Carton Erection Sequencing for Variable-Size Order Packing
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Solution Overview
Problem
Existing systems face difficulties in efficiently forming cartons from knock-down blanks, particularly those made of corrugated fibreboard, due to complex machinery and challenges in achieving clean retrieval and handoff by carton feeders/erectors, and require manual adjustments for different blank sizes.
Innovation Solution
A system comprising a first conveyor for transporting bins, a case construction apparatus, and a controller that adjusts components to form cases of varying sizes, along with a shuttle and end effector to manipulate knock-down blanks into carton sleeves, allowing for automated adaptation and sequential delivery of formed cases to packing stations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If specialized apparatus are used to handle flat, unfolded, and unsealed carton blanks, then carton formation can be achieved, but the device complexity increases and manual adjustments are required for different blank sizes
Solution Approach 1:
The patent employs adjustable guide walls and positioning mechanisms that can be dynamically reconfigured for different blank sizes. The guide walls are movable along the conveyor path, allowing the system to adapt to various carton dimensions without requiring complete machinery replacement or complex manual adjustments
Solution Approach 2:
The conveyor system is designed with universal handling capabilities that can process both flat unfolded blanks and partially erected cartons using the same apparatus. The system incorporates multiple functional zones (guiding, erecting, positioning) within a single integrated conveyor platform, reducing overall device complexity
2Productivity
If knock-down blanks are used instead of flat blanks, then packaging efficiency is improved, but clean retrieval and handoff by carton feeders becomes challenging
Solution Approach 1:
The patent introduces a specialized intermediary mechanism consisting of suction cups and transfer fingers that facilitate clean retrieval of knock-down blanks from packaging and smooth handoff to the conveyor system. This intermediary transfer mechanism bridges the gap between storage and processing, solving the retrieval challenge without compromising packaging efficiency
Solution Approach 2:
The system replaces traditional mechanical gripping methods with pneumatic suction cup technology for retrieving knock-down blanks. This substitution provides cleaner, more reliable retrieval and handoff operations, eliminating the dirt and misalignment issues associated with mechanical claws or fingers
3Adaptability or versatility
If manual adjustments are made for different blank sizes, then adaptability is reduced, but automation level decreases
Solution Approach 1:
The system automatically adjusts critical parameters such as guide wall positions, conveyor speed, and positioning mechanism settings based on the detected blank size. Sensors detect blank dimensions and trigger corresponding parameter changes in the system, enabling full automation while maintaining high adaptability to different carton sizes
Solution Approach 2:
The patent implements preliminary positioning and sizing detection mechanisms that prepare the system for upcoming blank variations. Before processing each blank, the system pre-adjusts guide walls and positioning elements based on advance detection, eliminating the need for manual adjustments during operation
Data Source
AI summary
A system and method of packing an order. A first sequence of bins corresponding to orders is transported on a first conveyor to a packing station. A case for each order is constructed by a case forming system, the case forming system able to construct cases from blanks of various sizes. The cases are transported from the case construction apparatus to the packing station in a second sequence, wherein the sequential order of the cases corresponds to the bins in the first sequence. The bin in the first sequence are brought to the packing station with the cases in the second sequence.