Automated Mattress Boxing Line for Variable Box Erection and Taping
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Solution Overview
Problem
Existing machines require manual labor to erect and tape custom-sized boxes for roll packed mattresses, which is time-consuming and costly, and lacks uniformity in construction.
Innovation Solution
An apparatus using 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 sealing and edge taping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual labor is used to erect and tape custom-sized boxes for roll packed mattresses, then flexibility in handling different box sizes is maintained, but labor time and costs increase significantly
Solution Approach 1:
The automated boxing system incorporates adjustable components that can dynamically adapt to different box sizes. The mechanism includes adjustable arm lengths, variable positioning systems, and programmable control that allow the same automated system to handle multiple box dimensions without requiring manual reconfiguration for each size.
Solution Approach 2:
The system changes operational parameters such as arm extension distance, gripper position, and taping location based on the detected box size. By programmatically adjusting these parameters, the system maintains flexibility across different mattress sizes while keeping the boxing process automated and efficient.
2Ease of operation
If manual construction of boxes is used, then complex box configurations can be handled, but uniformity in construction is lost
Solution Approach 1:
The automated system incorporates sensors and control systems that provide feedback on box position, flap alignment, and taping application. This feedback loop ensures that each boxing operation maintains consistent quality and uniformity, while the programmable nature of the system allows it to handle various box configurations through standardized procedures.
3Productivity
If automated actuators are used to erect boxes, then labor requirements are reduced, but device complexity increases
Solution Approach 1:
The automated boxing system is divided into separate functional modules: a picker actuator for拾取 flattened boxes, a transport actuator for moving boxes through the system, and an erector actuator for erecting and taping boxes. This segmentation allows each component to be optimized independently and simplifies maintenance while achieving 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
Reduces labor requirements, improves efficiency, ensures uniform box construction, and provides ergonomic benefits by automating the boxing process for roll packed mattresses.
Implementation Method 1
The picker actuator has suction cups which are actuated by a controller to pick up the uppermost flattened box
Implementation Method 2
activating suction cups of the transport actuator to grip a bottom surface of the flattened box
Implementation Method 3
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.