A method for folding displays using an Automatic Display Assembly Machine (“ADAM”), the method comprising:
- inserting a Pre-Packaged Weekender (“PPW”) display into the ADAM for assembly;
- receiving, using an in-feed conveyor of the ADAM, the PPW display and transporting it with conveyor rollers to a folding staged position;
- squaring, using an injector assembly, the PPW display for erecting;
- erecting, using an erector assembly comprising a side action beam and a bottom suction assembly, the PPW display to form a rectangular, erected PPW display,
- wherein the side action beam is a lateral beam comprising a number of suction cup rail assemblies disposed along a length thereof, and
- wherein the side action beam actuates 90 degrees and uses the number of suction cup rail assemblies to grab and erect the PPW display;
- lowering a main actuator assembly and a head actuator assembly of the ADAM toward the erected PPW display;
- capturing, using a number of suction cups of a number of head beam assemblies disposed on a downward facing surface of a center head beam of the head actuator assembly, a first face of the erected PPW display,
- wherein the first face of the erected PPW display comprises a number of front shelves corresponding to a number of back shelves disposed on a second face of the erected PPW display, and
- wherein each front shelf of the number of front shelves corresponds to one of the number of head beam assemblies;
- lifting, using the head beam assemblies, the number of front shelves of the erected PPW display, and collapsing, using side strikers of side action assemblies, left and right side-gussets of the number of front shelves, wherein the side action assemblies comprise flippers, flipper rotary pistons, and flipper stroke pistons;
- releasing, by removing suction from the number of suction cups of the number of head beam assemblies, the first face of the erected PPW display;
- holding, by lowering the head actuator assembly, the number of front shelves into place;
- forming and folding, using the flippers of the side action assemblies, shelf support rails corresponding to the number of front shelves;
- pressing, using tab strikers of the head beam assemblies, the number of front shelves into receiving pockets of the corresponding shelf support rails, to form latched front shelves;
- pushing, using back strikers of a number of back striker assemblies, the number of back shelves towards the number of front shelves;
- lowering, using the head actuator assembly, the number of head beam assemblies toward the back striker assemblies;
- retracting the back striker assemblies while using the head beam assemblies to capture the back shelves and prevent them from lowering;
- locking the back shelves into the front shelves by actuating the tab strikers to press a thumb tab connected to each back shelf into a receiving hold of the corresponding front shelf while using the flippers to hold the front shelves in place;
- holding, using the bottom suction assembly, the PPW display while retracting the tab strikers and the center head beam of the head actuator assembly along with the flippers, creating an assembled PPW display;
- and
- discharging the assembled PPW display.