Custom Container Stacking via Volume Correction
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Solution Overview
Problem
In materials handling facilities, optimizing the picking and stacking of items for shipping is challenging due to the need for stable container configurations that maximize space utilization and minimize labor and shipping costs, while ensuring product safety and structural stability.
Innovation Solution
A packaging information system that includes a planning service, product dimension estimator, container recommendation service, and stacking engine to plan stable stacking configurations for containers, recommending the use of custom or standard containers based on item dimensions and shipping requirements, and utilizing custom container forming devices to create optimal container sizes for efficient stacking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If containers are stacked to maximize space utilization, then storage capacity increases, but structural stability may be compromised
Solution Approach 1:
The stacking engine plans the complete stacking configuration in advance before physical stacking occurs. It determines the optimal arrangement of containers on transportation units, considering stability requirements and space utilization, and provides sequencing instructions to guide the stacking process in the correct order, preventing structural issues before they arise
Solution Approach 2:
The system dynamically adjusts stacking configurations based on real-time factors such as container dimensions, weights, and destination requirements. The stacking engine can modify the planned configuration as containers are added or removed, maintaining structural stability while maximizing space utilization throughout the stacking process
2Quantity of substance
If custom containers are created to optimize stacking configurations, then space utilization improves, but device complexity increases
Solution Approach 1:
The system modifies container dimension parameters to create custom containers that optimize stacking configurations. By adjusting length, width, and height parameters of containers based on the planned stacking arrangement, the system achieves better space utilization while managing complexity through automated parameter optimization
Solution Approach 2:
The patent replaces manual container creation and stacking processes with an automated information system that includes a stacking engine and custom container forming device. This substitution of mechanical/manual operations with automated systems reduces operational complexity while improving space utilization through optimized configurations
3Reliability
If containers are stacked in a stable configuration, then product safety improves, but labor costs increase due to additional planning and sequencing
Solution Approach 1:
The stacking engine automatically plans stacking configurations and generates sequencing instructions without requiring manual intervention. The system serves itself by autonomously determining optimal arrangements, container assignments, and stacking sequences, reducing labor requirements while maintaining product safety through stable configurations
Solution Approach 2:
The system incorporates feedback mechanisms where the stacking engine receives information about container characteristics, transportation unit constraints, and stacking progress, then adjusts the planned configuration accordingly. This feedback loop ensures product safety is maintained while optimizing the stacking process to reduce labor costs
Data Source
AI summary
The disclosure describes, in part, a system and method for improving the stacking of containers on or in a transportation unit. In some implementations, a stacking configuration may be planned that identifies containers and a position for those containers in the stacking configuration. As part of the planning, a volume correction may be identified that if corrected would improve the stability of the stacking configuration. A planned custom container may also be identified and one or more dimension values of the planned custom container modified based on the volume correction. The modified planned custom container may be added to the planned stacking configuration to improve the stability of the stacking configuration.