High-throughput protective material insertion plunger

Abstract

A packaging system includes a sensor system that detects a height of a container, a plunger that moves downward to insert a piece of protective material into the container, a positioning system that positions the container under the plunger, and a controller communicatively coupled to the sensor system and the plunger. The controller receives an indication of a height of the container from the sensor system and determines a first plunger depth based on the indication of the height of the container. While the container is positioned under the plunger, the controller causes the plunger to move downward from a retracted position to the first plunger depth at a first rate and to move from the first plunger depth to a second plunger depth at a second rate. The first rate is greater than the second rate.

Description

HIGH-THROUGHPUT PROTECTIVE MATERIAL INSERTION PLUNGERSPECIFICATIONBACKGROUND

[0001] The present disclosure is in the technical field of insertion of protective materials into shipping containers. More particularly, the present disclosure is directed to insertion of protective materials into shipping containers in ways that minimize that time required for insertion of the protective materials.

[0002] When articles are packaged in a container or box for shipping, there are frequently void spaces in the container. Protective materials for articles of different sizes and shapes are commonly used to cushion articles and / or fill the void spaces in the shipping containers during shipping. There are numerous types and forms of protective materials for this purpose including waste paper, embossed paper, laminated bubble paper, plastic beads, pre-inflated bubble film, inflatable bubble film, foam pads, and the like. These forms of cushioning material are capable of being placed around articles to protect the articles during shipment and to fill the void space in the container.

[0003] While these protective material materials are effective in protecting articles during shipment, they can be time-consuming to properly handle and use in a packaging facility for efficient packaging. In particular, inserting such protecting articles into boxes can slow the throughput of the flow of boxes through a packaging facility. It would be advantageous to automate the process of inserting protecting articles into boxes while also reducing the amount of time required to insert a packaging articles into each box to maximize throughput of boxes through a packaging facility.SUMMARY

[0004] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0005] In a first embodiment, a packaging system includes a sensor system configured to detect a height of a container, a plunger configured to move downward to insert a piece of protective material into the container through a top of the container, a positioning system configured to position the container under the plunger, and a controller communicatively coupled to the sensor system and to the plunger. The controller is configured to receive an indication of the height of the container from the sensor system, determine a first plunger depth based on the indication of the height of the container, and, while the container is positioned under the plunger, cause the plunger to move downward from a retracted position to the first plunger depth at a first rate and to move from the first plunger depth to a second plunger depth at a second rate. The first rate is greater than the second rate.

[0006] In a second embodiment, the first rate of the precenting embodiment is a maximum rate of operational movement of the plunger.

[0007] In a third embodiment, the second rate of any of the preceding embodiments is selected based on a predetermined maximum force to be exerted by the plunger on contents in the container.

[0008] In a fourth embodiment, the plunger of any of the preceding embodiments comprises pins that extend downward toward the container and wherein ends of the pins are configured to push the piece of protective material downward as the plunger is moved downward.

[0009] In a fifth embodiment, the controller of the preceding embodiment is configured to determine the first plunger depth based on a position of the ends of the pins with respect to the top of the container when the plunger is at the first plunger depth.

[0010] In a sixth embodiment, wherein the position of the ends of the pins of the preceding embodiment with respect to the top of the container when the plunger is at the first plunger depth is one of the group consisting of: a vertical position of the ends of the pins at a verticalposition of the top of the container; and a vertical position of the ends of the pins above a vertical position of the top of the container by a predetermined offset.

[0011] In a seventh embodiment, the plunger of any of the fourth to sixth embodiments further includes a frame and bushings. Each of the pins is coupled to the frame via one of the bushings that allows the pin to slide vertically with respect to the frame.

[0012] In an eighth embodiment, wherein movement of the plunger of the preceding embodiment from the first plunger depth to the second plunger depth comprises movement of the frame of the plunger from the first plunger depth to the second plunger depth. The bushings permit the pins to independently slide upward as the pins encounter resistance from contents within the container while the plunger moves from the first plunger depth to the second plunger depth.

[0013] In a nineth embodiment, the controller of any of the fourth to eighth embodiments is configured to determine the second plunger depth based on a predetermined amount of movement of the pins with respect to a moveable frame of the plunger.

[0014] In a tenth embodiment, the controller of any of the preceding embodiments is configured to determine the second plunger depth based on one or more of the indication of the height of the container or a scanned height of contents of the container.

[0015] In an eleventh embodiment, the controller of any of the preceding embodiments is configured to determine the second plunger depth based on an amount of resistance encountered by the plunger from either the container or contents in the container as the plunger is moved downward from the first plunger depth.

[0016] In a twelfth embodiment, the sensor system of any of the preceding embodiments comprises a sensor configured to detect a physical height of the container as the container is conveyed through the packaging system. The indication of the height of the container comprises an indication of the detected physical height of the container.

[0017] In a thirteenth embodiment, the sensor system of any of the preceding embodiments comprises a scanner configured to scan a code associated with the container.

[0018] In a fourteenth embodiment, the code of the preceding embodiment includes the indication of the height of the container. The sensor system is configured to send the indication of the height of the container scanned from the code.

[0019] In a fifteenth embodiment, the code of any of the thirteenth to fourteenth embodiments includes an indication of the container. The indication of the height of the container includes the indication of the container. The controller is configured to look up a stored height of the container based on the indication of the container.

[0020] In a sixteenth embodiment, a method includes detecting, by a sensor system, a height of a container; positioning, by a positioning system, the container under a plunger; inserting, by the plunger, a piece of protective material into the container through a top of the container; and controlling, by a controller, movement of the plunger to insert the protective material into the container. The movement of the plunger is controlled by the controller receiving an indication of the height of the container from the sensor system, determining a first plunger depth based on the indication of the height of the container, and, while the container is positioned under the plunger, causing the plunger to move downward from a retracted position to the first plunger depth at a first rate and to move from the first plunger depth to a second plunger depth at a second rate. The first rate is greater than the second rate.

[0021] In a seventeenth embodiment, the plunger of the preceding embodiment comprises pins that extend downward toward the container and wherein ends of the pins are configured to push the piece of protective material downward as the plunger is moved downward.

[0022] In an eighteenth embodiment, the controller of the preceding embodiment determines the first plunger depth based on a position of the ends of the pins with respect to the top of the container when the plunger is at the first plunger depth.

[0023] In a nineteenth embodiment, a non-transitory computer-readable medium has instructions embodied thereon for execution by a controller. The controller is communicatively coupled to a sensor system configured to detect a height of a container and to a plunger configured to move downward to insert a piece of protective material into the container through a top of the container. The instructions comprise instructions that, in response to execution by the controller, cause the controller to: receive an indication of the height of the container from the sensor system; determine a first plunger depth based on theindication of the height of the container; and, while the container is positioned under the plunger, cause the plunger to move downward from a retracted position to the first plunger depth at a first rate and to move from the first plunger depth to a second plunger depth at a second rate. The first rate is greater than the second rate.

[0024] In a twentieth embodiment, the plunger of the preceding embodiment comprises pins that extend downward toward the container and wherein ends of the pins are configured to push the piece of protective material downward as the plunger is moved downward.

[0025] Ina twenty-first embodiment, the instructions of the preceding embodiment comprise instructions that, in response to execution by the controller, cause the controller to determine the first plunger depth based on a position of the ends of the pins with respect to the top of the container when the plunger is at the first plunger depth.BRIEF DESCRIPTION OF THE DRAWING

[0026] The foregoing aspects and many of the attendant advantages of the disclosed subject matter will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:

[0027] Figs. 1A and IB depict side and perspective view's, respectively, of an embodiment of plunger that can be used to insert a piece of protective material into a container, in accordance with the embodiments described herein;

[0028] Figs. 2A and 2B depict side and perspective view's, respectively, of the plunger shown in Figs. 1A and IB in an extended position, in accordance with the embodiments described herein;

[0029] Figs. 3A to 3D depicted instances of an embodiment of the plunger shown in Figs. 1A and IB inserting a piece of protective material into a container, in accordance with the embodiments described herein;

[0030] Figs. 4A to 4C depict an embodiment of a method of using the plunger shown in Figs. 1 A and IB to insert the protective material into a container in a way that address both the desire to reduce the time required to insert the protective material into the container whiledecreasing the risk of damaging objects in the container, in accordance with the embodiments described herein;

[0031] Figs. 5 A to 5C depict an embodiment of a method of using the plunger shown in Figs. 1A and IB to insert the protective material into a container in a way that is similar to the method shown in Figs. 4A to 4C where the container shown in Figs. 5A to 5C is a different size from the container shown in Figs. 4A to 4C, in accordance with the embodiments described herein;

[0032] Fig. 6 depicts an embodiment of a packaging system that has a plunger which inserts protective materials into containers, in accordance with the embodiments described herein;

[0033] Figs. 7 A to 7C depict an example of a method of the packaging system shown in Fig. 6 inserting a piece of protective material into one container, in accordance with the embodiments described herein;

[0034] Figs. 8A to 8C depict an example of a method of the packaging system shown in Fig. 6 inserting a piece of protective material into another container, in accordance with the embodiments described herein;

[0035] Fig. 9 depicts an example embodiment of a system that may be used to implement some or all of the embodiments described herein; and

[0036] Fig. 10 depicts a block diagram of an embodiment of a computing device, in accordance with the embodiments described herein.DETAILED DESCRIPTION

[0037] Figs. 1A and IB depict side and perspective views, respectively, of an embodiment of plunger 10 that can be used to insert a piece of protective material into a container. The plunger 10 includes pins 12 that extend downw ard. When the plunger 10 is positioned above a container (e.g., a shipping box), the pins 12 extend downward toward the container. As discussed in greater detail below, the lower ends of the pins 12 are configured to push a piece of protective material downward as the plunger 10 is moved downward toward the container. In the depicted embodiment, the pins 12 include six pins thar are arranged in an array that is two pins deep and three pins wide. It will be apparent that, in other embodiments, the pins 12 can include any number of pins and be in any type of arrangement.

[0038] The plunger includes a movable frame 14. The pins 12 are slidingly coupled to the movable frame 14. In particular, the pins 12 are permitted to slide downward with respect to the movable frame 14 to the point shown in Figs. 1A and IB. The pins 12 are biased downward by gravity and an upward force on the ends of the pins 12 that overcomes the force of gravity will cause the pins 12 to slide upward with respect to the movable frame 14. In the depicted embodiment, each of the pins 12 is capable of moving with respect to the movable frame 14 independently of the other pins 12.

[0039] The plunger 10 further includes rods 16. The rods 16 are fixedly coupled to the movable frame 14 such that movement of the rods 16 will cause a corresponding movement of the movable frame 14. The rods 16 are slidingly coupled to a stationary frame 18. The movements of the rods 16 with respect to the stationary frame 18 can be controlled, such as by a controller (as discussed below). When a container is located above a container, the rods 16 can be moved downward with respect to the stationary frame 18 such that the movable frame 14 and the pins 12 move downward. Additionally, after the pins 12 insert a piece of protective material into a container, the rods 16 can be moved upward with respect to the stationary frame 18 such that the movable frame 14 and the pins 12 are retracted from the container.

[0040] In Figs. 1 A and IB, the plunger 10 is arranged in a retracted position with the rods 16 lifted upward. In the depicted embodiment, the rods 16 are lifted upward in the retracted position such that the movable frame 14 is proximate the stationary frame 18. The ends of the pins 12 are also retracted to the highest possible point with respect to the stationary frame 18 while there is no force counteracting the effect of gravity on the position of the pins 12 with respect to the movable frame 14.

[0041] Figs. 2A and 2B depict side and perspective views, respectively, of the plunger 10 in an extended position. From the retracted position shown in Figs. 1 A and IB to the extended position shown in Figs. 2A and 2B, the rods 16 have been moved downward with respect to the stationary frame 18 to cause the movable frame 14 and the pins 12 to move downward. When a protective material is located on the lower ends of the pins 12 when the rods 16 are moved downward to cause the movable frame 14 and the pins 12 to move downward, this downward movement can cause the protective material to be moved downward on the ends of the pins 12. In particular, when the plunger 10 is located above an open shipping container,the downward movement can cause the protective material to be inserted into the shipping container as the protective material is moved downward on the ends of the pins 12.

[0042] Figs. 3 A to 3D depicted instances of an embodiment of the plunger 10 inserting a piece of protective material 20 into a container 30. In the depicted embodiment, the protective material is a sheet of air cellular material (e.g., BUBBLE WRAP brand air cellular material). In other embodiments, the protective material can be a strand of inflated pillows, a pad of crumpled paper, or any other type of protective material. In the depicted embodiment, the container 30 is a box (e.g., a cardboard box) with an open top. The container 30 also holds objects 32 and 34. It will be apparent that the container 30 can hold any number of objects from a single object to any plurality objects. In the particular embodiment shown in Figs. 3 A and 3B, the objects 32 and 34 have different heights.

[0043] As can be seen in Figs. 3A to 3D, the container 30 is located on a positioning system 40. The positioning system 40 is configured to position the container 30 under the plunger 10. In various embodiments, the positioning system 40 can be a conveyor belt, a set of rollers, a movable surface, or any other type of positioning system. For example, in the case of the positioning system 40 being a conveyor belt, the conveyor belt can advance the container 30 until the container 30 is located under the plunger 10, as shown in in the position of the container 30 under the plunger 10 in Fig. 3A.

[0044] In Fig. 3 A, the container 30 is located above the plunger 10 with the protective material 20 on the ends of the pins 12. The protective material 20 can be held on the ends of the pins 12 mechanically (e.g., with grippers on the ends of the pins), pneumatically (e.g., drawing a vacuum through an orifice on the ends of the pins 12, or in any other way. In Fig. 3 A, the plunger 10 is in the retracted position above the container 30. The retracted position of the plunger 10 is sufficiently withdrawn such that the container 30 can be moved underneath the plunger 10 without contacting the pins 12 or the protective material 20 held by the ends of the pins 12.

[0045] From the instance shown in Fig. 3 A to the instance shown in Fig. 3B, the rods 16 have been moved downward with respect to the stationary frame 18. The downward movement of the rods 16 have caused corresponding downward movements of the movable frame 14 and the pins 12. This downward movement of the pins 12 has caused the protective material 20to approach the top of the container 30. However, at the instance shown in Fig. 3B, the protective material 20 has not yet reached the opening of the container 30.

[0046] From the instance shown in Fig. 3B to the instance shown in Fig. 3C, the rods 16 have been moved downward further with respect to the stationary frame 18. At the instance shown in Fig. 3C, the protective material 20 has already passed through the opening of the container 30. The protective material 20 has not yet reached the tops of the objects 32 and 34. Because the protective material 20 has not yet reached the tops of the objects 32 and 34, the effect of gravity on the pins 12 has not been opposed in the instance shown in Fig. 3C. This allows the pins 12 to continue hanging downward as far as possible from the movable frame 14.

[0047] From the instance shown in Fig. 3C to the instance shown in Fig. 3D, the rods 16 have been moved do wn ward further with respect to the stationary frame 18. At the instance shown in Fig. 3D, the protective material 20 has come into contact with the tops of the objects 32 and 34. The rods 16 have been moved downward beyond the point at which the protective material 20 has contacted the tops of the objects 32 and 34. This further downward movement of the rods 16 has caused the movable frame 14 to continued moving downward. However, once the protective material 20 under the ends of the pins 12 contacts one of the objects 32 and 34, the objects 32 and 34 exerted a force on the pins 12 to counteract gravity and stop the downward movement of the pins 12. The pins 12 are able to stop moving downward with respect to the movable frame 14 because the pins 12 are slidingly movable with respect to the movable frame 14. In some embodiments, the movable frame 14 includes bushings, wherein each of the pins 12 is coupled to the movable frame 14 via one of the bushings to allow the pins 12 to independently slide vertically with respect to the movable frame 14. It will be apparent that the ability of the pins 12 to independently move with respect to the movable frame 14 allow the pins 12 to accommodate the different heights of the objects 32 and 34.

[0048] After the instance shown in Fig. 3D, the protective material 20 can be released from the ends of the pins 12 and the plunger 10 can be retracted from the container 30. This leaves the protective material 20 inserted into the container 30. After the plunger 10 is retracted, the container 30 can be moved from the position below the plunger 10, such as by the positioning system 40 moving the container 30 from the position below the plunger. The container 30can also be closed for shipping the objects 32 and 34 with the protective material 20 located above the objects 32 and 34.

[0049] One problem with the method shown in Figs. 3A to 3D is the potential for damaging the objects 32 and 34 as the protective material 20 is inserted into the container 30. In particular, there is a desire to reduce the time required to insert the protective material 20 into the container 30. The time can be reduced by increasing the speed at which the plunger 10 inserts the protective material 20 into the container 30. However, fast movements of the pins 12, together with the weight of the pins 12, can cause damage to the objects 32 and 34.Conversely, the risk of damage to the objects 32 and 34 can be reduced by reducing the speed at which the plunger 10 inserts the protective material 20 into the container 30. However, slow er movements of the plunger 10 increases the amount of time required to insert the protective material 20 into the container 30.

[0050] Figs. 4A to 4C depict an embodiment of a method of using the plunger 10 to insert the protective material 20 into a container 50 in a way that address both the desire to reduce the time required to insert the protective material 20 into the container 50 while decreasing the risk of damaging objects in the container 50. In Fig. 4A, the plunger 10 is in the retracted position with the protective material 20 on the ends of the pins 12. The container 50 has been positioned under the plunger 10 by the positioning system 40. With the plunger 10 in the retracted position, the ends of the pins 12 are located at a retracted position 22 above the container 50.

[0051] Fig. 4A also depicts a first plunger depth 24 and a second plunger depth 26. In some embodiments, the first plunger depth 24 is based on a position of the ends of the pins 12 with respect to the top of the container 50 when the plunger 10 is at the first plunger depth 24. In some cases, the first plunger depth 24 is the vertical position of the ends of the pins 12 at a vertical position of the top of the container 50. In some cases, the first plunger depth 24 is the vertical position of the ends of the pins 12 above a vertical position of the top of the container 50 by a predetermined offset (e.g., an offset that is based on a thickness of the protective material 20). In some cases, the second plunger depth 26 is selected based on one of a scanned height of the contents of the container 50, a location at which the contents in the container 50 cause the plunger 10 to encounter as it inserts the protective material 20, or an offset from the top of the container 50 downward into the container 50. In some cases, theplunger 10 can include a sensor configured to detect movement of the pins 12 with respect to the movable frame 14 and the second plunger depth 26 is selected based on a predetermined amount of movement of the pins 12 with respect to the moveable frame (e.g., any movement of any of the pins 12 with respect to the moveable frame, a predetermined distance that any of the pins 12 move with respect to the moveable frame 14, etc ).

[0052] From the instance shown in Fig. 4A to the instance shown in Fig. 4B, the plunger 10 has moved downward from the retracted position. In particular, the rods 16 have been moved downward until the ends of the pins 12 are at the first plunger depth 24. As shown in the depicted embodiment, the plunger 10 has moved downward from the retracted position to the first plunger depth 24 at a first rate Vi. In some cases, the first rate Vi is the maximum operational movement of the plunger 10. When the first rate Vi is the maximum operational movement of the plunger 10, the initial movement of the plunger 10 to the first plunger depth 24 at the first rate Vi can minimizes the amount of time required to extend the plunger 10 to the first plunger depth 24. If the first plunger depth 24 is defined properly, the lowering of the plunger 10 to the first plunger depth 24 at the first rate Vi will not cause the pins 12 or the protective material 20 to contact the container 50 or any objects therein while the plunger 10 moves at the first rate Vi.

[0053] From the instance shown in Fig. 4B to the instance shown in Fig. 4C, the plunger 10 has moved downward from the first plunger depth 24. In particular, the rods 16 have been moved downward until the ends of the pins 12 are at the second plunger depth 26. As shown in the depicted embodiment, the plunger 10 has moved downward from the first plunger depth 24 to the second plunger depth 26 at a second rate V2. The first rate V 1 is greater than the second rate V2 so that the ends of the pins 12 move more slowly through the container 50 to the second plunger depth 26 than the pins 12 moved before the plunger 10 reached the first plunger depth 24. In this way, the plunger 10 moves more quickly to move the protective material 20 in proximity with the top of the container 50 and then the plunger 10 moves more slowly as the protective material 20 passes through the container 50 toward any contents of the container 50. This two-rate approach reduces the amount of time that the plunger 10 moves the protective material 20 to the container 50 and then slows to move the protective material 20 into the container 50 to minimize the risk of damaging any contents of the container 50.

[0054] Figs. 5 A to 5C depict an embodiment of a method of using the plunger 10 to insert the protective material 20 into a container 60 in a way that is similar to the method shown in Figs. 4A to 4C where the container 60 is a different size from the container 50. Notably, the container 60 is shorter than the container 50. In Fig. 5 A, the plunger 10 is in the retracted position. The first plunger depth 24 in Fig. 5 A is at a different location than the first plunger depth 24 was at in Fig. 4A. In particular, the first plunger depth 24 in Fig. 5A is located based on the height of the container 60, which is lower than the height of the container 50. The second plunger depth 26 in Fig. 5A is at approximately the same location as the second plunger depth 26 in Fig. 4A. It will be apparent that the first and second plunger depths 24 and 26 can be the same or different for different containers based on the size of the containers. As discussed in greater detail below, the plunger 10 can be part of a packaging system that is able to determine or detect characteristics (e.g., heights) of containers as they are moved on the positioning system 40 and before the containers reach the position under the plunger 10 so that the first plunger depth 24 and / or the second plunger depth 26 can be adjusted for each container based on one or more characteristics of the container.

[0055] From the instance shown in Fig. 5 A to the instance shown in Fig. 5B, the plunger 10 has moved downward from the retracted position to the first plunger depth 24. As shown in the depicted embodiment, the plunger 10 has moved downward from the retracted position to the first plunger depth 24 at a first rate Vi. From the instance shown in Fig. 5B to the instance shown in Fig. 5C, the plunger 10 has moved downward from the first plunger depth 24 to the second plunger depth 26. As shown in the depicted embodiment, the plunger 10 has moved downward from the first plunger depth 24 to the second plunger depth 26 at a second rate V2. The first rate V 1 is greater than the second rate V2 so that the ends of the pins 12 move more slowly through the container 60 to the second plunger depth 26 than the pins 12 moved before the plunger 10 reached the first plunger depth 24. If the first rate Vi and the second rate V2 are the same rates in both the method in Figs. 4A to 4C and the method in Figs. 5 A to 5C, the total time required for the plunger 10 to move from the retracted position 22 to the second plunger depth 26 in the method of Figs. 5 A to 5C than would be required in the method of Figs. 4 A to 4C.

[0056] As noted above, the plungers described herein can be a part of a packaging system that is capable of detecting characteristics of the containers into which the plunger insertsprotective materials. Fig. 6 depicts an embodiment of a packaging system 100 that has a plunger 110 which inserts protective materials into containers. The packaging system 100 includes a plunger 110 configured to insert a piece of protective material 120 into a container through a top of the container. The plunger 110 can be any of the embodiments of plungers described herein, including the plunger 10. In the depicted embodiment, the plunger 110 includes pins 112, a movable frame 114, and rods 116. The pins 112, the movable frame 114, and the rods 116 of the plunger 110 can function similarly to the pins 12, the movable frame 14, and the rods 16 of the plunger 10. In particular, the rods are fixedly coupled to the movable frame 114 such that movements of the rods 116 cause corresponding movements of the movable frame 114. The pins 112 are slidably coupled to the movable frame 114 and biased downward by gravity.

[0057] Fig. 6 also depicts a piece of protective material 120 that is held by the ends of the pins 112. The protective material 120 can be any type of protective material 120, such as air cellular material, packing paper, and the like. The packaging system 100 includes a supply 122 of the protective material. In the depicted embodiment, the supply 122 is in the form of a roll of the protective material; in other embodiments, the supply 122 of the protective material can take any other form. The packaging system 100 further includes a cutter 124 configured to cut pieces of the protective material from the supply 122 so that individual pieces of the protective material can be inserted into individual containers by the plunger 110 as the plunger 110 moves downward through the top of the container.

[0058] The packaging system 100 further includes a positioning system 140 that holds containers 130 and 132. In the depicted embodiment, the positioning system 140 is a conveyor belt. In other embodiments, the positioning system 140 can include a series of rollers, a moving surface, a track, any other positioning system, or any combination thereof. The positioning system 140 is configured to support and advance containers. In the depicted embodiment, the positioning system 140 supports containers 130 and 132 and is configured to move the containers 130 and 132 in a downstream direction that is indicated by the arrows (i.e., from left to right when viewing Fig. 6). The positioning system 140 is further configured to position containers under the plunger 110. At the moment shown in Fig. 6, the positioning system has positioned the container 130 under the plunger 110. After themoment shown in Fig. 6, the positioning system 140 can further advance the container 132 to positing the container 132 under the plunger 110.

[0059] The packaging system 100 further includes a sensor system 150 that is configured to detect heights of containers. In the depicted embodiment, the sensor system 150 is positioned proximate the upstream side of the positioning system 140 and is configured to detect heights of containers as the containers are moved by the positioning system 140. The sensor system 150 can include one or more sensors arranged to detect characteristics of the containers. In some embodiments, the sensor system 150 can include a code scanner (e.g., a barcode scanner, a QR code scanner) configured to scan a code (e.g., a barcode, a QR code, etc.) associated with the container. The code can include either an indication of a height of the container or an indication of the container from which a controller can look up a height of the container. In some embodiments, the sensor system 150 includes a sensor configured to detect a physical height of the container as the container is conveyed through the packaging system 100 by the positioning system 140. The sensor system 150 can generate an indication of the height of the container that includes an indication of the detected physical height of the container by the sensor. In some embodiments, the sensor system includes a curtain scanner that is arranged across the positioning system such that the containers on the positioning system pass under the curtain scanner. The curtain scanner is configured to detect heights of the contents of the containers (e.g., one or more objects in the container) as the containers pass under the curtain scanner. In other embodiment, the sensor system 150 can include any other sensor configured to detect any characteristic about the containers.

[0060] The packaging system 100 further includes a controller 160. In the depicted embodiment, the controller 160 is communicatively coupled with each of the plunger 110, the positioning system 140, and the sensor system 150. The controller 160 is configured to receive information from and / or cause actions to be performed by each of the plunger 110, the positioning system 140, and the sensor system 150.

[0061] In some embodiments, the controller 160 can cause the plunger 110 to move by sending corresponding instructions to the plunger 110. For example, the controller 160 can send instructions to the plunger 110 that cause the plunger 110 to move from the retracted position to the first plunger depth at the first rate and / or instructions that cause the plunger 110 to move from the first plunger depth to the second plunger depth at the second rate. Insome embodiments, the controller 160 can receive from the plunger 110 indications of an amount of resistance encountered by the plunger 110 from either a container or contents in a container as the plunger is moved downward from the first plunger depth. In some embodiments, the controller 160 can determine a second plunger depth based on the amount of resistance received from the plunger 110.

[0062] In some embodiments, the controller 160 can send instructions to the positioning system 140 to position one of the containers 130 and 132 under the plunger 110. In some embodiments, the positioning system 140 can send indications of the positions of the containers 130 and 132 to the controller 160. For example, the positioning system 140 can send the controller 160 an indication that the container 130 is located under the plunger 110; in response, the controller 160 can send instructions to the plunger 110 that cause the plunger 110 to move from the retract position to the first and / or second plunger depths.

[0063] In some embodiments, the controller 160 can receive information from the sensor system 150 about the containers. For example, the sensor system 150 can send an indication of a height of the container 130 to the controller 160 and the controller 160 can determine a first plunger depth for the container 130 based on the indication of the height received from the sensor system 150. In some embodiments, the sensor system 150 can send an indication of the heights of the contents of the container 130 to the controller 160 and the controller 160 can determine the second plunger depth based on the indication of the heights of the contents of the container 130. In some embodiments, the sensor system 150 can send an indication of a length of the container 130 to the controller 160 and the controller 160 can send instructions to the positioning system 140 that cause the positioning system 140 to center the container 130 under the plunger 110.

[0064] The controller 160 is capable of processing information about multiple containers in the packaging system at the same time. For example, at the instance shown in Fig. 6, the container 130 and the container 132 are both located on the positioning system 140. The container 130 is located under the plunger 110 and is ready to have the piece of protective material inserted by the plunger 110. The container 132 is located on the positioning system 140 upstream of the container 130 and downstream of the sensor system 150. The containers 130 and 132 have different heights, and the controller 160 can determine different first plunger depths and / or different second plunger depths for each of the containers 130 and 132.At the instance shown in Fig. 6, the controller 160 can control the plunger 110 to insert the piece of the protective material 120 based on the first and second plunger depths of the container 130 while also determining the first plunger depth and / or different second plunger depth of the container 132 based on information received from the sensor system 150 about the container 132. It will be apparent that any number of containers can be in the packaging system 100 and processed by the controller 160.

[0065] The controller 160 is capable of causing the packaging system 100 to perform any of the methods described based on the information received from and / or the instructions sent to the various elements of the packaging system 100. Figs. 7A to 7C depict an example of a method of the packaging system 100 inserting the piece of protective material 120 into the container 130 and Figs. 8 A to 8C depict an example of a method of the packaging system 100 inserting the piece of protective material 120 into the container 132. It is noted that, in Figs. 7A to 8C, the plunger 110 further includes a stationary frame 118 that is similar to the stationary frame 18 of the plunger 10. In the depicted embodiment, the stationary frame 118 remains in a fixed vertical location with respect the upper surface of the positioning system 140. The rods 116 are slidingly movable with respect to the stationary frame 118 and the plunger can include an actuator (e.g., solenoid, pneumatic system, hydraulic system, etc.) to controllingly move the rods 116 with respect to the stationary frame 118.

[0066] Fig. 7A depicts a portion of the packaging system 100 at the moment shown in Fig. 6. In particular, the positioning system 140 has positioned the container 130 under the plunger 110 and the plunger 110 is in the retracted position. The controller 160 can determined the first plunger depth for the container 130 based on an indication of the height of the container 130 received from the sensor system 150. At the point shown in Fig. 7A, the controller 160 can cause the plunger 110 to move from the retracted position to the first plunger depth.

[0067] Fig. 7B shows the plunger 110 at the first plunger depth. From the instance shown in Fig. 7A to the instance shown in Fig. 7B, the controller 160 has caused the plunger 110 to move from the retracted position to the first plunger depth at a first rate. In some examples, the first rate is a maximum operational rate of the plunger 110 to move the rods 116 with respect to the stationary frame 118. In the depicted embodiment, the piece of protective material 120 is proximate the open top of the container 130 when the plunger 110 is at the first plunger depth. In particular, the piece of protective material 120 has not yet entered thecontainer 130 when the plunger 110 is at the first plunger depth. The controller 160 can determine the second plunger depth of the container 130 based on any characteristics of the container 130, such as a predetermined offset into the container 130 from the top of the container 130, a detected height of the contents of the container 130, an amount of resistance on the plunger 110 as the plunger 110 moves from the first plunger depth toward the second plunger depth, or a maximum amount of resistance on the plunger 110 permitted during insertion of the piece of protective material 120.

[0068] Fig. 7C shows the plunger 110 at the second plunger depth. From the instance shown in Fig. 7B to the instance shown in Fig. 7C, the controller 160 has caused the plunger 110 to move from the retracted position to the second plunger depth at a second rate. The first rate at which the plunger 110 moved from the retracted position to the first plunger depth is greater than the second rate at which the plunger 110 moved from the first plunger depth to the second plunger depth. The lower second rate reduces the chance of the contents of the container 130 being damaged by the insertion of the piece of protective material 120 into the container 130. In the depicted embodiment, the piece of protective material 120 and the ends of the pins 112 are located inside of the container 130 when the plunger 110 is at the second plunger depth. From the point shown in Fig. 7C, the controller 160 can cause the plunger 110 to release the piece of protective material 120 from the ends of the pins 112 and then retract from the second plunger depth to the retracted position. In some embodiments, the controller 160 can cause the plunger to retract from the second plunger depth to the retracted position at a rate that is greater than the second rate, such as the first rate.

[0069] Fig. 8 A depicts a portion of the packaging system 100 after the positioning system 140 has advanced the container 132 downstream from the position of the container 132 shown in Fig. 6. In particular, the positioning system 140 has positioned the container 132 under the plunger 110 with the plunger 110 in the retracted position. The controller 160 can determined the first plunger depth for the container 132 based on an indication of the height of the container 132 received from the sensor system 150. At the point shown in Fig. 8A, the controller 160 can cause the plunger 110 to move from the retracted position to the first plunger depth.

[0070] Fig. 8B shows the plunger 110 at the first plunger depth. From the instance shown in Fig. 8A to the instance shown in Fig. 8B, the controller 160 has caused the plunger 110 tomove from the retracted position to the first plunger depth at a first rate. In some examples, the first rate is a maximum operational rate of the plunger 110 to move the rods 116 with respect to the stationary frame 118. In the depicted embodiment, the piece of protective material 120 is proximate the open top of the container 132 when the plunger 110 is at the first plunger depth. In particular, the piece of protective material 120 has not yet entered the container 132 when the plunger 110 is at the first plunger depth. When comparing Figs. 7B and 8B, it is apparent that the first plunger depth of the container 130 is higher than the first plunger depth of the container 132. This different is due, at least in part, to the different in heights of the containers 130 and 132. The controller 160 can determine the second plunger depth of the container 132 based on any characteristics of the container 132, such as a predetermined offset into the container 132 from the top of the container 132, a detected height of the contents of the container 132, an amount of resistance on the plunger 110 as the plunger 110 moves from the first plunger depth toward the second plunger depth, or a maximum amount of resistance on the plunger 110 permitted during insertion of the piece of protective material 120.

[0071] Fig. 8C shows the plunger 110 at the second plunger depth. From the instance shown in Fig. 8B to the instance shown in Fig. 8C, the controller 160 has caused the plunger 110 to move from the retracted position to the second plunger depth at a second rate. The first rate at which the plunger 110 moved from the retracted position to the first plunger depth is greater than the second rate at which the plunger 110 moved from the first plunger depth to the second plunger depth. The lower second rate reduces the chance of the contents of the container 132 being damaged by the insertion of the piece of protective material 120 into the container 132. In the depicted embodiment, the piece of protective material 120 and the ends of the pins 112 are located inside of the container 132 when the plunger 110 is at the second plunger depth. When comparing Figs. 7C and 8C, it is apparent that the second plunger depth of the container 130 is higher than the second plunger depth of the container 132, but the second plunger depth of the container 130 is deeper into the container than the second plunger depth in the container 132. From the point shown in Fig. 8C, the controller 160 can cause the plunger 110 to release the piece of protective material 120 from the ends of the pins 112 and then retract from the second plunger depth to the retracted position. In some embodiments, the controller 160 can cause the plunger to retract from the second plungerdepth to the retracted position at a rate that is greater than the second rate, such as the first rate.

[0072] Fig. 9 depicts an example embodiment of a system 210 that may be used to implement some or all of the embodiments described herein. In the depicted embodiment, the system 210 includes computing devices 2201, 2202, 220?. and 2204 (collectively computing devices 220). In the depicted embodiment, the computing device 220i is a tablet, the computing device 2202 is a mobile phone, the computing device 22 3 is a desktop computer, and the computing device 2204 is a laptop computer. In other embodiments, the computing devices 220 include one or more of a desktop computer, a mobile phone, a tablet, a phablet, a notebook computer, a laptop computer, a distributed system, a gaming console (e.g., Xbox, Play Station, Wii), a watch, a pair of glasses, a key fob, a radio frequency identification (RFID) tag, an ear piece, a scanner, a television, a dongle, a camera, a wristband, a wearable item, a kiosk, an input terminal, a server, a server network, a blade, a gateway, a switch, a processing device, a processing entity, a set-top box, a relay, a router, a network access point, a base station, any other device configured to perform the functions, operations, and / or processes described herein, or any combination thereof.

[0073] The computing devices 220 are communicatively coupled to each other via one or more networks 230 and 232. Each of the networks 230 and 232 may include one or more wired or wireless networks (e.g., a 3G network, the Internet, an internal network, a proprietary network, a secured network). The computing devices 220 are capable of communicating with each other and / or any other computing devices via one or more wired or wireless networks. While the particular system 210 in Fig. 9 depicts that the computing devices 220 communicatively coupled via the network 230 include four computing devices, any number of computing devices may be communicatively coupled via the network 230.

[0074] In the depicted embodiment, the computing device 2203 is communicatively coupled with a peripheral device 240 via the network 232. In the depicted embodiment, the peripheral device 240 is a scanner, such as a barcode scanner, an optical scanner, a computer vision device, and the like. In some embodiments, the network 232 is a wired network (e.g., a direct wired connection between the peripheral device 240 and the computing device 220s), a wireless network (e.g., a Bluetooth connection or a WiFi connection), or a combination of wired and wireless networks (e.g., a Bluetooth connection between the peripheral device 240and a cradle of the peripheral device 240 and a wired connection between the peripheral device 240 and the computing device 220s). In some embodiments, the peripheral device 240 is itself a computing device (sometimes called a “smart” device). In other embodiments, the peripheral device 240 is not a computing device (sometimes called a “dumb” device).

[0075] Depicted in Fig. 10 is a block diagram of an embodiment of a computing device 300. Any of the computing devices 220 and / or any other computing device described herein may include some or all of the components and features of the computing device 300. In some embodiments, the computing device 300 is one or more of a desktop computer, a mobile phone, a tablet, a phablet, a notebook computer, a laptop computer, a distributed system, a gaming console (e.g., an Xbox, a Play Station, a Wii), a watch, a pair of glasses, a key fob, a radio frequency identification (RFID) tag, an ear piece, a scanner, a television, a dongle, a camera, a wristband, a wearable item, a kiosk, an input terminal, a server, a server network, a blade, a gateway, a switch, a processing device, a processing entity, a set-top box, a relay, a router, a network access point, a base station, any other device configured to perform the functions, operations, and / or processes described herein, or any combination thereof. Such functions, operations, and / or processes may include, for example, transmitting, receiving, operating on, processing, displaying, storing, determining, creating / generating, monitoring, evaluating, comparing, and / or similar terms used herein. In one embodiment, these functions, operations, and / or processes can be performed on data, content, information, and / or similar terms used herein.

[0076] In the depicted embodiment, the computing device 300 includes a processing element 305, memory 310, a user interface 315, and a communications interface 320. The processing element 305, memory 310, a user interface 315, and a communications interface 320 are capable of communicating via a communication bus 325 by reading data from and / or writing data to the communication bus 325. The computing device 300 may include other components that are capable of communicating via the communication bus 325. In other embodiments, the computing device does not include the communication bus 325 and the components of the computing device 300 are capable of communicating with each other in some other way.

[0077] The processing element 305 (also referred to as one or more processors, processing circuitry, and / or similar terms used herein) is capable of performing operations on someexternal data source. For example, the processing element may perform operations on data in the memory 310, data receives via the user interface 315, and / or data received via the communications interface 320. As will be understood, the processing element 305 may be embodied in a number of different ways. In some embodiments, the processing element 305 includes one or more complex programmable logic devices (CPLDs), microprocessors, multicore processors, co processing entities, application-specific instruction-set processors (ASIPs), microcontrollers, controllers, integrated circuits, application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs), programmable logic arrays (PLAs), hardware accelerators, any other circuitry, or any combination thereof. The term circuitry may refer to an entirely hardware embodiment or a combination of hardware and computer program products. In some embodiments, the processing element 305 is configured for a particular use or configured to execute instructions stored in volatile or nonvolatile media or otherwise accessible to the processing element 305. As such, whether configured by hardware or computer program products, or by a combination thereof, the processing element 305 may be capable of performing steps or operations when configured accordingly.

[0078] The memory 310 in the computing device 300 is configured to store data, computerexecutable instructions, and / or any other information. In some embodiments, the memory 310 includes volatile memory (also referred to as volatile storage, volatile media, volatile memory circuitry, and the like), non-volatile memory (also referred to as non-volatile storage, non-volatile media, non-volatile memory circuitry, and the like), or some combination thereof.

[0079] In some embodiments, volatile memory includes one or more of random access memory (RAM), dynamic random access memory (DRAM), static random access memory (SRAM), fast page mode dynamic random access memory (FPM DRAM), extended data-out dynamic random access memory (EDO DRAM), synchronous dynamic random access memory (SDRAM), double data rate synchronous dynamic random access memory (DDR SDRAM), double data rate type two synchronous dynamic random access memory (DDR2 SDRAM), double data rate type three synchronous dynamic random access memory' (DDR3 SDRAM), Rambus dynamic random access memory (RDRAM), Twin Transistor RAM (TTRAM), Thyristor RAM (T-RAM), Zero-capacitor (Z-RAM), Rambus in-line memory module (RIMM), dual in-line memory module (DIMM), single in-line memory module(SIMM), video random access memory (VRAM), cache memory (including various levels), flash memory, any other memory that requires power to store information, or any combination thereof.

[0080] In some embodiments, non-volatile memory includes one or more of hard disks, floppy disks, flexible disks, solid-state storage (SSS) (e.g., a solid state drive (SSD)), solid state cards (SSC), solid state modules (SSM), enterprise flash drives, magnetic tapes, any other non-transitory magnetic media, compact disc read only memory (CD ROM), compact disc-rewritable (CD-RW), digital versatile disc (DVD), Blu-ray disc (BD), any other non- transitory optical media, read-only memory (ROM), programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), flash memory (e.g., Serial, NAND, NOR, and / or the like), multimedia memory cards (MMC), secure digital (SD) memory cards, Memory Sticks, conductive-bridging random access memory (CBRAM), phase-change random access memory (PRAM), ferroelectric random-access memory (FeRAM), nonvolatile random access memory (NVRAM), magneto-resistive random access memory (MRAM), resistive random-access memory7(RRAM), Silicon Oxide-Nitride-Oxide-Silicon memory (SONOS), floating junction gate random access memory (FJG RAM), Millipede memory, racetrack memory, any other memory that does not require power to store information, or any combination thereof.

[0081] In some embodiments, memory 310 is capable of storing one or more of databases, database instances, database management systems, data, applications, programs, program modules, scripts, source code, object code, byte code, compiled code, interpreted code, machine code, executable instructions, or any other information. The term database, database instance, database management system, and / or similar terms used herein may refer to a collection of records or data that is stored in a computer-readable storage medium using one or more database models, such as a hierarchical database model, network model, relational model, entity relationship model, object model, document model, semantic model, graph model, or any other model.

[0082] The user interface 315 of the computing device 300 is in communication with one or more input or output devices that are capable of receiving inputs into and / or outputting any outputs from the computing device 300. Embodiments of input devices include a keyboard, amouse, a touchscreen display, a touch sensitive pad, a motion input device, movement input device, an audio input, a pointing device input, a joystick input, a keypad input, peripheral device 240, foot switch, and the like. Embodiments of output devices include an audio output device, a video output, a display device, a motion output device, a movement output device, a printing device, and the like. In some embodiments, the user interface 315 includes hardware that is configured to communicate with one or more input devices and / or output devices via wired and / or wireless connections.

[0083] The communications interface 320 is capable of communicating with various computing devices and / or networks. In some embodiments, the communications interface 320 is capable of communicating data, content, and / or any other information, that can be transmitted, received, operated on, processed, displayed, stored, and the like.Communication via the communications interface 320 may be executed using a wired data transmission protocol, such as fiber distributed data interface (FDDI), digital subscriber line (DSL), Ethernet, asynchronous transfer mode (ATM), frame relay, data over cable service interface specification (DOCSIS), or any other wired transmission protocol. Similarly, communication via the communications interface 320 may be executed using a wireless data transmission protocol, such as general packet radio service (GPRS), Universal Mobile Telecommunications System (UMTS), Code Division Multiple Access 2000 (CDMA2000), CDMA2000 IX (IxRTT), Wideband Code Division Multiple Access (WCDMA), Global System for Mobile Communications (GSM), Enhanced Data rates for GSM Evolution (EDGE), Time Division- Synchronous Code Division Multiple Access (TD-SCDMA), Long Term Evolution (LTE), Evolved Universal Terrestrial Radio Access Network (E-UTRAN), Evolution-Data Optimized (EVDO), High Speed Packet Access (HSPA), High-Speed Downlink Packet Access (HSDPA), IEEE 802.11 (WiFi), WiFi Direct, 802.16 (WiMAX), ultra wideband (UWB), infrared (IR) protocols, near field communication (NFC) protocols, Wibree, Bluetooth protocols, wireless universal serial bus (USB) protocols, or any other wireless protocol.

[0084] As will be appreciated by those skilled in the art, one or more components of the computing device 300 may be located remotely from other components of the computing device 300 components, such as in a distributed system. Furthermore, one or more of the components may be combined and additional components performing functions describedherein may be included in the computing device 300. Thus, the computing device 300 can be adapted to accommodate a variety of needs and circumstances. The depicted and described architectures and descriptions are provided for exemplary purposes only and are not limiting to the various embodiments described herein.

[0085] Embodiments described herein may be implemented in various ways, including as computer program products that comprise articles of manufacture. A computer program product may include a non-transitory computer-readable storage medium storing applications, programs, program modules, scripts, source code, program code, object code, byte code, compiled code, interpreted code, machine code, executable instructions, and / or the like (also referred to herein as executable instructions, instructions for execution, computer program products, program code, and / or similar terms used herein interchangeably). Such non- transitory computer-readable storage media include all computer-readable media (including volatile and non-volatile media).

[0086] As should be appreciated, various embodiments of the embodiments described herein may also be implemented as methods, apparatus, systems, computing devices, and the like. As such, embodiments described herein may take the form of an apparatus, system, computing device, and the like executing instructions stored on a computer readable storage medium to perform certain steps or operations. Thus, embodiments described herein may be implemented entirely in hardware, entirely in a computer program product, or in an embodiment that comprises combination of computer program products and hardware performing certain steps or operations.

[0087] Embodiments described herein may be made with reference to block diagrams and flowchart illustrations. Thus, it should be understood that blocks of a block diagram and flowchart illustrations may be implemented in the form of a computer program product, in an entirely hardware embodiment, in a combination of hardware and computer program products, or in apparatus, systems, computing devices, and the like earn ing out instructions, operations, or steps. Such instructions, operations, or steps may be stored on a computer readable storage medium for execution buy a processing element in a computing device. For example, retrieval, loading, and execution of code may be performed sequentially such that one instruction is retrieved, loaded, and executed at a time. In some exemplary embodiments, retrieval, loading, and / or execution may be performed in parallel such that multipleinstructions are retrieved, loaded, and / or executed together. Thus, such embodiments can produce specifically configured machines performing the steps or operations specified in the block diagrams and flowchart illustrations. Accordingly, the block diagrams and flowchart illustrations support various combinations of embodiments for performing the specified instructions, operations, or steps.

[0088] For purposes of this disclosure, terminology such as “upper,” “lower,” “vertical,” “horizontal,” “inwardly,” “outwardly,” “inner,” “outer,” “front,” “rear,” and the like, should be construed as descriptive and not limiting the scope of the claimed subject matter. Further, the use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” “coupled,” and “mounted” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings. Unless stated otherwise, the terms “substantially,” “approximately,” and the like are used to mean within 5% of a target value.

[0089] The principles, representative embodiments, and modes of operation of the present disclosure have been described in the foregoing description. However, aspects of the present disclosure which are intended to be protected are not to be construed as limited to the particular embodiments disclosed. Further, the embodiments described herein are to be regarded as illustrative rather than restrictive. It will be appreciated that variations and changes may be made by others, and equivalents employed, without departing from the spirit of the present disclosure. Accordingly, it is expressly intended that all such variations, changes, and equivalents fall within the spirit and scope of the present disclosure, as claimed.

Claims

CLAIMSWhat is claimed is:

1. A packaging system comprising: a sensor system configured to detect a height of a container; a plunger configured to move downward to insert a piece of protective material into the container through a top of the container; a positioning system configured to position the container under the plunger; and a controller communicatively coupled to the sensor system and to the plunger, wherein the controller is configured to: receive an indication of the height of the container from the sensor system, determine a first plunger depth based on the indication of the height of the container, and while the container is positioned under the plunger, cause the plunger to move downward from a retracted position to the first plunger depth at a first rate and to move from the first plunger depth to a second plunger depth at a second rate, wherein the first rate is greater than the second rate.

2. The packaging system of claim 1 , wherein the first rate is a maximum rate of operational movement of the plunger.

3. The packaging system of claim 1, wherein the second rate is selected based on a predetermined maximum force to be exerted by the plunger on contents in the container.

4. The packaging system of claim 1, wherein the plunger comprises pins that extend downward toward the container and wherein ends of the pins are configured to push the piece of protective material downward as the plunger is moved downward.

5. The packaging system of claim 4, wherein the controller is configured to determine the first plunger depth based on a position of the ends of the pins with respect to the top of the container when the plunger is at the first plunger depth.

6. The packaging system of claim 5. wherein the position of the ends of the pins with respect to the top of the container when the plunger is at the first plunger depth is one of the group consisting of: a vertical position of the ends of the pins at a vertical position of the top of the container; and a vertical position of the ends of the pins above a vertical position of the top of the container by a predetermined offset.

7. The packaging system of claim 4. wherein the plunger further comprises a frame and bushings, wherein each of the pins is coupled to the frame via one of the bushings that allows the pin to slide vertically with respect to the frame.

8. The packaging system of claim 7, wherein movement of the plunger from the first plunger depth to the second plunger depth comprises movement of the frame of the plunger from the first plunger depth to the second plunger depth, and wherein the bushings permit the pins to independently slide upward as the pins encounter resistance from contents within the container while the plunger moves from the first plunger depth to the second plunger depth.

9. The packaging system of claim 4, wherein the controller is configured to determine the second plunger depth based on a predetermined amount of movement of the pins with respect to a moveable frame of the plunger.

10. The packaging system of claim 1, wherein the controller is configured to determine the second plunger depth based on one or more of the indication of the height of the container or a scanned height of contents of the container.

11. The packaging system of claim 1, wherein the controller is configured to determine the second plunger depth based on an amount of resistance encountered by the plunger from either the container or contents in the container as the plunger is moved downward from the first plunger depth.

12. The packaging system of claim 1, wherein the sensor system comprises a sensor configured to detect a physical height of the container as the container is conveyed throughthe packaging system, and wherein the indication of the height of the container comprises an indication of the detected physical height of the container.

13. The packaging system of claim 1, wherein the sensor system comprises a scanner configured to scan a code associated with the container.

14. The packaging system of claim 13, wherein the code includes the indication of the height of the container, and wherein the sensor system is configured to send the indication of the height of the container scanned from the code.

15. The packaging system of claim 13, wherein the code includes an indication of the container, wherein the indication of the height of the container includes the indication of the container, and wherein the controller is configured to look up a stored height of the container based on the indication of the container.

16. A method comprising: detecting, by a sensor system, a height of a container; positioning, by a positioning system, the container under a plunger; inserting, by the plunger, a piece of protective material into the container through a top of the container; and controlling, by a controller, movement of the plunger to insert the protective material into the container by the controller: receiving an indication of the height of the container from the sensor system, determining a first plunger depth based on the indication of the height of the container, and while the container is positioned under the plunger, causing the plunger to move downw ard from a retracted position to the first plunger depth at a first rate and to move from the first plunger depth to a second plunger depth at a second rate, wherein the first rate is greater than the second rate.

17. The method of claim 16, wherein the plunger comprises pins that extend downward toward the container and wherein ends of the pins are configured to push the piece of protective material downward as the plunger is moved downward.

18. The method of claim 17, wherein the controller determines the first plunger depth based on a position of the ends of the pins with respect to the top of the container when the plunger is at the first plunger depth.

19. A non-transitory computer-readable medium having instructions embodied thereon for execution by a controller, wherein the controller is communicatively coupled to a sensor system configured to detect a height of a container and to a plunger configured to move downward to insert a piece of protective material into the container through a top of the container, wherein the instructions comprise instructions that, in response to execution by the controller, cause the controller to: receive an indication of the height of the container from the sensor system; determine a first plunger depth based on the indication of the height of the container; and while the container is positioned under the plunger, cause the plunger to move downward from a retracted position to the first plunger depth at a first rate and to move from the first plunger depth to a second plunger depth at a second rate, wherein the first rate is greater than the second rate.

20. The non-transitory computer-readable medium of claim 19, wherein the plunger comprises pins that extend downward toward the container and wherein ends of the pins are configured to push the piece of protective material downward as the plunger is moved downward.

21. The non-transitory computer-readable medium of claim 20, wherein the instructions comprise instructions that, in response to execution by the controller, cause the controller to determine the first plunger depth based on a position of the ends of the pins with respect to the top of the container when the plunger is at the first plunger depth.

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