Custom Box Forming for Accurate Variable Shipment Packaging
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Solution Overview
Problem
Existing packaging systems for varying shipment sets face challenges in creating custom-sized boxes, leading to inefficiencies such as wasted materials, increased postage, and incorrect packaging due to outdated database information and issues with pre-folded boxes having open sides, which can cause items to fall or roll out.
Innovation Solution
A system comprising a control unit that receives information from a database and acquires current information on items to calculate custom-sized box dimensions, using a box forming station to create boxes with an open top and side walls, and a packaging station to arrange items, with a lid placing station for closure, ensuring accurate verification of the shipment set and minimizing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pre-folded boxes with open sides are used for packaging, then packaging speed is improved, but items may fall or roll out of the box
Solution Approach 1:
The box is pre-folded with side panels erected before packaging, preparing the containment structure in advance. The open top design allows easy item placement while the pre-erected side panels provide immediate lateral containment to prevent items from falling or rolling out during the packaging process.
2Volume of stationary object
If custom-sized boxes are created from cardboard rolls, then packaging volume is optimized, but process time increases
Solution Approach 1:
Cardboard blanks are pre-cut and pre-creased into various box size configurations and stored ready for use. When packaging is needed, the appropriate pre-prepared blank is selected and quickly folded, eliminating the time-consuming steps of measuring, cutting, and creasing during the actual packaging process.
Solution Approach 2:
The system uses multiple pre-cut cardboard blanks in different sizes, each optimized for specific packaging volumes. This segmentation allows the packaging system to quickly select the most appropriate pre-prepared blank for the items being packaged, rather than creating a custom size each time.
3Extent of automation
If database information is used to determine box size, then packaging automation is improved, but outdated information leads to incorrect packaging
Solution Approach 1:
The system incorporates feedback mechanisms to verify and update database information. When items are scanned or identified during the packaging process, the system can cross-check dimensions against the database and make real-time adjustments, ensuring that even if database information is outdated, the packaging decisions are based on accurate, current data.
Data Source
AI summary
A system for automating packaging of varying shipment sets comprises a control unit for receiving from a database stored information on the size and number of items forming a shipment set according to a dispatch order, an information acquiring device for acquiring current information on the items being actually arranged for said shipment set, said information acquiring device being communicatively coupled with said control unit and said control unit being configured to calculate, either based on the information from said database or from the information acquiring device, the dimensions of a custom sized cardboard box for packaging the shipment set, a box forming station for forming said custom sized cardboard box having a bottom wall, four side walls and an open top, a packaging station for packaging the items forming the shipment set into said custom sized cardboard box, and a lid placing station for closing said custom sized cardboard box with an appropriate lid, wherein said control unit is configured for performing a verification using the current information from said information acquiring device and the stored information from said database to verify that the actual shipment set is formed according to the dispatch order.