Void Fill System Using Sensor Scanning for Carton Volume Measurement
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Solution Overview
Problem
Existing cartoning machines lack an efficient system for optimizing void fill in cartons, which can lead to inadequate protection of products during shipping.
Innovation Solution
A void fill system that uses sensors such as cameras, lasers, and RFID to scan cartons before, during, and after filling, determining the carton volume and current contents to calculate the required void fill amount, and communicate with dispensers to automatically dispense the appropriate void fill material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional packaging methods are used without void fill optimization, then the packaging process is simple, but product protection during shipping is inadequate
Solution Approach 1:
The system performs preliminary scanning and measurement of the carton and its contents before void fill dispensing. Sensors capture images and calculate void spaces in advance, allowing the system to prepare and dispense the appropriate amount of void fill material before the packaging is completed, ensuring optimal product protection from the start
Solution Approach 2:
The system uses sensors to continuously monitor the carton filling process and provides feedback on the actual void spaces present. This feedback loop allows the void fill dispenser to adjust the amount and distribution of fill material in real-time, optimizing product protection while avoiding over-packaging
2Productivity
If manual void fill estimation is used, then the equipment required is minimal, but the packaging efficiency and accuracy are low
Solution Approach 1:
The system replaces manual visual estimation and manual void fill placement with automated sensor-based detection and mechanical dispensing. Cameras and imaging sensors automatically capture carton dimensions and content volume, while a controlled dispensing mechanism automatically delivers the precise amount of void fill material needed, dramatically improving packaging efficiency and accuracy
Solution Approach 2:
The system enables the packaging process to be self-sufficient by automatically detecting void spaces and dispensing the appropriate amount of fill material without human intervention. The integrated sensor system and dispenser work together to autonomously optimize each carton's packaging, increasing productivity while reducing labor requirements
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
The system ensures optimal packaging by accurately determining the void fill needs based on carton volume and contents, enhancing product protection and efficiency in the packaging process.
Implementation Method 1
The void fill system may comprise one or more sensors (e.g., one or more cameras, lasers, infrared devices, radar, LIDAR, light curtains, code readers—QR, barcode, scanners, or the like—, RFID sensor, or the like)
Implementation Method 2
The void fill system may comprise one or more sensors (e.g., one or more cameras, lasers, infrared devices, radar, LIDAR, light curtains, code readers—QR, barcode, scanners, or the like—, RFID sensor, or the like)
Data Source
AI summary
A void fill system may be used to scan a carton before, during, or after pre-fill material is dispensed into the carton, one or more products are packaged into the carton, and/or when void fill material is dispensed to the carton having the one or more products. The void fill system may include one or more sensors, which may be used identify the carton and/or identify the carton volume. The one or more sensors may also be used to identify the current carton volume (e.g., of the products, fill material, etc.). The information captured by the void fill system may be used to determine a proposed packaging recipe (e.g., suggest a carton, void fill, product configuration, etc.) based on supplier or customer preferences, product information, shipping information, or the like, to provide a notification with recommendations regarding the packaging process, and/or to automatically dispense void fill material.