Stacking Engine for Stable Container Arrangement Planning
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Solution Overview
Problem
In materials handling facilities, optimizing the stacking of containers for transport or storage is challenging due to instability, leading to increased labor costs, product damage, and reduced shipping efficiency, as existing methods lack a systematic approach to ensure structural stability and optimal space utilization.
Innovation Solution
A packaging information system that includes a planning service, product dimension estimator, container recommendation service, and stacking engine to dynamically plan stable stacking configurations for containers, utilizing custom container forming devices to adjust dimensions and recommend optimal container sizes based on item dimensions, weight, and destination requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If containers are stacked to maximize space utilization, then shipping efficiency improves, but structural stability deteriorates leading to product damage
Solution Approach 1:
The system performs preliminary planning of stacking configurations before actual stacking occurs. The stacking engine calculates optimal stacking arrangements in advance, considering stability requirements and space utilization, then directs the stacking mechanism to execute the pre-planned configuration. This prevents instability issues during the stacking process itself.
Solution Approach 2:
The system dynamically adjusts stacking configurations based on real-time factors such as container weights, dimensions, and destination requirements. The stacking engine reoptimizes stacking arrangements as new containers are added or removed from the facility, ensuring stability is maintained while maximizing space utilization throughout the stacking process.
2Ease of operation
If manual stacking methods are used, then flexibility is maintained, but labor costs increase and stacking speed decreases
Solution Approach 1:
The stacking system operates autonomously without requiring manual intervention. The stacking engine automatically calculates optimal configurations, and the stacking mechanism automatically executes the stacking process. The system self-manages the entire stacking operation, eliminating labor costs while maintaining flexibility through programmable adaptability to different container types and destinations.
Solution Approach 2:
The system replaces manual mechanical stacking operations with an automated control system. The stacking engine uses computational algorithms to determine optimal stacking arrangements, substituting human decision-making with automated computer-based planning. This increases stacking speed while maintaining operational flexibility through software-configurable parameters.
3Volume of stationary object
If unstable stacking configurations are used, then space utilization increases, but product damage occurs and labor costs increase due to rework
Solution Approach 1:
The stacking engine incorporates feedback mechanisms that monitor stacking stability and adjust configurations accordingly. The system evaluates potential stacking arrangements against stability criteria and feedback from actual stacking results, continuously refining its planning algorithms to maximize space utilization while ensuring stacking stability and preventing product damage.
Data Source
AI summary
The disclosure describes, in part, a system and method for improving the stacking of containers on or in a transportation unit. In some implementations, a stacking configuration may be planned that identifies containers and a position for those containers in the stacking configuration. The stacking configuration may be planned based on dimension values of the containers such that when stacked the stacking configuration remains stable. In addition, to improve the efficiency at which containers may be stacked, the disclosure describes that containers and/or the picking of items for those containers may be sequenced so that the containers, when packed and routed, arrive in a manner that allows efficient stacking.