Automated Packaging Apparatus with Geometric Void Detection
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Solution Overview
Problem
Current packaging technologies, especially foam-in-place systems, rely heavily on manual estimation and insertion of packaging materials, leading to inefficiencies, material waste, and reduced productivity due to the need for skilled operators to calculate and place the correct volume and shape of packaging materials within containers to effectively protect articles during shipping.
Innovation Solution
An automated apparatus and method that uses sensors and processing means to detect the geometric shape of containers and articles, calculate the necessary packaging material volume, and determine the optimal dispensing and insertion modality, allowing for precise and efficient automated dispensing and insertion of packaging materials, including foam-in-place bags or loose fill products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual estimation and insertion of packaging materials is used, then the process is simple and flexible, but productivity is reduced and material waste increases
Solution Approach 1:
The system automatically detects void space geometry and calculates optimal packaging material parameters without human intervention. The machine serves itself by autonomously determining bag dimensions, foam expansion ratios, and insertion strategies based on real-time container scanning data, eliminating the need for skilled operators to manually estimate and calculate packaging requirements.
Solution Approach 2:
Manual mechanical estimation and insertion operations are replaced by an automated system combining optical/geometric scanning, computational algorithms, and automated dispensing mechanisms. The system substitutes human cognitive and manual labor with sensor-based detection and algorithmic processing to determine packaging material specifications and control dispensing parameters.
2Manufacturing precision
If skilled operators manually calculate and place packaging materials, then material placement accuracy is improved, but labor costs increase and productivity decreases
Solution Approach 1:
The system incorporates real-time feedback loops where sensors continuously scan container and article geometry, the control unit processes this data to calculate optimal packaging parameters, and the dispensing mechanism adjusts its operation based on these calculations. This closed-loop feedback system ensures precise material placement while maintaining high throughput by automatically adapting to variations in container and article dimensions.
Solution Approach 2:
The system performs preliminary detection and calculation of void space geometry, bag dimensions, and foam expansion requirements before the actual packaging material dispensing occurs. This advance planning allows the system to pre-determine optimal insertion strategies and material quantities, ensuring accurate placement while maintaining continuous high-speed operation without manual intervention during the critical dispensing phase.
3Reliability
If foam-in-place systems are used, then packaging effectiveness is improved, but sensitivity to parameter settings increases leading to more waste
Solution Approach 1:
The system automatically determines optimal foam-in-place parameters including bag length, width, filling percentage, and expansion ratios based on detected void space geometry. The machine self-adjusts all critical parameters without requiring operator expertise or manual calculation, eliminating the sensitivity to parameter settings while maintaining packaging effectiveness through algorithmic optimization of foam expansion characteristics.
4Productivity
If automated dispensing is implemented, then productivity increases, but initial equipment complexity and cost increase
Solution Approach 1:
The automated packaging system is designed with multi-functional capabilities that allow a single integrated platform to handle various container types, article configurations, and packaging material forms (bags, loose fill, foam). The system's detection unit, control unit, and dispensing mechanism can adapt to different packaging scenarios without requiring separate specialized equipment, thereby increasing productivity while managing overall system complexity through consolidation of functions.
Data Source
AI summary
An apparatus, and the methods therefore, that automatically detects, elaborates and interprets the geometry of a container (2) and of one or more of the contained articles (3), and supplies and inserts, automatically, packaging material into the container in a suitable manner and amount. The apparatus comprises one or more sensors (6) for measuring the geometric profile of the container (2) and of the contained articles (3). The apparatus comprises in addition processing means (14) that acquire the measurement data of the geometric profile and elaborates packaging instructions. The apparatus comprises also devices for the dispensing (42) and insertion (43) of packaging material into the container (2). The apparatus can be equipped with a conveying device (4) for transporting the containers to the measuring sensor (6) and to the dispensing device (42) and insertion means (43) of the packaging material.