Adjustable Folding Units for Custom Packaging Box Formation
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Solution Overview
Problem
Existing packaging systems require human intervention to identify and adjust box sizes, leading to errors and inefficiencies in packaging a variety of products of different shapes and sizes, especially with the increasing demand for online retail and diverse merchandise.
Innovation Solution
A method and system that automatically form packaging boxes using at least four folding units with controllable gripping elements and adjustable folding flaps, allowing for the creation of custom-sized boxes based on article dimensions without human intervention, minimizing forces exerted on packed items, and enabling the packaging of delicate or low-weight products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If human operators identify and adjust box sizes manually, then packaging accuracy can be maintained, but packaging speed decreases and human error increases
Solution Approach 1:
The system enables self-service automation where the packaging machine automatically identifies article dimensions via sensors, selects appropriate blank sizes, and adjusts folding units without human intervention. The control unit autonomously manages the entire process from article detection to box formation, eliminating the need for manual operator input while maintaining high precision through automated measurement systems.
Solution Approach 2:
Manual mechanical adjustment by operators is replaced with automated sensing and control systems. Optical or capacitive sensors detect article dimensions, and the control unit processes this data to automatically position folding units and select blank sizes, substituting human decision-making with electronic control mechanisms that operate at higher speeds without error.
2Device complexity
If standard sized blanks are used for all products, then device complexity is reduced, but packaging versatility deteriorates
Solution Approach 1:
The system employs dynamic adjustability where folding units and blank selection are not fixed but can be automatically reconfigured for different product sizes. The control unit receives real-time dimension data from sensors and dynamically positions folding flaps and selects appropriate blank sizes, enabling the same machine to handle a wide variety of product dimensions without manual reconfiguration.
Solution Approach 2:
The packaging machine achieves multi-functionality by incorporating adjustable folding units that can accommodate different box configurations and sizes. A single device performs multiple packaging tasks for various product types by automatically adapting its folding pattern and blank selection based on the detected article dimensions, eliminating the need for multiple dedicated machines.
3Manufacturing precision
If strong gripping forces are applied to hold the blank, then positioning accuracy improves, but damage to delicate articles increases
Solution Approach 1:
The system employs pneumatic gripping elements that provide controlled, uniform holding force on the blank material. Pneumatic actuators create suction or pressure-based gripping that securely positions the blank without concentrated mechanical stress points, ensuring the blank remains stable during folding while delicate articles placed on it are protected from damage by distributed rather than localized forces.
Data Source
Figure 1
Figure 2A~2B
Figure 2C~2D
AI summary
Method and system for automatically forming packaging boxes. At least four folding units each provided with a controllable gripping element support a custom sized blank supporting an article in a supporting station. The at least one of the folding units is configured for folding respective side and/or end panels of the blank upwardly. The at least four folding units comprise a front pair of folding units and a rear pair of folding units positioned at a longitudinal distance from the front pair of folding units, and the folding units of the front pair and the folding units of the rear pair are positioned at a respective transverse distance from each other. Said longitudinal distance and/or said transverse distance are adjustable.