A box orthopedic sleeve system

Abstract

The utility model provides a kind of box orthopaedic sleeve box system, it is related to the technical field of automated production, the box orthopaedic sleeve box system includes product positioning unit, box orthopaedic unit and grabbing mechanism.Product positioning unit is positioned to sleeve box station with product;Box orthopaedic unit is located at the sleeve box station, and the box orthopaedic unit is equipped with mutually perpendicular first locating surface and second locating surface;Grabbing mechanism is used to grab and move carton;Wherein, the grabbing mechanism is configured as: grab carton, so that the first side of the carton abuts against the first locating surface, in the state of maintaining the first side and the first locating baffle abut, move the carton, so that the second side adjacent to the first side abuts against the second locating surface, and then the carton is sleeved on the product.Box correction before sleeve is realized, solve the problem of high automatic sleeve failure rate and poor stability caused by carton deformation in prior art.

Description

Technical Field

[0001] This utility model relates to the field of automated production technology, and in particular to a box-shaped box-fitting system. Background Technology

[0002] At the end of the production line for large products such as air conditioner units, carton packaging is a crucial step. Traditionally, this step is mainly done manually, usually requiring two or more workers to work together to fit pre-formed cartons onto the products. This manual method has significant drawbacks: firstly, it is labor-intensive and workers are prone to fatigue; secondly, production efficiency is limited by the speed of manual operation, resulting in an unstable cycle time that is difficult to meet the needs of large-scale production; and finally, the consistency of manual operation is poor, which may lead to fluctuations in packaging quality.

[0003] To address these issues, the industry has seen attempts to use industrial robots for automated carton packing. Existing automation solutions typically involve using robots to pick up cartons and move them above the products for packing. However, in practical applications, the success rate and stability of such automation solutions are often unsatisfactory, especially when handling large, thin-walled cartons, where a technical challenge remains unresolved.

[0004] Specifically, after being stacked, transported, or gripped by a robot's suction cup, the inherent non-rigid nature of cardboard boxes causes them to deform. The original rectangular opening often transforms into a rhombus or an irregular parallelogram. When a robot carries such deformed cardboard boxes for nesting, the inner walls of the boxes interfere with or collide with the corners of the products, leading to nesting failure.

[0005] Therefore, it is necessary to improve the existing automatic packing technology for products in order to overcome the shortcomings of the existing technology. Summary of the Invention

[0006] To overcome the problems existing in related technologies, the purpose of this utility model is to provide a box-shaping and box-packing system. This box-shaping and box-packing system sets up a box-shaping unit with mutually perpendicular positioning surfaces, and the gripping mechanism sequentially abuts the gripped carton against the two positioning surfaces to forcibly restore its right-angle shape, thereby overcoming the problems of high failure rate and poor stability of automatic box packing caused by carton deformation in the prior art.

[0007] A box-type orthopedic enclosure system, comprising: The product positioning unit has a box-packing station, and the product positioning unit is used to position the product at the box-packing station. A box-shaped straightening unit is provided at the box-fitting station, and the box-shaped straightening unit is provided with a first positioning surface and a second positioning surface that are perpendicular to each other; A gripping mechanism used to grip and move cardboard boxes; The grasping mechanism is configured as follows: Grasp the carton so that its first side abuts against the first positioning surface. While maintaining the first side abutting against the first positioning baffle, move the carton so that its second side, adjacent to the first side, abuts against the second positioning surface. Then, place the carton onto the product.

[0008] Furthermore, the box-shaped straightening unit includes a first positioning baffle and a second positioning baffle that are fixedly installed, wherein the first positioning baffle and the second positioning baffle are perpendicular to each other; The positioning surface of the first positioning baffle constitutes the first positioning surface, and the positioning surface of the second positioning baffle constitutes the second positioning surface.

[0009] It employs a non-powered mechanical baffle structure. Requiring no additional drive components (such as cylinders or motors) or sensors, its structure is very simple and its manufacturing cost is low. Furthermore, the absence of moving parts means fewer potential points of failure, stable and reliable operation, and virtually no maintenance required. In addition to achieving the aforementioned excellent orthopedic effects, it offers the additional advantages of simple structure, low cost, and high reliability.

[0010] Furthermore, the box-shaped unit is located above the product positioning unit and is higher than the product located at the box-making station.

[0011] The straightening unit is located above the product positioning unit, and the straightening action is performed directly above the product. Therefore, after the carton is straightened, the gripping mechanism only needs to perform a single, vertically downward movement to complete the box placement. This layout avoids long-distance horizontal movement of the carton after straightening, reducing the risk of secondary deformation that may occur due to movement. It simplifies the robot's movement trajectory, shortens the work cycle time, and improves overall production efficiency.

[0012] Furthermore, the product positioning unit includes: The product conveyor line has the aforementioned box-packing station for conveying the product to the box-packing station; Product arrival detector, used to detect whether the product has arrived at the packaging station; A first product positioning mechanism is used to limit the product in the width direction of the product conveyor line; The second product positioning mechanism is used to limit the product along the length of the product conveyor line.

[0013] The product positioning unit comprises a product conveyor line, a detector, and a first product positioning mechanism and a second product positioning mechanism for limiting the width and length directions, respectively. It provides a complete solution for precise product positioning in both the X and Y planes. The product is firmly positioned in both length and width directions, so regardless of any slight deviation in the incoming material location, the final product position at the packing station will be unique and highly accurate. This provides a reliable benchmark for subsequent high-precision packing operations, ensuring that the shaped cartons are accurately aligned with the product, further guaranteeing a high success rate for packing.

[0014] Furthermore, the first product positioning mechanism includes a first driving member, a push plate, and a limiting baffle. The first driving member is connected to the push plate, and the first driving member and the limiting baffle are respectively disposed on both sides of the product conveying line. The first driving member is used to drive the push plate to move along the width direction of the product conveying line. The second product positioning mechanism includes a second driving member, which is used to block the movement of the product along the length of the product conveyor line.

[0015] The first and second product positioning mechanisms employ drive components (such as cylinders), resulting in fast response speeds, precise positioning, and ease of automation control via PLCs or other controllers. This provides a technologically mature, cost-effective, and reliable method for precise product positioning.

[0016] Furthermore, the box-shaped orthopedic enclosure system also includes: A box pressing unit is located at the box-packing station and is used to press down the carton.

[0017] During the carton-sleeving process, especially for larger or tightly fitted cartons, the friction between the inner wall of the carton and the product surface can hinder its smooth sliding, and may even cause the top of the carton to arch. An additional carton-pressing unit applies extra active downward pressure to the top of the carton during sleeve placement, effectively overcoming frictional resistance. This ensures the carton can be smoothly and completely sleeved, avoiding issues such as misalignment or jamming caused by friction, and improving the final packaging quality.

[0018] Furthermore, the housing pressing unit includes a third driving component and a pressure plate. The third driving component is connected to the pressure plate and is used to drive the pressure plate to move in the vertical direction.

[0019] One specific implementation of the carton pressing unit consists of a third driving component (such as a cylinder) and a pressure plate. This structure, employing a driving component and pressure plate, allows for convenient control of the timing, stroke, and force of the pressing action to accommodate cartons of different sizes. It provides a versatile, flexible, and reliable auxiliary pressing method.

[0020] Furthermore, the carton-shaping and crimping system also includes a secondary positioning device for pre-positioning the carton before the gripping mechanism grips it. The secondary positioning device includes: Fixed right-angle positioning base; A pushing mechanism is used to push the carton toward the right-angle positioning base.

[0021] The gripping mechanism first picks up a carton from the hopper and moves it to a secondary positioning device. This device, via a pushing mechanism, propels the carton towards a fixed right-angle positioning base for pre-positioning. The gripping mechanism then picks up the pre-positioned carton again and performs the subsequent boxing process. Without pre-positioning, the position and orientation of the incoming cartons are random, requiring the gripping mechanism to use a vision system to identify the gripping points, increasing cost and complexity. With the addition of the secondary positioning device, each carton to be gripped is pre-placed in a fixed reference position. The gripping mechanism can use fixed programmed points for gripping, eliminating the need for visual guidance. This significantly simplifies the control system and programming complexity of the gripping mechanism, reduces equipment costs, and makes the gripping action faster and more stable, improving the cycle time and reliability of the entire automated process.

[0022] Furthermore, the pushing mechanism includes a first pushing mechanism and a second pushing mechanism; The first pushing mechanism and the second pushing mechanism are respectively used to push the carton along the two right-angle positioning sides of the right-angle positioning base.

[0023] The pushing mechanism includes a first pushing mechanism and a second pushing mechanism that push the carton along the two right-angled sides of the right-angled positioning base, respectively. Through the coordinated action of the two pushing mechanisms, it is ensured that both adjacent sides of the carton are tightly fitted with the two reference sides of the positioning base. This achieves high-precision two-dimensional planar pre-positioning, which is more reliable and accurate than single-sided pushing.

[0024] The beneficial effects of this utility model are as follows: This utility model provides a carton-shaping and crimping system. The system includes a carton-shaping unit with first and second perpendicular positioning surfaces. Through a specific action of the gripping mechanism, the first side of the carton is first brought into contact with the first positioning surface. Then, while maintaining this contact, the carton is moved so that the second side comes into contact with the second positioning surface. Because cartons (especially large ones) are non-rigid, their openings often change from rectangular to rhomboid after being gripped. In existing technology, directly crimping such deformed cartons onto products is prone to failure due to corner interference. Through the specific "first positioning, then translational straightening" action, the two rigid, perpendicular positioning surfaces forcibly reshape the deformed carton held by the gripping mechanism, restoring its opening to a standard rectangle. The carton is straightened to a regular shape just before crimping, allowing it to be smoothly and without interference onto the positioned product below. This solves the problem of automatic crimping failure caused by carton deformation, greatly improving the success rate of automated crimping and the system's operational stability. Attached Figure Description

[0025] Figure 1 This is an overall schematic diagram of the box-shaped orthopedic sleeve system provided in the embodiments of this application; Figure 2 This is an overall top view of the box-shaped orthopedic sleeve system provided in the embodiments of this application; Figure 3 This is a schematic diagram of the gripping mechanism provided in the embodiments of this application; Figure 4 This is a schematic diagram of the gripping fixture provided in the embodiments of this application; Figure 5 This is a schematic diagram of the product positioning unit, the box straightening unit, and the box pressing unit provided in the embodiments of this application; Figure 6 This is a schematic diagram of the secondary positioning device for the box provided in the embodiments of this application; Figure 7 This is a schematic diagram of the state in which the first side of the carton abuts against the first positioning surface provided in the embodiments of this application; Figure 8 This is a top view of the state in which the first side of the carton abuts against the first positioning surface provided in the embodiments of this application; Figure 9 This is a schematic diagram of the state in which the second side of the carton abuts against the second positioning surface provided in the embodiments of this application; Figure 10 This is a top view of the state in which the second side of the carton abuts against the second positioning surface, as provided in the embodiments of this application.

[0026] Figure label: 100. Product positioning unit; 110. Product conveyor line; 120. Product arrival detector; 130. First product positioning mechanism; 131. First driving component; 132. Push plate; 133. Limiting baffle; 140. Second product positioning mechanism; 141. Second driving component; 200. Box-shaped straightening unit; 210. First positioning baffle; 220. Second positioning baffle; 300. Gripping mechanism; 310. Six-axis industrial robot; 320. Gripping fixture; 400. Housing pressing unit; 410. Third driving component; 420. Pressure plate; 500. Secondary positioning device for the box body; 510. Right-angle positioning base; 521. First pushing mechanism; 522. Second pushing mechanism. Detailed Implementation

[0027] Preferred embodiments of the present invention will now be described in more detail with reference to the accompanying drawings. While preferred embodiments of the present invention are shown in the drawings, it should be understood that the present invention may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that the present invention will be thorough and complete, and will fully convey the scope of the present invention to those skilled in the art.

[0028] Example 1 like Figures 1 to 10 As shown, this embodiment provides a box-shaped orthotic box-shaped system, which includes a gripping mechanism 300, a product positioning unit 100, and a box-shaped orthotic unit 200.

[0029] The gripping mechanism 300 is responsible for performing all physical operations related to the cartons, including picking up cartons from the stockpile, transporting them to designated workstations, and completing shaping and packing actions according to a specific trajectory. For example... Figure 3 , Figure 4 As shown, in this embodiment, the gripping mechanism 300 is preferably a six-axis industrial robot 310, with a fixture specifically designed for gripping cartons, such as an array of multiple vacuum suction cups, installed at its end.

[0030] The 310 six-axis industrial robot was chosen because of its high flexibility and freedom of movement, enabling it to perform complex spatial trajectory movements. This is crucial for executing precise composite orthogonal actions such as "contact, translation, and lowering." Using a vacuum suction cup as a fixture provides a stable and reliable gripping force without damaging the surface of the cardboard box.

[0031] In addition to the preferred six-axis industrial robot 310, any gripping mechanism 300 capable of performing a compound actuation action of "approaching, translating, and lowering" can be used. In other embodiments, for example, for situations where the motion trajectory is relatively fixed, a lower-cost gantry robot (i.e., an XYZ three-axis Cartesian robot) or a SCARA robot suitable for high-speed planar operations can also be used. Similarly, the gripping fixture 320 is not limited to a vacuum suction cup; depending on the weight and rigidity of the cardboard box, it can be replaced with an internal support airbag clamp (which expands from the inside of the cardboard box to achieve fixation) or a side mechanical gripper.

[0032] The product positioning unit 100 is a device installed at the packing station. Its function is to accurately position the product transported from the upstream process in three-dimensional space (especially on the horizontal plane) so that it is in the exact same position every time it is packed.

[0033] The accuracy and repeatability of product positioning are fundamental to the success of automated carton packing. The carton packing action performed by the gripping mechanism 300 is based on a pre-set program and coordinate points. If the actual position of the product deviates, but the carton is still lowered according to the programmed trajectory, it will inevitably cause the carton to collide with the corners of the product, resulting in packing failure. Therefore, a product positioning unit 100 must be set up to eliminate the uncertainty of the incoming material position.

[0034] There are many ways to achieve product positioning. For example, the product can be pushed from two directions to a fixed mechanical block by a pneumatic or electric push rod, or adaptive positioning can be achieved by a vision sensor in conjunction with a movable block. Alternatively, for products with specific shapes, a special positioning mold with grooves or protrusions can be designed.

[0035] The box-shaped straightening unit 200 is a physical reference device, which has a first positioning surface and a second positioning surface that is perpendicular to the first positioning surface. The two surfaces together form a standard right-angled space.

[0036] The fundamental reason for setting up this unit lies in the non-rigid nature of cardboard boxes. After a cardboard box is gripped by a suction cup, due to uneven force or the release of its own stress, its opening almost always changes from an ideal rectangle to a rhombus shape. If the box is directly fitted, the deformed opening cannot be smoothly fitted into a rectangular product. The function of the box straightening unit 200 is to provide a "forced calibration" process at the moment before fitting. By having two adjacent sides of the cardboard box abut against the two vertical positioning surfaces of this unit one after the other, the rigid constraint of the positioning surfaces "squeezes" the deformed cardboard box back into a standard cuboid shape, thus clearing the way for subsequent precise fitting.

[0037] The simplest way to implement the first and second positioning surfaces is with two fixed, perpendicular steel plates or profiles. In more demanding applications, the positioning surfaces can also be composed of rows of freely rotating rollers to reduce friction when the cartons are pressed together; alternatively, the positioning surfaces themselves can be movable baffles driven by servo motors that can actively apply clamping force to accommodate cartons of different sizes.

[0038] The complete workflow of this embodiment is as follows: The product to be packaged enters the boxing station via the conveyor line, and the product positioning unit 100 is activated to precisely limit and fix the product.

[0039] The gripping mechanism 300 moves to the cardboard box stacking area, and its end fixture is activated to grab a cardboard box from above. At this time, the opening of the grabbed cardboard box is usually in an irregular diamond shape.

[0040] The gripping mechanism 300 carries the deformed cardboard box smoothly to a position above the box-shaping unit 200. Subsequently, the gripping mechanism 300 performs a precise combination of descent and lateral movement, causing one of the first sides of the cardboard box to fully contact and abut against the first positioning surface of the box-shaping unit 200.

[0041] Under program control, the gripping mechanism 300 must maintain continuous contact between the first side and the first positioning surface before performing the next action. This means that the gripping mechanism 300 must continuously apply a small but constant force or position locking command directed towards the first positioning surface to ensure that the carton does not detach or deflect. Under this condition, the gripping mechanism 300 then moves the entire carton along a direction parallel to the first positioning surface until the second side adjacent to the first side also contacts and is completely abutted against the second positioning surface.

[0042] When two adjacent sides of the carton are firmly pressed against two mutually perpendicular positioning surfaces, the opening of the carton is forced back to a standard rectangle. While maintaining this corrective state, the gripping mechanism 300 descends smoothly along a direction perpendicular to the horizontal plane (i.e., the Z-axis direction), accurately and precisely placing the carton, now restored to its standard shape, onto the product already positioned below from top to bottom.

[0043] After confirming that the carton has been fully seated, the fixture of the gripping mechanism 300 releases the carton (e.g., by closing the vacuum), then lifts it up and returns it to its initial position, ready to execute the next work cycle.

[0044] Example 2 like Figures 1 to 10As shown, this embodiment, based on the box-shaped orthosis system described in Embodiment 1, provides a more detailed definition of the specific physical structure and spatial layout of the box-shaped orthosis unit 200 and the product positioning unit 100. The aim is to provide a specific engineering solution that is simple in structure, highly reliable, and easy to implement.

[0045] In this embodiment, the carton straightening unit 200 consists of two independent, fixedly installed physical components: a first positioning baffle 210 and a second positioning baffle 220. Both baffles are rigid structures, for example, made of thick steel plates or robust metal profiles. The working surface of the first positioning baffle 210, which contacts the carton, constitutes the first positioning surface; similarly, the working surface of the second positioning baffle 220 constitutes the second positioning surface. These two baffles are precisely set to be perpendicular to each other during installation, thereby forming a stable and standard right-angle reference in space.

[0046] The design of the box-type orthotic unit 200, consisting of two fixed, mutually perpendicular baffles, is based on a comprehensive consideration of reliability, cost, and maintainability. This solution is a purely mechanical structure, containing no driving components (such as motors or cylinders), transmission components, or sensors. The absence of moving parts means the elimination of wear, fatigue, and control signal delays, thereby significantly improving the stability and reliability of the equipment and reducing the failure rate. Manufacturing and installing two fixed metal baffles is far less expensive than constructing a complex orthotic device with an active drive and control system. This makes the technical solution of this invention highly economical. The baffles can be designed to be very robust, sufficient to withstand the long-term, repetitive impact forces generated by the gripping mechanism 300 during orthotic movements without deformation or displacement, ensuring the long-term accuracy of its right-angle reference.

[0047] While a fixed baffle is the preferred method, the box-shaped straightening unit 200 can also be implemented in other ways in other application scenarios. For example: The first positioning baffle 210 and the second positioning baffle 220 can be installed on a linear guide rail with a scale instead of being fixedly welded or bolted. This allows the operator to manually adjust the positions of the two baffles to accommodate different sizes of cartons, improving the flexibility of the equipment.

[0048] In a more automated production line, the first positioning baffle 210 and the second positioning baffle 220 can be driven by a servo motor or a stepper motor, respectively, and fully automatic and rapid specification switching can be achieved through a program preset in the control system.

[0049] To reduce friction during the contact and movement of the carton, the working surface of the baffle can be covered with a low-friction material, such as a polytetrafluoroethylene (PTFE) film, or the positioning surface of the baffle can be designed to consist of a row of non-powered rollers to further improve the smoothness of the orthopedic movements.

[0050] In this embodiment, the relative positions of the carton straightening unit 200 and the product positioning unit 100 are optimized. Specifically, the entire carton straightening unit 200 (i.e., the right-angled device composed of the first positioning baffle 210 and the second positioning baffle 220) is positioned directly above the product positioning unit 100. This means that after the product is accurately positioned below, the carton straightening action will be completed in the space vertically above it.

[0051] Because the straightening station and the carton-packing station overlap vertically, once the carton is straightened into a standard rectangle, the gripping mechanism 300 does not need to perform any long-distance horizontal movement. It only needs to perform a single, direct vertical downward movement to complete the carton packing. This greatly shortens the movement path, reduces the work cycle time, and thus improves overall production efficiency.

[0052] After the shaping is completed, if long-distance horizontal transport is required, the acceleration, deceleration, and vibration during the movement of the carton may cause it to deform slightly again. The layout of this embodiment minimizes the time and displacement between "shaping completion" and "carton fitting start," ensuring that the carton is fitted in the most standard shape, thereby improving the success rate of carton fitting.

[0053] Integrating the two functional units vertically allows for more efficient use of vertical space and reduces the overall footprint of the equipment in the factory workshop compared to a linear layout that separates the orthopedic station and the housing station.

[0054] While a vertical layout is optimal, other layouts can be used in special cases where factory ceiling height is limited or other processes interfere. For example, the carton-shaping unit 200 can be positioned to the side of the product positioning unit 100. After the gripping mechanism 300 completes the carton shaping at this station, it moves horizontally a short distance to the top of the product and then descends vertically to complete the carton placement. In some dual-station or circular production lines, the shaping station and the carton placement station can be located on opposite sides of a rotating worktable, with station switching achieved by rotating the worktable.

[0055] More specifically, such as Figure 5 As shown, the box-shaped straightening unit 200 in this embodiment is structurally embodied as a gantry frame structure spanning above the product conveyor line 110. The core functional components of this frame are the first positioning baffle 210 and the second positioning baffle 220.

[0056] The first positioning baffle 210 consists of two fixed upright plates arranged parallel to each other along the length of the product conveyor line 110. This ensures that the entire side of the carton receives stable and continuous support when the gripping mechanism 300 performs subsequent translational movements.

[0057] The second positioning baffle 220 is specifically a fixed upright plate that is perpendicular to the width direction of the product conveyor line 110 and spans across it.

[0058] These two positioning baffles are rigidly connected by a sturdy frame. This open gantry frame design provides ample space for product conveying and positioning below, and also facilitates the entry of the gripping mechanism 300 (such as an industrial robot) from the side or above to perform orthopedic movements.

[0059] Example 3 like Figures 1 to 10 As shown, this embodiment provides a box-shaped orthopedic sleeve system. Based on the box-shaped orthopedic sleeve system described in Embodiment 1, the composition and working method of the product positioning unit 100 are described in detail.

[0060] Throughout the automated packing process, the packing action performed by the gripping mechanism 300 is based on pre-programmed, fixed spatial coordinates. Therefore, to ensure successful packing every time, it is essential to ensure that the product, the target of packing, appears in the pre-set packing station in the exact same position and orientation each time. However, conventional industrial conveyor lines inherently possess positioning errors. For example, the product may slightly shift left or right on the conveyor belt, or its final stopping position may differ by millimeters due to the inertia of the conveyor belt's start and stop. These minute deviations are sufficient to cause the failure of high-speed, high-precision packing operations.

[0061] To eliminate this uncertainty, the product positioning unit 100 in this embodiment is an independent mechatronics module. Its core function is to perform forced, high-precision two-dimensional planar positioning of the incoming product before the boxing action occurs. In this embodiment, the product positioning unit 100 specifically consists of the following four parts: Product conveyor line 110 is the basic carrier for products to enter the positioning unit. Its function is to carry and transport products from the upstream process to the approximate area of ​​the packaging station.

[0062] The product arrival detector 120 is responsible for real-time monitoring of whether a product enters the product conveyor line 110 and determining whether the leading edge of the product has reached the preset trigger position.

[0063] The first product positioning mechanism 130 is responsible for limiting the product in the width direction (i.e., perpendicular to the direction of product movement) of the product conveyor line 110.

[0064] The second product positioning machine is responsible for limiting the product along the length of the product conveyor line 110 (i.e., the direction in which the product moves forward).

[0065] The working process of the product positioning unit 100 in this embodiment is as follows: 1. The product is placed on the product conveyor line 110 and moves toward the boxing station as the conveyor line runs.

[0066] 2. When the front end of the product blocks or triggers the product arrival detector 120 installed at a specific position on the conveyor line, the detector immediately outputs an arrival signal to the central controller of the system.

[0067] 3. Upon receiving the positioning signal, the controller immediately activates the first product positioning mechanism 130. This mechanism (e.g., a liftable pneumatic stop) moves rapidly, extending from below or to the side of the conveyor line to block the product from moving forward. At this point, even if the product conveyor line 110 is still running, the product will be firmly held in place by the stop, and its position in the length direction will be precisely fixed.

[0068] 4. Simultaneously or shortly after the product is limited in the length direction, the controller drives the first product positioning mechanism 130. This mechanism (e.g., a pneumatic pusher mounted on one side of the conveyor line) is activated, smoothly pushing the product from the side until the other side of the product is in close contact with a fixed reference baffle or guardrail set on the other side of the conveyor line.

[0069] 5. After the above steps, the X and Y coordinates of the product on the horizontal plane are completely locked, the positioning process is completed, and the system can execute the subsequent box-fitting action at any time.

[0070] Reference Figure 5 The specific physical structure of the product positioning unit 100 in this embodiment will be described.

[0071] Product conveyor line 110 is a horizontal conveyor belt that runs through the entire device, i.e., an assembly line, which forms the base for product movement.

[0072] The product arrival detector 120 is specifically a photoelectric sensor installed on one side of the product conveyor line 110. This sensor is typically used in pairs, including a transmitter and a receiver for emitting and receiving a light beam. When a product passes by, the light beam is blocked, generating an electrical signal indicating that the product has arrived, triggering subsequent positioning actions.

[0073] The first product positioning mechanism 130, used for limiting the product along the length of the product conveyor line 110, is specifically implemented by a cylinder in this embodiment. The cylinder is mounted on the side of the product conveyor line 110, and the movement direction of its piston rod is perpendicular to the surface of the conveyor line. Upon receiving a signal that the product has reached its designated position, the cylinder actuates, extending its piston rod to act as a rigid stop, blocking the product's forward movement and completing the length-direction positioning.

[0074] The second product positioning mechanism 140, used for limiting the product in the width direction of the product conveyor line 110, is implemented in this embodiment by two parts working together: One part is a limiting baffle 133 fixedly installed on one side of the product conveyor line 110. It is a fixed long strip baffle extending along the length of the conveyor line, providing a stable and straight reference surface.

[0075] The other part is a movable pushing assembly located on the opposite side. This assembly is specifically composed of a cylinder and a pusher plate 132. After the length direction positioning is completed, the cylinder drives the pusher plate 132 connected to it to push the product laterally in a direction perpendicular to the product conveyor line 110 (i.e., the width direction) until the other side of the product is tightly against the fixed limiting baffle 133, thus completing the width direction positioning.

[0076] Each component of the product positioning unit 100 can be implemented using other equivalent technical solutions to achieve the same function.

[0077] For product conveyor line 110, in addition to the common belt conveyor, depending on the weight, shape and production environment of the product, it can be replaced with roller conveyor, chain conveyor, or even an automated guided vehicle (AGV) to directly transport and park the product at the boxing station.

[0078] For the product positioning detector 120, in addition to the photoelectric sensor preferred in this embodiment, it can also be replaced as needed with: proximity switches, such as inductive sensors (for metal products) or capacitive sensors; laser rangefinders, which can more accurately control the stopping position of the product; mechanical limit switches, which are triggered by physical contact with the product and have a simple and reliable structure; and machine vision systems, which use cameras and image processing algorithms to identify the position and posture of the product, offering the highest flexibility and adaptability to the positioning of various different products.

[0079] For the first product positioning mechanism 130 and the second product positioning mechanism 140, the driving and limiting methods are also diverse. Besides using a cylinder-driven push plate 132 or stop, it can be replaced with an electric push rod or servo cylinder, which can more precisely control the pushing speed, position, and force, suitable for the gentle positioning of fragile products; a servo motor combined with a ball screw or rack and pinion mechanism can achieve high-precision, high-speed positioning. A double-sided synchronous clamping mechanism, in the width direction, can use grippers or stops that move simultaneously from both sides towards the center to achieve automatic centering positioning of the product, rather than unilateral pushing. A lifting positioning nest is designed with a positioning template or "nest" that matches the shape of the product's bottom. After the product is roughly in place, it rises from below the conveyor line, lifting the product away from the conveyor line and precisely embedding it into the nest, achieving extremely high-precision positioning.

[0080] Example 4 like Figures 1 to 10 As shown, this embodiment provides a box-shaping and box-packing system, which adds a box-pressing unit 400 to the above embodiment. This aims to improve the system's operational success rate and final packaging quality.

[0081] The carton pressing unit 400 is an independent, active force-applying device that can be installed directly above the carton fitting station, near the carton straightening unit 200, or integrated into its structure. Its basic components include a third drive element 410 and a pressure plate 420 connected to the end of the drive element. The third drive element 410 is the power source, responsible for providing a vertically downward driving force; the pressure plate 420 is the actuating component that directly contacts the carton, and its shape and area are designed to evenly apply the force generated by the third drive element 410 to the top surface of the carton.

[0082] Ideally, the shaped carton, guided by gravity and the gripping mechanism 300, should fit smoothly onto the product. However, in actual production, obstacles often arise, especially in the following situations: when the carton's dimensions have a small tolerance to the product's dimensions (i.e., a tight fit), or when the product surface is not smooth, significant friction occurs between the inner wall of the carton and the outer surface of the product. This friction hinders the carton's downward sliding; for large or thin-walled, soft-material cartons, when their downward sliding is obstructed, the downward force from the gripping mechanism 300 may cause the carton itself to buckle and deform, such as arching at the top or bulging outwards on the sides, instead of sliding smoothly as a whole. At high carton-fitting speeds, air between the product and the carton is difficult to expel quickly, creating air pressure resistance, which also hinders the carton-fitting process.

[0083] In these situations, relying solely on the carton's own weight and the guiding force of the gripping mechanism 300 may not be sufficient to overcome the aforementioned resistance. Therefore, a dedicated carton-pressing unit 400 is added. Its purpose is to apply an additional, controllable, vertically downward active pressure during the critical stage of carton fitting, forcibly helping the carton overcome various resistances, ensuring that it can be smoothly and completely fitted into place, and avoiding problems such as carton jamming, incomplete fitting, or damage to the carton due to uneven force.

[0084] Reference Figure 5 The specific physical structure of the box pressing unit 400 in this embodiment will be described.

[0085] In this embodiment, the housing pressing unit 400 consists of two pressing assemblies arranged at intervals along the length of the equipment. Each pressing assembly comprises a third driving member 410 and a pressure plate 420. The third driving member 410 is responsible for providing a linear driving force for reciprocating up and down. The pressure plate 420 is a horizontally arranged long strip plate, one end of which is connected to the movable end of the third driving member 410.

[0086] The pressure plates 420 of the two pressing components are parallel to each other and span directly above the product conveying path below. This ensures that multiple pressure plates 420 can simultaneously contact and act on different positions on the top of the large carton during the pressing action. When all the third drive components 410 are activated synchronously, a uniformly distributed downward pressure is applied to the entire top force-bearing surface of the carton. This structure ensures the smoothness and uniformity of the force through multi-point pressing, effectively preventing the carton from tilting or localized deformation due to uneven force during the pressing process. On the other hand, the elongated design of the pressure plates 420 increases the contact area with the carton, avoiding potential damage to the carton surface due to stress concentration.

[0087] The collaborative workflow of the housing pressing unit 400 in this embodiment is as follows: 1. The gripping mechanism 300 lowers the shaped carton vertically so that its open end fits over the top of the product, and continues to lower it a short distance.

[0088] 2. Once the control system confirms that the carton has been initially fitted (this can be determined by the Z-axis coordinate of the gripping mechanism 300 or by a time delay), it issues a command to activate the carton pressing unit 400. The third drive unit 410 is activated, driving the pressure plate 420 to move downwards until it contacts the top surface of the carton.

[0089] 3. Subsequently, the third drive unit 410 continuously outputs a stable thrust, applying a constant downward pressure to the carton through the pressure plate 420. At the same time, the gripping mechanism 300 can continue its predetermined descent trajectory, and the two work together to push the carton downward.

[0090] 4. Once the carton has been placed in place, the fixture of the gripping mechanism 300 releases the carton. At the same time, the third drive component 410 of the carton pressing unit 400 moves in the opposite direction, causing the pressure plate 420 to lift and reset, making room for the next work cycle.

[0091] To accommodate different cost budgets, control precision requirements, and product types, the housing pressure unit 400 can be implemented in a variety of different ways.

[0092] The third drive unit 410 can be selected from several options: Pneumatic cylinders are the most common and cost-effective method, offering advantages such as fast response, simple structure, and ease of maintenance. The output downward pressure can be easily controlled by adjusting the air source pressure. Electric linear actuators, or electric cylinders, offer more precise position and speed control compared to pneumatic cylinders. This is particularly useful for applications requiring precise control of the downward stroke or speed.

[0093] The servo motor, in conjunction with the ball screw mechanism, not only allows for precise control of position and speed, but also enables highly accurate force control through torque control mode. It is suitable for packaging precision products where strict pressure requirements are necessary.

[0094] The structure of the pressure plate 420 can be selected in several ways: One-piece flat panel, the simplest structure, suitable for cardboard boxes with flat tops.

[0095] The hollow frame structure, while ensuring contact area and structural rigidity, can reduce the weight of the pressure plate 420 itself, thereby allowing the use of a smaller third drive component 410, reducing cost and energy consumption.

[0096] The pressure plate 420 with soft cushioning pads has an added layer of elastic material such as rubber or polyurethane on the contact surface. This can protect the surface of the carton from scratches or dents while applying pressure, and can better adapt to minor unevenness on the top of the carton.

[0097] The pressure plate 420 with free rollers can minimize horizontal friction while applying downward pressure if the carton may still have slight horizontal displacement during the pressing process. This allows the carton to make adaptive fine adjustments.

[0098] In some designs, the function of the housing pressing unit 400 may not exist as a separate component, but rather be integrated into the fixture of the gripping mechanism 300. For example, one or more small pneumatic or electric cylinders can be additionally installed as third drive components 410 at the center or around the suction cup array. After gripping is completed, these small drive components can extend to achieve the pressing function. This approach results in a compact structure, but places higher demands on the design of the fixture.

[0099] Example 5 like Figures 1 to 10 As shown, this embodiment provides a carton-shaping and crimping system. Based on the above embodiment, a secondary carton positioning device is added to the upstream carton feeding stage to pre-position the carton. This aims to improve the stability and efficiency of the entire automated process and reduce reliance on complex sensing systems.

[0100] The carton secondary positioning device is an independent mechanical system located at the gripping station of the gripping mechanism 300 (robot). Its core function is to precisely adjust a carton with a relatively arbitrary position and orientation to a fixed, pre-set reference position. In this embodiment, the device mainly consists of two parts: a fixed right-angle positioning base 510 and a pushing mechanism.

[0101] The fixed right-angle positioning base 510 is an L-shaped, rigidly fixed mechanical structure that provides two mutually perpendicular, precise physical reference planes. This right angle is the ultimate goal of all positioning actions.

[0102] The pushing mechanism is the main power component in the device, responsible for pushing the carton. To achieve precise positioning on a two-dimensional plane, the pushing mechanism is further divided into a first pushing mechanism 521 and a second pushing mechanism 522. The movement directions of these two pushing mechanisms are perpendicular to each other, and they are used to drive two adjacent sides of the carton so that they can eventually fit tightly against the two reference surfaces of the fixed right-angle positioning base 510.

[0103] Without a secondary positioning device for cardboard boxes, automated systems face a dilemma. One option is to require human operators to place the boxes in the same position in the grasping area with extremely high precision each time. This is not only demanding on workers and prone to errors, but also diminishes the purpose of automation. The other option is to equip the robot with a sophisticated vision recognition system (including industrial cameras, light sources, image processing software, etc.) to allow the robot to visually identify the actual position and angle of each box before grasping it. While a vision system is feasible, it significantly increases the initial investment cost, system complexity, and debugging difficulty. Furthermore, it is susceptible to interference from factors such as changes in ambient lighting and variations in printed patterns on the boxes, affecting stability.

[0104] Therefore, the fundamental purpose of introducing a cardboard box secondary positioning device is to replace the expensive and complex vision guidance system with a simple, reliable, and low-cost purely mechanical method. It actively positions the cardboard box to an absolute coordinate point, allowing the robot to grasp it blindly. The robot does not need to know where the cardboard box was initially placed; it only needs to be programmed with a fixed grasping coordinate. This greatly simplifies the robot's control logic, reduces system costs, and fundamentally ensures the high repeatability and reliability of the grasping action.

[0105] The workflow of the carton secondary positioning device in this embodiment is as follows: 1. A robot or a person places a cardboard box to be used on the support frame of the device. At this time, the accuracy requirement for placement is very low; it is only necessary to ensure that the cardboard box is roughly within the working area.

[0106] 2. The system detects that the feeding is complete by using a simple sensor (such as a photoelectric switch to detect that an object has been placed in, or in conjunction with an automation program) and then starts the positioning program.

[0107] 3. Simultaneously or sequentially drive the first pushing mechanism 521 (e.g., a cylinder parallel to the X-axis) and the second pushing mechanism 522 (e.g., a cylinder parallel to the Y-axis) to operate until the two mutually perpendicular sides are fully in contact and abut against the two positioning arms of the fixed right-angle positioning base 510.

[0108] 4. After both pushing mechanisms have completed their strokes, the two adjacent sides of the carton are firmly confined within the L-shaped right-angled base. At this point, the position and orientation of the carton on the horizontal plane are uniquely determined. The robot then grasps the carton and moves it to the preset, fixed grasping coordinate point to perform the grasping action, followed by subsequent straightening and box-stuffing processes.

[0109] Each part of the carton secondary positioning device can be implemented using other equivalent technical solutions: Regarding the driving method of the pushing mechanism: In addition to the common cylinder drive, for occasions requiring more precise speed and position control, an electric cylinder or servo motor combined with a ball screw can be used; for lighter cartons, a motor combined with a linkage mechanism can also be used to realize the reciprocating motion of the push plate 132; in some designs, two miniature conveyor belts can also be used as the pushing mechanism, and the cartons can be "transmitted" to the corner of the positioning base by controlling the rotation of the conveyor belts.

[0110] For the structure of the fixed right-angle positioning base 510: In order to reduce the friction of the carton during the pushing process, the two reference surfaces of the positioning base can be replaced by a row of freely rotating non-powered rollers instead of solid baffles; in order to adapt to cartons of different sizes and specifications, the positioning base can be designed to be adjustable, and the positions of its two positioning arms can be adjusted manually or automatically.

[0111] Alternative solutions for the overall positioning logic include: besides the dual-axis pushing to a fixed right angle, a four-sided clamping and centering solution can be used. This solution eliminates the fixed right-angle base, replacing it with push plates 132 that can move in four directions. The four push plates 132 move synchronously towards the center, clamping and positioning the carton at the geometric center of the device. This method is particularly suitable for production lines that need to accommodate various carton sizes; for lighter cartons with flat bottoms, a vibration ramp positioning solution can also be used. The device's bearing surface is designed as a platform with a slight inclination angle and a weak vibration function, with a fixed right-angle guard at the lowest point of the platform. After the carton is placed on the platform, under the combined action of gravity and vibration, it will automatically slide towards and stably rest against the right-angle guard, achieving passive positioning without an active pushing mechanism.

[0112] Example 6 like Figures 1 to 10 As shown, this embodiment provides an automatic carton packing method, implemented through the carton shaping and packing system described in the previous embodiment. The system includes a product positioning unit 100, a gripping mechanism 300 (e.g., a robot), and a carton shaping unit 200 with mutually perpendicular first and second positioning surfaces. The core of this method lies in introducing a unique, physical contact-based carton shape correction step before formal packing, aiming to fundamentally solve the problem of automated packing failure caused by carton deformation. This automatic packing method includes the following steps: Step 1: The product positioning unit 100 positions the product to the packaging station; The second step is for the robot to pick up the cardboard box; Third step: The robot brings the first side of the cardboard box abutting against the first positioning surface; then, while maintaining the first side abutting against the first positioning surface, the robot moves the cardboard box until the second side adjacent to the first side abuts against the second positioning surface. Step 4: Place the shape-corrected cardboard box onto the product at the box-making station. The first step is the preparation phase of the entire automation process. Its task is to ensure that the product to be packaged is accurately fixed within the pre-defined boxing working area, and that its position and posture remain highly consistent in each cycle. The automated equipment executes a pre-programmed trajectory, which "assumes" that the target object (product) is always in a fixed coordinate position. If the product's position deviates, the subsequent boxing actions performed by the robot according to the fixed trajectory will inevitably result in interference and collisions. Therefore, accurate product positioning is an absolute prerequisite for ensuring the successful execution of all subsequent steps. In a typical implementation, the product enters the boxing station along a conveyor line. When the product triggers a sensor (such as a photoelectric switch), the conveyor line pauses or the product is stopped by a blocking mechanism, completing coarse positioning in the length direction. Subsequently, one or more drive components (such as cylinders or servo push rods) push the product from the side towards a fixed mechanical reference surface, completing fine positioning in the width direction. Through these two directional limits, the product is firmly locked in the boxing station, and its spatial coordinates are uniquely determined.

[0113] The second step is the robot's material handling action. The robot moves to the cardboard box storage area and picks up a ready-to-use cardboard box. This is a necessary step in preparing materials for subsequent packaging. It is important to emphasize that it is in this step that the deformation of the cardboard box begins to emerge. Whether it is the natural deformation of the cardboard box during stacking, or the inward or outward contraction of the top opening due to uneven force when the robot's suction cups grasp it from above, the opening will change from an ideal rectangle to an irregular rhombus or parallelogram. According to the preset program, the robot moves its end effector to above a known picking point. The suction cup array on the end effector generates negative pressure through a vacuum generator, firmly adhering to the top surface of the cardboard box. Subsequently, the robot lifts the cardboard box vertically, detaching it from the stack, and prepares to move it to the next workstation.

[0114] The third step is a continuous, constrained compound action designed to force the deformed cardboard box back into a standard rectangle. Directly using the deformed box for nesting is the root cause of failure. This step physically shapes the non-rigid cardboard box by leveraging a rigid, standard right-angle reference (composed of a first and second positioning surface). Maintaining the first side against the first positioning surface provides a continuous constraint, preventing the box from rotating or escaping during the second-direction contact, thus ensuring the determinism and reliability of the corrective action. The robot carries the cardboard box to the box corrective unit 200. The robot executes movement commands, smoothly placing one of the first sides of the box against the first positioning surface and applying a small thrust to ensure a tight fit. Coordinates perpendicular to the first positioning surface are locked or continuously compensated to ensure the fit is not disrupted; simultaneously, the robot moves along a direction parallel to the first positioning surface. During this movement, the second side of the box gradually approaches and eventually contacts the second positioning surface. This step is complete when the robot moves to the preset coordinate point or its force sensor detects that the contact force in the second direction reaches a threshold. At this point, the cardboard box is firmly "squeezed" into a perfect right-angle corner, and its opening shape is forcibly corrected to a rectangle.

[0115] The fourth step is the final assembly, where the carton, now restored to its standard shape, is fitted over the product. After the previous correction step, the robot maintains the carton's shape (i.e., keeps it against the two positioning surfaces) while performing a purely vertical downward linear motion. The rectangular opening of the carton precisely aligns with the rectangular outline of the product, smoothly sliding down until it is fully fitted. Once the carton is in place, the robot releases it (e.g., by de-vacuuming) and then lifts it back to its original position.

[0116] In the above embodiment, the robot and the cardboard box are moved to adapt to the fixed first and second positioning surfaces. In another feasible embodiment, the robot can move the grasped cardboard box to a roughly fixed position in the air, and then the movable first and second positioning surfaces (e.g., baffles driven by cylinders or servo motors) move in respectively to clamp and correct the cardboard box from two directions.

[0117] In the above embodiments, position control is the primary method. In more sophisticated systems, the correction steps can be performed using force control. For example, the robot moves the carton against the first positioning surface until the force sensor reading at its end reaches a preset value (e.g., 5 Newtons). Then, in this force control mode, it moves in a second direction until the force reading in the second direction also reaches the set value. This method can better adapt to minute changes in the carton's stiffness.

[0118] For carton packing processes with large interference fits or significant friction, an independent auxiliary pressing device (i.e., the carton pressing unit 400 in the aforementioned embodiment) can be activated simultaneously with the fourth step to apply additional pressure from the top of the carton, assisting the robot in completing the carton packing action more smoothly.

[0119] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps set forth in these embodiments do not limit the scope of this application. Any specific values ​​in all examples shown and discussed herein should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0120] Furthermore, it should be noted that the use of terms such as "first" and "second" is merely for ease of distinction, and unless otherwise stated, these terms have no special meaning and therefore should not be construed as limiting the scope of protection of this application.

[0121] The above description is merely a preferred embodiment of this utility model and is not intended to limit the scope of this utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A box-shaped orthopedic case system, characterized in that, include: The product positioning unit (100) has a box-packing station, and the product positioning unit (100) is used to position the product at the box-packing station; A box-shaped straightening unit (200) is provided at the box-making station. The box-shaped straightening unit (200) is provided with a first positioning surface and a second positioning surface that are perpendicular to each other. A gripping mechanism (300) for gripping and moving cartons; The gripping mechanism (300) is configured as follows: Grasp the cardboard box so that the first side of the cardboard box abuts against the first positioning surface. While maintaining the first side of the cardboard box abutting against the first positioning surface, move the cardboard box so that the second side of the cardboard box adjacent to the first side abuts against the second positioning surface. Then, put the cardboard box on the product.

2. The box-shaped orthopedic housing system according to claim 1, characterized in that: The box-shaped straightening unit (200) includes a first positioning baffle (210) and a second positioning baffle (220) that are fixedly installed, wherein the first positioning baffle (210) and the second positioning baffle (220) are perpendicular to each other; The positioning surface of the first positioning baffle (210) constitutes the first positioning surface, and the positioning surface of the second positioning baffle (220) constitutes the second positioning surface.

3. The box-shaped orthopedic housing system according to claim 1, characterized in that: The box-shaped unit (200) is located above the product positioning unit (100) and is higher than the product located at the box-making station.

4. The box-shaped orthopedic housing system according to claim 1, characterized in that: The product positioning unit (100) includes: The product conveyor line (110) has the box-packing station for conveying the product to the box-packing station; Product arrival detector (120) is used to detect whether the product has arrived at the packaging station; A first product positioning mechanism (130) is used to limit the product in the width direction of the product conveyor line (110); The second product positioning mechanism (140) is used to limit the product along the length of the product conveyor line (110).

5. The box-shaped orthopedic housing system according to claim 4, characterized in that: The first product positioning mechanism (130) includes a first driving member (131), a push plate (132), and a limiting baffle (133). The first driving member (131) is connected to the push plate (132). The first driving member (131) and the limiting baffle (133) are respectively disposed on both sides of the product conveying line (110). The first driving member (131) is used to drive the push plate (132) to move along the width direction of the product conveying line (110). The second product positioning mechanism (140) includes a second drive member (141) for blocking the movement of the product along the length of the product conveying line (110).

6. The box-shaped orthopedic housing system according to claim 1, characterized in that: The box-shaped orthopedic enclosure system also includes: A box pressing unit (400) is provided at the box-packing station and is used to press down the carton.

7. The box-shaped orthopedic housing system according to claim 6, characterized in that: The housing pressing unit (400) includes a third driving member (410) and a pressure plate (420). The third driving member (410) is connected to the pressure plate (420) and is used to drive the pressure plate (420) to move in the vertical direction.

8. The box-shaped orthopedic housing system according to claim 1, characterized in that: The carton-shaping and crimping system further includes a secondary positioning device (500) for pre-positioning the carton before the gripping mechanism (300) grips it. The secondary positioning device (500) includes: Fixed right-angle positioning base (510); A pushing mechanism is used to push the carton toward the right-angle positioning base (510).

9. The box-shaped orthopedic housing system according to claim 8, characterized in that: The pushing mechanism includes a first pushing mechanism (521) and a second pushing mechanism (522); The first pushing mechanism (521) and the second pushing mechanism (522) are respectively used to push the carton along the two right-angle positioning sides of the right-angle positioning base (510).

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