock fans and loading dock
lights usually are supplied with a cord and plug for an electrical
outlet.
[0053] An advantage of the present invention is to operate loading
dock equipment, track shipments and track inventory simultaneously
through an automation state with or without a manual process. As a
safety feature and energy saver, the manual process must be
energized to function by way of the automation process.
[0054] The automation dock door equipment process is controlled by
a sensing means such as a limit switch, photo eye, motion detector,
magnetic switch, or laser. These devices are commercially available
and well known in the art. When the dock door is raised the loading
dock traffic automation and inventory control panel system is
energized and all selector switches are functional When the dock
door is lowered the loading dock traffic and inventory control
panel system is de-energized. The selector switches and all
functions associated with the selector switches on the control
panel are de-energized. If the selector switches had not been
previously turned off, when the dock door is lowered the loading
dock spot light and loading dock fan are automatically
de-energized, thus saving energy. When the dock door is lowered the
dock leveler selector switch is de-energized and is inoperable,
preventing damage to the dock door with an unexpected dock leveler
operation attempt from an dock worker employee.
[0055] The device of the present invention automates the loading
dock area with a traffic and inventory control panel system 10. The
automation process includes an optional truck control notification
automation system 90, 91, inside traffic signal dock lights 20, 21,
outside traffic signal dock lights 22, 23, loading dock spot lights
30, 31, loading dock fans 40, 41 and electric dock leveler 50,
51.
[0056] Supply voltage 80 is applied to loading dock traffic
automation and inventory control system 10 by means of common
wiring. Said voltage is applied to the circuitry inside loading
dock traffic automation and inventory control system 10 by main
disconnect switch 101. When the contacts of main disconnect switch
101 are closed, power is delivered to the open contacts 116, 117,
118, 119 of contactors 112, 113, 114, and 115, respectively. Power
fuse blocks 105 are provided in series with said supply voltage to
provide overcurrent protection. One leg of the three phase supply
voltage 80 is applied to the remaining circuitry of the traffic and
inventory control panel system 10, via fuses 222, 224. Receptacle
220 is an optional, externally wired device used to provide
electrical power for low-current applications such as a radio, bar
code scanner, etc.
[0057] Prior to opening overhead dock door 60, 61, switches 12/13,
14, 16/17 and 18 mounted to control panel face 11 are de-energized.
When a truck is present at the door opening and overhead dock door
60, 61 is opened, sensing means 65, 66 sends a signal to control
relay 150, 151. Sensing means 65, 66 are commercially available
devices which signal motion. Examples are an electric eye, motion
detector, limit switch, or any common device. Control relay 150,
151 is energized, closing contacts 152, 153, 154, 155, 158, and
159, and opening contacts 156 and 157. The closure of contacts 152,
153 provides electrical power to switches 12/13, 14, and 16/17, 18,
respectively. An operator may now manually actuate any or all of
the switches.
[0058] Closing contacts 154, 155 and opening contacts 156, 157
causes inside traffic signal dock lights 20, 21 to change color
from red to green and outside traffic signal dock lights 22, 23 to
change color from green to red. Optionally, an internal transformer
and flasher 210, 212 may be provided, which reduces the supply
voltage to the inside traffic signal dock lights 20, 21 and outside
traffic signal dock lights 22, 23, eliminating the need for a
transformer and flasher inside those devices.
[0059] Closing contacts 158, 159 provides a power signal to
optional external devices 90, 91. For example, these devices could
be a truck bar code scanner system or a truck control device such
as means to override the truck's transmission, preventing it from
being moved while the loading dock door is still open.
[0060] Depending on how the loading dock area is configured, any
combination of electric or manual dock levelers may be present. In
this example, both doors are equipped with electric dock levelers
50, 51. Selector switches 12, 16 are specified as `Dock
leveler/Of/Fan`. Selector switches 12, 16 are three-position spring
return left to center momentary contact switches. To operate, turn
selector switch 12, 16 to the left for a moment. This energizes
dock leveler contactors 113, 115. Contacts 117 of dock leveler
contactor 113 close, applying power to dock leveler motor 107,
turning it on. Likewise, contacts 119 of dock leveler contactor 115
close, applying power to dock leveler motor 106. When released, the
switches spring to center while the dock leveler motors complete
their operating duty cycles. In the event a manual loading dock
leveler is present at the loading dock, the associated selector
switch 12, 16 would not have a dock leveler energize position.
Instead, the associated selector switch 13, 17 is a two-position
switch with an off position and a fan on position only.
[0061] When switch 12, 16 or 13, 17 is turned to the right, fan
motor contactor 112, 114 is energized, closing contacts 116, 118,
energizing fan motor 109, 108. Selector switches 14, 18 are the
loading dock spot light selector switches, which are turned to the
right to energize loading dock spot lights 30, 31, respectively,
and turned to the left do de-energize loading dock spot lights 30,
31. The selector switches are classified as pilot devices, 30 mm
oil tight type, rugged industrial operator that are of a durable
one piece casting, silver contacts carry heavy duty ratings.
Selector switch has positive action indexing, attractive chrome
plating on the locknut and designed to provide long, trouble free
service in the most demanding industrial applications.
[0062] When overhead dock doors 60, 61 are closed, sensing means
65, 66 are triggered, signalling control relays 150, 151. Control
relays 150, 151 de-energize, opening contacts 152, 153, 154, 155,
158, and 159, and closing contacts 156 and 157. The opening of
contacts 152, 153 removes electrical power from switches 12/13, 14,
and 16/17, 18, respectively. This removes power from all devices
associated with these switches, and also prevents them from being
inadvertently activated, adding to safety and saving energy.
Opening contacts 154, 155 and closing contacts 156, 157 causes
inside traffic signal dock lights 20, 21 to change color from green
to red and outside traffic signal dock lights 22, 23 to change
color from red to green. If an optional inventory control and/or
truck control device 90, 91 is installed, opening contacts 158, 159
sends a signal to the optional inventory control and/or truck
control device 90, 91.
[0063] Control panel enclosure 15 is mounted on the interior wall
of the building next to loading dock door 60. One control panel
enclosure 15 can service one or two loading dock door areas 70, 75.
The left two selector switches 12/13, 14 on control panel face 11
control the left dock door area equipment and the right two
selector switches 16/17, 18 on control panel face 11 control the
right dock door area equipment. Wall mount enclosure 15 includes
internal mounting panel 100 to support all enclosure
components.
[0064] Control panel 15 includes main disconnect 101 with external
operating handle 102 to interrupt power from the incoming 208 Volt,
3 phase power source. Power fuse blocks 105 include fuses in each
fuse block to provide a means of individual short circuit
protection.
[0065] Contactors 116, 117, 118, 119 are rated to operate 208 Volt,
3 phase 60 Hz for motors 106, 107, 108, and 109. Line terminals 110
are located at the tops of contactors 116, 117, 118, 119 and load
terminals 112 at the bottom. Shading coil on the magnet insures
positive sealing of the armature. Arc box is made of a glass filled
thermoset material to prevent tracking and prevents flashover.
Contacts are made of silver cadmium oxide. Fixed mount control
relay 150, 151 is supplied to operate the traffic Signal dock
lights, suitable for industrial use, with high contact reliability
The device of the present invention includes a surge suppressor on
the control relay coil designed to work in conjunction with devices
in this control panel.
[0066] Control panel 15 of this invention includes terminal block
200 to wire external devices, (sensing means 60, 65, loading dock
spotlight 30, 31, traffic signal dock light 20, 21, 22, 23, and
optional truck control devices 90, 91). Terminal block 200 is
designed to provide ease of wiring of all external devices to the
control panel. Molded material prevents tracking across terminals,
large surface area permits ease of screwdriver insertion. There is
a clear indication where field wires are installed; white marking
strip showing a number for each wire. Screw terminals exist for
ease of wiring, and there is a dedicated terminal for each external
wire.
[0067] FIGS. 2 and 8 through 10 illustrate the 120 Volt, single
phase, 60 Hz embodiment of the device of the present invention.
This embodiment concerns a situation when only one electric dock
leveler is present. The standard loading dock control panel for
electrical dock levelers are usually one single control box system
supplied with each individual specific piece of dock leveler
equipment. Traditionally, control boxes are made to manually
operate one specific piece of equipment.
[0068] Loading dock fans and loading dock lights usually are
supplied with a cord and plug for an electrical outlet.
[0069] An advantage of the present invention is to operate loading
dock equipment, track shipments and track inventory simultaneously
through an automation state with or without a manual process. As a
safety feature and energy saver, the manual process must be
energized to function by way of the automation process.
[0070] The automation dock door equipment process is controlled by
a sensing means such as a limit switch, photo eye, motion detector,
magnetic switch, or laser. These devices are commercially available
and well known in the art. When the dock door is raised the loading
dock traffic automation and inventory control panel system is
energized and all selector switches are functional. When the dock
door is lowered the loading dock traffic and inventory control
panel system is de-energized. The selector switches and all
functions associated with the selector switches on the control
panel are de-energized. If the selector switches had not been
previously turned off, when the dock door is lowered the loading
dock spot light and loading dock fan are automatically
de-energized, thus saving energy. When the dock door is lowered the
dock leveler selector switch is de-energized and is inoperable,
preventing damage to the dock door with an unexpected dock leveler
operation attempt from an dock worker employee.
[0071] The device of the present invention automates the loading
dock area with a traffic and inventory control panel system 10. The
automation process includes an optional truck control notification
automation system 90, 91, inside traffic signal dock lights 20, 21,
outside traffic signal dock lights 22, 23, loading dock spot lights
30, 31, loading dock fans 40, 41 and electric dock leveler 50,
51.
[0072] Supply voltage 80 is applied to loading dock traffic
automation and inventory control system 10 by means of common
wiring. Said voltage is applied to the open contacts 116, 117, 118
of contactors 112, 113, and 114, respectively. Prior to opening
overhead dock door 60, 61, switches 12/13, 14, 16/17, and 18
mounted to control panel face 11 are de-energized. When a truck is
present at the door opening and overhead dock door 60, 61 is
opened, sensing means 65, 66 sends a signal to control relay 150,
151. Sensing means 65, 66 are commercially available devices which
signal motion. Examples are an electric eye, motion detector, limit
switch, or any common device. Control relay 150, 151 is energized,
closing contacts 152, 153, 154, 155, 158, and 159, and opening
contacts 156 and 157. The closure of contacts 152, 153 provides
electrical power to switches 12/13, 14, and 16/17, 18,
respectively. An operator may now manually actuate any or all of
the switches.
[0073] Closing contacts 154, 155 and opening contacts 156, 157
causes inside traffic signal dock lights 20, 21 to change color
from red to green and outside traffic signal dock lights 22, 23 to
change color from green to red. Optionally, an internal transformer
and flasher 210, 212 may be provided, which reduces the supply
voltage to the inside traffic signal dock lights 20, 21 and outside
traffic signal dock lights 22, 23, eliminating the need for a
transformer and flasher inside those devices.
[0074] Closing contacts 158, 159 provides a power signal to
optional external devices 90, 91. For example, these devices could
be a truck bar code scanner system or a truck control device such
as means to override the truck's transmission, preventing it from
being moved while the loading dock door is still open.
[0075] Depending on how the loading dock area is configured, any
combination of electric or manual dock levelers may be present. In
this example, only one door is equipped with an electric dock
leveler 50.
[0076] The second door 61 is equipped with manual dock leveler 55.
Selector switch 12 is specified as `Dock leveler/Of/Fan`. Selector
switch 12 is a three-position spring return left center momentary
contact switch. To operate, turn selector switch 12 to the left for
a moment. This energizes dock leveler contactor 113. Contacts 117
of dock leveler contactor 113 close, applying power to dock leveler
motor 107, turning it on. When released, the switch springs to
center while the dock leveler motor complete its operating duty
cycle. In the event a manual loading dock leveler is present at the
loading dock, the associated selector switch 12, 16 would not have
a dock leveler energize position. Instead, the associated selector
switch 13, 17 is a two-position switch with an off position and a
fan on position only.
[0077] When switch 12, 17 is turned to the right, fan motor
contactor 112, 114 is energized, closing contacts 116, 118,
energizing fan motor 109, 108. Selector switches 14, 18 are the
loading dock spot light selector switches, which are turned to the
right to energize loading dock spot lights 30, 31, respectively,
and turned to the left do de-energize loading dock spot lights 30,
31. The selector switches are classified as pilot devices, 30 mm
oil tight type, rugged industrial operator that are of a durable
one piece casting, silver contacts carry heavy duty ratings.
Selector switch has positive action indexing, attractive chrome
plating on the locknut and designed to provide long, trouble free
service in the most demanding industrial applications. When
overhead dock doors 60, 61 are closed, sensing means 65, 66 are
triggered, signalling control relays 150, 151.
[0078] Control relays 150, 151 de-energize, opening contacts 152,
153, 154, 155, 158, and 159, and closing contacts 156 and 157. The
opening of contacts 152, 153 removes electrical power from switches
12/13, 14, and 16/17, 18, respectively. This removes power from all
devices associated with these switches, and also prevents them from
being inadvertently activated, adding to safety and saving energy.
Opening contacts 154, 155 and closing contacts 156, 157 causes
inside traffic signal dock lights 20, 21 to change color from green
to red and outside traffic signal dock lights 22, 23 to change
color from red to green. If an optional inventory control and/or
truck control device 90, 91 is installed, opening contacts 158, 159
sends a signal to the optional inventory control and/or truck
control device 90, 91.
[0079] Control panel enclosure 15 is mounted on the interior wall
of the building next to loading dock door 60. One control panel
enclosure 15 can service one or two loading dock door areas 70, 75.
The left two selector switches 12/13, 14 on control panel face 11
control the left dock door area equipment and the right two
selector switches 16/17, 18 on control panel face 11 control the
right dock door area equipment. Wall mount enclosure 15 includes
internal mounting panel 100 to support all enclosure
components.
[0080] Contactors 116, 117, 118 are rated to operate 120 Volt,
single phase 60 Hz for motors 107, 108, and 109. Line terminals 110
are located at the tops of contactors 116, 117, 118 and load
terminals 112 at the bottom. Shading coil on the magnet insures
positive sealing of the armature. Arc box is made of a glass filled
thermoset material to prevent tracking and prevents flashover.
[0081] Contacts are made of silver cadmium oxide. Fixed mount
control relay 150, 151 is supplied to operate the traffic signal
dock lights, suitable for industrial use, with high contact
reliability.
[0082] The device of the present invention includes a surge
suppressor on the control relay coil designed to work in
conjunction with devices in this control panel.
[0083] Control panel 15 of this invention includes terminal block
200 to wire external devices, (sensing means 60, 65, loading dock
spotlight 30, 31, traffic signal dock light 20, 21, 22, 23, and
optional truck control devices 90, 91). Terminal block 200 is
designed to provide ease of wiring of all external devices to the
control panel. Molded material prevents tracking across terminals,
large surface area permits ease of screwdriver insertion. There is
a clear indication where field wires are installed; white marking
strip showing a number for each wire. Screw terminals exist for
ease of wiring, and there is a dedicated terminal for each external
wire.
* * * * *