Augmented Reality Packing Instructions for Pallet Load Optimization
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Solution Overview
Problem
The challenge in the supply chain is efficiently packing and stacking items on pallets and in containers to prevent damage during shipment, while also optimizing space usage, as existing methods often result in improper configurations that reduce shipment strength and airflow resistance.
Innovation Solution
A warehouse management system and instruction rendering devices are used to generate and visualize packing plans, providing users with augmented reality instructions and feedback to properly pack and load items onto pallets or containers, utilizing sensors and databases to calculate optimal configurations and orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manual packing methods are used, then device complexity is low, but manufacturing precision (packing configuration accuracy) deteriorates
Solution Approach 1:
The patent introduces an intermediary system consisting of sensors, processors, and display devices that mediate between the packing plan generation and the actual packing execution. The system captures images of pallets and items, processes this data to generate optimized packing plans, and displays visual instructions to workers, thereby improving packing accuracy without requiring complex automated machinery
Solution Approach 2:
The patent replaces manual mechanical packing decisions with an automated information processing system. Instead of relying on worker experience and manual calculation, the system uses image processing and computational algorithms to automatically determine optimal packing configurations, substituting mechanical problem-solving with digital processing
2Productivity
If packing plans are generated manually, then device complexity is low, but productivity deteriorates
Solution Approach 1:
The system performs preliminary actions by capturing images of pallets and items before the packing process begins. The processing system then analyzes these pre-captured images to generate packing plans in advance, allowing workers to receive optimized instructions before actual packing starts, thereby increasing packing speed
Solution Approach 2:
The patent establishes continuous operation through automated image capture and processing that occurs continuously during the packing workflow. The system continuously monitors and updates packing plans based on real-time images, ensuring that packing decisions are always current and optimized, which maintains high productivity throughout the packing process
3Reliability
If items are packed without optimized configurations, then device complexity is low, but shipment strength and airflow resistance deteriorate
Solution Approach 1:
The patent implements feedback mechanisms where the processing system continuously analyzes images of packed items and adjusts packing plans accordingly. The system provides visual feedback to workers through display devices, showing optimal placement positions and configurations, which enables real-time corrections to improve shipment strength and airflow
Solution Approach 2:
The system changes critical packing parameters such as item orientation, placement position, and stacking configuration based on analyzed image data. By dynamically adjusting these parameters to optimize packing density and structural integrity, the system improves shipment strength and airflow resistance without requiring complex physical modifications
4Quantity of substance
If space optimization is not considered, then device complexity is low, but loss of substance (wasted space) increases
Solution Approach 1:
The patent transitions from two-dimensional packing views to three-dimensional spatial optimization by analyzing the depth, width, and height dimensions of pallets and items. The processing system calculates optimal three-dimensional configurations that maximize space utilization, allowing items to be arranged in ways that would be difficult to visualize manually
Solution Approach 2:
The system dynamically adjusts packing configurations based on the specific dimensions and shapes of items being packed. Rather than using fixed packing patterns, the system adapts its recommendations in real-time based on the actual items detected in images, optimizing space utilization for each unique packing scenario
Data Source
AI summary
A system and method are disclosed for a supply chain entity having an inventory of one or more items and a warehouse management system receiving orders for one or more items, determining a container for the one or more items, and generating a packing plan for the items. Aspects of the embodiments may include one or more instruction rendering devices having a sensor and a displaying augmented reality instructions and feedback.