VEHICLE LEVELER WITH DOOR LOCK

Abstract

A vehicle leveler includes a first section with a leading edge and a trailing edge, the trailing edge being positioned farther from the driveway than the leading edge. The leveler also includes a second section with a leading edge and a trailing edge, the leading edge of the second section being positioned farther from the driveway than the trailing edge of the second section. The vehicle leveler has a door interlock system with at least one pair of photoelectric sensors with a sensor path. When a vehicle is loaded onto or unloaded from the vehicle leveler and at least one of the vehicle doors is opened, the door blocks the sensor path of the photoelectric sensors and prevents the vehicle leveler from lowering or raising.

Description

This application is a continuation in part of patent application serial number 17 / 322,889, filed on May 17, 2021, which is a continuation in part of patent application serial number 17 / 174,301, filed on February 11, 2021, which is a continuation in part of patent application serial number 17 / 026,642, filed on September 21, 2020, which is a continuation in part of patent application serial number 16 / 376,910, filed on April 5, 2019, issued on October 27, 2020 as U.S. Patent No. 10,815,103. Such prior applications are incorporated herein by reference in their entirety. Field of Invention The present invention relates to vehicle levelers and more particularly to a vehicle leveler having multiple surface angles, as well as to a leveler with a door interlock system. Background of the Invention A variety of truck levelers have been designed to adjust the height of different trailers to properly match the trailer bed to the dock height. Aligning the trailer and dock heights facilitates the loading and unloading of goods. One such device is seen in the US patent. Patent No. 4,624,446 issued to Gould, describing a reinforced platform pivotally mounted to the ground at one end and including a support assembly having hydraulic cylinders. In operation, the rear wheels of a truck trailer rest on the platform, and then the hydraulic cylinders raise the unmounted end of the platform until the trailer platform is equal to the height of the dock. A similar device is shown in U.S. Patent No. 4,765,792 issued to Cherry, et al., which also describes a pivotally mounted, hydraulically raised platform. In addition to Gould's description, the device includes mounting the hydraulic system inward from the unmounted end of the platform and an opening at the unmounted end of the platform to accommodate a truck restraint device. Another design is described in U.S. Patent No. 6,368,043 issued to Leum, et al., which discloses a low-profile truck leveler. In this design, a low-profile leveler is achieved through the use of a raised rear beam and two side beams that extend above the top surface of the platform. Additionally, a center beam increases the leveler's strength and rigidity. Prior art vehicle levelers typically have certain disadvantages. Most vehicle levelers have ramp surfaces that are not very adjustable. This is a clear disadvantage when vehicles are being loaded or unloaded. Prior art levelers also cannot accommodate all types of vehicles. This is yet another disadvantage. Some prior art levelers have certain defects and disadvantages that this device addresses. Specifically, it would be advantageous to have a vehicle leveler that is highly adjustable and can raise both the front and rear axles of a vehicle simultaneously to minimize the slope of the vehicle's interior floor, thus allowing for safer loading and unloading of goods. It would also be advantageous to have a vehicle leveler with a photoelectric sensor system, such that when a vehicle is on the lift and its door is open, it blocks the photoelectric sensor's path, preventing the vehicle leveler from lowering and potentially causing injury or damage. In summary, there are problems and deficiencies in vehicle levelers of the previous technology, and it is these needs that the present device addresses. Objects of the Invention It is an object of this invention to provide a vehicle leveler that is highly adjustable and can raise the front and rear axles of a vehicle at the same time to minimize the slope of the internal floor of the vehicle or trailer. Another object of this invention is to provide a vehicle leveler that incorporates a photoelectric sensor to prevent the vehicle leveler from descending when the sensor's path is blocked. These and other objects of the invention will become evident from the following description and drawings. Brief Description of the Invention The preferred embodiment of the invention includes a vehicle leveler for use with a driveway comprising a first portion having a leading edge and a trailing edge, the trailing edge being disposed farther from the driveway than the leading edge and forming a ramp section. The first portion has a flat section adjacent to the trailing edge, the flat section being disposed approximately parallel to the substantially flat driveway. The second portion also includes an extension portion extending from the trailing edge of the second portion to the rear of the leveler and includes a substantially flat section disposed approximately parallel to the substantially flat driveway. The first and second portions are unitary structures that are separated from each other until they are removably joined together by a connecting device.It is highly preferable that the vehicle leveler include opposing side portions that extend along the second portion and the extension portion and are in contact with them; the opposing side portions have an upper surface that forms a walkway. In highly preferred applications, two or more vehicle levelers can be installed adjacent to each other, and an extended walkway surface can be removably installed between each vehicle leveler to form a large surface for use by the vehicle driver. It is preferable that the extended walkway surface and the top surface form one large walkway for the vehicle driver. In some preferred embodiments, each vehicle leveler has two opposing top surfaces, each of which forms a separate walkway. The walkway can extend the entire length of the top surface in some preferred embodiments, or it can extend only a portion of the length of the top surface. Preferably, the walkway and extended walkway surface include a metal grating for a safe contact surface for the driver of the vehicle walking on the walkway or extended walkway surface. Each of the first and second portions are preferably unitary structures that are separated from each other until they are removably joined together by a connecting device. It is highly preferred that the second portion, which includes the extension portion, can be moved between a folded and a raised position to accommodate varying dock heights for loading and unloading goods from vehicles. It is also preferable that the ramp section can be of different lengths and heights to accommodate a single rear-axle vehicle, as well as a large trailer. Highly preferred modalities include a door interlock system that has at least one pair of photoelectric sensors with a sensor path and a vehicle with doors. When a vehicle is loaded onto or unloaded from the vehicle leveler and at least one of the vehicle doors is opened, the door blocks the sensor path of the photoelectric sensors and prevents the vehicle leveler from moving. It is preferable that the at least one pair of photoelectric sensors prevent the vehicle leveler from lowering or raising. Preferred configurations may also include multiple sets of photoelectric sensors, each of which is placed in varying locations adjacent to the vehicle leveler. Preferably, at least one pair of photoelectric sensors is mounted on a building. Highly preferred modes have at least one pair of photoelectric sensors that operate independently of the power supply to the vehicle leveler, so that the at least one pair of photoelectric sensors can stop the lowering or raising of the vehicle leveler by stopping the power supply to the motor. It is also preferred that the vehicle door can be of different dimensions and that the vehicle can be of any size that the vehicle leveler can accommodate. Preferably, the at least one pair of photoelectric sensors includes at least one photocell receiver and at least one photocell emitter. Brief Description of the Drawings The drawings illustrate preferred configurations that include the device features and elements described above. The device will be easily understood from the descriptions and drawings. In the drawings: Figure 1 is a perspective view of the vehicle leveler; Figure 2 is a top view of the vehicle leveler in Figure 1; Figure 3 is a perspective view of the vehicle leveler of Figure 1 with a truck on the leveler and the leveler in the folded position; Figure 4 is a perspective view of the vehicle leveler of Figure 1 with a truck on the leveler and the leveler in the raised position; Figures 5-6 are perspective views of the vehicle leveler in the raised position; Figure 7 is a perspective view of the vehicle leveler of Figure 1 in the folded position with a trailer on the leveler; Figure 8 is a perspective view of the vehicle leveler of Figure 1 with a vehicle driver using the upper surface / walkway; Figure 9 is a top view of the vehicle leveler illustrating the top surface / walkway that extends partially along the length of the leveler; Figure 10 is a top view of the vehicle leveler illustrating the top surface / walkway that extends further along the length of the leveler; Figure 11 is a front view of the leveler illustrating the opposite side portions and extended walkway surface; Figure 12 is a front view of the extended walkway surface; Figure 13 is a front view of two levelers installed side by side and illustrating the large walkway; Figure 14 is a top view illustrating four vehicle levelers installed adjacent to each other with a large walkway between the levelers; Figure 15 is a perspective view of the vehicle leveler in Figure 1 with the vehicle doors open; Figure 16 is an enlarged view taken along line 16-16 of Figure 15; Figure 17 is an interior view of a dock door illustrating the photoelectric sensors and sensor path; Figure 18 is a perspective view of a photoelectric sensor; Figure 19A and Figure 19B are electrical schematics of the control box and Figure 20 is an electrical schematic of the power unit. Detailed Description of Preferred Options Figures 1-20 show a preferred embodiment of the present invention. The vehicle leveler 10, as shown in Figure 1, includes three primary portions, a first portion 12, a second portion 24, and an extension portion 30, and is designed to be used in conjunction with a substantially flat driveway 18 near a loading dock wall 46. Furthermore, the leveler 10 can be moved between a lowered position 36, shown in Figures 1 and 3, and a raised position 38, shown in Figures 4-6. The first portion 12 has a ramp section 20 that is sloped upwards and a flat section 22 adjacent to the ramp section 20. The first portion 12 includes a leading edge 14 and a trailing edge 16. The trailing edge 16 is disposed farther from the driveway 18 than the leading edge 14. The trailing edge 16 is part of the flat section 22. The flat section 22 is disposed approximately parallel to the substantially flat driveway 18. Figure 1 illustrates that the second portion 24 has a leading edge 26 and a trailing edge 28. The leading edge 26 of the second portion 24 is removably attached to the trailing edge 16 of the first portion 12, as shown in Figures 1, 3-4. Figure 5 illustrates that the first portion 12 and second portion 24 are removably attached, as it shows the first and second portions 12, 24 separated. The leading edge 26 of the second portion 24 is positioned farther from the driveway 18 than the trailing edge 28 of the second portion 24. The second portion 24 also includes an extension portion 30 as can be seen in Figures 1-7. The extension portion 30 extends from the rear edge 28 of the second portion 24 towards the rear of the leveler 10 (closer to the loading dock wall 46) and includes a substantially flat section 32 arranged parallel to the substantially flat inlet 18. Figure 2 illustrates that the first portion 12 and second portion 24 include a metal grate 42 on a steel plate to make contact with the wheels of a vehicle as the vehicle enters and exits the leveler 10. The metal grate 42 on a steel plate is a material that is both durable and also provides greater traction for vehicles when they are going up or down the leveler 10. Figures 1-7 illustrate that each of the first portion 12 and second portion 24 are unitary structures that are separated from each other, as seen in Figure 5, until they are removably joined together by a connecting device 34, as best seen in Figures 1 and 3-4. The connecting device 34 is located on the front edge 26 of the second portion 24 and connects to the rear edge 16 of the first portion 12. The flat section 22 of the first portion 12 faces the connecting device 34 since the connecting device 34 is located on the front edge 26 of the second portion 24. The drawings illustrate that the second portion 24, which includes the extension portion 30, can be moved between a folded position 36, as seen in Figures 1, 3, and 7, and a raised position 38, as seen in Figures 4–6, to accommodate different dock heights for loading and unloading goods from vehicles. Figures 4–7 show a variety of different vehicle types that can use the leveler. 10. Depending on the vehicle's length, the leveler 10 can be customized in several ways, including the extension portion 30 consisting of multiple identical extension portions that are removably joined together to accommodate a longer vehicle. Figure 2 illustrates a leveler 10 with more than one extension portion 30. In a configuration with multiple extension portions 30, each extension portion 30 is removably secured to another extension portion 30. In this configuration, a first extension portion 30 extends from the trailing edge 28 of the second portion 24 toward the rear of the leveler 10. Each extension portion 30 includes a substantially flat section 32 arranged approximately parallel to the substantially flat inlet 18.In some modalities, the multiple portions of extension 30 may vary in length and do not have to be identical in length. The leveler 10 can be manufactured so that the ramp section 20 can be of different lengths and heights to accommodate a single rear-axle vehicle, as well as a large trailer. Figures 1 and 6 illustrate a ramp section 20 with a different length and height. The ramp section 20 and flat section 22 can be manufactured with different lengths and heights to accommodate single rear-axle pickup trucks and trailers, as well as tractor trailers with a ground clearance of 16 meters (53 feet). Therefore, the leveler 10 can be manufactured so that any of the first portion 12, second portion 24, or extension portion 30 can be of different lengths and heights to accommodate a variety of vehicle types and sizes.For example, Figures 3-4 show a box truck on leveler 10, Figures 5-6 show a larger vehicle on leveler 10, and Figure 7 illustrates a very large trailer on leveler 10. With the leveler 10, both the front and rear axles of a vehicle can be raised to minimize the slope or incline of the interior floor surface 40 of a trailer or vehicle, thus making loading and unloading goods safer. Figures 3-7 illustrate a variety of vehicles on the leveler 10, and the dotted line in Figures 3-4 illustrates the vehicle's interior floor surface 40. Figures 4-6 illustrate vehicles on the leveler 10 with both the front and rear axles raised. Figure 6 illustrates that the leveler 10 may include opposing side walls 52 (see Figure 2) with a light mounting channel 44 having at least one light 50 (which could be a single light, multiple lights, or a string light) integrated into the light mounting channel 44. The light or lights 50 assist vehicles, such as trailers, when reversing or moving away from the leveler 10. A lifting system is also incorporated in the leveler 10 in the form of hydraulic lifts 48 that make contact with the inlet 18 as seen in Figure 1. The hydraulic lifts 48 raise the second portion 24 including the extension portion 30 of the leveler 10. However, any other lifting system known in the art could also be used. The leveler 10 may also include wheel guides 54 shown in Figure 1, which may be located on any or all of the first portion 12, second portion 24, or extension portion 30. Figure 1 illustrates wheel guides 54 on the first portion 12. The wheel guides 54 act to guide the trailer wheels into the appropriate position for loading and unloading goods. The relationship between the first portion 12 and the driveway 18, as well as the relationship between the second portion 24 and the driveway 18, can also be defined in terms of angles, as shown in Figures 1-7. The ramp section 20 of the first portion 12 is inclined to the driveway 18 at approximately 1 to 15 degrees from parallel with the driveway 18. The second portion 24 extends from the first portion 12 to the rear of the leveler 10 and includes a drop section 56 that descends to the substantially flat driveway 18 at an angle of approximately 115 degrees from parallel with the substantially flat driveway 18. In operation, a vehicle (sometimes including a large trailer) is backed up to leveler 10 to place its rear wheels on the first portion 12, specifically the ramp section 20. Therefore, the wheels and trailer are raised from the driveway 18 as they back up on the ramp section 20. As the vehicle backs up to leveler 10, the rear wheels move into the second portion 24, or slope section 56, and begin to descend toward the driveway 18. As the rear wheels continue to back up, they make contact with the extension portion 30, and at this point, depending on the length and size of the trailer or vehicle, the rear of the trailer or vehicle may now be in contact with the loading dock wall 46.Depending on the length of the vehicle or trailer, the front wheels may be in contact with the first section 12, as shown in Figures 3-4, or the trailer may be so large that only the rear wheels are on the leveler 10, as shown in Figure 7. Once the rear wheels have moved back as far as they can on the leveler 10, the lifting system can be engaged to raise the trailer to the appropriate height for safely loading and unloading goods. The leveler 10 can raise both the front and rear wheels of the vehicle to minimize the slope of the vehicle's interior floor, allowing for safer loading and unloading. Figures 8-14 illustrate that the vehicle leveler 10 includes opposing side portions 58 that extend along and make contact with the first portion 12, the second portion 24, and the extension portion 30. As best seen in Figures 9-10, the opposing side portions 58 have a top surface 60 that forms a walkway 60. The walkway, also referred to herein as the top surface 60, is a safety feature used by a driver when entering or exiting a vehicle using the vehicle leveler 10. Figure 8 illustrates a driver using the walkway 60. Figure 10 illustrates that the top surface / walkway 60 can be extended the entire length of the second portion 24 and the extension portion 30, whereas Figure 9 illustrates that the top surface / walkway 60 can only extend a portion of the length of the second portion 24 and extension portion 30. Figure 11 illustrates opposing side portions 58, also known as the top surface / walkway 60. Figure 12 is a more detailed view of only the extended walkway surface 62, which is mounted between two vehicle levelers to form a large walkway 64. Figures 13-14 illustrate that two or more vehicle levelers 10 can be installed adjacent to each other and that the extended walkway surface 62 can be removably installed between each vehicle leveler 10 to form a large walkway 64 for use by the vehicle driver. In Figure 14, each vehicle leveler 10 has two opposing side portions 58 with top surfaces 60, each of which forms a separate walkway. Figure 14 illustrates four vehicle levelers 10 installed side by side. Figure 14 also illustrates that the extended walkway surface 62 forming the large walkway 64 is a step (two or more walkway surfaces 62 can be joined together to make a large walkway 64 or the walkway surface 62 can be manufactured to be wider and can be a large walkway 64) that is wide so that the vehicle driver has a wider walking surface to help him get on and walk around the adjacent trailers. Figures 15-18 illustrate that the door interlock system 78 has at least one pair of photoelectric sensors 80 with a sensor path 82 and a vehicle 84 with doors 86. When a vehicle is loaded onto or unloaded onto the vehicle leveler 10 and at least one of the vehicle's doors 86 is opened, the door 86 blocks the sensor path 82 of the photoelectric sensors 80 and prevents the vehicle leveler 10 from moving, as shown in Figure 15. The vehicle door 86 can be of different dimensions, and the vehicle 84 can be any size vehicle that can use the vehicle leveler 10. When the photoelectric sensors 80 are blocked, they prevent the vehicle leveler 10 from lowering or raising. Multiple sets of photoelectric sensors can be used and placed in different locations adjacent to the vehicle leveler 10. The photoelectric sensors 80 are mounted on the wall of a building 76 as seen in Figures 16-17, although they can also be mounted anywhere a photoelectric sensor can be used. The photoelectric sensors 80 can operate independently of the power supply for the vehicle leveler, enabling them to stop the lowering or raising of the vehicle leveler 10 by cutting off power to a motor. Figure 18 illustrates that the photoelectric sensor 80 includes at least one photocell receiver 88 and at least one photocell emitter 90. Figures 19I and 19B are an electrical schematic of the control box. Figure 20 is an electrical schematic of a power supply in the power unit enclosure that houses a battery. The power supply has a lower current draw than a power supply unit with an AC motor. The battery powers a 12-volt DC power system that requires a large amount of energy for a short period of time. The battery can be charged over a period of time with a lower building power requirement, allowing the use of a 120-volt, 15-amp circuit to power a dock door. A wide variety of materials is available for the 10 various parts discussed and illustrated herein. Although the device has been described in conjunction with specific embodiments thereof, it will be understood that many alternatives, modifications, and variations will be evident to those skilled in the art. Accordingly, clause 15 is intended to encompass all such alternatives, modifications, and variations that fall within the spirit and broad scope of the appended claims.

Claims

1. A vehicle leveler for use with a driveway, characterized in that it comprises: a first portion having a leading edge and a trailing edge, wherein the trailing edge is disposed further from the driveway than the leading edge and forms a ramp section, the first portion having a flat section adjacent to the trailing edge, the flat section being disposed approximately parallel to the substantially flat driveway, a second portion having a leading edge and a trailing edge, wherein the leading edge of the second portion is removably attached to the trailing edge of the first portion and the leading edge of the second portion is disposed further from the driveway than the trailing edge of the second portion,The second portion also includes an extension portion extending from the rear edge of the second portion to the rear of the leveler and includes a substantially flat section arranged approximately parallel to the substantially flat driveway and opposite side portions extending along and contacting the first portion, second portion and extension portion; the opposite side portions have an upper surface forming a walkway 21 and a door interlocking system having at least one pair of photoelectric sensors with a sensor path and a vehicle with doors; wherein, when a vehicle is loaded or unloaded onto the vehicle leveler and at least one of the vehicle doors is opened, the door blocks the sensor path of the photoelectric sensors and prevents the vehicle leveler from moving.

2. The vehicle leveler of claim 1, characterized in that at least one pair of photoelectric sensors prevents the vehicle leveler from descending.

3. The vehicle leveler of claim 1, characterized in that at least one pair of photoelectric sensors prevents the vehicle leveler from rising.

4. The vehicle leveler of claim 1, characterized in that the at least one pair of photoelectric sensors consists of multiple sets of photoelectric sensors, each of which is placed in variable locations adjacent to the vehicle leveler.

5. The vehicle leveler of claim 1, characterized in that at least one pair of photoelectric sensors are mounted on a building.

6. The vehicle leveler of claim 1, characterized in that the at least one pair of photoelectric sensors operates independently of the power supply for the vehicle leveler, so that the at least one pair of photoelectric sensors can stop the descent or elevation of the vehicle leveler by stopping the power supply to the motor.

7. The vehicle leveler of claim 1, characterized in that the vehicle door can be of variable dimensions and the vehicle can be of a size that can use the vehicle leveler.

8. The vehicle leveler of claim 1, characterized in that the at least one pair of photoelectric sensors includes at least one photocell receiver and at least one photocell emitter.

9. A vehicle leveler for use with a substantially flat driveway, the leveler being capable of moving between a lowered position and a raised position, the leveler in the lowered position being characterized in that it comprises: a first portion having a leading edge at the front of the leveler and a substantially flat section, wherein the substantially flat section is inclined from the substantially flat driveway between approximately 1 and 15 degrees from parallel with the substantially flat driveway; a second portion extending from the inclined portion towards the rear of the leveler including a substantially flat section, wherein the substantially flat section is inclined towards the substantially flat driveway between approximately 1 and 15 degrees from parallel with the substantially flat driveway;an extension portion extending from the second portion to the rear of the leveler and including a substantially flat section arranged parallel to the substantially flat driveway and opposite side portions extending along and contacting the first, second, and extension portions, the opposite side portions having an upper surface forming a walkway and a door interlocking system having at least one pair of photoelectric sensors with a sensor path and a vehicle with doors; wherein, when a vehicle is loaded or unloaded onto the vehicle leveler and at least one of the vehicle doors is opened, the door blocks the sensor path of the photoelectric sensors and prevents the vehicle leveler from lowering or rising.

10. The vehicle leveler of claim 9, characterized in that at least one pair of photoelectric sensors prevents the vehicle leveler from descending.

11. The vehicle leveler of claim 9, characterized in that at least one pair of photoelectric sensors prevents the vehicle leveler from rising.

12. The vehicle leveler of claim 9, characterized in that the at least one pair of photoelectric sensors consists of multiple sets of photoelectric sensors, each set being placed in variable locations adjacent to the vehicle leveler.

13. The vehicle leveler of claim 9, characterized in that at least one pair of photoelectric sensors are mounted on a building.

14. The vehicle leveler of claim 9, characterized in that the at least one pair of photoelectric sensors operates independently of the power supply for the vehicle leveler, so that the at least one pair of photoelectric sensors can stop the descent or elevation of the vehicle leveler by stopping the power supply to the motor.

15. The vehicle leveler of claim 9, characterized in that the vehicle door can be of variable dimensions and the vehicle can be of a size that can use the vehicle leveler.

16. The vehicle leveler of claim 9, characterized in that the at least one pair of photoelectric sensors includes at least one photocell receiver and at least one photocell emitter.

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