Modular Blank Delivery System for Multi-Type Container Production
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Solution Overview
Problem
Existing box forming machines lack the ability to continuously produce multiple types of corrugated containers from different blanks without requiring manual adjustment or reconfiguration, as they do not have a system for selectively feeding various blanks and controlling the forming process.
Innovation Solution
A machine with a blank delivery system featuring modular blank hoppers and a transfer assembly that can deliver different blanks to a container forming system, combined with a control system allowing operators to program recipes for forming various container types, including different depths and printing, enabling continuous production of multiple container types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single-type blank feeding system is used, then the machine structure is simple, but the machine cannot continuously produce multiple types of containers
Solution Approach 1:
The machine is divided into independent functional modules: multiple blank hoppers (each for different blank types), a transfer mechanism with selectable positioning, and a forming system. This segmentation allows each module to be independently configured and controlled, enabling multi-type container production without requiring complete machine redesign.
Solution Approach 2:
The machine incorporates a universal blank receiving system that can accept multiple types of blanks through separate hoppers, a universal transfer mechanism that can position different blanks, and a universal forming system that adapts to create various container types. This multi-functionality is achieved through programmable control that coordinates the universal components for different production scenarios.
2Productivity
If manual adjustment is required for different container types, then the machine structure is simple, but production efficiency decreases due to stopping and reconfiguration
Solution Approach 1:
The machine performs self-service through automatic blank selection and feeding. The control system automatically selects the appropriate blank type from multiple hoppers based on the desired container type, positions it using the transfer mechanism, and feeds it to the forming system without operator intervention. This eliminates manual reconfiguration and enables continuous production.
Solution Approach 2:
The machine incorporates feedback mechanisms where sensors detect blank presence and type, and the control system receives feedback on container formation status. This feedback loop enables automatic adjustment and continuous operation, as the system can detect when a blank is ready, when forming is complete, and when to transition to the next container type without manual input.
3Adaptability or versatility
If multiple blank hoppers and transfer assembly are added, then the machine can produce diverse containers, but the device complexity increases
Solution Approach 1:
The machine merges multiple functions into integrated components. The transfer mechanism combines positioning, selection, and feeding functions in a single coordinated system. The control system merges program management, sensor processing, and actuator coordination into a unified control architecture. This merging reduces the effective complexity by integrating functions rather than having separate systems for each function.
Data Source
AI summary
A blank delivery system for use in a machine for forming a container from a blank sheet of material is described herein. The blank delivery system includes a blank loading assembly that includes a plurality of blank hoppers. Each blank hopper is configured to hold a plurality of blanks for forming a different type of container. A blank transfer assembly is coupled to each blank hopper of the plurality of blank hoppers. The blank transfer assembly is configured to convey the blanks from each blank hopper to a container forming system of the machine.