The was an existing prototype of what a box aligner might look like, so my first step was to familiarize myself with that and identify any areas for improvement. 

After identifying areas to improve the existing design, the scope of the project was expanded significantly to create a new design that met the objectives above. I broke the project up into two components: box holding and the sliding stage. I began with ideas for box holding, since I had already updated the design of the sliding action for the 2nd prototype. 

Bench Testing

• A front-loading hinged lid idea was the most favored after bench testing 

• Fixed clips made loading with the lid impractical due to the flexible nature of the box edges (see video below)

• Began testing ideas to actuate clips to constrain the box edges. 

• From previous bench testing it seemed that one clip on the middle of each side constrained the edges adequately 

• Came up with a design which linked the actuation of rotating clips to reduce the number of steps for the user

• Combined the lid and rotating clips concepts into a first prototype of a box holding method

1st Prototype

Specific Challenges with aligner design

There were a few project specific criteria that motivated a lot of the design decisions made above and going forward:

• Very minimal clearance across the back edge of the box when in place for packing due to other keep-outs

• Any clips that extend into the box must be low profile to avoid packed contents

• Clips cannot retract while lid is closed to avoid disturbing packed contents

• First prototype (above) included clips linked with steel cable and a handle for the user to rotate them, as well as a hinged lid and lead-ins for the box

• Clips were clamped onto the cable using bolts on a small flat on each pulley which was part of the clip

• Built first prototype using custom parts I made in house, assembled, then tested the loading action

• Bench testing summary:

  • Wanted to figure out a better way to link clips to the cable

  • Started with new custom washers that I hoped wouldn't damage the cable, but holding force was too low

  • Experimented with using multiple wraps and leveraging the capstan equation to avoid the need for clamping

  • Found that a design could be made such that the cable would break before the clip slipped with only 3 wraps. 

• However, linking the clips to the cable with friction alone eliminated any adjustability they had 

  • The next design made it such that the clips were removable and adjustable relative to their linked pulleys

Final Prototype Testing Videos

• Final prototype performed as designed 

• Proceeded to build another one to prepare for installation in multiple locations