The project scope involves designing an advanced semi-automated machine to integrate with the existing production line. This machine will collect all the customer's product boxes and rearrange them based on their shape and size. After collection, the product boxes will be packed into a carton case in the required pattern with the assistance of an operator. Taking time of collating the product boxes should be less than 1 sec and the complete cycle time to pack a case should be less than 5 min. The machine should be capable of accommodating various shapes and sizes of both the customer’s products and the carton cases.
Material Handling
Case Packer
The Customer has expertise in the design and manufacture of Secondary Packaging Machinery, they specialise in end-of-line packaging. The scope of the Customer’s requirement varies based on the needs of end Customers.
Scope
Challenge
- Designing the machine to handle variable product sizes with a tool-free, quick, and easy changeover.
- Integrating the system with the existing product line and Collating boxes into the required matrix and filling them into the carton case and automating the loading of product boxes into the carton case.
- Developing a custom, cost-effective solution with a cycle time of 5 min per pack.
Solution
To achieve the project scope and overcome the challenges, a semi automatic Case packer machine was designed with the following solutions
Integration and Collection: Designed a semi-automatic case machine to integrate with the existing production line, to collect the product boxes and feeding them into the new system.
Automated Collation: The machine automatically collates boxes into the correct packing pattern using a pneumatic cylinder and pawl mechanism after they are gathered from the feed system.
Adjustable Loading Station: A horizontal loading station was developed to handle various carton case sizes, featuring a scissor mechanism for height adjustment. The operator sets the height for each carton case size before starting the packaging process.
Box Loading Process: The operator places a carton case onto the horizontal loading station, positioning the open end over the loading funnel.
Carton Case Positioning: Pressing the foot pedal activates a pneumatic cylinder and linkage mechanism, tilting the loading unit to 90 degrees and aligning the carton case with the entry chute.
Automatic Filling: Product boxes are automatically filled into the aligned carton case through the entry chute.
Case Handling: The filled carton is pneumatically lowered and transferred via a roller conveyor to the next case taper station.
Versatile Design: The machine accommodates variable sizes and features a tool-free changeover setup.
Value and Benefits
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