Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
  • B65B65/00—Details peculiar to packaging machines and not otherwise provided for; Arrangements of such details
  • B65B65/003—Packaging lines, e.g. general layout
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
  • B65B55/00—Preserving, protecting or purifying packages or package contents in association with packaging
  • B65B55/20—Embedding contents in shock-absorbing media, e.g. plastic foam, granular material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
  • B65B65/00—Details peculiar to packaging machines and not otherwise provided for; Arrangements of such details

Definitions

• 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.
• a packer pulls articles itemized on a list of articles to be shipped and places them in a container.
• 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.
• dunnage dispenser 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 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.
• 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).
• 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.
• a transport network can also include a way to divert nonconforming containers that fail to meet the predetermined criteria.
• a packaging method provided herein includes 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.
• 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.
• 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.
• 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.
• 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.
• 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.
• a packaging system in another embodiment, 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.
• 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.
• 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.
• 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.
• 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.
• 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 dispensing station, and a controller.
• the controller automatically routes containers via the transport network to selected dunnage dispensing stations.
• 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.
• 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.
• 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.
• 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. 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. 8 is a flowchart illustrating a packaging process in accordance with an embodiment of the invention. DETAILED DESCRIPTION
• 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.
• container loading stations 12 such as, for example, loading stations 12a, 12b, 12c and 12d
• 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.
• 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.
• 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 determining whether or not the container meets the predetermined criteria.
• the embodiment of the system 10 shown in FIG. 1 optionally can include one or more closing stations 102 for closing the container 20, and optionally, the system 10 can include one or more shipping stations 104 for processing the container for shipping.
• 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.
• 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.
• FIGS. 2 and 3 showing one particular exemplary system 300 and FIG. 3 showing one path a container 20 can follow through the system.
• the loading stations 12 can include a box erector 32 for erecting the containers 20, such as cardboard boxes, from flat blanks 34.
• a 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.
• RSC typically has four flaps, with one set of opposing flaps typically spanning at least half the distance between them.
• 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 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.
• 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.
• 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.
• the articles 16 can be loaded into the container 20 in a variety of ways.
• a packer can place the articles 16 in a container 20 by hand.
• 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).
• 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, place the article or articles 16 in the container 20 without any assistance from a packer.
• 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.
• the transport network 24 can include a conveyor network that generally starts, stops, transports and orients the container 20 as needed, in which case fewer, if any, people are needed. In a highly 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.
• the transport network 24 includes a conveyor 60 such as, for example, 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 when a container has left a zone.
• a supervising controller such as controller 26 typically controls the operation of each zone.
• 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.
• 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.
• 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.
• 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 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 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 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.
• 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 pulsed laser beam can be deflected by a rotating mirror 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.
• 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.
• the width 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.
• 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.
• 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.
• 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 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.
• 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 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.
• 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.
• a void determination station 70 generally can automatically provide void volume data at a faster rate than a dunnage dispenser 52 can provide 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.
• the void volume can be determined indirectly.
• a sensor such as a bar code sensor, could detect an identifier, such as a bar code, that identifies the 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.
• 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 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 (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 image, etc.
• the database can also provide container dimensions and empty container volume information.
• 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.
• 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 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 airbag is inflated within a container until the walls of the container move outward, which indicates that the container is full.
• 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 dispensed can be predetermined based on the volume of the largest potential container, or can be guided by one or more sensors.
• 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.
• 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.
• RSC flaps In this system, RSC flaps must be in the down position, folded outside the container, or a shoe box-style container must be employed.
• flap handling equipment 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.
• 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.
• the controller 26 functions to control one or more components of the system 10.
• 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.
• 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.
• 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).
• PLCs programmable logic controllers
• ROM read-only memory
• RAM random-access memory
• 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.
• 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.
• 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.
• an operator panel 114 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 1 14 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.
• 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.
• 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.
• 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.
• 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.
• 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 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.
• 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 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 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.
• 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.
• 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.
• 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.
• 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 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 transporting mechanisms (such as a conveyor, pusher, screw, roller, movable support, etc.), pneumatic or electromagnetically powered devices, or even gravity.
• mechanical feeding or transporting mechanisms such as a conveyor, pusher, screw, roller, movable support, etc.
• pneumatic or electromagnetically powered devices or even gravity.
• 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
• 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 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. 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.
• 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. 6,253,806, for example.
• 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 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.
• 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).
• 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.
• 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.
• the packer can close and seal the container 20 using tape, straps, or an adhesive.
• 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.
• the container 20 is routed 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.
• FIG. 8 illustrates an exemplary methodology for an automated packaging system.
• the steps or blocks shown represent functions, actions or events performed.
• 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).
• each block 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.
• 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 20 is then routed in step 202 to a selected one of a plurality of void determination 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.
• 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 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.
• 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.
• 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, 68o, 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.
• articles 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.
• the transport network 24 can include any combination of the different types of transport lines.
• 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.
• 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 into the loading stations 12a and 12b, or integrated into the dispensing stations 14a, 14b and 14c.
• the transport line between the sensor and the station can be very short, such as, for example, less than a foot.
• 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. 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.
• 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.
• 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.
• the container 20 optionally can be removed from the system after it passes the dunnage dispensers 14.
• 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.
• 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.
• 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.
• 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.
• the container 20 is automatically filled with the determined volume of dunnage.
• 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.
• respective transport lines 68n and 68o transport containers to a shared closing station 102b.
• 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 shipping station 104b that is shared with automatic dunnage dispensing stations 14b and 14c.

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• 2005
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