Knocked-Down Case Inspection and Erection with Sensor Feedback
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Solution Overview
Problem
Current systems lack efficiency in determining and adjusting to the precise dimensions of knocked-down cases to ensure accurate erection and sealing, often resulting in cases that do not meet specified dimensions, leading to inefficiencies and potential failures in the assembly process.
Innovation Solution
A system and method that utilize a data acquisition system with sensors and robotic arms to measure the dimensions of knocked-down cases, adjust pick-off points, conveyor locations, and operational parameters of tools such as plows and tape heads based on the measured dimensions, ensuring accurate assembly and adjustment to meet specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional fixed-dimension case erection systems are used, then device complexity is reduced, but manufacturing precision deteriorates because cases cannot be accurately adjusted to meet specified dimensions
Solution Approach 1:
The system performs preliminary inspection of knocked-down case dimensions before erection using sensors and data acquisition systems. This advance measurement allows the system to detect dimension variations and pre-adjust operational parameters, ensuring cases meet specified dimensions before the erection process begins, thereby improving manufacturing precision without requiring complex real-time adjustment mechanisms during erection.
Solution Approach 2:
The system implements feedback control by continuously monitoring case dimensions through sensor arrays and comparing measured values against specification ranges. Based on this feedback, the system dynamically adjusts operational parameters such as pick-off point locations, conveyor positions, and tool settings to compensate for dimension variations, maintaining high manufacturing precision while managing device complexity through intelligent control algorithms.
2Productivity
If manual inspection and adjustment methods are used, then device complexity is reduced, but productivity deteriorates due to time-consuming measurement and adjustment processes
Solution Approach 1:
The system replaces manual inspection and adjustment operations with automated sensor-based measurement and computer-controlled adjustment mechanisms. Optical sensors, laser scanners, and automated positioners eliminate the need for manual measurement and physical adjustment, dramatically increasing case erection throughput while managing device complexity through integrated control systems that coordinate multiple automated components.
Solution Approach 2:
The system enables self-service operation where the case erection system automatically inspects its own input materials, detects dimension variations, and adjusts its operational parameters without external intervention. This self-regulating capability increases productivity by eliminating manual inspection steps while keeping the control system manageable through automated decision-making algorithms.
3Reliability
If dimension variations in knocked-down cases are not detected, then device complexity is reduced, but reliability deteriorates because assembly failures occur when cases are out of specification
Solution Approach 1:
The system performs preliminary dimension inspection of knocked-down cases before they enter the erection process. By detecting dimension variations in advance and adjusting operational parameters accordingly, the system prevents assembly failures caused by out-of-specification cases, thereby improving reliability without requiring complex real-time intervention systems during erection.
Solution Approach 2:
The system implements feedback control by monitoring case dimensions through sensor arrays and comparing measured values against specification ranges. Based on this feedback, the system dynamically adjusts operational parameters such as pick-off point locations, conveyor positions, and tool settings to compensate for dimension variations, ensuring reliable assembly while managing device complexity through intelligent control algorithms that process feedback information.
Data Source
AI summary
Techniques for corrugate and chipboard knocked-down case inspection and assembly are described herein. In one example, the disclosed techniques include a method to inspect and assemble a knocked-down case. In the example, a measurement of at least one aspect of the knocked-down case is obtained. A difference is determined between the obtained measurement and a standard measurement and/or a range of standard measurements. Programming of a case-handling tool is executed that is based at least in part on the determined difference. In an example, the programming is configured to adjust for and/or compensate for differences between the actual knocked-down case and a knocked-down case that is within a specification. A case-handling tool is operated responsive to the executed programming to at least partially erect the knocked-down case into an erected case.