Random Box Sealer Height Measurement via Mechanical Plunger
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Solution Overview
Problem
Existing random box sealers face issues with accurately determining the height of boxes due to packaging materials or products protruding, incorrect sensor readings, and incomplete sealing of bottom flaps, leading to jamming, damage, and increased costs from expensive sensors.
Innovation Solution
An automatic random box sealer with a control system, conveyor, first box measurer using an inductive positioning system to accurately determine box height by engaging top flaps, and a second measurer for width, combined with a flap closer and tape applicator to ensure proper sealing, reducing reliance on expensive sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If expensive sensors are used to determine box height, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces expensive optical sensors with a mechanical measurement system. A carriage equipped with a plunger physically contacts the top flaps of the box to determine box height. This mechanical approach eliminates the need for complex sensor systems while providing accurate measurements, directly resolving the contradiction between measurement precision and device complexity.
2Extent of automation
If sensors are used to detect box height, then automation is improved, but reliability deteriorates due to incorrect readings from protruding packaging or products
Solution Approach 1:
The mechanical plunger system physically contacts the top flaps to establish a reliable reference point for box height measurement. This mechanical contact method is not affected by protruding packaging materials or products, as the plunger specifically engages with the box structure itself rather than relying on optical detection that can be fooled by surface irregularities.
Solution Approach 2:
The patent introduces top flaps as an intermediary element between the box and the measurement system. The flaps serve as a reliable interface that the carriage plunger can consistently engage with, providing a stable reference point for height measurement that is independent of the box contents or packaging materials.
3Adaptability or versatility
If a single sealer is used for random size boxes, then adaptability is improved, but manufacturing precision deteriorates due to difficulty in accurately positioning for different heights
Solution Approach 1:
The patent employs a dynamically adjustable carriage system that can move vertically along the conveyor to match different box heights. The carriage is positioned based on real-time measurements taken from each box, allowing the sealing mechanism to adapt its position dynamically. This dynamic adjustment capability enables a single sealer to maintain high sealing precision across boxes of varying sizes.
Solution Approach 2:
The system uses feedback from the mechanical measurement process to control carriage positioning. The plunger measures the actual box height, and this measurement feeds back to the control system, which then adjusts the carriage position accordingly. This closed-loop feedback ensures that the sealing operation is precisely positioned for each box, maintaining manufacturing precision while handling random sizes.
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 solution accurately determines box dimensions, prevents jamming and damage, and reduces costs by eliminating the need for expensive sensors, ensuring efficient and reliable sealing of boxes of varying sizes.
Implementation Method 1
The inductive positioning system includes a stationary sensor and a movable target. The sensor is stationary and the target moves relative to the sensor as the carriage moves.
Data Source
AI summary
Various embodiments of the present disclosure provide a box sealer including a first box measurer including a top flap engager configured to move downwardly from a disengaged position above a box at a box measuring position to an engaged position in which the top flap engager engages one or more of the four upright open top flaps of the box. The amount of movement of the top flap engager is partially used to determine the height of the box. The determined height is then used to position a combined flap closer and flap sealer at an appropriate position.