Sensor-Based Cushioning Production for Variable Container Volumes
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Solution Overview
Problem
Current methods for upholstering objects in containers are complex and resource-intensive, leading to unnecessary production and transportation of cushioning materials, which increases costs and time consumption.
Innovation Solution
A method that uses sensors to detect the remaining empty volume in a container and produces cushioning material only when necessary, with automated transportation via gravity or a robot, eliminating the need for complex transport devices and reducing resource usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cushioning material is produced and transported for every container, then all containers are ensured to have cushioning protection, but unnecessary production and transportation occur increasing costs and time consumption
Solution Approach 1:
The system changes the parameter of cushioning material production from a constant state (always produce) to a variable state (produce only when needed), based on the detected empty volume parameter. This resolves the contradiction by making production conditional on actual need, ensuring protection when required while avoiding unnecessary production and time consumption when not required.
Solution Approach 2:
The system enables self-service by using sensors to automatically detect empty volume and trigger production only when necessary. The container essentially serves itself by providing volume information that determines whether cushioning material should be produced, eliminating the need for universal production and reducing time and resource waste.
2Productivity
If cushioning material is produced only when empty volume exceeds limit, then unnecessary production is avoided saving time and resources, but containers with insufficient empty volume may lack adequate cushioning
Solution Approach 1:
The system implements feedback by continuously monitoring the empty volume parameter and using this information to control the production decision. The sensor feedback loop ensures that production occurs if and only if the empty volume exceeds the predetermined limit, maintaining both productivity (by avoiding unnecessary production) and reliability (by ensuring protection when volume conditions are met).
Solution Approach 2:
The system applies dynamics by making the production process adaptive and responsive to changing conditions (empty volume). Rather than a static always-produce approach, the system dynamically adjusts production based on real-time volume assessment, optimizing both efficiency and protection reliability.
3Manufacturing precision
If complex transport devices with separate drives are used, then cushioning material can be precisely transported into containers, but device complexity and costs increase
Solution Approach 1:
The system extracts and removes the complex drive mechanism from the transport device, relying instead on gravity to perform the transportation function. This simplification maintains adequate placement precision while dramatically reducing device complexity and costs, as gravity provides sufficient force for the application.
Solution Approach 2:
The transport system uses self-service by utilizing gravity as a free, naturally occurring force to move cushioning material into containers. No external power source or complex control system is needed—the material essentially transports itself under gravitational influence, achieving both simplicity and functional effectiveness.
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
This approach minimizes unnecessary production and transportation of cushioning materials, saving time and resources while ensuring precise placement, thus reducing costs and improving efficiency.
Implementation Method 1
detecting and/or determining a variable characterizing a residual empty volume of the container by means of at least one sensor
Implementation Method 2
the cushioning material be transported into the container by gravity. This eliminates the need for a complex transport device with a separate drive
Data Source
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AI summary
The invention relates to a method for cushioning objects (22a-c) in a container (20), said method comprising the following steps: a. detecting and/or determining a variable characterising a residual empty volume of the container (20) by means of at least one sensor, and b. automatically producing at least one cushioning means (64) depending on the variable characterising the residual empty volume of the container (20). According to the invention, a cushioning means (64) is produced only when this results from a comparison of the variable characterising the residual empty volume of the container (20) with a limit value.