Universal Loading Assembly for Horizontal and Vertical Cartoning
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Solution Overview
Problem
Existing cartoning systems require costly duplication of parts and space due to the need for separate equipment for horizontal and vertical cartoners, leading to inefficiencies and increased downtime from malfunctions like jamming.
Innovation Solution
A loading system with a moveable carriage and continuous loop that can operate in both horizontal and vertical configurations, allowing for adjustable speeds and synchronized movement to facilitate efficient package insertion and carton closure, eliminating the need for additional equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate equipment is used for horizontal and vertical cartoners, then each configuration can be optimized for its specific function, but costly duplication of parts and floor space is required
Solution Approach 1:
The loading assembly is designed with a universal carriage and loop mechanism that can perform both horizontal and vertical cartoning operations. The carriage can be positioned at different heights and orientations, and the loop can be configured to accommodate packages of various sizes and shapes, allowing a single piece of equipment to replace what would traditionally require separate horizontal and vertical cartoning machines
Solution Approach 2:
The system transitions between horizontal and vertical operations by changing the spatial orientation of the carriage and loop assembly. The carriage can move along horizontal and vertical axes, and the entire assembly can be repositioned in three-dimensional space to accommodate different cartoning configurations, effectively using dimensional flexibility to achieve multi-functionality
2Adaptability or versatility
If separate equipment is used for horizontal and vertical cartoners, then each configuration can be optimized for its specific function, but costly duplication of parts is required
Solution Approach 1:
The loading assembly uses a universal carriage with adjustable positioning mechanisms, a continuous loop with variable speed control, and reusable trays that can accommodate both horizontal and vertical cartoning. This single multi-functional assembly eliminates the need for duplicate sets of cartoning-specific parts that would be required for separate horizontal and vertical machines
Solution Approach 2:
The system incorporates dynamic, adjustable components including the carriage positioning system, loop speed control, and tray configuration options. These dynamic elements allow the same physical parts to be reconfigured for different operations, reducing the total quantity of specialized parts needed compared to fixed, dedicated equipment
3Productivity
If complicated mechanisms are used in vertical cartoning to achieve high speed insertion, then filling speed increases, but system complexity and cost increase
Solution Approach 1:
The continuous loop provides uninterrupted, continuous motion for package transport and insertion. The loop runs continuously without stopping or reversing, maintaining constant productive action while simplifying the overall mechanism compared to systems that require complex acceleration, deceleration, and direction-changing components
Solution Approach 2:
The system combines package conveyance, positioning, and insertion functions into a single integrated continuous loop mechanism. By merging these functions into one continuous motion system rather than using separate mechanisms for each function, the design achieves high filling speed with reduced complexity
4Ease of operation
If additional equipment such as product conveyors and loading systems is used in horizontal cartoning, then package insertion capability is improved, but system cost and floor space occupation increase
Solution Approach 1:
The loading assembly merges the functions of product conveyance, positioning, and insertion into a single integrated carriage and loop system. The carriage moves packages along the loop, positions them precisely, and inserts them into cartons all through one coordinated mechanism, eliminating the need for separate conveyor systems, positioning devices, and loading mechanisms that would otherwise be required
Data Source
AI summary
A loading assembly for a packaging system includes a carriage coupled and reciprocally moveable relative to a support structure. The carriage is moveable relative to the support structure along a longitudinal axis in a first direction and a second direction opposite said first direction. A continuous loop configured with a plurality of spaced apart receptacles is moveably supported by the carriage. The loop includes a first portion that is moved at a continuous speed relative to the support structure, and a second portion that is alternatively moved and stopped relative to the support structure. Various methods of loading a receptacle are also provided.