Mech 2503
INTRODUCTION TO DESIGN
ASSIGNMENT 2
FUNCTIONAL ANALYSIS OF A CORRUGATED CARDBOARD
BOX MANUFACTURING SYSTEM
Student Name
|
Metric ID
|
Semester
|
June – September 2020
Program
|
AME 302
Lecturer
|
Mdm. Annie Yap Ai Kin
Submission Date
|
11th of August, 2020
1 | FUNCTIONAL ANALYSIS
1.1 | BLACK BOX SYSTEM MODEL
Input
Function
Virgin Kraft paper
Output
Corrugated cardboard box
(medium and liner)
Cardboard offcuts/scraps
Dry corn starch powder (glue)
Heat + Thermal energies
Water
Light energy
Oxygen
Sound energy
Coal
Wax / Water/Grease resistant coating
Electrical energy
Electromechanical energy
(switches, buttons, levers, relays)
Chemical energy
Digital signal (control system)
Analog signal (heat content)
Analog signal (moisture content)
Analog signal
(intensity of capacitance –
electrostatic field based on
materials’ dielectric permittivity)
Digital signal (light/optical)
1|Page
Making
corrugated
cardboard boxes
(sans printing
process).
Mechanical energy
(kinetic energy + potential energy)
Digital signal (on/off trigger)
Digital signal (information)
1.2 | FUNCTIONAL DECOMPOSITION
Chemical energy
Air
Coal
Flame
Electrical energy
Detect
temperature.
Corrugate or flute
the medium.
Convert chemical
energy into heat energy.
*B
Condensed water
Heat
energy
Reel of
medium paper
Steam-heat at
350 – 365 ˚F.
Heat energy
Cooling
water
Remove heat and
reduce pressure.
A
Press by rolling
against corrugated
profile.
Analog
signals
Analog
signals
Activate splicer
sensing element.
Kinetic energy
Corrugated/Fluted
medium
Sound energy
Digital
signals
On or start
system.
Activate
temperature
sensing element.
Activate
pressure sensing
element.
Detect pressure.
Detect presence
of paper reel.
Digital
signals
Detect depletion
of paper reel.
Display real-time
information on
computer.
Digital signal
Join the layers.
Apply glue to
crests of corrugated
medium.
Bond layer of inner
liner to medium.
Bond layer of outer
liner to board
composite.
Reload reel.
Convert electrical
energy into
kinetic energy.
Corn
starch
glue
Reel of
liner sheet
*A
Steam-heat to cure
glue.
2|Page
Actuate shaft
motor.
Heat energy
Condensed water
Board composite
B
C
Electrical energy
Actuate motors.
Sort blanks.
Actuate saw
motor.
*C
Straight-cut the
board to blanks.
Kinetic
energy
Apply wax-coating
or water/grease
resistant for wet
container boxes.
Convert electrical energy
into kinetic energy.
Convert electrical
energy into
kinetic energy.
Wax or
water/grease
resistant coating
Kinetic energy
Stack layers to compact
predetermined
quantities.
Inspect for
quality.
Digital signal
Form boxes.
Separate blanks
into distinctive
layers.
Conduct warp test
to gauge the
flatness of blanks.
Perform Cobb test
to measure
moisture content.
Trim and punch the boards
to subtle shapes for
making flaps and handles.
Test for glue strength,
bursting strength,
compression, and
dimensional accuracy.
Corrugated
cardboard
boxes
Check quality
for final time.
Trim and perforate
intricate slots and
holes on cardboards.
Cardboard offcuts
(to be recycled)
Electrical
energy
3|Page
Convert electrical
energy into heat
energy.
Cardboard
offcuts (to be
recycled)
Fold and join
parts.
Heat
energy
Coat hot glue
with wax.
Condense the
overlapping
panels to level out
thickness.
Score and bend
parts to be folded.
Cold glue
Wax
Apply glue to
sections to be
adhered together.