Flexible Container Sealing Defect Prevention via Optical Detection

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Solution Overview

Problem

Fulfillment centers face inefficiencies in processing and shipping orders due to the high volume of packages, with flexible containers like bubble wrap mailers being susceptible to damage during handling, leading to defects and potential damage to items inside.

Innovation Solution

Implementing a defect prevention system using camera and laser systems integrated into flexible container sealing systems to determine item size and position, preventing items too large or improperly placed from being sealed, thus reducing the risk of container damage and improving packing quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual packing is used to handle high volume orders, then processing speed can be maintained, but packing quality deteriorates and containers become defective

Engineering Contradiction:

Improveprocessing speedVSAvoidpacking quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent replaces manual mechanical packing operations with an automated system that uses camera imaging and laser measurement to detect item characteristics. The system automatically determines whether items fit within flexible containers and generates sealing instructions, eliminating the need for manual inspection while maintaining high packing quality standards.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables the flexible container sealing system to automatically assess item suitability for packaging without human intervention. The imaging and measurement systems allow the container itself to 'evaluate' whether it can properly contain the item, with the system self-regulating the sealing process based on detected dimensions and positioning.

Inventive Principle:

Principle #25Self-service

2Productivity

If automated sealing systems are implemented to increase productivity, then processing speed improves, but the ability to detect and prevent defects deteriorates

Engineering Contradiction:

Improveprocessing speedVSAvoiddefect detection capability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent replaces manual visual inspection with automated optical imaging systems (cameras) and laser measurement systems. These systems capture images and measurements of items placed in flexible containers, automatically analyzing whether items are properly positioned and sized for the container, thereby maintaining defect detection capability while enabling automated high-speed operation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system introduces an intermediary detection layer between item placement and container sealing. The camera and laser systems act as intermediaries that capture and analyze item characteristics, providing data to the control system that determines whether sealing should proceed, thus ensuring defect prevention without slowing down the automated process.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If items are quickly placed in flexible containers to maintain throughput, then processing efficiency improves, but the risk of container damage increases

Engineering Contradiction:

ImprovethroughputVSAvoidcontainer damage risk

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The system performs preliminary detection and assessment of item characteristics before the sealing operation. The camera and laser systems capture images and measurements in advance, allowing the control system to determine item suitability and positioning before the container is sealed, preventing damage while maintaining quick throughput.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system takes preliminary action to prevent container damage by detecting potential problems before sealing occurs. The imaging and measurement systems identify items that are too large or improperly positioned, and the control system prevents sealing of such containers, thereby counteracting the risk of damage before it can occur during the high-speed packing process.

Inventive Principle:

Principle #9Preliminary anti-action

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

Enhances packing quality, reduces the likelihood of container defects, increases processing speed, and improves throughput in fulfillment centers by ensuring items are safely packed in flexible containers.

Implementation Method 1

A camera system may be used to image the item placed into the flexible container

Methodology Applied

Scientific EffectImage capture: Photography

Implementation Method 2

A laser system may be used to determine whether the item is disposed within a predetermined distance of a front end of the flexible container

Methodology Applied

Scientific EffectLaser measurement: LIDAR

Data Source

PatentUS11365020B1Defect prevention for flexible container sealing systems

Publication Date: 2022.06.21 AMAZON TECH INC

AI summary

Systems, methods, and computer-readable media are disclosed for defect prevention for flexible container sealing systems. In one embodiment, an example flexible container sealing system may include a first camera configured to image an item disposed in a flexible container, a laser system configured to detect presence of items, a cutting assembly configured to cut a material that forms the flexible container, a sealing assembly configured to seal one or more ends of the flexible container, and a computer system configured to determine, using the first camera, a height of the item disposed in the flexible container.