Carton Forming Machine Controlled Motion Track
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Solution Overview
Problem
Existing carton forming and feeding machines require complex engineering and lack individualized control, making it difficult to handle different carton sizes and efficiently load products into cartons, especially when reorienting products for insertion.
Innovation Solution
A machine using a controlled motion track with movers and vacuum cups to pick and erect carton blanks in a linear direction, allowing for precise handling and variable speed operation, along with a cam follower assembly for product reorientation and loading into cartons.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a rotary feeder with cams, gears, and linkages is used to pick and erect cartons, then the carton forming function is achieved, but the device complexity increases and individualized control becomes difficult
Solution Approach 1:
The patent replaces the traditional rotary mechanical system with cams, gears, and linkages with a linear controlled motion system. The mover carries the picker along a linear track that can be precisely controlled to stop at the hopper position, eliminating the need for complex rotary mechanical components while achieving the same carton picking and erection function.
Solution Approach 2:
The system is divided into independent functional modules: a linear track for controlled motion, a mover that can be independently positioned, a picker mechanism for engaging cartons, and a stationary hopper. This segmentation allows each component to be optimized independently and simplifies the overall system architecture compared to an integrated rotary mechanism.
2Adaptability or versatility
If a rotary feeder arrangement is used for carton picking, then the carton can be erected, but individualized control of the picking structures is not possible leading to complications with different carton sizes
Solution Approach 1:
The linear track is designed to be dynamically controllable, allowing the mover to be positioned at different locations along the track and to stop at precisely controlled intervals. This dynamic positioning capability enables the system to adapt to different carton sizes and types by adjusting the motion parameters, providing individualized control that was not possible with fixed rotary mechanisms.
3Productivity
If product loading requires reorienting the product for insertion into the carton, then the loading function is achieved, but the device complexity and time consumption increase
Solution Approach 1:
The linear track system allows product delivery mechanisms to be pre-positioned along the track at optimal locations. Products can be delivered to the mover at different points during its travel, and the linear motion allows for smooth, controlled product insertion into the carton without the time-consuming reorientation operations required by rotary systems.
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
Enables precise and efficient handling of various carton sizes and product loading with reduced mechanical complexity, allowing for independent control of carton formation and product delivery, improving the reliability and flexibility of the carton forming and feeding process.
Implementation Method 1
The picker may comprise at least one vacuum cup for engaging the carton blank, the vacuum cup being mounted to the mover by a support including a vacuum source for supplying vacuum pressure to the vacuum cup
Data Source
AI summary
A machine for forming a carton from a carton blank. The machine includes at least one mover including a picker for picking the carton blank from the hopper and associating the carton blank with the mover. A controlled motion track is provided for moving the at least one mover and picker along a path of travel to a stationary position for engaging the carton blank in the hopper. A further aspect relates to maintaining a suction force on the carton blank during conveyance, including along a linear portion of the track associated with a lugged conveyor for assisting in erecting the blank into a carton. Another aspect relates to a rotatable bucket for receiving and supporting the product, and a controlled motion track for positioning the bucket and associated product for delivery to the carton. Related methods are also described.