Automatic Carton Magazine Loading with Fallen Blank Correction

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Solution Overview

Problem

Existing automated systems for loading carton blanks into a magazine often result in improper conditioning, leading to issues such as miss-feeds, jams, and carton damage due to uneven stacking and out-of-position blanks, which disrupt the cartoning process.

Innovation Solution

A carton handling system with a carriage assembly and carton handling tool that moves in two axes to position and condition carton blanks, including a finger to lift fallen blanks and compression jaws to maintain a desired parallelogram shape, ensuring consistent placement and alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If automated means are used to empty master cases onto the magazine, then operator labor is reduced, but proper conditioning of the slug of carton blanks is difficult to achieve

Engineering Contradiction:

Improveautomation of master case emptyingVSAvoidconditioning precision of carton blanks

Core Design Contradiction:

Extent of automationVSManufacturing precision

Solution Approach 1:

The conditioning operation is segmented into multiple specialized stations: a first conditioning station for initial slug formation and a second conditioning station for final precision adjustment. This segmentation allows each station to perform specific conditioning tasks, achieving both automation and precision that would be difficult to accomplish at a single station.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A carriage assembly with a conditioning tool acts as an intermediary mechanism between the automated master case emptying and the final magazine placement. The carriage moves along the magazine to position and condition the slug of carton blanks, mediating between the automated loading process and the precision conditioning requirement.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If the slug of carton blanks is placed on the horizontal magazine without proper conditioning, then loading speed is maintained, but carton damage and miss-feeds occur

Engineering Contradiction:

Improveloading speedVSAvoidfeed reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The slug of carton blanks undergoes preliminary conditioning at the first conditioning station before final placement on the magazine. This preliminary action ensures the blanks are properly formed and positioned, preventing damage and miss-feeds during the subsequent feeding process while maintaining overall loading speed.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The conditioning process is integrated continuously into the loading operation. The carriage assembly conditions the slug in-place on the magazine during the loading cycle, eliminating interruptions and maintaining continuous productive action while ensuring proper blank positioning and orientation.

Inventive Principle:

Principle #20Continuity of useful action

3Manufacturing precision

If manual patting and adjusting is used to condition the slug, then proper blank placement is achieved, but production time is increased

Engineering Contradiction:

Improveblank placement precisionVSAvoidconditioning time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The manual patting and adjusting operation is replaced with an automated conditioning tool that uses controlled mechanical forces. The tool applies standardized pressure and positioning mechanisms to achieve precise blank placement without requiring manual intervention, thereby maintaining precision while reducing conditioning time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Ease of operation

If the master case is inverted and dumped onto the magazine, then loading operation is simplified, but carton blanks become out-of-position and require reconditioning

Engineering Contradiction:

Improveloading operation simplicityVSAvoidcarton blank positioning

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The inversion and dumping operation is extracted as a separate preliminary step, and the conditioning tool is designed specifically to correct the positioning issues resulting from this extraction. The tool targets and adjusts only the out-of-position blanks, allowing the simple inversion-dumping operation to continue while compensating for its positioning deficiencies.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of trying to maintain proper positioning during the inversion and dumping process, the system accepts the out-of-position state and corrects it in reverse during the conditioning operation. The conditioning tool works backwards from the dumped position to restore the correct blank orientation and placement.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS12351419B2Automatic magazine loader for supplying carton blanks to carton magazine

Publication Date: 2025.07.08 RA JONES & CO INC

AI summary

A carton handling system for a carton blank magazine. The carton handling system includes a carriage assembly with a carton handling tool. The carriage assembly moves the carton handling tool in two axes of motion to receive a slug of carton blanks and to position the slug of carton blanks in the carton blank magazine. The carton handling system further includes a finger carried on the carton handling tool. The carton handling tool is movable to engage the finger with an underside of a fallen carton blank lying at an end of an advancing stack of blanks in the carton blank magazine so as to lift the fallen carton blank against a preceding blank at the end of the advancing stack of blanks. The carton handling tool is also movable to position the slug of carton blanks at an endmost blank in the advancing stack of blanks.