US3860132A

US3860132A - Brick regrouping method

Info

Publication number: US3860132A
Application number: US419888A
Authority: US
Inventors: Gerald L Stuart; Forrest A Paschal
Original assignee: Individual
Current assignee: Individual
Priority date: 1972-07-28
Filing date: 1973-11-28
Publication date: 1975-01-14
Anticipated expiration: 1992-01-14

Abstract

Bricks arranged in a plurality of stacks on kiln cars in doublelayer courses having a prescribed number of bricks in each row and column are first transferred to an intermediate table by means of a first, side gripper pickup head. The side gripper pickup head includes several pair of gripper members which grip the bricks at the ends of the rows thereof and compact the rows in preparation for the first head to lift and transfer the bricks to the intermediate table. A second, end gripper pickup head includes several pairs of gripper segments, movable with respect to each other, to grip the bricks at the ends of the columns, lift and adjust the row-wise spacing therein to arrange the bricks into courses having a different number of bricks in the rows thereof than the courses on the kiln cars. The second pickup head then transfers the bricks held therein to an off-bearing conveyor leading to a stacking and strapping station.

Description

Unite States extent [191 Stuart et al.

[ BRICK REGROUPING METHOD [76] Inventors: Gerald L. Stuart, Homewood Acres; Forrest A. Paschal, 418 W. Dolphin St,, both of Siler City, NC. 27344 22 Filed: Nov. 28, 1973 [21] App]. No.: 419,888

Related U.S. Application Data [62] Division of Ser. No. 276,031, July 28, I972, Pat. No.

Primary Examiner-Robert J. Spar Assistant ExaminerGeorge F. Abraham Jan. 14, 1975 [57] ABSTRACT Bricks arranged in a plurality of stacks on kiln cars in double-layer courses having a prescribed number of bricks in each row and column are first transferred to an intermediate table by means of a first, side gripper pickup head. The side gripper pickup head includes several pair of gripper members which grip the bricks at the ends of the rows thereof and compact the rows in preparation for the first head to lift and transfer the bricks to the intermediate table. A second, end gripper pickup head includes several pairs of gripper segments, movable with respect to each other, to grip the bricks at the ends of the columns, lift and adjust the row-wise spacing therein to arrange the bricks into courses having a different number of bricks in the rows thereof than the courses on the kiln cars. The second pickup head then transfers the bricks held therein to an off-bearing conveyor leading to a stacking and strapping station.

2 Claims, 3 Drawing Figures BRICK REGROUPING METHOD This application is a division of application Ser. No. 276,031, filed July 28, 1972, which has matured into US. Pat. No. 3,776,398.

BACKGROUND OF THE INVENTION In accordance with conventional practices, bricks are arranged for firing on kiln cars in a plurality of stacks, two or three stacks across the width of the kiln car and two-four stacks along the length thereof. The number of stacks may vary depending on the the size of the kiln car, and each stack includes a plurality of double-layer courses, each successive course having the headers thereof facing perpendicular to the headers of the preceding course. Each course comprises a plurality of rows and columns, with the bricks in each column arranged end to end, and the bricks in the rows being spaced apart from side to side.

The courses on the kiln car do not generally correspond to the courses in the final strapped package as far as the number of bricks in each row is concerned. Therefore, the courses cannot be removed from the kiln car and stacked atop each other toform the package because of the difference in the number of bricks in each row. It is also true that the number of bricks in each column on the kiln car is not'the same as the number of bricks in each columnof the finished'package, however this is immaterial as the stacker" receives bricks continuously fed in lengthwise ofthecolumns and forms the bricks into one long continuous package, which issubsequently cutoff to desired lengths in a well known manner.

Regrouping of the bricks from the kiln car into courses having rows of proper number for the final package does presenta problem, however, which has been solved previously by completely breakingdown the courses from the kiln car into single rows on an off bearing conveyor, moving the bricks in singlefile along the conveyor and regrouping by some mechanism at the end of the conveyor into rows of the proper length, said rows being reformed into coursesand stacked in the final package. It is quite obvious that this procedure requires extra operations, is thus slower and more expensive.

SUMMARY OF Tl-IE PRESENT'INVENTION In accordance with the present invention, there is provided an apparatus which includes the combination of a first side gripper head and a second end gripper head. The first, side gripper head includes aplurality of gripper members which pick up the uppermost course from each of several stacks on the kiln car simulta-.

neously, and transfer them to an intermediate table while closingthe spaces between thebricks in each row, yet leaving the spaces between adjacent courses.

The second, end gripper head includes a plurality of pairs of grippersegrnents, laterally movable with respect to each other, which grip the bricks on the ends or headers of the bricks in the courses deposited upon the table, lift the bricks, and deposit themon an offbearing conveyor. During the transfer and as the bricks are held therebetween the gripper segments are moved laterally to rearrange the courses so that the rows thereof have a prescribed number of bricks therein. The off-bearing conveyor then carries the bricks to a stacking and strapping station already formed in courses rather than rows. The bricks are thereby regrouped from courses on the kiln car having a prescribed number of bricks in each row to courses on the off-bearing conveyor having the correct number of bricks in each row for the finalpackaging operation.

It is therefore an object of the present invention to provide an improved method and apparatus for transferring bricks from a kiln car to a stacking and strapping station more economically and without completely breaking down the courses from the kiln can.

It is another object of the present invention to provide a method and apparatus for transferring bricks from a kiln car to a conveyor leading to a stacking and strapping machine and simultaneously regrouping the courses of one row length on the kiln car into courses of proper row length for the final package.

It is yet another object of the present invention to provide a method and apparatus of the type described wherein the uppermost courses on several stacks of the kiln car are transferred to an intermediate table with the rows in each course compacted, then transferred to an off-bearing conveyor with simultaneous regrouping into courses having rows of proper length for stacking andstrapping into the final package.

Other objects of the invention will become apparent upon reading the following detailed description of a preferred embodiment of the invention, along with an inspection of the accompanying drawings, in which:

FIG. 1 is a plan view of the apparatus according to the present invention with the side gripper mechanism (shown in phantom lines) positioned above one end of the kiln car and the end gripper mechanism (phantom lines) positioned above the intermediate table;

FIG. 2 is a side elevation view of the apparatus illustratedin FIG. 1; and

FIG Sis a perspective view of the end-gripper apparatus alone.

Turning now to the drawings, and particularly FIGS. land 2, it is conventional practice in the brick making industry to position bricks on kiln cars K for firing in thekiln. As described hereinabove, the bricks are conventionally stacked-on the kiln cars in a plurality of stacks S, the number of stacks S depending on the size of the kiln car K. Each stack S includes a plurality of double-layer courses stacked one atop each other with the headers of successive courses facing in a direction perpendicular to the headers of the courses above and below in order to achieve more even distribution of the heat over each brick. Each course or each layer thereof comprise a plurality of rows R of bricks spaced sidewise from each other and also arranged in columns C with the bricks thereof generally abutting in end to end relationship.

Kiln cars K are initially moved to a receiving position beneath one end of a frame 10 which in turn comprises upstanding corner columns l2, 14 supporting an upper horizontal frame 16 extending from a point overlying kiln car K to a point at the other end above an offbearing conveyor 38. An intermediate table 28 is supported in any well known manner intermediate the ends of frame 16 for reasons to be hereinafter discussed.

A carriage 18 having wheels 20 is movably mounted on opposite side members of frame 16. A motor 22 connected to one axle 19 of carriage l8 selectively drives carriage 18 back and forth in a horizontal path between a first position where one end of the carriage overlies the receiving position and a second position where the same end of the carriage overlies intermediate table 28.

A first pickup head or side gripper head 24 is suspended from carriage 18 at the first end by means of a hydraulic cylinder 26 or other similar means for reciprocating head 24 in a vertical path between an upper position, and one of several lower pickup or release positions. So arranged first pickup head 24 is adapted to picking up one or more double-layer courses of brick from kiln car K and deposit them at the intermediate table 28. Such a pickup head is described in detail in US. Letters Pat. No. 3,669,283, issued June 13, I972 and assigned to the assignee of the present application, except that said patent shows a pickup head for lifting courses from only one stack at a time. The present application utilizes a pickup head in which a plurality of gripper pairs lift bricks from one, two, three or any number of stacks simultaneously. As illustrated in FIGS. 1 and 2, eight courses are lifted from kiln car K and transferred simultaneously. The uppermost double-layer course is removed from each stack simultaneously as the first pickup head 24 grips the bricks along opposite sides of each course (against the ends of rows R) and transfers the courses removed following planar reorientation of alternate ones and longitudinal compacting of the rows R in each, and places the courses on the intermediate table 28.

The loaded kiln cars K supporting the stacks are moved along conventional tracks (not shown) to the position beneath one end of frame 10, where the car is halted while a first group of stacks beneath the first pickup head 24 are removed therefrom. Kiln car K is then indexed forwardly for a portion of its length, passing beneath the receiving station whereby the next series of stacks of bricks may be unloaded. After unloading of all stacks on the kiln car, the empty car is moved further forward in the direction of the previously emptied car, and passes eventually from beneath the receiv ing station.

As substantially taught by the previously identified US. Pat. No. 3,669,283, the first pickup head 24 comprises a first gripping means or gripper frame 25 mounted for multi-directional movement above kiln car K at the unloading station by means of carriage 18 as, previously mentioned. Hydraulic cylinder 26 depends from carriage 18, the piston of which is attached to head 24, which in turn includes a preselected number of pivotally movable frames 25 each of which supports a gripper pair. Each gripper pair grips the uppermost double-layer course from one of the stacks when activated. Frames 25 are so connected to the pickup head 24 as to permit horizontal pivotal movement of the frames through an arc of at least 90. In unloading a kiln car K, the first pickup head 24 is lowered onto the uppermost course of each of the stacks to be unloaded, and grippers (not shown) grip the upper course of each stack along opposite ends of the rows, compacting the rows thereof in the direction of their length. The first pickup head 24 is then raised, carriage 18 moved to its second position overlying intermediate table 28, and the grippers caused to release the compacted courses onto the table. While transporting alternate courses between the kiln car and the intermediate table, frames 25 pivot 90 in a horizontal plane so that each course deposited upon the conveyor has its rows R extending in the same direction, notwithstanding the alternating header-stretcher orientation of the courses within the stacks initially upon the kiln car. After unloading the uppermost course from the stacks and depositing them on table 28, first pickup head 24 returns to the unloading position and similarly successively unloads the next course.

Intermediate table 28 is simply some type of flat stationary surface supported by frame 10 or from the floor onto which the bricks are temporarily placed and may, if desired, include a plurality of upstanding guides or walls 29 arranged on the table between the courses placed thereon to prevent toppling of the bricks as they are positioned by the first pickup head 24.

The second pickup head 30 includes a second gripping means 32, to be discussed more fully hereinafter, also supported from carriage 18 at the other end therefor for reciprocal movement in a vertical direction similar to that of first pickup head 24 by means of a hydraulic cylinder 34 or other similar means. As first pickup head 24 is moved from its first position to its second position, the second pickup head 30 is moved from its first position above intermediate table 28 to its second or discharge position overlaying offbearing conveyor 32. Therefore, as the first pickup head 24 is moving one course of bricks to the intermediate table 28, the second pickup head 30 is moving the preceding course of bricks from the intermediate table 28 to the discharge position above offbearing conveyor 38.

Turning now to FIG. 3 for a more detailed illustration of second pickup head 30, a plate is attached to the piston of hydraulic cylinder 34 and thus moves up and down in response thereto. A pair of

side frame members

52, 54 are attached to opposite edges of plate 50 and extend transversely thereto along the length of and above either side of intermediate table 28. Cross braces 56 extend between and connect side frame members 54 and support three activating means in the form of

air cylinders

58, 60, 62 thereon.

As illustrated in FIG. 1 in the embodiment herein described, the bricks are placed on table 28 in two ranks of courses, there being four courses in each rank. Each course in turn includes three rows of brick with eight bricks in each row compacted into side-by-side relationship by the first pickup head. It is then desired to regroup this arrangement of brick into courses having three rows with eleven bricks in each row, and in such an arrangement as illustrated on conveyor 38 in FIG. 1, there will be formed two ranks of courses with three courses in each rank, the outer courses in each rank.

having rows of brick with eleven in each row while the middle courses include rows of bricks with ten in each row. The thought is that the operator can add the extra brick in each row of the middle courses as he is conducting his other operations from spare brick gathered, for example, from the bricks removed from certain courses to form the tyne layers somewhere along conveyor 38 (not shown).

In order to regroup the brick from the arrangement shown on table 28 to the arrangement shown on conveyor 38 in FIG. 1, the second pickup head 30 includes means for sliding selected columns of bricks in said courses one way or the other longitudinally of the

frame members

52, 54. In this regard a series of frames 64a-64f are suspended from side frame members by means of T-hangers 66, and certain of said frames 64b, 64c, and 64e include

upstanding brackets

68, 70, '72 in turn attached to the free end of the pistons of

cylinders

62, 60, 58 respectively. End gripper members .32 are formed as gripper sements 32a-322 as illustrated in FIG. 3, and operatively attached to frames 64af according to any of several well known manners. There are basically three types of gripper segments, one being the type shown by segments 32a, 32f, which grip the ends of rows having eight bricks, a second type 32b, 32e, grip only three brick rows, while the third type 32c, 32d grip five brick rows. Some of the segments, i.e., 32b, 32c and 32e are slidable relative to the other gripper members in response to movement of one of

air cylinders

58, 60, 62 which activate frames 64b, 64c and 64e.

In FIG. 3, the segmented grippers 32a-32f are positioned for picking up on intermediate table 28 as is evident that the grippers are set to pick up four pairs of doublelayer courses (see FIG. 1). After pickup head 30 is lifted,

air cylinders

58, 60 and 62 are activated to slide gripper segment 32b laterally into contact with gripper segment 32a forming a pair of double-layer courses with rows of eleven brick. At the same time gripper segment 32e is slid into engagement with gripper segment 32f forming another pair of double-layer courses having eleven bricks in each row. The two middle gripper segments 32c and 32d are also moved into engagement with each other which then forms a third pair of double-layer courses, however in these courses, there are only bricks in each row, to which another brick will be added as described hereinbefore. The brick are then positioned so as to be set down at the discharge position with one rank of double-layer courses in trays 40 on offbearing conveyor 38 and the other rank of courses deposited on side table 42. As the offbearing conveyor carries the first rank of courses away from the area, the pusher 44 moves the second rank onto succeeding trays 40 on the conveyor 38. The courses as a result of the regrouping are the proper row size for stacking and strapping without the necessity of breaking the courses down into single rows, as has been necessary hereinbefore.

Although the specification describes one illustrative embodiment in which bricks are regrouped from courses of eight in a row to 11 in a row, it is obvious that other combinations of regroupings may be formed by utilizing the apparatus illustrated hereinabove.

Further, although a preferred embodiment has been described and illustrated, it is obvious that certain modifications and improvements might be made to the apparatus and method described hereinabove without departing from the spirit of the invention, the scope of which is to be determined by the following claims.

What is claimed is:

1. Method of transferring brick from a kiln car, on which the bricks are arranged in a plurality of stacks, each having double-layer courses with a first prescribed number of bricks in each row and column, the bricks in each row having spaces therebetween, to a conveyor on which the bricks are arranged in courses having a second different prescribed number of bricks in each row and wherein the bricks in each row are compacted together comprising the steps of:

a. transferring the uppermost course from several of said stacks by simultaneously gripping said rows at the ends thereof, moving the bricks in said rows together, lifting and moving said courses to an intermediate table;

b. gripping the bricks in said courses deposited on said intermediate table on the ends of said columns, lifting said courses and moving some bricks row-wise with respect to others to change the rowwise spacing of the bricks in said courses; and

c. transferring said courses to said conveyor.

2. The method according to claim 1 wherein alternate courses on said kiln car are arranged with the headers facing perpendicular to the headers of the intermediate courses, and wherein step (a) includes pivoting said alternate courses so that the headers of all courses placed on the intermediate table face in the same direction.

Claims

1. Method of transferring brick from a kiln car, on which the bricks are arranged in a plurality of stacks, each having double-layer courses with a first prescribed number of bricks in each row and column, the bricks in each row having spaces therebetween, to a conveyor on which the bricks are arranged in courses having a second different prescribed number of bricks in each row and wherein the bricks in each row are compacted together comprising the steps of: a. transferring the uppermost course from several of said stacks by simultaneously gripping said rows at the ends thereof, moving the bricks in said rows together, lifting and moving said courses to an intermediate table; b. gripping the bricks in said courses deposited on said intermediate table on the ends of said columns, lifting said courses and moving some bricks row-wise with respect to others to change the row-wise spacing of the bricks in said courses; and c. transferring said courses to said conveyor.

2. The method according to claim 1 wherein alternate courses on said kiln car are arranged with the headers facing perpendicular to the headers of the intermediate courses, and wherein step (a) includes pivoting said alternate courses 90* so that the headers of all courses placed on the intermediate table face in the same direction.