Automated Packaging System with Perpendicular Wrapping Stations
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Solution Overview
Problem
Current packaging systems face challenges in efficiently packaging items of varying sizes and quantities, often resulting in material waste and suboptimal protection, especially when creating custom-sized boxes.
Innovation Solution
A system that uses multiple wrapping stations with different packaging materials, including foil and cardboard, to create a custom-sized package by wrapping materials in perpendicular directions, minimizing waste and optimizing protection through scanning and automated material calculation and cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a custom sized box is created from a roll or stack of cardboard by cutting out a custom sized blank, then the packaging can be adapted to items of varying sizes, but the amount of material waste increases
Solution Approach 1:
The patent transitions from creating boxes by cutting 2D blanks from cardboard rolls (traditional approach) to wrapping 3D pre-cut cardboard blanks around items (innovative approach). This dimensional change allows the packaging material to conform to the item's shape without requiring excessive material removal, thereby reducing waste while maintaining adaptability to various item sizes.
Solution Approach 2:
The system changes the parameters of the packaging approach by using pre-cut blanks with specific dimensions and shapes that can be wrapped around items. Instead of varying the blank size continuously from a roll, the system uses discrete pre-cut blanks with optimized dimensions that reduce material waste while still adapting to different item sizes through the wrapping process.
2Loss of substance
If multiple wrapping stations with different packaging materials are used to create custom-sized packages, then material waste is minimized and protection is optimized, but the system complexity increases
Solution Approach 1:
The patent divides the packaging system into multiple wrapping stations, each handling specific packaging materials (foil, bubble paper, cardboard). This segmentation allows each station to be optimized for its specific material type and function, reducing overall material waste through specialized handling while organizing the complexity into manageable, modular units rather than a single complex system.
Solution Approach 2:
Each wrapping station is designed to handle its specific packaging material type universally, with the ability to process various items through the same station. This multi-functionality reduces the need for highly specialized equipment for each material type, thereby reducing system complexity while still achieving optimized material usage and protection for different item requirements.
3Productivity
If automated packaging is implemented for items varying in size and number, then packaging speed increases, but material waste occurs due to lack of precise material calculation
Solution Approach 1:
The system performs preliminary actions by pre-cutting cardboard blanks to optimized dimensions before the packaging process. This preliminary preparation ensures that when automated packaging occurs at high speed, the material is already in the correct form, eliminating the need for on-the-fly cutting that would generate waste. The pre-cut blanks are designed with precise dimensions that minimize material waste while accommodating various item sizes.
Solution Approach 2:
The system incorporates feedback mechanisms that scan items to determine their dimensions and automatically select appropriate pre-cut blank sizes. This feedback loop ensures that the packaging material matches the item size precisely, preventing over-packaging and material waste while maintaining high automated packaging speeds through rapid material selection and application.
Data Source
AI summary
System (10) for automatically packaging items varying in size and number for shipment, comprising a unit (32) for acquiring size information of one or more item(s) to be packaged, an inner packaging material feeding unit (24) for feeding an inner packaging material, an outer packaging material feeding unit (26) for feeding an outer packaging material, a first wrapping station (16) for wrapping said inner packaging material around one or more item(s) to be packaged to create an inner packing surrounding the item(s) in a first direction and a second wrapping station (18) for wrapping said outer packaging material around said inner packing to create an outer packing surrounding the inner packing in a second direction, said second direction being substantially perpendicular to said first direction, wherein the first and the second wrapping stations are adapted to form said inner packing and said outer packing such that the inner and the outer packing form a combined package enclosing the packaged item(s) from all sides.