Automated Packaging Optimization via 3D Image Analysis
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Solution Overview
Problem
The existing automated packaging systems for custom-sized cardboard boxes face inefficiencies due to the need for manual preparation and imaging of individual items to obtain size information, which slows down the packaging process and results in suboptimal use of cardboard and potential damage from unwanted folds in zigzag-folded cardboard.
Innovation Solution
A method and apparatus that use image processing and computer systems to analyze the arrangement of items, suggest optimal orientations and positions, and provide feedback to operators to modify arrangements for efficient automated packaging, avoiding unwanted folds and optimizing cardboard usage without requiring manual preparation steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual preparation and imaging of individual items is performed to obtain size information, then packaging optimization can be achieved, but the packaging process speed decreases
Solution Approach 1:
The patent replaces manual preparation and imaging operations with an automated optical imaging system that captures images of items on the conveyor belt and automatically processes size information through computer algorithms, eliminating the need for manual measurement and data entry while maintaining packaging optimization
Solution Approach 2:
The system enables self-service by automatically capturing item images, processing size information, and generating packaging recommendations without requiring operator intervention for measurement and data collection, allowing the packaging process to proceed at full speed while still achieving optimization
2Adaptability or versatility
If zigzag folded cardboard is used to create custom sized boxes, then box-making flexibility is improved, but unwanted folds may appear in the blanks causing damage or crashes
Solution Approach 1:
The system performs preliminary digital imaging and calculation of blank dimensions before the actual cutting and folding process, allowing the computer system to determine optimal blank sizes and positions that avoid unwanted folds from the zigzag folded cardboard, preventing damage before it occurs
Solution Approach 2:
The imaging system provides feedback on item dimensions and arrangement, allowing the computer system to calculate and adjust blank positions and sizes to avoid unwanted folds, creating a closed-loop control system that prevents damage while maintaining box-making flexibility
3Object-affected harmful factors
If the maximum blank size is limited by the distance between folds in zigzag folded cardboard, then unwanted folds are avoided, but waste material increases
Solution Approach 1:
The system dynamically adjusts blank dimensions and positions based on real-time imaging data and item arrangements, allowing optimal utilization of the cardboard web between folds while minimizing waste, rather than using fixed conservative size limits
Solution Approach 2:
The computer system calculates and changes blank parameters (size, position, orientation) based on imaging data to maximize material utilization within the constraints of the zigzag fold spacing, reducing waste while avoiding unwanted folds
Data Source
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AI summary
An apparatus for optimizing automated packaging of a shipment set, said shipment set comprising one or more items (88, 90) arranged in an arrangement for being automatically packaged, the apparatus comprising at least one image obtaining device (94) for obtaining three-dimensional image data of said arrangement and at least one computer system and a signaling device (96), the computer system adapted for processing said image data to obtain information on the dimensions of individual items (88,90) present in said arrangement and on the orientation and position of said items in said arrangement, performing an analysis of said information with respect to at least one optimization criterion and depending on said analysis, generating signals indicating to either proceed with automated packaging of said arrangement or to modify or to divert said arrangement, and the signaling device (96) adapted for receiving the signals generated.