Camera-Guided Box Erecting Arm Assembly for Variable Blanks

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Solution Overview

Problem

Existing box erecting machines struggle with efficiently expanding cardboard box blanks of varying sizes and shapes, often leading to inefficiencies and potential operator injuries due to manual adjustments.

Innovation Solution

A box erecting apparatus equipped with a camera for image recognition of score lines, an arm assembly for precise folding, and a controller for automated adjustments, allowing for the expansion of box blanks into usable containers with reduced human intervention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If automated box erecting machines are used to expand box blanks, then productivity is improved, but the machines struggle to efficiently handle varying sizes and shapes of box blanks

Engineering Contradiction:

Improvebox expansion speedVSAvoidaccommodation of varying box sizes

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The arm assembly is designed with dynamic positioning capabilities, allowing it to adjust its position and orientation based on the specific dimensions and configuration of each box blank. The controller coordinates the arm's movements to accommodate varying box sizes while maintaining automated expansion operations

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes operational parameters such as arm position, folding angle, and expansion force based on the detected box blank characteristics. The controller modifies these parameters in real-time to optimize the expansion process for different box sizes and shapes

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If manual adjustments are made to accommodate different box sizes, then adaptability is improved, but operator safety deteriorates due to potential injuries

Engineering Contradiction:

Improveadjustment to box variationsVSAvoidoperator injury risk

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The system performs self-adjustment through automated arm positioning and folding operations. The controller manages the entire expansion process without requiring operator intervention, allowing the machine to adapt to different box sizes while eliminating operator exposure to mechanical hazards

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical adjustments by operators are replaced with an automated control system that manages the arm assembly's movements and folding operations, substituting human mechanical actions with automated mechanical and electronic control

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If automated arm assembly is used for precise folding, then manufacturing precision is improved, but device complexity increases

Engineering Contradiction:

Improvefolding accuracyVSAvoidapparatus structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The arm assembly is divided into multiple independently controllable segments or components, each responsible for specific folding actions. This segmentation allows for precise control of individual folding operations while maintaining a manageable overall system structure

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS12384127B2Box erecting apparatus and method

Publication Date: 2025.08.12 TAIWAN SEMICONDUCTOR MANUFACTURING CO LTD

AI summary

An apparatus and method for expanding a box blank into a box, the apparatus comprising an arm assembly, a controller, a camera and a box blank conveyor. The arm assembly includes a folding arm having a position in a first direction and a rotational angle controlled by the controller based on a position of a feature of the box blank in the field of view of the camera. The camera captures images of the box blank which are used to position the arm assembly and to evaluate the need to reject a box blank.