Container Forming Machine Pre-Forming and Mandrel Assembly
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Solution Overview
Problem
Existing machines struggle to automatically form containers with lids and trays from complex blanks due to the difficulty in folding multiple side panels.
Innovation Solution
A machine with a pre-forming section and a mandrel assembly that partially forms the container by folding side panels and further forming the tray by partially folding the front panel assembly, while the mandrel assembly engages the tray bottom panel to form corners and fold the roll-over panel to form the front wall.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual folding is used to form containers with multiple side panels, then folding accuracy and container quality are improved, but production speed and productivity deteriorate
Solution Approach 1:
The forming process is divided into multiple stations (first station for lid and tray formation, second station for front panel folding, third station for side panel folding). Each station performs a specific folding operation on specific panels, allowing automated sequential processing that maintains precision while increasing overall productivity.
Solution Approach 2:
The blank is pre-positioned on the deck with pre-formed features before entering the forming stations. The bar structure pre-defines the folding paths and positions for panels, enabling automated machines to replicate precise manual folding actions without requiring complex real-time positioning systems.
2Productivity
If automated folding machines are used for complex multi-panel containers, then production speed is improved, but device complexity and machine configuration requirements worsen
Solution Approach 1:
The bar structure serves multiple functions: it acts as a support element during folding, a positioning guide for panels, and a transfer mechanism between stations. The mandrel assembly performs multiple operations (corner formation, panel folding, lid positioning) in a single integrated unit, reducing the need for separate specialized machines.
Solution Approach 2:
The bar acts as an intermediary element between the deck and the panels being folded. It transfers force during folding operations, maintains panel positions during transfer, and guides the folding path without requiring complex control systems or sensors to track panel positions in real-time.
3Manufacturing precision
If multiple folding stations are implemented to handle complex panels, then manufacturing precision is improved, but loss of time between operations increases
Solution Approach 1:
The deck continuously feeds blanks through the forming stations without interruption. The bar maintains constant contact with the blank throughout the process, ensuring continuous guidance and support. Panels are folded at different stations in sequence without removing the blank from the forming path, eliminating idle time between operations.
Solution Approach 2:
Multiple folding operations that would traditionally be performed separately are combined into integrated station assemblies. The mandrel assembly combines corner formation, panel folding, and lid positioning operations into a single coordinated action, reducing the total number of separate operations and transfer points.
Data Source
AI summary
Provided herein is a machine for forming a container from a blank including a tray and a lid. The machine has an upstream end where the blank is loaded and a downstream end where the container is discharged and includes a frame, a pre-forming assembly, and a mandrel assembly. The pre-forming assembly is configured to partially form the lid and the tray by folding each of a plurality of side panels of the blank and further form the tray by partially folding a front panel assembly of the blank, the front panel assembly including a front panel and a roll-over panel. The mandrel assembly is mounted to the frame and configured to engage a bottom panel of the tray to form each of a plurality of corners of the tray and fold the roll-over panel to form a front wall of the container.