Robotic Case Erecting Tool for Flap Alignment
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Solution Overview
Problem
Existing robotic case erecting systems fail to consistently and precisely position the edges of major flaps in a parallel relationship, leading to cases that are not sufficiently square and true when sealed.
Innovation Solution
A tool for robotic case erecting that uses suction cups and a slide rod mechanism to attach to and guide the case, ensuring the major flaps are aligned and sealed without gaps or overlaps, by regulating the extension of suction cups and maintaining the case level as it moves through a plow and tape head.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a robotic arm is used to close major flaps by gripping the case and moving it against a plow, then automation is improved, but manufacturing precision deteriorates because the edges of major flaps cannot be consistently positioned in a parallel relationship
Solution Approach 1:
A passive plow is introduced as an intermediary device between the robotic arm and the case flaps. The plow acts as a fixed reference structure that guides and positions the major flaps during the closing operation, enabling the robotic arm to achieve precise parallel positioning without direct manipulation of the flaps themselves
Solution Approach 2:
The case structure itself is utilized to achieve precise positioning. By designing the case with specific geometric features and utilizing the inherent rigidity of the case walls and flaps, the system leverages the case's own structure to maintain alignment and positioning accuracy during the automated closing process
2Ease of operation
If existing processes are used to bend major flaps and position them against a plow, then the case can be closed, but manufacturing precision deteriorates resulting in gaps or overlaps between flap edges
Solution Approach 1:
The plow is positioned and configured in advance to establish the correct final position and orientation of the major flaps before the closing operation begins. The plow's fixed geometry pre-determines the parallel relationship between flap edges, ensuring that when the flaps are bent and pressed against the plow, they achieve the desired alignment without gaps or overlaps
Solution Approach 2:
The case closing operation is divided into distinct functional zones: the plow region for positioning and alignment, the taping region for sealing, and the robotic manipulation zone for movement. This segmentation allows each zone to be optimized for its specific function, with the plow dedicated solely to achieving precise parallel positioning of the flaps
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 tool enables precise alignment and sealing of case flaps, ensuring the case is square and true, improving the robotic arm's ability to close the flaps without gaps or overlaps, thus enhancing the overall precision and reliability of the case erecting process.
Implementation Method 1
A tool for use with a robotic arm includes a pair of suction cups configured to attach to a case
Data Source
AI summary
The disclosure describes techniques for erecting cases, and particularly example structures and example methods for use in a case erecting system using a robotic arm. A tool for use in robotic case erecting may be used in conjunction with a robotic arm. Use of the tool assists in keeping a case level as the case moves along a conveyor, where a plow closes the major flaps and a tape head tapes edges of the flaps together, thereby sealing the bottom of the case. The tool also assists in regulating the gap between the major flaps, so that the gap and/or any overlap of the flaps is minimized. Accordingly, the tool assists the robotic arm to close the case in a more precise manner.