Autonomous Box Routing Between Modular Packaging Stations
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional end-of-line box processing systems require fixed conveyor systems, limiting flexibility in station placement, worker movement, and increasing processing delays due to the need for a predetermined path, which hampers reconfiguration and efficiency.
Innovation Solution
A packaging system utilizing autonomous mobile robots to transport boxes between modular, standalone end-of-line processing stations, controlled by a system controller to selectively direct boxes to required stations, bypassing unnecessary operations, and allowing flexible station placement and movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed conveyor system is used for end-of-line box processing, then the processing path is predetermined and stable, but flexibility in station placement and worker movement is limited
Solution Approach 1:
The system replaces static conveyor paths with dynamic autonomous mobile robots that can autonomously navigate and adapt their routes in real-time. The robots use onboard sensors and controllers to dynamically adjust their movement between processing stations, enabling flexible station placement without requiring fixed infrastructure.
Solution Approach 2:
The patent substitutes the mechanical conveyor system with autonomous mobile robots equipped with sensors and control systems. This replacement transitions from a rigid mechanical transmission system to a flexible intelligent navigation system, allowing stations to be placed anywhere within the workspace while maintaining efficient material flow.
2Productivity
If a fixed conveyor system with predetermined path is used, then system structure is simple, but processing delays occur due to inability to bypass unnecessary stations
Solution Approach 1:
The autonomous robots dynamically calculate and adjust their routes based on real-time processing requirements. When a box does not require processing at a particular station, the robot autonomously bypasses that station, optimizing the processing path and eliminating unnecessary waiting time that would occur in fixed conveyor systems.
Solution Approach 2:
The system enables selective skipping of processing stations based on the specific requirements of each box. The controller determines which stations can be bypassed and directs the autonomous vehicle to skip those stations, allowing the system to rush through unnecessary operations and maintain high processing speed.
3Adaptability or versatility
If modular standalone stations are used with autonomous vehicles, then reconfiguration is easier and flexibility improves, but system complexity increases
Solution Approach 1:
The system divides the processing system into modular standalone stations that can be independently positioned and configured. Each station operates as an independent unit that communicates with the central controller, allowing flexible reconfiguration of the processing line without affecting other stations. The autonomous vehicles serve as flexible connectors between these modular units.
Solution Approach 2:
The autonomous mobile robots serve multiple functions: they transport boxes between stations, navigate autonomously using onboard sensors, communicate with the central controller, and adapt their routes in real-time. This multi-functionality consolidates what would otherwise require separate systems, managing complexity while enabling flexible reconfiguration.
4Ease of operation
If fixed conveyor systems are used, then infrastructure requirements are minimal, but worker movement around and within the system is restricted
Solution Approach 1:
The patent replaces the fixed mechanical conveyor infrastructure with autonomous mobile robots that operate in open workspace. This substitution removes physical barriers and fixed pathways, creating an open environment where workers can move freely around and between stations while the robots autonomously handle material transport.
Data Source
AI summary
A packaging system for end-of-line box processing includes two or more end-of-line box processing stations each configured to perform one or more end-of-line processing operations, an autonomous vehicle, and a controller. The box processing stations include a supply of boxes, a product delivery station where objects to be shipped are placed in a box, and a sensor for detecting characteristics of the box and the objects in the box. The autonomous vehicle is configured to autonomously transport the box from the product delivery station to selected ones of the two or more box processing stations. The controller is in communication with the sensor and the autonomous vehicle, and is configured to selectively direct the autonomous vehicle to transport the box from the product delivery station to other selected ones of the two or more box processing stations, based at least in part on information from the sensor.