WO2007089269A2

WO2007089269A2 - Non-palletized cage handling system and method

Info

Publication number: WO2007089269A2
Application number: PCT/US2006/024867
Authority: WO
Inventors: Daryl Austin; Edward J. Horeth
Original assignee: Matrix Scientific, Llc
Priority date: 2005-06-27
Filing date: 2006-06-27
Publication date: 2007-08-09
Also published as: WO2007089269A3

Abstract

A cage handling system and method for transporting a cage component between a cart and a washing system is provided. The system may include a docking station and an in-feed conveyor. The docking station includes a lift finger that is positioned to directly contact a bottom surface of the cage component. The in-feed conveyor is positioned downstream of the docking station and upstream of the washing system. The docking station transports the cage component from the cart to the in-feed conveyor, and the in-feed conveyor transports the cage component to the washing system so that the cage components can be cleaned. The method includes passing the lift finger through a cut-out defined in the cart, positioning the lift finger in direct contact with the bottom surface of the cage component, transporting the cage component from the cart to the washing system using the docking station and the in-feed conveyor.

Description

NON-PALLETIZED CAGE HANDLING SYSTEM AND METHOD

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 60/694, 177 filed on June 27, 2005.

TECHNICAL FIELD

The present invention relates to a non-palletized cage handling system and method; more particularly, to a system and method that transports laboratory animal cages to a cage washing system so that the cages may be cleaned; and most particularly, to a system and method that includes a docking station and an in-feed conveyor that are capable of transporting the cages between a cart and the washing system without the use of a pallet.

BACKGROUND OF THE INVENTION

A conventional cage system for holding small laboratory animals is typically a three piece assembly having a clear plastic cage bottom, a grill for holding food and water, and a lid that attaches to the bottom and holds the grill in place. A suitable bedding material, such as cedar shavings, may be added to the bottom portion of the cage assembly to absorb animal waste and spilled food.

While in use, the bedding becomes soiled, thereby necessitating the need for frequent cleaning of the cages. The cleaning process requires disassembly of the cage, removal of the soiled bedding from the bottom portion of the cage, washing, and drying the cage elements. In order to start the process of cleaning the cages, the dirty cages are typically stacked on top of one another and placed on a component rack or pallet. The pallets are then arranged on a cart and transported to the cage washing system. Robotic arms are known to assist laboratory personnel with the cleaning process. Therefore, after the cages are transported to the cage washing system, the robotic arms remove the soiled cage bottoms from the pallet, invert the cage bottoms to empty the soiled bedding material, and place the empty/soiled cage bottoms in an appropriate position on a conveyor. Since the pallet may also come into contact with the soiled material, the pallet is also placed on the conveyor by the robots so that they may be cleaned. The conveyor advances the cage bottoms and the pallets through a chamber or tunnel wash system, wherein the cage bottoms and pallets are cleaned by a suitable process, usually involving high pressure streaming water. Furthermore, a drying process is typically accomplished by subjecting the cleaned, yet wet cage bottoms and pallets, to high velocity heated air. The other cage components, such as the grill and lid, may be cleaned in a similar manner.

Upon completion of the cleaning process, an automated device, such as an additional robotic arm (i.e., clean side robot), places the cleaned pallet onto a stationary out-feed conveyor, clean bedding is added to the cages, and the cages are stacked on the clean pallet. Once a sufficient number of cages are stacked on the pallet, the out-feed conveyor is turned on and the pallet is moved to an end of the conveyor to be loaded onto a cart so that the cages may be returned to service. The use of pallets to support the cage components in existing cage washing systems presents a number of drawbacks and deficiencies. For instance, the need to transport the pallets to the washing system, wash the soiled pallets, and the subsequent handling of the pallets on the clean side of the washing system slows down the cage washing process. Therefore using the pallets reduces the number of cages that can be washed within a given period of time. Further, the cost of setting up the cage washing system is increased because of the need to provide for a clean side robot to handle the pallets on the clean side of the washing system. Moreover, the need to handle and wash the pallets increases the operational cost of the washing system.

Accordingly, there exists a need for a cage handling system and method that eliminates the need to handle and wash pallets, thereby increasing the overall efficiency of the cage washing system. In addition, there is a need for a cage handling system and method that reduces the startup and operational costs of existing cage washing systems. The present invention fills these needs as well as other needs.

SUMMARY OF THE INVENTION In order to overcome the above stated problems, the present invention provides a non-palletized cage handling system and method that transports a cage component between a cart and a cage washing system without having to handle and wash a pallet.

The present invention comprises a handling system for transporting at least one cage component between a cart and a washing system. The system includes a clocking station and a first conveyor. The docking station includes at least one lift finger that is positioned to directly contact a bottom surface of the cage component. The first conveyor is positioned between of the docking station and the washing system. The docking station transports the cage component between the cart and the first conveyor, and the first conveyor transports the cage component between the washing system and the docking station.

The docking station may further include a cross-member mounted between a pair of lift posts, wherein the lift posts operate to move the lift finger in a vertical direction relative to a support surface. The docking station may also include at least one outer wheel guide mounted with the lift post to place the cart in proper alignment with the docking station. Further, the cart may include a plurality of stacked cage components arranged in a series of stacks, wherein the docking station includes a number of lift fingers corresponding to the number of cage component stacks, and wherein the first conveyor includes a number of conveyors corresponding to the number of lift fingers on the docking station.

The present invention is also directed to a handling system for transporting at least one cage component to a washing system, the cage component including a bottom surface having a first width. The system includes a cart, a docking station, and an in-feed conveyor positioned downstream of the docking station and upstream of the washing system. The cart has a base with at least two lateral supports defining a cut-out therebetween. The cut-out has a second width that is less than the first width, wherein the cage component is supported on the lateral supports. The docking station includes at least one lift finger having a third width that is less than the second width. The lift finger operates to pass through the cut-out so that the lift finger is positioned in direct contact with the bottom surface of the cage component. The docking station transports the cage component from the cart to the in-feed conveyor, and then the in-feed conveyor transports the cage component to the washing system so that the cage components can be cleaned.

In addition, the base may include a front face having a cut-out defined therein, wherein the front face cut-out has a width equal to the second width, wherein the front face cut-out is aligned with the cut-out defined between the lateral supports.

The present invention also provides a method of transporting at Jeast one cage component to a washing system, the cage component including a bottom surface having a first width. The method includes providing a cart having a base, the base having at least two lateral supports defining a cut-out therebetween, the cut-out having a second width that is less than the first width. The method also provides a docking station including at least one lift finger, the lift finger having a third width that is less than the second width. The method further provides an in-feed conveyor positioned downstream of the docking station and upstream of the washing system, supporting the cage component on the lateral supports, passing the lift finger through the cut-out, positioning the lift finger in direct contact with the bottom surface of the cage component, transporting the cage component from the cart to the in-feed conveyor using the docking station, and transporting the cage component to the washing system using the in-feed conveyor so that the cage components can be cleaned.

BRIEF DESCRIPTION OF THE DRAWINGS The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become appreciated and be more readily understood by reference to the following detailed description of one embodiment of the invention in conjunction with the accompanying drawings, wherein: FIG. 1 is a flow diagram of an automated cage washing system;

FIG. 2 is a perspective view of a first embodiment of an automated cage handling apparatus on a soil side of the washing system;

FIG. 3 is a perspective view of an automated cage handling apparatus similar to the one shown in FIG. 2 on a clean side of the washing system; FIG. 4 is a perspective view of the automated cage handling apparatus shown in FIG. 2;

FIG. 5 is a perspective view of a second embodiment of an automated cage handling apparatus;

FIG. 6 is a plan view of the automated cage handling apparatus shown in FIG. 5;

FIG. 7 is a side view of the automated cage handling apparatus shown in FIG. 5;

FIG. 8 is a front view of the automated cage handling apparatus shown in FIG. 5; FlG. 9 is a perspective view of the automated cage handling apparatus shown in FIG. 5 being used on the clean side of two side-by-side washing systems;

FIG. 10 is a perspective view of a cart suitable for use as part of a non- palletized cage handling system which operates to load the cages on the washing system;

FIG. 11 is a perspective view of a non-palletized cage handling system in accordance with the present invention, which operates to load the cages on the washing system; FIG. 12 is a perspective view of the cage handling apparatus shown in

FIG. 11 in a lift mode;

FIG. 13 is a perspective view of the cage handling apparatus shown in FIG. 11 in a loading mode; and

FIG. 14 is a perspective view of the cage handling apparatus shown in FIG. 11 showing the relative widths of a cut out portion of a cart base, a cage bottom, and a lifting finger on a docking station.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to the drawings in detail, and specifically to FIG. 1 , a system for cleaning animal cages is shown and is designated as reference numeral 10. The system utilizes a pair of loading/unloading robots, referred to hereinafter as a soil side robot 1 1 , and a clean side robot 12. Additionally, the system also utilizes an optical arranger robot 19. Using robots in the washing system 10 is beneficial in that they limit human exposure to the soiled cages, and reduce the repetitive steps associated with the loading and unloading the cage components.

With additional reference to FIG. 2, one or more soiled cage bottoms 16a arrive at the cleaning area on a component cart 13, or any other suitable device for transporting a plurality of soiled bottoms. Cart 13 further comprises at least one soiled component rack or pallet 14a that operates to hold a plurality of soiled cage bottoms 16a. Pallet 14a holding one or more soiled cage bottoms 16a is removed from cart 13 and attached to an in-feed conveyor 22. Once pallet 14a is securely placed on in-feed conveyor 22, the pallet 14a holding soiled cage bottoms 16a advances toward soil side robot 11. Soil side robot 11 grasps one or more cage bottoms 16a from pallet 14a, inverts cage bottoms 16a over a soiled bedding receptacle 28 (FIG. 1 and 9), or any device suitable for receiving the soiled bedding from cage bottoms 16a, and places cage bottoms 16a in an inverted fashion (open end facing down) on a tunnel washer conveyor 24 which passes through a tunnel wash system 15, such as, for example, a continuous driven belt tunnel washer. Furthermore, soil side robot 11 also grasps, inverts, and places pallets 14a on tunnel washer conveyor 24 so they may be cleaned by tunnel wash system 15. Once an appropriate number of soiled cage bottoms 16a and pallets

14a are received into tunnel washing system 15, cage bottoms 16a and pallets 14a are washed and dried by an appropriate means. As best seen in FIGS. 1 and 3, upon completion of the wash/dry process in tunnel washing system 15, clean cage bottoms 16b and pallets 14b advance on tunnel washer conveyor 24, toward a clean bedding dispenser 18, which may be a stand-alone device or conveyorized. Prior to reaching conveyorized clean bedding dispenser 18, pallets 14b are removed from tunnel washer conveyor 24 by clean side robot 12 and placed either in a holding location or location that is suitable to receive clean cage bottoms 16b, such as an out-feed conveyor 56. Cleaned cage bottoms 16b drop from tunnel washer conveyor 24 to an inline conveyor 17. Inline conveyor 17 further comprises a receiving end 26 and a dispatch end 27. The drop from tunnel washer conveyor 24 to inline conveyor 17 causes clean cage bottoms 16b to invert (open end facing up) when clean cage bottoms 16b enter receiving end 26 of inline conveyor 17. The reorientation of clean cage bottoms 16b enables cage bottoms 16b to receive clean bedding from clean conveyorized bedding dispenser 18. While an inline tunnel type conveyorized bedding dispenser is described, any suitable bedding dispenser may be used.

The turbulent conditions of the tunnel washing process, as well as the reorientation of cage bottoms 16b onto inline conveyor 17, cause cage bottoms 16b to become skewed or disoriented. System 10 further comprises an optical arranger robot system for detecting skewed or disoriented cage bottoms 16b on inline conveyor 17, and placing cage bottoms 16b in an orderly arrangement upon a cage bottom re-grip station 20. Additionally, the optical arranger robot system can detect and reorient various cage bottoms, such as wire baskets used to transport water bottles, or serve to dispense bedding into cage bottoms.

In operation, as cage bottoms 16b with clean bedding progress toward dispatch end 27 of inline conveyor 17, they pass below an optical eye 25. Optical eye 25 is mounted on an elevated stationary structure 23 above inline conveyor 17. Optical eye 25 is aptly positioned to view a predetermined area of inline conveyor 17. While FIG. 3 shows optical eye 25 mounted on an elevated stationary structure 23, optical eye 25 may be mounted upon any suitable structure, such as, for example, optical arranger robot 19. Specifically, optical eye 25 transmits a video signal, presenting the position of the skewed cage bottoms to an encoding device (not shown). The encoding device serves to convert the video signals received from optical eye 25 into command signals suitable for guiding optical arranger robot 19.

Optical arranger robot 19 may be mounted adjacent to dispatch end 27 of inline conveyor 17 and cage bottom re-grip station 20 as illustrated in FIG. 3, or in any suitable position. As skewed cage bottoms progress toward optical arranger robot 19, optical arranger robot 19 receives a command signal from the encoding device (not shown), providing the position of the cage bottoms, and enabling the optical arranger robot 19 to grasp the cage bottoms and place them on cage bottom re-grip station 20. From cage bottom re-grip station 20, cage bottoms 16b are lifted by clean side robot 12, and stacked on clean pallet 14b so that cage bottoms 16b may be returned to service. Alternatively, clean side robot 12 may transfer cage bottoms 16b from re-grip station 20 directly to out-feed conveyor 56. While the description above describes the cleaning of cage bottoms

16b, the system 10 may be used for cleaning various other cage components, such as grills for holding food and water and cage lids.

Referring now to FIG. 4, a perspective view of a loading/unloading robot is shown and is designated as reference numeral 60. Robot 60 comprises a stationary mounting base or base rail 30 having an upper side 31 and a lower side 32. Lower side 32 of stationary mounting base 30 is generally in communication with the floor or support surface. Upper side 31 of stationary mounting base 30 serves as a track or guideway 35 to allow an arm assembly 40 to move along a horizontal axis (Y direction). Lower side 32 of stationary mounting base 30 further comprises a plurality of leveling screw assemblies 34 and leveling screws 33, thereby providing a means of assuring the stationary mounting base 30 is in stable communication with the floor. While this particular embodiment illustrates the stationary mounting base 30 positioned for mounting to the floor, it is understood that the stationary mounting base 30 may be mounted to a wall, ceiling, or in a pit, if so desired. Additionally, stationary mounting base 30 further comprises a first side wall 36 and a second side wall 37, each sidewall terminating at a respective upper guide 38 and 39. Upper guides 38 and 39 are substantially perpendicular to sidewalls 36 and 37, respectively, and extend outward therefrom. Arm assembly 40 comprises an assembly carriage plate 41 , a vertical rail 42, and an arm section 43. Carriage plate 41 serves as the pedestal for arm assembly 40, and is in slidable communication with stationary mounting base 30. More particularly, carriage plate 41 further comprises a carriage plate upper surface 44 and a carriage plate lower surface 45. Carriage plate lower surface 45 has a plurality of pillow blocks 46 extending downward therefrom. Pillow blocks 46 each comprise a pillow block inner wall 47 having a groove 48 and bearing (not shown). Grooves 48 are adapted to receive upper guides 38 and 39, so that carriage plate 41 is in slidable communication with the stationary mounting base 30. Furthermore, carriage plate 41 comprises a means for receiving the pneumatic and power lines necessary to control arm assembly 40. A flexible cable tray 29 may be used to provide the electronic and pneumatic connections needed to operate arm assembly 40.

In operating robot 60, carriage plate 41 may be propelled along stationary mounting base 30, in the Y direction, via a rack and pinion system (not shown). The rack runs the length of track 35 between sidewalls 36 and 37, and below carriage plate 41. Lower surface 45 of carriage plate 41 further comprises a servo motor with a pinion (not shown), wherein the pinion engages the rack to propel carriage plate 41 along stationary mounting base 30. Carriage plate 41 further comprises a carriage plate turret assembly

51. Vertical rail 42 extends in the Z direction, wherein vertical rail 42 and turret plate 51 are rotatable about said carriage plate 41. Additionally, vertical rail 42 serves to provide vertical lift for arm section 43.

Arm section 43 comprises a vertical coupler 54, having a vertical coupler turret 55 attached thereto. Extending outward from vertical coupler turret 55 is a grasping arm 52. Grasping arm 52 comprises a rectangular frame 53 having a pair of padded gripper clamping bars 49 and 50 and pneumatic cylinders (not shown) for opening and closing padded gripper clamping bars 49 and 50. Upon actuation of the pneumatic cylinders (not shown), one or more cage bottoms 16a, 16b or wire baskets may be clamped between padded gripper clamping bars 49 and 50. Additionally, when robot 60 is used as soil side robot 11 , vertical coupler turret 55 serves to rotate grasping arm 52 in the B direction, providing a means for removing soiled bedding from cage 16a, as well as reorientation of cages 16a prior to placement on tunnel washer conveyor 24. As best seen in FIGS. 5-8, an automated cage handling apparatus or robot is provided and is designated with reference numeral 100. Robot 100 is an alternative embodiment to robot 60 and may be used as soil side robot 11 or clean side robot 12. As previously mentioned, some cage washing facilities produce a high volume of soiled cages that need to be cleaned in an efficient manner. Thus, it may be necessary to use two cage washing systems to meet the high demand. It is not uncommon for a cage washing facility to have limited floor space. Given the limited space in these types of facilities, cage washing systems are typically positioned next to each other in a side-by-side relationship. While two robots 60 may be positioned side-by-side to service the two separate washing systems, the limited floor space in cleaning facilities may make it problematic to find the space to position two robots 60 next to each other. In general, as best seen in FIG. 9, robot 100 may include two arm assemblies 102a, 102b that operate independently of one another to service two or more cage washing systems at the same time while minimizing the amount of floor space used in the cleaning facility. It will also be understood that robot 100 could be used with only one arm assembly until the need arises to add a second arm assembly if the cage washing demand arises.

As best seen in FIGS. 5-8, arm assemblies 102a, 102b are slidably coupled with a base rail 104, which in turn rests on a support surface 106. In particular, base rail 104 may include a top wall 108, a bottom wall 1 10 and a pair of opposing side walls 1 12, 1 14. Side walls 112, 114 may be parallel with one another and positioned generally perpendicular with respect to support surface 106. Two posts 116 extend from bottom wall 1 10 of base rail 104 and are coupled with a pair of support feet 118 and lateral braces 120. Each support foot 118 is adapted to contact support surface 106 and stabilize robot 100. In addition, one or more leveling screws 122 may be adjustably connected to support feet 118 to assure that base rail 104 is in stable communication with support surface 106.

Base rail 104 may include one or more vertical tracks 124 that allow arm assemblies 102a, 102b to be slidably coupled with opposing side walls 112, 1 14 of base rail 104. For example, tracks 124 may include a plurality of guides 126 that are coupled with base rail 104 and extend longitudinally along a portion of base rail 104.

Arm assemblies 102a, 102b include an assembly carriage plate 128, a vertical rail or post 130, and an arm section 132. Specifically, each carriage plate 128 extends from opposite side walls 112, 114 and serves as the base for each arm assembly 102a, 102b. Carriage plate 128 is coupled with track 124 so that it is in slidable communication with base rail 104. More particularly, carriage plate 128 may include a pair of channels that are adapted to receive guides 126 of track 124. In operating robot 100, carriage plate 128 may be propelled along base rail 104, in the Y direction, via a rack and pinion system (not shown). The rack runs the length of track 124 and is positioned between track 124 and carriage plate 128. Carriage plate 128 may further comprise a servo motor with a pinion (not shown), wherein the pinion engages the track 124 to propel carriage plate 128 along base rail 104. One or more stops 136 are positioned adjacent to guides 126 and are adapted to engage a side surface 138 of carriage plate 128 to prevent carriage plate 128 from sliding off track 124.

As best seen in FIGS. 6-8, vertical rail 130 includes a side surface 140 that may be mounted to a front face 142 of carriage plate 128. Therefore, as carriage plate 128 slides in the Y direction along base rail 104, vertical rail 130 also slides along in the Y direction with carriage plate 128. It will be understood that side surface 140 of vertical rail 130 may have a circular, rectangular, square or any other cross-sectional shape and be directly slidably coupled with base rail 104. It will also be understood and appreciated that a side surface 140 of post 130 may be directly coupled with base rail 104 so that post 130 is slidably coupled with base rail 104, instead of using carriage plate 128 to couple base rail 104 with post 130.

With particular reference to FIGS. 7 and 8, vertical rail 130 may be oriented generally perpendicular to support surface 106. In addition, a track 144 may be mounted on a side surface 140 of vertical rail 130 to slidably connect to arm section 132 thereto so that arm section 132 may move in the Z direction. As best seen in FIG. 7, vertical rail 130 may extend in a perpendicular direction relative to a longitudinal axis of base rail 104.

As best seen in FIGS. 5-8, arm section 132 includes a vertical coupler 146, a turret assembly 148, and a cage gripping mechanism 150. Vertical coupler 146 has a rail plate 152 that is adapted to be slidably connected to track 144 on vertical rail 130, which allows arm section 132 to move in the Z direction. As best seen in FIGS. 5 and 8, vertical rail 130 has a stop 154 mounted at an upper portion thereof to prevent arm section 132 from sliding off the top of vertical rail 130. A bottom edge 156 of rail plate 152 is adapted to engage carriage plate 128 to prevent arm section 132 from sliding off the bottom of vertical rail 130.

As best seen in FIGS. 5-8, turret assembly 148 is mounted to vertical coupler 146 and is coupled with cage gripping mechanism 150 to allow gripping mechanism 150 to rotate in the B direction. Thus, gripping mechanism 150 is rotated about an axis that is perpendicular to side walls 112, 1 14. When robot 100 is used as soil side robot 11 , turret 148 is used to rotate frame 60 in the B direction to assist in removing soiled bedding from cage bottoms 16a, as well as reorientation of cages 16a prior to placement on tunnel washer conveyor 24.

Gripping mechanism 150 operates to handle the cage bottoms 16a, 16b in the cage washing system 10 and reduces the need for humans to handle the cage bottoms 16a, 16b. Gripping mechanism 150 may extend generally perpendicular to side wall 1 12, 114 of base rail 104 and includes a shaft 158 that connects turret assembly 148 with a cage holding frame 160. Shaft 158 may extend in a direction that is generally perpendicular to side walls 112, 1 14 and generally parallel with support surface 106.

As best seen in FIGS. 5 and 6, a plurality of clamping mechanisms or padded gripper bars 162 are movably mounted to an inside mounting surface 164 of holding frame 160 and may be moved toward and away from an opposing gripping surface 166 to hold cage bottoms 16a, 16b within frame 160. Clamping mechanisms 162 may be mounted to inside mounting surface 164 by one or more pneumatic cylinders 167, and operate to move clamping mechanisms 162 toward and away from opposing gripping surface 166. As best seen in FIG. 9, robot 100 is positioned between two cage washing systems 10a, 10b and is operating as soil side robot 11. Arm assemblies 102a, 102b may be controlled by a main control unit 168 or a local controller 170 to operate as an automated cage handling apparatus. Robot 100 may be programmed so that arm assemblies 102a, 102b independently service cage washing systems 10a, 10b. The use of dual independent arm assemblies 102a, 102b makes the process of washing cages using two cage washing systems 10a, 10b faster and more efficient than if a single stationary arm assembly were used to service both washing systems 10a, 10b. Moreover, utilizing a single base rail 104 to support two arm assemblies 102a, 102b is an efficient use of floor space in a washing facility. While FIG. 9 shows robot 100 being used as soil side robot 11 , it will be understood that robot may also be used as clean side robot 12.

Some parts of the operation of the clean side of cage washing system 10 shown in FIG. 9 are similar to the operation shown in FIG. 2. However, the following discussion is a description of a non-palletized or palletless cage handling system 178 in accordance with the present invention that transports the cage bottoms 16a to washing system 10 without using pallets 14. This eliminates the need to wash and subsequently handle pallets 14 on the soil side and the clean side of washing system 10 using soil side robot 1 1 and clean side robot 12.

As best seen in FIG. 10, a component cart 179 may include a base frame 180 movably supported on support surface 106 by a plurality of casters or wheels 182. Base 180 includes side edges 183 and a rear edge 185, wherein a pair of side sections 192 extends upwardly from side edges 183, and wherein a rear section 193 extends upwardly from rear edge 185. Base 180 and side sections 192 define an opening 190 that allow cage bottoms 16 to be inserted and removed from cart 179.

In general, with reference to FIGS. 9, 10, and 11 , base 180 is adapted to support one or more cage bottoms 16a, which may be arranged in stacks. Base 180 is coupled with and supported by side sections 192 and rear section 193. Base 180 may include a front surface 186 and a plurality of lateral supports 187a, 187b, 187c, 187d, and 187e that extend from front surface 186 to rear edge 185. Adjacent lateral supports 187a-187e are spaced apart from one another to define a cut-out 184 that has a width Wi that is less than a width W₂ of bottom surface 208 of cage bottoms 16a. Thus, opposing edges of cage bottom 16a are supported by adjacent lateral supports 187a- 187e wherein cut-out 184 is positioned beneath a central portion of bottom surface 208 of cage bottom 16a thereby providing an exposed lifting surface. Furthermore, a cut-out 191 may also be defined in front surface 186 of base 180 and positioned in conjunction with cut-out 184. Cut-out 191 allows palletless handling apparatus 178 to be positioned underneath bottom surface 208 of cage bottoms 16a and aligned with the exposed lifting surface of bottom surface 208 of cage bottom 16a adjacent to cut-out 184. It will be understood that cut-out 191 may have the same width W₁ as cut-out 184 defined by adjacent lateral supports 187a-187e.

Palletless cage handling apparatus 178 includes a docking station 194 and an in-feed conveyor 196. Docking station 194 is positioned upstream of in-feed conveyor 196 and operates to transport cage bottoms 16a from cart 179 to in-feed conveyor 196. Docking station 194 includes a cross-member 198 positioned between a pair of lift posts 200. One or more lift fingers 202 are supported by cross-member 198, each including a conveyor belt 204. Further, it will be understood that lift fingers 202 may be parallel with one another. Lift posts 200 may operate to lift cross-member 198 and lift fingers 202 from support surface 106 to the same level as in-feed conveyor 196 using hydraulic, pneumatic or another type of lifting mechanism. Each of lift fingers 202 has a width W₃ that is less than the widths W₄ of cut-outs 191 so that lift finger 202 may pass through cut-outs 191 , be positioned underneath the exposed lifting surface of cage bottom 16a, and lift cage bottom 16a to a desired position. Docking station 194 also includes a pair of outer guides 210 that may be aligned with casters 182 on cart 179 to properly align cart 179 with docking station 194. Outer guides 210 may be coupled with lift posts 200 and are positioned parallel with lift fingers 202.

In-feed conveyor 196 is positioned downstream of docking station 194 and operates to transport cage bottoms 16a from docking station 194 to soil side robot 11 (i.e., robot 100). In-feed conveyor 196 may include a corresponding number of independent conveyors 212 as there are lift fingers 202 in docking station 194. Conveyors 212 are preferably aligned with lift fingers 202 in docking station 194 so that cage bottoms 16a make a smooth transition from docking station 194 to in-feed conveyor 196. Additionally, in- feed conveyor 196 may include retention walls 214 to reduce the chance that a cage component 16a will become misaligned on the conveyor 212. In-feed conveyor 196 is supported by a base 216 that is at a height that will allow robot 100 to easily and efficiently grasp and move cage bottoms 16a to tunnel wash conveyor 24. The operation of the palletless cage handling apparatus is shown in FIGS. 11-14. First, as best seen in FIG. 1 1 , one or more cage bottoms 16a are loaded into cart 179 so that the side edges of cage bottoms 16a are supported by lateral supports 187a-187e, and so cut-out 184 is positioned underneath a portion of bottom surface 208. Cart 179 is then moved toward docking station 194 so that casters 182 are placed in outer guides 210. As cart 179 is slid toward docking station 194, lift fingers 202 are inserted within cut-outs 191 and aligned with cage bottoms 16a underneath their bottom surface 208 as best seen in FIG. 12. Cart 179 is pushed toward docking station 194 until cart 179 comes into contact with lift posts 200. As best seen in FIG. 12, once cart 179 is positioned in contact with docking station 194, lift fingers 202 move through cut-outs 191 so that they come into contact with bottom surface 208, and lift fingers 202 lift cage bottoms 16a to the same level as in-feed conveyor 196. Since the cage bottoms 16a are now fully supported by lift fingers 202, cart 179 may be removed and taken away to retrieve additional soiled cage bottoms 16a. As best seen in FIG. 14, the conveyors on each of the lift fingers 202 may then be turned on to move and load cage bottoms 16a onto the corresponding conveyor on in-feed conveyor 196 toward soil side robot 11. It will be understood and appreciated that each of the lift fingers 202 may operate at the same speed or may operate independently of one another.

As best seen in FIG. 9, soil side robot 11 , which is shown as robot 100, grasps one or more cage bottoms 16a from in-feed conveyor 196, inverts cage bottoms 16a over soiled bedding receptacle 28, or any device suitable for receiving the soiled bedding from cage bottoms 16a, and places cage bottoms 16a in an inverted fashion (open end facing down) on tunnel washer conveyor 24 leading to a tunnel wash system 15, such as, for example, a continuous driven belt tunnel washer. Once an appropriate number of soiled cage bottoms 16a are received into tunnel washing system 15, cage bottoms 16a are washed and dried by an appropriate means.

As best seen in FIG. 3, upon completion of the wash/dry process in tunnel washing system 15, clean cage bottoms 16b advance on tunnel washer conveyor 24, toward clean conveyorized bedding dispenser 18. Since there are no pallets that need to be washed or dried using palletless cage handling system 178, pallets 14b do not need to be removed from tunnel washer conveyor 24 by clean side robot 12 and do not need to be placed either in a holding location or location that is suitable to receive clean cage bottoms 16b, such as an out-feed conveyor 56. As such, the clean side robot 12 is not needed in the cage washing system shown in FIG. 9 as described in more detail below.

With continued reference to FIG. 3, cleaned cage bottoms 16b drop from tunnel washer conveyor 24 to an inline conveyor 17. Inline conveyor 17 further comprises a receiving end 26 and a dispatch end 27. The drop from tunnel washer conveyor 24 to inline conveyor 17 causes clean cage bottoms 16b to invert (open end facing up) when clean cage bottoms 16b enter receiving end 26 of inline conveyor 17. The reorientation of clean cage bottoms 16b enables cage bottoms 16b to receive clean bedding from clean conveyorized bedding dispenser 18. While an inline tunnel type conveyorized bedding dispenser is described, any suitable bedding dispenser may be used. The turbulent conditions of the tunnel washing process, as well as the reorientation of cage bottoms 16b onto inline conveyor 17, cause cage bottoms 16b to become skewed or disoriented. System 10 further comprises an optical arranger robot system for detecting skewed or disoriented cage bottoms 16b on inline conveyor 17, and placing cage bottoms 16b in an orderly arrangement upon a cage bottom re-grip station 20, directly on a cart, or on out-feed conveyor 56. Additionally, the optical arranger robot system can detect and reorient various cage components, such as wire baskets used to transport water bottles, or serve to dispense bedding into cage bottoms. Since cage bottoms 16a are placed on cart 179 without being supported by pallets 14, and given that lift fingers 202 have the ability to lift and transport a stack of cages directly from cart 179 to wash system 10, the need to remove pallets 14 from the cart and subsequently washing them is eliminated. Thus, the cage washing efficiency is increased and operational costs of the system are reduced. Furthermore, as described in more detail below, the use of the palletless handling apparatus and method can eliminate the need for clean side robot 12 since pallets 14 no longer need to be handled on the clean side of the cage washing system. This further reduces the startup and operational costs of the cage washing system. It will also be understood that palletless cage handling system 178 may be used on the clean side of the washing system 10. For instance, palletless cage handling system 178 may be used in place of out-feed conveyor 56 (FIG. 3). In this case, the optical arranger robot system would operate to place cage bottoms 16b on an out-feed conveyor similar to the one identified with reference numeral 196 (FIG. 10). The out-feed conveyor would then transport cage bottoms 16b to a docketing station similar to the docking station identified with reference numeral 194. The palletless cage handling system on the clean side would operate substantially the same as the system 178 used on the soil side of the washing system 10, but it would work in reverse order so that cage bottoms 16b are transported from inline conveyor 17 to an out-feed conveyor, then to a docking station, which then loads cage bottoms 16b onto a cart without the use of a pallet. While this arrangement includes the use of an optical arranger robot, it does not require the use of a clean side robot 12, which reduces the start-up and operational cost of washing system 10.

Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein. All features disclosed in the specification, including the claims, abstract, and drawings, and all the steps in any method or process disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. Each feature disclosed in the specification, including the claims, abstract, and drawings, can be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

Claims

CLAIMSWhat is claimed is:

1. A handling system for transporting at least one cage component between a cart and a washing system, the system comprising: a docking station including at least one lift finger, said lift finger is positioned to directly contact a bottom surface of the cage component; and a first conveyor positioned between said docking station and the washing system, wherein said docking station transports the cage component between the cart and said first conveyor, and wherein said first conveyor transports the cage component between the washing system and said docking station.

2. A handling system in accordance with claim 1 , wherein said docking station includes a pair of lift posts coupled with said lift finger, wherein said lift posts operate to move said lift finger in a vertical direction relative to a support surface.

3. A handling system in accordance with claim 2, wherein said docking station includes a cross-member mounted between said lift posts and coupled with said lift finger.

4. A handling system in accordance with claim 2, wherein said docking station includes at least one outer wheel guide mounted with said lift post.

5. A handling system in accordance with claim 1 , wherein said lift finger includes a second conveyor that transports the cage component between the cart and said first conveyor.

6. A handling system in accordance with claim 1 , wherein the cart includes a plurality of stacked cage components arranged in a series of stacks, and wherein said docking station includes a number of lift fingers corresponding to the number of cage component stacks.

7. A handling system in accordance with claim 6, wherein said first conveyor includes a number of conveyors corresponding to the number of said lift fingers on said docking station.

8. A handling system for transporting at least one cage component to a washing system, the cage component including a bottom surface having a first width, the system comprising: a cart having a base, said base having at least two lateral supports defining a cut-out therebetween, said cut-out having a second width that is less than the first width; a docking station including at least one lift finger, said lift finger having a third width that is less than said second width; and an in-feed conveyor positioned downstream of said docking station and upstream of the washing system, wherein the cage component is supported on said lateral supports, wherein said lift finger operates to pass through said cut-out so that said lift finger is positioned in direct contact with the bottom surface of the cage component, wherein said docking station transports the cage component from the cart to said in-feed conveyor, and wherein said in- feed conveyor transports the cage component to the washing system so that the cage components can be cleaned.

9. A handling system in accordance with claim 8, wherein said base includes a front face having a cut-out defined therein, wherein said front face cut-out has a width equal to said second width, wherein said front face cut-out is aligned with said cut-out defined by said lateral supports.

10. A handling system in accordance with claim 8, wherein said docking station includes a pair of lift posts coupled with said lift finger, wherein said lift posts operate to move said lift finger in a vertical direction relative to a support surface.

11. A handling system in accordance with claim 10, wherein said docking station includes a cross-member mounted between said lift posts and coupled with said lift finger.

12. A handling system in accordance with claim 10, wherein said docking station includes at least one outer wheel guide mounted with said lift post.

13. A handling system in accordance with claim 8, wherein said lift finger includes a conveyor that transports the cage component from said cart to the in-feed conveyor.

14. A method of transporting at least one cage component to a washing system, the cage component including a bottom surface having a first width, the method comprising: providing a cart having a base, said base having at least two lateral supports defining a cut-out therebetween, said cut-out having a second width that is less than the first width; providing a docking station including at least one lift finger, said lift finger having a third width that is less than said second width; providing an in-feed conveyor positioned downstream of said docking station and upstream of the washing system; supporting the cage component on said lateral supports; passing said lift finger through said cut-out; positioning said lift finger in direct contact with the bottom surface of the cage component; transporting the cage component from the cart to said in-feed conveyor using said docking station; and transporting the cage component to the washing system using the in- feed conveyor so that the cage components can be cleaned.

15. A method in accordance with claim 14, wherein said lift finger is lifted vertically relative to a support surface after said lift finger is placed in contact with the bottom surface of the cage component.

16. A method in accordance with claim 15, wherein said lift finger is lifted vertically to the same height as said in-feed conveyor.

17. A method in accordance with claim 14, wherein said docking station transports the cage components to said in-feed conveyor using a conveyor.