Vertical Unstacking of Corrugated Cardboard Stacks
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Solution Overview
Problem
Existing methods for forming corrugated cardboard boxes are inefficient and labor-intensive, leading to musculoskeletal disorders in operators due to manual handling and difficulties in gripping and unstacking cardboard stacks, especially when blanks are lightweight and tend to stick together, causing errors and waste.
Innovation Solution
A device and method that vertically lift and process cardboard stacks, using suction and robotic arms to grip and unstack blanks without manual intervention, allowing for continuous operation and accurate handling of all cutouts, including those at the bottom of pallets, with optional identification and gluing, and eliminating the need for complex sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual loading of magazines is used, then operators can load pallets, but operators experience musculoskeletal disorders due to repetitive manual handling of heavy cardboard
Solution Approach 1:
The patent replaces manual mechanical handling with a suction-based gripping system that uses vacuum pressure to hold and transfer cardboard blanks. This substitution eliminates the need for operators to manually lift and move heavy cardboard, resolving the contradiction between automation and operational simplicity.
Solution Approach 2:
The invention employs a suction cup mechanism powered by vacuum pressure to grip and transport cardboard blanks from pallets to magazines. This pneumatic approach provides automated loading capability while maintaining relatively simple system architecture, addressing both automation and complexity concerns.
2Reliability
If side grippers are used to lift stacks, then multiple sheets can be moved, but exact and repetitive gripping is difficult to achieve
Solution Approach 1:
The patent replaces mechanical side grippers with a suction-based system that uses vacuum pressure to hold cardboard blanks. This substitution provides precise and consistent gripping capability, as the suction force can be uniformly applied and easily controlled, achieving both high reliability and ease of operation.
Solution Approach 2:
The invention changes the gripping mechanism from mechanical force application to vacuum pressure control. By adjusting vacuum pressure parameters, the system achieves reliable and repetitive gripping of cardboard blanks with consistent positioning, resolving the contradiction between gripping accuracy and operational ease.
3Measurement precision
If optical measurement systems are used to measure cutout positions, then precise positioning is achieved, but the system becomes too expensive and complex
Solution Approach 1:
The patent extracts the measurement function from complex optical systems and implements it through simpler means. By using the existing suction cup positioning mechanism combined with basic sensors to detect when a blank is properly positioned, the system achieves sufficient measurement precision without the expense and complexity of sophisticated optical measurement equipment.
Solution Approach 2:
The invention replaces expensive, complex optical measurement systems with simpler, more economical sensing mechanisms. The basic position detection using simple sensors integrated with the suction cup system provides adequate precision at a fraction of the cost and complexity of optical measurement systems.
4Productivity
If high-speed box formation is implemented, then productivity increases, but manual loading frequency must increase causing more operator strain
Solution Approach 1:
The patent replaces manual loading operations with an automated suction-based system that can continuously supply cardboard blanks to the box formation process. This substitution enables high-speed production while completely eliminating operator exposure to repetitive manual handling, resolving the contradiction between productivity and operator health.
Solution Approach 2:
The invention implements continuous automated loading through the suction cup system that can continuously pick up and transfer blanks from pallets to magazines without interruption. This continuous operation enables high-speed box formation while eliminating the need for operators to perform repetitive loading tasks, addressing both productivity and health concerns.
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
Enables high-speed, uninterrupted formation of packaging boxes while improving operator safety and reducing waste by automating the unstacking and processing of cardboard blanks, ensuring accurate and efficient handling of all cutouts without manual handling and complex sensor systems.
Implementation Method 1
means for unstacking the blanks by suction
Data Source
Figure 1
Figure 1A~1C
Figure 2~3
AI summary
The invention relates to a device (1) and a method for preparing a packaging box (2, 74) from at least one storage location (3) for a stack (4, 68, 69) of corrugated cardboard cut-outs, including means (6) for moving the stack forward while same is being unstacked and means (7) for unstacking the cut-outs by means of suction. Since the cut-outs are stacked vertically, the means (6) for moving the stack forward comprise a plate (8) for lifting the stack vertically up to an engagement plane (9) for the cut-out (28) located on top. The device comprises means (27) for locating the X, Y, Z position (pi) of the top cut-out in the storage location and means (29) for calculating the X, Y, Z path, comprising a vertical component, and means for unstacking on the basis of said position (pi), which are designed to control the movement of said unstacking means between a position (9) for grasping the cut-out and a position for positioning same a predetermined work station likewise located at X, Y, Z.