Note: Descriptions are shown in the official language in which they were submitted.
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PACKAGING SYSTEM AND METHOD
FIELD OF THE INVENTION
This invention relates generally to a packaging system for providing a
quantity of dunnage material for insertion into containers in which one or
more
articles are to be packed for shipping.
BACKGROUND
In a typical application, a packer pulls articles itemized on a list of
articles to
be shipped and places them in a container. Before shipping the articles, a
protective
packaging material or other type of dunnage is placed around the article in
the
container. The dunnage material fills at least a portion of any voids and/or
cushions
the article during shipment to prevent or minimize movement of the article
relative to
the container and/or prevent or minimize damage to the article during
transport.
Some commonly used dunnage materials are plastic foam peanuts, plastic bubble
pack, air bags and crumpled paper material.
An operator of a dunnage dispenser observes the container as it is being
filled with dunnage material and stops the dispenser when the container
appears to
be full. The container is then closed for shipment. Some exemplary dispensers
include: plastic peanut dispensers, which are often associated with an air
delivery
system; foam-in-place dispensers, air bag machines and paper dunnage
converters.
Oftentimes a dispenser operator overfills the container with the result that
more dunnage material is placed in the container than was needed to adequately
protect the article and/or fill the void in the container. In other instances,
the
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operator puts too little dunnage material in the container, whereupon the
article has
more room to move in the container and/or can be damaged during shipment.
Over-filling and under-filling typically become more of a problem as the
speed of the dispensing operation increases. Today, void-fill dispensers, in
particular paper dunnage converters, can deliver a strip of dunnage material
at rates
in excess of fifty feet per minute (about one-quarter of a meter per second).
SUMMARY
A system and methodology for automating a void-filling packaging
operation is provided. A packaging system provided herein comprises a
packaging
system, comprising a plurality of dunnage dispensing stations, each of which
has at
least one dunnage dispenser from which a dunnage material can be dispensed;
and
a transport network for conveying containers to and from at least two dunnage
dispensing stations for dunnage to be placed therein, wherein the transport
network
includes a mechanism for routing each container to a particular dispensing
station
based on a characteristic of the container. The dispensing stations can be
arranged
along a portion of the transport network such that one or more containers can
be
conveyed to multiple dispensing stations sequentially in series and/or in
parallel.
The system can also include a supply of dunnage that can be dispensed at at
least
one dunnage dispensing station. The supply can include a dunnage conversion
machine that can convert a stock material into a relatively less dense dunnage
material and supply it to one or more dunnage dispensing stations. The supply
of
dunnage can include, for example, one of air bags, crumpled paper, foam
strips,
foam peanuts, and paper strips.
The system also can include a controller for controlling one or more
elements of the system. These elements can include, for example, one or more
loading stations where one or more articles are placed in one or more
containers for
transport, one or more intermediate stations upstream of at least one dunnage
dispensing station that includes a void sensor for sensing a characteristic of
the void
volume in the container, and/or one or more devices, such as sensors, for
determining whether the container conforms to predetermined criteria. In the
latter
instance, a transport network can also include a way to divert nonconforming
containers that fail to meet the predetermined criteria.
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A packaging method provided herein comprises the following steps: routing
a container to a dunnage dispensing station selected from a plurality of
dunnage
dispensing stations based on routing criteria that includes a characteristic
of the
container; and supplying dunnage to a container at a dunnage dispensing
station.
The routing criteria can include, for example, the availability of dunnage
dispensing
stations, characteristics of the dunnage material, characteristics of the
container,
characteristics of the void in the container, and/or characteristics of the
article to be
shipped in the container. Supplying dunnage can include, for example,
determining
the void volume in the container.
In an embodiment, a method also includes assigning an identifier to each
container and tracking the container as it moves through the packaging system.
An embodiment provides a system and method characterized by one or
more void sensing stations that sense characteristics of a void volume of a
container, one or more dunnage dispensing stations that can dispense dunnage
material based on the sensed characteristics of the void sensing stations, and
a
transport network for conveying the container from one of the void sensing
stations
to a selected one or more of the dunnage dispensing stations.
Optionally, an embodiment of a packaging system includes at least one
sensor that senses at least one characteristic of a container, and a
controller that
determines whether the container is suitable for placing dunnage material
therein
based on the sensed characteristic of the container. A packaging system can
include one or more dunnage dispensing stations where dunnage is dispensed for
insertion in a void in a container, with at least one dunnage dispensing
station being
capable of dispensing multiple types of dunnage material.
Another embodiment of a packaging method can include the following steps:
routing the container to a dunnage dispensing station selected from a
plurality of
dunnage dispensing stations based on routing criteria, and supplying dunnage
to a
container at a dunnage dispensing station.
Optionally, the routing step can include routing based on routing criteria
that
includes one or more of characteristics of the dunnage material,
characteristics of
the container, characteristics of the void in the container, and
characteristics of the
article to be shipped in the container.
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An embodiment of the invention can include one or more of the following
steps: determining the type of dunnage dispensed, controlling the quantity of
dunnage dispensed, measuring characteristics of the container, and consulting
a
database to determine the void volume.
In another embodiment of the invention, a packaging system includes one
or more void sensing stations that sense characteristics of a void volume of a
container; a plurality of dunnage dispensing stations that can dispense
dunnage
material based on the sensed characteristics of the void sensing stations; and
a
transport network for moving the container from one of the void sensing
stations to
a selected one of the dunnage dispensing stations.
In an embodiment of the invention, a packaging method includes
determining a void volume of a container, conveying the container to a
selected
one of a plurality of dunnage dispensing stations, and dispensing dunnage
material based on the void volume of the container.
In an embodiment of the invention, a packaging system includes a sensor
that senses a characteristic of a container, and a controller that determines
whether the container is suitable for placing dunnage material therein based
on
the sensed characteristic of the container.
In another embodiment of the invention a packaging method includes
sensing at least one characteristic of a container; and determining whether
the
container is suitable for placing dunnage material therein based on the sensed
characteristic.
In an embodiment of the invention, a packaging system includes a plurality
of dunnage dispensing stations where dunnage is dispensed to place in a void
in
a container, at least one dunnage dispensing station being capable of
dispensing
multiple types of dunnage material.
In an embodiment of the invention, an automated packaging sytem for
filling the void in a container includes a plurality of loading stations for
loading
containers, a plurality of dunnage dispensing stations, a transport network
linking
the loading station to the plurality of dunnage dispensing stations for
transporting
the containers from the plurality of loading stations to one or more dunnage
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dispensing station, and a controller. The controller automatically routes
containers via the transport network to selected dunnage dispensing stations.
Optionally, the system can include one or more of: a void volume detection
device upstream of at least one dispensing station for obtaining information
indicative of the void volume in the container and providing the obtained
information to the controller; a controller that determines a volume of
dunnage to
be dispensed at a dunnage dispensing station as a function of the information
indicative of the void volume and directs a dunnage dispensing station to
automatically dispense the determined volume of dunnage; a void volume
detection device that includes a sensor that obtains measurements of the
container; and a void volume detection device that includes a sensor that
obtains
data indicative of the topography of the contents of the container; wherein
the data
indicative of the void volume is obtained from one of a bar code, an RFID
chip,
and data stored in a database.
In an embodiment of the invention an automated system for packaging
articles in a container includes a loading station for loading one or more
articles in
a container; means for identifying a characteristic of the container; means
for
determining a volume of dunnage to dispense into the container; a plurality of
dunnage dispensers; and means for routing the container from the loading
station
to a selected one of the plurality of dunnage dispensers. The selected dunnage
dispenser provides the determined volume of dunnage into the container.
Optionally, the system can include means for determining that the container
is not suitable for automatic filling of dunnage as a function of the
identified
characteristic; and/or one or more dunnage dispensers that include one or more
dunnage converters that convert a stock material into a dunnage product.
In accordance with an embodiment of the invention, an automatic
packaging system includes a loading station for loading a container; a sensor
for
obtaining a characteristic of the loaded container; a dunnage dispensing
station
for automatically placing dunnage in the container; a transport network for
moving
the container from the loading station to the dunnage dispensing station; and
a
controller for determining as a function of the obtained characteristic
whether to
place dunnage in the loaded container.
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Optionally, whether to place dunnage in the loaded container is a function
of whether the container conforms to a predetermined criteria; and/or the
transport
network comprises a container diverter to divert a non-conforming container;
and/or the container diverter comprises a mechanism to remove the container
from the transport network; and/or the container diverter comprises a
mechanism
to route the container to a manual station.
The foregoing and other features are hereinafter fully described and
particularly pointed out in the claims, the following description and the
annexed
drawings set forth in detail one or more illustrative embodiments of the
invention.
These embodiments are but a few, however, of the various ways in which the
principles of the invention can be employed.
BRIEF DESCRIPTION OF THE APPENDED DRAWINGS
FIG. 1 is a diagrammatic view of a packaging system in accordance with
the invention.
FIG. 2 is a plan view of an embodiment of a packaging system in
accordance with the invention.
FIG. 3 is a schematic side elevation view of a path a container might take
through a packaging system.
FIG. 4 is a perspective view of a standard regular slotted container (RSC)
for use with the system of FIG. 1.
FIG. 5 is a side elevation view of a void volume scanner used in the system
of FIG. 1.
FIG. 6 is an end view of the void volume scanner of FIG. 5, looking from
the line 6-6 of FIG. 5.
FIG. 7 is a cross-sectional view of a container in which several articles
have been placed, with the remaining void being denoted by cross-hatching.
FIG. 8 is a flowchart illustrating a packaging process in accordance with an
embodiment of the invention.
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DETAILED DESCRIPTION
Referring now to the drawings, and initially to FIG. 1, an exemplary
packaging system in accordance with an embodiment of the invention is
indicated
generally at 10. The system 10 includes one or more container loading stations
12 such as, for example, loading stations 12a, 12b, 12c and 12d, and multiple
dunnage dispensing stations 14, such as, for example, dunnage dispensing
stations 14a, 14b, 14c, 14d, 14e, 14f and 14g. At a loading station 12 one or
more articles 16 (FIG. 3) are placed into a container 20. Then at a dunnage
dispensing station 14 a dunnage material is dispensed and is placed in the
void in
the container 20. The void is the space in the container 20 that is not taken
up by
the one or more articles 16.
The system 10 also can include one or more intermediate stations 22 as
may be needed to assist the dunnage dispensing stations 14; a transport
network
24 that moves the containers 20 through the stations; and/or a system
controller
26 for controlling one or more actions in the system 10, such as controlling
the
flow of containers 20 through the system 10. FIG. 1 illustrates a transport
network
24 that can route the containers 20 in several different ways through the
system
10, such as, for example, from multiple stations to a common station, and from
a
single station to multiple subsequent stations. Although plural stations of a
given
type (container loading, intermediate, etc.) are shown in FIG.1, for a given
application only a single station of a given type may be sufficient, and/or no
station
of a given type may be needed.
Optionally, one or more of the intermediate stations 22 can include a device
for determining whether or not the container meets predetermined criteria
before
receiving dunnage. In addition, optionally one or more of the intermediate
stations
can include a void determination station or device 30 (FIG. 3) to determine
the
void volume in the container 20. The void determination device 30 can be used
to
identify the void volume to calculate the required volume of dunnage to fill
the
void. The void determination device 30 can also function as a device for
3o determining whether or not the container meets the predetermined criteria.
The embodiment of the system 10 shown in FIG. I optionally can include
one or more closing stations 102 for closing the container 20, and optionally,
the
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system 10 can include one or more shipping stations 104 for processing the
container for shipping.
As will be appreciated, the system 10 can be configured in an embodiment
that minimizes or eliminates the need for a packer or other operator, thereby
reducing the time required for packing a container and/or increasing the
reliability
of the packing operation. The system can use, for example, a machine that can
dispense and insert the dunnage into the container at a rate faster than that
of a
packer, thereby reducing the packing time. In addition, the system can be
configured, for example, to improve reliability because the correct volume of
dunnage can be automatically calculated, thereby reducing or eliminating
overfill
and underfill problems. The various stations in the illustrated system 10 will
be
described in further detail with reference to FIGS. 2 and 3, FIG. 2 showing
one
particular exemplary system 300 and FIG. 3 showing one path a container 20 can
follow through the system.
Loading stations
As shown in FIGS. 2 and 3, the loading stations 12 can include a box
erector 32 for erecting the containers 20, such as cardboard boxes, from flat
blanks 34. Other types of containers can be used with this system 10 and a box
erector is not required. The box erector can be, for example, a task area at
which
box blanks are converted into a box by a packer, or an automatic device that
automatically converts a box blank into a box. The box erector can even be an
apparatus that fabricates the box on site.
An exemplary container 20 is a regular slotted container (RSC), and
another type of container is a shoe-box style container. Alternatively,
another type
of shipping container can be used in this system 10. An RSC typically has four
flaps, with one set of opposing flaps typically spanning at least half the
distance
between them.
Referring briefly to FIG. 4, an RSC has a specified relationship between the
width of the container W and the height of the side flaps 36 and end flaps 38.
The
flaps 36 and 38 typically have a height that is one half the width W of the
container, for example. Accordingly, the height H of the side walls 40 and the
end
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walls 42 of the container 20 (i.e., the height of the container when closed)
can be
determined from a measure of the height of the container 20 with the flaps 36
and
38 upright in their unfolded state. The height of the side and end walls 40
and 42
(the height of the article-containing portion of the container 20) will be a
known
fraction of the height of the container when the flaps 36 and 38 are upright
and
unfolded. Those skilled in the art will appreciate that the height H can be
determined in other ways, such as when the flaps 36 and 38 are-folded down,
which provides a direct measurement of the height of the side and end walls 40
and 42 of the container 20.
Multiple loading stations can be arranged in series so that multiple stations
can supply the one or more articles 16 to a container 20 as the container 20
sequentially moves past multiple loading stations. For example and as
illustrated
in FIG. 1, a first article or articles can be placed in a container at a first
station 12c,
and then the container can be transported to a second station 12d where a
second article or articles can be placed in the container. The articles can be
different from one another or the same.
Alternatively, multiple loading stations can be arranged in parallel. As
illustrated in FIGS. I and 2, loading stations 12a and 12b, which are arranged
in
parallel relationship, can be used at the same time for packing separate
containers, or independently of one another, such that if needed or desired
one
loading station can be taken off line without requiring the entire system 10
to be
shut down.
The article or articles 16 can be supplied for loading in the container in
several ways. Before being placed in the container 20, the one or more
articles
16 can be retrieved from storage and placed in a temporary receptacle (not
shown), such as a tote, from which one or more articles 16 are then pulled for
placement in the container 20. The articles 16 can be supplied randomly,
without
a predictable pattern as to which articles will be required for placing in a
particular
container 20, or a loading station can be dedicated to supplying one or more
articles 16 based on one or more criteria. Some criteria that could be used
include container dimensions, shipping company, shipping mode, article
fragility,
article weight, article size, article relationships, etc.
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The articles 16 can be loaded into the container 20 in a variety of ways.
For example, a packer can place the articles 16 in a container 20 by hand.
-Alternatively, the packer can initiate or otherwise control or supervise one
or more
steps that are performed by one or more devices that place the article or
articles
16 in the container 20 (such as a pick-and-place robot (not shown), which can
move an article into the container and optionally also orient the article
relative to
the container). Moreover, the articles 16 can be placed in the container 20
independent of any external control by an operator. In this latter example,
one or
more machines or other devices, controlled by the controller 26, for example,
1o place the article or articles 16 in the container 20 without any assistance
from a
packer.
Transport Network
The transport network 24 transports the containers 20 between stations,
typically in a downstream direction through the system 10. Any method or
combination of methods of physically moving the containers 20 through the
system 10 can be employed. For example, the transport network 24 can include a
conveyor network that generally starts, stops, transports and orients the
container
as needed, in which case fewer, if any, people are needed. In a highly
20 automated system, there may only be needed one or a few people to supervise
and troubleshoot transport problems for multiple lines within the network.
The transport network 24 can include multiple conveyor lines 68 that define
paths through the system 10. In FIG. 1, these lines 68a-68z are shown
schematically and diverge and come together to selectively route the
containers
along a path, such as 68b, 68f, 68m, 68t through the system 10. In FIG. 3, the
transport network 24 includes a conveyor 60 such as, for example, a zero
pressure accumulating conveyor. In a zero pressure accumulating conveyor, a
conveyor is divided into multiple zones, each of which is sized to support at
least
one container. The containers move from an upstream zone to the next
downstream zone as the downstream zone clears. Each zone can be powered
separately, stop gates or other means can be employed to regulate the flow of
containers from and within each zone, and sensors can be used to determine
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when a container has left a zone. A supervising controller such as controller
26
typically controls the operation of each zone.
Intermediate Stations
The optional intermediate station or stations 22 are located between the
loading stations 12 and the dunnage dispensing stations 14. The intermediate
stations 22 can include a void determination station or device 70 for
acquiring data
representative of the void volume to help the dunnage dispensing stations 14
dispense a controlled quantity of dunnage.
The void determination device 70 acquires data that can be used to
determine the void volume and thereby determine how much dunnage to put into
the container 20. The void volume can be determined by measuring
characteristics of the container 20, the void and/or the contents directly. An
exemplary void determination device is described in commonly owned U.S. Patent
No. 5,897,478, which is hereby incorporated herein by reference. The void
determination device 70 in FIG. 3 includes a void volume scanner 72 having a
scan area through which a container 20 can be conveyed. The void volume data
obtained can be stored in an electronic storage device, which can be part of
the
controller 26, for example.
Optionally, the void volume can be measured by hand, using a measuring
tool to measure one or more characteristics of the container. These
measurements can be compared with dimensions in a look-up table to determine
the void volume indirectly, or the void volume can be calculated directly from
the
measurements.
The void volume also can be measured with contour sensing for mapping
the topography of the void volume, using electromagnetic imaging techniques
and
devices, such as high frequency radar, ultrasound, laser, machine vision, etc.
An imaging sensor or sensors can be used to create a stereoscopic image, from
which a three-dimensional model can be created for calculating the void
volume.
Alternatively, a two-dimensional array of relatively movable rods can be
deployed over the container to extend into the container to probe the depth.
Each
rod would measure the depth at its position in the array by extending downward
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until it encountered the top of an article 16 or a surface of the container
20. With a
map of the topography, the dunnage can be directed to those areas requiring
the
most fill.
An exemplary void volume scanner is described in International Patent
Publication No. WO 2004/041653.
In FIGS. 5 and 6, an exemplary void volume scanner 72 can be seen to
include a frame 74 having a pair of uprights 76 straddling the conveyor 60 and
a
cross beam 78 supported atop the uprights 76 at a fixed distance from the
upper
surface of the conveyor 60. The uprights 76 can be floor supported, for
example, or
1o can be mounted to the conveyor 60.
The void volume scanner 72 includes one or more sensors 80, such as a
weigh scale, an optical, infrared, ultrasonic, laser or other type of sensor,
for
obtaining data representative of the volume of the empty space or void in a
container 20 in which the articles 16 have been placed for packing. In the
illustrated
embodiment, the sensors 80 include a height sensor 82 for providing an output
representative of a height of a container 20, a width sensor 84 for providing
an
output representative of a width of the container 20, and a contour sensor 86
for
providing an output representative of a contour of the container 20,
particularly its
interior and the one or more articles 16 in the container 20.
The contour sensor 86, shown mounted to the cross beam 78 above the
conveyor 60, preferably but not necessarily is of a type that continuously
senses the
top surface of the one or more articles 16 in the container 20 as the conveyor
60
moves the container 20 therebeneath.
An exemplary contour sensor 86 is a non-contact optic laser scanner that
operates by measuring the time of flight of laser light pulses, such as the
Sick Optic
LMS 200-30106 laser scanner. The laser scanner emits a pulsed laser beam that
is
reflected from the interior of the container and any articles placed therein.
The
reflection is registered by the laser scanner's receiver. The time between
transmission and reception of the reflected impulse is directly proportional
to the
3o distance between the laser scanner and the surface from which it was
reflected. The
pulsed laser beam can be deflected by a rotating mirror
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inside the scanner so that a fan-shaped scan is made of the surrounding area,
whereby the contour of the article (e.g., distance from a fixed reference
point/plane) can be determined from the sequence of impulses received. The fan
beam is oriented perpendicular to the movement path of the container past the
sensor. Thus the contour of container 20 and the articles 16 therein passing
the
contour sensor 86 is progressively measured as the container 20 moves past the
sensor 86.
The width sensor 84 can be any suitable sensor for determining the width
of the container 20 passing thereby. In the illustrated embodiment, the width
1o sensor 84 is an infrared distance sensor that can be used to measure the
distance
a first side 40a (FIG. 4) of the container 20 is spaced from the sensor or
other
reference point. In order for this embodiment to yield the width of the
container,
the location of an opposing side 40b (FIG. 4) of the container is registered
at a
known fixed distance from the width sensor 84 which, as shown, can be mounted
to one of the uprights 76 of the scanner frame 74 at a location just above the
level
of the conveyor 60. To this end, the containers 20 can be registered against a
guide rail 90 on the side of the conveyor 60 opposite the width sensor 84,
which
guide rail 90 is at a known distance from the width sensor 84 and thus
functions
as a zero reference. One side of the container also is oriented to be parallel
the
guide rail 90. Accordingly, the width of the container will be the difference
between the location of the guide rail 90 and the measured location of the
side of
the container nearest the width sensor 84. Any suitable means can be employed
to register the container against the guide rail 90 or otherwise place the
container
20 in a desired consistent orientation, such as a pneumatically operated arm,
a
low friction surface formed by a roller conveyor, for example, inclined toward
the
guide rail, etc.
The height sensor 82 can be any suitable sensor for determining a height
of the container 20. An exemplary sensor 82 includes an array 92 of emitters
and
an array 94 of receivers disposed on opposite transverse sides of the scan
area.
In the illustrated exemplary embodiment, the emitter and receiver arrays 92 or
94
are mounted to respective scanner frame uprights 76. Each array includes a row
of emitters/receivers that is oriented perpendicular to the plane of the
conveyor
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60. Accordingly, the emitter array 92 produces a curtain of light that is
sensed by
the receiver array 94. As a container 20 moves through the curtain, the
curtain
will be interrupted by the container up to the height of the container,
whereby a
measurement of the container height can be obtained.
A separate sensor can be provided to measure the length of the container.
In the illustrated embodiment, however, the container length is determined
indirectly by measuring the length of time the container takes to pass any one
of
the sensors, such as the width sensor 84, and by knowing the speed at which
the
conveyor 18 moves the container past the sensor. The length of time multiplied
by the speed of the conveyor 60 yields the length of the container. If the
speed of
the conveyor is a known constant, then only the length of time needs to be
measured to determine the length of the container. If the speed of the
conveyor
varies, stops, starts, or for other reasons, a conveyor speed sensor can be
used
to measure the conveyor speed and communicate the same to the controller 26
for processing. The speed sensor, for example, can be an encoder interfaced
with the conveyor drive motor for providing a series of pulses, the rate of
which
are proportional to the speed of the motor and thus the speed of the conveyor.
The controller can be calibrated to convert the pulse rate to a container
speed that
can be multiplied with the time measured by the width sensor for the container
to
pass by the width sensor to determine the length of the container.
The void volume also can be measured without a contour sensor 86 or
other methods of mapping the topography of the void volume, using such
features
as weight differential and volume displacement. Using the average density of
shipped articles, the void volume can be calculated from the weight of the
container before and after loading. The weight difference divided by the
density
would yield an approximate void volume. The approximate void volume would on
average be accurate enough to allow automatic filling of the void from the
dunnage dispensing equipment. A volume displacement technique uses the
volume of fluid (such as a gas) to determine the void volume from the known
empty volume of a shipping container.
Since a void determination station 70 generally can automatically provide
void volume data at a faster rate than a dunnage dispenser 52 can provide
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dunnage for insertion into each container 20, the same void volume
determination
station 70 can be used to acquire void volume data that can be used to
determine
the amount of dunnage material to be dispensed from each multiple dunnage
dispensing stations 14e, 14f, 14g. This can improve the throughput through the
system 10, as well as increase the flexibility of the system 10 via the
routing
criteria.
Optionally, instead of taking measurements to determine the void volume,
the void volume can be determined indirectly. For example, a sensor, such as a
bar code sensor, could detect an identifier, such as a bar code, that
identifies the
1o article or multiple articles 16 and/or the container 20, and from that
information a
data set could be consulted that would either give their respective volumes
from
which the void volume can be calculated or the void volume for that particular
combination of articles and container can be stored in and retrieved from the
data
set.
Another way to identify the container 20 and determine the void volume is
by sensing one or more characteristics of the container, including container
dimensions, container size, weight, etc. and looking up the void volume that
most
closely corresponds to the detected characteristics. For further information
on an
exemplary method of determining the void volume indirectly, reference can be
made to International Patent Publication No. WO 98/56663, which is hereby
incorporated herein by reference in its entirety.
Each container 20 and/or article 16 can include a unique identifier that can
be detected by an identification sensor 100, as shown in FIG. 2. Once a
particular
container 20 has been assigned a unique identifier, that unique identifier can
be
used to associate data with that container 20 throughout the system 10, like a
license plate or name tag. Separate identification sensors 100 can be used at
one
or more locations within the system 10, as shown in FIG. 3, and/or an
identification sensor can be an integral component of the void volume scanner
72.
The identifier can take any form including a label, hardware identifiers
3o embedded in the container, radio frequency identification (RFID) tags,
colors,
shapes, numbers, holes, protrusions, surface texture, patterns, dimensions of
the
container, thermal image, ultraviolet image, weight, electronic article
surveillance
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(EAS) tags, etc. An EAS tag includes a microwave tag, an electromagnetic (EM)
tag or an acousto-magnetic tag, for example.
The container identification sensor 100 can include an optical system to
obtain an image of the container 20 or a portion thereof that can be
electronically
analyzed for identification. For example, a digital camera can be placed in a
position that allows for a digital picture to be made of each container. The
picture
can then be compared to pictures of standard containers in a database. The
container can be identified from its dimensions or an identifier marking such
as,
for example: dots, numbers, shapes, holes, color, thermal pattern, ultraviolet
1o image, etc. The database can also provide container dimensions and empty
container volume information.
Alternatively, the container identification sensor can detect radio frequency
(RF) tags. An RF tag typically is associated with a container at the loading
station
12 and is associated with the container throughout the packaging process. When
the container is erected and dedicated to an order, an order specific RF tag
is
adhered to the container or placed inside the container. Order specific
information
(container contents, external container dimensions and empty container volume,
for example) can be stored on the tag and is downloaded by an RF tag reader
positioned upstream of the dunnage dispenser. The tag information is sent to
an
information processor that can retrieve container content information from a
database. A tag retrieval station can be employed to recycle the RF tags at
the
end of the packaging process to make the system more cost effective. Another
exemplary container identifier is a bar code. Bar code labels typically are
attached to an outer surface of the container.
In some situations the void volume can be determined from the container
identifier, such as when a known volume of articles is placed in a particular
type of
container. Once a sensor detects the container identifier, that information
can be
communicated to a processor having or linked to a database that provides, for
example: article volume, container dimensions, void volume, empty container
volume, etc. The void volume thus can be predetermined and retrievable or can
be calculated from the volumes of the contents of the container and the empty
container volume and/or dimensions of the container. The information can be
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automatically uploaded to manual, semi-automated or fully automated dunnage
dispensers.
An embodiment also contemplates sequentially routing containers 20 to
dunnage dispensing stations 14 without detecting an identifier for the
container,
either at the void determination station 70 or at the dunnage dispensing
station 14,
or anywhere in the system 10. Since the void determination station 70 acquires
the void volume data for containers 20 provided in sequence, that data or
related
data representative of the amount of dunnage material to be dispensed can be
communicated directly to the dunnage dispensing station 14 to which the
container 20 is routed. Thus, if three containers 20a, 20b, 20c pass through
the
void determination station 70 in sequence, data can be communicated to the
respective dunnage dispensing station 14 to which each container is routed
without reading a bar code label on the containers. In this case, the void
volume
data is associated with a particular container by its place in a sequence and
the
routing of the container to a particular dispensing station. Consequently,
container identification is effected by keeping track of where a given
container has
been moved in the system.
An operator can initiate or otherwise control one or more steps that are
performed by one or more devices that determine the required quantity of
dunnage. Alternatively, the void volume can be determined automatically,
without
external intervention or control by a person. As is apparent from the above
description, however, the intermediate stations are not always needed. In some
situations the void volume does not have to be determined. For example, the
void
volume can be filled until the container is full. The system 10 simply needs
to
know when to stop filling the container 20, using sensors, backpressure or
mechanical resistance.
In one known method, for example, an airbag is inflated within a container
until the
walls of the container move outward, which indicates that the container is
full.
As yet another alternative for instances where the void volume does not
need to be determined, the container 20 can be deliberately overfilled and the
excess dunnage removed to obtain the desired degree of fill. The excess
dunnage removed can be returned to the supply thereof. The amount of dunnage
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dispensed can be predetermined based on the volume of the largest potential
container, or can be guided by one or more sensors. For example, a container
can be transported under a continuous waterfall of flowable dunnage at a rate
sufficient to allow the largest anticipated void to be filled, and then any
excess
dunnage can be removed and recycled through a recycling hopper and
transported back into a fill hopper, for example, along with any overflow.
In this case, the void volume around the articles in the container does not
have to be determined. A swiping or blow-off apparatus can be employed to
remove excess dunnage at the top of the container. In this system, RSC flaps
1o must be in the down position, folded outside the container, or a shoe box-
style
container must be employed. In the case of an RSC, flap handling equipment
must be employed to prepare the container for filling and to raise the flaps
again
for sealing the container, i.e. to move the flaps up and down as needed.
Another type of intermediate station 22, is a go/no go station for
determining whether a container conforms to predetermined criteria. The
predetermined criteria can include factors that makes the container suitable
for
receiving dunnage and/or that would prevent the container from closing
properly,
for example. The functions of the go/no go station optionally can be performed
by
a void volume scanner 70 or other component of the system 10. Thus the go/no
go station can be its own intermediate station, or part of one or more of the
other
stations. For example, the void determination station 70 also can include one
or
more sensors used to determine whether the container is suitable for receipt
of
dunnage, i.e., whether a non-conforming fault condition exists.
One or more fault conditions could make the container unsuitable for
receiving dunnage, in which case a nonconforming container requires special
processing. Special processing can include repositioning an article in a
container,
manually dispensing the desired amount of dunnage and placing it in the void
in
the container and/or reintroducing the container to the transport network 24
after
resolving the nonconforming fault condition. The controller 26 can provide a
signal to alert an operator to the existence of nonconforming fault conditions
for
which an operator's attention is desired before the container can continue.
Additionally or alternatively, upon detecting one of these or other fault
conditions
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where a container falls outside acceptable operating criteria, the controller
26 can
automatically route the container to a separate conveyor for special
processing by
an operator.
Nonconforming fault conditions include, for example, an indication that no
container is detected, a flap of a container partially or completely blocks
the
opening into a container, one or more measured container dimensions is below
minimum and/or above maximum thresholds, container weight is below a
minimum and/or above a maximum threshold, a void volume equal to the
container volume (which would indicate that there is no article in the
container) or
exceeds container volume (which can indicate that the container is overfull),
weight (empty or overweight), conditions that would prevent the container from
closing properly, such as articles extending above a certain height, etc. A
nonconforming fault condition also can indicate a situation that fails to meet
other
predetermined criteria, such as a narrow but deep void volume, that might
require
special processing by an operator.
Controller
As above mentioned, the controller 26 functions to control one or more
components of the system 10. For example, the controller 26 can route
containers 20 along the transport network 24 from the loading stations 12 to
the
dunnage dispensing stations 14, as well as the void determination stations 70
when included, and/or controllably dispense dunnage material for placement in
the void volume. In addition, optionally the controller 26 can track
containers 20
through the system 10.
The various functions of the controller 26 can be performed by a single
processor unit, such as a control unit for the void determination stations 70,
or the
functions can be distributed among several processor units, each having
separate
processors, such as among a control unit for one or more void determination
stations 70, one or more control units for the dunnage dispensing stations 14,
a
separate (possibly remotely located) microprocessor of a personal computer, or
combinations thereof.
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The controller 26 can be any one of a number of commercially available
processors or combinations thereof, such as programmable logic controllers
(PLCs) and general purpose processing chips with various output and input
ports
and associated electronic data storage devices including read-only memory
(ROM) and random-access memory (RAM). The controller 26 also can provide
wireless communications capabilities, including cellular, infrared, wireless
modem,
microwave, radio frequency, satellite communications technology, etc., for
remote
control, data transfer and other communications purposes. The communications
can be one-way or two-way. Wireless communications can be advantageous for
remote control, monitoring and diagnostics; updating software; and eliminating
or
minimizing wiring to and from the system, as but a few examples. The
controller
26 can be controlled by suitable software that among other things uses data
received from the scanning sensors to determine container length, width,
height
and interior contour, and thus the void volume, as well as determining the
amount
of dunnage material to be dispensed for insertion into that volume, the type
of
dunnage material to be dispensed and/or the speed at which the dunnage
material is dispensed.
The controller 26 can be equipped with various ports (not shown) for
connection with various elements of the system 10, including input devices,
such
as a foot switch 110 for the dunnage converter 52, a conveyor speed sensor
112,
a mouse, a keyboard, a keypad, a touch screen, etc.; and output devices such
as
an operator panel, a display 114 for the dunnage converter 52, a nonconforming
container indicator (not shown), a container sensor (not shown), etc.
For example, an operator panel 114 (FIG. 3) for the dunnage converter 52
can be equipped with a touch screen as an input device, or a personal computer
can have a touch screen or other input device associated therewith. The
operator
panel 114 and/or controller 26 can have a monitor for displaying the various
indicators and/or other information, such as the measured dimension of the
container 20, the total volume of the container 20, the volume of the contents
of
the container 20, an identification of the container 20 and the volume of the
void
above the container contents 16, etc.
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Additionally, the operator panel 114 and/or controller 26 can be provided
with a selector device enabling the selection of a void-fill density from a
plurality of
void-fill densities. The selector device is an input device, and can include a
dial
whereby a desired density can be dialed in, a mouse pointer, a touch screen
with
one or more input regions, a keyboard or keypad for entry of a desired void-
fill
density, a foot switch, etc. In accordance with the selected void-fill
density, the
controller can vary the amount of dunnage material to be dispensed per
measured
volume of void, thereby to provide the selected void-fill density. That is,
the
controller can be programmed to have a default setting where it will command a
predetermined amount of dunnage to be dispensed for each unit volume of
measured void. If minimal protection is needed, for example, the operator can
select a lower void-fill density and the controller will command, for example,
10%
less dunnage material to be dispensed per given unit of measured top-fill
void.
This will result in a lower density fill of the container 20 and will consume
a smaller
quantity of dunnage material. On the other hand, if greater protection is
needed
and/or the articles packed in the container 20 are heavier, the operator can
select
a higher void-fill density and the controller 26 will command, for example,
10%
more dunnage material to be dispensed per given unit of measured top-fill
void.
The containers 20 cannot only be filled with different densities of dunnage,
but
different densities can be provided to different segments of the void volume,
so
that more or less dunnage can be provided to different volume segments of the
container.
Additionally or alternatively, the controller 26 can be programmed to select
a density and/or a dunnage fill speed based on shipping criteria. The shipping
criteria can be provided by a label, a bar code, or other features of the
container
and/or the articles packaged therein. Some examples of shipping criteria
include
void volume, container size, container weight, a specified transportation
company,
a specified mode of transport (water, land or air transport, for example; or
truck or
train transport; or local or long distance transport; etc.), features of the
article
(oversize, fragility, etc.), type of dunnage material being used (closed-cell
foam,
expanding foam, air pillows, paper dunnage, flowable dunnage, etc.) or
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combinations thereof. The invention is not limited to the listed shipping
criteria.
As noted, these are but a few general examples of potential shipping criteria.
The controller 26 also can record the amount of dunnage dispensed by the
dunnage dispensers and other events, such as when the instructions to a
dispenser were overridden by an operator to provide more or less dunnage to a
container, in addition to tracking the shipping criteria and other data. This
information can be used to improve the system over time either manually or
automatically, identify packaging trends, and identify maintenance needs. For
example, if under particular shipping criteria an operator frequently manually
overrides the dunnage dispensing instructions and dispenses additional
dunnage,
then the instructions for the shipping criteria can be automatically updated
to
instruct a dispenser to dispense additional dunnage for that shipping
criteria. As
another example, if a small number of the available dunnage dispensers are
used
for a particular shipping criteria and that shipping criteria is being applied
more
frequently, then the controller 26 might generate a report with an indication
that
additional dispensers need to be assigned to that shipping criteria.
In one embodiment, the controller 26 is operable to process the void
volume data acquired by the void determination stations 70. The controller 26
then determines the amount of dunnage material needed to place in the void
left in
the container 20 when the one or more articles 16 have been placed in the
container (or the bottom wall of the container if not overlain by an article).
In FIG.
7, this void 120 is illustrated by the cross-hatching. After the void volume
is
determined, the controller can command the dunnage dispensing station 14 to
dispense the determined amount of dunnage. The dunnage can flow directly into
the container 20 and/or be placed or guided into the container 20 by an
operator.
Dunnage Dispensing Stations
At the dunnage dispensing stations 14 a controlled amount of dunnage is
dispensed and placed in the void 120 (FIG. 7) in the container 20 around the
article or multiple articles 16 to minimize or prevent the articles from
shifting during
transport and to protect them from damage. Each dunnage station 14 includes or
is connected to a supply of dunnage. An exemplary dunnage dispensing station
is
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shown in International Patent Application Publication No. WO 2003/089163,
which
is incorporated herein by reference. The present invention contemplates use of
any type of dunnage dispensing device or means.
The containers 20 can be delivered to a dunnage dispensing station 14
randomly, or based on one or more routing criteria. Exemplary routing criteria
include container size, container weight, packing priority, shipping
destination,
dunnage type, mode of shipment, shipping company, void geometry, void volume
density, article fragility, dunnage dispensing station availability, etc.
As with the loading stations 12, and as shown in FIG. 1, in an embodiment
1o the dunnage dispensing stations 14 can be arranged in series, such as, for
example, dunnage dispensing stations 14f and 14g. With such an arrangement
multiple in line stations can supply dunnage to a container sequentially, such
as
for dispensing one or more types of dunnage, one or more quantities of
dunnage,
dunnage to a batch of containers simultaneously and/or one or more densities
of
dunnage, for example.
Optionally the dunnage dispensing stations 14 can be arranged in parallel ,
such as, for example, dunnage dispensing stations 14a - 14e. With such an
arrangement, dunnage can be dispensed for multiple containers substantially
simultaneously (i.e., at about the same time) and independently of one another
such that, for example, a dunnage dispensing station 14 can be taken off line
for
maintenance or for refilling without impacting the entire system. Optionally
each
of these dunnage dispensing stations 14 can be dedicated to a particular
container 20 based on routing criteria, as discussed below.
The dunnage dispensing stations 14 can each supply a single type or
multiple types of dunnage, or respective stations can provide dunnage having
one
or more different characteristics. For example, the containers 20 can be
filled with
different densities of dunnage, including different densities in different
areas of a
single container. If the topography, geometry or contour of a surface of the
void
volume is known, more or less dunnage can be provided to different areas
according to that known information.
The supply of dunnage at each station 14 can include a dunnage
dispenser, such as a hopper or other storage container. Additionally or
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alternatively, the dunnage dispenser can be a dunnage converter 52 as shown in
FIG. 3, for converting a stock material into a relatively less dense dunnage
product. The dunnage can be provided in a common supply for multiple dunnage
dispensers or each dispensing station 14 can have its own supply.
In the case of a dunnage converter 52, the dunnage can be produced on
site, since a dunnage converter 52 and the stock material together typically
occupy less space than an equivalent stored volume of dunnage material. The
dunnage dispenser also can include any type of suitable mechanism for moving
the dunnage toward or into the container, including mechanical feeding or
1o transporting mechanisms (such as a conveyor, pusher, screw, roller, movable
support, etc.), pneumatic or electromagnetically powered devices, or even
gravity.
Dunnage
Suitable dunnage includes any material that can be placed in the void in
the container 20. Several examples of different types of dunnage include
continuous strip dunnage, discrete pad-like dunnage, expandable dunnage, and
flowable dunnage.
A continuous dunnage strip or strips can be used to fill the void volume.
Exemplary dunnage of this type includes paper, typically crumpled or otherwise
formed into a three-dimensional shape that takes up a greater volume than the
area and thickness of the stock material; a strip of soft or rigid foam having
a
predetermined width and/or either a predetermined length or a variable length;
a
strip of air bags; an air bag "tube" having a predetermined cross-sectional
area
that can be formed in a range of lengths; a strip of bubble pack, typically
formed
from a pair of plastic sheets affixed to each other to entrain pockets of air
"bubbles" between the sheets; an extruded-in-place strip or tube of foam that
forms as it is dispensed from an outlet; and linked dunnage, such as chains of
linked dunnage segments or sausage links. With respect to paper dunnage,
optionally the paper can be formed into a strip.
Linked dunnage includes relatively low density portions connected by a
higher density material, and generally can occupy a greater volume than a
similar
size and number of unconnected low density dunnage portions. Linked dunnage
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includes, for example, connected air bags, with lower density portions
connected
by higher density portions, etc.
The continuous strips of dunnage can be fed directly into the void in a
container using a chute with rotating members to "shoot" the strip into the
container or into an intermediate chamber or other holding location from which
the
strip can be pushed, dropped or otherwise moved into the container. The strips
also could be wound into a coil and then sections can be withdrawn from the
coil
as needed.
Dunnage segments or discrete dunnage units are sections of dunnage.
1o Typically, when using discrete pad-like dunnage, one or more dunnage pads
having one common length or different lengths are placed in the void volume.
Otherwise, the pad-like dunnage can be similar in shape to respective dunnage
strips described above. Exemplary dunnage pads include paper pads formed, for
example, by crumpling or otherwise forming a paper sheet or sheets into a
three-
dimensional shape that takes up a greater volume than the area and thickness
of
the stock material; discrete or connected sections of soft or rigid foam; air
bags
having a predetermined size and shape; air bag "tubes" having a predetermined
cross-sectional area that can be formed in predetermined lengths; and sheets
of
bubble pack of predetermined lengths, etc. Optionally the paper can be coated
to
increase its mass; and/or portions of the paper can be cut or otherwise
removed
to reduce its mass.
Discrete pad-like dunnage can be oriented and placed in a container by a
pick-and-place robot, pushed into a container from a holding location or
dropped
or otherwise fed into the container directly from a hopper or dunnage
conversion
machine. An exemplary pad-producing dunnage dispenser, such as is disclosed
in U.S. Patent No. 5,123,889, for example, can convert one or more plies of
sheet
stock material (such as kraft paper) into a relatively less dense dunnage
material.
Expandable dunnage expands to fill a range of volumes. Some examples
of expandable dunnage include: foam-in-a-bag, where the chemical components
of a foam are placed in a sealed bag, typically made of some type of polymer
suitable for controlled activation; and inflate-in-place air pillows that can
be inflated
inside the container to fill the void volume, as described in U.S. Patent No.
CA 02576085 2012-07-16
6,253,806, for example. In foam-in-a-bag dunnage, the foam expands within the
bag
to fill an enclosed volume, either the bag itself or the void in a closed
volume. The
expanded foam solidifies in a shape that approximates the shape of the void
volume. The bag can be placed in the container, which is then closed and the
foam
fills the closed volume, or, particularly when the shape of the void volume is
known,
the foam-in-a-bag can be solidified in a mold having the desired shape before
it is
placed in the container.
Flowable dunnage includes a plurality of relatively small dunnage products
that can flow into the void in the container. Some examples of flowable
dunnage
1o include: foam "peanuts," paper peanuts, air bag "ravioli" formed of small
air bags,
etc.
The flowable dunnage product can include multiple sizes within the supply.
Flowable dunnage typically is dispensed first to a hopper for storage, and
then fed
through tubes or chutes into the container. One exemplary flowable dunnage
dispenser is disclosed in U.S. Patent No. 6,672,037. A vibration table also
can be
used to ensure that the flowable dunnage settles into the void volume in the
container.
The type of dunnage dispenser or converter 52 employed typically will be
dunnage-dependent. For each dunnage product there can be multiple ways to
deliver and place the dunnage in the container 20 other than the exemplary
methods described herein. The dunnage dispenser 52 also can include self-
limiting
features that stop delivery of the dunnage once a sensor is triggered, such as
an
electromagnetic sensor, mechanical trigger or backpressure sensor. For
example, a
limiting plate with a passage therethrough can be placed over the opening in a
container, and a gate valve, butterfly valve or other valve can be used to
allow
flowable dunnage to pass through the limiting plate. The plate effectively
closes the
top of the container, but allows the dunnage to fill the container until one
or more
sensors are triggered to indicate that the container is full. One example is
disclosed
in U.S. Provisional Patent Application No. 60/624,348, filed November 2, 2004.
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The dunnage supplied at each dunnage dispensing station 14 can be
placed in the container 20 entirely by hand; or the dunnage can be placed by a
packer initiating or otherwise controlling one or more steps that are
performed by
one or more devices that place the dunnage in the container 20 (such as a pick-
and-place robot). As another alternative, the dunnage can be placed in the
container independent of any external control. In this latter example, one or
more
devices, controlled by the controller 26, for example, automatically place the
dunnage in the void volume in the container 20 without any assistance from a
packer.
Container Closing Station
The container closing station 102 is where the container is closed and
prepared for shipping. After dispensing the dunnage, the container 20 is
transferred to a container closing station 102 to close the container 20.
Devices
for automatically closing a container 20, typically referred to as "box
closers," are
known and can be used in the final step of the packing process to
automatically
close and seal the container for shipment. In the case of a RSC container, the
container 20 can be automatically sealed using automatic flap folding
equipment
integral to or ancillary to an automatic box sealing device, including but not
limited
to random case sealers, tapers, and strapping equipment. If a shoe box-style
container 20 is used, the container 20 is sealed using hot glue or strapping
equipment that secures a separate lid on the container, using hot glue, tape
or
straps, for example, to close the container 20 and secure it for shipping.
Shipping
labels also can be applied automatically, meaning than in many instances the
operator's involvement in the packaging process can be minimal or nonexistent,
freeing the operator to deal with non-conforming fault conditions and/or
placing
articles in more containers.
Alternatively, the packer can close and seal the container 20 using tape,
straps, or an adhesive. Alternatively, the packer performs some steps, such as
folding flaps down or placing the lid on the container, and other steps are
performed by a container closing mechanism. Finally, the container 20 is
routed
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to a shipping station 104. There the containers 20 can be sorted by
destination,
mode of transport, etc. and further bundled for shipment, if necessary.
Exemplary Method of Operation
FIG. 8 illustrates an exemplary methodology for an automated packaging
system. The steps or blocks shown represent functions, actions or events
performed. If embodied in software, each block may represent a module,
segment or portion of code that comprises one or more executable instructions
to
implement the specified logical function(s). If embodied in hardware, each
block
1o may represent one or more circuits or other electronic devices to implement
the
specified logical function(s). Computer software applications generally
involve
dynamic and flexible processes such that the functions, actions or events
performed by the software and/or the hardware can be performed in other
sequences different than the one shown.
With reference to FIGS. 3 and 8, an exemplary system can operate in the
following manner. One or more containers 20 are erected by a container erector
32 at one of one or more loading stations 12 where one or more articles 16
subsequently are placed in the container for shipping at step 200. The
container
is then routed in step 202 to a selected one of a plurality of void
determination
20 stations 70 for determining the void volume, if the void volume is needed.
This
step is not always necessary and in some cases can be omitted, as previously
mentioned. A container identifier also can be detected at step 204, if
required.
The container 20 is examined for suitability for receiving dunnage, i.e. for a
fault
condition, at step 206. If a nonconforming fault condition exists the
container 20
can be diverted for special handling by an operator in step 208. If there is
no
nonconforming fault condition, the dunnage requirements for the void volume
are
determined at step 210. The container 20 is routed to a selected one of a
plurality
of dunnage dispensing stations 14 in step 212 where dunnage is dispensed and
placed in the void volume in step 214.
A prescribed amount of dunnage can be dispensed automatically, based
on the determined void volume. The container 20 can be automatically
positioned
at the outlet of a dunnage dispenser 14a and dunnage can be dispensed
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automatically, directly into the container 20, without intervention by an
operator, or
the dunnage can be dispensed automatically but not directly into the container
20
or can be dispensed under the direction of an operator for subsequent
placement
in the container 20. After the prescribed amount of dunnage material has been
dispensed and either dispensed directly into the container 20 or placed in the
container 20 in a subsequent step, the container 20 can be passed on for
further
processing, such as routing the container 20 through a container closer at the
container closing station 130 in step 216 and closing the container 20 in step
218
and then routing the container 20 through a shipping station 132 at step 220
for
further transport to a remote location.
Returning now to FIG. 2, this figure illustrates an exemplary embodiment of
a packaging system 300. The system 300 includes a plurality of loading
stations
12a, 22b; a transport network 24 having a plurality of transport lines 68b,
68c, 68f,
68g, 68h, 68m, 68n, 680, and 68t, for example; a container diverter 301;
diverter
lines 68aa, 68bb, 68cc; router gates 302a and 302b; an intermediate station
22a;
and dunnage dispensing stations 14a, 14b, 14c, and 14d. During normal
operation, articles (not shown) are placed in containers 20 at parallel
loading
stations 12a and 12b. The articles may be placed in the containers manually or
via an automated system. The containers 20 travel to an intermediate station
22a
via either transport lines 68b or 68c, or a combination thereof.
The transport lines 68 are illustrated as multiple conveyers, i.e. transport
lines 68b, 68c, 68f, 68g, 68h, 68m, 68n, 68o, and 68t, etc. The transport
network
24 can include any means, however, for transporting the containers 20 between
two or more stations, such as, for example: one or more conveyers, which may
be driven by motors, gravity, pneumatically, manually; one or more chutes;
etc. In
addition, the transport network 24 can include any combination of the
different
types of transport lines. Moreover, the length of each transport line 68
generally is
dependent on the distances between the stations. In some embodiments, the
sensors or components described herein with respect to different or separated
stations may be integrated into a single station. For example, a sensor for
determining whether the container should be automatically filled with dunnage
has
been described with respect to an intermediate station, but could be
integrated
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into the loading stations 12a and 12b, or integrated into the dispensing
stations
14a, 14b and 14c. In such a case, the transport line between the sensor and
the
station can be very short, such as, for example, less than a foot.
At intermediate station 22a data or information regarding the container 20
and/or its contents is obtained. The data is obtained via one or more sensors
(not
shown) and the data can include, for example, the topography of the contents
of
the container 20, the size of the container 20, the location of the contents,
etc. A
controller 26 determines whether the loaded container 20 is suitable for
automatic
dunnage insertion as a function of the data obtained at intermediate station
22a.
1o If the loaded container 20 is not suitable for automatic dunnage insertion,
for
example, if the contents of the container 20 are above the top of the
container 20,
the container 20 is moved to diverter line 68aa, by the container diverter
301. In
one embodiment, the container diverter 301 is a pneumatically-operated piston
that pushes the container 20 onto diverter line 68aa. The container diverter
301
can include any means for diverting the container 20 to the diverter line
68aa,
such as, for example, a switching bar, a trap door, a pick-and-place robot,
etc. In
another embodiment, the container diverter 301 does not physically remove the
container 20 from the transport lines leading to the dunnage dispensing
stations
14. Instead, the controller 24, instructs the dispensing stations 14 to allow
the
container to pass through the dispensing station 14 without inserting dunnage
into
the container 20, thereby indirectly removing the container 20 from the
transport
line. In this case, the container 20 optionally can be removed from the system
after it passes the dunnage dispensers 14.
Returning to the illustrated embodiment, the diverter line 68aa is a means
for physically removing the container 20 from the transport line leading to
the
automatic dunnage dispensers 14a, 14b and 14c. Optionally, the diverter line
68aa can include a transport line to a diversion station 14d where the non-
conforming condition can be resolved. Dunnage can be placed in the container
at
the diversion station 14d, or the container 20 can then be reintroduced to a
transport line 68f, 68g or 68h leading to the automatic dunnage dispensing
stations 14a, 14b and 14c, or can be transported to a dunnage dispensing
station
(not shown) outside of the transport network 24.
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If a container 20 is suitable for packing (e.g., there is no non-conforming
fault condition), the controller 26 can control a series of router gates 302a
and
302b that are controllably opened and closed by the controller 26 to direct
the
container to a selected dunnage dispensing station 14. The first router gate
302a
is used to route the container 20 to either dunnage dispensing station 14a or
on
toward the second router gate 302b and dunnage dispensing stations 14b and
14c. The router gates 302a and 302b each include respective pneumatically-
operated swing arms 304a and 304b. If the first swing arm 304a is activated or
otherwise placed in a closed condition, the container 20 is routed to a first
transport line 68f and to automatic dunnage dispenser 14a. If the first swing
arm
304a is open and the second swing arm 304b is activated or otherwise placed in
a
closed position, the container 20 is routed to transport line 68g and to
automatic
dunnage dispensing station 14b. Otherwise, if both swing arms 304a and 304b
are open, the container will be directed to transport line 68h and to
automatic
dunnage dispensing station 14c. The router gates 302a and 302b can include any
means of routing the container 20 to a selected automatic dunnage dispensing
station 14a, 14b, or 14c such as, for example, a single arm, a robotic arm, a
bush
bar, a rotating table, a plate, etc.
The controller 26 determines the volume of dunnage to be placed in the
container 20 as a function of the data obtained at intermediate station 22a.
The
controller 26 provides a signal to the selected dunnage dispensing station
14a,
14b or 814c. The controller 26 thus instructs the dunnage dispenser, such as a
dunnage converter (not shown), to dispense the required volume of dunnage. At
automatic dunnage dispensing stations 14a, 14b and 14c the container 20 is
automatically filled with the determined volume of dunnage.
From dunnage dispensing station 14a, the container 20 moves on transport
line 68m to a closing station 102a, where the container is closed, and then on
to a
shipping station 104a via transport line 68t. From dunnage dispensing stations
14b and 14c, respective transport lines 68n and 68o transport containers to a
shared closing station 102b. In the illustrated embodiment, the diversion
dunnage
dispensing station 14d transports a container to a closing station 102c via
transport line 68bb and then transport line 68cc transports the container to a
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shipping station 104b that is shared with automatic dunnage dispensing
stations
14b and 14c.
Although the invention has been shown and described with respect to
certain preferred embodiments, it is obvious that equivalent alterations and
modifications will occur to others skilled in the art upon the reading and
understanding of this specification and the annexed drawings. In particular
regard
to the various functions performed by the above described components, the
terms
(including a reference to a "means") used to describe such components are
intended to correspond, unless otherwise indicated, to any component which
1o performs the specified function of the described component (i.e., that is
functionally equivalent), even though not structurally equivalent to the
disclosed
structure which performs the function in the herein illustrated exemplary
embodiments of the invention. In addition, while a particular feature of the
invention can have been disclosed with respect to only one of the several
embodiments, such feature can be combined with one or more other features of
the other embodiments as may be desired and advantageous for any given or
particular application.
32
