System and Method for Automated Assembly of Pre-Folded Display Units
Background of the Invention
Field of the Invention
The present invention pertains to the field of automated assembly systems, specifically machinery for automatically erecting and assembling pre-folded and pre-glued display units. This system enables high-speed, consistent assembly of point-of-purchase displays, significantly reducing labor costs and improving reliability in retail and packaging operations.
Description of the Related Art
Current methods for assembling retail displays primarily rely on manual labor, which is often time-consuming, inconsistent, and costly. Existing automation solutions struggle with the complexity of folding and assembling pre-glued displays, especially when accommodating various sizes and styles. Additionally, many automated systems risk damaging displays during assembly or fail to square and secure all components properly. Therefore, there is a need for a reliable, automated solution that can efficiently handle the assembly of pre-folded display units while maintaining structural integrity and consistency.
Summary of the Invention
The invention provides an automated system that utilizes synchronized mechanisms to receive, erect, and assemble pre-folded display units. Key components include an auto-feed mechanism, conveyor systems, and multiple specialized assemblies, such as an erector assembly, bottom suction assembly, and head assembly beam. These components work in unison to precisely control the folding and assembly process, delivering a cost-effective, reliable system capable of handling various display sizes and configurations while ensuring consistent quality.
Detailed Description of the Invention
System Overview
The system includes the following primary components:
Auto-Feed System:
Dual magazine design, each with a 40-display capacity.
Automated transfer mechanism for movement between loading and staging positions.
Height adjustment feature for consistent display feeding.
Main Assembly Components:
Erector Assembly: Uses vacuum cups and mechanical arms to initiate the display opening process.
Bottom Suction Assembly: Stabilizes the display unit during erection.
Head Assembly Beam: Manages front shelf folding and gusset manipulation.
Tab Strikers: Secure display components in final positions.
Conveyor System: Transports displays through each assembly stage.
Key Process Steps
Display Loading and Staging:
Operator loads approximately 40 flat displays into the auto-feed magazine.
The system automatically transfers displays to the staging position.
Height adjustment mechanism maintains a consistent pickup location for reliable transfer.
Display Erection:
Injector mechanism moves a single display to the staging position.
Erector assembly secures the display using vacuum cups.
Bottom suction cups stabilize the display during the erection phase.
Mechanical arms convert the flat display into a rectangular prism shape.
Shelf Assembly:
The head assembly beam descends to capture the front of the display.
Side strikers collapse gussets for the front shelf.
Tab strikers secure shelf support rails, while back strikers push the rear shelf into place.
A final locking mechanism engages all display components securely.
Control and Monitoring Systems
Sensors: Photoelectric sensors verify display positioning and orientation.
Programmable Logic Controller (PLC): Manages timing, synchronization, and overall system control.
Error Detection Systems: Identifies misaligned or damaged displays to ensure quality.
Safety Systems: Emergency stop functions and safety interlocking mechanisms are in place for operator protection.
Safety Features
Guard Panels: Equipped with safety interlocks to protect operators.
Emergency Stop Buttons: Positioned at key locations for rapid shutdown if needed.
Motion Control Safety Zones: Ensures operator safety around moving parts.
Fault Detection and Shutdown: Automatic fault detection and shutdown for added safety.
Claims
Automated Assembly System:
A system for automated assembly of pre-folded display units, comprising an auto-feed mechanism, conveyor system, erector assembly with vacuum cups, head assembly beam, and multiple striker mechanisms for securing display components.
Auto-Feed Mechanism:
Dual magazines with a minimum 40-display capacity.
Automated transfer between load and staged positions.
Height adjustment system for consistent feeding.
Erector Assembly:
Includes a vacuum cup array for secure grip and mechanical arms for controlled display opening.
Equipped with a bottom suction system to maintain stability during the erection process.
Head Assembly Beam:
Features synchronized motion control, an integrated vacuum system, and multiple strike points for precise component assembly.
Automated Assembly Method:
Loading multiple flat displays into an auto-feed system, transferring individual displays to assembly position, erecting displays with vacuum and mechanical systems, securing components through synchronized striking actions, and verifying assembly completion via sensor systems.
Assembly Verification Process:
Includes photoelectric sensing for display position, vacuum pressure monitoring, component alignment verification, and final quality control checks.
Abstract
The invention is an automated system for erecting and assembling pre-folded display units. It integrates synchronized mechanisms, including an auto-feed system, erector assembly, bottom suction assembly, and head assembly beam, to perform high-speed, precise assembly of displays. The system accommodates various sizes and styles, maintains structural integrity, and includes error detection and safety features for reliable, consistent production.
Advantages and Benefits
High-Speed Operation: Allows consistent, rapid assembly of display units.
Reduced Labor Costs: Minimizes manual handling and assembly time.
Improved Consistency: Ensures uniform quality across all assembled displays.
Versatile Design: Accommodates various display sizes and configurations.
Error Detection: Integrated systems prevent damage and maintain quality.
Safety Features: Comprehensive protection for operators through safety interlocks and emergency stop options.
Use Cases and Applications
Retail Display Manufacturing: High-volume production of point-of-purchase displays.
Packaging Facilities: Integrates seamlessly with packing operations.
Distribution Centers: Enables on-demand display assembly and preparation.
Custom Display Production: Adaptable for different display designs and configurations.
Technical Considerations
The system incorporates advanced motion control and pneumatic systems for precise timing and movement. Modularity in design allows for easy maintenance and future upgrades, while the control system enables quick adjustments to handle varying display sizes and configurations, ensuring consistent quality.