WO2025015376A1

WO2025015376A1 - An apparatus and method for unpacking a shipping container

Info

Publication number: WO2025015376A1
Application number: PCT/AU2024/050760
Authority: WO
Inventors: Corey Carl; Cameron Davies
Original assignee: Ygcc Holdings Pty Ltd
Current assignee: Ygcc Holdings Pty Ltd
Priority date: 2023-07-17
Filing date: 2024-07-16
Publication date: 2025-01-23
Anticipated expiration: 2026-01-17

Abstract

The present invention relates to an apparatus and method for unpacking a shipping container. In one form, the apparatus includes: an elongate base frame including a first end having a pallet inlet and a pallet outlet arranged above the pallet inlet and an opposed second end configured to be located adjacent an opening to the shipping container and having a pallet loading section, said base frame defining a pallet transfer pathway extending between the pallet inlet and the pallet outlet via the pallet loading section; and a lifting mechanism operatively associated with the second end of the base frame for lifting a pallet received via the pallet inlet to the pallet loading section.

Description

AN APPARATUS AND METHOD FOR UNPACKING A SHIPPING CONTAINER

TECHNICAL FIELD

[0001 ] The present invention relates to an apparatus and method for unpacking a shipping container, particularly for enhancing the productivity of a container unpacking team.

BACKGROUND

[0002] Shipping containers are widely used to transport cargo. Usually, the cargo includes goods packed in cartons, boxes or the like, which are stacked atop one another in a container. Typically, a container is packed without any extraneous material, such as, pallets and the like, so as to maximise available space. This is commonly referred to as “loose stacking” or “loose stacked”.

[0003] The unpacking of cartons packed in shipping container often requires the cartons to be placed atop pallets for further transportation away from the location where the shipping container is unpacked. This can be a time consuming and laborious task, typically involving a manual labour force manually carrying each carton or box to a pallet located partially within, or outside, the shipping container. The labour-intensive nature of this process can lead to fatigue, injuries and occupational health risks.

[0004] Advancements in automation and technology have introduced new opportunities to enhance efficiency, reduce labour costs, and improve safety in the container unpacking process. Automation solutions, such as, e.g., robotic arms, conveyor systems, and Al-driven sorting algorithms, are gradually being adopted to address similar challenges faced in related industries.

[0005] However, fully automated solutions require a significant upfront investment, particularly in the purchase and installation of automation equipment. Additionally, further expenses are incurred in facility modifications and integration with existing infrastructure and systems. Moreover, fully automated unpacking systems require regular maintenance, calibration, and repair to ensure optimal performance, resulting in downtime and increased costs.

[0006] Apart from the implementation and maintenance costs, automated unpacking systems are also limited in their specific application. For example, adapting an automated system to handle different types of containers or changing other operational requirements requires costly modifications and further downtime.

[0007] Accordingly, for now and the foreseeable future, the applicant foresees that automated solutions do not have the capacity to be more cost effective and productive than human involvement in the process.

[0008] However, there is a need to enhance the productivity of current manual labour forces through an engineered solution at a fraction of the cost of a fully automated system.

[0009] It will be clearly understood that, if a prior art publication is referred to herein, this reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country.

SUMMARY OF INVENTION

[0010] Embodiments of the present invention provide an apparatus and method of use for unpacking a shipping container, which may at least partially address one or more of the problems or deficiencies mentioned above or which may provide the public with a useful or commercial choice.

[0011 ] According to a first aspect of the present invention, there is provided an apparatus for use in unpacking a shipping container including: an elongate base frame including a first end having a pallet inlet and a pallet outlet arranged above the pallet inlet and an opposed second end configured to be located at least adjacent an opening to the shipping container and having a pallet loading section, said base frame defining a pallet transfer pathway extending between the pallet inlet and the pallet outlet via the pallet loading section; and a lifting mechanism operatively associated with the second end of the base frame for lifting a pallet received via the pallet inlet to the pallet loading section.

[0012] Advantageously, the present invention provides an apparatus and method for the efficient unpacking of shipping containers onto pallets with a manual labour force while minimise contact with wheeled material handling equipment and the associated safety risks. The apparatus and method offer a convenient approach to maximise the utilisation of the human workforce through an engineered solution, ensuring efficiency and safety at a relatively low cost compared to automated solutions. Additionally, clear specifications around the speed of the stock flow and pallet loading allows human operators to provide pallet predictability to customers in the supply chain, thereby helping manage and maximise stock flow.

[0013] As indicated, the apparatus of the present invention is for use in the efficient unpacking of goods loose stacked in a shipping container. It will therefore be convenient to hereinafter describe the present invention with reference to this example application. However, a person skilled in the art will appreciate that the apparatus of the present invention is capable of broader applications and may be used in any instance where goods needs to be efficiently unpacked atop a pallet, such as, e.g., in warehouses and distribution centres or in the unloading of goods from other transit container and/or vehicles.

[0014] Generally, a shipping container, or freight container, is a reusable transport and storage unit for moving products between locations. The container typically has the shape of a rectangular prism defined by a base, an opposed top wall, opposed end walls and opposed side walls extending longitudinally between the opposed end walls. The container is typically formed from corrugated steel and is usually formed to standardized dimensions.

[0015] Conveniently, shipping containers are designed to be intermodal, i.e., moved from one mode of transport to another without unloading and reloading, e.g., shipping, truck and train.

[0016] Each container includes at least one opening through which the container can be loaded or unloaded. Usually, the at least one opening is defined by a pair of hinged doors defining at least one of the end walls or a part of a side wall of the container.

[0017] As indicated, the apparatus includes a base frame to support and convey the pallet inlet, the pallet outlet, the pallet loading section and the lifting mechanism relative to the opening of a shipping container.

[0018] The base frame may be of any suitable size, shape and construction and may be formed from any suitable material or materials.

[0019] Generally, the base frame may be formed from metal, preferably steel or aluminium.

[0020] In some embodiments, the base frame may be circular, or oval-shaped.

[0021 ] In other embodiments, the base frame may be in the shape of a triangle, square, rectangle, pentagon, hexagon or octagon, for example.

[0022] In preferred embodiments, the base frame may have a rectangular shape defined by the first end, the second end and a pair of opposed sides extending therebetween, preferably longitudinally.

[0023] Preferably, the base frame may define two working levels, i.e., a lower level on which the pallet inlet may be located and an upper level on which the pallet outlet and the pallet loading section may be located. The lifting mechanism may traverse the lower level and the upper level.

[0024] The base frame may be formed from two or more frame members joined together.

[0025] For example, in some embodiments the base frame may include at least a pair of longitudinally extending side frame members extending between the first and second ends. The pair of longitudinally extending side frame members may define the opposed sides of the base frame. The pair of side frame members may be joined together by one or more transversely extending cross frame members. The respective outermost cross frame members may define the first and second ends. [0026] In other embodiments, the base frame may include an upper pair of opposed longitudinally extending side frame members extending between the first and second ends and a lower pair of opposed longitudinally extending side frame members extending between the first and second ends. Each pair of longitudinally extending side frame members may be joined together by one or more transversely extending cross frame members. Again, the upper and lower pairs of side frame members may define the sides of the frame and the outermost cross frame members may define the first and second ends. The upper and lower pairs of side frame members may be joined together by one or more vertically extending frame members, preferably located at least at each corner defined by an intersection of the side frame members with the outermost cross frame members.

[0027] In yet other embodiments, the base frame may include a primary frame defining the pallet inlet and the pallet outlet and part of the pallet transfer pathway and a subframe defining the pallet loading section and accommodating the lifting mechanism. Both the primary frame and the subframe may include upper and lower pairs of opposed longitudinally extending side frame members extending between opposed ends and joined together by one or more transversely extending cross frame members and vertically extending frame members. The primary frame and the subframe may be joined together in an end to end arrangement to form the base frame using conventional welding techniques and/or with one or more mechanical fasteners.

[0028] The upper and lower pairs of side frame members may additionally respectively define the upper and lower levels of the two working levels.

[0029] The various frame members may be joined together using conventional welding techniques and/or with one or more mechanical fasteners.

[0030] The frame members may each be of tubular construction, solid construction, plate construction or any combination thereof, preferably tubular with a substantially rectangular cross section.

[0031 ] The base frame may preferably have an elongate shape extending longitudinally between the first and second ends.

[0032] The base frame may be fixed or portable, preferably the latter.

[0033] In some embodiments, the base frame may be wheeled, track-mounted, or sled mounted for transportation.

[0034] In some embodiments, the base frame may include a trailer, or be mounted atop a trailer, configured to be towed by a vehicle. [0035] In some embodiments, the base frame may be configured to be carried and/or towed by a wheeled material handling equipment, such as, e.g., a mobile pallet dolly frame.

[0036] In some embodiments, the base frame may include legs extending downwardly from the frame for supporting the frame atop a support surface. Typically, the apparatus may include at least four legs located at least in each corner of the base frame.

[0037] In some embodiments, the legs of the base frame may be adjustable to adjust a height of the base frame relative to a support surface.

[0038] For example, in some such embodiments each leg may have an adjustable length, such as, e.g., a telescopic arrangement. Typically, the leg may include at least two telescopic portions, including a lower telescopic portion configured to be telescopically received in a lower end of an upper telescopic portion.

[0039] In other such embodiments, each leg may include an actuating mechanism for adjusting a length of the leg. Any suitable actuating mechanism may be used, such as, e.g., one or more linear actuators capable of moving between extended and retracted positions.

[0040] In some embodiments, an underside of the base frame, each leg, or a lower end of a lowermost telescopic portion may include a foot operatively associated therewith for supporting the base frame relative to the support surface. The foot may be formed from rubber, plastic or metal material or materials.

[0041 ] The foot may include a flanged lower portion for at least partially stabilising the base frame relative to the support surface.

[0042] In some embodiments, each foot may be height adjustable for making minor height adjustments to the base frame relative to the support surface. The foot may be height adjustable in any suitable way.

[0043] In other embodiments, an underside of the base frame, each leg, or a lower end of a lowermost telescopic portion may include one or more wheels operatively associated therewith for supporting and conveying the base frame relative to the support surface.

[0044] Like with foot, the one or more wheels may be height adjustable for making minor height adjustments to the base frame relative to the support surface. The one or more wheels may be height adjustable in any suitable way.

[0045] For example, in some embodiments, each of the one or more wheels may be associated with an actuating mechanism for adjusting a height of the base frame relative to the support surface. Again, any suitable type of actuating mechanism may be used. [0046] Generally, the actuating mechanism may include one or more linear actuators each capable of moving between an extended position and a retracted position for adjusting a height of the base frame relative to the support surface.

[0047] The one or more linear actuators may include any one of a pneumatic ram, a hydraulic ram, a rigid chain actuator, a screw jack or a screw motor.

[0048] In other embodiments, each of the one or more wheels may be height adjustable by rotating the wheel relative to the base frame, or leg, to which it is threadingly fastened.

[0049] Typically, at least one of the one or more wheels may further include brake mechanism for parking and retaining the apparatus in a desired location.

[0050] In some embodiments, at least one of the one or more wheels may further include a propulsion system for propelling the apparatus along a support surface.

[0051 ] In some such embodiments, a pair of wheel assemblies located on opposite sides of the apparatus may function to steer or guide the apparatus, e.g., by differential steering.

[0052] In other such embodiments, a single wheel assembly at or near either the first or second ends of the apparatus may be swivel-mounted to the base frame, or leg, for steering or guiding the apparatus.

[0053] The propulsion system may include at least one drive motor to drive propulsion of the apparatus.

[0054] In some such embodiments, the at least one drive motor may be associated with a lead, or frontmost, wheel assembly located at or near the second end of the apparatus for selectively driving the apparatus in a forward or reverse direction.

[0055] In other such embodiments, the at least one drive motor may be associated with rear wheel assembly, or assemblies, for selectively driving the apparatus in a forward or reverse direction.

[0056] For example, in some such embodiments, the at least one drive motor may be used to move at least the second end of the apparatus at least partially into the opening of a shipping container. Advantageously, moving at least the second end of the apparatus into the opening of the shipping container may enhance productivity by shortening the distance the contents of the container has to be manually carried before being loaded atop a pallet.

[0057] In some embodiments, the at least one drive motor may also be used to brake momentum of the apparatus. [0058] The at least one drive motor may be an electric motor, a hydraulic motor or a combustion engine.

[0059] In preferred embodiments, a wheel-mounted said apparatus may be remotely controlled and guided relative to a shipping container.

[0060] In such embodiments, an operator may use a remote controller to control the apparatus to move to a desired location.

[0061 ] As indicated, the base frame includes a pallet inlet and a pallet outlet arranged above the pallet inlet at the first end of the base frame, preferably vertically above.

[0062] Generally, the pallet inlet may be located at the first end atop the lower level of the base frame and the pallet outlet may be located at the first end atop the upper level of the base frame.

[0063] The pallet inlet may preferably include an opening configured to receive at least one pallet therein, preferably two pallets in a stacked arrangement.

[0064] The opening may be defined at the first end of the base frame by the cross frame members extending transversely between the respective pairs of upper and lower longitudinally extending side frame members and the vertically extending frame member extending between respective upper and lower side frame members on each side.

[0065] The pallet inlet may include one or more guides, rails, or rollers and the like to facilitate alignment and insertion of at least one pallet into the pallet inlet, preferably by wheeled material handling equipment although manual insertion of empty pallets is also envisaged.

[0066] In some embodiments, the pallet inlet include may include one or more guides in the form of angled plates for guiding and aligning a pallet received therein relative to the pallet transfer pathway. The one or more guides may preferably include a pair of angled plates extending inwards from the opposed vertical frame members.

[0067] In some embodiments, the pallet inlet may further include at least one displacement member extending downwardly from the upper level of the base frame for displacing stacked pallets into a serial arrangement. In such embodiments, the displacement member may displace an upper pallet in a stacked arrangement such that it slides serially behind a lower pallet as the pallet are conveyed towards the second end along the pallet transfer pathway.

[0068] The at least one displacement member may typically be in the form of a plate extending downwards from the upper level a height to contact and obstruct movement of an upper pallet received in a stacked arrangement via the pallet inlet such that the upper pallet slides off and serially behind the lower pallet. [0069] As indicated, the pallet outlet may be located atop the upper level of the base frame at the first end. The pallet outlet may provide unimpeded access to a loaded said pallet so that the tines of wheeled material handling equipment may readily access and remove said loaded pallets.

[0070] In some embodiments, the pallet outlet may further include a turntable for orienting a loaded pallet for pickup by wheeled material handling equipment.

[0071 ] The turntable may include a platform rotationally coupled to the upper level of the base frame at the first end. The platform may preferably have a circular shape. The rotational coupling may enable the platform to swivel about a vertical axis relative to a remainder of the base frame.

[0072] The rotational coupling may be of any form known in the art. For example, in some embodiments the rotational coupling may include a turntable bearing.

[0073] The turntable may be manually turned or may be driven by an actuator, for example. Any suitable type of actuating mechanism may be used.

[0074] In some embodiments, the actuating mechanism may include a drive motor, such as, e.g., an electric motor, a hydraulic motor or a combustion engine operatively associated with a first part of the rotational coupling for rotating a second part of the rotational coupling relative to the first part.

[0075] In other embodiments, the actuating mechanism may include one or more linear actuators as previously described. Reciprocating movement of the linear actuators between extended and retracted positions may impart rotational movement to part of the rotational coupling relative to the other part for rotating the platform relative to the base frame.

[0076] Advantageously, the vertical arrangement of the pallet inlet and outlet relative to each other enables a streamlined workflow. For example, wheeled material handling equipment may unload at least one pallet into the pallet inlet and then pick up a loaded pallet from the pallet outlet in a single work cycle without the need for complex manoeuvring or repositioning of the equipment relative to the apparatus.

[0077] Moreover, positioning of the pallet inlet and pallet outlets at the first end of the apparatus furthest away from the opening of the shipping container minimises worker contact with any wheeled material handling equipment and the safety risks associated therewith.

[0078] As indicated, the base frame includes a pallet loading section located at the second end of the base frame, preferably atop the upper level of the base frame at the second end.

[0079] Like the pallet outlet, the pallet loading section may provide unimpeded access for workers located in and about the opening of the shipping container to be able to load a pallet. [0080] The pallet loading section may include one or more guides, rails or rollers to convey a loaded pallet to the pallet outlet.

[0081 ] Advantageously, the pallet loading section may be at height by way of being located on the upper level of the base frame so as to minimise lifting, bending or crouching of a worker when loading a pallet stationed therewith with the contents of the container. Accordingly, the pallet loading section may reduce the risk of potential injuries that may occur as a result of the manual handling of the contents of the container onto pallets.

[0082] As indicated, the base frame defines a pallet transfer pathway extending from the pallet inlet to the pallet outlet via the pallet loading section.

[0083] The pallet transfer pathway may be of any suitable size, shape and construction to facilitate the passage of empty pallets received via the pallet inlet for loading at the pallet loading section and pick up at the pallet outlet, preferably via a guided conveyance mechanism.

[0084] Advantageously, the use of a guided conveyance mechanism facilitates the smooth and controlled movement of pallets with or without loaded containers along the transfer pathway, enhancing the efficiency and effectiveness of the apparatus in handling palletised goods.

[0085] In some embodiments, the guided conveyance mechanism may include one or more conveyor sections, such as, e.g., a belt conveyor, a chain conveyor, a slat conveyor or a roller conveyor, for guiding and facilitating movement of a pallet along the pallet transfer pathway from the inlet to the outlet via the pallet loading section.

[0086] In other embodiments, the guided conveyance mechanism may include one or more wheels, rollers, plain bearing pads or the like mounted on an upper surface the upper and lower levels of the base frame for guiding and facilitating movement of a pallet from the pallet inlet to the pallet outlet via the pallet loading section.

[0087] In some such embodiments, the guided conveyance mechanism may further include a pair of rails extending parallel to the sides of the base frame alongside the pallet transfer pathway for guiding movement of a pallet from the pallet inlet to the pallet outlet via the pallet loading section. The rails may have any suitable profile shape to prevent pallets deviating to either side of the pallet transfer pathway. For example, the rails may be substantially L-shaped.

[0088] In yet other embodiments, the guided conveyance mechanism may include at least a pair of track sections mounted on an upper surface the upper and lower levels of the base frame and a mounting platform for receiving a pallet atop, said mounting platform including one or more track mounting portions on each side for facilitating movement of the mounting platform from the pallet inlet to the pallet outlet via the pallet loading section. [0089] The track mounting portions may include one or more wheels, rollers, plain bearing pads or the like configured to be moveable along the track sections.

[0090] The track sections may guide the respective track mounting portions between the inlet and the outlet. Each track section may be mounted adjacent a side of the base frame along the upper and lower levels, preferably extending longitudinally between the first and second ends.

[0091 ] Each track section may be substantially elongate. Each track section may have a substantially constant cross sectional profile.

[0092] In some such embodiments, each track section may have a channel for guiding passage of the respective track mounting portions along the channel.

[0093] In preferred embodiments, the guided conveyance mechanism may include one or more chain conveyor sections mounted atop the upper surface of the lower level of the base frame and extending from the first end to the second end and one or more roller conveyor sections mounted atop the upper section of the upper level of the base frame.

[0094] Typically, the guided conveyance mechanism may further include a drive mechanism for driving movement of pallets along the pallet transfer pathway, particularly along the lower level of the base frame. Any suitable drive mechanism may be used.

[0095] For example, in some embodiments, the drive mechanism may include a drive motor associated with one or more sprockets of the chain conveyor sections for driving movement of chains of the chain conveyor.

[0096] In other embodiments, the drive mechanism may include one or more motorized roller tubes of the roller conveyor sections.

[0097] The drive motor may preferably be an electric motor.

[0098] By including a drive mechanism, the chain conveyor section on the lower level of the base frame may advantageously draw in pallets loaded in the pallet inlet and drive their movement towards the lifting mechanism.

[0099] In other embodiments, the drive mechanism may include one or more linear actuators mounted underneath the roller conveyor sections and configured to incline the section in a direction in which movement is desired.

[00100] As indicated, the apparatus includes a lifting mechanism operatively associated with the second end of the base frame for lifting a pallet received via the pallet inlet to the pallet loading section, preferably from the lower level to the upper level of the base frame. Any suitable type of lifting mechanism may be used.

[00101] For example, in some embodiments the lifting mechanism may include one or more jacks, typically located on a lower surface of the base frame at or near the second end, preferably adjacent the chain conveyor sections.

[00102] Any suitable type of jack may be used. For example, in some embodiments, each jack may include a base mounted atop the lower level of the base frame, a threaded shaft rotatably coupled to the base and a load receiving carriage configured to raise a pallet received thereatop to the pallet loading section.

[00103] In other embodiments, the lifting mechanism may include one or more linear actuators, typically mounted underneath or to a bottom of the base frame and capable of moving between an extended position and a retracted position. The extended and retracted positions may correspond with raised and lowered positions of a pallet relative to the base frame.

[00104] Any suitable linear actuator may be used. For example, the one or more linear actuators may include a pneumatic ram, a hydraulic ram or a rigid chain actuator (also known as a linear chain actuator, a push-pull actuator, an electric chain actuator, a zip chain actuator or a column forming chain actuator).

[00105] In yet other embodiments, the lifting mechanism may include a panel operatively associated with a winch and drive motor, such as, e.g., an electric motor or combustion engine operatively associated with a winch, a cable and a pulley. In such embodiments, a pallet may be received atop the platform on the lower level of the base, which may then be raised to the upper level by drawing in the cable with the winch. The platform may then be lowered again to the lower level for receiving another pallet by letting out the cable again with the winch.

[00106] In further embodiments, the lifting mechanism may be servomotor or stepper motor configured to raised and lower a panel between the lower and upper levels of the base frame for respectively raising pallet to the upper level.

[00107] In preferred embodiments, the lifting mechanism may include a scissor lift located on the lower level of the base frame at the second end and capable of movement between a lowered position for receiving a pallet atop on the lower level and a raised position in which the pallet is raised to the upper level of the base frame.

[00108] The scissor lift may include a platform atop of which the pallet is received and a mechanical linkage system for vertically moving the platform between the lower and upper levels of the base frame. The mechanical linkage system include a pair of interconnected, folding supports. Movement of the supports may be driven by an actuating mechanism. [00109] The scissor lift may be manually actuated with a hand crank, for example. Conversely, the scissor lift may include an actuating mechanism for driving movement of the scissor lift between raised and lowered positions.

[00110] The actuating mechanism may include one or more linear actuator as previously described.

[0011 1] In some embodiments, the platform of the lifting mechanism may include one or more conveyor sections as previously described mounted atop for facilitating movement of a pallet on and off the platform.

[00112] In other embodiments, the pallet loading section may further include a pair of conveyor sections mounted to the upper level of the base frame at the second end and moveable relative to the base frame for receiving a pallet elevated and presented to the upper level by the lifting mechanism. The pair of conveyor sections may extend longitudinally along each side of the upper level at least partially towards the first end of the base frame.

[00113] The conveyor sections may preferably be roller conveyor sections.

[00114] In some such embodiments, the pair of conveyor sections may pivot or slide laterally relative to a longitudinal direction of the base frame for providing clearance for the lifting mechanism to elevate a pallet to the upper level. Once elevated above the upper level, the pair of conveyor sections may pivot or slide back to receive the pallet when the lifting mechanism lowers again to the lower level.

[00115] In some such embodiments, each of the conveyor sections may be mounted atop a hinged bracket hingedly coupled to an outer side edge of the upper level of the base frame and configured to pivot outwards relative to a longitudinal axis of the base frame. The pivoting movement of the respective brackets may be driven by an actuator mechanism, preferably a linear actuator as previously described.

[00116] Each hinged bracket may enable each respective conveyor section to pivot over a range of about 90° between a clear position in which the section is held clear for passage of the lifting mechanism and a receiving position in which the section is substantially planar with the upper level for receiving the elevated platform atop.

[00117] In other such embodiments, each of the conveyor sections may be mounted atop a bracket slidably mounted to the upper level of the base frame and configured to slide outwards and inwards relative to each other. The sliding movement of the brackets may be driven by an actuator mechanism, preferably a linear actuator as previously described. [00118] In some embodiments, the apparatus may further include a retaining mechanism operatively associated with the base frame for retaining the apparatus in position relative to the shipping container. Any suitable type of retaining mechanism may be used.

[00119] In some embodiments, the base frame may further include a pair of elongate retaining members configured to be moveable between a retracted position and a protruding position in which the members protrude outwards from each side of the apparatus in direction substantially perpendicular to a longitudinal axis of the base frame to respectively engage with a side wall of the shipping container.

[00120] Typically, each retaining member may have an outer end dimensioned and shaped to be engageable in recesses defined in the side walls of the shipping container so as to substantially maintain a location of the apparatus in a desired position relative to the shipping container against forces resulting from impact by wheeled material handling equipment loading and unloading pallets from the apparatus.

[00121] In some such embodiments, movement of the elongate retaining members between the retracted and protruding positions may be manually actuated by hand.

[00122] In other such embodiments, movement may be driven by an actuating mechanism. Any suitable actuating mechanism may be used.

[00123] In preferred such embodiments, the actuating mechanism may include one or more linear actuator as previously described.

[00124] In some embodiments, the apparatus may further include a barrier mechanism for selectively barring movement of a pallet from the pallet loading section until it has been completely loaded. Any suitable barrier mechanism may be used.

[00125] For example, in some embodiments the barrier mechanism may include a bar or rod transversely slidable across an upper level of the base frame adjacent the pallet loading section. The bar or rod may be selectively slidable across the base frame to control movement of a loaded pallet along the upper level of the pallet transfer pathway.

[00126] In some such embodiments, movement of the bar or rod may be manually actuated by hand.

[00127] In other such embodiments, movement of the bar or rod may be driven by an actuating mechanism as previously described.

[00128] In other embodiments, the barrier mechanism may preferably include at least one gate or door hinged connected to the base frame by one or more mounting brackets and configured to pivot between a barrier position in which the at least one gate or door extend transversely across the upper level of the base frame adjacent the pallet loading section to control movement of a loaded pallet along the upper level of the pallet transfer pathway.

[00129] Like the bar or rod, movement of the at least one gate or door may be selective and may be manually actuated or driven by an actuating mechanism, preferably the latter.

[00130] In preferred embodiments, the barrier mechanism may include a pair of doors hingedly coupled to hinge stiles mounted to, and extending upwards from, either side of the base frame and configured to be selectively pivotable between a closed position in which the doors act as a physical barrier transversely extending across the upper level of the base frame adjacent the pallet loading section and an open position in which the doors pivot open providing a clear pallet transfer pathway. Movement of doors between the closed and open positions may be driven by an actuating mechanism controllable an operator.

[00131] Again, any suitable actuating mechanism may be used, typically one or more linear actuators extending between each door and it respective hinge stile.

[00132] In use, the barrier mechanism may advantageously function as an access point ensuring each pallet may be safely loaded in the pallet loading section without fear of the pallet being conveyed to the pallet outlet prematurely.

[00133] In such embodiments, the roller conveyor sections of the pallet loading section may include a graded descent towards the pallet outlet so that as soon as the barrier mechanism is selectively opened a loaded pallet is biased to roll towards the pallet outlet.

[00134] In some embodiments, the apparatus may further include a wrapping section between the barrier mechanism and the pallet outlet for wrapping a loaded pallet in pallet wrap - a highly stretchable plastic film - prior to the wrapped and loaded pallet being unloaded by wheeled material handling equipment.

[00135] The wrapping section may be of any suitable size, shape and form for wrapping loaded pallets as they pass through the section.

[00136] Generally, the wrapping section may include a vertically oriented spindle mounted to, and extending upwards from a side of the base frame. The spindle may be loaded with a roll of pallet wrap.

[00137] In use, when a loaded pallet passes through the barrier mechanism it is conveyed atop the turntable located at the pallet outlet. An operator may then manually attach an end of the pallet wrap to the loaded pallet and actuate the turntable to rotate and draw and wrap pallet wrap from the spindle around the loaded pallet.

[00138] In some embodiments, the spindle may be part of a wrapping machine including a cutter for cutting the wrap once a desired amount has been wrapped about the loaded pallet.

[00139] In some embodiments, the apparatus may further include an onboard controller for controlling operation of the various conveyor sections, the lifting mechanism, the turntable, the barrier mechanism, the retaining mechanism and the various actuating mechanisms.

[00140] The controller may preferably be a microcomputer, including one or more processors and a memory. The processor may include multiple inputs and outputs coupled to components of the apparatus.

[00141] For example, the controller may be operatively associated with the conveyor sections, the lifting mechanism and the barrier mechanism for controlling passage of a pallet along the pallet transfer pathway. For example, the controller may receive data from the barrier mechanism to determine when the pallet loading section has been vacated and the lifting mechanism may elevate another empty pallet to the pallet loading section.

[00142] The controller may also be in communication with one or more sensors and safety interlocks operatively associated with retaining mechanism, the barrier mechanism and the lifting mechanism, in particular.

[00143] Any suitable type of sensors and safety interlocks known in the art may be associated with components of the apparatus to provide data and safety.

[00144] For example, the sensor may provide data indicative of the position of the retaining members of the retaining mechanism relative to the base frame, the position of the doors of the barrier mechanism, the position of the platform of the lifting mechanism, the orientation of the turntable relative to the base frame, and/or the position of the roller conveyor sections of the pallet loading section.

[00145] The sensors and safety locks may include any one of proximity sensors, contact sensors, infrared sensors, laser sensors, LiDAR sensors and cameras.

[00146] For example, in some embodiments, the barrier mechanism may be equipped with one or more safety interlocks to ensure that the turntable and/or the wrapping machine, if present, are not operable until the doors of the barrier mechanism are again in the closed position.

[00147] Likewise, the one or more safety interlocks may ensure that the lifting mechanism is not operable until the doors of the barrier mechanism have closed. [00148] In some embodiments, the controller may further include a remote controller enabling an operator to remotely control operation of the apparatus.

[00149] In other embodiments, the controller may include one or more buttons, switches or dials located on the base frame. The one or more buttons, switches or dials may be electrically connected to the various actuating mechanisms.

[00150] In some embodiments, the apparatus may further include at least one modem configured to be in communication with the onboard controller for the transmission of data to an external processing device.

[00151] The at least one modem may be in communication with the external processing device either directly or indirectly via at least one remotely accessible server. In some such embodiments, the at least one modem may be a cellular modem. In other such embodiments, the at least one modem may be a radio modem.

[00152] The controller may preferably be in communication with the external processing device over a communications network, preferably a wireless communications network. The network may include, among others, the internet, LANs, Wi-Fi (WLAN) communication, WANs, GPRS network, a mobile communications network, a satellite communications network, a radio network, an RF communication network, an infrared communication network, Bluetooth™ or the like, and may include wireless communications links.

[00153] The at least one remotely accessible server may be any appropriate server computer, distributed server computer, cloud-based server computer, server computer cluster or the like. The server may typically include one or more processors and one or more memory units containing executable instructions/software to be executed by the one or more processors.

[00154] The server may generally be in communication with the apparatus and may be configured to transmit communications between the apparatus and the external processing device.

[00155] The communications between the onboard controller and the external processing device, optionally via the remotely accessible server, may include the operational data, such as, e.g., the number of pallet unloaded from a shipping container. Advantageously, this may enable operators to provide pallet predictability to customers in the supply chain, thereby helping manage and maximise stock flow.

[00156] According to a second aspect of the present invention, there is provided a method of unpacking a shipping container with the apparatus according to a first aspect of the present invention, said method including: loading at least one pallet into the pallet inlet of the apparatus; conveying said at least one pallet from the pallet inlet to the lifting mechanism at the second end of the apparatus; lifting said at least one pallet to the pallet loading second for loading with contents from the shipping container; and conveying a loaded said at least one pallet to the pallet outlet for handling by wheeled material handling equipment.

[00157] The method may include one or more features or characteristics of the apparatus as hereinbefore described.

[00158] The loading may include loading a pallet or two stacked pallets into the pallet inlet of the apparatus with wheeled material handling equipment.

[00159] Preferably, a chain conveyer extending between the pallet inlet and the lifting mechanism may draw the at least one pallet into the pallet transfer pathway.

[00160] In embodiments in which two stacked pallets are loaded, a displacement member extending downwards from the upper level may displace and slide an upper pallet of the two stacked pallets into a serial arrangement with the lower pallet.

[00161] As indicated, said conveying said pallet to the lifting mechanism may include conveying the at least one pallet along the chain conveyor to the lifting mechanism.

[00162] The lifting may include elevating the at least one pallet with a scissor lift to the pallet loading section.

[00163] The lifting may additionally include temporarily pivoting a pair of conveyor sections defining the pallet loading section out of the way to provide clearance for the lifting mechanism to elevate the at least one pallet to the upper level of the base frame.

[00164] Once elevated above the upper level, the pair of conveyor sections may pivot back to receive the pallet while the lifting mechanism lowers again to the lower level.

[00165] The conveying the loaded pallet to the pallet outlet may include conveying the loaded pallet along one or more roller conveyor sections extending from the pallet loading section to the pallet outlet.

[00166] In some embodiments, the conveying may additionally include selectively opening a barrier mechanism to release the loaded pallet to be conveyed to the pallet outlet.

[00167] In embodiments in which the apparatus includes the wrapping section, the method may include a further step of wrapping the loaded at least one pallet prior to handling by the wheeled material handling equipment.

[00168] The wrapping may include attaching an edge of pallet wrap to the loaded at least one pallet and actuating the turntable to rotate the loaded at least one pallet and wrap the pallet wrap about the loaded at least one pallet.

[00169] In some embodiments, the method may include an initial step of positioning the apparatus relative to the opening of the shipping container, preferably positioning the first end at least partially in the opening.

[00170] In some embodiments, the method may include a subsequent initial step of activating the retaining mechanism so as to substantially maintain a location of the apparatus relative to the shipping container against forces resulting from impact by wheeled material handling equipment loading and the loading and unloading of pallets to and from the apparatus.

[00171] Any of the features described herein can be combined in any combination with any one or more of the other features described herein within the scope of the invention.

[00172] The reference to any prior art in this specification is not, and should not be taken as an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge.

BRIEF DESCRIPTION OF DRAWINGS

[00173] Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of Invention in any way. The Detailed Description will make reference to a number of drawings as follows:

[00174] Figure 1 is an upper perspective view of an apparatus for use in unpacking a shipping container according to an embodiment of the present invention;

[00175] Figure 2 is an upper perspective view of a base frame of the apparatus as shown in Figure 1 ;

[00176] Figure 3 is an upper perspective view of part of a lower level of the apparatus as shown in Figure 1 ;

[00177] Figure 4 is an upper perspective view showing part of the lower level of the apparatus as shown in Figure 3 with the base frame removed; [00178] Figure 5 is a plan view of the apparatus as shown in Figure 1 ;

[00179] Figures 6A and 6B are upper perspective views, respectively, showing a lifting mechanism of the apparatus in lowered and raised positions;

[00180] Figure 7 is an upper perspective view showing part of a pallet loading section of the apparatus as shown in Figure 1 ;

[00181] Figure 8 is an upper perspective view showing a pallet outlet part of the apparatus as shown in Figure 1 ;

[00182] Figures 9 to 11 are upper perspective views respectively showing stages in unpacking of a shipping container with the apparatus as shown in Figure 1 ; and

[00183] Figure 12 is an upper perspective of the apparatus according to another embodiment of the present invention.

DETAILED DESCRIPTION

[00184] Figures 1 to 12 show an apparatus (100) and parts thereof for use in unpacking a shipping container according to embodiments of the present invention.

[00185] Figures 1 to 11 show a first embodiment of the apparatus (100).

[00186] Referring to Figure 1 , the apparatus (100) includes an elongate base frame (110) including a first end (112) having a pallet inlet (120) and a pallet outlet (130) arranged above the pallet inlet (120) and an opposed second end (114) configured to be located at least adjacent an opening of the shipping container and having a pallet loading section (140). The base frame (110) defines a pallet transfer pathway (150; indicated by the arrow) extending between the pallet inlet (120) and the pallet outlet (130) via the pallet loading section (140). The apparatus (100) further includes a lifting mechanism (160) operatively associated with the second end (114) of the base frame (110) for lifting a pallet received via the pallet inlet (120) to the pallet loading section (140).

[00187] Referring to Figure 2, the base frame (110) is configured to support and convey the pallet inlet (120; not shown), the pallet outlet (130; not shown), the pallet loading section (140; not shown) and the lifting mechanism (160; not shown) relative to the opening of a shipping container.

[00188] The base frame (110) is formed from metal and has a generally rectangular shape defined by the first end (112), the opposed second end (114) and a pair of opposed sides (116) extending longitudinally therebetween.

[00189] The base frame (110) defines two working levels, namely a lower level (170) on which the pallet inlet (120; not shown) is located and an upper level (180) on which the pallet outlet (130; not shown) and the pallet loading section (140; not shown) are located. The lifting mechanism (160; not shown) traverses the lower level (170) and the upper level (180).

[00190] As shown, the base frame (110) is formed from a plurality of frame members joined together.

[00191] Specifically, the base frame (110) includes a primary frame (210) defining the pallet inlet (120; not shown) and the pallet outlet (130; not shown) and part of the pallet transfer pathway (150; not shown) and a subframe (220) defining the pallet loading section (140; not shown) and accommodating the lifting the mechanism (160; not shown). Both the primary frame (210) and the subframe (220) respectively include upper and lower pairs of opposed longitudinally extending side frame members (212A, 212B, 222A, 222B) extending between opposed ends (112, 114) and joined together by one or more transversely extending cross frame members (214, 224) and vertically extending frame members (216, 226).

[00192] The primary frame (210) and the subframe (220) are joined together in an end to end arrangement to form the base frame (110) using conventional welding techniques and/or with one or more mechanical fasteners.

[00193] The upper and lower pairs of the side frame members (212A, 212B, 222A, 222B) define the lower and upper levels (170, 180) of the base frame (110).

[00194] The various frame members (212A, 212B, 222A, 222B, 214, 224, 216, 226) are joined together using conventional welding techniques and/or with one or more mechanical fasteners.

[00195] The frame members (212A, 212B, 222A, 222B, 214, 224, 216, 226) are of a tubular construction with a substantially rectangular cross section.

[00196] The base frame (110) has an elongate shape extending longitudinally between the first and second ends (112, 114).

[00197] The apparatus (110) is portable so that it can be moved relative to the opening of a shipping container, preferably such that the second end (114) is at least partially received in the shipping container. For example, and referring briefly to Figures 9 to 11 , the base frame (110) includes a pair of wheels (910) extending from an underside of the frame at or near the first end (112) and the second end (114) of the apparatus (100) is configured to be manoeuvred relative to the opening of a shipping container with wheeled material handling equipment, such as, e.g., a mobile pallet dolly frame, as shown.

[00198] Referring to Figure 3, and as indicated, the base frame (110) includes a pallet inlet (120) and a pallet outlet (130; not shown) arranged vertically above the pallet inlet (120) at the first end (112) of the apparatus (100).

[00199] The pallet inlet (120) includes an opening configured to receive up to two pallets in a stacked arrangement.

[00200] The opening is defined at the first end (112) of the base frame (110) by the cross frame members (214) extending transversely between the respective pairs of upper and lower longitudinally extending side frame members (212A, 212B) and the vertically extending frame member (216) extending between respective upper and lower side frame members (212A, 212B) on each side.

[00201] The pallet inlet (120) includes a pair of opposed guides (122) mounted on either side of the inlet (120) to facilitate alignment and insertion of pallets into the pallet inlet (120). The guides (122) include a pair of angled plates extending inwards from the opposed vertical frame members (216).

[00202] Referring back to Figure 1 , the pallet outlet (130) is located atop the upper level (180) of the base frame (110) at the first end (112).

[00203] The pallet outlet (130) provides unimpeded access to a loaded pallet so that the tines of wheeled material handling equipment can readily access and remove the loaded pallet.

[00204] As shown, the pallet outlet (130) further includes a turntable (132) for orienting a loaded pallet for pickup by wheeled material handling equipment.

[00205] The turntable (132) includes a platform (134) rotationally coupled to the upper level (180) of the base frame (110) at the first end (112). The platform (134) has a circular shape and is rotationally coupled to the base frame by turntable bearing enabling the platform (134) to swivel about a vertical axis relative to a remainder of the base frame (110).

[00206] The turntable (132) is configured to be manually turned.

[00207] As indicated, the base frame (110) includes a pallet loading section (140) located at the second end (114) of the base frame (110) atop the upper level (180).

[00208] Like the pallet outlet (130), the pallet loading section (140) provides unimpeded access for workers located in and about the opening of the shipping container to be able to load a pallet thereon.

[00209] As shown, the pallet loading section (140) includes a pair of roller conveyor sections (142) for receiving pallet via the lifting mechanism (160) and for conveying a loaded pallet to the pallet outlet (130). The pair of roller conveyor sections (142) will be discussed in detail later. [00210] As indicated by the blue arrow, the base frame (110) defines a pallet transfer pathway (150) extending from the pallet inlet (120) to the pallet outlet (130) via the pallet loading section (140).

[0021 1 ] The pallet transfer pathway (150) facilitates the passage of pallets received via the pallet inlet (120) for loading at the pallet loading section (140) and pick up at the pallet outlet (130) via a guided conveyance mechanism.

[00212] Referring to Figure 3, the guided conveyance mechanism on the lower level (170) includes three chain conveyor sections (310).

[00213] Referring again to Figure 1 , the guided conveyance mechanism on the upper level (180) includes three roller conveyor sections (320), including the pair of roller conveyor sections (142) at the second end (114), the roller conveyor section (136) mounted atop the platform (134 of the turntable (132) located at the first end (112), and a roller conveyor section (190) located therebetween.

[00214] Referring to Figure 4, and as mentioned, the apparatus (100) includes a lifting mechanism (160) operatively associated with the second end (114; not shown) of the base frame (110; not shown) for lifting a pallet received via the pallet inlet (120; not shown) to the pallet loading section (150; not shown) from the lower level (170; not shown) to the upper level (180; not shown) of the base frame (110; not shown).

[00215] As shown, the lifting mechanism (160) includes a scissor lift.

[00216] Referring to Figures 6A and 6B, the scissor lift is capable of movement between a lowered position as shown in Figure 6A for receiving a pallet atop and a raised position as shown in Figure 6B in which the pallet is raised to the upper level (180; not shown) of the base frame (110; not shown).

[00217] The scissor lift includes a platform (162) atop of which the pallet is received and a mechanical linkage system (164) for vertically moving the platform (162) between the lower and upper levels (170, 180; not shown) of the base frame (110; not shown). The mechanical linkage system (164) includes a pair of interconnected, folding supports (166). Movement of the supports (166) between the raised and lowered positions is driven by a pair of linear actuators (168).

[00218] Referring to Figure 7, when the lifting mechanism (160) is elevated, the pair of roller conveyor sections (142) mounted to the upper level (180; not shown) of the base frame (110; not shown) are configured to slide laterally relative to a longitudinal direction of the base frame (110; not shown) for providing clearance for the lifting mechanism (160) to elevate a pallet to the upper level (180; not shown). [00219] Once elevated above the upper level (180), the pair of conveyor sections (142) slide back inwards to receive the pallet while the lifting mechanism (160) lowers again to the lower level (170; not shown).

[00220] Movement of the pair of roller conveyor sections (142) in a lateral direction towards and away from each other is driven by a linear actuator (148).

[00221] Referring to Figure 4, the apparatus (100) further includes a retaining mechanism (410) operatively associated with the base frame (110; not shown) for retaining the apparatus (100) in position relative to a shipping container.

[00222] The retaining mechanism (410) includes a pair of elongate retaining members (412) configured to be slidable between a retracted position and a protruding position, as shown, in which the members (412) protrude outwards from each side (116; not shown) of the apparatus (100) in direction perpendicular to a longitudinal axis of the base frame (110; not shown).

[00223] Referring to Figure 5, the elongate retaining member (412) are configured to protrude outwards and respectively engage with a side wall of the shipping container, as shown.

[00224] Each retaining member (412) has an outer end dimensioned and shaped to be engageable in recesses defined in the side walls of the shipping container so as to substantially maintain a location of the apparatus (100) in a desired position relative to the shipping container against forces resulting from impact by wheeled material handling equipment loading and unloading pallets from the apparatus.

[00225] Movement of the elongate retaining members (412) between the retracted and protruding positions is driven by an actuating mechanism in the form of one or more linear actuators.

[00226] Referring back to Figure 1 , the apparatus (100) further includes a barrier mechanism (510) for selectively barring movement of a pallet from the pallet loading section (140) until it has been completely loaded.

[00227] As shown, the barrier mechanism (510) includes a pair of doors (512) hingedly coupled to hinge stiles (514) mounted to, and extending upwards from, either side (116) of the base frame (110) and configured to be selectively pivotable between a closed position in which the doors (512) act as a physical barrier transversely extending across the upper level (180) of the base frame (110) adjacent the pallet loading section (140) and an open position, as shown, in which the doors (512) pivot open providing a clear pallet transfer pathway (150).

[00228] Movement of doors (512) between the closed and open positions is driven by an actuating mechanism controllable an operator. [00229] Advantageously, the roller conveyor sections (142) of the pallet loading section (140) are pivotable to provide a graded descent towards the pallet outlet (130) so that as soon as the barrier mechanism (510) is selectively opened a loaded pallet is biased to roll towards the pallet outlet (130) across the three roller conveyor sections (320).

[00230] The apparatus (100) further includes a wrapping section (610) between the barrier mechanism (510) and the pallet outlet (130) for wrapping a loaded pallet in pallet wrap - a highly stretchable plastic film - prior to the wrapped and loaded pallet being picked up/unloaded by wheeled material handling equipment.

[00231] Referring to Figure 8, the wrapping section (610) includes a vertically oriented spindle (612) mounted to, and extending upwards from a side (116) of the base frame (110).

[00232] The spindle (612) can be loaded with two rolls of pallet wrap.

[00233] In use, when a loaded pallet passes through the barrier mechanism (510; not shown) it is conveyed atop the turntable (132) located at the pallet outlet (130). An operator may then manually attach an end of pallet wrap to the loaded pallet and rotate the turntable (132) to draw and wrap pallet wrap from the spindle (612) around the loaded pallet.

[00234] A method of using the apparatus (100) is now described in detail with reference to Figures 9 to 11 .

[00235] As an initial step, the apparatus (100) is positioned at least partially in the opening of a shipping container and the retaining mechanism (410) is deployed.

[00236] Subsequently, one or more empty pallets are loaded into the pallet inlet (120). The empty pallets are drawn in by the three chain conveyor sections (310) to the lifting mechanism (160).

[00237] The empty pallets are then individually elevated by the lifting mechanism to the pallet loading section (140) at the second end (114) of the upper level (180) of the base frame (110).

[00238] As each empty pallet is elevated, the pair of roller conveyor sections (142) mounted to the upper level (180) of the base frame (110) at the pallet loading section (140) slide laterally relative to a longitudinal direction of the base frame (110) for providing clearance for the lifting mechanism (160) to elevate the pallet. Once elevated above the upper level (180), the conveyor sections (142) slide back inwards to receive the pallet atop while the lifting mechanism (160) lowers again to the lower level (170).

[00239] Referring to Figure 9, one elevated the empty pallet is loaded with contents from the shipping container by a manual labour team. [00240] Referring to Figure 10, once loaded, the barrier mechanism (510) opens to allow passage of the loaded pallet through the opposed doors (512) to the pallet outlet (130).

[00241] The loaded pallet is conveyed to the pallet outlet by three roller conveyor sections (320).

[00242] Referring to Figure 11 , once received in the pallet outlet (130), the doors (512) of the barrier mechanism (510) close and pallet wrap is manually attached to the loaded pallet.

[00243] Once the doors (512) close, the lifting mechanism (160) elevates another empty pallet to the pallet loading section (140), while the loaded pallet is wrapped on the other side of the barrier mechanism (510)

[00244] The pallet is then rotated relative to the spindle (612) of the wrapping section (610) by manual rotation of the turntable (132) causing the pallet wrap to be drawn from the spindle (612) and wrapped about a content of the loaded pallet.

[00245] The wrapped, loaded pallet is now ready for pick-up from the pallet outlet (130) via wheeled material handling equipment.

[00246] Figure 12 shows a second embodiment of the apparatus (100). For convenience, features that are similar or correspond to features of the first embodiment will be referenced with the same reference numerals.

[00247] Referring to Figure 12, the apparatus (100) includes an elongate base frame (110) including a first end (112) having a pallet inlet (120) and a pallet outlet (130) arranged above the pallet inlet (120) and an opposed second end (114) configured to be located at least adjacent an opening of the shipping container and having a pallet loading section (140). The base frame (110) defines a pallet transfer pathway (150; not labelled) extending between the pallet inlet (120) and the pallet outlet (130) via the pallet loading section (140). The apparatus (100) further includes a lifting mechanism (160) operatively associated with the second end (114) of the base frame (110) for lifting a pallet received via the pallet inlet (120) to the pallet loading section (140); and a barrier mechanism (510) for selectively barring movement of a pallet from the pallet loading section (140) until it has been completely loaded.

[00248] The barrier mechanism (510) includes a pair of doors (512) hingedly coupled to hinge stiles (514) mounted to, and extending upwards from, either side (116) of the base frame (110) and configured to be selectively pivotable between a closed position, as shown, in which the doors (512) act as a physical barrier transversely extending across the upper level (180) of the base frame (110) adjacent the pallet loading section (140) and an open position in which the doors (512) pivot open providing a clear pallet transfer pathway (150). [00249] Movement of doors (512) between the closed and open positions is driven by an actuating mechanism controllable an operator.

[00250] Advantageously, the roller conveyor sections (142) of the pallet loading section (140) are pivotable to provide a graded descent towards the pallet outlet (130) so that as soon as the barrier mechanism (510) is selectively opened a loaded pallet is biased to roll towards the pallet outlet (130) across the three roller conveyor sections (320; not labelled).

[00251] The apparatus (100) further includes a wrapping section (610) between the barrier mechanism (510) and the pallet outlet (130) for wrapping a loaded pallet in pallet wrap - a highly stretchable plastic film - prior to the wrapped and loaded pallet being picked up/unloaded by wheeled material handling equipment.

[00252] In the present specification and claims (if any), the word ‘comprising’ and its derivatives including ‘comprises’ and ‘comprise’ include each of the stated integers but does not exclude the inclusion of one or more further integers.

[00253] Reference throughout this specification to ‘one embodiment’ or ‘an embodiment’ means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases ‘in one embodiment’ or ‘in an embodiment’ in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

[00254] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims (if any) appropriately interpreted by those skilled in the art.

Claims

1 . An apparatus for use in unpacking a shipping container including: an elongate base frame including a first end having a pallet inlet and a pallet outlet arranged above the pallet inlet and an opposed second end configured to be located at least adjacent an opening to the shipping container and having a pallet loading section, said base frame defining a pallet transfer pathway extending between the pallet inlet and the pallet outlet via the pallet loading section; a lifting mechanism operatively associated with the second end of the base frame for lifting a pallet received via the pallet inlet to the pallet loading section; and a barrier mechanism for selectively barring movement of the pallet from the pallet loading section until the pallet has been completely loaded.

2. The apparatus of claim 1 , wherein the elongate base frame defines two working levels including a lower level on which the pallet inlet is located and an upper level on which the pallet outlet and the pallet loading section are located.

3. The apparatus of claim 2, wherein the lifting mechanism traverses the lower level and the upper level.

4. The apparatus of any one of claims 1 to 3, wherein the elongate base frame is height adjustable relative to a support surface.

5. The apparatus of any one of claims 1 to 4, wherein the pallet inlet includes an opening configured to receive at least one pallet therein.

6. The apparatus of claim 5, wherein the opening of the pallet inlet is configured to receive two pallets in a stacked arrangement.

7. The apparatus of any one of claims 1 to 6, wherein the pallet inlet includes one or more guides, rails and rollers to facilitate alignment and insertion of at least one pallet into the pallet inlet by wheeled material handling equipment.

8. The apparatus of claim 7, wherein the one or more guides include a pair of angled plates extending inwards for guiding and aligning the at least one pallet received therein relative to the pallet transfer pathway.

9. The apparatus of claim 7 or claim 8 when dependent on claim 2, wherein the pallet inlet further includes at least one displacement member extending downwardly from the upper level of the base frame for displacing stacked pallets into a serial arrangement.

10. The apparatus of claim 9, wherein the at least one displacement member includes a plate extending downwards from the upper level of the base frame to a height to contact and obstruct movement of an upper pallet received in a stacked arrangement via the pallet inlet such that upper pallet slides off and serially behind a lower pallet in the stacked arrangement.

11 . The apparatus of any one of claims 1 to 10, wherein the pallet outlet is configured to provide unimpeded access to a loaded said pallet so that tines of wheeled material handling equipment can access and remove said loaded said pallet.

12. The apparatus of any one of claims 1 to 11 , wherein the pallet outlet further includes a turntable for orienting a loaded said pallet for pickup by wheeled material handling equipment.

13. The apparatus of any one of claims 1 to 12, wherein the pallet loading section includes one or more guides, rails and rollers to convey a loaded said pallet towards the pallet outlet.

14. The apparatus of any one of claims 2 to 13, wherein the pallet loading section is located on the upper level of the base frame at a height so as to minimise lifting, bending or crouching of a worker when loading a pallet stationed therewith with contents of the shipping container.

15. The apparatus of any one of claims 1 to 14, wherein the pallet transfer pathway further includes a guided conveyance mechanism to facilitate passage of empty said pallets received via the pallet inlet for loading at the pallet loading section and pick up at the pallet outlet.

16. The apparatus of claim 15, wherein the guided conveyance mechanism includes one or more conveyor sections selected from a belt conveyor, a chain conveyor, a slat conveyor and a roller conveyor.

17. The apparatus of any one of claims 2 to 18, wherein the barrier mechanism includes at least one gate or door hingedly connected to the base frame by one or more mounting brackets and configured to pivot between an open position and a barrier position in which the at least one gate or door extends transversely across the upper level of the base frame adjacent the pallet loading section to control movement of a loaded said pallet along the upper level of the pallet transfer pathway.

18. The apparatus of claim 17, wherein the barrier mechanism includes a pair of doors hingedly coupled to hinge stiles mounted to, and extending upwards from, each side of the base frame and configured to be selectively pivotable between a closed position in which the doors act as a physical barrier transversely extending across the upper level of the base frame adjacent the pallet loading section and an open position in which the doors pivot open providing a clear said pallet transfer pathway.

19. The apparatus of claim 18, wherein movement of the pair of doors between the open and closed positions is driven by an actuating mechanism.

20. A method of unpacking a shipping container with the apparatus according to any one of claims 1 to 19, said method including: loading at least one pallet into the pallet inlet of the apparatus; conveying said at least one pallet from the pallet inlet to the lifting mechanism at the second end of the apparatus; lifting said at least one pallet to the pallet loading second for loading with contents from the shipping container; and conveying a loaded said at least one pallet to the pallet outlet for handling by wheeled material handling equipment.