Carton Decasing System With Inverting Assembly
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Solution Overview
Problem
Current automated systems for removing cartons from their cases often result in manual handling, leading to repetitive strain injuries and inefficiencies due to difficulties in maintaining cartons in an ordered stack, as existing systems struggle to prevent cartons from being dislodged during removal.
Innovation Solution
An automated system featuring an inverting assembly and carton decasing assembly that reorients cases, uses adjustable guides and containment rods to grip and hold cartons in place, and a stack pusher assembly to maintain alignment and forward motion, ensuring cartons are removed from cases while maintaining a stacked configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated removal systems are used to remove cartons from cases, then productivity is improved, but cartons may be dislodged or fail to maintain ordered stack configuration during removal
Solution Approach 1:
The system divides the carton stack into individually addressable units by using multiple pick-up means (first and second pick-up means) that can independently engage and manipulate specific cartons or groups of cartons within the stack, allowing precise control over removal sequences
Solution Approach 2:
The system performs preliminary actions by positioning and clamping the pick-up means to engage cartons before the actual removal motion occurs, ensuring proper grip and alignment is established in advance to prevent dislodging during the removal process
2Reliability
If manual handling is used to remove cartons from cases, then cartons can be carefully maintained in stack order, but repetitive strain injuries occur and productivity decreases
Solution Approach 1:
The system enables self-service by having the automated pick-up means perform the careful handling functions that previously required human operators, with the mechanical system independently managing the precise manipulation and removal of cartons without human intervention
Solution Approach 2:
The system replaces the human mechanical handling system with an automated mechanical pick-up system that uses clamps and controlled motion to replicate and improve upon the careful handling previously performed by human workers
3Extent of automation
If current automated removal systems are used, then some automation is achieved, but additional restacking operations are required due to dislodged cartons
Solution Approach 1:
The system ensures continuity of useful action by designing the pick-up means to maintain secure engagement with cartons throughout the entire removal and transfer process, preventing dislodging that would otherwise require interrupting the workflow for restacking operations
Data Source
Figure 1
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Figure 3A
AI summary
A carton decasing system for removing stacks of cartons or carton blanks from cases or containers includes a case infeed conveyor on which the cases with the cartons or carton blanks stacked therein are moved to an inverting assembly. The inverting assembly reorients the cases and places the cases with the cartons stacked therein on a decasing assembly which removes the cases from the stacks of cartons. The stacks of cartons are thereafter conveyed along a magazine conveyor with the stacks of cartons supported by a stack pusher assembly as the cartons are moved to a discharge point at the distal end of the magazine conveyor.