Automated Bulk Bin Former Apparatus for Single-Station Assembly
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Solution Overview
Problem
Existing methods for forming bulk bins are not fully automated, requiring significant time and manpower, and often necessitate multiple machines and more space, as they are either manual, semi-automatic, or create collapsible bins that need further assembly for use.
Innovation Solution
A fully automated system that includes an erecting and constructing station, a collapsed body blank supply station, and a bottom blank supply station, where a collapsed body blank is opened and a bottom blank is applied with glue and aligned to the side walls, allowing for the formation of a ready-to-use bulk bin at a single station.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual or semi-automatic forming methods are used, then the bulk bin can be formed with sufficient strength, but the productivity is low and time consumption is high
Solution Approach 1:
The patent replaces manual mechanical operations with an automated forming machine that uses controlled mechanical forces to open the collapsed body blank and seal the bottom wall. The machine employs a opening mechanism with controlled blades or cutters to systematically open the collapsed structure, and a sealing mechanism with heated or pressed sealing surfaces to bond the bottom wall to the side walls, eliminating manual labor while maintaining structural integrity
Solution Approach 2:
The patent utilizes parameter changes in the forming process, including temperature control for thermal sealing of the bottom wall, pressure application for bonding, and controlled expansion forces to open the collapsed body blank. These parameter changes enable automated formation while maintaining the strength requirements for bulk bin construction
2Strength
If multiple separate machines are used for forming, then the bulk bin can be formed with proper strength, but the factory space requirement increases
Solution Approach 1:
The patent merges multiple forming operations into a single integrated machine that performs body blank opening, bottom wall sealing, and structural reinforcement in one continuous process. The combined machine eliminates the need for separate opening machines, sealing machines, and reinforcement stations, thereby reducing factory space requirements while maintaining the strength requirements for bulk bin construction
Solution Approach 2:
The forming machine is designed with multi-functional capabilities, incorporating opening mechanisms, sealing systems, reinforcement devices, and positioning systems within a single apparatus. This universal machine can handle all forming operations for bulk bins of various sizes, eliminating the need for multiple specialized machines and reducing overall factory space consumption
3Volume of moving object
If a collapsible bulk bin is formed, then the machine can be compact, but the bin requires additional assembly and space when in use
Solution Approach 1:
The patent applies preliminary action by pre-opening the collapsed body blank and pre-sealing the bottom wall to the side walls during the forming process. The machine systematically opens the collapsed structure in a controlled manner and bonds the bottom wall before the bin is discharged, so that the bin is fully assembled and ready for immediate use, eliminating the need for post-formation assembly while maintaining compact storage capability
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 system enables the rapid and efficient production of fully formed, ready-to-use bulk bins with reduced labor and space requirements, improving productivity and efficiency in the formation process.
Implementation Method 1
applying glue to the flaps as the bottom blank is moved from the bottom blank supply station to the erecting and constructing station
Data Source
AI summary
A machine for automated construction of a bulk bin includes an erecting and construction station, a collapsed body blank supply station and a bottom blank supply station. A body bank pick mechanism picks a collapsed body blank from the collapsed body blank supply station and moves the collapsed body blank into the erecting and constructing station. A body blank opening assembly at the erecting and constructing station opens the collapsed body blank and forms an opened body blank. A bottom blank pick mechanism picks a bottom blank from the bottom blank supply station. A conveying device moves the bottom blank to the erecting and constructing station and beneath the opened body blank. A bottom blank fixing system applies the bottom blank to the opened body blank with flaps of the bottom blank secured to side walls of the opened body blank to produce an open bulk bin structure.