Continuous Tape Packaging for Variable-Size Item Streams
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Solution Overview
Problem
Existing packaging solutions are not adapted for efficiently packaging items of varying sizes, leading to frequent changeovers and inefficiencies, particularly in low-volume production runs, and do not facilitate automated layered palletization.
Innovation Solution
A system and method for continuous packaging of items with varying dimensions using packing tapes supplied vertically, featuring a belt conveyor, positioning module, stabilization module, and a joining module, with adaptable materials and minimal operator intervention, enabling automated and efficient packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If bulk trusses are used to position products, then products can be positioned in free spaces, but automation for layered palletization is not facilitated
Solution Approach 1:
The patent replaces bulk trusses with a robotic system that uses vision guidance and automated manipulation to position individual items. The robot picks items from a supply container and places them in target locations on the pallet, eliminating the need for mechanical bulk positioning structures while enabling full automation of the palletization process
Solution Approach 2:
The system uses vision sensors to automatically detect and locate items in the supply container and on the pallet, allowing the robot to self-correct its positioning without human intervention. The vision system provides real-time feedback that enables the robot to adapt to item variations and maintain precise placement accuracy throughout operation
2Manufacturing precision
If packaging equipment is designed for specific product sizes, then packaging precision is improved, but changeovers require frequent re-equipment
Solution Approach 1:
The robotic system dynamically adjusts its motion paths, gripper positions, and packaging material application based on real-time vision feedback about item dimensions and orientation. This dynamic adaptability allows the same equipment to precisely package items of varying sizes without requiring physical reconfiguration or changeovers
Solution Approach 2:
The robot is designed with a universal end-effector and programmable control that enables it to handle multiple item types, sizes, and packaging configurations through software reconfiguration rather than physical re-equipment. The system can switch between different packaging patterns and material applications by loading new programs, making it universally applicable to various product lines
3Manufacturing precision
If items are packaged individually with strict positioning, then packaging accuracy is improved, but automation becomes more complex
Solution Approach 1:
The vision system serves as an intermediary between the robot and the items, providing accurate spatial information about item locations, orientations, and dimensions. This visual feedback mechanism enables the robot to achieve high positioning accuracy without requiring complex mechanical positioning structures, sensors, or control systems directly on the packaging equipment
Data Source
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AI summary
A system for unitary packaging of a stream of individual items (101) moved on a belt conveyor (110), characterized in that it comprises: at least two packing tape feeders (130) configured to provide at least one packing tape (131) along each side of the stream of the items (101); an item position stabilization module (140) configured to hold still the frontmost individual item (101) of the stream of items (101) to be packaged as it is surrounded on the sides by the packing tapes (131); a packing tape joining module (150) for joining the packing tapes (131) in a position between the item (101) held by the item position stabilization module (140) and its adjacent item (101) downstream; and a controller (102) configured to coordinate the operation of the system.