Corrugated Box Forming with Fixed Reference Edge Mandrel
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Solution Overview
Problem
Existing methods for forming corrugated cardboard boxes around a mandrel are inefficient when adapting to changes in box size, requiring complex adjustments and precision in positioning elements, which complicates the process and reduces productivity.
Innovation Solution
The method involves positioning the blank relative to a fixed reference edge on the mandrel, allowing for precise placement and folding regardless of mandrel size, using a vertical storage magazine and advanced unstacking and guiding systems to maintain high precision and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the blank is positioned empirically with adjustment freedom on the mandrel, then the positioning tolerance is acceptable for coating operations, but the device complexity increases when modifying mandrel sizes
Solution Approach 1:
Instead of moving the mandrel or coating elements when changing box sizes, the invention inverts the approach by keeping the mandrel and coating elements fixed, and instead adjusting the blank size and positioning. The blank is fed from a vertical magazine at different levels to accommodate different mandrel sizes without moving any coating or pressing elements.
Solution Approach 2:
The invention uses a fixed reference edge on the mandrel that serves as a consistent positioning target. By copying this reference edge position across different mandrel sizes, the system maintains consistent positioning without requiring physical adjustment of the mandrel or coating elements.
2Manufacturing precision
If the coating and pressing elements are adjusted for each mandrel size, then the manufacturing precision is maintained, but the productivity decreases due to complex folding and adjustment time
Solution Approach 1:
The blanks are pre-positioned in a vertical magazine with their reference edges aligned at consistent levels. This preliminary positioning eliminates the need for adjustment during the coating process, allowing continuous high-speed operation without stopping to reposition elements for different mandrel sizes.
Solution Approach 2:
The system dynamically adapts to different mandrel sizes by varying the blank dimensions and feed position from the vertical magazine, while keeping the coating and pressing mechanisms static. This dynamic adjustment of the blank rather than the machinery maintains precision without sacrificing productivity.
3Device complexity
If a fixed reference edge system is used on the mandrel, then the device complexity is reduced and compactness is improved, but the measurement precision requirements increase for blank placement
Solution Approach 1:
The vertical magazine serves as an intermediary mechanism that handles the precision positioning of blanks. By delegating the measurement and positioning function to the magazine's fixed-level feed system, the main coating device remains simple and compact while achieving high precision through the specialized positioning subsystem.
Data Source
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AI summary
The invention relates to a method and device for producing a corrugated cardboard box through gluing, based on a cut-out (43), comprising a series of flaps comprising at least four main rectangular flaps with a rectangular fastening tab (49) at the end, said box being arranged to be automatically installed around a mandrel (55, 56) of which the shape complements the inside of the box. The flat cut-out is removed from a stack by taking the top cut-out from a constant-level vertical storage facility of a stack (21) of cut-outs (22), after gluing the tab (49) and flaps, said cut-out is placed in a predetermined location, and the main flap is moved to be adjacent (44) to the main flap (47) to which the fastening tab (49) is connected, exactly opposite a lower or upper surface (45) of the mandrel, such that the lower or upper edges (53) of the mandrel are exactly opposite the fold lines of the cut-out opposite thereto, then said adjacent flap is pressed against the mandrel by upward or downward movement, the flaps are automatically folded around the edges of the mandrel, and the tab (49) previously glued onto the side edge of the adjacent flap by pressure is then pressed against said tab around a reference edge (51) of the mandrel on the side opposite said lower or upper surface.