Carton Erecting Shuttle Gripping Bottom Panel
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Solution Overview
Problem
Current systems for forming cartons from knock-down blanks, especially those made of corrugated materials, require complex machinery and face difficulties in achieving clean retrieval and handoff, particularly when forming cartons from flattened tubular configurations.
Innovation Solution
A carton forming system that includes a shuttle with a bed and grippers to place and open knock-down carton blanks into a carton sleeve by gripping the bottom side panel and raising the top side panel, using an end effector and shuttle drive apparatus to advance horizontally and open the blank into a carton sleeve configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If complex machinery is used to form cartons from knock-down blanks, then the carton formation capability is improved, but the device complexity increases
Solution Approach 1:
The system divides the carton formation process into distinct functional modules: a magazine for storing blanks, a retrieval mechanism with suction cups, an opening mechanism with spreader bars, and a conveyor system. Each module performs a specific function, allowing the complex task of carton formation to be broken down into manageable segments that can be independently optimized and maintained.
Solution Approach 2:
The carton feeder apparatus is designed to handle multiple types of knock-down blanks and carton configurations through adjustable components. The spreader bars can be repositioned to accommodate different carton sizes, and the suction cup array can adapt to various blank geometries, making the system universally applicable to different carton formation tasks without requiring complete redesign.
2Ease of operation
If specialized apparatus for flat unfolded blanks is used, then the handling of flat blanks is simplified, but the ability to handle knock-down blanks is lost
Solution Approach 1:
The system employs dynamic, adjustable components rather than fixed structures. The spreader bars are positioned to engage with the folded edges of knock-down blanks, and their spacing can be adjusted to match different carton dimensions. This dynamic adjustability allows the same apparatus to efficiently handle both flat unfolded blanks and knock-down blanks, bridging the gap between specialized handling requirements.
3Productivity
If suction cups and arcuate motion are used for retrieval and opening, then the blank retrieval is improved, but the handoff cleanliness and precision are compromised
Solution Approach 1:
The system introduces intermediate transfer points and guide structures between the retrieval phase and the final positioning phase. After suction cups retrieve the blank and the spreader bars open it, intermediate guide walls and positioning fixtures ensure precise alignment before the blank is transferred to the conveyor. This intermediary positioning step maintains both the productivity benefits of automated retrieval and the precision required for accurate handoff.
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 efficiently erects cartons from knock-down blanks with improved handling and processing capabilities, reducing complexity and enhancing the ability to handle different sizes and types of carton blanks without manual adjustments, thus streamlining the carton formation process.
Implementation Method 1
gripping said bottom side panel of said blank with a gripper of said base
Implementation Method 2
advancing said shuttle in a horizontal direction so as to open said knock-down carton blank into a carton sleeve
Data Source
AI summary
In erecting a carton from a knock-down carton blank, the blank is placed on a base of a bed of a shuttle such that a bottom side panel of the blank abuts the base. The bottom side panel of the blank is then gripped with a gripper of the base and a top side panel of the blank is raised while advancing the shuttle in a horizontal direction so as to open said knock-down carton blank into a carton sleeve.