Packaging Object Tracking Without Printed Marks
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Solution Overview
Problem
Existing packaging systems face challenges in efficiently tracking object locations within form-fill-seal machines, leading to flawed packages and inefficient use of space due to reliance on printed marks on packaging material, which can be disrupted during the packaging process.
Innovation Solution
A tracking system that independently tracks object locations using sensors and encoders to maintain a digital table of object positions, allowing precise control of packaging material placement and label application without relying on printed marks, ensuring accurate sealing and labeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If printed marks on packaging material are used to track object locations, then the tracking system can identify object positions, but the print marks can be disrupted during the packaging process leading to tracking errors and flawed packages
Solution Approach 1:
The patent removes the dependency on printed marks on the packaging material by extracting the tracking function to a separate, independent system. The tracking system now uses sensors to detect objects directly on the conveyance system, separating the tracking function from the packaging material and eliminating the problem of disrupted print marks.
Solution Approach 2:
The patent introduces an intermediary tracking system that uses sensors and encoders to detect object positions. This intermediary system acts as a mediator between the conveyance system and the packaging process, providing reliable location information without relying on the packaging material's printed marks.
2Loss of information
If regular print marks are required on packaging material for tracking, then object locations can be monitored, but the package appearance is degraded and graphic regions are compromised
Solution Approach 1:
The tracking information extraction is separated from the packaging material's graphic design. The system extracts position data using sensors that detect objects on the conveyance system, eliminating the need to incorporate tracking marks into the packaging material's appearance.
Solution Approach 2:
The patent creates a digital copy of object position information through sensors and encoders, rather than relying on physical print marks on the packaging material. This digital representation preserves the integrity of the packaging material's graphic regions while providing accurate tracking data.
3Loss of information
If the packaging system relies on marks on packaging material for tracking, then object positions can be identified, but the system complexity increases and flaws are not efficiently detected
Solution Approach 1:
The patent replaces the mechanical/optical system of printed marks and mark-detection cameras with an electronic sensing system using sensors and encoders on the conveyance system. This substitution simplifies the overall system by using the existing motion control infrastructure for tracking purposes.
Solution Approach 2:
The system implements feedback through encoders that continuously monitor the position of the conveyance system and provide real-time location data to the controller. This feedback mechanism enables accurate tracking without requiring complex mark-detection systems.
4Strength
If padded mailers with trapped air are used for cushioning, then object protection during shipment is achieved, but storage space requirements increase
Solution Approach 1:
The patent transitions from static, pre-inflated air cushioning to dynamic, on-demand inflation. The inflatable cushioning material remains compact during storage and is inflated only when needed for packaging, reducing storage volume while maintaining protection capability.
Solution Approach 2:
The inflatable cushioning material is stored in a compact, nested state within the packaging system and expands only when required for a specific packaging operation, similar to a nested doll structure that occupies minimal space until activated.
5Volume of stationary object
If inflatable mailers are used with on-demand inflation, then storage space is reduced, but the inflation process becomes slow and labor-intensive
Solution Approach 1:
The patent implements continuous automated inflation as an integrated part of the packaging process flow. The inflatable cushioning material is automatically inflated by the packaging system without interrupting the overall packaging operation, maintaining continuous productive action.
Solution Approach 2:
The inflatable cushioning material is designed to self-inflate through automated mechanisms within the packaging system, eliminating the need for manual labor. The system performs the inflation service automatically as part of the packaging sequence.
Data Source
AI summary
A packaging system includes a conveyance system, a package forming system, and a tracking system. The conveyance system is configured to receive objects and to convey the objects through the packaging system. Spacing between the objects is non-uniform as the objects are received by the conveyance system. The package forming system is configured to feed a packaging material to form a tube of the packaging material and to seal the tube of the packaging material around the objects to form packages of the packaging material around the objects. The tracking system configured to track locations of the objects as the objects are conveyed through the packaging system on the conveyance system. In some cases, the tracking system is configured to track locations of the objects independently of any marks on the packaging material and/or independently of the location of inducting documents placed on the objects.