Flowable Dunnage Dispenser with Variable Aperture Shutter
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Solution Overview
Problem
Current dunnage dispensing systems face challenges in accurately filling containers, often resulting in over-filling or under-filling, which can lead to damage during shipment, and existing automation solutions are complex and costly due to the need for void volume measurement or recirculation systems.
Innovation Solution
A system with a variable size outlet and shutter mechanism that automatically dispenses flowable dunnage into a container without measuring the void volume, using sensors to control the aperture size and position for precise filling, and includes a wiper to remove excess dunnage, allowing for efficient and accurate filling without operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a packer manually dispenses dunnage and observes the container filling process, then the packer can control the filling process, but the packer may over-fill or under-fill the container leading to improper protection
Solution Approach 1:
The system enables self-service filling by using sensors to automatically detect container fill level and control the dunnage dispenser, eliminating the need for manual observation and control while ensuring proper filling accuracy
Solution Approach 2:
The system implements feedback control by using sensors to continuously monitor the container fill level and adjust the dispensing process accordingly, preventing both over-filling and under-filling
2Productivity
If the dispenser speed is increased to improve productivity, then more containers can be filled faster, but over-filling and under-filling problems become more severe
Solution Approach 1:
The system uses sensors to provide real-time feedback on container fill level, enabling the control system to adjust dispensing speed and amount dynamically, maintaining filling accuracy even at high dispensing speeds
Solution Approach 2:
The system replaces manual mechanical observation and control with automated sensor-based detection and control systems, enabling precise filling control at higher speeds
3Reliability
If a probe-based system is used to sense void volume and control dunnage dispensing, then filling accuracy can be improved, but the system complexity and expense increase significantly
Solution Approach 1:
The system extracts and simplifies the essential function of void detection by using simple sensors to detect container fill level rather than complex probe-based void volume measurement systems, reducing overall system complexity
Solution Approach 2:
The system uses simple, inexpensive sensors to detect fill level rather than expensive complex probe systems, achieving adequate accuracy without significant cost increase
4Loss of substance
If a recirculation system is used to remove excess dunnage and reuse it, then material utilization improves, but system complexity and cost increase
Solution Approach 1:
The system intentionally dispenses slightly more dunnage than the minimum required (excessive action) to ensure adequate protection, eliminating the need for complex recirculation systems to recover and reuse material
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system ensures proper filling of containers with dunnage, preventing damage by eliminating the need for void volume measurement and recirculation systems, thereby reducing complexity and cost while maintaining efficient operation.
Implementation Method 1
a shutter for opening and closing the outlet. The extent to which the shutter opens can be varied to define the variable size outlet when open
Implementation Method 2
a wiper for removing excess dunnage from the container
Data Source
AI summary
A system (10) for dispensing dunnage material includes a chute (30) connectable to a supply (20, 40) of flowable dunnage. A container (12) or a bottom of the chute (30) is moved into a dispensing position where the bottom of the chute (30) is proximate the fill plane of the container (12). A controller (16) selectively opens a shutter (50) at the bottom of the chute (30) to dispense dunnage and then closes the shutter (50) to separate the dispensed dunnage from the dunnage in the chute (30) while also removing the dunnage above the fill plane of the container (12). The chute (30) includes at least one substantially horizontal plate member (54) that is openable to selectively vary the size of an aperture (52) created thereby at the bottom of the chute (30) for dispensing dunnage material therethrough.