Case Handling Conveyor With Moving Sensor Seal Verification
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Automated packing systems face issues with improperly sealed cases and misapplied labels, leading to spills during shipping and palletizing, and struggle to handle randomly sized cases effectively.
Innovation Solution
An automated case handling system with a programmable CPU control unit, a self-contained conveyor, and sensors to determine case dimensions and verify sealing and labeling, capable of applying labels and redirecting improperly sealed cases, which can be easily integrated into existing systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If automated packing systems are used to handle randomly sized cases, then productivity and automation extent are improved, but the system cannot properly detect and verify sealing and labeling on varying case dimensions
Solution Approach 1:
The patent employs a movable sensor support that can dynamically adjust its position along the case length, combined with a first sensor that determines case dimensions and communicates this information to control the sensor support movement. This dynamic adjustment allows the second sensor to accurately detect sealing and labeling on cases of varying dimensions, resolving the contradiction between automation and measurement precision.
Solution Approach 2:
The system implements feedback through the first sensor that determines case dimensions and communicates this information to the control unit, which then controls the movement of the movable sensor support. This feedback loop ensures that the detection system adapts to each case's specific dimensions, maintaining measurement precision while handling randomly sized cases in an automated manner.
2Device complexity
If fixed sensor positions are used in automated packing systems, then device complexity is reduced, but the system cannot handle randomly sized cases effectively
Solution Approach 1:
Instead of using multiple fixed sensors for different case sizes, the patent employs a single movable sensor support that can be dynamically repositioned based on the actual case dimensions detected by the first sensor. This dynamic approach reduces device complexity compared to having multiple fixed sensor arrays while maintaining the ability to handle randomly sized cases.
Solution Approach 2:
The movable sensor support serves multiple functions by being repositionable to detect sealing and labeling on cases of any size. This universal detection mechanism eliminates the need for size-specific fixed sensor arrangements, reducing overall system complexity while enhancing adaptability to handle various case dimensions.
3Measurement precision
If manual inspection of sealed cases and labels is performed, then measurement precision for detection is improved, but productivity and automation extent deteriorate
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated optical sensing system. The second sensor on the movable sensor support detects sealing and labeling automatically as cases pass through, while the first sensor determines case dimensions. This substitution maintains high detection precision equivalent to manual inspection while dramatically increasing productivity by eliminating manual intervention in the automated packing line.
Solution Approach 2:
The system performs self-inspection through the integrated sensor arrangement where the first sensor automatically determines case dimensions and the second sensor automatically detects sealing and labeling quality. This self-service detection mechanism eliminates the need for manual inspection while maintaining high measurement precision, thereby preserving both productivity and detection accuracy in the automated system.
Data Source
AI summary
The present invention provides an automated case handling system and method. The automated case handling system can determine the existence of a proper seal on a case, the location of a label or other criteria or place a label or other information on a case. It can be a self-contained unit that can be easily inserted into an existing case handling line. To facilitate easy installation, the disclosed embodiment is powered by electricity and can be configured to plug into a single power source. The automated case handling system has a control unit for controlling the operation. A first sensor determines the dimensions of a case. A second sensor is mounted on the moveable sensor support. The second sensor senses predetermined criteria on a case as the second sensor is moved along a case. The second sensor provides a detection signal to the control unit as to the existence of the predetermined criteria on a case. The detection signal gives a go authorization to the control unit to release a case or a no-go to redirect the case along a secondary travel path.