Vision-Guided Box Erecting for Variable Blank Folding Accuracy

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Solution Overview

Problem

Existing box erecting machines struggle with efficiently accommodating various box sizes and reducing operator injury and increasing productivity in high-volume production environments.

Innovation Solution

A box erecting machine equipped with a camera system to accurately determine score line positions, an arm assembly for precise folding, and a conveyor system to handle box blanks, allowing for automatic adjustment to different box sizes and rejecting defective blanks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual box erection is used, then flexibility in handling various box sizes is maintained, but productivity is low and operator injuries occur

Engineering Contradiction:

Improvebox erection speedVSAvoidmanual intervention level

Core Design Contradiction:

ProductivityVSExtent of automation

Solution Approach 1:

The system uses vision guidance to automatically detect score lines and guide the folding arm, enabling the machine to self-adjust to different box sizes without manual programming or intervention, thus achieving high productivity while maintaining flexibility

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical operation with an automated system combining vision sensors, controllers, and robotic folding arms, eliminating manual intervention while maintaining adaptability through real-time visual feedback

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If automated box erecting is implemented, then productivity increases, but adaptability to various box sizes decreases

Engineering Contradiction:

Improvehigh-volume production capabilityVSAvoidaccommodation of various box sizes

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The system dynamically adjusts the folding arm position and motion trajectory based on real-time vision detection of score line locations, allowing the automated erector to adapt to various box sizes while maintaining high-speed operation

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The vision system continuously detects score line positions and provides feedback to the controller, which adjusts the folding arm accordingly, enabling the automated system to adapt to different box configurations without reducing productivity

Inventive Principle:

Principle #23Feedback

3Manufacturing precision

If precise score line detection is used, then folding accuracy improves, but device complexity increases

Engineering Contradiction:

Improvefolding accuracyVSAvoidcamera system and control complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The vision system acts as an intermediary between the box blank and the folding arm, detecting score lines and translating them into guidance signals for the folding arm, achieving high precision without requiring complex mechanical positioning mechanisms

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS20250346014A1Box erecting apparatus and method

Publication Date: 2025.11.13 TAIWAN SEMICONDUCTOR MANUFACTURING CO LTD

AI summary

An apparatus and method for expanding a box blank into a box, the apparatus comprising an arm assembly, a controller, a camera and a box blank conveyor. The arm assembly includes a folding arm having a position in a first direction and a rotational angle controlled by the controller based on a position of a feature of the box blank in the field of view of the camera. The camera captures images of the box blank which are used to position the arm assembly and to evaluate the need to reject a box blank.