Automated Case Erecting Unit with Segmented Robotic Arm
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Solution Overview
Problem
Existing case erecting units are large, expensive, difficult to move, and require significant floor space, making them inflexible and costly to maintain, and they struggle with folding thick or rigid case blanks effectively.
Innovation Solution
A compact automated case erecting unit using a robotic arm with suction cups for gripping, which performs a series of perpendicular movements to fold case blanks into a compact shape, minimizing space requirements and allowing for the use of thick or rigid materials, and a supporting device with transversally positioned gaps to facilitate folding, enabling efficient use in various production environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional case erecting units are used, then case erection function is achieved, but device size and floor space requirement increase
Solution Approach 1:
The case erecting unit is divided into modular components including a picking and handling device, a supporting device with gaps, and control means. This segmentation allows each component to perform specific functions within a compact footprint, reducing overall floor space while maintaining full case erection capability
Solution Approach 2:
The supporting device incorporates transversally positioned gaps that utilize vertical and lateral spatial dimensions rather than only horizontal footprint. By folding cases through these vertically-oriented gaps, the system achieves case erection in a three-dimensional space-efficient manner, reducing the area occupied on the factory floor
2Adaptability or versatility
If traditional case erecting units are used, then case erection function is achieved, but device weight and mobility decrease
Solution Approach 1:
The unit is segmented into separate functional modules (picking device, supporting device, control means) that can be independently manufactured and assembled. This modular construction reduces overall weight compared to monolithic traditional units while maintaining complete case erection functionality
Solution Approach 2:
The case blanks themselves are designed with thin-walled flexible structures that can be folded through the transversally positioned gaps. This flexibility allows the system to handle thin-material cases without requiring heavy-duty mechanical structures, thereby reducing device weight while maintaining erosion capability
3Adaptability or versatility
If traditional case erecting units are used, then case folding is achieved, but maintenance cost and complexity increase
Solution Approach 1:
By segmenting the case folding process into discrete steps performed by separate modular components, each module can be independently maintained and repaired. The transversally positioned gaps provide clear access points for maintenance activities, reducing downtime and maintenance costs compared to integrated traditional systems
Solution Approach 2:
The control means automatically coordinates the folding sequence through the transversally positioned gaps, reducing the need for manual intervention and complex mechanical linkages. This automated control simplifies the system, making it easier to maintain and repair with lower operational costs
4Adaptability or versatility
If perpendicular movement for flap folding is used, then folding of thick/rigid materials is improved, but device complexity increases
Solution Approach 1:
Instead of complex lateral or vertical folding mechanisms, the invention uses transversally positioned gaps oriented perpendicular to the case blank's main plane. This dimensional approach allows thick and rigid materials to be folded through a straightforward perpendicular motion, simplifying the mechanism while effectively handling difficult materials
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 solution provides a flexible, inexpensive, and space-efficient case erecting system that can be easily moved between production lines, effectively handling different case sizes and materials, reducing maintenance costs and improving the folding process for thick or rigid blanks.
Implementation Method 1
A compact automated case erecting unit using a robotic arm with suction cups for gripping
Data Source
AI summary
By the method, a case having four sidewalls and at least four flaps at the bottom of the case is erected from a blank in a number of steps. The automated case erecting unit for use in erecting case blanks comprises a supporting device (9) and a picking and handling device (2), said picking and handling device being a robot with a robotic arm, wherein said robotic arm comprising a picking member (3) with a first leg and a second leg, which are placed perpendicularly and are locked in relation to each other, each leg comprising gripping means for picking up case blanks.