Real-Time Custom Packaging System for Variable-Shape Articles
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Solution Overview
Problem
Existing packaging systems in fulfillment centers often use standard-sized packaging, leading to inefficiencies such as larger-than-needed boxes, increased use of filler materials, and higher resource consumption, resulting in waste and environmental impact.
Innovation Solution
A system and method for automatically forming article-size-appropriate packaging in real time using a fully recyclable packaging material, which is customized to the specific dimensions and shape of each article through data gathered by a detecting device as the article moves along a conveyor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If standard-sized packaging is used, then packaging availability is improved, but packaging size optimization deteriorates
Solution Approach 1:
The packaging system transitions from static standard-sized boxes to a dynamic packaging solution where the box size is continuously adjusted to match the actual article dimensions. The conveyor system moves articles past a packaging material source while a forming mechanism creates custom-sized packages in real-time, making packaging size adaptive rather than fixed.
Solution Approach 2:
The system changes the packaging parameter from fixed standard dimensions to variable dimensions that are calculated based on the specific article being packaged. The detecting device measures article dimensions, and the forming mechanism uses these parameters to create packaging that precisely fits each article, optimizing volume while maintaining availability through real-time formation.
2Reliability
If larger packaging is used, then article protection is improved, but resource consumption deteriorates
Solution Approach 1:
Instead of using uniformly large packaging for all articles, the system applies packaging material locally and precisely where needed. The forming mechanism creates packaging structures that conform to the specific shape and size of each article, providing protection only in the areas required by the article's geometry, thereby reducing overall material consumption.
Solution Approach 2:
The packaging system is self-adjusting, using detecting devices to measure article dimensions and automatically configuring the forming mechanism to create appropriately-sized packaging. This self-service approach eliminates the need for manual intervention or pre-programmed standard sizes, allowing the system to optimize packaging for each article independently.
3Reliability
If filler materials are added, then article protection is improved, but packaging complexity deteriorates
Solution Approach 1:
The system performs preliminary measurement of the article dimensions using detecting devices before the packaging is formed. This advance detection allows the forming mechanism to calculate and create the precise packaging shape needed, eliminating the need for subsequent filler materials to fill gaps or provide protection, thereby simplifying the overall packaging process.
4Volume of moving object
If custom packaging is formed in real-time, then packaging optimization is improved, but manufacturing complexity deteriorates
Solution Approach 1:
The packaging system is divided into separate functional modules: a detecting device that measures article dimensions, a control system that calculates required packaging size, and a forming mechanism that physically creates the package. This segmentation allows each component to be optimized independently while working together to achieve real-time custom packaging formation.
Data Source
AI summary
A system, apparatus, and method for automatically packaging one or more articles is disclosed. The system, apparatus, and method processes incoming articles having different and/or similar shapes and in random orientations for packaging. The system, apparatus, and method form shipping-ready customized packages, based, at least in part, on data associated with an individual article and gathered by a detecting device as the individual article moves along a first conveyor towards a packaging station of the system. The customized packages are configured to conform to each individual article's shape and size. The packaging preferably is fully recyclable and is made from paper which is expandable to create a cushioning layer around the packaged article.