Automated Cushioning Filling via Sensor-Based Space Analysis
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Solution Overview
Problem
Conventional cushioning member filling in boxes is labor-intensive, skill-dependent, and prone to errors, leading to inefficient packing and potential damage to goods due to subjective worker determination, with existing systems lacking automation and using environmentally harmful materials.
Innovation Solution
A cushioning member filling apparatus and method that utilizes sensors to analyze box and loading space information, a controller to determine cushioning member sizes, numbers, and positions, and automated makers and fillers to precisely fill eco-friendly cushioning members into the remaining space of a box.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual operation by workers is used to fill cushioning members, then flexibility and adaptability are maintained, but productivity is limited and manufacturing precision deteriorates due to skill deviation
Solution Approach 1:
The system performs self-measurement of box dimensions and self-calculation of cushioning member requirements, eliminating the need for manual assessment while maintaining adaptability to different box sizes and configurations
Solution Approach 2:
Manual mechanical operations are replaced with an automated system combining optical sensors, controllers, and robotic filling mechanisms, thereby increasing productivity while maintaining precision through computational algorithms
2Adaptability or versatility
If manual operation by workers is used to fill cushioning members, then adaptability to different situations is maintained, but manufacturing precision deteriorates due to subjective determination
Solution Approach 1:
The system continuously measures the actual box dimensions and loading state, then adjusts the cushioning member filling plan accordingly, ensuring precise fitting while adapting to variations in box size and goods configuration
Solution Approach 2:
Subjective human judgment is replaced with objective sensor-based measurement and algorithmic calculation, eliminating variability due to worker skill levels while maintaining adaptability through programmable logic
3Reliability
If excessive number of cushioning members are filled into the box, then reliability of goods protection is improved, but productivity deteriorates due to increased material usage and difficulty in sealing
Solution Approach 1:
The system calculates and fills only the precise number of cushioning members needed to fill remaining spaces, avoiding both insufficient protection and excessive material usage, thereby optimizing the balance between protection and efficiency
Solution Approach 2:
The system dynamically adjusts the number, size, and placement of cushioning members based on measured box dimensions and loading configurations, ensuring optimal protection with minimal material usage
Data Source
AI summary
Disclosed is a cushioning member filling apparatus and method. The cushioning member filling apparatus according to the present invention may include: a sensor module for acquiring box space information having first space information about the entire space of a box with a set of goods loaded therein and second space information about a loading space occupied by the set of goods in the entire space of the box; a controller for producing a cushioning member making schedule and a cushioning member filling schedule according to the acquired box space information; a cushioning member maker for making cushioning members to be filled into the box according to the cushioning member making schedule; and a cushioning member filler for picking up the cushioning members received from the cushioning member maker and filling the cushioning members into the box according to the cushioning member filling schedule.