Tray Forming Assembly With Turret-Piston Precision Folding
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Solution Overview
Problem
Existing methods for forming trays are inefficient and lack a systematic approach to process blanks into trays, particularly for applications involving food products and containers, which require precise folding and assembly to ensure structural integrity and ease of handling.
Innovation Solution
A system and method involving a blank feeder assembly, tray forming assembly, and components like turret and piston assemblies to systematically fold and form trays from blanks, utilizing mechanisms such as denicking wheels and flap folding assemblies to create trays with enhanced structural features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manual tray forming methods are used, then flexibility in handling different blank types is maintained, but productivity and manufacturing precision deteriorate due to inefficiency and lack of systematic approach
Solution Approach 1:
The tray forming system is divided into distinct functional modules: a blank feeder assembly for supplying blanks, a tray forming assembly with turret and piston sub-assemblies for forming operations, and a blank distribution mechanism. This segmentation allows each module to be optimized independently while working together systematically, resolving the contradiction between productivity and complexity by organizing complexity into manageable, coordinated segments
Solution Approach 2:
The turret assembly incorporates multiple female tray forming members that can process different blank types, and the piston assembly with male forming member serves multiple forming functions. This multi-functionality enables the system to maintain high productivity across various tray types without requiring separate dedicated equipment for each blank variation, thus improving productivity while controlling overall system complexity
2Manufacturing precision
If simple blank processing is used, then device complexity is reduced, but manufacturing precision and structural integrity deteriorate due to lack of precise folding and assembly mechanisms
Solution Approach 1:
The blank distribution mechanism pre-positionS blanks in correct orientation and location before forming operations begin. The turret assembly pre-configures multiple female forming members with precise geometric features that will guide the folding action. This preliminary preparation ensures that when forming occurs, precision is achieved through pre-established conditions rather than complex real-time control, resolving the contradiction between manufacturing precision and device complexity
Solution Approach 2:
The piston assembly acts as an intermediary between the turret assembly and the blank material. It translates rotational motion from the turret into linear forming pressure, mediating the complex interaction between multiple forming members and the blank. This intermediary mechanism simplifies the overall control architecture while maintaining precise folding and assembly through controlled mechanical advantage
3Productivity
If rapid tray formation is implemented, then productivity is improved, but manufacturing precision may deteriorate due to rushed folding and assembly processes
Solution Approach 1:
The turret assembly rotates continuously, bringing different female forming members into position with the piston assembly in a continuous cycle. The blank feeder assembly continuously supplies blanks, and the distribution mechanism continuously positions them. This continuous operation maintains high productivity while ensuring each forming action completes fully before the next begins, preventing rushed or incomplete folding that would compromise precision
Solution Approach 2:
The system employs periodic indexing of the turret assembly where each rotation position corresponds to a complete forming cycle with one blank. This periodic action allows the system to maintain rapid throughput through continuous rotation while ensuring that at each discrete position, the full sequence of folding and assembly operations completes with adequate time and precision before the next blank is processed
Data Source
AI summary
A method of forming a tray includes obtaining a blank, the blank having a plurality of panels and a plurality of end flaps foldably connected to a respective panel of the plurality of panels. The method further includes positioning the blank in a blank feeder assembly of a system for forming a tray, moving the blank to a tray forming assembly, the tray forming assembly including a tray forming assembly, the tray forming assembly including a turret assembly comprising a plurality of female tray forming members, the tray forming assembly further comprising a piston assembly including a male forming member, positioning the blank between the turret assembly and the piston assembly, and moving the piston assembly into at least partial engagement with the turret assembly to form a tray from the blank.