Carton Blank Alignment Device Using Inclined Roller Mechanism
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Solution Overview
Problem
Current filling machines face inefficiencies due to misalignment of carton blanks, which leads to manual intervention, production stoppages, and loss of time, as operators must visually correct the alignment of carton blanks with varying thickness and height, often shipped in batches that shift during transport.
Innovation Solution
An alignment device comprising alignment members, such as rollers and fixed counter members, that apply forces to carton blanks to align them in parallel, allowing for simultaneous alignment with reduced force and minimizing friction, and can be motorized or used manually to ensure accurate stacking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If an operator manually checks and adjusts carton blank alignment, then alignment accuracy is improved, but production time is lost and productivity decreases
Solution Approach 1:
The alignment device enables the carton blank stack to self-align through the interaction between the pushing member and the inclined surface. The system automatically corrects misalignment without requiring manual intervention, as the inclined surface guides the blanks into proper alignment as they are pushed forward.
Solution Approach 2:
The alignment device processes the carton blank stack in segments rather than all at once. The pushing member applies force to only a portion of the stack at a time, allowing gradual alignment while reducing the total force required and enabling continuous operation without stopping production.
2Manufacturing precision
If all carton blanks are aligned simultaneously, then alignment completeness is improved, but the force required increases significantly
Solution Approach 1:
The pushing member applies alignment force to only a portion of the carton blank stack at any given time, rather than attempting to align all blanks simultaneously. This partial action approach reduces the total force required while still achieving complete alignment of the entire stack through continuous operation.
Solution Approach 2:
The alignment device uses a movable pushing member that can dynamically adjust its position along the stack length. This dynamic approach allows the system to apply force progressively through the stack, maintaining manageable force levels while achieving complete alignment of all blanks.
3Stability of the object's composition
If alignment members contact the entire height of carton blanks, then alignment stability is improved, but friction increases and alignment difficulty increases
Solution Approach 1:
The alignment device applies contact and force only at specific locations on the carton blanks rather than across the entire height. The pushing member contacts the blanks at a localized area, and the inclined surface provides guidance at a specific angle, creating optimal alignment conditions with minimal friction and effort.
4Device complexity
If a simple alignment device is used, then device complexity is reduced, but alignment precision for twisted or non-parallel blanks decreases
Solution Approach 1:
The alignment device introduces an inclined surface dimension that converts linear pushing motion into rotational and lateral movement of the carton blanks. This dimensional transformation allows the simple pushing mechanism to effectively correct twists and non-parallel arrangements by guiding blanks along the inclined plane, achieving high alignment precision without complex mechanisms.
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 alignment device efficiently aligns carton blanks in parallel, reducing manual intervention and production downtime by allowing for automated or manual adjustment, ensuring consistent stacking and improved filling machine operation.
Implementation Method 1
one of them being a roller (11) that can easily roll on the carton blanks (14) so that they are pushed in a perpendicular direction to a length (X) of the carton blank (14) stack
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
An alignment device for aligning stacked carton blanks: The carton blanks comprises a first edge and a second edge, the second edge positioned opposite the first edge. The alignment device comprises at least a first and a second alignment member (11,12). The first alignment member is arranged adjacent to the first edge and adapted to exert a force onto the first edge and wherein the second alignment member is arranged opposite the second edge and adapted to exert a force onto the second edge, and the first alignment members is a roller (11).