Roll-Formed Container Scoring and Dynamic Sizing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Fulfillment centers face inefficiencies in packing and shipping due to the complexity of handling diverse item sizes and shapes, leading to waste and environmental impact from non-recyclable materials and oversized containers.
Innovation Solution
The development of roll-formed containers made from recyclable materials, formed around items using a system of rollers and folders to create custom-sized containers with various configurations, including sensors for precise item measurement and automated adhesive application, reducing waste and improving processing speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If fixed-size containers are used for shipping, then container manufacturing is simple and standardized, but containers are oversized relative to items resulting in waste and increased environmental impact
Solution Approach 1:
The container formation system dynamically adjusts container dimensions based on real-time item measurements. Rollers and folders are positioned variablely to create custom-sized containers that precisely fit each item, transforming the static fixed-size container approach into a dynamic adaptive system that minimizes packaging waste while handling diverse item sizes and shapes
Solution Approach 2:
The system changes the dimensional parameters of containers based on measured item characteristics. By varying length, width, and height parameters according to actual item size, the system eliminates the waste associated with oversized fixed containers while maintaining manufacturing feasibility through automated roll-forming processes
2Productivity
If custom-sized containers are created for each item, then packing efficiency and reduced waste are achieved, but the complexity of the packaging system increases
Solution Approach 1:
The patent replaces manual measurement and container selection with an automated optical measurement system using cameras and image processing. This substitution of mechanical/manual operations with optical sensing and computational analysis streamlines the process, achieving custom-fit packaging efficiency while reducing operational complexity through automation
Solution Approach 2:
The system enables self-service packaging by automatically measuring items, calculating optimal container dimensions, and forming custom-sized containers without manual intervention. The automated roll-forming mechanism responds to measured item parameters and creates appropriately sized containers autonomously, improving productivity while managing system complexity through self-regulating processes
3Speed
If manual measurement and container selection is used, then system complexity is low, but processing speed and throughput are reduced
Solution Approach 1:
The system implements continuous measurement and container formation operations. Items are measured continuously as they move through the fulfillment center, and containers are formed continuously based on real-time measurements. This eliminates discontinuous manual measurement and selection processes, maintaining high processing speed while managing automation complexity through integrated continuous operations
Data Source
AI summary
Systems and methods are disclosed for longitudinal scoring of roll-formed containers. In one embodiment, an example system may include a first scoring device having a first rolling die, a first arm coupled to the first rolling die, a second rolling die, a second arm coupled to the second rolling die, and a first support member configured to support the first arm and the second arm. The first arm and the second arm may be configured to: (i) slide along the first support member, such that a distance between the first rolling die and the second rolling die is adjusted, and (ii) rotate about the first support member from a first position to a second position, such that the first rolling die and the second rolling die move from the first position to the second position. The first scoring device may score ends of the packaging material.