Automated Box Forming Machine with Dual Pick-Up Devices
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Solution Overview
Problem
Current packaging systems for e-commerce require manual intervention to select and form boxes, which is time-consuming and inefficient, especially for large volumes of varied item dimensions, necessitating a more automated and flexible solution to optimize box usage and reduce labor intervention.
Innovation Solution
A packaging system that includes a box-forming machine capable of automatically picking up flattened cartons, forming boxes, and closing them using pick-up devices and forming units, allowing for quick and efficient box production while operators focus on inserting items, with sensors and control systems for optimal box sizing and filling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual box preparation is used, then flexibility in handling various object dimensions is maintained, but time consumption and labor requirements increase significantly
Solution Approach 1:
The system segments the box preparation process into distinct automated functions: carton selection, opening, forming, and closing are handled by separate robotic units. This allows each component to be optimized for its specific function while working together to achieve overall automation, resolving the contradiction between flexibility and productivity.
Solution Approach 2:
The system enables self-service through automated robotic manipulation of cartons throughout the entire preparation process. The robots autonomously select, open, form, and close cartons without human intervention, eliminating manual labor while maintaining adaptability to various object dimensions through programmable control.
2Productivity
If automatic box preparation systems are implemented, then productivity and automation level increase, but device complexity and space requirements increase
Solution Approach 1:
The robotic system is designed with multi-functionality to perform multiple operations (selecting, opening, forming, closing) using a unified automated platform. This reduces the need for separate dedicated machines for each function, thereby controlling device complexity while maintaining high productivity and automation levels.
3Device complexity
If operators manually prepare boxes, then system simplicity is maintained, but loss of time in box preparation increases
Solution Approach 1:
The system performs preliminary actions by pre-positioning and pre-forming cartons automatically before the packing operation begins. The robotic units prepare cartons in advance and make them ready for immediate use, eliminating the time operators would otherwise spend on manual preparation while keeping the overall system architecture relatively simple.
4Productivity
If automated pick-up and forming mechanisms are used, then box formation speed increases, but device complexity and safety requirements increase
Solution Approach 1:
The system uses intermediary robotic manipulators that handle carton manipulation tasks. These robotic intermediaries bridge the gap between the stationary carton supply and the packing station, enabling fast automated box formation while consolidating complexity into manageable robotic components with integrated safety features.
Data Source
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AI summary
Packaging system (10) to pack objects (101) in boxes (11) comprising: - a supply station (104) to supply objects (101) of a purchase order batch; - an insertion station (105) to insert in a box (11) a specific batch picked up from said supply station; - a closing station (106) to close said box (11); - a storage unit (16, 17) configured to house a respective group of cartons (12) in a flattened-out state; - a box-forming machine (100) configured to carry out both an automatic pick-up of a corresponding carton (12) in a flattened-out state from said storage unit (16, 17), and a subsequent automatic forming of the box (11) a starting from the picked-up carton (12), wherein said box-forming machine (100) comprises a first pick-up device (33) and a second pick-up device (52) respectively slidably mounted on said storage unit (16, 17) to slide along a respective linear path, said first pick-up device (33) remaining in a shared transfer space (25) when it moves the carton.