Adaptable Box Forming Machine with Adjustable Sealing Heads
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Solution Overview
Problem
Existing box forming machines require multiple dies for different box sizes, leading to time-consuming changes and stock management issues, and struggle with precise positioning and folding of covering blanks, especially when fold-over flaps are not glued.
Innovation Solution
A forming machine with movable columns and heads that adapt to different box sizes, using heat sealing tape and glue for assembly, and a positioning device with cameras and actuators for precise placement of covering blanks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple dies are used for different box sizes, then box size variety is achieved, but device complexity and stock management burden increase
Solution Approach 1:
A single die is designed to form boxes of multiple different sizes by adjusting the position of the sealing heads and folders, eliminating the need for multiple dedicated dies for different box dimensions. The die structure includes adjustable components that can be repositioned to accommodate various box sizes while maintaining forming precision.
Solution Approach 2:
The die incorporates movable and adjustable components, particularly the sealing heads and folders that can be repositioned along the die structure. This dynamic adjustment capability allows the same die to adapt to different box sizes without requiring physical replacement of the entire die assembly.
2Adaptability or versatility
If die changes are performed for different box sizes, then box size adaptability is achieved, but production time is lost during changeover
Solution Approach 1:
The die uses adjustable sealing heads and folders that can be repositioned quickly between different box size configurations without requiring complete die replacement. This dynamic adjustment mechanism significantly reduces changeover time compared to traditional approaches that require swapping entire dies.
Solution Approach 2:
The die structure is pre-configured with multiple positioning stations and adjustable components that are ready for quick reconfiguration. The sealing heads and folders can be preliminarily positioned at different locations along the die, allowing operators to switch between box sizes by simply adjusting component positions rather than performing extensive reconfiguration.
3Manufacturing precision
If positioning precision is improved for covering blanks, then covering accuracy is enhanced, but device complexity increases
Solution Approach 1:
The positioning device replaces complex mechanical positioning mechanisms with a camera-based optical system. Cameras capture images of the covering blanks and boxes, and a control unit processes these images to determine precise positioning, eliminating the need for intricate mechanical positioning devices while achieving high positioning accuracy.
Solution Approach 2:
The positioning system uses optical copies (camera images) of the covering blanks and boxes to determine positioning information. Instead of using complex mechanical sensors or contact-based measurement systems, the invention captures visual copies and processes them computationally to achieve precise positioning with simpler physical hardware.
4Manufacturing precision
If folding elements are added to ensure correct folding of covering blanks, then folding accuracy is improved, but device complexity increases
Solution Approach 1:
The covering machine uses a camera-based optical system to monitor and control the folding process, replacing complex mechanical folding guidance mechanisms. The control unit processes camera images to detect the position and orientation of fold-over flaps, enabling precise folding control without requiring intricate mechanical guidance devices.
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
Enables efficient production of boxes of various sizes without the need for multiple dies, improves positioning precision, and ensures correct folding of covering blanks, reducing operational time and inventory costs.
Implementation Method 1
a plurality of sealing heads equipped with corresponding heatable pressers movable towards and away from the box to press the pieces of heat sealing tape against the respective edges
Data Source
AI summary
A forming machine (2) for forming a box (60) from a blank (6) made of paper or cardboard, including a base (6a) and side panels (6a, 6b, 6c, 6d) connected to the base (6a), comprises: a working zone configured to receive the blank (6); a plurality of folders (21) positioned in the working zone and configured to interact with the side panels (6a, 6b, 6c, 6d) of the blank (6) to fold them and dispose them parallel to a vertical direction (V), with respective lateral borders juxtaposed to define vertical edges of the side wall of the box (60); a plurality of heads (22), including respective pressers (222) that are movable towards and away from each other, wherein each presser (222) is configured to press a respective vertical edge from the outside of the space inside the box (60).