Automated Flexible Article Packaging With Offset Loading
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for packaging flexible articles, such as gloves, into boxes are inefficient and prone to causing bulging or damage to the boxes due to manual labor or existing automated systems that push gloves into boxes, leading to misalignment, friction-induced tears, and difficulties in closing the flaps.
Innovation Solution
An automated system using a pair of end effectors to load flexible articles into an erected box with movable flaps, where the articles are positioned offset to create gaps that allow for smooth flap closure, preventing obstruction and reducing friction, and a controlled arm for transferring and orienting the box for efficient sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If packaging machines push gloves into packaging boxes through side openings, then automated loading is achieved, but friction causes tears and damage to the boxes
Solution Approach 1:
The system performs preliminary actions by pre-aligning the glove stack with the box opening and using guide structures to direct the loading path. The automated arm positions the glove stack precisely before insertion, preventing misalignment and reducing friction during the pushing operation, thereby avoiding box tears while maintaining automation.
2Adaptability or versatility
If workers manually stack and insert gloves into packaging boxes, then flexibility in quantity is maintained, but labor intensity is high and efficiency is low
Solution Approach 1:
The system incorporates dynamic adjustments through programmable automated arms and adjustable guide structures that can adapt to different glove stack quantities and configurations. The system maintains flexibility by allowing dynamic reconfiguration of the loading mechanism while achieving high throughput through automation, resolving the contradiction between adaptability and productivity.
3Manufacturing precision
If stacked gloves are manually flattened to fit into packaging boxes, then alignment is improved, but the operation is inefficient and unreliable causing unflatten stacked gloves
Solution Approach 1:
The system replaces manual flattening operations with an automated mechanical pressing mechanism. The automated arm applies controlled force to flatten and align the glove stack precisely before insertion, eliminating the inefficiency and unreliability of manual flattening while maintaining high productivity through automation.
4Extent of automation
If gloves are pushed into packaging boxes, then automated loading is achieved, but gloves become misaligned or disoriented affecting flap closing
Solution Approach 1:
The system introduces intermediary guide structures and alignment mechanisms that mediate between the automated loading process and the final glove positioning. These guide structures ensure that gloves remain aligned and oriented correctly during the automated pushing operation, preventing misalignment that would affect flap closing while maintaining automation.
Data Source
AI summary
An automated method and system for packaging a stack of flexible articles are disclosed. The method comprises: loading, by a pair of end effectors, the stack of flexible articles into an erected box having a first open end and a second open end, leaving a first gap therebetween; moving, by a first flap closing mechanism, the flap of the first open end from the open configuration to the closed configuration; pushing, by a pushing mechanism, the stack of flexible articles towards the first gap, thereby forming a second gap between the second open end and the stack of flexible articles; and moving, by a second flap closing mechanism, the flap of the second open end from the open configuration to the closed configuration.