A method of product shipping package design improvement

Abstract

A method for improving the design of product transportation packaging includes seven steps: market research and road condition collection, physical experiment and simulation virtual test of existing scheme, comprehensive simulation virtual test of existing scheme, improved design, physical experiment and simulation virtual test of improved scheme, comprehensive simulation virtual test of improved scheme, and software of three-dimensional and simulation virtual test process. The method perfects the overall process of transportation packaging design, realizes overall evaluation and optimization design of packaging system, improves the accuracy of packaging system performance test results by combining computer simulation virtual technology and physical experiment, greatly improves the protection and stability of packaging system, and improves the efficiency of packaging design and generation of virtual test model by programming the packaging design process.

Description

Technical Field

[0001] This invention belongs to the field of packaging design technology and relates to a method for improving the design of product transport packaging. Background Technology

[0002] Product transport packaging design is the most crucial step before a product enters the distribution process. The quality of the packaging design directly determines the product's breakage rate, thus affecting the overall cost. Existing packaging design methods mainly revolve around cushioning packaging design. In the 1970s, MTS Corporation in the United States, in collaboration with the Packaging College of Michigan State University, proposed a five-step method for cushioning packaging design. In 1986, FCBreak et al. of Lansmont Corporation in the United States added a step to the five-step method, forming the widely used six-step method for cushioning packaging design. The six steps mainly include: ① Determining the product's distribution environment conditions; ② Determining the product's fragility and other characteristics; ③ If the product's fragility is low, improving the design of weak components in the product to increase its fragility; ④ Designing the cushioning structure based on the product's fragility and the characteristics of the cushioning material, and determining its optimal dimensions; ⑤ Comprehensively considering factors such as breakage rate, cost, and environmental protection, optimizing the packaging system design, and producing prototype transport packaging; ⑥ Testing and evaluating the prototype packaging according to national standards and other requirements.

[0003] Existing technologies often emphasize cushioning structure design but lack a holistic evaluation of transport packaging. Even after testing, no further improvement or optimization designs are proposed. Packaging testing primarily involves physical experiments with short durations that are difficult to control, resulting in limited physical quantities and an inability to obtain continuous spatial and temporal results. This fails to fully reveal the structural response and vibration deformation mechanisms during the drop test. Furthermore, the design process is complex, lacking a systematic framework, and consumes significant human and material resources, increasing the cost of packaging design and testing. Summary of the Invention

[0004] The purpose of this invention is to provide an improved design method for product transport packaging, solving the problems existing in the prior art. This invention improves the design process for transport packaging systems, enabling better evaluation of packaging solutions and significantly enhancing the safety and stability of product transport packaging design. By combining computer simulation virtual technology with physical experiments, it improves the accuracy of test results for packaging systems and solves the problem of testing large packages that cannot be tested. Furthermore, by proceduralizing the overall design process, it reduces the time required for design and testing, improving the overall efficiency of transport packaging design.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A method for improving the design of product transport packaging, characterized by comprising the following steps: Step 1: Market Research and Road Condition Data Collection. Collect and analyze various types of damage to product transport packaging, conduct preliminary analysis of the causes of packaging system damage, collect and analyze road condition information, and obtain relevant road condition data such as impact and vibration response to provide basic data for physical testing and virtual testing of the packaging system. Step 2: Physical experiments and corresponding virtual simulation tests of the existing packaging scheme. Determine the testing standards for transport packaging, and conduct physical experiments and corresponding virtual tests on the existing packaging system of the product accordingly. Obtain the physical experiment results and virtual test results, and compare the degree of agreement between the two results. If the results are roughly consistent, it indicates that the virtual simulation test model is reliable. If they are inconsistent, modify the simulation model parameters and recalculate until the virtual simulation model is determined to be reliable. Step 3: Comprehensive simulation and virtual testing of existing packaging solutions. A comprehensive simulation and virtual test will be conducted on the existing product packaging solutions, including random vibration analysis, harmonic response analysis, horizontal and vertical impact analysis, and lifting analysis. This will provide a comprehensive evaluation of the existing packaging solutions and prepare for the next step of design improvement. Step 4: Improve the design. Based on the analysis of simulation and virtual test results, identify design flaws, and make targeted improvements to the packaging system or product design, and establish corresponding 3D models; Step 5: Conduct certain physical experiments and corresponding simulation virtual tests on the improved product transportation packaging system. Referring to the process in Step 2, compare and analyze the results of the physical experiments and simulation virtual tests of the improved scheme to ensure the reliability of the simulation virtual test model of the improved scheme. Step 6: Referring to the process in Step 3, conduct a comprehensive simulation virtual test on the improved product transport packaging system. If the improved solution meets the product transport packaging protection requirements, it is considered a qualified solution; otherwise, repeat Steps 4-6 until the solution is qualified. Step 7: For qualified solutions, software-based modeling process for 3D and simulation virtual testing is used to improve the efficiency of packaging design output and virtual test model generation.

[0006] The beneficial effects of this invention are: The proposed method for improving transport packaging design first determines the product's distribution environment and causes of damage through research. Then, it conducts physical experiments and virtual simulation tests on existing packaging solutions. The accuracy of the virtual simulation test results is determined by comparing the conformity between the two methods. A comprehensive virtual simulation test is then performed. Next, the existing solution is improved, and the improved design is verified through virtual simulation tests and physical experiments to ensure the reliability of the virtual test model. A comprehensive virtual simulation test is then conducted on the improved solution to fully evaluate it. Finally, for qualified solutions, the 3D and virtual simulation test modeling processes are software-based, and related design programs are developed. This method improves the overall process of transport packaging design, enabling comprehensive evaluation and improvement of the packaging system. By combining computer simulation virtual testing technology with physical experiments, the accuracy of packaging system performance test results is improved. Virtual simulation testing can address the testing of large packaging components that cannot be tested in physical experiments. The overall process significantly improves the protectiveness and stability of the packaging system. Finally, the software-based 3D geometric modeling and virtual simulation test modeling processes improve the efficiency of packaging design output and virtual test model generation, shorten design time, and enhance the overall efficiency of packaging system design and performance testing. Attached Figure Description

[0007] Figure 1 This is a flowchart illustrating the improved design method for product transport packaging according to the present invention. Figure 2 This is a schematic diagram of the geometric model of the existing packaging solution in this embodiment; Figure 3 This is a schematic diagram of the impact response spectrum collected during transportation in this embodiment; Figure 4 This is a schematic diagram of the vibration response spectrum collected during transportation in this embodiment; Figure 5 This is a schematic diagram of the surface drop in this embodiment; Figure 6 This is a schematic diagram of the acceleration curve of the drop test of the existing solution in this embodiment; Figure 7 This is a schematic diagram of the acceleration curve of a single product in the drop simulation test of the existing solution in this embodiment; Figure 8 This is a schematic diagram of the overall acceleration curve of the product in the drop simulation test of the existing solution in this embodiment; Figure 9 This is a schematic diagram of the power density curve of random vibration analysis in the existing scheme of this embodiment; Figure 10 This is a schematic diagram of the response acceleration amplitude of the existing scheme in this embodiment for harmonic response analysis; Figure 11This is a schematic diagram of the horizontal impact analysis acceleration-time curve of the existing scheme in this embodiment; Figure 12 This is a schematic diagram of the acceleration-time curve of the lateral fork lift analysis in the existing scheme of this embodiment; Figure 13 This is a schematic diagram of the geometric model of the improved scheme in this embodiment; Figure 14 This is a schematic diagram of the acceleration-time curve of the drop test of the improved scheme in this embodiment; Figure 15 This is a schematic diagram of the acceleration curve of a single product in the drop simulation test of the improved scheme in this embodiment; Figure 16 This is a schematic diagram of the power density curve of random vibration analysis in the improved scheme of this embodiment; Figure 17 This is a schematic diagram of the response acceleration amplitude of the harmonic response analysis of the improved scheme in this embodiment; Figure 18 This is a schematic diagram of the horizontal impact analysis acceleration-time curve of the improved scheme in this embodiment; Figure 19 This is the acceleration-time curve of the tempered glass closest to the impact baffle at an initial impact velocity of 1.01 m / s in this embodiment. Implementation

[0008] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0009] like Figure 1 As shown, a method for improving the design of product transportation packaging includes seven steps: market research and road condition data collection, physical experiments and simulation virtual testing of existing solutions, comprehensive simulation virtual testing of existing solutions, improved design, physical experiments and simulation virtual testing of improved solutions, comprehensive simulation virtual testing of improved solutions, and software-based 3D and simulation virtual testing processes. Example

[0010] The method of the present invention will be specifically explained below with reference to an example of tempered glass bulk transport packaging design.

[0011] Step 1: Conduct market research and collect transportation route information on existing tempered glass packaging solutions. This packaging system combines 35 pieces of tempered glass, each measuring 2092×698×9mm, into a large-scale packaging system. Figure 2 This is a schematic diagram of the interior of an existing packaged box for tempered glass. Market research indicates that its cushioning structure design has poor lateral stability, and the paper guards and strapping are prone to loosening. This often leads to collisions between the tempered glass pieces during transportation, and the presence of sharp corners in the packaging structure can easily scratch the glass.

[0012] The main mode of transportation is road transport. The most common cause of damage during transport is drops. Road condition data is collected using transport recorders, and waveform characteristics can be used to analyze road conditions based on four events: impact, vibration, drops, and normal events. Figure 3 The impact response spectrum collected during transportation is displayed. Figure 4 The vibration response spectrum collected during transportation is displayed.

[0013] Step 2: Determine the drop test standard, conduct physical experiments and virtual simulation tests on the existing integrated packaging scheme for tempered glass, and compare and analyze the consistency of the results. According to Scheme 2 in "GB / T 4857.17-2017 Packaging Transport Packages Basic Tests Part 17: General Rules for Developing Performance Test Outlines", a more stringent method is selected to conduct experimental tests on the packaging scheme. Specifically, the test is conducted according to standard GB / T 5398-2016 Test Methods for Large Transport Packages, with drop tests divided into three types: surface drop, edge drop, and corner drop. Figure 5 This is a schematic diagram of a surface drop test. Taking a surface drop test as an example, the Lansmont TestPartner 3 data acquisition system is used to collect data from the tempered glass assembly packaging system. It can collect response data from any single piece of glass. Taking the middle tempered glass piece (numbered 18) as an example, an accelerometer is installed on this piece of glass near the center edge of the drop point, ultimately measuring the drop height. h The acceleration-time curve at 1=36.5cm is shown below. Figure 6 As shown.

[0014] A commercial finite element method (FEM) simulation software was used to model and simulate an existing tempered glass packaging system. First, a geometric model of the packaging system was established, the material models of each component were determined, and relevant material parameters were tested. Next, a mesh was created, the contact types between components were set, and loads were applied according to test standards to complete the virtual simulation test model in the software. Using the finite element simulation software, an animation of the surface drop process of the packaging system could be observed. The entire drop process lasted 0.25 seconds. The acceleration-time curve of the tempered glass during the entire drop process was then extracted, as shown in the figure. Figure 7 and 8 As shown. Since the sensor was installed on the tempered glass in the middle during the test, the acceleration curve of the corresponding tempered glass in the middle was extracted from the virtual drop test. Figure 7 The acceleration-time curve of the tempered glass during the entire drop process is shown. Figure 8 This is the acceleration-time curve of all 35 pieces of tempered glass during the entire drop process. Through analysis of... Figure 6 and Figure 7A comparative analysis of the experimental and simulation results revealed that the shapes, trends, and amplitude levels of the curves were consistent, indicating that the simulation model is reliable.

[0015] Step 3: Since the existing packaging scheme's simulation virtual test model is reliable, a comprehensive simulation virtual test can be performed on the existing tempered glass packaged solution, including tests such as random vibration, harmonic response analysis, horizontal impact, inclined plane impact, lateral lifting, and drop analysis. Figure 9 The PSD power spectral density curve of the tempered glass assembly package along the transverse direction of the package obtained from the road condition data collection in step 1 is shown. The random vibration stress-strain response contour map of this scheme under this excitation is shown below. Figure 10 As shown. Figure 11 The response acceleration amplitude of all tempered glass in the existing assembly package along the lateral direction is analyzed for harmonic response. Figure 12 The acceleration-time curves of the tempered glass closest to the impact baffle during an inclined plane impact with an initial velocity of 1.01 m / s are shown. Figure 13 Displays fork lifting speed v Acceleration-time curve of the tempered glass closest to the fork plug at 0.1 m / s.

[0016] Step 4: Analyze the simulation results, identify the defects in the existing tempered glass packaging solutions, and propose improved designs to obtain the improved packaging and product structure drawings. Figure 14 The improved scheme is shown in three-dimensional geometric model.

[0017] Step 5: Conduct drop tests and virtual drop simulation tests on the improved design. The relevant drop environment conditions and load conditions are the same as in Step 2. Here, we will also use a surface drop as an example. Figure 15 Displayed drop height h The acceleration-time curve of the tempered glass in the middle of the improved scheme in the drop test at 1=36.5cm. Figure 16 The acceleration-time curves for the entire drop process of the glass at a drop height of 36.5 cm are displayed. Comparative analysis of the two results shows that the curve shapes and amplitude levels are roughly consistent, indicating that the improved finite element simulation model is reliable.

[0018] Step 6: Based on the validated improved packaging system simulation virtual test model, conduct a comprehensive simulation virtual test on the improved packaging system. The test steps are the same as in Step 3. Figure 17 Random vibration stress-strain response contour plot of the improved packaging scheme for tempered glass under the same PSD curve excitation as the original scheme; Figure 18 To improve the response acceleration amplitude of all tempered glass transverse harmonic response analysis under the packaging scheme; Figure 19The acceleration-time curves of the tempered glass closest to the impact baffle are shown at an initial impact velocity of 1.01 m / s.

[0019] Based on the drop test results of the improved design, the maximum acceleration of each piece of tempered glass was 543.676 m / s². 2 The value is approximately 54.4G. It is known that the brittleness value of tempered glass itself is 100G. The brittleness value of the improved glass is much smaller than its original brittleness value, so it meets the existing surface drop requirements. Moreover, the maximum peak acceleration of the improved solution is much smaller than that of the existing solution, indicating that the improved solution has better protective performance. The maximum response acceleration results of random vibration, harmonic response analysis and horizontal impact analysis are all smaller than those of the existing packaging solution, indicating that the improved packaging solution has a significant improvement in protective performance. The improved solution meets the requirements in all aspects.

[0020] Step 7: Software-based 3D geometry and simulation virtual test modeling of the improved finalized design scheme. Based on secondary development technology of commercial CAD software, for the finalized tempered glass transport packaging scheme, the known conditions required for scheme generation are clarified, the output format is determined, and scheme generation software is developed. This software can input the initial parameters for generating the relevant geometric models of each component, perform parametric geometric modeling, and finally automatically generate drawings and other scheme output formats, achieving a universal effect where the scheme output format changes with the input initial parameters. Reliable simulation virtual test models are established for the existing and improved packaging systems. The entire modeling process is standardized and streamlined. Based on secondary development technology of CAE software, parametric modeling of the relevant modeling process is performed, and related software is developed. This software can input the initial parameters required for simulation modeling of various load conditions of the entire packaging system and can automatically generate corresponding simulation models based on these parameters. The software can also output and display simulation results in various curve formats. Simultaneously, the software can extend the material model and its parameters, store simulation results from each iteration to avoid redundant calculations, and can also be extended for various required load conditions.

Claims

1. A method of improving the design of a product shipping package, characterized by, Includes the following steps: Step 1: Market research and road condition data collection: We statistically analyze various damage phenomena of product transportation packaging, conduct preliminary analysis of the causes of packaging system damage, collect and analyze road condition information, and obtain road condition data related to impact and vibration response, providing basic data for physical testing and virtual testing of packaging systems. Step 2: Physical experiments and corresponding simulation virtual tests of existing packaging solutions: Determine the testing standards for transport packaging, and conduct physical experiments and corresponding virtual tests on the existing packaging system of the product accordingly. Obtain the results of the physical experiments and the results of the virtual tests, and compare the degree of agreement between the two results. If the results are roughly consistent, it indicates that the simulation virtual test model is reliable. If they are inconsistent, modify the simulation model parameters and recalculate until the reliability of the simulation virtual model is determined. Step 3: Comprehensive virtual simulation testing of existing packaging solutions: A comprehensive simulation virtual test is conducted on the existing packaging scheme for the product, including random vibration analysis, harmonic response analysis, horizontal and vertical impact analysis, and lifting analysis, to comprehensively evaluate the existing packaging scheme and prepare for the next step of design improvement. Step 4: Improve the design: Based on the analysis of simulation virtual test results, design defects were identified, and targeted improvements were made to the packaging system or product design, and corresponding three-dimensional models were established. Step 5: Conduct certain physical experiments and corresponding simulation virtual tests on the improved product transportation packaging system. Referring to the process in Step 2, compare and analyze the results of the physical experiments and simulation virtual tests of the improved scheme to ensure the reliability of the simulation virtual test model of the improved scheme. Step 6: Referring to the process in Step 3, conduct a comprehensive simulation virtual test on the improved product transport packaging system. If the improved solution meets the product transport packaging protection requirements, it is considered a qualified solution; otherwise, repeat Steps 4-6 until the solution is qualified. Step 7: For qualified solutions, software-based modeling process for 3D and simulation virtual testing is used to improve the efficiency of packaging design output and virtual test model generation.

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