Assembly process at Win Ent.
       Optimization of packaging for 1U units.        

  We are talking about packaging 1U units, which are sent to the end user.

  At the moment, we use two inserts that hold the unit in a cardboard box. When the unit is installed, the external dimensions of the foam (which correspond to the inner size of the box) - 580 mm x 420 mm x 125 mm (height).

  They fit tightly into the box and do not allow the unit to move or swim in the middle of the box, during transportation.

  The dimensions of the box into which the unit is finally packed are shown in the photo below.



  We can not change the dimensions of this box.

  On the other hand, we have a number of inserts that we already have and we hope to re-use them. This requires some changes that can be made.

  In the picture - the standard inserts, which are used for packaging and delivery of three units together, in one box.
When 3 unit is installed, the external dimensions of the foam (which correspond to the inner size of the box) - 560 mm x 385 mm x 280 mm (height). We cut them in half, in order to check how they fit into final packaging.

   
  This fully corresponds to the unit and is placed in a box.



  As you can see, we have gaps that must be filled in some way. First on the top.



  The second is on the long side of the unit.



  The third is on the short side.



  The final variable that is needed in this puzzle is the size of the box in which 3 units come in, together. It's next.



  Good. This is all data on the dimensions that we have.



  Possible Solution:

1.1 Both inserts are precut (to 2 pieces on the long side, as in the third photo), from the condition that they are 125 mm high. They are exactly the same inserted into the box. The middle unit is clamped between the inserts when the lid is closed.

1.2 Along each side of the box is inserted a flat foam (height of 125 mm and thickness of 20 mm and 11 mm), in order to center the unit.

1.3 The missing foam from the bottom (where the middle unit was inserted), is compensated by another piece of foam, the size of 1U unit and a thickness of ~20 mm.

  The disadvantage of this method is that the pieces of foam are made large volume and do not fit in a box for simultaneous transportation. That is, additional boxes are needed in which these pieces will be delivered.



  Second Possible Solution:

  2.1 Change the size of the box for 3 units, so that the internal size is 580 mm x 420 mm x 250 mm (height). In this case, it is twice as high as the final box and we can put 2 units there in our existing foam (our final foam for right now).

 We changed the size of the box. At the same time, it is necessary to change the design of the foam inserts. It will be better if the size of the inserts corresponds to our final dimensions. Then we can use them again.

  2.2 In the middle of the box there should be not two foam inserts, but 4. The third unit will be between them.



  A place for the middle unit should be provided. This means that each insert must have a cut (slot) for the middle unit.



  2.3 For final packaging, we must have an insert that will fill this space (different color only for example, that would make it visible).



  In the case of this size ("A+B"), this insert will be held by friction. In case of size as an "A" only, we will fix it in position by using hot glue or so.

  The thickness of this insert should be exactly half (1/2) of the thickness of 1U unit.

  The advantage of the
Second Solution is that the pieces of foam are small and can be sent in one box, together with three 1U units.

  We have more solutions, but these two look the simplest. If you need more information, I will be glad to answer through e-mail.

 



Aprill 11, 2017  SKootS

 
 

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