Automated Mattress Boxing Line for Custom Box Erection and Taping
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Solution Overview
Problem
The existing process of manually erecting and taping custom-sized boxes for roll packed mattresses is labor-intensive and time-consuming, with labor being difficult to find and expensive.
Innovation Solution
An apparatus and method utilizing picker, transport, and erector actuators to automate the process of erecting cardboard boxes, inserting a roll packed product, and taping them closed, with manual intervention for final flap closure and seam application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual labor is used to erect and tape boxes for roll packed mattresses, then flexibility in handling custom-sized boxes is maintained, but labor costs increase and productivity decreases
Solution Approach 1:
The boxing process is divided into distinct functional modules: a picker actuator for retrieving flattened boxes, a transport actuator for moving boxes through the system, and an erector actuator for erecting and taping boxes. Each module performs a specific task, allowing the system to handle custom-sized boxes efficiently while maintaining manageable complexity through functional decomposition
Solution Approach 2:
The automated apparatus is designed to handle multiple box sizes and configurations using the same core actuators and mechanisms. The system can process different custom-sized boxes for various mattress dimensions without requiring separate equipment, improving productivity while keeping the device complexity reasonable through multi-functional design
2Loss of time
If manual labor is used to construct boxes, then adaptability to different box sizes is maintained, but time consumption increases
Solution Approach 1:
Boxes are pre-flattened and stacked in a standardized configuration before entering the automated system. This preliminary preparation allows the picker, transport, and erector actuators to quickly process boxes without manual intervention, significantly reducing boxing time while maintaining ease of operation through standardized input formats
Solution Approach 2:
The automated apparatus performs all boxing operations independently without requiring manual labor for erecting or taping. The system feeds itself flattened boxes from a stack, processes them through the erection mechanism, and outputs finished boxes, eliminating time-consuming manual operations while maintaining simplicity through automation
3Extent of automation
If automated actuators are used to erect boxes, then labor requirements decrease, but device complexity increases
Solution Approach 1:
Each actuator (picker, transport, erector) is designed with specific local qualities optimized for its function. The picker actuator has gripping mechanisms suited for handling flattened boxes, the transport actuator has movement capabilities matched to conveyance requirements, and the erector actuator has positioning precision tailored for box erection. This localized optimization reduces overall system complexity while achieving high automation levels
Solution Approach 2:
The actuator system is organized in a nested structure where the picker actuator feeds into the transport actuator, which in turn feeds into the erector actuator. Each actuator is positioned and sized to work within the confines of the previous stage, creating a compact nested arrangement that reduces space requirements and simplifies system integration while maintaining high automation
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
The apparatus reduces labor requirements, ensures uniform box construction, and improves efficiency by automating the boxing process, providing ergonomic benefits and reducing downtime.
Implementation Method 1
The picker actuator has suction cups which are actuated by a controller to pick up the uppermost flattened box with the picker actuator and transporting the flattened box to a transfer location
Implementation Method 2
moving a transport actuator to the transfer location and activating suction cups of the transport actuator to grip a bottom surface of the flattened box
Implementation Method 3
moving an erector actuator to a position adjacent to the transport actuator and activating suction cups of the erector actuator to grip a top surface of the flattened box
Data Source
AI summary
An apparatus is provided for carrying out a method of erecting a flattened box, taping one end shut, inserted a roll packed mattress and taping the other end to complete the process. A controller controls the operation of the mostly automated process. An operator inputs certain parameters to control the process. Different size boxes and corresponding different size roll packed mattresses may be packaged on the same apparatus.