Dynamic Carton Sizing via Optical Measurement and Adaptive Cutting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing container sizing methods are inadequate for made-to-order packaging applications, as they either result in waste due to fixed carton sizes, require bespoke blanks, or are suited for short production runs with varying contents, leading to inefficient shipping costs and material usage.
Innovation Solution
A container sizing system comprising a frame, controller, cutters, markers, and measuring means that dynamically adjusts the size of cartons by determining the footprint and height of contents, allowing for precise cutting and creasing of vertical edges and walls to create foldable panels, enabling flexible adaptation to different container sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a single carton blank size is used and modified by cutting to suit contents, then material waste increases, but device complexity remains low
Solution Approach 1:
The system dynamically adjusts carton dimensions by measuring actual content size and controlling cutting/creasing operations in real-time, transforming a static single-size carton approach into a dynamic adaptive system that minimizes waste while maintaining operational simplicity
Solution Approach 2:
The patent replaces manual measurement and marking operations with an automated optical measurement system and controller that precisely determines carton dimensions and directs cutting/creasing operations, reducing material waste through accurate sizing without significantly increasing device complexity
2Adaptability or versatility
If multiple fold lines are added to upper panels for height adjustment, then adaptability increases, but carton erection and closure reliability deteriorates
Solution Approach 1:
Instead of providing multiple static fold lines, the system dynamically creates the appropriate number and position of fold lines based on measured content height, ensuring reliable carton closure while maintaining adaptability to different package sizes
Solution Approach 2:
The system changes the parameters of fold line configuration (number, position, depth) based on the measured content dimensions, optimizing both adaptability and closure reliability for each specific packaging scenario rather than using fixed multiple fold lines
3Adaptability or versatility
If bespoke carton blanks are manufactured for different sizes, then adaptability improves, but manufacturing cost increases
Solution Approach 1:
The system enables a single carton blank design to dynamically adapt to different package sizes through automated measurement and selective cutting/creasing operations, eliminating the need for multiple bespoke blank designs while maintaining full size adaptability
Solution Approach 2:
The patent makes a universal carton blank design serve multiple functions by programmatically adjusting cut and crease positions based on content size, replacing the need for multiple specialized blank designs and reducing manufacturing complexity and cost
4Productivity
If cartons are creased before erection based on known content configuration, then productivity increases for short runs, but adaptability to made-to-order packages decreases
Solution Approach 1:
The system performs preliminary measurement of content dimensions before carton erection and uses this information to pre-program the cutting and creasing operations, enabling fast execution similar to pre-creased systems while maintaining adaptability to any content configuration through automated measurement
Solution Approach 2:
The patent replaces the need for pre-stacked content configurations with an optical measurement system that automatically determines content dimensions, enabling made-to-order adaptability while maintaining high productivity through automated control of cutting and creasing operations
Data Source
AI summary
A carton sizing system that has a frame, a controller, one or more cutters movably mounted to the frame and operatively connected to the controller, one or more markers movably mounted to the frame and operatively connected to the controller. The carton sizing system also has a measuring means that is operatively connected to the controller and configured to determine, in use, the footprint of an open top carton and to determine the height of one or more objects contained within the carton. The controller is configured to position the one or more cutters based on the determined footprint and to cut vertical edges of the carton based on the determined height and also to position the one or more markers based on the determined footprint and height and to score or crease vertical walls of the carton between the vertical edges to at least partially define foldable panels.