Automated Box Opening With Top, Side, and Edge Perforation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing devices and systems for opening cardboard boxes are inefficient, often requiring manual intervention when automated processes fail to completely open the boxes, leading to production line disruptions.

Innovation Solution

A system comprising a scanning station for measuring box dimensions, a conveyor assembly, and dedicated stations for perforating the top, sides, and edges of the box, utilizing adjustable mechanisms to accommodate various box sizes and shapes, ensuring complete automated opening.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If automated perforation is applied to top and sides only, then partial opening is achieved, but complete opening fails and production line halts

Engineering Contradiction:

Improveautomated opening capabilityVSAvoidopening completeness

Core Design Contradiction:

Extent of automationVSReliability

Solution Approach 1:

The box opening process is divided into three distinct perforation stages: top perforation, side perforation, and edge perforation. Each stage targets a specific portion of the box with dedicated perforation mechanisms, ensuring complete coverage of all box surfaces that require opening.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention extends the perforation process from two dimensions (top and sides) to three dimensions by adding edge perforation. The edge perforation mechanism addresses the previously neglected vertical edges of the box, completing the dimensional coverage of all box surfaces.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If manual intervention is used for unopened boxes, then opening completeness improves, but productivity decreases due to line halts

Engineering Contradiction:

Improveopening completenessVSAvoidproduction line efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The automated edge perforation mechanism operates continuously as boxes move through the system on the conveyor. The edge perforation wheel engages with box edges in sequence without interrupting the production flow, maintaining continuous operation and eliminating manual intervention stops.

Inventive Principle:

Principle #20Continuity of useful action

3Device complexity

If fixed perforation mechanisms are used, then device complexity is reduced, but adaptability to various box sizes decreases

Engineering Contradiction:

Improveperforation mechanism simplicityVSAvoidbox size accommodation

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The perforation mechanisms incorporate adjustable components that can dynamically adapt to different box dimensions. The edge perforation wheel position and depth can be adjusted based on box size variations, allowing the system to handle multiple box types without requiring complete mechanism redesign.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS12415642B2Devices, systems and processes for facilitating opening of boxes

Publication Date: 2025.09.16 DISH NETWORK LLC

AI summary

An opening station for facilitating box opening may include a scanning station, an edge opening station, and a conveyor assembly. The scanning station is configured to measure a length “L”, height “H”, and/or width “W” of a substantially square box having a top, a bottom, two sides, and two edge portions. The edge opening station is configured to perform perforation operations on at least one of the two edge portions. A complete box opening system may include the scanning station, edge opening station, conveyor, and at least one of a top opening station and a side opening station.