Cushioning station, cushioning system and method

Abstract

A method is described which comprises: determining sensor information (SI) associated with a pre-packed shipping container (900) pre-packed with at least one shipping product (910), wherein the determined sensor information (SI) characterizes a position of respective free spaces (920) within the at least one pre-packed shipping container (900); conveying the at least one pre-packed shipping container (900) from an input section (210) into a cushioning section (220); providing a plurality of cushioning materials (800), in particular of different types and / or sizes, in at least one output section (410) depending on the determined sensor information (SI) associated with the at least one shipping container (900);Picking up one or more of the cushioning materials (800) provided in the at least one dispensing section (410) depending on the determined sensor information (SI); and arranging the picked-up one or more of the cushioning materials (800) in one of the free spaces (920) within the pre-packed at least one shipping container (900) located in the cushioning section (220) depending on the determined sensor information (SI).

Description

[0001] The invention relates to advances in the field of cushioning of shipping products in shipping containers.

[0002] In distribution centers for e-commerce applications, small to medium-sized cardboard boxes, acting as shipping containers, are filled with several different shipping products, which usually already have a certain robustness due to their primary packaging. The packer secures these boxes by inserting suitable cushioning materials or protective packaging, such as paper pads or bubble wrap bags, to ensure that they survive further transport to the end customer undamaged.

[0003] The problems of the prior art are solved by a padding station according to claim 1, by a padding system according to a dependent claim, and by a method according to a further dependent claim.

[0004] One aspect of the description concerns the following object: A cushioning station comprising a sensor device; a conveying device; a plurality of cushioning material dispensers configured to provide cushioning materials of different types and / or sizes in at least one dispensing section; a handling system; and a control unit configured with the sensor device, the conveying device, the plurality of cushioning material dispensers, and the handling system to perform the following: Determining sensor information associated with at least one pre-packed shipping container pre-packed with at least one shipping product, wherein the determined sensor information characterizes a position of respective free spaces within the at least one pre-packed shipping container;Transporting the at least one pre-packed shipping container from an entry section to a cushioning section; providing a plurality of cushioning materials, in particular of different types and / or sizes, depending on the sensor information associated with the at least one shipping container; picking up one of the plurality of provided cushioning materials depending on the sensor information; and arranging the respective cushioning material in one of the free spaces within the pre-packed at least one shipping container located in the cushioning section, depending on the sensor information.

[0005] By using sensor information and the multiple cushioning material dispensers, it becomes possible to automatically arrange different cushioning materials in the shipping container.

[0006] The multiple cushioning material dispensers mimic the manipulation or variation of the cushioning material usually available at a packing station by an experienced packer.

[0007] Advantageously, a process or cushioning station is provided which can optimally supply cushioning material of various types and lengths in a minimal quantity to create sufficient protection for the shipping products contained in the shipping container during shipping.

[0008] Accordingly, the shipping products do not need to be sent individually to a recipient, but can be arranged in a common shipping container addressed to the recipient.

[0009] This allows for savings on the padding material necessary for protective function while simultaneously increasing the level of protection. Consequently, there are cost and environmental benefits. Connecting the padding station to an inventory management system is no longer necessary.

[0010] An advantageous example is characterized in that the transport device comprises: a fixing system which fixes the shipping container in the cushioning section at least during a period in which the at least one cushioning material is introduced into the associated space.

[0011] This prevents the shipping container from unintentionally moving out of the cushioning position when the cushioning material is pressed into the empty space with a pressing force.

[0012] An advantageous example includes a hold-down device for fixing the at least one shipping product in the shipping container at least during the arrangement of the at least one cushioning material.

[0013] This advantageously keeps the shipped product in its position and prevents or reduces unintentional shifting of the product within the shipping container. This also supports the cushioning process.

[0014] An advantageous example comprises a separation section arranged downstream of the cushioning section in the direction of flow for receiving shipping containers; and a slide which, in the event of a fault detected in relation to the shipping container, conveys the at least one shipping container into the separation section.

[0015] This allows for manual follow-up checks or manual re-padding.

[0016] An advantageous example is characterized by the fact that at least one machine-trained function operates the conveying system, the majority of cushioning dispensers, and the handling system depending on the sensor information associated with the pre-packed shipping container.

[0017] One aspect of the description concerns the following item: An upholstery system comprising at least one, and in particular several, upholstery stations according to the aspect described above.

[0018] An advantageous example is characterized by the fact that at least two cushioning stations are connected in series.

[0019] An advantageous example is characterized by the fact that at least two padding stations are connected in parallel to each other.

[0020] A third aspect of the description concerns the following subject matter: A method comprising: determining sensor information associated with a pre-packed shipping container, which is pre-packed with at least one shipping product, wherein the determined sensor information characterizes a position of respective free spaces within the at least one pre-packed shipping container; conveying the at least one pre-packed shipping container from an input section to a cushioning section; providing a plurality of cushioning materials, in particular of different types and / or sizes, in at least one output section depending on the determined sensor information associated with the at least one shipping container; receiving one of the plurality of cushioning materials provided in the at least one output section depending on the determined sensor information;and arranging the respective majority of cushioning materials in one of the free spaces within the pre-packed shipping container located in the cushioning section, depending on the sensor information obtained.

[0021] An advantageous example comprises determining at least one cushioning configuration associated with the pre-packed shipping container as a function of the sensor information; wherein the provision of the at least one cushioning means, the picking up of the at least one cushioning means and the arrangement of the at least one cushioning means are carried out as a function of the determined cushioning configuration.

[0022] Determining the upholstery configuration advantageously establishes a sequence of upholstery steps.

[0023] An advantageous example is characterized in that determining the at least one cushioning configuration comprises: determining at least one first data set of at least one cushioning parameter relating to the cushioning material to be provided and at least one gap parameter relating to the assigned gap of the shipping container; determining at least one target degree of agreement between the determined at least one cushioning parameter and the at least one gap parameter; comparing the first data set and the at least one target degree of agreement with a previously determined second data set, which includes at least one previously determined cushioning parameter and at least one gap parameter, and an actual degree of agreement associated with the second data set;and selection of the determined first data set for carrying out padding if the comparison indicates sufficient padding quality, or repeated determination of the first data set and the target degree of agreement if the comparison does not indicate sufficiently good padding quality.

[0024] Advantageously, dynamic feedback is provided to optimize decision-making, and quality control is performed on the pairwise assignment of padding material to gaps or empty spaces. This effectively prevents a decline in padding quality.

[0025] An advantageous example is characterized by the fact that at least one machine-trained function determines the at least one cushioning configuration associated with the pre-packed shipping container as a function of the at least one sensor information.

[0026] Using a machine-trained function offers advantages in determining the cushioning configuration. Firstly, it allows for the realization of cushioning targets optimized to customer requirements. Secondly, the high complexity involved in arranging protective packaging can be mapped to the cushioning station and its operation using the machine-trained function.

[0027] An advantageous example is characterized in that determining the at least one padding configuration comprises: determining a plurality of padding configurations and their respective associated confidence values, in particular by means of differently machine-trained and / or differently configured functions, especially those differing in their structure; selecting a padding configuration from the plurality of padding configurations depending on the confidence values, in particular selecting the padding configuration with the highest confidence value; wherein the provision of the at least one padding means, the picking up of the at least one padding means and the arrangement of the at least one padding means are carried out depending on the selected padding configuration.

[0028] An advantageous example includes determining the respective availability of cushioning materials from the majority of cushioning material dispensers; wherein the determination of the at least one cushioning configuration associated with the pre-packed shipping container is additionally carried out depending on the determined availability of cushioning materials.

[0029] The advantage of this approach is that the padding configuration is tailored to the padding materials available at the padding station. This prevents the determination of a padding configuration that is impossible due to a lack of padding material. Furthermore, it enables the provision of a trained function that successfully handles a wide variety of complex padding scenarios.

[0030] An advantageous example is characterized in that the padding configuration comprises one or more padding steps ordered in a temporal sequence, wherein one of the padding steps includes at least one padding parameter relating to the padding material to be provided and an interstitial parameter, in particular relating to the position within the empty interstitial space in which the at least one associated and provided padding material is to be placed.

[0031] Advantageously, there are clear instructions for arranging the cushioning materials or protective packaging using the cushioning station.

[0032] An advantageous example is characterized in that the procedure comprises: determining and verifying a confidence value which represents an assessment of the actual applicability of the determined cushioning configuration to the pre-packed shipping container, in particular depending on the at least one sensor information; providing, picking up and arranging the at least one cushioning means if the confidence value indicates the applicability of the cushioning configuration, or isolating the pre-packed shipping container in an isolation section if the confidence value does not indicate applicability of the cushioning configuration.

[0033] This means that cushioning material is only placed in the shipping container if the confidence level indicates it. This prevents damage to the shipped products. Furthermore, it ensures that the shipping container can be sealed without problems at the subsequent sealing station.

[0034] An advantageous example includes determining and verifying the cushioning quality associated with the at least one cushioning material arranged in the shipping container as a function of at least one other sensor information; and transporting the shipping container to an output section for transfer to a subsequent station in the case of sufficient cushioning quality, or separating the shipping container equipped with cushioning material in a separation section in the case of insufficient cushioning quality.

[0035] This creates a segregation mechanism to allow potentially poorly or insufficiently padded shipping containers to be manually inspected.

[0036] An advantageous example is characterized in that determining the padding quality associated with the at least one padding means includes determining an actual degree of agreement between at least one padding parameter relating to the padding provided and the associated gap parameter relating to the gap associated with the padding means.

[0037] The degree of agreement and its storage can be used to create feedback for future padding processes.

[0038] An advantageous example is characterized in that picking up the at least one cushioning element comprises: determining a gripping pose, wherein the gripping pose comprises grasping a gripper of the handling system in a section of the cushioning element which is opposite a planned insertion section of the cushioning element for insertion into the associated space; and gripping the at least one cushioning element depending on the determined gripping pose.

[0039] Advantageously, the padding material is thus already gripped appropriately for the associated gap, i.e., on the side of the padding material that is opposite the opening of the gap when inserted into the gap.

[0040] An advantageous example is characterized in that the arrangement of the at least one cushioning element comprises: determining a first trajectory starting from a receiving position in which the cushioning element was gripped in the at least one output section by the handling system, to an intermediate position in which the gripped cushioning element is located in front of an outer opening of the associated free space; determining a second trajectory starting from the intermediate position to a final position in which the cushioning element is arranged within the associated space; moving the gripped cushioning element along the first trajectory to the intermediate position; and moving the gripped cushioning element along the second trajectory.

[0041] Advantageously, the positioning of the padding material can be carried out in two movement steps, allowing, for example, force measurement during the passage of the second trajectory, as this force measurement also determines the quality of the padding.

[0042] An advantageous example includes determining and verifying an actual counterforce while moving along the second trajectory; and moving the gripped padding means along the second trajectory as long as the actual counterforce is below a counterforce threshold, or terminating the movement along the second trajectory if the determined actual counterforce exceeds the counterforce threshold.

[0043] This successfully prevents damage to the shipping product or shipping container when the cushioning material is added.

[0044] An advantageous example includes fixing, in particular holding down, the at least one shipping product, which limits the free space, at least during the movement of the gripped cushioning material along the second trajectory.

[0045] The advantage is that the shipped product stays in place and does not slip unintentionally.

[0046] A fourth aspect of the description concerns the following item: A padding station or a padding system comprising several padding stations, which is designed to carry out the procedure according to the third aspect.

[0047] The drawing shows: Figure 1: A cushioning station in schematic view; Figure 2: An example of the cushioning station in a perspective schematic view; Figure 3: A schematic flowchart of a method for operating the cushioning station; Figures 4 and 5: Further schematic flowcharts; Figures 6 to 8: Examples of a machine-trained function; Figures 9 and 10: Examples of training and operation of the machine-trained function; Figure 11: An exemplary depiction of a cushioning system; Figures 11 to 14: Sensor information associated with a shipping container and the cushioning of the shipping container; and Figure 15: A cushioning configuration relating to the shipping container from the Figures 11 to 14 .

[0048] The following refers to the Figure 1 and 3 Reference is made. Figure 1 shows a padding station 100 in schematic form. Figure 3 shows a flowchart of a procedure for operating the upholstery station 100.

[0049] A conveying device 200 is configured to receive at least one shipping container 900 pre-packed with a shipping product 9010 in an inlet section 210 of the conveying device 200, to convey the at least one pre-packed shipping container 900 from an inlet section 210 into a cushioning section 220 of the conveying device 200 and to hold it there, and subsequently to transport the pre-packed shipping container 900, which is at least partially provided with a cushioning material 800a-d, from the cushioning section 220 into an outlet section 230 of the conveying device 200.

[0050] The pre-packed shipping container 900 can, for example, already contain product 910 and optionally also a pre-installed cushioning material. Accordingly, the measures described here are also applied to the aforementioned shipping container 900 containing shipping product 910 and the cushioning material. Thus, any existing cushioning material is recognized as a shipping product and treated accordingly. In one implementation, the cushioning material already present in the shipping container is recognized as such and processed further with appropriate parameters.

[0051] Multiple cushioning material dispensers 400 are configured to provide cushioning material 800 of different types and / or sizes in at least one dispensing section 410. The cushioning material dispensers 400 are designed, for example, to provide different lengths of cushioning material with a fixed width and height. Cushioning material 800 is also referred to as protective packaging. The cushioning material 800 is used to block and brace the shipping products 910 within the shipping container 900.

[0052] A handling system 500 is designed to receive at least one cushioning material 800 provided in the at least one dispensing section 410 and to arrange it in the at least one empty space 920 within the pre-packed at least one shipping container 900 located in the cushioning section 220 of the transport device 200.

[0053] A control unit 600 is designed to equip or provide at least one shipping container 900 with cushioning material 800 using a sensor device 300, the transport device 200, the majority of cushioning material dispensers 400 and the handling system 400.

[0054] The control unit 600 comprises at least one processor 610 and one memory unit 620. The procedures described here are stored as a computer program product on the memory unit 620. The computer program product is executable on the processor 610.

[0055] According to step 1002, it is monitored whether at least one pre-packed shipping container 900 arrives at the receiving area. This is checked in step 1004. If the shipping container 900 has been accepted at the receiving area, the process proceeds to step 1010. If no shipping container is detected, the process proceeds to step 1002.

[0056] After receiving 1010 of the at least one pre-packed shipping container 900 in the entry section 210, sensor information SI is determined 1030 by means of the sensor device 300, which is associated with a pre-packed shipping container 900, which is pre-packed with the at least one shipping product 910, wherein the determined sensor information SI characterizes a position of respective free spaces 920 within the at least one pre-packed shipping container 900.

[0057] For example, a stereo camera is used as a sensor device 300 to capture a three-dimensional image. Object shells for the inner walls and the shipping products 910 arranged in the shipping container 900 can then be created from this three-dimensional image. These object shells associated with the shipping container 900 provide an input parameter for a function that determines a cushioning configuration associated with the shipping container 900.

[0058] The acquisition of sensor information (SI) 1030 includes capturing the dimensions of the shipping container 900, capturing its internal topography, capturing the content type (such as an assessment of the fragility of the shipping product 910), and identifying gap characteristics or interstitial parameters. A single or multiple individual sensors can be used. The gap characteristics include, for example, information on the position and size, particularly the volume, of the gap or free space 920. In a further development, the gap characteristics also include information on the fragility of the shipping products 910 adjacent to the gap. Naturally, the sensor information (SI) can be processed in intermediate steps to, for example, comprehensively transfer gap characteristics, including position and size, to the machine-trained function for determining the cushioning configuration.

[0059] The transport of at least one pre-packed shipping container 900 from the incoming section 210 to the cushioning section 220 takes place. The determination of the sensor information SI depends on the position of the respective sensor, which is why the transport can take place before or after this.

[0060] A determination 1040 of the respective availability V of cushioning materials 800 of the majority of cushioning material dispensers 400 is carried out, wherein a subsequent determination 1050 of the at least one cushioning configuration K associated with the pre-packed shipping container 900 is additionally carried out depending on the determined availability V of cushioning materials 800.

[0061] According to the example of Figure 7The availability V is supplied to the machine-trained function F in order to determine, depending on this, the cushioning configuration K adapted to the available cushioning material types and associated with at least one shipping container 910.

[0062] Thus, at least one cushioning configuration K associated with the pre-packed shipping container 900 is determined based on the sensor information Sl. The provision 1100 of the at least one cushioning material 800, the picking up 1110 of the at least one cushioning material 800, and the arrangement 1120 of the at least one cushioning material 800 are carried out based on the determined cushioning configuration K.

[0063] The evaluation of the sensor information SI, and thus also the gap characteristics or interspace parameters, is carried out in an example by outputting the cushioning configuration K in step 1050, where determining 1050 of the at least one cushioning configuration K comprises: determining 1950 at least one first data set of at least one cushioning material parameter P_800s concerning the cushioning material to be provided and at least one interspace parameter P_900s concerning the assigned interspace of the shipping container 900; determining 1952 at least one target degree of agreement Us between the determined at least one cushioning material parameter P_800s and the at least one interspace parameter P_900s;Compare in 1954 the first data set and the at least one target degree of agreement Us with a previously determined second data set, which includes at least one previously determined padding parameter P_800s and at least one space parameter P_900s, and an actual degree of agreement Ui associated with the second data set; and select the determined first data set to carry out padding if the comparison indicates sufficient padding quality, or repeat the determination of the first data set and the target degree of agreement Us if the comparison does not indicate sufficiently good padding quality.

[0064] The actual or target degree of conformity, in one example, represents the maximum force required to insert the padding material into the designated empty space. Alternatively or additionally, the actual or target degree of conformity represents a positive or negative dimension resulting from the subtraction of the padding material dimension and the space dimension.

[0065] Of course, the feedback in the operation of the upholstery station from previously carried out upholstery processes can also be omitted or designed differently.

[0066] For example, feedback can be achieved by generating training data during the operation of the upholstery station 100. The function for determining the upholstery configuration is trained using the station-specific training data.

[0067] The machine-trained function F of one of the Figures 6 to 10Function 1050 determines at least one cushioning configuration K associated with the pre-packed shipping container 900 as a function of at least one sensor information Sl. Of course, instead of a machine-trained function, a differently designed function, for example a deterministic one, can also be used.

[0068] When determining a padding configuration K, for example, a target degree of agreement is compared between the gap characteristics of an empty space and the padding characteristics or parameters of the available padding types. If a high degree of agreement is determined, the associated padding parameters are linked to the gap. The gap parameters and the associated padding parameters are provided as a padding step. Each padding step includes a result indicating which padding material should be placed in which gap or space according to the associated padding parameters.

[0069] One of the gap parameters is, for example: an internal dimension such as width, height, length of the gap; an internal contour of the gap; a required protection factor of at least one of the shipping products; or an indicator of the accessibility of the empty gap to be filled with cushioning material.

[0070] One of the upholstery parameters is, for example: an external dimension such as width, height, length of an upholstery material to be manufactured; a density of an upholstery material; a damping level of an upholstery material to be manufactured; or a flexibility of an upholstery material to be manufactured.

[0071] It is done according to the Figure 3 and one of the Figures 6 to 8a determination 1060 and verification 1070 of a confidence value C, which represents an assessment of the actual applicability of the determined cushioning configuration K to the pre-packed shipping container 900, in particular depending on the at least one sensor information Sl.

[0072] According to the Figure 3 and the Figures 6 to 8 At least one machine-trained function F is used to operate the conveying device 200, the majority of cushioning dispensers 400 and the handling system 500 depending on the sensor information SI associated with the pre-packed shipping container 900.

[0073] After providing 1100 at least one of the plurality of cushioning materials 800, in particular of different types and / or sizes depending on the cushioning configuration, in at least one output section 410, the respective plurality of cushioning materials 800 provided in the at least one output section 410 are picked up 1110 depending on the determined sensor information SI and the picked-up respective plurality of cushioning materials 800 are arranged 1120 in one of the free spaces 920 within the pre-packed at least one shipping container 900 located in the cushioning section 220 depending on the determined sensor information Sl.

[0074] The provisioning 1100, receiving 1110 and arranging 1120 takes place depending on the sensor information SI determined with the at least one shipping container 900, in particular depending on a determined cushioning configuration K, which is determined depending on the sensor information SI.

[0075] The provision 1100, picking up 1110, and arranging 1120 of the at least one cushioning material 800 takes place if the confidence value indicates the applicability of cushioning configuration K. The segregation 1080 of the pre-packed shipping container 900 in a segregation section 240 takes place if the confidence value does not indicate the applicability of cushioning configuration K.

[0076] In step 1130, it is checked whether a further padding step should be carried out according to the determined padding configuration. If so, the process proceeds to step 1100. If it is determined in step 1130 that no further padding steps need to be carried out, the arrangement of padding materials in padding station 100 is complete.

[0077] This is followed by the determination 1140 of further sensor information SI2 associated with the at least one shipping container 900, which characterizes at least one position of at least one cushioning material 800 arranged in the space 920 of the shipping container 900.

[0078] The additional sensor information SI2 includes, for example, another digital image of the shipping container 900 and / or a counterforce determined in the area of ​​the handling system 500 when the cushioning material 800 is introduced into the empty space.

[0079] Determining 1150 and verifying 1160 the cushioning quality associated with at least one cushioning agent 800 is carried out depending on at least one further sensor information SI2. If the cushioning quality is sufficient, the shipping container 900 is transported 1170 to an output section 230 for transfer to a subsequent station. However, if the cushioning quality is insufficient, the shipping container 900, equipped with cushioning agent 800, is separated 1180 into a separation section 240.

[0080] Determining the upholstery quality associated with the at least one upholstery material 800 includes determining an actual degree of agreement Ui between at least one upholstery parameter P_800 concerning the provided upholstery material 800 and the associated space parameter P_900 concerning the space 900 associated with the upholstery material 800.

[0081] The storage unit 1151 then contains assigned data sets comprising at least one cushion parameter P_800, at least one gap parameter P_900, and at least one actual agreement coefficient Ui. These data sets can be used for future training, thus providing training data.

[0082] In Figure 2 This is an example of the upholstery station 100 from Figure 1 shown. The conveying device 200 includes, for example, a roller conveyor and other elements controlling the flow of the shipping containers 900.

[0083] In the entrance section 210, a light barrier 212 registers the arrival of a shipping container 900. If the cushioning station 100 is ready to receive another shipping container 900, the gate 214, schematically depicted as a barrier, is opened.

[0084] The sensor device 300 includes, for example, a camera for capturing a digital image. The camera is directed towards the opening of the shipping container 900, which provides a view of the interior of the shipping container 900, so that the digital image contains information about the arrangement of shipping products 910, the arrangement of the inner walls of the shipping container 900, and the arrangement of the empty spaces between an inner wall and one of the shipping products 910 or between several shipping products 910. A lighting device 310 is associated with the sensor device 300, which emits light towards the opening of the shipping container 900.

[0085] In the example shown, the 400a-b upholstery dispensers provide upholstery material 800a-b in the form of paper pads of varying widths. The 400c-d upholstery dispensers provide upholstery material 800c-d in the form of air cushions of varying widths.

[0086] A supply of raw material for the production of a paper pad as cushioning material comprises, as in the case of the cushioning material dispensers 800a-b, for example, sheet-shaped material which is provided in a compact form, such as by means of a roll of sheet-shaped material or by means of a rectangular stack of zigzag-folded sheet-shaped material.

[0087] In another example, according to the 800c-d cushioning dispensers, the starting material is plastic film and is supplied in a compact form, e.g., on a roll. The plastic film is converted into bags, inflated with compressed air, and sealed.

[0088] Other examples of upholstery dispensers not shown include dispensers for foam upholstery or pourable individual upholstery materials.

[0089] In one example, a sensor is provided in the respective upholstery dispenser 400 to detect an end of the starting material for the production of the respective upholstery 800 or an end of the availability of an upholstery type upholstery dispenser-individual.

[0090] The elements described in this text as cushioning materials can alternatively be referred to as protective packaging or protective packaging materials. Similarly, other terms derived from the concept of cushioning materials, such as cushioning material configuration or cushioning material parameters, can also be referred to as protective packaging material configuration or protective packaging parameters.

[0091] In the example shown, the handling system 500 comprises a robot arm 510 fixed to a ceiling above the conveyor 200 and a robot hand 520 as a gripping device. Alternatively or additionally, a vacuum or negative pressure gripper can be used instead of the robot hand.

[0092] The transport device 200 comprises a fixing system 222 which fixes the shipping container 900 in the cushioning section 220 at least during a period in which the at least one cushioning material 800 is introduced into the associated space 920, at a cushioning position.

[0093] In the example shown, the fixing system 222 comprises a gate 224, schematically depicted as a barrier, which stops the shipping container 900 being conveyed in a conveying direction 204 via the conveying device 202. A slide 226 pushes the stopped shipping container 900 against a wall 228 opposite the slide 226, thus bringing the shipping container 900 into the cushioning position in the cushioning section 220.

[0094] In another example, the handling system 500 includes a hold-down device 700 for holding down the products defining the empty space, in order to prevent unintentional displacement of the products during the insertion of the cushioning material. The hold-down device 700 secures the at least one shipping product 910 in the shipping container 900 at least during the arrangement of the at least one cushioning material 800.

[0095] The schematically depicted hold-down device 700 is fixed horizontally above the padding section 220 and can also be designed as a robot arm with distal fixing end.

[0096] A slide gate 242 is provided which, in the event of a fault detected in relation to the shipping container 900, pushes at least one shipping container 900 into the segregation section 240.

[0097] The control unit 600 activates the slide gate 242 to move the shipping container 900 into the segregation section 240 if the cushioning quality is deemed insufficient. From segregation section 240, the shipping containers 900 are manually removed, inspected, manually re-cushioned if necessary, and then returned to the input section 210. Automatic re-cushioning may then occur, or the control unit 600 determines that sufficient cushioning is present, and the shipping container 900 is then made available in the output section 230 for transfer to a sealing station.

[0098] In Figure 4 will be with reference to the Figure 1 and 2The picking up 1110 of the at least one cushioning element 800 is described in more detail. Picking up 1110 comprises determining 1112 a gripping pose, wherein the gripping pose includes a gripper 520 of the handling system 500 engaging a section of the cushioning element 800 that is opposite a planned insertion section of the cushioning element 800 for insertion into the associated space 920. Picking up 1110 comprises grasping 1114 of the at least one cushioning element 800 depending on the determined gripping pose.

[0099] According to Figure 5The arrangement 1120 of the at least one cushioning element 800 comprises determining 1122 a first trajectory starting from a receiving position in which the cushioning element was gripped by the handling system 500 in the at least one output section 410, to an intermediate position in which the gripped cushioning element 800 is located in front of an outer opening of the associated free space 920. Subsequently, a second trajectory 1124 is determined starting from the intermediate position to a final position in which the cushioning element 800 is arranged within the associated space 920. The gripped cushioning element 800 is then moved 1126 along the first trajectory to the intermediate position. After moving 1126, the gripped cushioning element 800 is moved 1132 along the second trajectory.

[0100] Subsequently, a determination 1134 and a verification 1136 of the actual counterforce are performed during movement 1132 along the second trajectory. The movement 1132 of the gripped cushioning material 800 along the second trajectory continues as long as the actual counterforce, which is introduced from the shipping container 900 via the cushioning material 800 into the handling system 500, is below a pre-stored counterforce threshold or one individually determined for the space. The movement 1132 along the second trajectory is aborted 1138 if the determined actual counterforce exceeds the counterforce threshold.

[0101] The abort step 1138 can indicate sufficient cushioning, allowing a move to step 1144. In step 1144, the cushioning material 800 is released.

[0102] In step 1142, it is checked whether the end position of the second trajectory has been reached. If this is not the case, the process proceeds to step 1132. If this is the case, the gripper 520 releases the cushioning material 800, and the cushioning material 800 is then at the desired end position of the second trajectory.

[0103] Fixing 1128, in particular holding down, of the at least one shipping product, which limits the free space 920, takes place at least during the movement 1128 of the gripped cushioning material 800 along the second trajectory. Fixing 1128 may also be omitted.

[0104] The method comprises releasing 1146 the fixing of the shipping products which are arranged around the space which is filled with at least one cushioning material, as soon as the respective cushioning material arranged in the space is released by the handling system 500.

[0105] The procedure includes moving or moving 1148 the gripper for the cushioning material along a third trajectory into a rest position or to grip another cushioning material.

[0106] Figure 8Figure 1050 shows a further example for determining the padding configuration K, Kc, where the determination comprises: determining a plurality of padding configurations Ka, Kb and their respective associated confidence values ​​Ca, Cb, in particular by means of differently machine-trained and / or differently configured functions Fa, Fb, which differ from one another, especially in their structure; and selecting a padding configuration Kc from the plurality of padding configurations Ka, Kb depending on the confidence values ​​Ca, Cb, in particular selecting the padding configuration Ka with the highest confidence value Ka. The provision of the at least one padding means 800, the retrieval of the at least one padding means 800, and the arrangement of the at least one padding means 800 are carried out depending on the selected padding configuration K.

[0107] A device 650 for training a model or the function F is in Figure 9 The training data Et, for example, comprehensive sensor information SI and at least one associated cushioning configuration K, are provided.

[0108] The arrangement comprises the artificial neural network with an input layer 652. At time step i, an input tensor of the input E is passed to the input layer. For the input E, the output O is determined or is pre-known in the form of a classification or prediction, which, for example, includes a cushioning configuration and an associated confidence parameter or value. From the output O, at time step i, a tensor with observed values ​​Otrain is determined, which are assigned to the observed values ​​of the tensor Et. Each of the time series of the input E is assigned to one of three input nodes. In a forward path of the artificial neural network, at least one hidden layer follows the input layer. In the example, the number of nodes of the at least one hidden layer is greater than the number of input nodes. This number is to be considered a hyperparameter and is preferably determined separately.In this example, four nodes are provided in the hidden layer. The artificial neural network is learned, for example, using gradient descent in the form of backpropagation. The training of the model or function F is therefore supervised.

[0109] In the forward path, the example includes an output layer 654 after at least one hidden layer. Prediction values ​​are output at output layer 654. In this example, each prediction value is assigned an output node.

[0110] In each time step i, a tensor O'train is determined containing the prediction values ​​for that time step i. In the example, this tensor, along with the column vector of observed values ​​Otrain, is fed to a training device 656. The training device 656 is configured to determine a prediction error using a loss function LOSS, specifically a mean square error, and to train the model M using this function and an optimizer, specifically an Adam optimizer. The loss function LOSS is determined in the example based on a deviation, specifically the mean square error, from the values ​​of the tensor of observed values ​​Otrain and the tensor of prediction values ​​O'train.

[0111] The training is terminated as soon as a predetermined criterion is met. In this example, the training is terminated if the loss no longer decreases over several time steps, i.e., if the mean square error does not decrease.

[0112] Test data is then fed into the trained model or function F. The function F is generated through training with the training data. The function F is then evaluated using the test data, particularly with regard to the mean µ and covariance Σ.

[0113] Figure 10 Figure 660 shows a device for determining a cushioning configuration K. An input interface 662 serves to receive the at least one sensor information SI associated with at least one pre-packed shipping container or data derived therefrom.

[0114] The machine-trained function F is used to determine the padding configuration K. The padding configuration K is determined based on the received sensor information SI. An output interface 664 is used to send or provide the determined padding configuration K.

[0115] The trained function F, in the form of an artificial neural network, propagates the majority of parameters Pa-z, determined based on the sensor signals SI. The parameters Pa-z are provided in an input area 652 of the function F, and a prediction V is provided in an output area 654 of the function. A classifier 670 determines the padding configuration K as a function of the prediction V.

[0116] An identifier ID is transmitted together with the majority of sensor signal parameters Pa-z, whereby the function F for determining the padding configuration K is selected from a majority of functions stored in the data memory 672 via the identifier ID.

[0117] The trained function F is used to provide the prediction V for classification based on the given parameters P. The same data preprocessing steps are performed as with the training data. For example, scaling and the determination of input and output data are carried out. In this example, this determination takes place during the operation of the padding station.

[0118] As described for the training, a column vector of the input E in the form of the provided parameters P is passed to the input layer 652 for a time step i. Subsequently, in contrast to the training, the classification device or classifier 670 performs a classification of the supplied parameters depending on the prediction values ​​V.

[0119] The results obtained for the operation of the upholstery station are transferred, for example in the form of the upholstery configuration K, to the output interface for further processing on the upholstery station side.

[0120] A confidence value associated with the padding configuration and determined in parallel by the function F indicates, for example, the quality of the determined padding configuration. If this value exceeds a threshold, a padding instruction that can be implemented at the padding station is available. The threshold is preferably a further parameter.

[0121] To carry out the described procedures, instructions for a computer program are provided in particular, which implement the described functions.

[0122] Figure 11Figure 2 shows a cushioning system 2000 in a schematic perspective view. Shipping containers fed in via an input section 2100 are detected by a sensor device 3000. The signals SI3 determined by the sensor device 3000 are fed to a control unit 6000. Depending on the supplied signals SI3 and the resulting control of a switch 2200, the control unit 6000 decides which of the paths P1 and P2 a pre-packed shipping container located in the input section 2100 is fed into. In the example shown, path P1 comprises cushioning stations 100a and 100b connected in series. Path P2 contains only a single cushioning station 100c. The individual cushioning stations 100a and 100c differ, for example, in the number of available cushioning material types. In one example, the control units of cushioning stations 100a-c are combined in the control unit 6000.The outlet section 230 and the isolation section 240 can each only be implemented once for the system 2000 shown. Of course, separate outlet sections 230 and isolation sections 240 are also conceivable.

[0123] Figure 12 Figure 1 shows an example of sensor information SI. The sensor information SI is a digital two-dimensional image taken from a top view of the open shipping container 900. The shipping products 910a-d were arranged in the shipping container 900 in a prior manual packing step according to packing instructions given to the packer.

[0124] According to Figure 13The sensor information SI characterizes or includes the position and size of the empty spaces 920a-b. The information about the position and size, as well as further information relating to the respective space, is inherent in the sensor information SI, i.e., contained within the sensor information SI.

[0125] In Figure 14 Is the shipping container 900 made from the Figures 12 and 14 The example shows a container already equipped with cushioning materials 800a-c according to the cushioning configuration K determined based on the sensor information SI. Cushioning material 800a is an air cushion. Cushioning materials 800b-c are paper pads of the same width but different lengths. In this example, cushioning material 800c does not fill the entire assigned space 920b. However, cushioning material 800b prevents both shipping product 910c and shipping product 910d from shifting.

[0126] The padding configuration K comprises one or more padding steps #1-#3 ordered in a temporal sequence R, wherein one of the padding steps #1-#3 includes at least one padding parameter P_800 relating to the padding material 800 to be provided and an intermediate space parameter P_920 in particular relating to the position within the empty intermediate space 920 at which the at least one assigned and provided padding material 800 is to be inserted.

[0127] According to the upholstery configuration K of the Figure 15 First, according to the cushioning material parameter P_800b and the space parameter P_920b, the cushioning material 800b is generated and placed in the space 920b of the shipping container 900. Figures 12-14The cushioning material 800c is introduced, preventing unwanted movement of shipping products 910b and 910c. In step #2, cushioning material 800c is then created as a paper pad with a different length than cushioning material 800b, according to the cushioning parameter P_800c, and positioned in the space 920b according to the gap parameter 920b. This prevents movement of shipping product 910d. In step #3, cushioning material 800a is created as an air-filled film pad and positioned in the space 920a. As this example demonstrates, the order in which the cushioning materials are arranged plays a crucial role both in the successful cushioning process itself and in achieving the desired level of protection during shipping.

Claims

1. A cushioning station (100) comprising: a sensor device (300); a conveying device (200); a plurality of cushioning dispensers (400); a handling system (500); and a control unit (600) configured with the sensor device (300), the conveying device (200), the plurality of cushioning dispensers (400), and the handling system (400) to perform the following: determining (1030) sensor information (SI) associated with at least one prepackaged shipping container (900) prepackaged with at least one shipping product (910), wherein the determined sensor information (SI) characterizes a position of respective free spaces (920) within the at least one prepackaged shipping container (900); conveying (1020) the at least one pre-packed shipping container (900) from an entry section (210) into a cushioning section (220);Providing (1100) a plurality of cushioning means (800), in particular of different types and / or sizes, depending on the determined sensor information (SI) associated with the at least one shipping container (900); receiving (1110) a respective one of the plurality of provided cushioning means (800) depending on the determined sensor information (SI); and arranging (1120) the respective one of the plurality of cushioning means (800) in one of the free spaces (920) within the pre-packed at least one shipping container (900) located in the cushioning section (220) depending on the determined sensor information (SI).

2. The cushioning station (100) according to claim 1, wherein the conveying device (200) comprises: a fixation system (222) which fixes the shipping container (900) in the cushioning section (220) at a cushioning position at least during a period in which the at least one cushioning means (800) is introduced into the associated space (920).

3. The cushioning station (100) according to claim 1 or 2 comprising: a hold-down device (700) for fixing the at least one shipping product (910) in the shipping container (900) at least during the arrangement of the at least one cushioning means (800).

4. The cushioning station (100) according to one of the preceding claims, comprising: a separation section (240) arranged downstream of the cushioning section (220) for receiving shipping containers (900); a pusher (242) which, in the event of a detected error with respect to the shipping container (900), pushes the at least one shipping container (900) into the separation section (240).

5. The cushioning station (100) according to any one of the preceding claims, wherein at least one machine-trained function (F) operates the conveying system (200), the plurality of cushioning dispensers (400) and the handling system (500) in dependence on the sensor information (SI) associated with the prepacked shipping container (900).

6. A method comprising: determining (1030) sensor information (SI) associated with a pre-packed shipping container (900) pre-packed with at least one shipping product (910), wherein the determined sensor information (SI) characterizes a position of respective free spaces (920) within the at least one pre-packed shipping container (900); conveying (1020) the at least one pre-packed shipping container (900) from an input section (210) into a cushioning section (220); providing (1100) a plurality of cushioning means (800), in particular of different types and / or sizes, in at least one output section (410) depending on the determined sensor information (SI) associated with the at least one shipping container (900);Receiving (1110) a respective one of the plurality of provided cushioning means (800) provided in the at least one output section (410) as a function of the determined sensor information (SI); and arranging (1120) the received respective one of the plurality of cushioning means (800) in one of the free spaces (920) within the pre-packed at least one shipping container (900) located in the cushioning section (220) as a function of the determined sensor information (SI).

7. The method according to claim 6, comprising: determining (1050) at least one cushioning configuration (K) associated with the prepacked shipping container (900) as a function of the sensor information (SI); and wherein the providing (1100) of the at least one cushioning means (800), the receiving (1110) of the at least one cushioning means (800), and the arranging (1120) of the at least one cushioning means (800) are carried out as a function of the determined cushioning configuration (K).

8. The method according to claim 7, wherein determining (1050) the at least one padding configuration (K) comprises: determining (1950) at least a first data set of at least one padding parameter (P_800s) relating to the padding to be provided and at least one gap parameter (P_900s) relating to the associated gap of the shipping container (900); determining (1952) at least one target degree of agreement (Us) between the determined at least one padding parameter (P_800s) and the at least one gap parameter (P_900s); comparing (1954) the first data set and the at least one target degree of agreement (Us) with a previously determined second data set, which comprises at least one previously determined padding parameter (P_800s) and at least one gap parameter (P_900s), and an actual degree of agreement (Ui) associated with the second data set;and selecting the determined first data set for performing padding if the comparison indicates sufficient padding quality, or repeating the determination of the first data set and the target degree of agreement (Us) if the comparison does not indicate sufficiently good padding quality.; 9. The method according to claim 7 or 8, wherein at least one machine-trained function (F) determines the at least one cushioning configuration (K) associated with the prepacked shipping container (900) in dependence on the at least one piece of sensor information (SI).

10. The method according to one of claims 7 to 9, wherein determining (1050) the at least one padding configuration (K) comprises: determining a plurality of padding configurations (Ka, Kb) and respective confidence values ​​(Ca, Cb) associated therewith, in particular by means of differently machine-trained and / or differently configured functions (Fa, Fb), in particular functions that differ from one another in their structure; selecting (1051) a padding configuration (Kc) from the plurality of padding configurations (Ka, Kb) depending on the confidence values ​​(Ca, Cb), in particular selecting the padding configuration (Ka) with the highest confidence value (Ka); and wherein providing (1100) the at least one padding means (800), receiving (1110) the at least one padding means (800), and arranging (1120) the at least one padding means (800) are carried out depending on the selected padding configuration (K).

11. The method according to one of claims 7 to 10, comprising: determining (1040) the respective availability (V) of cushioning means (800) of the plurality of cushioning means dispensers (400); and wherein the determination (1050) of the at least one cushioning configuration (K) associated with the prepackaged shipping container (900) is additionally carried out as a function of the determined availability (V) of cushioning means (800).

12. The method according to one of claims 7 to 11, wherein the padding configuration (K) comprises one or more padding steps (#1-#3) arranged in a time sequence (R), and wherein one of the padding steps (#1-#3) comprises at least one padding parameter (P_800) relating to the padding means (800) to be provided and a gap parameter (P_920), in particular relating to the position within the empty gap (920) in which the at least one assigned padding means (800) to be provided is to be introduced.

13. The method according to one of claims 7 to 12, comprising: determining (1060) and checking (1070) a confidence value (C), which represents an assessment of the actual applicability of the determined cushioning configuration (K) to the prepacked shipping container (900), in particular depending on the at least one piece of sensor information (SI); providing (1100), receiving (1110), and arranging (1120) the at least one cushioning means (800) if the confidence value indicates the applicability of the cushioning configuration (K), or separating (1080) the prepacked shipping container (900) in a separation section (240) if the confidence value does not indicate applicability of the cushioning configuration (K).

14. The method according to one of claims 6 to 13, comprising: determining (1140) further sensor information (SI2) associated with the at least one shipping container (900), which further sensor information characterizes at least one position of at least one cushioning means (800) arranged in the intermediate space (920) of the shipping container (900).

15. The method according to claim 14, comprising: determining (1150) and checking (1160) a padding quality associated with the at least one padding means (800) as a function of the at least one further sensor information item (SI2); and transporting (1170) the shipping container (900) to an exit section (230) for transfer to a subsequent station in the case of sufficient padding quality, or separating (1180) the shipping container (900) provided with padding means (800) in a separation section (240) in the case of insufficient padding quality.

16. The method according to one of the two preceding claims, wherein determining (1150) the padding quality associated with the at least one padding means (800) comprises determining an actual degree of agreement (Ui) between at least one padding parameter (P_800) relating to the provided padding means (800) and the associated gap parameter (P_900) relating to the gap (900) associated with the padding means (800).

17. A padding station (100) or a padding system (2000) comprising several padding stations (100), which is designed to carry out the method according to one of claims 6 to 16.

Images