EOAT Flap Tucking for Stable Knock-Down Box Opening
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Solution Overview
Problem
Current methods for preparing knock down flat (KDF) boxes, whether manual or automated, face inefficiencies due to boxes collapsing back to a flat position, leading to machine downtime and slow preparation times, especially when a percentage of boxes are glued shut.
Innovation Solution
An End of Arm Tool (EOAT) on a box transfer machine tucks at least one flap inward to hold the box open, allowing simultaneous lifting and opening, enabling efficient transfer and storage before loading or taping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a worker unfurls the box and folds at least one flap inward to prevent collapse, then the box can be held open for efficient transfer and storage, but the process requires additional manual steps and time
Solution Approach 1:
The system performs preliminary actions by automatically unfolding the box and tucking the flap inward during the box transfer process itself, rather than requiring separate manual steps. The EOAT is configured to engage the flap and tuck it inward as the box is being transferred, combining multiple operations into one automated sequence that eliminates idle time and manual intervention.
2Productivity
If automated machines are used to prepare boxes, then preparation speed increases, but machine downtime occurs when boxes are glued shut and cannot be unfurled
Solution Approach 1:
The EOAT is designed to attempt autonomous opening of each box by engaging and tucking the flap inward. If a box is glued shut and cannot be opened, the system continues to the next box without requiring manual intervention or causing machine downtime. The automated system serves itself by handling opening attempts independently, and the process is resilient to individual box failures.
3Ease of operation
If the box is transferred without tucking the flap inward, then the transfer process is simpler and faster, but the box collapses back to the flat position requiring additional support
Solution Approach 1:
The tucked flap itself serves as the support structure that maintains the box in the open position. By tucking the flap inward, the box creates its own stabilizing mechanism that prevents collapse without requiring external supports, stands, or additional devices. The box's own structure is modified to provide the stability needed for accumulation and transfer.
4Productivity
If multiple boxes are accumulated in the open configuration on a table, then final preparation steps can be completed efficiently, but the boxes require continuous support to prevent collapsing
Solution Approach 1:
Each box, through its tucked flap, becomes self-supporting and can maintain its open configuration without external support structures. This allows multiple boxes to be accumulated in the open position on a table or conveyor without requiring complex support systems, stands, or fixtures to prevent collapse, thereby simplifying the overall device while maintaining batch processing efficiency.
Data Source
AI summary
A process and apparatus to open knock down flat (KDF) boxes. An End of Arm Tool (EOAT) picks up a flat KDF box off a stack of boxes, opens the box, and tucks at least one of the flaps while the box is being transferred to a conveyor. When the box is released on the conveyor, the tucked flap allows the box to be held open as the top panel of the box rests on or presses against the edge of the flap. The open boxes may then be accumulated and quickly loaded or taped.