Custom Shipping Container Automation for Mixed-Item Box Sizing
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Solution Overview
Problem
Fulfillment centers face inefficiencies in processing and packaging orders due to the complexity of handling various items with different packaging types, leading to increased waste, environmental impact, and reduced throughput.
Innovation Solution
The implementation of automated custom shipping containers that use robotic systems to determine custom box dimensions and packing sequences, optimizing packing density and reducing material usage through synchronized processes and on-demand box generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated robotic systems are used to handle packages, then processing efficiency is improved, but the ability to handle various packaging types with different dimensions is reduced
Solution Approach 1:
The system dynamically adjusts robotic gripper force and positioning based on real-time detection of package dimensions, weight, and shape. The robotic system transitions from static pre-programmed handling to dynamic adaptive handling, allowing it to efficiently process diverse packaging types while maintaining high throughput speeds.
Solution Approach 2:
The system changes operational parameters (gripper force, speed, positioning coordinates) based on detected package characteristics. Sensors detect package parameters and the control system adjusts robotic operation parameters in real-time, enabling the automated system to handle various packaging types effectively.
2Productivity
If standard shipping containers are used, then packaging speed is improved, but material waste increases due to poor fit
Solution Approach 1:
The system performs preliminary detection of package dimensions before selecting and preparing the shipping container. By measuring package characteristics in advance and pre-calculating the optimal container size, the system avoids material waste while maintaining fast packaging speeds, as the correct container is ready before the packaging operation begins.
Solution Approach 2:
The system dynamically selects container size parameters based on detected package dimensions. Instead of using fixed standard container sizes, the system adjusts container parameter selection (length, width, height) to match the actual package dimensions, minimizing empty space and material waste while maintaining efficient packaging throughput.
3Adaptability or versatility
If manual packing operations are used, then adaptability to different items is improved, but processing speed is reduced
Solution Approach 1:
The automated system performs self-detection and self-adjustment for each package. Sensors automatically detect package characteristics, and the control system autonomously determines optimal handling parameters and container selection, eliminating the need for manual intervention while maintaining adaptability to different item types at high processing speeds.
4Productivity
If pre-manufactured containers are used, then container availability is improved, but customization to package dimensions is reduced
Solution Approach 1:
The system uses a universal container platform that can be quickly reconfigured for different package sizes. Instead of maintaining separate pre-manufactured containers for each size, the system employs adjustable container frames or expandable container designs that can adapt to various dimensions, providing both availability and customization benefits.
Data Source
AI summary
Systems, methods, and computer-readable media are disclosed for automated custom shipping containers. In one embodiment, an example system may include a depth camera, a first robotic arm configured to grasp objects, a box making machine configured to generate boxes, and a computer system. The computer system may be configured to determine a depth map of a first object and a second object using the depth camera, determine a first dimension of the first object, determine a second dimension of the second object, and determine a first box dimension for a box in which the first object and the second object are to be placed using the first dimension and the second dimension. The computer system may be configured to cause the box making machine to produce the box, and cause the first robotic arm to place the first object and the second object into the box.