Automated Box Corner Folding Mechanism with Synchronized Pressing
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Solution Overview
Problem
Existing machines for automated folding of box corners suffer from poor pressure distribution, leading to unstable and deformable corners, especially during transportation and displacement, and result in high production times and inefficiencies.
Innovation Solution
An assembly for automated folding of box corners featuring first and second folding means interconnected by a mechanical kinematic mechanism, with horizontal and vertical guides to ensure synchronized actuation, and a pusher device for precise folding, providing consistent pressure distribution independent of box height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If pneumatic devices and pressing devices are used for folding box corners, then automation is achieved, but pressure distribution is poor and corners become unstable and deformable
Solution Approach 1:
The pressing device is divided into multiple independent pressing elements (rollers or pressing bars) that can be individually positioned along the contact surface. Each element applies pressure locally, ensuring uniform pressure distribution across the entire contact area between the wall and wing, thereby preventing corner deformation while maintaining automation.
Solution Approach 2:
The pressing device is designed to apply pressure locally at multiple discrete points along the contact surface rather than as a single distributed force. This localized pressing approach ensures that each area of the contact surface receives appropriate pressure, improving corner stability and preventing deformation during the automated folding process.
2Extent of automation
If traditional folding devices are used, then automation is provided, but production times are high and efficiency is low
Solution Approach 1:
The folding mechanism is designed to continuously fold multiple corners of the box in sequence without interruption. The device processes all four corners of a box in a single continuous operation, eliminating the need for separate folding operations for each corner, thereby significantly reducing production time while maintaining full automation.
Solution Approach 2:
The device combines multiple folding functions into a single integrated mechanism that can fold multiple corners simultaneously or in rapid succession. By merging the folding operations for all corners into one device, the system achieves high automation while reducing the total time required compared to traditional sequential folding methods.
3Ease of manufacture
If pressing devices are used to glue corners, then corner formation is achieved, but pressure distribution depends on cardboard quality and creasing lines
Solution Approach 1:
The pressing device uses multiple segmented pressing elements that can be independently positioned and adjusted. This segmentation allows the device to compensate for variations in cardboard quality and creasing line quality by applying pressure at multiple discrete locations, ensuring consistent pressure distribution and reliable corner formation regardless of material variations.
Solution Approach 2:
The pressing device is designed with adjustable parameters such as pressing force, pressing speed, and element positioning that can be optimized for different cardboard qualities and creasing line configurations. This adaptability ensures consistent pressure distribution and reliable corner gluing across various material types while maintaining ease of manufacture.
Data Source
AI summary
An assembly for the automated folding of the corners of a box made of a relatively rigid laminar material, such as paper or cardboard, the box having a bottom wall, an upper wall, and two pairs of side walls, at least two walls having at least one tab to be folded to form a corner of the box, includes a first folding device to fold a first tab of at least one of the side walls along a first creasing edge, a second folding device to fold a second tab of at least one of the bottom or upper walls along a second creasing edge, and a mechanical connection kinematic mechanism between the first and the second folding device to fold the corner of the box in a coordinated manner. A method for the automated folding of a corner of a box using the assembly.