Automated Sampling Control for Folding Box Packaging Traceability
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Solution Overview
Problem
Current methods for sampling folding boxes in packaging machines lack a systematic and traceable approach, often resulting in incorrect packing and failure to detect damage caused during packaging, as they are typically done manually or before packaging is complete.
Innovation Solution
A method where the removal interval and sample number are forwarded to machine control, allowing for calculation of the required number of folding boxes per outer carton, enabling systematic and traceable sampling post-packaging, with additional boxes added for sampling, and a check code is applied to the outer carton to verify sampling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual sampling is performed by the machine operator, then sampling can be done flexibly, but the sampling process becomes untraceable and the number of folding boxes in the outer carton becomes incorrect
Solution Approach 1:
The machine control system automatically records sampling information including the number of samples taken, their positions in the outer carton, and generates traceable documentation. This feedback mechanism ensures complete traceability of the sampling process while maintaining operational flexibility through automated control.
Solution Approach 2:
The system automatically calculates and provides the correct number of additional folding boxes needed to compensate for sampling. The machine control autonomously manages the sampling process, eliminating the need for manual tracking and ensuring the outer carton always contains the correct number of boxes.
2Productivity
If samples are taken before packaging in outer boxes, then sampling can be performed, but damage caused by the packaging process itself cannot be detected
Solution Approach 1:
The system pre-calculates and prepares the correct number of additional folding boxes needed for sampling before the packaging process begins. This preliminary action ensures that samples can be taken after packaging without compromising the integrity of the packaging process or the ability to detect packaging damage.
Solution Approach 2:
Instead of sampling before packaging, the system is designed to sample after packaging by providing additional boxes in advance. This inverted approach allows detection of packaging damage while maintaining sampling efficiency through automated post-packaging sampling.
3Quantity of substance
If additional folding boxes are packed in outer boxes to compensate for sampling, then the correct number of boxes is maintained, but the sampling process becomes complex
Solution Approach 1:
The machine control system performs multiple functions: it calculates the number of additional boxes needed, tracks sampling positions, records sampling data, and manages the provision of additional boxes. This multi-functional approach simplifies the overall system by consolidating complexity into a single automated control unit rather than requiring separate mechanisms for each function.
Solution Approach 2:
The system replaces manual calculation and tracking of box quantities with automated electronic calculation and control. The machine control automatically determines the correct number of additional boxes and manages their provision, eliminating the need for complex manual procedures and reducing operational complexity.
Data Source
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AI summary
The sampling process for folding boxes (1) involves taking sample boxes from a packing machine. The preset number of samples and the sample extraction interval are fed into the control machine. After calculating the result per carton and/or per position by sampling, more of the required boxes are put through the filling and sampling process.