Foam box automatic stacking device

Abstract

This invention belongs to the technical field of foam box stacking equipment, specifically an automatic foam box stacking device. It includes a first mounting frame, a first conveyor belt at the top of the first mounting frame, a support frame on one side of the first mounting frame, a receiving frame fixedly installed inside the support frame, a fixed frame slidably installed inside the receiving frame, a speed-multiplying lifting mechanism between the support frame and the fixed frame, and multiple sets of foam box clamping structures fixedly installed inside the fixed frame. A second mounting frame is located on the side of the first mounting frame away from the support frame, a second conveyor belt is located at the top of the second mounting frame, a clamping and rotating mechanism is slidably installed above the second conveyor belt, and a stacking plate is rotatably installed below the second conveyor belt. Through the use of beams, a first counterweight, stacking plates, and lifting rods, three foam boxes can be combined in a left-right interlocking manner during foam box conveying, significantly increasing the friction and contact area between the boxes, ensuring neat and stable stacking.

Description

Technical Field

[0001] This invention belongs to the technical field of foam box stacking equipment, and particularly relates to an automatic foam box stacking equipment. Background Technology

[0002] In the field of stacking and packaging EPS (expandable polystyrene) after molding, manual handling still dominates. Although this method has a low initial equipment investment and high flexibility, it faces serious challenges such as continuously rising labor costs, production efficiency limited by the skill and physical strength of workers, and difficulty in ensuring product consistency. Faced with rising labor costs and higher requirements for production efficiency and quality, upgrading from labor-intensive to technology-intensive and achieving automated and low-energy production is a clear development trend in the EPS molding industry. Therefore, a considerable number of stacking and packaging systems have already appeared on the market.

[0003] For example, patent CN105668250B disclosed a box stacking system and method, including a conveying mechanism, a lifting system, and a box positioning mechanism. The lifting system is located on both sides of the conveying mechanism to control the lifting of the boxes, and the box positioning mechanism is located above the lifting system to fix the boxes lifted by the lifting system. It achieves automatic stacking of foam boxes through the cooperation of multiple mechanisms, but the foam boxes still require manual feeding to achieve stacking.

[0004] For example, patent CN219362558U discloses a foam box palletizing and depalletizing device, which includes a palletizing tray and a robotic arm placed on one side of the palletizing tray. A fixed plate is connected to the end of the robotic arm, and a first mounting plate and a second mounting plate are connected to the fixed plate. The semi-enclosed structure formed by the fixed plate, the first mounting plate, and the second mounting plate is adapted to the foam box. An industrial camera for accurately positioning the foam box is provided on the fixed plate. A first vacuum suction cup for adsorbing the side wall of the foam box is provided on the first mounting plate, along with an adjustment mechanism for adjusting the lateral and vertical positions of the first vacuum suction cup. A second vacuum suction cup for adsorbing the side wall of the foam box is provided on the second mounting plate, along with an adjustment component for adjusting the lateral position of the second vacuum suction cup. This technology mainly uses a robotic arm to pick up, place, and stack foam boxes. However, since the foam boxes need to be picked up and placed in designated positions, a certain degree of manual handling is still required. For example, they need to be straightened to prevent tilting or crisscrossing to ensure that the mechanical grippers can smoothly extend into the box.

[0005] The above two technologies are the mainstream foam box stacking equipment. Although they achieve automatic stacking of foam boxes, they both have certain shortcomings in use: Firstly, existing automatic foam box stacking equipment is used independently of the foam box forming machine. After the forming machine finishes forming the foam box, the foam box will fall off by itself along the arc plate at the outlet of the forming machine. After falling, the foam box needs to be sorted or moved by hand before the stacking process can be completed.

[0006] Secondly, the existing foam box stacking equipment still uses the same stacking principle as the previous boxes, which adopts a bottom-up method, with multiple boxes stacked on top of each other. However, the overall volume of foam boxes is large, and the stacking method leads to a significant increase in the stacking volume, low space utilization, and is not conducive to handling and transportation.

[0007] Finally, the existing foam box stacking equipment has a low degree of automation. Although it uses automated robotic arms for sorting, which can achieve efficient and stable operation, the initial equipment investment is huge and the technical skills required for operation and maintenance personnel are extremely high, making it difficult for many small and medium-sized enterprises to afford. Summary of the Invention

[0008] To overcome the shortcomings of existing technologies, this invention addresses the following technical problem: Existing foam box stacking equipment operates independently of the molding machine. After molding, the foam boxes require manual handling or secondary transport before stacking, and the stacking method still relies on bottom-up stacking, resulting in a significant increase in volume, low space utilization, and inconvenience for handling and transportation. Furthermore, although some equipment utilizes robotic arms, the degree of automation is limited, the equipment investment is substantial, and the technical requirements for operators and maintenance personnel are high, making it unaffordable for small and medium-sized enterprises.

[0009] To achieve the above objectives, the present invention provides the following technical solution: an automatic foam box stacking device, comprising a first mounting frame, a first conveyor belt at the top of the first mounting frame, a support on one side of the first mounting frame, a receiving frame fixedly installed inside the support, a fixed frame slidably installed inside the receiving frame, a speed-multiplying lifting mechanism between the support and the fixed frame, and multiple sets of foam box clamping structures fixedly installed inside the fixed frame. When the molding machine demolds, the fixed frame extends into the mold before the mold transfer and clamps the foam boxes by the foam box clamping structures. After the fixed frame clamps the foam boxes and moves downward, the foam boxes automatically fall onto the first conveyor belt. A second mounting frame is provided on the side of the first mounting frame away from the support. Multiple sets of corresponding second conveyor belts are provided at the top of the second mounting frame. A clamping and rotating mechanism is slidably installed above the second conveyor belts for eccentrically clamping the foam boxes, causing them to rise, fall, and rotate. A stacking plate is rotatably installed below each set of second conveyor belts. The stacking plate cooperates with the clamping and rotating mechanism to interlock and stack three foam boxes.

[0010] Optionally, the double-speed lifting mechanism includes a servo screw drive structure and a chain drive structure. The servo screw drive structure drives and connects to a lifting frame. The lifting frame and the fixed frame are driven and connected by a chain drive structure. The double-speed lifting mechanism completes the double-stroke pushing of the fixed frame.

[0011] Optionally, the foam box clamping structure includes multiple sets of clamping plates arranged in pairs on one side of the fixing frame, with the two clamping plates forming a flared shape. An L-shaped elastic plate is provided at the end of the clamping plate away from the fixing frame, and multiple rollers are rotatably installed at one end of the elastic plate, with the rollers clamping the foam box.

[0012] Optionally, an arc-shaped main conveyor belt is fixedly installed on the surface of each of the multiple sets of receiving racks. When the foam box held by the roller comes into contact with the main conveyor belt, it automatically falls off. The end of the stroke of the main conveyor belt abuts against one side of the first conveyor belt.

[0013] Optionally, both stacked box panels are L-shaped, and the two stacked box panels can be flipped over to merge the two foam boxes. A beam plate is slidably arranged under each pair of stacked box panels, and a counterweight linkage mechanism is arranged between the two stacked box panels and the beam plate.

[0014] Optionally, the clamping and rotating mechanism includes a lifting frame slidably disposed above each group of second conveyor belts. Two opposing third cylinders are fixedly installed inside the lifting frame. The output end of the third cylinder is rotatably connected to a clamping block through a bearing seat. The clamping centerline of the two clamping blocks is offset from the centerline of the foam box.

[0015] Optionally, an air pipe is also fixedly installed on one side of the lifting frame, with the air jet end of the air pipe away from the clamping centerline of the clamping block.

[0016] Optionally, connecting rods are slidably installed below multiple sets of the second conveyor belts. The counterweight linkage mechanism includes end rods fixedly installed at both ends of the beam plate. Lifting rods are fixedly installed inside the two end rods. The middle position of the bottom surface of the stacked box plate is rotatably connected to the top end of the lifting rod. Sliding grooves are opened at both ends of multiple beam plates. A first counterweight rod is slidably installed inside the sliding groove. The top end of the first counterweight rod is hinged to the short side of the stacked box plate, and a first counterweight block is fixedly installed at the bottom of the first counterweight rod.

[0017] Optionally, two opposing third mounting brackets are provided on the outside of the second mounting bracket. Lifting plates are connected to the two third mounting brackets through a servo screw drive system. A connecting rod is fixedly installed between the two lifting plates. The connecting rod is arranged horizontally below multiple beams. The upward movement of the connecting rod pushes the stacked box plates above the multiple beams to simultaneously realize the foam box fastening process.

[0018] Optionally, a second gantry frame is provided above the first conveyor belt on the side near the second conveyor belt, and a first gantry frame is provided on the other side above the first conveyor belt. Multiple first limit rods are fixedly installed between the second gantry frame and the first gantry frame, and multiple positioning plates are slidably provided below the second gantry frame.

[0019] In summary, compared with existing technologies, the beneficial effects of this solution are as follows: (1) The present invention, through the setting of beam plate, first counterweight rod, stacking plate, lifting rod and first counterweight block, can combine three foam boxes in the manner of "left and right interlocking in the middle" during the transportation of foam boxes. This concave and convex interlocking structure can significantly increase the friction and contact area between the boxes, prevent slippage due to vibration or tilting during assembly line handling, storage and stacking or transportation, and ensure neat and stable stacking. In addition, the interlocking stacking design allows the foam boxes to be stacked tightly and neatly, thereby saving a lot of storage and transportation space and reducing the floor area.

[0020] (2) This invention, through the arrangement of a fixed frame, a double-speed lifting mechanism, clamping plates, elastic plates, rollers, and a main conveyor belt, enables the fixed frame to extend into the molding machine after the foam box is formed, stably receiving the foam box product ejected from the mold and preventing it from falling and causing deformation or damage. At the same time, through the synergistic effect of the clamping plates and elastic plates, the rollers flexibly clamp the foam box, effectively preventing excessive force from damaging the surface of the box. The double-speed lifting mechanism, even with limited overall equipment height, ensures the lifting height of the fixed frame by doubling the stroke, ensuring smooth demolding and receiving of the foam box. Combined with the main conveyor belt, it can achieve an efficient and stable automated production process, significantly improving equipment operating efficiency and product production efficiency.

[0021] (3) By setting up a clamping and rotating mechanism, the present invention enables the clamping and rotating mechanism to accurately grasp and rotate the foam box, so that the box can be smoothly placed between two foam boxes that are about to be merged, and complete the assembly action of "left and right snapping together in the middle", effectively improving the assembly efficiency and structural stability, while reducing manual intervention and realizing fully automatic continuous operation.

[0022] (4) By integrating multiple functions such as sorting and palletizing, this invention can achieve full-process automated connection from demolding of the molding machine to automatic stacking, reduce intermediate transfer links, realize integrated molding and packaging, and improve the overall intelligent production level. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the overall three-dimensional structure from a first-view perspective in this invention; Figure 2 This is a front view structural diagram of the present invention; Figure 3This is a schematic diagram of the overall three-dimensional structure from a second perspective in this invention; Figure 4 for Figure 3 Enlarged structural diagram at point A in the diagram; Figure 5 This is a schematic diagram of the connecting rod structure in this invention; Figure 6 This is a schematic diagram of the stacked box plate structure in this invention; Figure 7 for Figure 5 Enlarged structural diagram at point B in the diagram; Figure 8 for Figure 3 Enlarged structural diagram at point C; Figure 9 for Figure 1 A magnified structural diagram at point D in the diagram; Figure 10 This is a schematic diagram of the material receiving rack from a first-view perspective in this invention; Figure 11 This is a schematic diagram of the receiving rack in this invention from a second perspective; Figure 12 This is a schematic diagram of the support structure in this invention; Figure 13 for Figure 12 Enlarged structural diagram at point E in the diagram; Figure 14 This is a schematic diagram of the clamping plate structure in this invention; Figure 15 for Figure 1 A magnified structural diagram at point F in the diagram; Figure 16 for Figure 1 A magnified structural diagram at point G in the diagram; Figure 17 for Figure 1 A magnified structural diagram of point H in the diagram.

[0024] In the diagram: First mounting frame 10; First conveyor belt 11; Bracket 12; Protective box 13; Servo motor 14; First lead screw 15; First moving block 16; Lifting frame 17; Fixed frame 21; Double-speed lifting mechanism 22; Clamping plate 23; Elastic plate 24; Roller 25; Fixed rod 26; Receiving frame 27; Main conveyor belt 28; First gantry frame 29; Mounting column 30; Limiting plate 31; Second gantry frame 32; First limiting rod 33; Ear plate 34; First cylinder 35; Positioning plate 36; Second mounting frame 37; Conveying plate 38; Second conveyor belt 39; Drive shaft 40; Third gantry frame 41; Second limit rod; 42; Third mounting bracket; 43; Fourth gantry frame; 44; Support platform; 441; Second cylinder; 45; Lifting frame; 46; Third cylinder; 47; Clamping block; 48; Air pipe; 49; Slide rod; 50; Servo screw drive structure; 51; Lifting plate; 53; Connecting rod; 54; Beam plate; 55; End rod; 56; Slide groove; 57; First counterweight rod; 58; Stacking box plate; 59; Lifting rod; 60; First counterweight block; 61; Second counterweight rod; 62; Second counterweight block; 63; Molding machine; 64; Fixed mold; 65; Moving mold; 66; Fourth cylinder; 67; First baffle; 68; Fifth cylinder; 69; Second baffle; 70. Detailed Implementation

[0025] To enable those skilled in the art to better understand the present invention, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings.

[0026] refer to Figure 1 An automatic foam box stacking device includes a first mounting frame 10, with a first conveyor belt 11 mounted on top of the first mounting frame 10. The first conveyor belt 11 is internally equipped with drive wheels for support. The friction between the drive wheels and the first conveyor belt 11 drives the first conveyor belt 11 to rotate continuously. Multiple foam boxes will fall onto the first conveyor belt 11 sequentially, and then the friction between the first conveyor belt 11 and the foam boxes will cause the foam boxes to move together. It should be noted that this automatic foam box stacking device is used in conjunction with a foam box forming machine. (See attached...) Figure 1-3 As can be seen, the first conveyor belt 11 is divided into multiple rows. The number of rows is set according to the number of columns of the mold in the molding machine. For example, if there are four columns of mold cavity in the molding machine, the area on the first conveyor belt will be divided into four columns. The specific number of columns is not limited.

[0027] Further reference Figure 1 , Figure 2 , Figure 10 and Figure 11A bracket 12 is provided on one side of the first mounting frame 10. Multiple fixing rods 26 are fixedly installed on one side of the bracket 12. Multiple sets of receiving racks 27 are fixedly installed on the surfaces of the fixing rods 26. An arc-shaped main conveyor belt 28 is fixedly installed on the surface of each set of receiving racks 27. The end of the main conveyor belt 28 abuts against one side of the first conveyor belt 11. A fixing frame 21 is slidably installed inside the receiving rack 27, and a foam box clamping structure is provided inside the fixing frame 21. It should be noted that in actual operation, the bracket 12 is positioned entirely below the molding machine. (See attached diagram.) Figure 2 The simplified diagram shows a molding machine, designated 64. Inside the molding machine 64 are a fixed mold 65 and a moving mold 66 for molding the foam box. After molding, the fixed mold 65 and the moving mold 66 move to the sides. After this movement, the molding machine uses a push rod to eject the foam box from the moving mold 66, completing the demolding process. The molding process using this machine is conventional existing technology and will not be elaborated upon in this application. Traditional equipment lacks a receiving structure, allowing the foam box to fall downwards arbitrarily. However, in this application, before the moving mold 66 pushes out the foam box, the fixing frame 21 is pushed to the front of the moving mold 66. At this time, the foam box pushed out from the moving mold 66 will go directly into the fixing frame 21 and be clamped and fixed by the foam box clamping structure in the fixing frame 21. It will not fall down randomly. Then the fixing frame 21 will move down and drive multiple foam boxes to move down. During the downward movement of multiple foam boxes, their bottom surfaces will gradually come into contact with the main conveyor belt 28. During the contact process, the foam box clamping structure will release the clamp, and the foam box will slide along the arc surface of the main conveyor belt 28 onto the first conveyor belt 11 to complete the receiving process.

[0028] Further reference Figure 12 and Figure 13Since this equipment is designed for use with various traditional foam molding machines, and the mold feeding height of traditional foam molding machines is uniform, the height of the support 12 is limited, and the fixed frame 21 needs to extend into the molding machine mold. Due to the height limitation, a speed-multiplying lifting mechanism 22 is provided between the support 12 and the fixed frame 21. The speed-multiplying lifting mechanism 22 of this application includes a servo screw drive structure and a chain drive structure. The servo screw drive structure includes protective boxes 13 located on both sides of the support 12. A servo motor 14 is fixedly installed inside the protective box 13, and a first screw 15 is fixedly installed at the output end of the servo motor 14. The first screw 15 rotates inside the protective box 13, and a first moving block 16 is threaded onto the surface of the first screw 15. A lifting frame 17 is slidably arranged on one side of the first moving block 16 relative to the support 12. The lifting frame 17 and the support 12 are connected by multiple sliders and slide rails, and the lifting frame 17 and the fixed frame 21 are also connected by multiple sliders and slide rails. In use, the servo motor 14 drives the first lead screw 15 connected to it to rotate. Since the first moving block 16 is threadedly engaged with the first lead screw 15, under the limit of the protective box 13, the first moving block 16 can move up and down on the surface of the first lead screw 15. During the upward movement of the first moving block 16, it will contact the bottom of the lifting frame 17, thereby pushing the lifting frame 17 to move upward.

[0029] Furthermore, refer to Figure 12 and Figure 13 The chain drive structure in the speed-multiplying lifting mechanism 22 includes four sprockets rotatably mounted on the inner two side walls of the lifting frame 17, located at the upper and lower ends of the two side walls. The sprockets are rotatably connected to the lifting frame 17 through bearing seats. The four sprockets are arranged in two groups, with each group connected by a chain drive. Multiple links of the chain are fixedly connected to the side wall of the fixed frame 21 through hinges. One sprocket in each group is externally connected to a servo motor, which drives the sprocket to rotate, thereby driving the chain to drive the hinges and the fixed frame 21 to achieve lifting motion. Thus, after the servo screw drive structure has raised the lifting frame 17 to a certain height, the chain drive structure continues to drive the fixed frame 21 to rise synchronously at the same speed, achieving a multiplication effect of lifting stroke. This effectively meets the need to complete large-stroke lifting in a limited space, while ensuring smooth operation, accurate positioning, and improving the overall operating efficiency of the equipment.

[0030] Further reference Figure 10 and Figure 14The foam box clamping structure includes multiple sets of two-to-one clamping plates 23 arranged on the side of the fixed frame 21 near the fixed mold. The clamping plates 23 are Z-shaped, and an L-shaped elastic plate 24 is provided at the end of the clamping plate 23 away from the fixed frame 21. The clamping plates 23 and the elastic plate 24 are integrally bent from steel plates. The elastic plate 24, which has a certain elasticity, can deform under external force, thereby achieving flexible clamping of the foam box surface. Multiple rollers 25 are rotatably installed at one end of the elastic plate 24. In this application, two opposing clamping plates 23 constitute a clamping unit. This clamping unit forms a flared shape between the two clamping plates 23, with the flared end of the flared shape facing the fixed mold. In actual operation, at least two clamping units are arranged on the end face of the fixed frame 21 in the area where each foam box is ejected in the molding machine 64, thereby ensuring that the foam box has at least four force-bearing areas on its exterior during clamping, ensuring clamping stability. It should also be noted that the number of clamping units is not limited and can be changed according to the size of the foam box. When the fixed frame 21 is raised into the molding machine 64, the push rod pushes the foam box out and pushes the foam box to the clamping unit and slides into contact with the two sets of rollers 25. Since the elastic plate 24 is elastically set, it will produce elastic deformation. At the same time, the elastic deformation pressure will also be applied to the foam box. Under the action of elastic pressure, the rollers are close to the side of the box, realizing adaptive clamping and positioning, thus clamping the foam box. Since the rollers 25 are rotated, it is easy to push the foam box in, which greatly improves the use effect.

[0031] Further reference Figure 3 , Figure 10 , Figure 11 and Figure 14 The bottom end of the main conveyor belt 28 is connected to the support 12. When the foam box is clamped, the fixing frame 21 drives it to move downward. When the foam box falls into the upper surface of the main conveyor belt 28, it continues to move downward. At this time, since the foam box is only in contact with the roller 25, when the bottom of the foam box is under pressure, the foam box will automatically detach from the roller 25 and slide downward through the arc-shaped main conveyor belt 28 until it is conveyed to the next station.

[0032] Further reference Figure 1 , Figure 12 and Figure 15 A first gantry 29 is fixedly installed on the upper surface of the first conveyor belt 11 near the support 12. Multiple sets of two corresponding mounting columns 30 are fixedly installed on the side of the first gantry 29 near the support 12. Each set of two mounting columns 30 works in conjunction with the main conveyor belt 28. A limit plate 31 is fixedly installed on the opposite side of each set of two mounting columns 30. When the foam box slides off the surface of the main conveyor belt 28, the limit plate 31 can block it, preventing the foam box from sliding off the main conveyor belt 28, ensuring the precise sliding trajectory of the foam box, and facilitating subsequent conveying work.

[0033] Further reference Figure 1 A second gantry 32 is fixedly installed on the upper surface of the first conveyor belt 11 at the end away from the first gantry 29. A plurality of first limiting rods 33 are fixedly installed between the second gantry 32 and the first gantry 29. The plurality of first limiting rods 33 divide the surface of the first conveyor belt 11 into multiple rows, thereby limiting the multiple foam boxes when conveying on the surface of the first conveyor belt 11, preventing them from shifting or tipping over during the conveying process.

[0034] Further reference Figure 1 and Figure 16 Multiple ear plates 34 are fixedly installed on the top of the second gantry 32 away from the first limit rod 33. A first cylinder 35 is fixedly installed on the surface of the ear plate 34. A positioning plate 36 is fixedly installed at the output end of the first cylinder 35. When the foam box is being conveyed, the first cylinder 35 drives the positioning plate 36 to move downward, blocking the foam box on the upper surface of the first conveyor belt 11. The foam box is released in an orderly manner through the external controller and control program, ensuring that the foam box is conveyed in an orderly manner and preparing for the subsequent stacking work.

[0035] Further reference Figure 1 , Figure 3 and Figure 17 Each column of the first mounting frame 10 is provided with a second mounting frame 37 on the side away from the bracket 12. Each second mounting frame 37 has two corresponding second conveyor belts 39 inside. The second conveyor belts 39 are driven to run continuously by the friction between the drive roller and the roller. At the same time, the foam box is moved along with the second conveyor belts 39 by the friction between the second conveyor belts 39 and the foam box. However, it should be noted that the two second conveyor belts 39 in each second mounting frame 37 are not connected and are suspended. When the foam boxes are conveyed from the first conveyor belt 11, they are positioned on the upper surface of each of the two sets of second conveyor belts 39, leaving the middle portion of the foam boxes empty to facilitate subsequent stacking. Drive shafts 40 are rotatably mounted on both ends of the second mounting frame 37. The drive shafts 40 pass through the rollers of multiple sets of second conveyor belts 39 and are driven by a motor, enabling the drive shafts 40 to drive the rollers of multiple second conveyor belts 39 to rotate. This allows multiple sets of second conveyor belts 39 to rotate simultaneously, ensuring the consistency of foam box conveying and facilitating the simultaneous stacking of multiple foam boxes, effectively improving work efficiency.

[0036] Further reference Figure 1 and Figure 17A third gantry 41 is fixedly installed at the end of the second mounting frame 37 away from the first conveyor belt 11. Multiple second limiting rods 42 are fixedly installed between the third gantry 41 and the second gantry 32. A conveying and stacking channel is formed between two adjacent second limiting rods 42. When the foam box is conveyed by the two second conveyor belts 39, it forms a limit to ensure that the foam box is located on the upper surface of each set of second conveyor belts 39, which facilitates the subsequent stacking of boxes.

[0037] Further reference Figure 3 , Figure 4 and Figure 8 Inside the second mounting bracket 37, near the drive shaft 40, multiple fourth cylinders 67 are fixedly mounted via sheet metal brackets. An L-shaped first baffle 68 is fixedly mounted at the output end of each fourth cylinder 67. The first baffle 68 is located approximately at the end of the second conveyor belt 39. When the first foam box is conveyed to one side on the two second conveyor belts 39, the working end of the fourth cylinder 67 pushes the first baffle 68 upwards, causing the bent vertical surface of the first baffle 68 to move above the second conveyor belt 39, thus blocking the first foam box. In the middle of the second mounting bracket 37, below the two second conveyor belts 39, a fifth cylinder 69 is fixedly mounted via sheet metal brackets. A second baffle 70 is fixedly mounted at the output end of the fifth cylinder 69. The width of the multiple second baffles 70 is less than the distance between the two second conveyor belts 39. When the first foam box on the second conveyor belt 39 is conveyed to the first baffle 68 and intercepted by the first baffle, the second conveyor belt 39 will continue to drive the second foam box to move. At this time, the working end of the fifth cylinder 69 pushes the second baffle 70 to move upward, and the second baffle 70 blocks it, so that the foam box no longer moves forward.

[0038] It should be noted that in this application, the second mounting bracket 37 and the external drives of the multiple cylinders are equipped with an industrial vision system and a ranging system, so that each cylinder can smoothly push the corresponding baffle to ensure that the foam box is successfully intercepted. After two foam boxes are intercepted, the third foam box will be transported by the second conveyor belt 39. When the industrial vision system detects that the third foam box has reached the preset position, the second conveyor belt 39 stops transporting, so that the three foam boxes remain stationary, facilitating the subsequent stacking of the boxes.

[0039] Further reference Figure 1 and Figure 9Located above the second intercepted foam box, a third mounting frame 43 is fixedly installed on the outside of the second mounting frame 37. A fourth gantry frame 44 is fixedly installed on the top of the third mounting frame 43. Multiple support platforms 441 are provided on the top of the fourth gantry frame 44. It should be noted that in this application, one support platform 441 corresponds to the stacking of foam boxes in two sets of second mounting frames 37. Two U-shaped lifting frames 46 are slidably installed below each support platform 441. The two lifting frames 46 are fixedly connected by a horizontal plate to achieve synchronous vertical sliding. Multiple second cylinders 45 are fixedly installed on the top of the support platform. The output end of the second cylinder 45 slides through the support platform 441 and is fixedly connected to the cross plate between the two lifting frames 46. A third cylinder 47 is fixedly installed on the U-shaped side of each lifting frame 46. The output end of the third cylinder 47 is rotatably connected to a clamping block 48 through a bearing seat. It should be noted that the clamping center line of the two corresponding clamping blocks 48 is not aligned with the center line of the foam box. Their clamping center line is located between one-third and one-fifth of the transverse length of the foam box (as shown in the attached figure). Figure 8 It should also be noted that no limiting structure is arranged on the outside of the clamping block 48 in this application, that is, after the clamping block 48 clamps the foam box, the foam box can be flipped over at will.

[0040] Specifically, when three foam boxes are conveyed and positioned, the positioning plate 36 moves downward to block subsequent foam boxes. At this time, the second cylinder 45 drives the connected lifting frame 46, the third cylinder 47, and the clamping block 48 to move downward. When the third cylinder 47 reaches the bottom of the second foam box, the output end of the third cylinder 47 pushes the clamping block 48 forward to clamp the foam box. After clamping the foam box, the lifting frame 46 moves upward. During the upward movement, since the clamping block 48 is not clamped in the middle of the foam box, and the clamping is offset from the middle of the foam box by a large margin, the foam box will rotate 90° to one side with the clamping block 48 and its connected bearing seat as the fulcrum. At this time, the opening of the foam box no longer faces upward but faces to one side, in preparation for subsequent stacking.

[0041] Further reference Figure 1 and Figure 8 Multiple sliding rods 50 are fixedly installed on the upper surface of the lifting frame 46, which slide through the support platform 441 to limit the fourth gantry frame 44 when it slides up and down, so as to ensure the stability of the lifting frame 46 when it drives the foam box to rise and fall.

[0042] Further reference Figure 3 , Figure 5 and Figure 6Below the opening between the two second conveyor belts 39 in the third mounting frame 43, there are two symmetrically arranged stacking plates 59. The stacking plates 59 are L-shaped with their two short sides facing each other. The stacking plates 59 are located below the foam boxes and between each set of two second conveyor belts 39. It should be noted that when the first foam box is intercepted, it will be exactly above the first stacking plate 59, while when the third foam box stops conveying, it will be above the second stacking plate 59.

[0043] After the second foam box in the middle is clamped, lifted, and flipped, the two stacking plates 59 flip upwards with the junction of their long and short sides as the center. Since the stacking plates 59 are L-shaped, the other two foam boxes can be flipped 90°. Simultaneously, the middle foam box is released from its clamps, allowing the two foam boxes to snap together from the left and right sides. During this process, the middle foam box falls downwards and is snapped together by the two foam boxes. After snapping, the middle foam box is wrapped by the flipped foam boxes on both sides, forming a tightly stacked structure. This interlocking structure significantly increases the friction and contact area between the boxes, preventing slippage due to vibration or tilting during assembly line handling, warehousing, or transportation. Compared to the traditional method of vertically stacking multiple foam boxes, it also reduces stacking space, saving significant storage and transportation space. After stacking, the foam boxes remain on the upper surface of the second conveyor belt 39 and are conveyed to one side by the second conveyor belt 39 to the next workstation. It should be noted that in actual operation, an automated packaging device is installed at the end of the second mounting rack to automatically package the stacked foam boxes, securing them with strapping or shrink film. After packaging, the foam box assembly is conveyed to the discharge end, where it is transferred by a robotic arm or conveyor mechanism to the storage area or transport vehicle.

[0044] Further reference Figure 3 , Figure 5 and Figure 6A servo screw drive system 51 is fixedly installed on the outer side of the third mounting frame 43. The servo drive system 51 includes a drive motor, a screw, a slide rail slider, and corresponding distance sensors, which are existing technologies and will not be described in detail here. A lifting plate 53 is connected to the drive end of the servo screw drive system 51, so two lifting plates 53 slide on the outer side of the third mounting frame 43. A connecting rod 54 is fixedly installed between the two lifting plates 53, and multiple beam plates 55 are slidably installed above the connecting rod 54. A counterweight linkage mechanism is arranged between the two stacking boxes 59 and the beam plates 55. During the clamping and lifting of the second foam box in the middle, the servo screw drive system 51 drives the lifting plate 53 to move upward. The lifting plate 53 drives the connecting rod 54 to move upward. The upward-moving connecting rod 54 pushes the beam plates 55 upward. During the upward movement of the beam plates 55, the counterweight linkage mechanism drives the two stacking boxes 59 to flip, thereby stacking the three foam boxes. It should be noted that in this application, the connecting rod 54 is arranged laterally below multiple beams 55, so when stacking foam boxes, the stacking of multiple foam boxes in the second mounting frame 37 can be completed simultaneously.

[0045] Further reference Figure 5 , Figure 6 and Figure 7 Multiple beams 55 have end rods 56 fixedly installed at both ends. A sliding rail slider structure is provided between the two ends of the end rods 56 and the second mounting frame 37 to ensure smooth sliding of the end rods 56 and the beams 55. Lifting rods 60 are fixedly installed inside the two end rods 56. The middle of the bottom surface of the stacked box plate 59 is rotatably connected to the top of the lifting rods 60 via a hinge seat. Multiple beams 55 have sliding grooves 57 at both ends. A first counterweight rod 58 is slidably installed inside the sliding grooves 57. The top of the first counterweight rod 58 is hinged to the short side of the stacked box plate 59 via a hinge seat, and a first counterweight block 61 is fixedly installed at the bottom of the first counterweight rod 58. When the connecting rod 54 moves upward, it drives the beam plate 55 to move upward as well, thereby driving the lifting rod 60 to push the stacked box plate 59 upward. At this time, the weight of the first counterweight block 61 pulls the short side of the stacked box plate 59, preventing it from rotating. Therefore, when the lifting rod 60 lifts the stacked box plate 59, it will cause the stacked box plate 59 to rotate in the center, and cause the first counterweight rod 58 to slide inside the slide groove 57, ensuring the normal operation of the equipment.

[0046] Further reference Figure 6 The long side of the stacking plate 59, away from the first counterweight rod 58, is hinged to a second counterweight rod 62. A second counterweight block 63 is fixedly installed at the bottom of the second counterweight rod 62. After the foam boxes are stacked, the stacking plate 59 moves downward. Through the gravity of the second counterweight block 63, the stacking plate 59 can be reset normally, improving the usage effect.

[0047] Example 2: An automatic foam box stacking device is disclosed. A second cylinder 45 moves the foam box upwards. An air pipe 49 is fixedly installed on one side of a lifting frame 46, with the outer end of the air pipe 49 pointing vertically downwards and located on the side of the foam box away from the clamping block 48. The air pipe 49 is connected to an external air jet device (such as an air pump), which is existing technology and will not be described in detail in this solution. After the foam box moves to a preset position, the air pipe 49 blows air towards one side of the foam box. Due to the eccentric clamping of the foam box, the air jet causes the foam box to rotate downwards by 90° around the clamping block 48, further ensuring the flipping effect. The device then moves the foam box downwards to a designated position to facilitate subsequent stacking operations.

[0048] Finally, it should be noted that this invention, an automatic foam box stacking device, aims to protect the various mechanical structures and related motion logic within this solution. Therefore, it does not provide a detailed description of the various sensors, detectors, and driving components required for actual operation of these mechanical structures. However, for those skilled in the art, various control systems and electrical connection methods, including various electrical components and driving components, can all be implemented using conventional techniques. As long as the beneficial effects or specific actions required to perform the aforementioned tasks are achieved, this solution is feasible and does not impose excessive restrictions.

[0049] The servo motor 14, first cylinder 35, second cylinder 45, third cylinder 47, fourth cylinder 67 and fifth cylinder 69 of the automatic stacking foam box device in this invention are all purchased from the market. Technical personnel in this industry only need to install and operate them according to the accompanying instruction manual, without the need for creative labor from technical personnel in this field.

[0050] It should be noted that the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a product or system comprising a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a product or system. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the product or system that includes that element.

[0051] The foregoing description illustrates and describes several preferred embodiments of this application. However, as previously stated, it should be understood that this application is not limited to the forms disclosed herein and should not be construed as excluding other embodiments. It can be used in various other combinations, modifications, and environments, and can be altered within the scope of the conception outlined herein through the foregoing teachings or techniques or knowledge in related fields. Any modifications and variations made by those skilled in the art that do not depart from the spirit and scope of this application should be within the protection scope of the appended claims.

Claims

1. An automatic stacking device for foam boxes, comprising a first mounting frame (10), characterized in that, A first conveyor belt (11) is provided on the top of the first mounting frame (10), and a bracket (12) is provided on one side of the first mounting frame (10). A receiving rack (27) is fixedly installed inside the bracket (12), and a fixed frame (21) is slidably installed inside the receiving rack (27). A speed-multiplying lifting mechanism (22) is provided between the bracket (12) and the fixed frame (21). Multiple sets of foam box clamping structures are fixedly installed inside the fixed frame (21). When the molding machine demolds, the fixed frame (21) extends into the mold before the mold is moved and is clamped by the foam box clamping structure. The fixed frame (21) clamps... After the foam box is lowered, it automatically falls onto the first conveyor belt (11). A second mounting frame (37) is provided on the side of the first mounting frame (10) away from the bracket (12). Multiple sets of corresponding second conveyor belts (39) are provided on the top of the second mounting frame (37). A clamping and rotating mechanism is slidably installed above the second conveyor belt (39) for eccentrically clamping the foam box to make it rise, fall and flip. A pair of corresponding stacking plates (59) are rotatably installed below each set of second conveyor belts (39). The stacking plates (59) are used in conjunction with the clamping and rotating mechanism to interlock and stack the three foam boxes. The foam box clamping structure includes multiple sets of clamping plates (23) arranged in pairs on one side of the fixed frame (21). The clamping plates (23) form a flared shape between them. An L-shaped elastic plate (24) is provided at one end of the clamping plate (23) away from the fixed frame (21). Multiple rollers (25) are rotatably installed at one end of the elastic plate (24). The rollers (25) clamp the foam box. The surfaces of the multiple sets of receiving racks (27) are all fixedly installed with arc-shaped main conveyor belts (28). When the foam box held by the roller (25) comes into contact with the main conveyor belt (28), it automatically falls off. The end of the stroke of the main conveyor belt (28) abuts against one side of the first conveyor belt (11). Both stacked box panels (59) are L-shaped. The two stacked box panels (59) can be flipped over to merge the two foam boxes. A beam plate (55) is slidably arranged below each pair of stacked box panels (59). A counterweight linkage mechanism is arranged between the two stacked box panels (59) and the beam plate (55).

2. The automatic stacking device for foam boxes according to claim 1, characterized in that, The double-speed lifting mechanism (22) includes a servo screw drive structure and a chain drive structure. The servo screw drive structure is connected to a lifting frame (17). The lifting frame (17) and the fixed frame (21) are connected by a chain drive structure. The double-speed lifting mechanism (22) completes double-stroke pushing of the fixed frame (21).

3. The automatic stacking device for foam boxes according to claim 1, characterized in that, The clamping and rotating mechanism includes a lifting frame (46) slidably disposed above each set of second conveyor belts (39). Two opposing third cylinders (47) are fixedly installed inside the lifting frame (46). The output end of the third cylinder (47) is rotatably connected to a clamping block (48) through a bearing seat. The clamping centerline of the two clamping blocks (48) is offset from the centerline of the foam box.

4. The automatic stacking device for foam boxes according to claim 3, characterized in that, An air pipe (49) is also fixedly installed on one side of the lifting frame (46), with the air jet end of the air pipe (49) being away from the clamping centerline of the clamping block (48).

5. The automatic stacking device for foam boxes according to claim 1, characterized in that, The counterweight linkage mechanism includes end rods (56) fixedly installed at both ends of the beam plate (55), and lifting rods (60) fixedly installed inside the two end rods (56). The middle position of the bottom surface of the stacked box plate (59) is rotatably connected to the top end of the lifting rod (60). Sliding grooves (57) are opened at both ends of the multiple beam plates (55). A first counterweight rod (58) is slidably installed inside the sliding groove (57). The top end of the first counterweight rod (58) is hinged to the short side of the stacked box plate (59), and a first counterweight block (61) is fixedly installed at the bottom of the first counterweight rod (58).

6. The automatic stacking device for foam boxes according to claim 1, characterized in that, The second mounting bracket (37) is provided with two opposing third mounting brackets (43). The two third mounting brackets (43) are connected to a lifting plate (53) by a servo screw drive system. A connecting rod (54) is fixedly installed between the two lifting plates (53). The connecting rod (54) is arranged horizontally below multiple beams (55). The connecting rod (54) moves upward to push the stacked box plates (59) above the multiple beams (55) to simultaneously realize the foam box fastening process.

7. The automatic stacking device for foam boxes according to claim 1, characterized in that, A second gantry (32) is provided above the first conveyor belt (11) on the side near the second conveyor belt (39), and a first gantry (29) is provided on the other side above the first conveyor belt (11). Multiple first limit rods (33) are fixedly installed between the second gantry (32) and the first gantry (29), and multiple positioning plates (36) are slidably provided below the second gantry (32).

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