U.S. patent application number 12/346636 was filed with the patent office on 2009-07-09 for hoist with detachable power and control unit.
Invention is credited to Ehsan Alipour, Thomas King, Benjamin Toru Mino, Clinton Slone, Mike Strasser.
Application Number | 20090173924 12/346636 |
Document ID | / |
Family ID | 35787880 |
Filed Date | 2009-07-09 |
United States Patent
Application |
20090173924 |
Kind Code |
A1 |
Alipour; Ehsan ; et
al. |
July 9, 2009 |
HOIST WITH DETACHABLE POWER AND CONTROL UNIT
Abstract
A hoist is powered by a separate power unit. The hoist unit
includes: a motor, a mounting connector, a spool, webbing, auto
cut-off and a first portion of a mating electrical connector. The
control unit includes a hollow pole, a hook, a second portion of
the mating electrical connector, a control switch, electrical
circuitry and a battery pack.
Inventors: |
Alipour; Ehsan; (San
Francisco, CA) ; Strasser; Mike; (Lafayette, CA)
; Mino; Benjamin Toru; (Chicago, IL) ; King;
Thomas; (San Francisco, CA) ; Slone; Clinton;
(Stanford, CA) |
Correspondence
Address: |
GREGORY SMITH & ASSOCIATES
3900 NEWPARK MALL ROAD, 3RD FLOOR
NEWARK
CA
94560
US
|
Family ID: |
35787880 |
Appl. No.: |
12/346636 |
Filed: |
December 30, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11192992 |
Jul 29, 2005 |
7227322 |
|
|
12346636 |
|
|
|
|
60592738 |
Jul 29, 2004 |
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Current U.S.
Class: |
254/362 ;
318/14 |
Current CPC
Class: |
B66D 3/26 20130101; B66C
1/10 20130101; B66C 1/14 20130101; B66D 3/20 20130101 |
Class at
Publication: |
254/362 ;
318/14 |
International
Class: |
B66D 1/12 20060101
B66D001/12; H02K 7/06 20060101 H02K007/06 |
Claims
1. A hoist system comprising: a motor capable of moving a load, a
first portion of a mating power connector coupled to said motor; a
power unit, including: a second portion of said mating power
connector, a power coupling capable of coupling said second portion
of said mating power connector to a power source; and at least one
motor control capable of activating and deactivating said motor
when said power unit is connect to said motor assembly; wherein
said motor unit and said power unit are separable.
Description
CROSS REFERENCE TO OTHER APPLICATIONS
[0001] This application is a continuation of U.S. application Ser.
No. 11/192,992, filed Jul. 29, 2005, which claims the benefit of
U.S. Provisional Application 60/592,738, filed on Jul. 29, 2004,
the specifications of which are hereby incorporated by reference in
their entirety.
FIELD OF THE INVENTION
[0002] The invention pertains to apparatus and methods for a hoist
to lift items. More particularly, the hoist motor is mounted
without installation of electrical wiring. The motor is driven by a
power source from a portable control unit.
BACKGROUND OF THE INVENTION
[0003] There are currently various types of hoists and winches that
are commercially available. There are three main categories:
mechanical, electrical and pneumatic. With the mechanical devices,
the user is required to provide the force necessary to operate the
hoist. In the electrical devices, an electrical system of a
selected voltage is installed and connected to the hoist. The
pneumatic devices use air or liquid to drive the motion. Both the
electrical and pneumatic systems require a permanent connection to
the power source. The permanent connection to power makes their
installation expensive and cumbersome especially when multiple
hoists need to be installed.
SUMMARY OF THE INVENTION
[0004] In general, the present invention provides a hoist that is
powered by a detachable power unit. A hoist system includes a motor
assembly having a load-moving member, a motor for moving of the
load-moving member, and a first portion of a mating power connector
coupled to said motor; and a separate power unit having a second
portion of the mating power connector and a power coupling capable
of coupling the second portion of said mating power connector to a
power source.
[0005] A second embodiment of the hoist system includes a motor
unit and a separate power unit. The motor unit has a motor, a spool
driven by the motor, a flexible load-moving or suspending member
attached to the spool and capable of being wound thereon and a
first portion of a mating power connector. The power unit has an
elongated body, a second portion of the mating power connector
located at or near one end of the body, a switch located at or near
the other end of the elongated body and a power source.
[0006] The load-suspending member may be formed of flexible, flat
webbing.
[0007] The power source for the power unit may be a rechargeable
battery pack. A charging station may be included to provide a
recharging site for one or more power units and/or one or more
independent battery packs. Alternately, the power source may be an
AC outlet or AC wiring.
[0008] The hoist system may include an automatic cut-off having a
pivoting lever with an opening surrounding the load-moving member,
a stopper connected to the load-moving member and a cut-off switch
located such that when the stopper reaches the lever, the stopper
pushes the lever to engage the switch.
[0009] The hoist system may also include a solenoid and brake,
wherein the solenoid moves the brake between a braking position and
a released position.
[0010] The hoist system may also include one or more of the
following: flat webbing forming the load-moving member, mounting
hardware to connect the motor unit to a support structure, one or
more planetary gears used to drive the spool.
[0011] An example method for moving loads includes the steps of
using a load moving system having a motor assembly with a motor for
moving a load-moving member, and a motor assembly power connector
coupled with the motor and a separate power unit having a power
unit power connector coupled to a power source; temporarily
contacting the motor assembly power connector and the power unit
power connector to provide power to the motor; completing a move of
the load-moving member; and separating the motor assembly power
connector and the power unit power connector. If desired, the power
unit power connector may then be used to perform the same method on
one or more additional motor assemblies.
[0012] The hoist embodiments disclosed here are easy to install.
The only limitation on location and installation is the support
structure needs to be able to withstand the amount of weigh to be
suspended from the hoist. No installation of over-head electrical
wiring electrical is needed. This benefit is magnified if a series
of hoists are used. For example, numerous hoist units may be
quickly and easily hung on the ceiling, walls or other secure
structure within a warehouse or other location using only a few
basic tools. One or a small number of control units may be used to
operate all of the hoists.
[0013] The hoist weight and size are reduced since the power
components are not a permanent portion of the hoist unit. This
makes installation easier, but also reduces the overall number of
components necessary and therefore the costs in situations where
multiple hoist units are used with a single or smaller number of
power units.
[0014] Additionally, if the hoist is to be used primarily to lift
under 200 pounds, the hoist can use a relatively small motor
capable of being powered for significant time from a small,
portable battery pack.
BRIEF DESCRIPTION OF THE DRAWING
[0015] FIG. 1 is a perspective view of the hoist.
[0016] FIG. 2 is a bottom view of the hoist.
[0017] FIG. 3 is an internal view showing the motor, brake, gearbox
and spool.
[0018] FIG. 4 is an exploded view of the spool.
[0019] FIGS. 5A and 5B show the hoist mounted to an angle iron
bracket and a glu-lam beam.
[0020] FIGS. 6A and 6B shows a hoist with hooks for hanging.
[0021] FIG. 7 is a perspective view of the power connector for the
hoist.
[0022] FIG. 8 is second embodiment of the power and hoist
connectors.
[0023] FIGS. 9A and 9B are side and detail views of the power
unit.
[0024] FIGS. 10A, 10B and 10C are embodiments of the power unit
that are collapsible.
[0025] FIG. 11 is an exploded view of the battery pack.
[0026] FIGS. 12A, 12B and 12C are views of charger units.
[0027] FIG. 13 shows a first hook configuration.
[0028] FIG. 14 shows a second hook configuration.
[0029] FIG. 15 shows a third hook configuration.
[0030] FIG. 16 is a perspective view of a loading platform.
[0031] FIG. 17 is a circuit diagram for the hoist.
[0032] FIG. 18 is a circuit diagram for the control panel on the
power unit.
DETAILED DESCRIPTION OF THE INVENTION
[0033] In general, the present invention provides a hoist that is
powered by a detachable power unit. A hoist system includes a motor
assembly having a load-moving member, a motor for moving of the
load-moving member, and a first portion of a mating power connector
coupled to said motor; and a separate power unit having a second
portion of the mating power connector and a power coupling capable
of coupling the second portion of said mating power connector to a
power source.
[0034] FIG. 1 is a perspective view and FIG. 2 is a bottom view of
the hoist unit 100. The hoist motor 10 is located within a hoist
housing 1. The motor 10 drives a spool 2 upon which webbing 7 or
cable is wound. An optional multidirectional automatic cut-off
system 110 is used to assure that a load is not raised above a safe
level. A power cable 22 extends downward from the hoist motor 10
and has a power connector 40 located at the lower end, seen in FIG.
7. A strain relief 6 may be included to decrease the wear on the
connection between the power cable 22 and the hoist casing 1.
[0035] An alternate embodiment could have the power connector 40
extending from or attached directly to the motor 10 or hoist
housing 1.
[0036] The example of a cut-off system 110 includes a lever 4, with
a center pivot point 3 allowing it to hinge in both directions, and
two switches 5. A stopper 39 at the lower end of the webbing 7,
seen in FIG. 13, is shaped in such a way to push the lever 4 when
the object has reached optimal height. In this embodiment, the
system is designed to prevent a user from raising an object above
the cut-off point, no matter which direction the webbing 7 is
spooled, clockwise or counter-clockwise.
[0037] In an alternate version, the system could wind the webbing 7
onto the spool 2 in only one direction, in which case a single
direction cut-off with a single switch could be used.
[0038] The hoist housing 1 is designed such that the power cable 22
with the power connector 40 can be wrapped around the housing 1 or
hooks 63 on the housing 1, as seen in FIG. 6B, may be used to
adjust the height at which the power connector 40 hangs. This
allows the hoist unit 100 to be hung and operated from various
heights. Alternately, the hoist power connector cable 22 could be
attached to the hoist mounting beam at a variable distance away
from the hoist unit 100; in effect using up some of the cable 22 to
allow the hoist power connector 40 to hang at the appropriate
height.
[0039] Optionally, several hoist units 100 could be daisy-chained
together such that each would share a common power source at the
end of the chain. An electronic controller could be used to address
the particular unit to be raised or lowered. This would preferably
be an AC motor driven hoist.
[0040] FIG. 3 is an internal view showing the motor 10, brake 9,
gearbox 8 and spool 2. In this example, raising and lowering of a
load is accomplished by means of a DC powered motor 10. The power
from the motor 10 may be geared down by means of a gear system.
Although other types of gear systems, such as worm gears, may be
used, the embodiment shown uses a two-stage planetary gear system.
One advantage of a planetary gearbox is its efficiency.
[0041] After the user has lifted the object to the desired height,
it is necessary to lock the spool 2 to prevent the object from
lowering due to its own weight. One example method used to lock the
spool 2 is to connect the motor 10 leads. One way to connect the
leads may be performed by the hoist power switch 36, seen in FIG.
12A. The internal wiring of the switch 36, located in the remote
power pole 120, can be configured such that when the switch 36 is
in the neutral position, both motor leads are connected to the
negative lead of the battery. Another way to connect the leads may
be located in the hoist power connector 40, seen in FIG. 7. A
switch 21 in the hoist power connector 40 shorts the motor leads
once the user removes the remote power unit 120 and disconnects the
short once the remote power unit 120 is put back in place. If both
of these configurations are present, the load will be securely held
in place until the user activates the motor 10 and thereby moves
the object up or down.
[0042] Additional braking may optionally be added to the hoist
system by using a solenoid 11 and spring combination to apply
pressure, thereby resisting rotation of the motor shaft when no
power is applied to the motor 10. Once power is applied to the
motor 10, the solenoid 11 and spring combination releases the
pressure and allows the motor shaft to rotate. This configuration
resists motion on the motor 10 side of the gearbox 8. When
resistance is provided on the motor 10 side, less force is needed
to prevent spool 2 rotation. When resistance is provided on the
spool 2 side additional resistance is required to prevent spool 2
rotation.
[0043] Alternately or in addition to the braking and holding
devices above, a further safety mechanism, such as a post or other
mechanical interlock may extend through openings in the spool edge
when no power is connected to the motor 10. In one embodiment, the
post would be automatically retracted or moved out of the way when
power is connected, but would be deployed when the power was lost,
thereby assuring that no significant rotation of the spool 2 could
take place when the power unit 120 is not connected.
[0044] FIG. 4 is an exploded view of the spool 2. The spool 2 may
be made of any sturdy and fairly durable material, such as metal,
wood, plastics, etc. In one embodiment, the spool 2 is made of
plastic to reduce abrasion and noise. A flexible load-moving or
suspending member 7 may take the form of webbing, cable, rope or
other materials that is used to move and/or suspend the load and
wind onto the spool 2. In the embodiment shown, webbing 7 is used
to prevent failure due to tangling or kinking. Webbing 7 also has
the benefit of tending to prevent the object from rotating while
being raised and lowered as may occur when cable or rope is used.
Lack of rotation reduces the danger of a spinning load accidentally
hitting a person or other object and may also aid the user by
providing consistent hanging, loading and unloading orientations.
Additionally, the webbing 7 wraps over itself, thereby consistently
increasing the functional diameter of the spool as it winds.
Consequently, the lifting speeds up as the object is raised and
slows down as the object is lowered. A slower speed close to ground
level allows safer and more precise lowering as the object
approaches the ground.
[0045] In one embodiment, the spool 2 is also designed to make the
webbing 7 easily replaceable by user. The end of the webbing 7
extends through an opening in a spool post 45 and spool core 46
wall. A removable threaded pin 12 extends through an opening 47 in
the end of the webbing 7 and secures the end of the webbing 7
within the center of the spool 2.
[0046] In other embodiments, other mechanisms may be used to raise
and lower a chain, rope, cable or telescoping arm, which is
supporting the load. For example, the load may be lifted by reeving
or passing a rope or rod through a hole, ring, pulley or block.
Another example embodiment would use the motor to drive a sprocket
gear, which would in turn engage a chain, thereby raising and
lowering the load end of the chain. The loose end of the chain may
be left dangling or drop into a collection chamber to keep it from
tangling with the load and other objects.
[0047] The hoist unit 100 may be mounted to virtually any type of
structure capable of supporting whatever object is to be held. In
the embodiment shown, mounting holes are located through the hoist
housing 1 as part of the hoist body to allow the hoist unit 100 to
be mounted to various wall, ceiling and structural features. The
holes are spaced to match with holes in typical perforated beams.
Custom mounting hardware may then be bolted to the hoist 100. A
mounting kit may be added to the hoist that includes hardware for
mounting to L beams, box beams, glu-lam beams, as well as various
other common large building ceiling structures. FIGS. 5A and 5B
show a couple of the options for mounting the hoist. In FIG. 5A,
the hoist 100 is mounted to a beam formed of L-shaped angle irons
16. In this case a spacer 15, nut 14, bolt 13 and a C-shaped washer
17 are used. The configuration and specific hardware used would
vary depending on the shape and design of the beam to which the
hoist 100 is being mounted. Another mounting example is show in
FIG. 5B, which depicts the hoist mounted to a glu-lam beam 18.
[0048] Alternatively, the hoist 100 could have a simple hook system
that allows it to be installed without tools, as seen in FIG. 6A.
In this version, a pair of hooks 60 would extend up from the casing
1 and could be used to hang the hoist 100 on a beam or other
elongated member. For further security, an optional pivoting arm 61
could be used to close the hook opening and assure that the hoist
could not be inadvertently pushed off the bar or beam. Various
mechanisms may be used to hold the pivoting arm in place, including
but not limited to, springs, hooks, detents, friction fitting, pins
62, screws and nuts.
[0049] Optionally, a leash or tether 64, seen in FIG. 6B, may be
added to the unit as a security measure in case the primary
mounting method or hardware fails. The leash or tether 64 could
take several forms. For example, one or more reinforcing wires or
cables 64 may be looped around the support beam.
[0050] In addition, an optional worm gear 65 may be used to reduce
the speed and prevent back drive.
[0051] FIG. 7 is a perspective view of the power connector 40 for
the hoist 100. The hoist power connector 40 has three contacts, one
contact being negative 20 and the other two being positive 19. This
allows the hoist power connector 40 to be connected from either
direction, while maintaining the polarity needed to keep the switch
direction constant. Alternatively, the hoist power connector could
have one positive contact and two negative contacts. Another
variation could use two leads, one positive and one negative or
ground.
[0052] FIG. 8 shows a variation of the connection between the power
unit 120 and the hoist connector 40. In this embodiment, the hoist
connector 40 and the power unit connector 23 are both
hook-shaped.
[0053] Alternative embodiments could have a hoist power connector
shaped like an inverted cone with a slot, such that the connection
point on the remote power pole would slide down the wire until it
hits the cone to make contact. The remote power pole connection
point would be Y-shaped to reach around the top of the inverted
cone, thereby allowing the hoist power connector to be approached
from any direction.
[0054] FIG. 9A is a side view of the power unit 120, and FIG. 9B is
a detail view of the power connector 23 from the power unit 120.
The power unit 120 takes the form of an elongated pole 24 having a
coordinating power connector 23 configured to engage the hoist
power connector 40, a set of controls 130 on the handle 26 and a
battery pack 25. The power unit 120 incorporates a double pole
triple throw switch to short the power pole contacts 28, 29 (which
connect to both motor leads 19, 20 when the power unit 120 is
attached to the hoist unit 100) to the negative terminal of the
battery pack 25 when in the neutral position.
[0055] A current limiting fuse may be installed in the power unit
120 and is placed in series with the battery pack 25. The fuse
prevents a user from sending too much current through the system,
thereby preventing excess current from forcing the hoist 100 to
lift a load beyond its load rating and causing harm to the user,
electrical failure or damage to the batteries 32.
[0056] In an alternative version, a clutch inside the hoist 100
could be used as a load limiter.
[0057] FIGS. 10A-10C are embodiments of the power unit that are
collapsible. In FIG. 10A, the power unit 140 is foldable. In this
case, some extra length of the internal wiring 142 is required to
allow for the wiring to extend around the opening created by the
fold. In FIGS. 10B and 10C, the power unit 150 telescopes. The unit
150 could have from 2 to any number of pieces forming the
telescopic lengths. In the version shown, the power unit 150 has
three sections, such that the when collapse, as seen in FIG. 10C,
the unit is a somewhat over one third of the length of the extended
power unit 150.
[0058] FIG. 11 is an exploded view of the example battery pack 25,
which in the rechargeable embodiment uses either a NiMH pack or a
NiCd pack. Various numbers, sizes and arrangements of cells 32 may
be used depending on the power needs of the motor 10 and loads to
be lifted. In the example shown, a set of 15 Sub C cells 32 wired
in series and placed inside an insulated housing 30 is used, for
example plastic. One or a series of electrical contacts 33 are used
to connect the battery pack 25 to the rest of the power unit
120.
[0059] FIG. 12A is a perspective view of the charger unit 34 with
two battery packs 25 in place, and FIG. 12B is an exploded view of
the charger unit 34 with one battery pack 25. The charging unit 34
includes a body and circuitry 38 to rapidly peak charge one or two
packs 25 simultaneously. The connection to the battery pack 25 is
formed by a charging contact 31 located on the outside of the
battery housing 30. There is a main bay 50 that accepts a battery
pack 25 mounted to the power unit 120 and a second bay 51 that
accepts a free battery pack 25. The main bay 50 has an arm and
retaining clip 37 that engages the power unit support collar 27,
which holds the pole 24 upright. The charger 34 can be mounted to
the floor or to the wall. Other versions could have a single
charging bay with or without the retaining clip 37 or additional
charging bays to hold several power units or several free battery
packs.
[0060] In FIG. 12C, a wall mounted charger unit 160 is shown. In
this case, the power unit connector 23 is hooked over a bar 162.
The battery contacts 31 of the power unit 120 are then leaned
against the charger contacts 38. A latching bar 164 may be added to
hold the power units 120 in place. If needed, the latching bar may
have a locking mechanism to prevent unauthorized persons from
accessing the power units 120.
[0061] Alternatively, the hoist could be driven by an AC motor.
However, the AC version would require the hoist to be powered from
an AC power source. One AC configuration would include a power unit
that is plugged in a wall outlet or be installed in the building
wiring. The corded control unit would then be used similar to the
DC units discussed herein.
[0062] Another variation of the hoist could be pneumatically
driven. An example of a pneumatic system would be connected to a
compressed air source. The power connection would connect the
compressed air to the hoist unit, and thereby provide the power to
raise and lower the load.
[0063] Many different hooks and connectors and loading holding
systems may be used with the hoist to hold virtually any type of
object. The hook configuration and usage would be dictated by the
particular needs of the user. The examples herein show a few of the
possible options to hold bicycles. These are shown in FIGS. 13, 14,
15 and 16.
[0064] FIG. 13 is a double vertical hook 60, which may be formed of
a bent metal rod with two hooks 61 that are bent past vertical.
[0065] FIG. 14 shows a double horizontal hook 70, which includes
two angled rods 72 spaced apart by a beam 74. At the end of each
rod 72 is webbing 75 and carabiner 76. To hang a bicycle the user
wraps one webbing 75 and carabiner 76 strap around the seat post
and the second around the stem. Both bicycles in this case are held
apart to prevent entanglement.
[0066] FIG. 15 shows a double angled hook 80 that holds two
bicycles by the handlebars. An auto-locking clip 82 hooks under the
handlebar and locks. Bicycles hang at approximately a 45-degree
angle and are separated from each other to reduce entanglement and
aid in unloading bicycle.
[0067] Any of the double hook versions may also be used to hold a
single bicycle or additional hardware could be added to hold
additional bicycles.
[0068] FIG. 16 depicts a double horizontal platform 90 that allows
a user to essentially roll a bicycle onto a platform 90 or rails.
The bicycles in this case are held by a system similar to bicycle
racks or car top bicycle carriers.
[0069] FIGS. 17 and 18 show examples of suitable circuitry for the
hoist system. FIG. 17 is a circuit diagram for the hoist. FIG. 18
is a circuit diagram for the control unit.
METHOD OF OPERATION
[0070] Any one or more of the embodiments shown may be used to
perform various methods for raising, lowering or otherwise moving
objects and loads. One example method for moving loads includes the
steps of using a load moving system having a motor assembly with a
motor for moving a load-moving member, and a motor assembly power
connector electrically coupled with the motor and a separate power
unit having a power unit power connector electrically coupled to a
power source; temporarily contacting the motor assembly power
connector and the power unit power connector to provide power to
the motor; completing a move of the load-moving member; and
separating the motor assembly power connector and the power unit
power connector. If desired, the power unit power connector may
then be used to perform the same method on one or more additional
motor assemblies.
[0071] Although the embodiments show have disclosed the device
being used for raising and lowering of free hanging loads,
alternate embodiments of the invention could use the telescopic rod
to move a load horizontally. Other embodiments could use pulleys or
other mechanisms to move loads horizontally, vertically or
diagonally with rigid load-moving members or along rails or tracks
using flexible load-moving members.
[0072] Many features have been listed with particular
configurations, options, and embodiments. Any one or more of the
features described may be added to or combined with any of the
other embodiments or other standard devices to create alternate
combinations and embodiments.
[0073] Although the invention has been fully described above, in
relation to various exemplary embodiments, various additions or
other changes may be made to the described embodiments without
departing from the scope of the present invention. Thus, the
foregoing description has been provided for exemplary purposes only
and should not be interpreted to limit the scope of the invention
as set forth in the following claims.
* * * * *