Automated Mattress Boxing Line for Variable Box Sizes
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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, making it difficult to find and expensive to hire labor, and lacks uniformity in construction.
Innovation Solution
An apparatus 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 sealing and edge taping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual labor is used to erect and tape boxes, 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: box feeder for presenting flattened boxes, erector for folding boxes to erected position, mattress inserter for loading products, and tape applicator for sealing. Each module performs a specific task independently, enabling automated high-speed operation while maintaining manageable system complexity through functional decomposition
Solution Approach 2:
Manual mechanical operations are replaced with automated mechanisms: the box feeder uses automated positioning and presentation mechanisms, the erector employs automated folding mechanisms with sensors and actuators, the mattress inserter uses automated loading systems, and the tape applicator utilizes automated dispensing and sealing mechanisms, all controlled by a central control system
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:
The automated system incorporates adjustable and reconfigurable components that allow it to adapt to different box sizes dynamically. The box feeder can present different flattened box configurations, the erector can adjust folding parameters for various box dimensions, and the mattress inserter can accommodate different product sizes, all while maintaining automated high-speed operation
Solution Approach 2:
The system changes operational parameters such as folding angles, positioning coordinates, and tape application points based on the specific box size being processed. Sensors detect box dimensions and the control system adjusts operational parameters in real-time to maintain adaptability across different box sizes while minimizing processing time
3Ease of operation
If automated apparatus is used, then labor requirements decrease, but initial investment and system complexity increase
Solution Approach 1:
The automated apparatus is designed as a multi-functional integrated system where a single machine performs multiple operations: the box feeder presents boxes, the erector folds them, the mattress inserter loads products, and the tape applicator seals them. This universal design consolidates what would otherwise require multiple separate devices into one cohesive unit, reducing operational complexity despite the sophisticated functions performed
Solution Approach 2:
A central control system acts as an intermediary between the various automated components and the operator. The controller coordinates the box feeder, erector, mattress inserter, and tape applicator, managing their interactions and sequences. This intermediary control layer simplifies operation by providing centralized management while handling the underlying complexity of coordinating multiple automated subsystems
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, 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 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.