Manual Void-Fill Dunnage Dispensing System
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Solution Overview
Problem
Inexperienced packers face difficulty determining the appropriate amount of void-fill dunnage needed to fill container voids, leading to inefficiencies in the packing process, and existing automated systems are costly.
Innovation Solution
A manual input system that allows packers to select a relative degree of container fill and identify container characteristics, with a controller determining the necessary dunnage quantity for dispensing, using options like 'nearly empty,' 'half full,' or 'nearly full' to guide dunnage dispensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a fully automated system is used to measure void volume and determine dunnage requirements, then packing accuracy is improved, but system cost increases significantly
Solution Approach 1:
The patent extracts the complex automated measurement system and replaces it with a simplified manual selection mechanism. Instead of using sensors, cameras, or computer vision to automatically measure void volume, the system uses pre-defined visual categories (empty, half full, three-quarters full, full) that packers can quickly identify and select from. This extraction of the measurement function to a simpler form resolves the contradiction between accuracy and cost.
Solution Approach 2:
The system changes the parameter of void volume measurement from continuous quantitative measurement to discrete categorical selection. Rather than requiring precise numerical measurement of void space, the system uses four distinct visual categories that capture the essential fill states. This parameter transformation enables accurate enough dunnage determination while dramatically reducing system complexity and cost.
2Device complexity
If an inexperienced packer manually determines dunnage requirements, then system cost is reduced, but packing speed and efficiency decrease
Solution Approach 1:
The system performs preliminary action by pre-defining the four visual categories of container fill states before the packing process begins. These pre-established categories (empty, half full, three-quarters full, full) serve as ready-to-use reference points that guide inexperienced packers quickly and accurately through the dunnage determination process without requiring training or complex calculations.
Solution Approach 2:
The system incorporates feedback through the visual selection mechanism, where the packer's observation of the container's fill state provides immediate feedback to the controller. The selected category directly determines the dunnage dispensing quantity, creating a simple feedback loop that enables inexperienced packers to operate efficiently with minimal cognitive load.
3Measurement precision
If automated systems are used to eliminate the need for packers, then packing accuracy is improved, but labor cost increases
Solution Approach 1:
The system enables self-service by allowing packers to independently and accurately determine dunnage requirements using their own observations and the pre-defined visual categories. The controller automatically calculates and dispenses the correct dunnage quantity based on the packer's simple category selection, making the system self-sufficient and eliminating the need for expensive automated measurement systems while maintaining accuracy.
Data Source
AI summary
A packaging system 100 includes a controller 102, an input device 104 in communication with the controller 102 that identifies one or more characteristics of the container, and a manual input device 106 in communication with the controller 102 that provides multiple input options for selection by a packer. The input options represent relative degrees to which a container is filled by one or more objects to be packaged. The controller 102 provides an output signal indicating a quantity of dunnage to dispense to the container based on the selected input option and the one or more identified characteristics of the container. Once the controller receives the container characteristics information, as well as the selected input option representing the relative degree to which the container is filled by the objects to be packaged, the controller can determine the number and lengths of dunnage strips that need to be provided to fill the remaining void in the container. Once the controller 102 has determined the amount dunnage that needs to be dispensed, the controller can signal a dunnage dispenser 110 to dispense the determined amount of dunnage.