Oscillating Cutting Module for Automated Filler Insertion
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Solution Overview
Problem
Current furniture packaging processes are labor-intensive and inefficient due to manual insertion of carton fillers and lack of flexibility in cutting cartons to exact sizes, leading to logistical challenges and material wastage.
Innovation Solution
A system integrating oscillating cutting modules and a glue applicator managed by robots, which automates the cutting and precise placement of carton fillers into packaging boxes, allowing for on-demand cutting to exact sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual insertion of carton fillers is used, then flexibility in handling different filler sizes is maintained, but labor intensity and time consumption increase significantly
Solution Approach 1:
The system segments the packaging process into distinct modules: an oscillating cutting module for precise filler cutting, a glue applicator for securing fillers, and a robot for placement. Each module handles specific tasks independently, enabling automated operation while maintaining flexibility through programmable control of each segment.
Solution Approach 2:
The oscillating cutting module automatically cuts filler cartons to required dimensions without manual intervention. The glue applicator self-regulates adhesive application, and the robot autonomously places fillers into boxes, collectively enabling the system to service itself through automated operations.
2Ease of manufacture
If pre-cutting of carton materials is performed in advance, then logistics are simplified, but material waste increases and flexibility is reduced
Solution Approach 1:
The system performs preliminary cutting actions automatically at the point of use through the oscillating cutting module. This eliminates the need for advance pre-cutting and storage of pre-cut fillers, allowing materials to be cut to exact dimensions only when needed, thereby reducing waste while maintaining logistical efficiency.
3Productivity
If automated cutting and placement systems are implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The oscillating cutting module serves multiple functions: it cuts filler cartons to various dimensions, adjusts cutting depth, and can accommodate different filler types. The robot system universally handles placement, positioning, and securing of fillers. This multi-functionality reduces the need for multiple specialized devices, managing complexity while maintaining high productivity.
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 system significantly reduces manual labor, enhances operational efficiency, optimizes factory space, minimizes material wastage, and streamlines packaging logistics, achieving a 20% increase in packaging line rate.
Implementation Method 1
Oscillating cutting modules use oscillating blades to cut the cardboard sheets into fillers of the required width
Implementation Method 2
Adhesive injection unit applies a small amount of glue to the fillers, ensuring controlled application to prevent waste and ensure strong adhesion
Data Source
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Figure 2
AI summary
This invention relates to an automatic system for inserting fillers into packaging, using cardboard cutters and glue applicators. The process begins with loading cardboard sheets (1, 2) onto a table, which are then fed by linear units (3, 4) to oscillating cutting modules (11, 12). These units, driven by stepper motors (5, 6, 7, 8), precisely cut the sheets into the required filler sizes. The cut fillers are transported via belt conveyors (9, 10) to a robot's working area (13, 14), where grippers (15, 16) pick them up and move them to an adhesive injection unit (20). Glue is applied, and the fillers are then inserted into moving boxes stabilized by holding mechanisms (18, 19). The entire system, mounted on wheels, can be easily transported and positioned along the packaging line for flexibility. This method enhances efficiency, reduces manual labor, and improves precision and consistency in packaging operations, with the filled boxes continuing along the conveyor for further packaging steps.