Asymmetric Top Flap Container Design for Automated Packaging
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Solution Overview
Problem
Existing packaging systems face inefficiencies due to product contact with top edges of containers during automated packaging, requiring manual corrections and increased costs with complex robotic end effectors for tilting capabilities.
Innovation Solution
A container design with varying top flap heights and a packaging system using a robotic arm with a fixed end effector that positions the product using lateral movements to avoid top flap contact, allowing for efficient and cost-effective packaging without tilting the product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the container is sized to closely fit the product to avoid movement during transport, then the product stability is improved, but the product frequently contacts the top edge of the top flaps during insertion, requiring manual corrections and decreasing manufacturing efficiency
Solution Approach 1:
The top flaps are segmented into two distinct groups: a first group extending to a first height and a second group extending to a second height greater than the first height. This segmentation allows the container to maintain a close fit for product stability while the higher second group of top flaps prevents contact during automated insertion, eliminating the need for manual corrections.
Solution Approach 2:
Different regions of the container have different flap heights tailored to their specific functions. The first group of top flaps extends to a lower height to allow proper product insertion, while the second group extends to a higher height to prevent contact and guide the product correctly. This local differentiation resolves the contradiction between close fit and smooth insertion.
2Object-affected harmful factors
If complex end effectors with tilting capabilities are used to move the product in a tilted orientation, then the product contact with top flaps is avoided, but the device complexity and cost increase substantially
Solution Approach 1:
Instead of modifying the robotic end effector to tilt the product (complex solution), the invention inverts the approach by modifying the container structure itself. The asymmetric top flaps with different heights create a guidance system that passively directs the product into the correct orientation during horizontal insertion, eliminating the need for complex tilting mechanisms.
Solution Approach 2:
The container structure performs the guidance and orientation function that would otherwise require complex robotic end effectors. The asymmetric top flaps self-guide the product into the correct position and orientation during insertion, making the system simpler and more cost-effective while still preventing harmful contact.
Data Source
AI summary
A container for packaging a product is provided with a plurality of side panels, a plurality of first top flaps, and a plurality of second top flaps. The plurality of side panels includes a first side panel, a second side panel, a third side panel, and a fourth side panel. The plurality of first top flaps, one first top flap extending from a top side of each of the first side panel and the second side panel to a first height. The plurality of second top flaps, one second top flap extending from a top side of each of the third side panel and the fourth side panel to a second height greater than the first height.