Optical Cutting of Package Sealing Elements

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Solution Overview

Problem

Manual opening of sealed packages in warehouse facilities is time-consuming, inefficient, and poses an injury risk due to the need for manual handling of cutting tools.

Innovation Solution

A cutting system utilizing optical radiation to cut, damage, or remove the sealing elements of packages, which includes an in-feed conveyor for package orientation, a cutting device with an optical radiation source, and a computing system for dynamic adjustment of cutting parameters to improve efficiency and reduce wear on equipment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual opening of packages is used, then workers have direct control over the opening process, but it is time-consuming and poses injury risk

Engineering Contradiction:
Improveworker safetyVSAvoidpackage opening speed
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The patent replaces manual mechanical cutting with an automated cutting system that uses a cutting tool guided by imaging devices and computing systems. This substitution eliminates worker exposure to cutting hazards while maintaining precise control over the cutting process, thereby improving safety without sacrificing productivity.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables packages to be opened automatically without human intervention in the critical cutting phase. The automated system performs the dangerous task itself, removing workers from harm's way while increasing processing speed through continuous operation capability.

Inventive Principle:
Principle #25Self-service

2Productivity

If automated cutting system is implemented, then processing speed increases and safety improves, but device complexity increases

Engineering Contradiction:
Improvepackage processing throughputVSAvoidcutting system complexity
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The imaging device serves multiple functions: it images the package for positioning, monitors the cutting process, and verifies cut quality. This multi-functionality reduces the need for separate systems for each task, thereby increasing productivity while limiting the growth of device complexity.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent combines the imaging, positioning, cutting, and verification functions into an integrated automated system. By merging these functions into a coordinated workflow controlled by a computing system, the patent achieves high throughput while managing complexity through systematic integration rather than separate independent systems.

Inventive Principle:
Principle #5Merging (Combining)

3Manufacturing precision

If optical radiation is used for cutting, then cutting precision and speed improve, but equipment wear and energy consumption increase

Engineering Contradiction:
Improvecut precisionVSAvoidoptical radiation energy consumption
Core Design Contradiction:
Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The system applies optical radiation only to the specific sealing element area that requires cutting, rather than treating the entire package. This partial action achieves the necessary cut precision while minimizing energy consumption by limiting the radiation application to only the required portion of the sealing element.

Inventive Principle:
Principle #16Partial or excessive action

Solution Approach 2:

The optical radiation is concentrated and applied locally to the sealing element with precise spatial control. This localized application ensures high cut precision at the target area while minimizing overall energy consumption by avoiding unnecessary radiation to surrounding areas.

Inventive Principle:
Principle #3Local quality

4Productivity

If dynamic adjustment of cutting parameters is implemented, then equipment wear reduces and throughput increases, but control system complexity increases

Engineering Contradiction:
Improveline throughputVSAvoidcontrol system complexity
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The imaging device provides real-time feedback on package position and cutting progress to the computing system. This feedback enables dynamic adjustment of cutting parameters such as tool position, speed, and optical radiation intensity, increasing throughput while managing complexity through closed-loop control that automatically adapts to varying conditions.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The cutting system transitions from static, pre-programmed parameters to dynamic, real-time parameter adjustment based on actual package characteristics and cutting progress. This dynamic control increases throughput by optimizing parameters for each specific cutting scenario while the computing system manages the complexity through automated decision-making algorithms.

Inventive Principle:
Principle #15Dynamics

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 enables faster and safer processing of packages by aligning and cutting sealing elements, reducing manual labor and equipment wear, while maintaining high throughput and minimizing line stoppages.

Implementation Method 1

The optical radiation source applies the optical radiation to cut, damage, ablate, remove, or pierce the sealing element (e.g., tape) on the package

Methodology Applied
Scientific EffectOptical radiation: Light

Data Source

PatentUS12172335B2Systems and methods for high throughput cutting of sealing elements on packages
Publication Date: 2024.12.24 WALMART APOLLO LLC
  • US12172335B2 patent drawing
  • US12172335B2 patent drawing
  • US12172335B2 patent drawing

AI summary

Systems and methods described herein are optimized for cutting sealing elements on packages using optical radiation. Packages can pass through a cutting device that applies the optical radiation to damage, vaporize, or cut the sealing element (e.g., tape) on the package. The systems and methods control several aspects of the cutting process to adjust throughput, improve efficiency, and reduce line stoppages. Systems can include an in-feed conveyor that orients packages and rejects packages that are out of specification, which can lead to issues such as jamming or damage to the equipment. Systems can include a variable-speed cut conveyor controlled by a computing system to dynamically adjust the speed of packages based upon historical cut quality, environmental measurement data, and height data related to a vertical dimension of the package.