Interactive Shipping Density Optimization for Containerized Parts
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Solution Overview
Problem
Current manual methods for optimizing shipping density of component parts in containers are time-consuming, inconsistent, and lack automation, failing to provide an optimized solution for freight and container investment costs.
Innovation Solution
A system and method that integrates computer-aided design (CAD), computer-aided manufacturing (CAM), and computer-aided engineering (CAE) tools with a software program to analyze and optimize shipping density using a parametric, analytical process, allowing for flexible design and engineering analysis, automated studies, and expert knowledge integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual techniques are utilized to determine rack density, then flexibility in design analysis is maintained, but the process becomes time-consuming and inconsistent
Solution Approach 1:
The patent replaces manual mechanical estimation techniques with automated computer-based simulation and analysis tools. The system uses software to perform virtual packaging studies, automatically calculating optimal rack densities and container configurations without manual intervention, thereby eliminating the time-consuming nature of manual methods while maintaining design flexibility.
Solution Approach 2:
The patent creates digital copies and models of physical components and packaging scenarios. By using computer-generated representations of parts, racks, and containers, the system can perform repeated virtual analyses instantly, allowing multiple density optimization scenarios to be evaluated without the time penalty of physical prototyping or manual calculation.
2Manufacturing precision
If manual estimation methods are used for rack density, then simplicity of operation is maintained, but manufacturing precision and consistency are compromised
Solution Approach 1:
The patent replaces imprecise manual estimation with computer-based simulation that provides exact calculations of rack density, container utilization, and freight costs. The automated system precisely models the three-dimensional space and component geometries to determine optimal packaging configurations, delivering high-precision results despite the increased complexity of the computational system.
Solution Approach 2:
The system performs self-service by automatically conducting the density optimization analysis without requiring manual intervention. The software independently imports component data, generates packaging scenarios, calculates densities, and produces results, thereby achieving high precision while the complexity is managed through automation rather than manual complexity.
3Productivity
If conventional analytical techniques are used, then ease of operation is maintained, but productivity and time efficiency are reduced
Solution Approach 1:
The patent replaces conventional manual analytical techniques with automated computer-based packaging planning software. The system automatically imports component geometry data, generates multiple packaging scenarios, and calculates optimal densities without manual intervention, dramatically improving productivity while the software interface maintains ease of operation through user-friendly controls and automated workflows.
Solution Approach 2:
The system performs preliminary actions by pre-importing component data from CAD systems and pre-configuring analysis parameters before the actual density optimization study. This preliminary setup automates routine tasks and prepares the system for rapid execution of packaging scenarios, thereby improving productivity while keeping the user's operational burden minimal.
4Measurement precision
If physical prototypes are prepared for analysis, then accuracy of analysis is improved, but time consumption and costs increase
Solution Approach 1:
The patent uses digital copies and virtual models of physical components instead of physical prototypes. The computer-based system imports precise geometric data from CAD files to create accurate digital representations, which are then used in virtual packaging simulations. This approach maintains measurement precision by using exact digital geometry while eliminating the time-consuming process of creating and manipulating physical prototypes.
Solution Approach 2:
The patent replaces physical prototype preparation and testing with computer-based virtual simulation. The system uses software to model packaging scenarios, calculate densities, and analyze configurations digitally, thereby achieving accurate measurements without the time and resource expenditure required for physical prototyping.
Data Source
AI summary
A system and method for interactively optimizing shipping density of racked parts by a user is provided. The system includes a user computer system, a communications network, a remotely located computer system, a data storage device a computer-generated model of a component part; a computer-generated model of a container for transporting the component part and an executable shipping density optimization software program. The methodology includes the steps of the user selecting the component part model and container. The methodology also includes the steps of analyzing the shipping density of component parts within the container. The methodology further includes the steps of identifying a bottleneck feature and modifying the bottleneck feature and determining the optimized density of the modified component parts in the container.