Carton Handling with Vacuum Mover and Flange Design
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Solution Overview
Problem
Robotic systems in warehousing and order fulfillment face challenges with tracking and handling of products due to a lack of common tracking identifiers and difficulties with flexible, environmentally friendly packaging materials that are troublesome for robotic handling.
Innovation Solution
A carton-handling and order fulfillment system comprising a pre-formed, open-topped carton with outwardly folded flanges and a mover with a vacuum system for secure transport, along with a lidding operation for sealing, using a carton and lid with adhesive for easy verification and tracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If robotic systems are used for automated handling, then productivity and automation extent are improved, but tracking and traceability of products become more difficult
Solution Approach 1:
The patent places a tracking identifier (such as an RFID tag or barcode) inside or on the product packaging, which is then nested within the carton. The mover carries the carton containing the tracked product, creating a nested structure where tracking information is preserved through multiple handling levels without requiring external monitoring at each stage.
Solution Approach 2:
The patent creates a digital copy or representation of the product's tracking information that travels with the physical product through the automated system. Scanners and sensors capture and transmit this information through the control system, maintaining a digital twin of the product's location and status throughout the automated handling process.
2Object-affected harmful factors
If environmentally friendly packaging materials are used, then harmful factors are reduced, but ease of operation by robotic systems deteriorates
Solution Approach 1:
The patent modifies the physical parameters of the packaging material by adding rigid flanges to the carton structure. These flanges change the mechanical properties of the packaging, providing robotic grippers with secure contact points while maintaining the use of environmentally friendly base materials such as recycled paper or biodegradable materials.
Solution Approach 2:
The patent segments the packaging structure into distinct functional elements: the main carton body made of environmentally friendly material, and separate rigid flanges that extend from the carton edges. This segmentation allows the eco-friendly material to be used for the bulk of the packaging while adding minimal structural components that enable robotic handling.
3Object-affected harmful factors
If thin and flexible packaging materials are used, then environmental safety is improved, but reliability of robotic retention deteriorates
Solution Approach 1:
The patent changes the structural parameters of the packaging by adding thick, rigid flanges that extend outward from the carton edges. These flanges provide robust mechanical features that robotic vacuum systems can reliably grip and retain, while the main body of the carton can still use thin, flexible, and environmentally friendly materials.
Solution Approach 2:
The patent creates a composite packaging structure combining different material properties: the main carton body uses thin, flexible, environmentally friendly material for resource efficiency, while the flanges use stiffer, more rigid material (possibly the same base material but with added structural reinforcement) to provide reliable mechanical engagement with robotic handling systems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient tracking and handling of products through secure carton retention and verification, facilitating the use of environmentally friendly packaging while accommodating various conveyance systems and manual or automated loading.
Implementation Method 1
The bellows are compressed to reduce a volume of the system and then expanded to draw a partial vacuum which applies a suction force between the suction cups and the flanges of the carton. The carton is thereby retained within the mover by the suction force.
Data Source
AI summary
An order fulfillment system is described that includes a carton and a mover configured to carry the carton throughout the system. The carton is a preformed, five-sided container with flanges extending outwardly from edges thereof. The mover includes a depression in a top surface thereof that nestably receives the carton therein. The mover may include a vacuum system to aid retention of the carton therein. The mover and carton may include indicia to enable identification and tracking thereof throughout the fulfillment process. A lidding process applies a lid that is adhered to the flanges of the carton and includes identifying indicia thereon. The system provides identification and verification of items placed in the carton and can be easily integrated into existing manual and automated fulfillment systems. A manual system allows a user to manually pick and load cartons and attach a carton lid via an adhesive.