Container Packing System Layer Descriptors
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Solution Overview
Problem
Current methods for packing boxes into containers, such as the 3D-BPP, face challenges in accommodating practical constraints and often yield unrealistic solutions due to their complexity and computational intensity, limiting their effectiveness in commercial applications.
Innovation Solution
The method involves creating layer descriptors with optimized single-layer arrangements and packing efficiencies, applying basic and practical constraints, and generating ordered loading instructions to maximize packing efficiency, reducing the 3D-BPP to a series of 2D-BPPs and then using techniques like FFD for efficient multi-bin packing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex 3D-BPP algorithms are used to optimize packing arrangements, then packing efficiency is improved, but computational complexity and time requirements increase significantly
Solution Approach 1:
The patent segments the complex 3D packing problem into multiple simpler 2D bin packing problems by dividing the container into horizontal layers. Each layer is packed independently using 2D-BPP algorithms, which are computationally less intensive. This segmentation allows the system to achieve high packing efficiency while reducing computational complexity and processing time.
2Manufacturing precision
If traditional 3D-BPP methods are applied, then theoretical optimization is achieved, but practical constraints such as box orientation and stacking limitations cannot be accommodated
Solution Approach 1:
The patent applies local quality by allowing different packing rules and constraints to be applied to different layers. Each layer can have customized orientation requirements, stacking limitations, and practical constraints based on the specific boxes being packed. This enables the system to accommodate practical constraints while maintaining optimization, as each layer's packing strategy is tailored to its specific requirements rather than applying a uniform theoretical approach throughout.
3Loss of energy
If fewer containers are used through optimized packing, then transportation cost is reduced, but the complexity of determining optimal packing arrangements increases
Solution Approach 1:
The patent performs preliminary action by pre-calculating and storing optimal 2D packing patterns for different box configurations in a database. During actual packing operations, the system retrieves pre-computed solutions rather than performing complex real-time optimization. This allows the system to minimize container usage and transportation costs while significantly reducing the time required to determine packing arrangements, as the computationally intensive optimization work has already been done in advance.
Data Source
AI summary
A method for loading boxes in containers is provided. Characteristics of a set of containers having substantially equal dimensions are obtained. Characteristics of a plurality of boxes to be packed into one or more of the set of containers are obtained. A set of layer descriptors is created, each layer descriptor including a layer thickness, identifiers of boxes assigned to the layer, and a description of an arrangement of the boxes in the layer. Each of the boxes is assigned to a single layer descriptor. An optimized assignment of the layer descriptors to containers is determined. An ordered list of box loading instructions for each container is generated. The boxes are loaded in their assigned containers according to the ordered list for the container.