Pivoting Mandrel Assembly for Adjustable Tapered Tray Forming
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional tray-forming equipment is often specific to a particular blank and tray configuration, requiring adjustments for different thicknesses or tapers, and relies on mandrel angle control, leading to inefficiencies and component wear.
Innovation Solution
A mandrel assembly with pivotally coupled forming elements that rotate in opposite directions, allowing for flexible formation of tapered trays with adjustable tapers, reducing the need for equipment modifications and minimizing component wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional mandrel assembly with fixed angle is used, then equipment structure is simple, but adaptability to different blank thicknesses and tray configurations is poor
Solution Approach 1:
The mandrel assembly incorporates a pivotal forming element that can dynamically adjust its angle of entry into the folding station. This dynamic adjustment capability allows the same equipment to accommodate different blank thicknesses and tray configurations without requiring structural modifications or component changes, thereby resolving the contradiction between adaptability and device complexity.
Solution Approach 2:
The invention changes the key parameter of mandrel entry angle from a fixed value to an adjustable variable. By enabling continuous adjustment of the forming element's pivotal angle, the system can optimize performance for different blank thicknesses and tray types, achieving high adaptability without increasing overall equipment complexity.
2Manufacturing precision
If additional components like flap pushers are added to control taper, then manufacturing precision is improved, but device complexity increases and reliability decreases due to component wear
Solution Approach 1:
The invention extracts and eliminates the need for additional flap pusher components by integrating taper control functionality directly into the pivotal mandrel assembly. The forming element's adjustable angle inherently controls the taper degree, removing the separate flap pusher mechanism and its associated wear and maintenance issues while maintaining manufacturing precision.
Solution Approach 2:
The invention merges the functions of mandrel advancement and taper control into a single pivotal forming element. By combining these functions, the system achieves precise taper control without requiring separate additional components, thereby improving reliability by reducing the number of parts subject to wear and failure.
3Manufacturing precision
If equipment is customized for specific blank and tray configurations, then manufacturing precision is maintained, but productivity decreases due to frequent adjustments and component replacements
Solution Approach 1:
The pivotal mandrel assembly is designed as a universal component that can handle multiple blank thicknesses and tray configurations through angle adjustment. This multi-functionality eliminates the need for frequent equipment customization and component replacement, thereby maintaining manufacturing precision while significantly improving productivity by reducing setup time and downtime.
4Adaptability or versatility
If mandrel assembly enters folding station at fixed angle, then device complexity is low, but adaptability to different taper degrees is poor
Solution Approach 1:
The mandrel assembly incorporates a pivotal forming element that can dynamically adjust its angle of entry into the folding station. This dynamic adjustment capability allows the same equipment to accommodate different blank thicknesses and tray configurations, thereby resolving the contradiction between adaptability and device complexity.
Solution Approach 2:
The invention changes the key parameter of mandrel entry angle from a fixed value to an adjustable variable. By enabling continuous adjustment of the forming element's pivotal angle, the system can optimize performance for different blank thicknesses and tray types, achieving high adaptability without increasing overall equipment complexity.
Data Source
AI summary
An apparatus including a mandrel assembly with a first side plate, a second side plate, first and second bars coupled to and extending between the first and second side plates, a first forming element pivotally coupled to the first bar and configured to rotate in a first direction by a first amount from a home position to a collapsed position, and a second forming element pivotally coupled to the second bar and configured to rotate in a second, opposite direction by a second amount from a home position to a collapsed position; and a folding station defining an opening that receives the mandrel assembly. Also provided is a method of forming a tapered tray from a blank.