Automated Packaging Machine with Variable-Geometry Die and Manipulator

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing packaging machines require manual adjustments and external processes for creating customized boxes, leading to reduced throughput and inefficiencies, as they often necessitate manual placement and removal of cut and creased sheets, limited dimension adjustment, and the formation of boxes with open bottoms.

Innovation Solution

A fully automatic machine that can create customized packaging items from a continuous sheet of corrugated cardboard, featuring a cutting and creasing unit, a variable-geometry die-forming unit, and a multifunctional manipulator for automatic sheet handling and forming, allowing for quick adjustment of dimensions and automatic formation of packages without manual intervention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual adjustment of distances between longitudinal members and tools is performed, then package dimensions can be changed, but throughput is dramatically reduced and adjustment time increases

Engineering Contradiction:

Improvepackage dimension variabilityVSAvoidthroughput

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent applies dynamics by replacing static manual adjustments with dynamic automated adjustment mechanisms. The longitudinal members and forming tools are equipped with motorized actuators that can automatically change positions based on pre-programmed parameters, enabling quick transitions between different package dimensions without manual intervention, thus maintaining high throughput while achieving dimension variability.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent replaces the manual mechanical adjustment system with an automated control system. Electronic sensors, motors, and control algorithms substitute for human operators who manually measured and adjusted distances, enabling faster and more precise positioning of forming tools and longitudinal members to create packages of variable dimensions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If external pushing systems are installed to shape the package, then box formation is achieved, but device complexity increases

Engineering Contradiction:

Improvepackage formation capabilityVSAvoidsystem complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent merges the pushing function into the die structure itself. The die incorporates integrated pushing surfaces and forming elements that directly shape the package as the sheet material is fed through, eliminating the need for separate external pushing systems. This integration reduces overall system complexity while maintaining effective package formation capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The die is designed to perform multiple functions including shaping, pushing, and forming the package automatically during the single-pass operation. The sheet material itself is guided and formed by the die geometry without requiring external assistance, enabling the system to be self-sufficient and reducing the number of additional components needed.

Inventive Principle:

Principle #25Self-service

3Extent of automation

If manual placement and removal of sheets is performed, then package forming is achieved, but automation level is reduced and throughput decreases

Engineering Contradiction:

Improvesheet handling automationVSAvoidthroughput

Core Design Contradiction:

Extent of automationVSProductivity

Solution Approach 1:

The patent implements continuous automated sheet handling where sheets are automatically fed into the die, formed, and ejected in a continuous cycle. The system includes automatic sheet feeding mechanisms, positioning systems, and ejection mechanisms that operate without interruption, maintaining continuous production flow and high throughput while achieving full automation of sheet handling operations.

Inventive Principle:

Principle #20Continuity of useful action

4Manufacturing precision

If limited adjustment range of actuator wings is used, then synchronization with die dimensions is achieved, but package dimension variability is restricted

Engineering Contradiction:

Improveactuator-die synchronizationVSAvoidpackage dimension range

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent applies dynamics by implementing multi-axis adjustable actuator mechanisms that can dynamically change their positioning and orientation. The actuators are equipped with adjustable arms and positioning systems that can adapt to various die cavity dimensions, enabling the system to maintain precise synchronization while accommodating a wide range of package sizes and configurations.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS10759133B2Machine for automatically manufacturing customized packaging items

Publication Date: 2020.09.01 PANOTEC SRL

AI summary

A machine for automatically manufacturing customized packaging items (I) from continuous laminar material, comprising at least one cutting and creasing unit (2) to form sheets (F) of laminar material with a plurality of cuttings and/or bendinglines (C), at least one variable-geometry forming unit (5) for forming the sheet (F) so cut and creased into a package (I) of predetermined dimensions, a multifunctional robotized manipulator (24) for automatically picking up one sheet (F) at a time from the cutting and creasing unit (2) and feeding the forming unit (5), the manipulator (24) being designed to automatically adapt to the predetermined dimensions of the packaging (I) on the forming unit (5) and interact therewith to form the packaging (I).