Automated Void Volume Measurement for Dunnage Dispensing
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Solution Overview
Problem
Current packaging systems for shipping lack an efficient method to automatically determine and dispense the precise amount of dunnage material needed to fill voids in containers, leading to potential shifting of articles during transport.
Innovation Solution
A system that includes a void volume data acquisition apparatus to measure the void volume in containers, a dunnage dispenser controlled by a logic device to dispense the appropriate amount of dunnage material, and a transport network to convey containers from the acquisition apparatus to the dispenser, using sensors and a database to determine the required dunnage based on container characteristics and dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated dispensers are used to dispense dunnage material, then productivity is improved, but measurement precision of void volume is required to maintain reliability
Solution Approach 1:
The patent replaces manual measurement methods with automated optical sensing systems (laser scanners, cameras, or other sensing devices) to non-contactedly measure container dimensions and void volume. This substitution enables high-speed automated measurement without mechanical contact, resolving the contradiction between productivity and measurement precision by providing both fast and accurate measurements.
Solution Approach 2:
The system creates a digital 3D model or representation of the container interior and its contents, then calculates void volume from this virtual copy rather than physically measuring. This allows rapid computation of the exact volume needed for dunnage material, maintaining precision while enabling high throughput through computational rather than mechanical measurement.
2Adaptability or versatility
If manual dispensing is used, then adaptability to different container types is improved, but productivity deteriorates
Solution Approach 1:
The automated dispenser system is designed with adjustable parameters including variable dunnage material flow rates, controllable dispensing durations, and adaptable container positioning mechanisms. These dynamic adjustments allow the same automated system to handle various container sizes and types while maintaining high productivity, eliminating the need to choose between automation and adaptability.
Solution Approach 2:
The system employs universal sensing and control mechanisms that can accommodate multiple container types through a single integrated platform. The optical sensing system and controller can identify and adapt to different container dimensions and configurations, providing multi-functional capability that maintains both productivity and adaptability simultaneously.
3Reliability
If dunnage material is over-dispensed, then reliability of article protection is improved, but loss of substance increases
Solution Approach 1:
The system incorporates real-time feedback loops where the measured void volume directly controls the dispensing quantity of dunnage material. Sensors monitor the actual amount of material dispensed and compare it against the calculated void volume, allowing the system to automatically adjust and prevent both under- and over-dispensing. This closed-loop control ensures precise material usage that maintains article protection reliability while minimizing waste.
Solution Approach 2:
The system dynamically adjusts dispensing parameters (flow rate, duration, quantity) based on the measured void volume of each container. By changing these parameters to match the specific requirements of each container rather than using fixed dispensing amounts, the system achieves precise material application that prevents both insufficient and excessive dunnage material usage.
Data Source
AI summary
A system, and associated components and methodology, that automatically acquires data representative of the space left in each of a series of containers (32) in which one or more articles have been placed for packaging, and dispenses a controlled amount of dunnage material based on that data from a selected one of a plurality of dunnage dispensers (12). The system includes void volume data acquisition apparatus (11) for acquiring void volume data for the containers sequentially supplied thereto and for associating the sequentially acquired void volume data with the container. The system also includes a plurality of dunnage dispensers remotely located relative to the void volume data acquisition apparatus to dispense a controlled amount of dunnage material for insertion into one of the containers selectively transported to that dispenser from the void volume data acquisition apparatus.