Automated Box Opening Apparatus with Multi-Blade Cutting Head
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Solution Overview
Problem
Manual cutting or opening of boxes is inefficient and unsafe in industrial settings, necessitating an automated solution that can integrate with existing handling systems to accommodate various box sizes and materials.
Innovation Solution
An automated box processing apparatus comprising a conveyor system, a programmable robotic arm, and a controller that determines box dimensions using sensors and performs programmed cut patterns with a cutting head featuring multiple cutting surfaces and pivotable blades, allowing for precise and efficient cutting of boxes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual cutting or opening of boxes is used, then simplicity of operation is maintained, but productivity and safety are poor
Solution Approach 1:
The system divides the box opening process into distinct functional zones: a first zone for receiving boxes, a second zone for cutting operations, and a third zone for discharged boxes. The conveyor belt is segmented into multiple independently controllable zones that can operate at different speeds and positions, allowing automated processing while maintaining operational simplicity through modular design.
Solution Approach 2:
A robotic arm with cutting element serves as the intermediary between the control system and the box cutting operation. The robotic arm receives commands from the controller and executes the cutting motion, while sensors provide feedback about box position and dimensions. This intermediary layer enables automated cutting without requiring complex direct control mechanisms.
2Productivity
If automated cutting systems are implemented, then productivity improves, but measurement and detection difficulty increases
Solution Approach 1:
The system performs preliminary measurement of box dimensions using sensors in the first conveyor zone before the cutting operation begins. The controller stores these dimension data and uses them to pre-program the robotic arm's cutting path and parameters. This preliminary action ensures that when the cutting zone is activated, the system already has the necessary measurement data, reducing real-time detection complexity.
Solution Approach 2:
Traditional mechanical measurement methods are replaced with optical and electronic sensors that non-contactively detect box dimensions. Laser sensors and cameras capture box geometry data, which is then processed by the controller to generate precise cutting instructions for the robotic arm, eliminating the need for complex mechanical measurement systems.
3Duration of action of moving object
If a single blade is used for cutting, then device complexity is reduced, but blade service life is limited
Solution Approach 1:
The cutting element is designed with multiple blades arranged in a circular pattern around a central axis, where each blade can perform cutting functions. The robotic arm can rotate the cutting element to different angular positions, allowing any of the multiple blades to be used for cutting operations. This multi-functional design extends blade service life by distributing wear across multiple blades while maintaining relatively simple individual blade structures.
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 apparatus enables efficient, safe, and customizable cutting of boxes, extending blade life and accommodating different box dimensions and materials, enhancing operational efficiency in handling systems.
Implementation Method 1
The programmable motion device is preferably a robotic arm capable of moving a cutting element in at least three substantially orthogonal axes
Implementation Method 2
The controller also uses a first laser sensor directed orthogonal to the conveyor to determine the height of the box and uses a second laser directed parallel to the conveyor to determine a length of the box
Implementation Method 3
uses a first laser sensor directed orthogonal to the conveyor to determine the height of the box
Implementation Method 4
the controller operates the robotic arm to perform the programmed cut pattern in the box with the cutting element
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 2C~3B
AI summary
An apparatus includes a conveyor, a programmable motion device, and a controller. The conveyor preferably includes actuatable rollers, and the programmable motion device is preferably a robotic arm. The controller operates the conveyor, a stopping rail, and a positioning rail to move and position a box in a cutting position relative to the robotic arm. The controller determines three dimension of the box and translates a programmed cut pattern to those determined dimensions. Based on the determined dimensions, the controller then operates the robotic arm to perform the programmed cut pattern in the box with the cutting element. The cutting element preferably has square blade so that each of the four blades can be used to cut a side of the box without having to rotate the cutting element during operation.