Box Assembly Machine with Stationary Forming Die

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Solution Overview

Problem

Existing machines for assembling boxes with independent rigid parts face challenges in achieving high precision during the coupling of lateral walls and base, leading to complex structures and defective assemblies due to lack of precision.

Innovation Solution

A machine with a central assembly station featuring a stationary forming die, inclined feeders, vertical columns, and horizontal push devices ensures precise engagement of peripheral flanges and end tongues, utilizing linear actuators and push skids for accurate positioning and assembly of side and head walls with the base.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If conventional machines with separate support structures and multiple mechanisms are used for assembling boxes, then the assembly process can be automated, but the machine complexity increases significantly and precision is insufficient leading to defective assemblies

Engineering Contradiction:

Improveautomation of box assemblyVSAvoidmachine structure complexity

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The machine divides the assembly process into distinct functional zones: inclined feeders deliver parts to vertical columns, horizontal push devices engage lateral walls, and a central forming die assembles the base. Each zone operates independently with specialized mechanisms, reducing overall system complexity while maintaining automation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces intermediary elements such as inclined guiding profiles that funnel lateral walls from feeders to assembly positions, and push skids that transfer head walls from vertical columns to the forming die. These intermediaries simplify the coordination between different machine components.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Extent of automation

If conventional machines with multiple mechanisms are used for box assembly, then automation is achieved, but manufacturing precision is insufficient causing defective assemblies and machine stoppages

Engineering Contradiction:

Improveautomation of box assemblyVSAvoidprecision of parts coupling

Core Design Contradiction:

Extent of automationVSManufacturing precision

Solution Approach 1:

The patent replaces complex multi-mechanism systems with streamlined mechanical actions: inclined feeders use gravity-assisted sliding along guiding profiles, vertical columns provide guided descent, and horizontal push devices use linear actuators for precise positioning. This substitution of complex mechanisms with simpler, more precise mechanical actions improves assembly precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The forming die employs controlled compression force and positioning parameters to ensure precise engagement of peripheral flanges with grooves and end tongues with notches. By optimizing these physical parameters, the machine achieves high precision in coupling independent rigid parts.

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If simple machines are used for box assembly, then the structure is easy to operate, but precision is insufficient leading to defective assemblies

Engineering Contradiction:

Improvesimplicity of machine operationVSAvoidprecision of parts coupling

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The inclined feeders automatically guide lateral walls along predefined paths using gravity and guiding profiles, eliminating the need for complex positioning mechanisms. The vertical columns self-align head walls during descent, and the forming die automatically positions and secures all parts through its compression and engagement mechanisms, achieving high precision through self-aligning features.

Inventive Principle:

Principle #25Self-service

4Manufacturing precision

If high precision coupling mechanisms are implemented, then assembly precision improves, but the machine complexity increases

Engineering Contradiction:

Improveprecision of parts couplingVSAvoidmachine structure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Instead of using complex mechanisms to force parts into alignment, the patent inverts the approach: the inclined feeders and vertical columns guide parts into predetermined positions using simple gravity-assisted motion, and the forming die then applies compression to secure the already-positioned parts. This inversion reduces complexity while maintaining precision.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS9914276B2Machine and method for assembling boxes

Publication Date: 2018.03.13 OBEIKAN MDF ESPANA

AI summary

A machine for assembling boxes comprising five independent parts including two head walls, two side walls and a base with peripheral flanges that engage with grooves in a lower portion of the side walls and the head walls. Ends of the head walls have end tongues that are inserted into notches adjacent to ends of the side walls. The machine includes a central assembly station comprising a base ring inside which a stationary forming die is disposed. A base of a box to be formed is positioned on a lower face of the stationary forming die such that while the base of the box is held in position, horizontal push devices are activated which move the head walls and the side walls towards the base of the box which is locked in position against the lower face of the stationary forming die.