Automated Dunnage Transfer via Alignment Reference Plane
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Solution Overview
Problem
Existing packaging systems require manual manipulation and alignment of dunnage products into packaging containers, which is inefficient and prone to errors, as operators need to ensure proper orientation and positioning to provide adequate protection during shipping.
Innovation Solution
A packaging system that uses sensors and a dunnage placement apparatus to align and orient dunnage products relative to packaging containers at an alignment reference plane, allowing for automated transfer without further manual intervention, utilizing a dunnage sensor to detect alignment, a package sensor to detect container alignment, and a controller to coordinate the transfer process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual manipulation is used to align and orient dunnage products, then flexibility and adaptability are maintained, but productivity is reduced and manual errors increase
Solution Approach 1:
The patent replaces manual mechanical manipulation with an automated mechanical transfer system. The dunnage placement apparatus uses sensors to detect the packaging container and automatically positions the dunnage product without manual intervention, thereby increasing productivity while maintaining precise alignment through mechanical guidance structures.
Solution Approach 2:
The system enables self-alignment through the alignment reference plane and sensor detection. The dunnage placement apparatus automatically detects container position and adjusts dunnage product placement accordingly, allowing the system to self-regulate without human input while maintaining high productivity.
2Manufacturing precision
If manual alignment is performed by operators, then positioning accuracy can be adjusted, but time consumption increases and consistency decreases
Solution Approach 1:
The alignment reference plane is pre-established to define the correct alignment position. Sensors detect when the packaging container reaches this pre-defined alignment position, eliminating the need for manual alignment adjustments and reducing transfer time while maintaining consistent precision.
Solution Approach 2:
Sensors provide real-time feedback on the packaging container's position relative to the alignment reference plane. This feedback mechanism ensures precise alignment by automatically detecting and responding to positional variations, maintaining manufacturing precision without increasing transfer time.
3Productivity
If automated transfer is implemented without alignment reference, then productivity increases, but alignment precision deteriorates
Solution Approach 1:
The alignment reference plane serves as an intermediary between the automated transfer system and the packaging container. It provides a fixed reference that guides the automated placement apparatus to achieve precise alignment and orientation without sacrificing transfer speed or requiring manual intervention.
Data Source
AI summary
A packaging system for transferring a dunnage product to a packaging container includes a dunnage sensor configured to detect the dunnage product registered at an alignment reference plane in a staging location. The packaging system also includes a package sensor configured to detect the packaging container registered at the alignment reference plane in a loading location. A dunnage placement apparatus is configured to transfer the dunnage product from the staging location to the packaging container in the loading location after both the dunnage sensor detects the dunnage product registered at the alignment reference plane in the staging location and the package sensor detects the packaging container registered at the alignment reference plane in the loading location.