Curved Corner Box Forming with Vacuum and Pusher Control
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Solution Overview
Problem
The existing methods for forming boxes with curved corners from a die-cut sheet are complex and require precise control of side flaps and fastening tabs, which cannot be achieved with traditional presser forming machines, leading to longer production times and higher costs compared to wrap-around devices.
Innovation Solution
An apparatus with a forming matrix, vacuum gripping devices, pusher devices, and an electronic control unit that anticipates the folding of side flaps and positions fastening tabs externally, allowing for precise control and efficient formation of boxes with curved corners, similar to presser forming machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional presser forming machines are used to form boxes with curved corners, then the process is simple, but the side flaps cannot be properly controlled and positioned
Solution Approach 1:
The forming process is divided into distinct phases: first raising side flaps using vacuum gripping devices, then positioning fastening tabs using pusher devices. This segmentation allows each component to be controlled independently, solving the problem of coordinating multiple elements simultaneously that plagues traditional presser machines.
Solution Approach 2:
The side flaps are raised and positioned in advance before the main forming operation. The vacuum gripping devices secure the flaps in their raised position, preparing them for subsequent bonding with fastening tabs. This preliminary action prevents the flaps from returning to the plane of the side walls during forming.
2Manufacturing precision
If wrap-around devices are used to form boxes with curved corners, then precise control of side flaps is achieved, but production time increases and costs rise
Solution Approach 1:
The complex mechanical wrap-around system is replaced with a combination of vacuum gripping devices and pusher devices operating within a presser forming machine. The vacuum system provides precise control without the mechanical complexity of wrap-around mechanisms, maintaining productivity while achieving the needed precision.
Solution Approach 2:
Vacuum gripping devices use pneumatic principles to hold and position side flaps during the forming process. This pneumatic control system provides precise positioning capability similar to wrap-around devices but with simpler mechanics and faster operation, reducing production time and cost.
3Device complexity
If side flaps are allowed to return to the plane of side walls during forming, then the process is simpler, but the box construction is ruined
Solution Approach 1:
The vacuum gripping devices apply a counteracting force to prevent the side flaps from returning to the plane of the side walls. By holding the flaps in their raised position during the forming process, the system counteracts the natural tendency of the flaps to collapse, ensuring proper box construction without complex additional mechanisms.
4Device complexity
If fastening tabs are positioned inside rather than outside the side flaps, then the forming process is simpler, but the tabs cannot effectively hold the flaps in position
Solution Approach 1:
Pusher devices act as intermediaries to position the fastening tabs externally relative to the side flaps. These devices precisely control the placement of tabs during the forming process, ensuring they overlap the flaps correctly for effective bonding. The pusher devices provide the necessary precision without requiring complex positioning mechanisms.
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
This solution enables the formation of high-quality boxes with curved corners while maintaining the operational speed and simplicity of presser forming machines, reducing production time and costs, and allowing for simultaneous formation of multiple boxes.
Implementation Method 1
two main vacuum gripping devices (31, 32), which are arranged outside the forming cavity (10') in opposite positions along the second axis (Y2)... each of these two main vacuum gripping devices (31, 32) being operable to grip from underneath one of the two side walls (F2, F3) of the die-cut sheet (F)
Implementation Method 2
four pusher devices (41, 42, 43, 44), which are arranged externally to the forming cavity (10'), each of these pushers (41, 42, 43, 44) being arranged near one of the four corners of the cavity... each of these pusher devices (41, 42, 43, 44) being operable to lift one of the four side flaps (G1', G1'', G2’, G2'') of the die-cut sheet (F) from the support plane (m)
Data Source
AI summary
An apparatus forms boxes with curved corners from a die-cut sheet. A forming matrix delimits a forming cavity by guides counterposed in pairs along two orthogonal axes. The guides define a die-cut sheet support plane. A forming head inserts inside the cavity to push the die-cut sheet to form a box. Vacuum gripping devices are arranged outside the cavity in opposite positions along the second axis and each grip from underneath the die-cut sheet to hold it on the support. Pusher devices are arranged outside and near one of the corners of the cavity. Each pusher device raises one side flap of the die-cut sheet from the support plane. An electronic control unit operates the main gripping devices, pusher devices and forming head according to the following sequence: actuating the gripping devices; actuating the pushers; deactivating the gripping devices; and inserting the forming head in the forming cavity.