Box Forming Carousel With Integrated Flap Folding for Compact Can Packaging
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Solution Overview
Problem
Small breweries face challenges in automating the packaging process due to limited space and resources, making it difficult to efficiently package small volumes of beer in boxes, which is labor-intensive and time-consuming.
Innovation Solution
A box forming carousel apparatus with a rotating carton retainer and folding assemblies that automate the process of forming and sealing boxes around cans, utilizing a frame, rotating carton retainer, and side carton folding assemblies to fold and glue flaps, along with a can loader and unloader to facilitate efficient packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual assembly is used to package cans in boxes, then labor flexibility is maintained, but packaging efficiency and productivity are low
Solution Approach 1:
The packaging system is divided into discrete modular stations arranged on a carousel, with each station performing a specific function (box insertion, can loading, flap folding, sealing). This segmentation allows the system to achieve automation benefits while maintaining manageable complexity through functional decomposition.
Solution Approach 2:
Multiple packaging operations (box positioning, can insertion, flap folding, sealing) that would traditionally require separate machines are merged into a single integrated carousel system, improving productivity by performing all operations in one continuous cycle without transfer between devices.
2Productivity
If traditional automated packaging systems are implemented, then packaging speed increases, but floor space requirements increase
Solution Approach 1:
The system transitions from a linear horizontal arrangement of packaging equipment to a vertical carousel configuration, utilizing the vertical dimension to stack operations. This allows multiple packaging stations to occupy a compact footprint while maintaining high-speed automated operation.
Solution Approach 2:
The carousel structure serves multiple functions simultaneously: it positions boxes, transports cans, sequences operations, and enables compact arrangement of all packaging components in a single space-efficient unit, replacing what would traditionally require multiple separate machines spread across large floor space.
3Ease of operation
If manual packaging is used, then equipment investment is reduced, but labor intensity and time consumption increase
Solution Approach 1:
The system is designed to be easily loaded with cans and boxes by operators, who simply place materials into designated loading zones. The automated carousel then handles all subsequent operations independently, minimizing the skill and effort required while achieving rapid packaging speeds that far exceed manual capability.
Data Source
AI summary
A box forming carousel apparatus including a frame, a rotating carton retainer, a first side carton folding assembly, a second side carton folding assembly and an axle. The frame has a bottom, and first and second sides. The rotating carton retainer is rotatably coupled to the frame and has a plurality of slot assemblies radially spaced apart, each slot assembly having a leading wall, a following wall and a base wall. Each slot assembly structurally configured to retain a box therein. The first side carton folding assembly is structurally configured to fold a plurality of flaps of the box on a first side thereof. The second side carton folding assembly is structurally configured to fold a plurality of flaps of the box on a second side thereof. The axle extends between the first side and the second side of the frame spaced apart from the bottom of the frame.