Shoulder Box Frame Deformation and Merging
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Solution Overview
Problem
The existing manufacturing processes for cap box-type cigarette packs are inefficient, particularly in merging the base part and frame, which hinders the production of a sufficient number of packs in a unit of time.
Innovation Solution
A multi-lane production method utilizing three coordinated and synchronously running production lines, where the frame is fed to a frame unit in a flat, folded position, and then deformed into a square shape using suction organs to fit inside the base part, with a continuous glue strip creating a permanent connection to the base side walls, enabling a three-dimensional structure formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional single-line production methods are used for merging base part and frame, then the process can be performed with simple equipment, but the production capacity is insufficient
Solution Approach 1:
The production process is divided into multiple independent production lines (first, second, and third production lines) that operate in parallel. Each line processes packs independently through the same sequence of operations (base part preparation, frame preparation, merging, wrapping), allowing simultaneous production of multiple packs and thereby increasing overall productivity without requiring a single complex multi-functional machine.
Solution Approach 2:
Multiple production lines are combined into a single integrated production system that shares common equipment resources. The base part preparation unit, frame preparation unit, merging unit, and wrapping unit are used by all three production lines, consolidating what would otherwise be three separate production systems into one coordinated facility.
2Ease of manufacture
If the frame is fed in a flat folded position and deformed into square shape, then the frame can fit inside the base part, but the deformation process adds complexity
Solution Approach 1:
The frame is prepared in a flat, folded position before entering the merging unit. This preliminary flattening and folding of the frame allows it to be compact and easy to handle during transport and positioning, while the actual deformation into the final square shape occurs only when needed during the merging process, separating the preparation step from the final assembly step.
Solution Approach 2:
The frame undergoes a dynamic transformation from a flat folded state to a three-dimensional square shape during the merging process. The frame is deformed by forces applied in the merging unit, allowing it to transition between different geometric configurations - flat for storage/transport, and three-dimensional for final assembly inside the base part.
3Reliability
If a continuous glue strip is applied to the frame, then a permanent dimensionally stable connection is achieved, but the gluing process adds time
Solution Approach 1:
A continuous strip of glue is applied along the entire perimeter of the frame rather than discrete glue dots or segments. This continuous application ensures uninterrupted bonding along the frame's edge, creating a permanent and dimensionally stable connection to the base part walls. The continuity of the glue application also suggests a continuous gluing process that can be integrated into the flow of the merging operation.
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
This method significantly enhances the manufacturing efficiency by allowing simultaneous processing of multiple packs, ensuring a stable and precise connection between the base and frame parts, thereby increasing production capacity.
Implementation Method 1
the frame is brought into the square shape according to the pack, preferably by movable (suction) organs, which hold the frame by grasping (outside) at two each other
Data Source
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AI summary
Method for manufacturing cigarette packs of the cap-box type, comprising a base (10) and a circumferential frame (17) arranged within the base (10), which rests against the base and side walls (13, 14). The frame (17), which is rectangular in its final position, is fed to a frame assembly (35) in a flat, folded state and erected by erecting elements, e.g., suction heads (54), by grasping the outside of frame sections (18). Simultaneously, it is deformed by means of stop pins (57) such that the outer contours of the frame (17) are smaller than the area of a base wall (12). The deformed frame (17) is lowered into the base (10) and formed into its final rectangular shape there.