Automated Box Erecting System with Stacking Fold Reinforcement
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Solution Overview
Problem
Conventional box erecting machines and processes are inefficient and unreliable when dealing with continuous corrugated material, as the stacking fold, a weak point in the box, can cause the box to bend instead of opening at the designated edge or corner crease, leading to inconsistent and troublesome packaging.
Innovation Solution
An automated box erecting system that includes a suction panel, folding arms, and a restraining bar to position and bend the major and minor flaps of the box in opposite directions, reinforcing the stacking fold by folding the flaps orthogonal to the sides, thereby strengthening the weak seam and ensuring proper opening at the box edge or corner crease.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional box erecting machines are used on continuous corrugated material, then the box can be opened at the designated edge or corner crease, but the stacking fold causes the box to bend instead, leading to inconsistent and troublesome packaging
Solution Approach 1:
The patent applies preliminary action by folding the flaps before the opening operation. The folding arms bend the major and minor flaps in opposite directions while the box is still in the unerected position, preparing the box structure in advance so that the stacking fold is reinforced and positioned correctly before the opening operation begins, preventing bending during erection
Solution Approach 2:
The patent applies preliminary anti-action by folding the flaps in opposite directions to counteract the potential bending effect of the stacking fold. By bending the flaps before opening, the system creates a counterbalancing structural configuration that prevents the stacking fold from causing unwanted bending during the opening operation
2Adaptability or versatility
If the stacking fold is located anywhere on the box, then flexibility in box size is achieved, but the weak point hinders conventional box erecting machines and processes
Solution Approach 1:
The system performs preliminary folding of flaps in opposite directions before the opening operation, preparing the box structure in advance to accommodate stacking folds at any location. This preliminary action reinforces the stacking fold area regardless of its position, enabling reliable erection of boxes with varying sizes and stacking fold locations
Solution Approach 2:
The invention achieves universality by creating a folding mechanism that works regardless of where the stacking fold is located on the box. The folding arms and suction panel system can handle boxes of different sizes with stacking folds at various positions, making the system adaptable to continuous corrugated material production where stacking fold location varies
3Manufacturing precision
If flaps are bent in opposite directions, then the stacking fold is reinforced and opening at the designated edge is ensured, but the process requires automated folding operations
Solution Approach 1:
The patent merges the folding operation with the opening operation by using the same automated erecting apparatus to perform both functions. The folding arms that bend the flaps in opposite directions are integrated into the opening mechanism, allowing the system to reinforce the stacking fold and open the box in a coordinated sequence without requiring completely separate equipment
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system efficiently erects boxes by strengthening the stacking fold, minimizing bending during the opening operation and ensuring consistent packaging regardless of the stacking fold's location, enhancing the reliability and efficiency of the box erecting process.
Implementation Method 1
The automated opening operation includes suctioning at least one side of the unerected box
Data Source
AI summary
A method for erecting a box includes positioning can unerected box in an automated erecting apparatus. The method further includes bending major and minor flaps on the unerected box relative to sides of the unerected box. The method further includes, while the major and minor flaps are bent relative to the sides of the unerected box, performing an automated opening operation on the unerected box, wherein the unerected box comprises a stacking fold.