Automated Packing System Corner Stabilization
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Solution Overview
Problem
Existing automated systems face challenges in efficiently handling and packing lightweight shipping containers, particularly cardboard boxes, which are prone to tipping during high-throughput operations, and require systems that can accommodate a variety of container sizes and securely stabilize them for efficient packing.
Innovation Solution
An automated packing system utilizing a multidirectional conveyor system with vacuum cups and programmable motion devices to secure and manipulate lightweight containers, incorporating weight sensing and multidirectional units to stabilize and rotate containers for precise packing, ensuring efficient handling and packing of various container sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated systems operate at high throughput to improve productivity, then packing speed increases, but lightweight containers become prone to tipping and require additional stabilization mechanisms
Solution Approach 1:
The system performs preliminary stabilization by positioning lightweight containers against a corner formed by two braces before the packing operation begins. This pre-positioning prevents tipping during high-speed automated packing operations.
Solution Approach 2:
The corner formed by two braces acts as an intermediary stabilization structure. The container is positioned against this corner, which provides mechanical support and prevents tipping during high-throughput operations.
2Adaptability or versatility
If the system accommodates a variety of container sizes to improve adaptability, then versatility increases, but the complexity of securing and positioning containers increases
Solution Approach 1:
The corner positioning system using two braces provides a universal solution that accommodates various container sizes. The same corner structure serves multiple containers of different dimensions without requiring size-specific securing mechanisms.
Solution Approach 2:
The system adapts to different container sizes by allowing the container to be positioned at different locations along the corner braces. The positioning parameters (distance from corner, orientation) are adjusted based on container dimensions while using the same basic securing mechanism.
3Adaptability or versatility
If human personnel perform manual packing to maintain flexibility, then adaptability to various goods is improved, but productivity and efficiency decrease
Solution Approach 1:
The automated system performs packing operations without human intervention. The robot or automated mechanism positions containers, places goods, and secures packages autonomously, maintaining flexibility through programmable control while dramatically improving productivity.
Solution Approach 2:
The system replaces manual human packing operations with an automated mechanical system. The automated container positioning and securing mechanisms perform functions that previously required human dexterity and judgment, achieving both efficiency and adaptability.
4Ease of operation
If containers are positioned freely on the conveyor to improve ease of operation, then loading efficiency increases, but container stability and positioning precision decrease
Solution Approach 1:
The corner formed by two braces serves as an intermediary positioning structure. Containers are guided to this corner, which provides a fixed reference point for precise positioning while maintaining ease of operation through the natural flow of the conveyor system.
Solution Approach 2:
The system provides localized precision positioning at the corner location where containers are secured. The two braces create a defined corner zone that ensures accurate positioning, while the rest of the conveyor system maintains free-flowing ease of operation.
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 maintains high throughput by stabilizing lightweight containers, allowing for efficient packing and scanning operations, reducing human intervention, and ensuring accurate placement and orientation of objects within containers.
Implementation Method 1
vacuum cups and programmable motion devices to secure and manipulate lightweight containers
Data Source
AI summary
An automated packing system for placing at least one object into a container is disclosed. The automated packing system includes an input conveyance system for providing empty containers to a packing station, a multidirectional unit at the packing station for receiving the container and for urging the container against a corner provided by two braces, a programmable motion device for packing the container with objects provided by source containers, and an output conveyance system for receiving the container from the multidirectional unit following packing.