U.S. patent application number 16/406090 was filed with the patent office on 2020-11-12 for material handling basket.
The applicant listed for this patent is Marlin Steel Wire Products, LLC. Invention is credited to Richard Bates, Drew A. Greenblatt, Andrew Montgomery.
Application Number | 20200354105 16/406090 |
Document ID | / |
Family ID | 1000004098138 |
Filed Date | 2020-11-12 |
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United States Patent
Application |
20200354105 |
Kind Code |
A1 |
Greenblatt; Drew A. ; et
al. |
November 12, 2020 |
MATERIAL HANDLING BASKET
Abstract
A material handling basket is provided comprising a base having
two opposing pairs of substantially vertical outer walls. First and
second sheet-metal dividers respectively extend between a first and
second pair of the opposed vertical outer walls, and have a tab at
each opposing end extending toward one of the walls of the first
and second pairs of walls. Each of the walls of the first pair of
walls has openings for accepting one of the tabs for positioning
the first dividers relative to the respective wall; and each of the
walls of the second pair of walls has openings for accepting one of
the tabs for positioning the second dividers relative to the
respective wall. Each of the tabs is rigidly joined to the
respective opening to retain the first and second dividers between
the first and second pairs of outer walls.
Inventors: |
Greenblatt; Drew A.;
(Potomac, MD) ; Montgomery; Andrew; (Laurel,
MD) ; Bates; Richard; (Baltimore, MD) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Marlin Steel Wire Products, LLC |
Baltimore |
MD |
US |
|
|
Family ID: |
1000004098138 |
Appl. No.: |
16/406090 |
Filed: |
May 8, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 9/06 20130101; B65D
7/28 20130101; B65D 25/04 20130101; B65D 7/08 20130101; B65D 25/22
20130101; B65D 7/16 20130101; B65D 21/0212 20130101 |
International
Class: |
B65D 6/04 20060101
B65D006/04; B65D 6/08 20060101 B65D006/08; B65D 25/22 20060101
B65D025/22; B65D 6/22 20060101 B65D006/22; B65D 21/02 20060101
B65D021/02; B65D 25/04 20060101 B65D025/04; B65D 6/02 20060101
B65D006/02 |
Claims
1. A basket comprising: a sheet-metal base having two opposing
pairs of substantially vertical outer walls, each of the outer
walls having a substantially horizontal bottom portion extending
from a bottom of the wall towards its opposite wall, each of the
walls joined to an adjacent wall to form a corner with the adjacent
wall; and a first sheet-metal divider extending between a first
pair of the opposed vertical outer walls; wherein the first divider
has a tab at each opposing end extending toward one of the walls of
the first pair of walls, and each of the walls of the first pair of
walls has an opening for accepting one of the tabs for positioning
the first divider relative to the respective wall; and wherein each
of the tabs is rigidly joined to the respective opening to retain
the first divider between the first pair of outer walls.
2. The basket of claim 1, comprising a second sheet-metal divider
extending between a second pair of the opposed vertical outer
walls; wherein the second divider has a tab at each opposing end
extending toward one of the walls of the second pair of walls, and
each of the walls of the second pair of walls has an opening for
accepting one of the tabs for positioning the second divider
relative to the respective wall; wherein each of the tabs is
rigidly joined to the respective opening to retain the second
divider between the second pair of outer walls; and wherein at
least one of the first and second dividers has a slot for engaging
the other one of the first and second dividers when the first and
second dividers are positioned relative to the first and second
pairs of outer walls.
3. The basket of claim 2, comprising a plurality of the first
dividers and a plurality of the second dividers, the pluralities of
first and second dividers each having slots for engaging each other
such that the pluralities of first and second dividers can be
positioned relative to each other to form a grid having a plurality
of intersections; wherein each wall of the first pair of outer
walls has openings for accepting the tabs of respective ones of the
plurality of first dividers, and each wall of the second pair of
outer walls has openings for accepting the tabs of respective ones
of the plurality of second dividers, and each of the first and
second dividers are respectively retained between the first and
second pairs of outer walls.
4. The basket of claim 1, wherein each of the corners of the base
comprises: a corner tab extending from one of the vertical outer
walls and contacting an adjacent outer wall; and a weld joint or a
rivet for rigidly attaching the corner tab to the adjacent outer
wall.
5. The basket of claim 3, wherein each of the intersections of the
grid comprises a first extended portion of one of the first
dividers and a second extended portion of one of the second
dividers, the first and second extended portions together forming a
prong which extends upwardly from a bottom of the basket; wherein
the prong has a plurality of outer surfaces for engaging one or
more inner surfaces of a workpiece to be supported in the basket by
the prong, the prong outer surfaces cooperating with each other and
with the one or more inner surfaces of the workpiece to hold the
workpiece in a predetermined position in the basket such that the
workpiece is substantially stationary relative to the basket.
6. The basket of claim 1, wherein each of the vertical outer walls
comprises a plurality of window openings.
7. The basket of claim 6, wherein one or more of the plurality of
openings in each of the outer walls comprises a finger hole for
allowing a user to insert a finger to lift the basket.
8. The basket of claim 1, wherein each outer wall of one of the
opposing pairs of vertical outer walls comprises a hoist arm for
engaging an overhead lifting device for lifting the basket.
9. The basket of claim 1, wherein each wall of one of the pairs of
vertical outer walls comprises a vertically-extending stacking tab
at a top of the wall, and a stacking slot at a bottom of the wall,
for engaging a corresponding stacking slot or stacking tab,
respectively, of a second basket, for stacking the basket and the
second basket.
10. The basket of claim 3, wherein the base further comprises a
bottom member extending between the horizontal bottom portions; and
wherein the first dividers and the second dividers each have a
bottom tab extending towards the bottom member, and the bottom
member has slots for engaging the bottom tabs of the first and
second dividers.
11. The basket of claim 10, wherein the bottom member has openings,
the basket further comprising a mesh member attached to the bottom
member and extending over the openings.
12. The basket of claim 3, wherein each of the tabs of each of the
first and second dividers is joined to the respective opening of
each of the outer walls by a weld, to respectively retain the first
and second dividers between the first and second pairs of outer
walls.
13. The basket of claim 5, further comprising a lid removably
attachable to a top of each of the vertical outer walls, the lid
comprising: a sheet-metal lid base having two opposing pairs of
substantially vertical outer lid walls corresponding to the two
opposing pairs of outer walls of the basket base, each of the lid
walls joined to an adjacent lid wall to form a corner with the
adjacent lid wall; and a lid bottom, extending between the outer
lid walls, for constraining movement of each of the workpieces
supported by each of the prongs when the lid is attached to the top
of the outer walls of the basket.
14. The basket of claim 13, wherein each wall of one of the pairs
of vertical outer walls of the basket comprises a
vertically-extending stacking tab at the top of the wall, and the
lid base has a lid slot at a bottom of each wall of a corresponding
one of the pairs of vertical outer lid walls for engaging the
corresponding stacking tab, for attaching the lid to the
basket.
15. The basket of claim 14, wherein each wall of one of the pairs
of vertical outer walls of the basket further comprises a stacking
slot at a bottom of the wall, for engaging a corresponding stacking
tab of an additional one of the baskets, for stacking the basket
and the additional basket; wherein the outer lid walls have a
height such that when the lid is attached to the basket, and the
basket and one or more of the additional baskets are stacked, a
total height of the stacked baskets and the lid is substantially
equal to a predetermined total height.
16. The basket of claim 13, wherein the lid comprises first and
second sheet-metal lid dividers respectively extending between
first and second pairs of the opposed vertical outer lid walls;
wherein each of the first and second lid dividers has a tab at each
opposing end extending toward one of the lid walls of the first and
second pairs of outer lid walls, and each of the lid walls of the
first and second pairs of outer lid walls has an opening for
accepting one of the tabs for positioning the first and second
dividers relative to the respective lid walls; wherein each of the
tabs is rigidly joined to the respective opening in one of the lid
walls to retain the first and second dividers between the first and
second pairs of outer walls; and wherein at least one of the first
and second lid dividers has a slot for engaging the other one of
the first and second lid dividers when the first and second lid
dividers are positioned relative to the first and second pairs of
outer lid walls.
17. The basket of claim 10, further comprising a sheet-metal lid
attachable to a top of each of the vertical outer walls by at least
one of a latch and a hinge; wherein the lid is for engaging the
grid for constraining movement of workpieces held by the grid.
18. A method of manufacturing a basket, the method comprising:
providing a sheet-metal base having two opposing pairs of
substantially vertical outer walls, each of the outer walls having
a substantially horizontal bottom portion extending from a bottom
of the wall towards its opposite wall, each of the walls joined to
an adjacent wall to form a corner with the adjacent wall; providing
a plurality of first sheet-metal dividers for extension between a
first pair of the opposed vertical outer walls, each of the first
dividers having a tab at each opposing end; providing a plurality
of second sheet-metal dividers for extension between a second pair
of the opposed vertical outer walls, each of the second dividers
having a tab at each opposing end; wherein the pluralities of first
and second dividers each have slots for engaging each other, and
each wall of the first pair of outer walls has openings for
accepting the tabs of respective ones of the plurality of first
dividers, and each wall of the second pair of outer walls has
openings for accepting the tabs of respective ones of the plurality
of second dividers; the method further comprising: engaging the
slots of the pluralities of first and second dividers with each
other to form a grid having a plurality of intersections; engaging
each tab of the pluralities of first and second dividers with a
corresponding opening in one of the walls of the first and second
pairs of outer walls to position the first dividers and second
dividers relative to the first and second pairs of outer walls; and
rigidly joining each of the tabs to the corresponding opening to
retain the first and second dividers between the first and second
pairs of outer walls.
19. The method of claim 10, wherein providing the sheet-metal base
comprises forming the horizontal bottom portion of each of the
outer walls integrally with one of the outer walls.
20. A basket comprising a prong having a cruciform cross-section,
the prong extending upwardly from a bottom of the basket; wherein
the prong has a plurality of outer surfaces for engaging one or
more inner surfaces of a workpiece to be supported in the basket by
the prong, the prong outer surfaces cooperating with each other and
with the one or more inner surfaces of the workpiece to hold the
workpiece in a predetermined position in the basket such that the
workpiece is substantially stationary relative to the basket.
Description
FIELD
[0001] Embodiments relate generally to material handling baskets
and methods of manufacturing such baskets.
BACKGROUND
[0002] Material handling baskets are often used for holding
workpieces (also referred to herein as "parts") during a
manufacturing process. For example, a number of parts may be
arranged in a two-dimensional array in a basket, each part in a
predetermined position, so that a robotic pick and place gripper
can automatically pick up the part. Conventional material handling
baskets are typically made of metal wire that is welded together,
with plastic supports called "prongs" attached to the metal wire
for vertical support of parts at predetermined locations in the
basket, so a robot gripper can pick up the part.
[0003] These conventional wire baskets have several important
disadvantages. They have many welds and are made of many parts,
especially when they have plastic prongs. This requires expensive
fixturing for manufacturing the baskets, and also requires many
manufacturing steps, resulting in high costs and manufacturing
time. Additionally, the welds cause heat distortion and
deformation, so the parts cannot be accurately located in the
basket with the parallelism and perpendicularity required by
precision robots and grippers. In particular, the plastic prongs
tend not to support parts with consistent perpendicularity, and may
allow parts to move and change position. This variation in
perpendicularity prevents robotic pick and place grippers from
picking up parts in their assigned space, causing the robots to
crash. This means the manufacturing machines cannot be run at full
speed, and require expensive personnel tending the robots to
correct problems.
[0004] Another disadvantage is that the vertical outside supports
or "ledges" typical of wire baskets can interfere with grippers due
to their size and position. These basket structures encroach into
useful space, effectively reducing the capacity of the baskets by
acting as obstacles to the free movement of the robot grippers. In
such cases, parts cannot be loaded onto prongs located next to the
vertical supports of the basket, thereby reducing manufacturing
efficiency.
[0005] There exists a need for a material handling basket that is
simpler and less expensive to manufacture, can be manufactured with
the proper precision, and holds parts with the accuracy needed by
robotic grippers. There also exists a need for a basket that
maximizes useful space for parts, and does not have supports and/or
welds that encroach into the interior of the basket and interfere
with grippers.
SUMMARY
[0006] One or more embodiments can include a material handling
basket comprising a sheet-metal base having two opposing pairs of
substantially vertical outer walls, each of the outer walls having
a substantially horizontal bottom portion extending from a bottom
of the wall towards its opposite wall, each of the walls joined to
an adjacent wall to form a corner with the adjacent wall. A first
sheet-metal divider extends between a first pair of the opposed
vertical outer walls, and has a tab at each opposing end extending
toward one of the walls of the first pair of walls. A second
sheet-metal divider extends between a second pair of the opposed
vertical outer walls, and has a tab at each opposing end extending
toward one of the walls of the second pair of walls. Each of the
walls of the first pair of walls has an opening for accepting one
of the tabs for positioning the first divider relative to the
respective wall; and each of the walls of the second pair of walls
has an opening for accepting one of the tabs for positioning the
second divider relative to the respective wall. Each of the tabs is
rigidly joined to the respective opening to retain the first and
second dividers between the first and second pairs of outer
walls.
[0007] Embodiments further include a basket comprising a prong
having a cruciform cross-section, the prong extending upwardly from
a bottom of the basket. The prong has a plurality of outer surfaces
for engaging one or more inner surfaces of a workpiece to be
supported in the basket by the prong, the prong outer surfaces
cooperating with each other and with the one or more inner surfaces
of the workpiece to hold the workpiece in a predetermined position
in the basket, such that the workpiece is substantially stationary
relative to the basket.
[0008] Embodiments further comprise method of manufacturing a
basket, the method comprising providing a sheet-metal base having
two opposing pairs of substantially vertical outer walls, each of
the outer walls having a substantially horizontal bottom portion
extending from a bottom of the wall towards its opposite wall, each
of the walls joined to an adjacent wall to form a corner with the
adjacent wall. A plurality of first sheet-metal dividers is also
provided for extension between a first pair of the opposed vertical
outer walls, each of the first dividers having a tab at each
opposing end. Additionally, a plurality of second sheet-metal
dividers is provided for extension between a second pair of the
opposed vertical outer walls, each of the second dividers having a
tab at each opposing end. The pluralities of first and second
dividers each have slots for engaging each other, and each wall of
the first pair of outer walls has openings for accepting the tabs
of respective ones of the plurality of first dividers, and each
wall of the second pair of outer walls has openings for accepting
the tabs of respective ones of the plurality of second
dividers.
[0009] The method further comprises engaging the slots of the
pluralities of first and second dividers with each other to form a
grid having a plurality of intersections; engaging each tab of the
pluralities of first and second dividers with a corresponding
opening in one of the walls of the first and second pairs of outer
walls to position the first dividers and second dividers relative
to the first and second pairs of outer walls; and rigidly joining
each of the tabs to the corresponding opening to retain the first
and second dividers between the first and second pairs of outer
walls.
[0010] Objects and advantages of embodiments of the disclosed
subject matter will become apparent from the following description
when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Embodiments will hereinafter be described in detail below
with reference to the accompanying drawings, wherein like reference
numerals represent like elements. The accompanying drawings have
not necessarily been drawn to scale. Where applicable, some
features may not be illustrated to assist in the description of
underlying features.
[0012] FIG. 1A is a top perspective view of a material handling
basket according to an embodiment of the present disclosure.
[0013] FIG. 1B is a top perspective view of a base of the basket of
FIG. 1A.
[0014] FIGS. 1C and 1D are perspective views of dividers of the
basket of FIG. 1A.
[0015] FIG. 1E is a top perspective view of a divider grid of the
basket of FIG. 1A.
[0016] FIG. 1F is partial perspective view of the basket of FIG.
1A.
[0017] FIG. 1G is a front view of a prong of the basket of FIG.
1A.
[0018] FIG. 1H is a cross-sectional view of the prong of FIG. 1G
supporting a workpiece.
[0019] FIG. 1I is a front perspective view of a lid for the basket
of FIG. 1A according to an embodiment of the present
disclosure.
[0020] FIG. 1J is a front view of a stack of three of the baskets
of FIG. 1A and the lid of FIG. 1I.
[0021] FIG. 2A is a top perspective view of a material handling
basket according to a further embodiment of the present
disclosure.
[0022] FIG. 2B is a bottom perspective view of the basket of FIG.
2A.
[0023] FIG. 2C is a top perspective view of a divider grid of the
basket of FIG. 2A.
[0024] FIG. 2D is top view of the basket of FIG. 2A.
[0025] FIG. 2E is top view of the basket of FIG. 2A holding
workpieces.
[0026] FIG. 2F is cross-sectional front view of the basket of FIG.
2A holding workpieces.
[0027] FIG. 2G is a top perspective view of a stack of two of the
baskets according to FIG. 2A.
[0028] FIG. 3A is top perspective view of a material handling
basket according to another embodiment of the present
disclosure.
[0029] FIG. 3B is a top view of the basket of FIG. 3A.
[0030] FIGS. 4A and 4B are top and bottom perspective views,
respectively, of a material handling basket according to another
embodiment of the present disclosure.
[0031] FIG. 5 is a flow chart of an exemplary method of
manufacturing a material handling basket according to an embodiment
of the present disclosure.
DETAILED DESCRIPTION
[0032] It should be understood that the principles described herein
are not limited in application to the details of construction or
the arrangement of components set forth in the following
description or illustrated in the following drawings. The
principles can be embodied in other embodiments and can be
practiced or carried out in various ways. Also, it is to be
understood that the phraseology and terminology used herein is for
the purpose of description and should not be regarded as
limiting.
[0033] Disclosed herein are material handling baskets for
supporting a plurality of workpieces in an array, and methods for
manufacturing such baskets. The disclosed baskets comprise a sheet
metal base and dividers which snap together, thereby eliminating
the need for fixturing during assembly. The base and dividers can
be laser cut for improved tolerances, and welded and/or riveted
together only on the exterior--not the interior or bottom--to
reduce heat distortion and improve parallelism. In certain
embodiments, the workpieces are supported in the disclosed basket
on cruciform prongs formed by the dividers. The prongs are
contoured to fit the workpieces so that they grip the workpieces,
enabling the workpieces to rest on the prongs accurately and
securely without falling off or moving, as disadvantageously occurs
with conventional baskets. The "low profile" of the disclosed
baskets' sheet metal construction, the precision of their
construction, and the ability of their prongs to securely hold
workpieces in the proper position, enable the disclosed baskets to
increase manufacturing throughput when used in conjunction with
robotic pick and place grippers and other such machines.
[0034] FIGS. 1A-1J illustrate an exemplary embodiment of a material
handling basket according to the present disclosure. In this
embodiment, a plurality of workpieces are held in predetermined
positions in the basket by an array of prongs. Referring now to
FIGS. 1A-E, a basket 100 comprises a sheet-metal base 101, such as
a steel or aluminum base, having two opposing pairs of
substantially vertical outer walls 102a, 102b, each of the outer
walls 102a, b having a substantially horizontal bottom portion
103a, 103b extending from a bottom of the wall 102a,b towards its
opposite wall 102a,b. Outer walls 102a,b are shown having different
lengths such that the basket 100 has an overall rectangular shape.
However, those of skill in the art will understand that outer walls
102a,b can have the same length if desired. In certain embodiments,
base 101 is laser cut and deburred, and formed from a single flat
sheet of metal, which is bent into the desired shape. Laser cutting
for the base 101 as well as other parts of basket 100 is
advantageous insofar as the basket 100 can be made to tighter
tolerances than conventional wire baskets. Consequently, workpieces
are held by basket 100 more consistently in the proper place.
[0035] Each of the walls 102a,b is joined to an adjacent wall
102a,b to form a corner 104 with the adjacent wall 102a,b. Each
corner 105 has a corner tab 105 extending from one of the vertical
outer walls (FIG. 1B shows corner tabs 105 extending from walls
102b) and contacting an adjacent outer wall 102a. A weld joint or a
rivet 106 rigidly attaches the corner tab 105 to the adjacent outer
wall 102a. The welds 106 can be; for example, conventional TIG or
MIG welds or resistance spot welds that are close to being flush
with the surface of the walls 102a, so they do not interfere with
placement of the basket 100 in a machine. In the alternative,
conventional rivets can be advantageously used to reduce
distortions to the metal from welding heat, and to provide
additional strength to the joints.
[0036] Each of the vertical outer walls 102a,b comprises a
plurality of window openings 107. In certain embodiments, some of
the plurality of openings in at least one pair of the outer walls
102a,b comprise finger holes 108 for allowing a user to insert a
finger or fingers to lift the basket 100. In these embodiments,
basket 100 does not need added handles that protrude and could
obstruct robotic grippers that are typically used in conjunction
with baskets 100 in a manufacturing context.
[0037] Referring particularly to FIGS. 1C-E, basket 100 further
comprises a grid 109 of substantially perpendicular first sheet
metal dividers 110 and second sheet metal dividers 111, all of
which are laser cut and deburred prior to assembly. The first
sheet-metal dividers 110 extend between a first pair of the opposed
vertical outer walls 102a, and the second sheet-metal dividers 111
extend between a second pair of the opposed vertical outer walls
102b. A plurality of the first dividers 110 has a tab 112 at each
opposing end extending toward one of the walls 102a of the first
pair of walls, and each of the walls 102a of the first pair of
walls has openings 113 each for accepting one of the tabs 112 for
positioning the first dividers 110 relative to the respective walls
102a. Likewise, a plurality of the second dividers 111 each have a
tab 114 at each opposing end extending toward one of the walls 102b
of the second pair of walls, and each of the walls 102b of the
second pair of walls has an opening 115 for accepting one of the
tabs 114 for positioning the second dividers 111 relative to the
respective walls 102b.
[0038] Additionally, each divider 110, 111 of the pluralities of
first and second dividers has slots 116, 117 for engaging each
other such that the first and second dividers 110, 111 can be
positioned relative to each other to form the grid 109 having a
plurality of intersections 118.
[0039] Each of the first divider tabs 112 is rigidly joined, as by
a weld joint 119, to a respective opening 113 in one of the walls
102a to retain the first dividers 110 between the outer walls 102a.
Likewise, each of the second divider tabs 114 is rigidly joined, as
by a weld joint 120, to a respective opening 115 in one of the
walls 102b to retain the second dividers 111 between the outer
walls 102b. Because the disclosed basket 100 includes only a small
number of welds, on exterior surfaces only and not on bottom or
interior surfaces, heat distortion during the manufacturing process
is reduced, and parallelism is improved versus conventional wire
baskets.
[0040] In the present embodiment, each of the intersections 118 of
the grid 109 comprises a first extended portion 121 of one of the
first dividers 110 and a second extended portion 122 of one of the
second dividers 111, the first and second extended portions 121,
122 together forming a prong 125 having a cruciform cross-section,
as shown close-up in FIG. 1F. Prong 125 extends upwardly from a
bottom of the basket 100. Basket 100 can hold an array of
workpieces on respective prongs 125. Referring now to FIGS. 1G-H,
prong 125 has a plurality of outer surfaces 126 for engaging one or
more inner surfaces 127a of workpiece 127 to be supported in the
basket 100 by the prong 125, the prong outer surfaces 126
cooperating with each other and with the one or more inner surfaces
127a of the workpiece 127 to hold the workpiece 127 in a
predetermined position in the basket 100 such that the workpiece
127 is substantially stationary relative to the basket 100.
[0041] In certain embodiments, the top portions 126a prong outer
surfaces 126 are contoured to fit the workpiece 127, advantageously
resulting in reduced abrasion between the prong 125 and the
workpiece 127, thereby avoiding marring and scratching of workpiece
127. Additionally, since the prongs 125 fit the workpieces 127, the
workpieces 127 rest accurately and securely in the basket 100
without falling off the prongs 125. This advantageously eliminates
the need for prongs having plastic tines, as in conventional
material handling baskets, which are costly to make and install,
and do not accurately align workpieces within the basket. Accurate
placement and retention of workpieces 127 in basket 100 is crucial
when basket 100 is to be used in conjunction with robotic grippers
that pick up the workpieces 127.
[0042] The disclosed basket 100 comprises mostly flat metal outer
and inner walls and surfaces, eliminating the wire supports and
ledges of conventional baskets, which encroach into useful space
and interfere with robotic grippers. The design of basket 100
enables robotic grippers to pick parts that are supported
practically anywhere in the basket 100 (i.e., at all the
intersections 118 of the grid 109), thereby improving
utilization.
[0043] Each of the vertical outer walls 102a,b of the base 101 also
comprises a vertically-extending stacking tab 130 at a top of the
wall 102a,b, and a stacking slot 131 at a bottom of the wall
102a,b. As shown in FIG. 1A, stacking tab 130 and slot 131 are each
for engaging a corresponding stacking slot 130 or stacking tab 131,
respectively, of a second basket 100, for stacking the basket 100
and the second basket 100. Those of skill in the art will
understand that additional baskets 100 can also be stacked, as
depicted in FIG. 1J showing three stacked baskets 100. Since the
stacking tabs and slots are integrated with the basket, they are
sturdy and eliminate the need for welds and ledges of conventional
wire baskets, which encroach into useful space and interfere with
robot grippers.
[0044] Referring now to FIGS. 1I-J, the disclosed basket 100 of
this embodiment can further comprise a removable lid 140 attachable
to a top of each of the vertical outer walls 102a,b. Lid 140
comprises a sheet-metal lid base 141 having first and second
opposing pairs of substantially vertical outer lid walls 142a, 142b
corresponding to the two opposing pairs of outer walls 102a, 102b
of the basket base 101, each of the lid walls 142a,b joined to an
adjacent lid wall 142a,b to form a corner 143 with the adjacent lid
wall 142a,b. Lid 140 also has a lid bottom 144 extending between
the outer lid walls 142a,b. Lid bottom 144 is for constraining
movement of each of the workpieces 127 supported by each of the
prongs 125 when the lid 140 is attached to the top of the outer
walls 102a,b of basket 100. This can be accomplished by the lid
bottom 144 engaging the grid 109 of basket 100 or the workpieces
127. In the illustrated example, openings 145 are provided in the
lid bottom 144 and engage workpieces 127. Thus, lid 140 will
constrain workpieces 127 if they are flipped over; for example, in
a parts washer.
[0045] In certain embodiments, the lid 140 comprises first and
second sheet-metal lid dividers 146, 147 respectively extending
between the first and second pairs of the opposed vertical outer
lid walls 142a,b. Each of the first and second lid dividers 146,
147 has a tab 148, 149 at each opposing end extending toward one of
the lid walls 142a,b of the first and second pairs of outer lid
walls, and each of the lid walls 142a, 142b has an opening 150, 151
for accepting one of the tabs 148, 149 for positioning the first
and second dividers 146, 147 relative to the respective lid walls
142a,b. Each of the tabs 148, 149 is rigidly joined, as by welding,
to the respective opening 150, 151 in one of the lid walls 142a,b
to retain the first and second dividers 146, 147 between the first
and second pairs of outer walls 142a,b. At least one of the first
and second lid dividers 146, 147 has a slot (not shown) for
engaging the other one of the first and second lid dividers 146,
147 when the first and second lid dividers 146, 147 are positioned
relative to the first and second pairs of outer lid walls
142a,b.
[0046] As discussed herein above and shown in FIG. 1A, each of the
vertical outer walls 102a,b of the basket 100 comprises a
vertically-extending stacking tab 130 at the top of the wall. The
lid base 141 has a corresponding lid slot 146 at a bottom of each
of the vertical outer lid walls 142a,b for engaging a corresponding
basket stacking tab 130, for attaching the lid 140 to the basket
100. FIG. 1J shows lid 140 attached to a basket 100.
[0047] As also discussed in detail herein above, a number of
baskets 100 can be stacked. As shown in FIG. 1J, the outer lid
walls 142a,b have a height h such that when the lid 140 is attached
to a basket 100, and the basket 100 and one or more additional
baskets 100 are stacked, a total height H of the stacked baskets
100 and the lid 140 is substantially equal to a predetermined total
height. Thus, the lid height h can be selected to adjust the total
height H so the stack fits inside a cavity, such as a cavity of a
parts washer.
[0048] An alternative embodiment of the disclosed basket will now
be described with reference to FIGS. 2A-2G. In this embodiment, the
dividers do not have extended portions that form cruciform prongs
to hold workpieces. Rather, the dividers form compartments to hold
workpieces, along with a bottom portion of the basket base.
Otherwise, the basket of this embodiment is similar or identical in
most major respects to the basket 100 of the embodiment of FIGS.
1A-E described herein above.
[0049] As shown in FIGS. 2A-D, a basket 200 comprises a sheet-metal
base 201, such as a steel or aluminum base, having two opposing
pairs of substantially vertical outer walls 202a, 202b, each of the
outer walls 202a,b having a substantially horizontal bottom portion
203a, 203b extending from a bottom of the wall 202a,b towards its
opposite wall 202a,b. Base 201 also has a bottom member 203c
extending between the horizontal bottom portions 203a,b. Bottom
member 203c can be formed integrally with the base 201 as shown in
FIGS. 2B. Outer walls 202a,b are shown having different lengths
such that the basket 200 has an overall rectangular shape. However,
those of skill in the art will understand that outer walls 202a,b
can have the same length if desired. In certain embodiments, base
201 is laser cut and deburred, and formed from a single flat sheet
of metal, which is bent into the desired shape. Laser cutting for
all the base 201 as well as other parts of basket 200 is
advantageous insofar as the basket 200 can be made to tighter
tolerances than conventional wire baskets. Consequently, workpieces
are held by basket 200 more consistently in the proper place.
[0050] Each of the walls 202a,b is joined to an adjacent wall
202a,b to form a corner 204 with the adjacent wall 202a,b. Each
corner 205 has a corner tab 205 extending from one of the vertical
outer walls and contacting an adjacent outer wall (in FIGS. 2A-B
corner tabs 205 extend from walls 202a). Rivets 206 or welds, which
are close to being flush with the surface of the walls 202a,
rigidly attach the corner tab 205 to the adjacent outer wall 202a.
Conventional rivets 206 can be advantageously used to reduce
distortions to the metal from welding heat, and to provide
additional strength to the joints. Each of the vertical outer walls
202a,b and the bottom member 203c comprises a plurality of window
openings 207.
[0051] Referring in particular to FIG. 2C, basket 200 further
comprises a grid 209 of substantially perpendicular first sheet
metal dividers 210 and second sheet metal dividers 211, all of
which are laser cut and deburred prior to assembly. The first
sheet-metal dividers 210 extend between a first pair of the opposed
vertical outer walls 202a, and the second sheet-metal dividers 211
extend between a second pair of the opposed vertical outer walls
202b. A plurality of the first dividers 210 has a tab 212 at each
opposing end extending toward one of the walls 202a of the first
pair of walls, and each of the walls 202a of the first pair of
walls has openings 213, each for accepting one of the tabs 212 for
positioning the first dividers 210 relative to the respective walls
202a. Likewise, a plurality of the second dividers 211 each have a
tab 214 at each opposing end extending toward one of the walls 202b
of the second pair of walls, and each of the walls 202b of the
second pair of walls has an opening 215 for accepting one of the
tabs 214 for positioning the second dividers 211 relative to the
respective walls 202b.
[0052] Each divider 210, 211 of the pluralities of first and second
dividers also has slots 216, 217 for engaging each other (similar
to slots 116 and 117 respectively shown in FIGS. 1C and 1D) such
that the first and second dividers 210, 211 can be positioned
relative to each other to form the grid 209 having a plurality of
intersections 218. Additionally, each divider 210 has a number of
bottom tabs 221 extending towards the bottom member 203c, each
divider 211 has a number of bottom tabs 222 extending towards the
bottom member 203c, and the bottom member 203c has corresponding
slots 223, 224 for engaging respective bottom tabs 221, 222.
[0053] Each of the first divider tabs 212 is rigidly joined, as by
a weld joint, to a respective opening 213 in one of the walls 202a
to retain the first dividers 210 between the outer walls 202a. Each
of the second divider tabs 214 is rigidly joined, as by a weld
joint, to a respective opening 215 in one of the walls 202b to
retain the second dividers 211 between the outer walls 202b.
Likewise, each of the bottom tabs 221, 222 is rigidly joined, as by
a weld joint, to a respective slot 223, 224 in bottom member 203c
to retain the first and second dividers 210, 211 to the bottom
member 203c. Because the disclosed basket 200 includes only a small
number of welds, on the exterior walls only and not on bottom or
interior surfaces, heat distortion during the manufacturing process
is reduced, and parallelism is improved versus conventional wire
baskets.
[0054] As shown in FIGS. 2D-F, basket 200 can hold an array of
workpieces 227 in respective compartments 226 formed by the grid
209 along with bottom member 203c and outer walls 202a,b. The
surfaces of the grid 209, the bottom member 203c, and (in some
compartments 226) the outer walls 202a,b cooperate with each other
to hold one workpiece 227 in a predetermined position in the basket
200.
[0055] Each outer wall 202a of the base 201 comprises one or more
hoist arms 208 for engaging an overhead lifting device (not shown)
for lifting the basket 200. Each outer wall 202a also includes one
or more stacking slots 228 at a bottom of the wall 202a. Each hoist
arm 208 acts as a vertically-extending stacking tab, for engaging a
corresponding stacking slot 228 of a second basket 200, for
stacking the basket 200 and the second basket 200, as depicted in
FIG. 2G. Those of skill in the art will understand that additional
baskets 200 can also be stacked.
[0056] In certain similar embodiments shown in FIGS. 3A-B, a basket
300 similar in most relevant respects to basket 200 has a bottom
member 301 with openings 302, and further comprises a mesh member
303 attached to the bottom member 301 and extending over openings
302. Basket 300 also differs from basket 200 in that it has a pair
of handles 304 rather than hoist arms, and the handles 304
facilitate stacking of multiple baskets 300.
[0057] In further similar embodiments shown in FIGS. 4A-B, a basket
400 similar in most relevant respects to basket 200 has a bottom
member 401 with openings 402, and further comprises a mesh member
403 attached to the bottom member 401 and extending over openings
402. Basket 400 also has a sheet-metal lid 404 attachable to a top
of each of the basket's vertical outer walls 405 by at least one or
more hinges 406 and latches 407. The lid 404 is for engaging the
grid 408 of dividers for constraining movement of workpieces (not
shown) held by the grid 408.
[0058] A method will now be described for manufacturing the
disclosed basket, with reference to FIGS. 1A-1E and the flow chart
of FIG. 5. At step 501, a sheet-metal base 101 is provided having
two opposing pairs of substantially vertical outer walls 102a,
102b, each of the outer walls having a substantially horizontal
bottom portion 103a, 103b extending from a bottom of the wall
towards its opposite wall, each of the walls 102a,b joined to an
adjacent wall to form a corner 104 with the adjacent wall. In
certain embodiments, base 101 is laser cut, and providing the
sheet-metal base 101 comprises forming the horizontal bottom
portion 103a,b of each of the outer walls 102a,b integrally with
one of the outer walls 102a,b.
[0059] At step 502, a plurality of first sheet-metal dividers 110
is provided for extension between a first pair of the opposed
vertical outer walls 102a, each of the first dividers 110 having a
tab 112 at each opposing end. At step 503, a plurality of second
sheet-metal dividers 111 is provided for extension between a second
pair of the opposed vertical outer walls 102b, each of the second
dividers 111 having a tab 114 at each opposing end. The pluralities
of first and second dividers 110, 111 each have slots 116, 117,
respectively, for engaging each other, and each wall of the first
pair of outer walls 102a has openings 113 for accepting the tabs
112 of respective ones of the plurality of first dividers 110, and
each wall of the second pair of outer walls 102b has openings 115
for accepting the tabs 114 of respective ones of the plurality of
second dividers 111. In certain embodiments, the dividers 110, 111
are laser cut.
[0060] At step 504, the slots 116, 117 of the pluralities of first
and second dividers 110, 111 are engaged with each other to form a
grid 109 having a plurality of intersections 118. Then, at step
505, each tab 112, 114 of the pluralities of first and second
dividers 110, 111 is engaged with a corresponding opening 119, 120
in one of the walls 102a,b of the first and second pairs of outer
walls to position the first dividers 110 and second dividers 111
relative to the first and second pairs of outer walls 102a,b.
Finally, at step 506, each of the tabs 112, 114 is rigidly joined
to the corresponding opening 113,115 to retain the first and second
dividers 110, 111 between the first and second pairs of outer walls
102a,b.
[0061] The "snap together" design of the disclosed basket reduces
manufacturing time and cost versus conventional welded-wire
baskets. For example, the disclosed baskets require no fixturing to
assemble, and also require a much smaller number of parts. At the
same time, the disclosed snap together design results in a stronger
basket than conventional welded wire baskets. It also improves
tolerances, facilitating the use of robotic pick and place
grippers.
[0062] While this invention has been described in conjunction with
a number of embodiments, it is evident that many alternatives,
modifications and variations would be or are apparent to those of
ordinary skill in the applicable arts. Accordingly, applicants
intend to embrace all such alternatives, modifications, equivalents
and variations that are within the spirit and scope of this
invention.
* * * * *