JP4903145B2 - Packing system and method - Google Patents

Abstract

An automated packaging system has a plurality of dunnage dispensing stations that can dispense dunnage and a transport network for conveying containers to and from at least two dispensing stations for dunnage to be placed therein. At at least one loading station upstream of a dispensing station articles are placed in the containers for shipping. Optionally, an intermediate void determination station determines how much dunnage to dispense.

Description

Detailed Description of the Invention

  The present invention claims a benefit on the filing date of the following provisional patent application. US provisional application serial number 60 / 669,712 filed on April 7, 2005, US provisional application serial number 60 / 655,645 filed February 22, 2005, filed January 18, 2005 All of U.S. Provisional Application Serial No. 60 / 644,736 and U.S. Provisional Application Serial No. 60 / 598,689 filed on Aug. 4, 2004 are all incorporated by reference herein.

〔Technical field〕
The present invention relates to a packaging system for supplying a packing material to a container in which one or more articles are packaged for shipment.

[Background Technology]
In a typical example, a person who packs items to be shipped takes out the items listed in the list of items to be shipped and places them in a container. Here, before shipping an article, a packing material for protecting the article or another kind of packing material is laid around the position where the article is placed in the container.

  The packing material is arranged to prevent or minimize the movement of the article in the container and to prevent or minimize the damage to the article during transportation. The packing material fills at least a part of the gap or reduces the impact on the article being transported.

  Commonly used packing materials include plastic foam peanuts, plastic bubble packs, air bags, and crumpled paper materials. .

  The operator of the dispenser that dispenses the packing material observes how the container is filled with the packing material and stops the dispensing machine when it thinks the container is full of loading material. The container is then closed for transport.

  Common distributors are plastic peanut distributors often used in air transportation systems, foam-in-place distributors, airbag machines, and paper packing material manufacturing machines. (Paper dunnage converters).

  Here, the distributor operator may stuff too much packing material into the container. In this case, more packing material will be packed into the container than is necessary to adequately protect the article and / or fill the gap in the container. Also, there may be too little loading material placed in the container by the operator. In this case, the article has room to move in the container and may be damaged during transportation.

  Overpacking and shortage of packing material becomes a greater problem, especially with increasing speed of distribution work. Today, dispensers that fill gaps, especially paper stock making machines, can produce elongated stock at speeds of 50 feet per minute (about a quarter of a meter per second) or more. .

[Summary of the Invention]
Here, a system and method for automating a packing operation to fill a gap is disclosed. Specifically, a plurality of loading material distribution stations each having at least one loading material distribution machine capable of distributing the loading material, and at least two loading materials for arranging the loading material in the container A packaging system is provided that transports a plurality of containers to a distribution station and a transport network that transports the plurality of containers from the loading material distribution station. The dispensing stations may be arranged in series and / or in parallel so that one or more containers can be sequentially transported to a plurality of dispensing stations along a part of the transport network. The system may also include a source of consignment material that can be distributed at at least one consignment distribution station. The source may comprise a load material conversion machine that can convert the storage material into a lower density load material and supply it to one or more load material distribution stations. The source of the loading material includes, for example, at least one of an airbag, twisted paper, an elongated foam piece, foam peanut, and an elongated paper piece.

  The system may further include a controller that controls one or more of the elements of the system. These elements include, for example, one or more packing stations that place one or more articles in one or more shipping containers or upstream of at least one packing material distribution station. And / or one or more intermediate stations with a gap sensor for detecting a characteristic of the gap volume in the container and / or one or more for determining whether the container meets a predetermined criterion or A plurality of devices (for example, sensors) may be included. In the latter example, the transportation network may further include a path to redirect non-conforming containers that do not satisfy the predetermined criteria.

  The packing method provided here includes a step of shipping a container from a plurality of packing material distribution stations to a selected packing material distribution station based on a criterion for designating a route, and the container is loaded at the packing material distribution station. Feeding the material. The criteria for designating the route include, for example, the effectiveness of the distribution material distribution station, the characteristics of the distribution material, the characteristics of the container, the characteristics of the gap in the container, and / or the goods shipped in the container. Features. The step of supplying the loading material may include, for example, a step of determining a gap volume in the container.

  In one embodiment, the method further includes assigning an identifier to each container and tracking the container as the container moves through the packaging system.

  In addition, in the embodiment, one or a plurality of gap detection stations that detect the characteristics of the gap volume of the container, and one or more that can distribute the packing material based on the characteristics detected by the gap detection station. And a transport network characterized by a transport network for moving the containers from one of the gap detectors to a selected one of the load distribution stations.

  Embodiments of the packaging system include at least one sensor that detects at least one of the characteristics of the container and whether the container is suitable for placing a packing material therein based on the detected characteristic of the container. And a controller for determining whether or not. The packaging system includes one or more packing material distribution stations that distribute the packing material to be placed in the gap of the container, and includes at least one packing material distribution station capable of distributing a plurality of types of packing material. May be.

  Another embodiment of the packing method includes the steps of shipping a container from a plurality of packing material distribution stations to a selected packing material distribution station based on routing criteria, and loading the container at the packing material distribution station. Supplying a floor covering.

  In addition, the shipping step is based on one or more criteria for designating a route including the characteristics of the packing material, the characteristics of the gap in the container, and the characteristics of the article to be shipped in the container. A step of shipping based on may be included.

  Embodiments of the present invention determine a type of loading material to be dispensed, control the amount of loading material to be dispensed, measure container characteristics, and consult a database to determine gap volume One or more of the steps may be included.

  In another embodiment of the present invention, the packaging system distributes the load material based on one or more gap detection stations that detect the characteristics of the gap volume of the container and the characteristics detected by the gap detection station. A plurality of load distribution material distribution stations, and a transport network for moving the containers from one of the gap detectors to a selected one of the load distribution material distribution stations.

  A packaging method according to an embodiment of the present invention includes a step of determining a gap volume of a container, a step of transporting the container to a selected one of a plurality of packing material distribution stations, and a load based on the gap volume of the container. Distributing the covering material.

  The packaging system according to the embodiment of the present invention determines whether or not the container is suitable for placing a packing material therein based on a sensor that detects the characteristic of the container and the detected characteristic of the container. Including a controller.

  A packaging method according to another embodiment of the present invention includes a step of detecting at least one of the characteristics of the container, and whether or not the container is suitable for placing a covering material therein based on the detected characteristic. Determining.

  A packaging system according to an embodiment of the present invention includes a plurality of load distribution material distribution stations that distribute the load distribution materials to be arranged in gaps in the container, and the at least one load distribution material distribution station includes a plurality of types of load distribution materials. The flooring can be dispensed.

  In an embodiment of the present invention, an automatic packing system for automatically filling a space in a container includes a plurality of packing stations for packing containers, a plurality of packing material distribution stations, and the plurality of packing stations. A transport network connecting the packing station and the plurality of packing material distribution stations and a controller for transporting the container group from one to a plurality of packing material distribution stations, wherein the controller selects The container is automatically shipped to the designated distribution material distribution station via the transportation network.

  If necessary, the system acquires information indicating the gap volume in the container upstream of at least one distribution station, and supplies the acquired information to the controller. A controller that manages the loading material distribution station to automatically distribute the determined amount of loading material, determining the amount of loading material to be distributed at the loading material distribution station using information indicating Even including one or more of a gap volume detection device including a sensor that acquires a measurement value of the container and a gap volume detection device including a sensor that acquires data indicating a shape characteristic of the contents of the container The data indicating the gap volume may be obtained from one of data stored in a barcode, an RFID chip, and a database.

  An automated system for packing items in a container according to an embodiment of the present invention includes a loading station for packing one or more items in a container, means for identifying the characteristics of the container, and dispensing to the container. Means for determining the amount of load material, a plurality of load material distributors, and means for shipping the container from the packing station to a selected one of the plurality of load material distributors. The selected load distribution material dispenser supplies the determined amount of the load distribution material to the container.

  If necessary, the system can utilize the identified features to determine a container that is not suitable for automatically filling the cover material and / or convert the storage material into a product for the load material. Including one or more loading material converters.

  An automatic packing system according to an embodiment of the present invention includes a packing station that packs containers, a sensor that acquires characteristics of the packed containers, and a load that automatically places a packing material in the containers. A flooring distribution station, a transport network for moving the containers from the packing station to the packing material distribution station, and whether the packing material is to be placed in the packed containers using the obtained characteristics. And a controller for determining whether or not.

  If necessary, the determination of whether or not to place a packing material in the packed container is based on the determination of whether the container meets a predetermined standard and / or the transportation network A container redirector that redirects incompatible containers, and / or the container redirector includes a mechanism that removes the containers from the transport network, and / or the container redirector is a manual station Includes a mechanism for shipping the container.

  These and other features are fully described below and are particularly addressed in the claims. The following description and the annexed drawings set forth in detail one or more embodiments of the invention. However, these embodiments are only a handful of various ways in which the principles of the present invention can be applied.

[Brief description of the drawings]
FIG. 1 is a schematic view of the packaging system of the present invention.

  FIG. 2 is a plan view showing an embodiment of the packaging system of the present invention.

  FIG. 3 is a side view showing an outline of a path through which the container passes in the packing system.

  4 is a perspective view of a standard rectangular expansion container (RSC) used in the system of FIG.

  FIG. 5 is a side view of the gap volume scanner used in the system of FIG.

  6 is a cross-sectional view of line 6-6 in the gap volume scanner of FIG.

  FIG. 7 is a cross-sectional view of a container in which a plurality of article groups are arranged in a state where a gap indicated by shading remains.

  FIG. 8 is a flowchart showing the packing process according to the embodiment of the present invention.

[Detailed explanation]
First, as shown in FIG. 1, a packaging system according to an embodiment of the present invention is indicated by 10. The system 10 includes one or more packing stations 12. Examples of the packing station 12 include packing stations 12a, 12b, 12c, and 12d. The system 10 also includes a plurality of loading material distribution stations 14. Examples of the plurality of packing material distribution stations 14 include packing material distribution stations 14a, 14b, 14c, 14d, 14e, 14f, and 14g. At the loading station 12, one or more articles 16 (see FIG. 3) are placed in the container 20. Then, the packing material distribution station 14 distributes the packing material and fills the gap in the container 20. The gap refers to a space in the container 20 that is not occupied by one or more articles 16.

  The system 10 may also include one or more intermediate stations 22 that assist the loading material distribution station 14 as required. The intermediate station 22 may be one of the systems 10 such as a transport network 24 that moves the container group 20 from the beginning to the end of the station and / or an operation that controls the flow of the container group 20 from the beginning to the end of the system 10. A system controller 26 that controls a plurality of operations may be further included.

  FIG. 1 shows an example in which the transport network 24 can transport the containers 20 in the system 10 by a plurality of routes. For example, it is transported from a plurality of stations to a common station, or transported from one station to a plurality of stations following the station. Although FIG. 1 shows a plurality of given type stations (eg, loading, intermediate, etc.), depending on the given application, one of the given types is shown. There may be cases where only one station is sufficient and / or no need for a given type.

  In addition, if necessary, the one or more intermediate stations 22 may be provided with a device for determining whether or not the container satisfies a predetermined standard before putting the packing material. Further, the intermediate station 22 may include a gap determination station that determines the volume of the gap in the container 20 or a gap determination device 30 (see FIG. 3). The clearance determination device 30 can be used to calculate the volume of the loading material necessary to fill the clearance. The gap determination device 30 can also be used to determine whether or not the container satisfies a predetermined standard.

  The system 10 shown in FIG. 1 may include one or more closure stations 102 that close the containers 20. The system 10 may also include one or more shipping stations 104 that perform processing for shipping the containers.

  The system 10 of the present embodiment minimizes or eliminates the demands on the person who performs packing and other operators, shortens the time required for packing the container, and / or increases the reliability of the packing operation. It is aimed.

  In the above system, in order to shorten the packing time, for example, a machine that distributes and fills the packing material into the container faster than a packer may use may be used. In addition, the above system may be configured such that, for example, an accurate volume of the loading material is automatically calculated in order to improve reliability. This can reduce or eliminate the possibility of overpacking or underfilling of the packing material. The various stations included in the system 10 will be described in more detail with reference to FIGS. FIG. 2 shows a system 300 that is one detailed embodiment of the present invention, and FIG. 3 shows one path through which the container 20 passes through the system.

[Packing station]
As shown in FIGS. 2 and 3, the packing station 12 may include a box assembly machine 32. The box assembly machine 32 assembles the container 20. The box assembly machine 32 assembles containers 20 such as cardboard boxes from flat papers 34. The system 10 may use other types of containers, in which case a box assembler is not necessary. The box assembly machine may be, for example, a work area where a packer makes a box from paper in a box, or a device that automatically makes a box from paper. Furthermore, the box assembly machine may be an apparatus that creates a box on site.

  The container 20 illustrated here is a rectangular slotted container (RSC), and the other type of container is a shoe-box style container. Other types of shipping containers can be used in the system 10. An RSC generally has four flaps and, generally, in a set of opposing flaps, each opposing flap extends longer than the midpoint of the distance between the flaps.

  A quick glance at FIG. 4 shows that in RSC there is a specific relationship between the width W of the container and the height of the side flaps 36 and end flaps 38. That is, in this typical example, the height of the flaps 36 and 38 is half the width W of the container. Therefore, the height of the side wall 40 and end wall 42 of the container 20 (the height of the container when closed) measures the height of the container 20 when the flaps 36 and 38 are unfolded upright. Can be determined. When the flaps 36 and 38 are erected and spread, the height of the side wall 40 and the end wall 42 (the height of the article accommodating portion of the container 20) can be obtained. Also, those skilled in the art will appreciate that the height H may be determined by other methods, for example when the flaps 36 and 38 are folded. That is, in such a case, the height of the side wall 40 and the end wall 42 of the container 20 may be directly measured.

  The plurality of packing stations may be arranged in series such that one or more articles 16 can be supplied to the container 20 as the container 20 sequentially passes through the plurality of packing stations. For example, as shown in FIG. 1, after the first article or group of articles is placed in the container at 12c, the container is transported to 12d, and the next article or group of articles is placed in the container at 12d. You may comprise as follows. The articles may be different from each other or the same.

  A plurality of packing stations may be arranged in parallel. As shown in FIGS. 1 and 2, the packing stations 12a and 12b are arranged in parallel. Thereby, separate containers can be packed at the same time. Also, if necessary, only one loading station can be taken offline without stopping the entire system 10.

  There are several ways to pack an article or group of articles 16 into a container. That is, before placing one or more articles 16 in the container 20, they may be removed from the storage and placed in a temporary storage location (not shown) such as a transport case (tote). Then, one or more articles 16 are taken out from the transfer case when placed in the container 20. Articles 16 may be supplied randomly if there is no predictable pattern for placing the articles in a particular container 20. On the other hand, the packing station may supply one or more articles 16 based on one or more criteria. In addition, the said reference | standard contains the dimension of a container, a transportation company, a transportation method, the fragility of an article | item, the weight of an article | item, the magnitude | size of an article | item, the relationship of an article | item, etc.

  There are various ways of placing the article 16 in the container 20. For example, the article 16 may be arranged in the container 20 by the hand of the packer. Alternatively, the packer may perform one or more steps on one or more devices that place the article 16 in the container 20 to place the article. In this case, the packer initiates, controls, or manages the above steps. In addition, as the apparatus, for example, an article placement robot (pick-and-place robot (not shown)) that can move an article into a container, and preferably can adjust the orientation of the article in the container. Can be mentioned. Also, the article 16 may be placed in the container 20 without operator control. In this case, one or more machines, or other devices, are controlled by, for example, the controller 26 so that the article or article 16 can be placed in the container 20 without any work by the packer.

[Transport network]
The transport network 24 transports the containers 20 from one station to another. The transport network 24 specifically transports the containers 20 from upstream to downstream of the system 10. Any method or combination of methods may be used as a method of physically moving the container 20 in the system 10. For example, as the transport network 24, a conveyor network that transports the containers 20 while starting and stopping as normal operations and changes the direction of the containers 20 as necessary can be applied. The transport network 24 requires only a small number of people, if any. In highly automated systems, one or more people are required to manage and solve transportation problems on multiple lines in the network.

  The transport network 24 may include a plurality of conveyor lines 68 that route the system 10. In FIG. 1, these lines 68a to 68z are schematically shown. The line selects a route while branching or converging, and conveys the container along a route such as 68b, 68f, 68m, and 68t. The transport network 24 shown in FIG. 3 includes a conveyor 60 configured by, for example, a zero pressure accumulating conveyor. In a zero pressure accumulating conveyor, the conveyor is divided into a plurality of areas, each area being sized to accommodate at least one container. The container moves from an upstream area to an adjacent downstream area. The movement is performed when the downstream area is free. Moreover, you may supply electric power to each area | region separately. A stop gate or other means for controlling the flow of the container between the regions or in the regions may be provided. Furthermore, you may provide the sensor which detects that the container left the area | region. Then, for example, an operation in each area may be controlled by a management controller such as the controller 26.

[Intermediate station]
An optional intermediate station 22 is arranged between the packing station 12 and the packing material distribution station 14. The intermediate station 22 may include a gap determination station or a gap determination device 70 for obtaining the gap volume data. Thereby, in the distribution of the loading material performed by the loading material distribution station 14, it is possible to assist in distributing the controlled amount.

  The gap determination device 70 is used to acquire data for determining the gap volume, and thereby it is possible to determine how much of the packing material is put into the container 20. The gap volume can be determined by directly measuring the characteristics of the container 20, the gap and / or the contents. A specific example of the gap determination device is described in, for example, US Pat. No. 5,897,478. Note that the gap determination device 70 shown in FIG. 3 includes a gap volume scanner 72 having a scanning area in an area where the container 20 is carried. The obtained gap volume data may be stored in an electronic storage device, and the electronic storage device may be included in the controller 26, for example.

  The gap volume may be manually measured using a measuring tool for one or more of the characteristics of the container. Then, the gap volume may be obtained by comparing these measured values with the dimensions of a lookup table for indirectly determining the gap volume, or directly calculated from the measured values to obtain the gap volume. May be.

  Furthermore, the gap volume may be obtained by detecting and measuring the outer shape of the gap volume. For this, an image forming technique using electromagnetic or an image forming apparatus can be used. For example, a device such as a high-frequency radar, an ultrasonic wave, a laser, or a machine vision can be used. The image forming sensor or the image forming sensor group can also be used to create a stereoscopic image. By using a three-dimensional model, the gap volume can be calculated.

  Further, instead of the above, the depth of the container can be examined by expanding a relatively movable rod arranged two-dimensionally on the container and extending it into the container. The depth can be measured from the position of the bar in the array when each bar is extended downward until it hits the top of the article 16 or the surface of the container 20. By using a map that shows the geometric features, the material can be directed to the area that needs to be filled the most.

  A specific example of the gap volume scanner is described in International Patent Publication No. WO2004 / 041653. This can be referred to as it is and combined here.

  The gap volume scanner 72 in the example of FIGS. 5 and 6 includes a frame 76 as shown. As shown, the frame 76 has a pair of upright portions 76 that straddle the conveyor 60 and the beam 78. The beam 78 is supported at the top of the upright portion 76 and is fixed at a position away from the upper surface of the conveyor 60 by a certain distance. The upright portion 76 may be fixed to the floor, for example, or may be mounted on the conveyor 60.

  The gap volume scanner 72 includes one or more sensors 80. Examples of the sensor 80 include a scale for weight measurement, optics, infrared rays, an ultrasonic laser, or other types of sensors. The sensor 80 can obtain data representing the space of the container 20 in which the article 16 to be packed is placed and the volume of the empty area. In the illustrated example, the sensor 80 includes a height sensor 82 that outputs data indicating the height of the container 20, a width sensor 84 that outputs data indicating the width of the container 20, and the outer shape of the container 20, particularly the interior thereof. And an outer shape sensor 86 for outputting data indicating the outer shape and the outer shape of the article 16 in the container 20.

  In the drawing, the outer shape sensor 86 is shown mounted on the beam 78 above the conveyor 60. The outer shape sensor 86 is not necessarily required, but is a type that always detects the upper surface of one or more articles 16 in the container 20 when the container 20 to be conveyed to the conveyor 60 passes the lower part of the outer shape sensor 86. Preferably there is.

  As the outer shape sensor 86, for example, a non-contact optical laser scanner that operates by measuring the moving time of a laser light pulse can be used. Specifically, Sick Optical LMS 200-30106 laser scanner etc. are mentioned. The laser scanner emits a pulsed laser beam, which is reflected from the interior of the container and from the articles inside. And this reflected light is recorded by the light-receiving part of a laser scanner. The time until the reflected light is transmitted and received is directly proportional to the distance between the laser scanner and the reflecting surface. Further, the traveling direction of the pulsed laser beam may be changed by a rotating mirror that rotates incident light provided inside the scanner. This allows a fan-shaped scan in the surrounding area, thereby impulses that have continuously received the outline of the article (ie the distance from a fixed reference point or reference plane). Can be determined from The fan-shaped beam is directed in a direction perpendicular to the path of movement of the container past the sensor. Thereby, the outer shape of the container 20 and the article 16 that passes the outer shape sensor 86 is gradually measured when the container 20 passes the sensor 86.

  Any sensor can be applied as the width sensor 84 as long as it can determine the width of the container 20 passing by the width sensor 84. In the illustrated example, the width sensor 84 is an infrared distance sensor and can be used to measure the distance between the sensor or other reference point and the first side surface 40a of the container 20 (see FIG. 4). . In this embodiment, in order to obtain the width of the container, the position of the side surface 40b (see FIG. 4) facing the container is obtained with a known fixed length. The width sensor 84 may be mounted on one of the upstanding portions 76 of the scanner frame 74 at a position just above the surface of the conveyor 60, for example, as shown. For this purpose, the container group 20 is pressed against the guide rail 90 on the opposite side of the width sensor 84 on the conveyor 60. The distance between the guide rail 90 and the width sensor 84 is known, and the guide rail 90 functions as a zero reference. One side of the container is directed parallel to the guide rail 90. As a result, the width of the container is determined by the difference between the position of the guide rail 90 and the position of the side surface closest to the width sensor 84 among the side surfaces of the container, measured by the width sensor 84. In addition, you may provide suitably the means to press a container on the guide rail 90, and the means to arrange | position each container 20 in a desired direction. As this means, for example, a pneumatically operated arm can be used, or for example, a low friction surface that is inclined toward the guide rail and formed by a roller conveyor can be used.

  The height sensor 82 may be any sensor that can determine the height of the container 20, and any sensor can be applied. In the illustrated example, the sensor 82 includes an array 92 of light emitting units (emitters) and an array 94 of light receiving units which are arranged to face each other in the cross section of the scanning region. In the illustrated example, the array 92 of light emitting units and the array 94 of light receiving units are mounted on each of the upright portions 76 of the scanner frame. Each array also includes a row perpendicular to the plane of the conveyor 60. Thereby, the array 92 of light emitters produces a curtain of light detected by the array 94 of receivers. Here, as the container 20 moves through the light curtain, the light curtain is blocked by the container to the height of the container. As a result, a measurement value of the height of the container can be obtained.

  Further, a separate sensor may be provided to measure the length of the container. However, in the illustrated example, the length of the container measures the length of time it takes for the container to pass through one of the sensors, such as the width sensor 84, and when the conveyor 18 passes the sensor. It is determined indirectly by acquiring the moving speed. That is, the length of the container can be calculated by multiplying the speed of the conveyor 60 by the length of the time. Moreover, when the speed of the said conveyor is a known constant, the length of the said container can be determined only by calculating | requiring the length of the said elapsed time. Here, when the speed of the conveyor changes, for example, when the conveyor stops, starts to move, or when the speed of the conveyor changes for other reasons, a conveyor speed sensor may be used. By providing the conveyor speed sensor, the speed of the conveyor can be measured, and the measured speed can be transmitted to the controller 26 and processed by the controller 26. The speed sensor may be, for example, an encoder that supplies a series of pulses interfaced with a motor that drives a conveyor. Since the motor speed increases in proportion to the pulse speed, the pulse speed and the conveyor speed are proportional. Then, the controller converts the speed of the pulse into the speed of the container, and obtains the length of the container by multiplying the speed of the container and the time measured by the width sensor of the container. Good.

  In addition, the gap volume is measured without using an external sensor 86 or other means for measuring the outer shape of the gap volume by using a feature such as a difference in weight or volume displacement. You can also. When using the average density of the article to be transported, the gap volume can be calculated from the weight of the container before and after the article is loaded. That is, a value obtained by dividing the difference in weight by the density can be calculated as an approximate gap volume. The approximate gap volume is generally accurate enough to allow automatic filling of the gap from the load distribution device. In volume replacement technology, the volume of fluid (such as gas) is used to determine the gap volume from the known volume of an empty shipping container.

  In addition, the gap determination station 70 can automatically supply the gap volume data automatically at a speed faster than the speed at which the loading material distributor 52 inserts the packing material into the container 20. 70 may be used to obtain gap volume data for determining the amount of loading material distributed from a plurality of loading material distribution stations 14e, 14f, 14g. This can improve the throughput of the system 10 and increase the flexibility of the system 10 via the routing criteria.

  Then, instead of performing the measurement for determining the gap volume as described above, the gap volume can be obtained indirectly. For example, a sensor such as a bar code sensor can detect an identifier such as a bar code that identifies the article 16 and / or the container 20. Then, the data set can be examined based on the information, and the respective volumes for which the gap volume can be calculated or the gap volume in a specific combination of the article and the container can be obtained. These can be stored and pulled from the data set.

  Also, as a method of identifying the container 20 and determining the gap volume, one or more characteristics of the container including the dimensions of the container, the size of the container, the weight, etc. are detected, and the closest to the detected characteristics. There is also a method for examining the corresponding gap volume. A specific example of indirectly determining the gap volume is described in International Patent Publication No. WO 98/56663, and can be combined here by referring to it as it is.

  Each container 20 and / or article 16 may include a unique identifier that is detected by a specific sensor 100, as shown in FIG. Here, when a unique identifier is assigned to a certain container 20, the unique identifier functions like a license plate or a name tag, and is used in the system 10 to link data and the container 20. As shown in FIG. 3, the separated specific sensor group 100 can be used at one or more locations within the system 10 as shown in FIG. 3, and the specific sensor is a component of the gap volume scanner 72. There may be.

  Identifiers are labels, hardware identifiers embedded in containers, radio frequency identification (RFID) tags, colors, shapes, numbers, holes, protrusions, surface structures, patterns, container dimensions, thermal images, Anything such as an ultraviolet image, weight, electronic article surveillance (EAS) tag, etc. can be applied. The EAS tag includes, for example, a microwave tag, an electromagnetic (EM) tag, or an acoustomagnetic tag.

  The container identification sensor 100 may include an optical system for obtaining an image of the container 20 or a part thereof, which can identify the container 20 by electrical analysis. For example, a digital camera that takes a picture of each container may be arranged. Then, the photograph may be compared with the photograph of the reference container stored in the database. Moreover, the said container may be identified by the dimension, and you may put the mark for identification. For example, marks such as dots, numbers, shapes, holes, colors, temperature patterns, and ultraviolet images may be provided. Further, the database may include information indicating the dimensions of the container and the volume of the empty container.

  Further, the container specifying sensor may detect a radio frequency (RF) tag. For example, an RF tag is attached to the container at the packing station 12 and the RF tag and the container are associated during the packing process. When the containers are assembled and processed in order, an order-designated RF tag is attached to the container or placed inside the container. Ordering information (eg, container contents, container exterior dimensions, or empty container volume) is stored in a tag and read by an RF tag reader located upstream of the load distribution machine. Also good. The tag information may be sent to an information processing apparatus that can retrieve the contents of the container from the database. In order to increase the cost efficiency of the system, a tag removal station may be provided for reusing the RF tag at the end of the packaging process. Furthermore, a barcode is mentioned as an example of the identifier of a container. Bar code labels are generally attached to the outer surface of the container.

  Here, the gap volume may be determined from the container identifier. That is, the case where an article having a known volume is arranged in a specific type of container. When the sensor detects the container identifier, the information is transmitted to a processing device that has or is connected to a database. The database supplies, for example, article quantities, container dimensions, gap volumes, empty container volumes, and the like. Therefore, the gap volume may be obtained and read in advance, or may be calculated from the volume of the container, the volume of the empty container, and / or the dimensions of the container. Further, the above information may be automatically uploaded to a manual, semi-automatic or fully automatic loading material distributor.

  In the example shown in the figure, the container group 20 is sequentially transported to the packing material distributor group 14 without detecting the container identifier anywhere in the gap determination station 70, the packing material distribution station 14, or the system 10. Is intended. Since the gap determination station 70 acquires the gap volume data of the containers 20 that are sequentially supplied, the data or related data indicating the amount of the packing material to be distributed is used as the packing material distribution station 14 that is the transport destination of the container 20. You may make it transmit directly to. As a result, if the three container groups 20a, 20b, and 20c pass through the gap determination station 70 in order, the distribution of each packing material that is the container transport destination without reading the barcode label of each container. Data may be transmitted to the station 14. In this case, the container and the gap volume data of the container are associated with the order of the container and the route through which the container is conveyed to a certain loading material distributor. That is, the container can be identified by keeping track of the movement of the container within the system.

  The determination of the gap volume may be performed by an operator performing start or control of one or more steps performed by one or more devices that determine the required amount of loading material. Alternatively, it may be automatically determined without any manual intervention from outside or manual control. However, as is apparent from the above description, an intermediate station is not necessary. That is, it may not be necessary to determine the gap volume. For example, when filling until the container is full. In this case, the system 10 need only know when to stop filling the container 20 using sensors, backpressure or mechanical resistance. For example, in known methods, the airbag is inflated inside the container until the container wall moves outward, thereby confirming that the container is full.

  As yet another example in which it is not necessary to determine the gap volume, there is a case where the container 20 is intentionally filled exceeding the limit, and then the excess packing material is removed in order to obtain a desired degree of filling. Can be mentioned. In this case, the removed excess packing material may be returned to its supply source. The amount of loading material to be distributed can be determined in advance based on the maximum loading capacity of the container, or can be determined by one or more sensors. For example, a flowable dunnage may be continuously dropped like a waterfall and transported underneath at a rate sufficient to fill the maximum anticipated gap in the container. Then, the excess packing material overflowing from the container may be removed, and for example, the excess packing material may be reused using a reuse hopper and returned to the filling hopper.

  In such a case, it is not necessary to determine the gap volume around the article in the container. In order to remove excess packing material at the upper part of the container, a swiping apparatus or a blow-off apparatus can be used. In this system, the RSC flap needs to be folded out of the container and positioned below. Or in this system, it is necessary to use a shoe-box type container. When using RSC, the container needs to be prepared for filling and the flap needs to be raised again to seal the container, so use a flap gripping device to move the flap up and down when needed There is a need.

  Another example of the intermediate station 22 is a go / no go station that determines whether a container meets predetermined criteria. The predetermined criteria may include, for example, factors that cause the container to be in a proper state for receiving a load and / or factors that prevent the container from being properly closed. The function of the go / no-go station may be performed by the gap volume scanner 70 and other elements of the system 10. That is, the go / no-go station may itself be an intermediate station or may be part of one or more other stations. For example, the clearance determination station 70 includes one or more sensors for determining whether the container is in a state suitable for receiving a load material, i.e., includes an incompatible defect state. May be.

  One or more fault conditions can cause the container to be in an unsuitable state for receiving the load material. In this case, the nonconforming container needs to be specially treated. This special process includes repositioning the items in the container, manually dispensing the required amount of packing material, and packing the packing material into the voids in the container, and / or non-compliant defects. After the situation is resolved, the process of reintroducing the container into the transport network 24 is included. Also, since it is desirable for the operator to be aware that an incompatible defect condition exists before processing of the container continues, the controller 26 may issue a signal alerting the presence of the incompatible defect condition. In addition to or instead of this, the controller 26 automatically removes the container when it detects a defect condition as described above or otherwise (a condition that the container deviates from a processable standard). It may be led to another conveyor, and the operator may perform special processing on the conveyor.

  Non-conforming defect states include the following states, for example. A state in which the container is not detected, a state in which the container flap partially or completely plugs the opening, a state in which one or more measured container dimensions are less than the minimum threshold value, and / or a threshold value A state in which the container weight is less than the minimum threshold value, and / or a condition in which the container is larger than the maximum threshold value, the gap volume is equal to the container volume (there may be no article in the container) ), Or the gap volume exceeds the volume of the container (indicating the possibility that the container has overflowed), the weight is empty or overloaded, or the container cannot be closed properly (eg above a certain height) Etc.). Further, the non-conforming defect state may indicate a situation that requires special processing by the operator and does not satisfy a predetermined standard other than the above, for example, a situation where the gap is narrow and deep.

〔controller〕
As described above, the controller 26 functions to control one or more components of the system 10. For example, the controller 26 may guide the container 20 from the packing station 12 to the packing material distribution station 14 via the transport network 24 and, if included, to the gap determination station 70 as well. Also good. Further, the distribution of the packing material disposed in the gap may be controlled. The controller 26 may track the container 20 in the system 10.

  Various functions of the controller 26 can be implemented in a single processing unit, such as the control unit of the clearance determination station 70. Also, the above functions can be shared by several control units each having a separate processing device. For example, the control unit of one or more gap determination stations 70, one or more control units of the packing material distribution station 14, a separate (or remotely located) microprocessor of a personal computer, or these It can be assigned to a control unit such as a combination.

  The controller 26 may be a commercially available processing device or a combination thereof. For example, programmable logic controllers (PLCs) and processing chips that are used for general purposes, have various input / output ports, and include electronic data storage devices such as ROM and RAM can be used. The controller 26 may also have a wireless communication function for remote control, data transfer, and other communications. For example, what is mentioned here is only an example, but may have a wireless communication function such as a cellular system, an infrared ray, a wireless modem, a microwave, a radio frequency, and a satellite communication technology. Note that the communication may be unidirectional or bidirectional. Wireless communication is suitable for remote control, monitoring, analysis, and the like. Also, wireless communication is suitable for software updates, and eliminates or minimizes the wiring used in the system. Further, the controller 26 may be controlled by appropriate software. This software determines the length, width, height, and internal shape of the container based on the data received from the detection sensor. Then, the amount of loading material to be inserted into the gap is determined based on these data. Similarly, the type of distribution material to be distributed and the distribution speed of the distribution material can also be determined.

  The controller 26 may include various ports (not shown) for connecting various elements of the system 10. For example, an input device such as a foot switch 110, a conveyor speed sensor 112, a mouse, a keyboard, a keypad, and a touch screen touch of the packing material converter 52, an operator panel, a display device 114 of the packing material converter 52, a nonconforming container Examples include output devices such as a display (not shown) and a container sensor (not shown).

  For example, the operator panel 114 (see FIG. 3) of the packing material converter 52 may be provided with a touch screen as an input device, or may be provided with a personal computer having a touch screen. Other input devices may be provided. The operator panel 114 and / or the controller 26 may include a monitor that displays the various indicators and / or other information. The monitor can display, for example, the measurement dimensions of the container 20, the total volume of the container 20, the volume of the container 20, information for identifying the container 20, the volume of the gap above the container content 16, and the like.

  Furthermore, the operator panel 114 and / or the controller 26 may be provided with a selection device that enables selection of one gap filling density from a plurality of gap filling densities. The selection device is an input device and may include a dial that can be set to a desired density by dial adjustment. As the selection device, for example, a mouse pointer, a touch screen having one or a plurality of input areas, a keyboard or keypad for inputting a desired gap filling density, a foot switch, or the like can be used. The controller may change the amount of the packing material distributed per unit volume of the measured gap volume according to the selected gap filling density, thereby realizing the selected gap filling density. In other words, the controller may be programmed to have an initial setting that commands the dispensing of a predetermined amount of loading material per unit volume of the measured gap. For example, if protection is minimal, the operator may select a lower gap fill density. As a result, the controller designates, for example, an amount that is 10% less as a distribution amount for a given unit of the measured top-fill void for filling the container to the full container. . As a result, the filling density of the container 20 is reduced, and the consumption of the packing material is reduced. On the other hand, if strict protection is required and / or if the items packed in container 20 are heavy, the operator may select a higher gap filling density. As a result, the controller designates, for example, an amount 10% larger as the distribution amount for the predetermined unit of the measured gap volume for filling the container to the full container. Further, the container can be filled by changing the density of the packing material, and different portions of the vacant space can be filled with different densities. In this case, a part of the space of the container is supplied with a larger amount of material in a certain part and a smaller amount of packing material in a certain part.

  In addition to or in lieu of the above configuration, the controller 26 may be programmed to select the density and / or packing material fill rate based on shipping criteria. It should be noted that a label, a barcode, or other characteristic points of the container may be used as the standard for shipping, or an article packed in the container may be used as the standard for shipping. Examples of shipping standards include gap volume, container size, container weight, transport company, transport method (water transport, land transport, or air transport, such as transport by truck or train, short distance or long distance transport, etc.) , Characteristics of articles (size exceeding specified value, fragile etc.), type of packing material used (closed-cell foam, expanding foam, air pillows) Paper packing material, fluid packing material, etc.), or a combination thereof. Note that the above-described shipping standards are merely some examples of general shipping standards, and the present invention is not limited to the above examples.

  Also, in addition to tracking shipping rules and other data, the controller 26 may increase the amount of packing material distributed by the packing material distributor, for example, the amount of packing material that the operator places in the container. You may make it record the quantity of the covering material distributed by the event, such as when the instruction | indication to a distribution machine is reversed in order to reduce it. With this information, system overtime can be improved manually or automatically. In addition, this makes it possible to identify the packaging tendency and confirm the necessity of maintenance. For example, under certain shipping criteria, if an operator frequently manually changes the packing material distribution instructions to distribute additional packing materials, the shipping standard instructions may be sent to the distributor. It is automatically updated to instruct it to dispense additional load material according to the criteria. Also, as another example, if there are fewer available litter distributors under a certain shipping standard, when the shipping standard is applied more frequently, the controller 26 may A report may be generated that additional distributors need to be allocated for the reference.

  An embodiment in which the controller 26 processes the gap volume data obtained by the gap determination station 70 is also possible. In this case, the controller 26 is placed in the gap left in the container 20 (or the bottom of the container if not covered by the article) when the one or more articles 16 are placed in the container. Determine the amount of packing material required. In FIG. 7, the gap 120 is indicated by a mesh-like shadow. After the gap volume is determined, the controller may instruct the consignment dispensing station 14 to dispense the determined amount of consignment. It should be noted that the loading material may be poured directly into the container 20, or the loading material may be arranged or introduced by an operator.

[Loading material distribution station]
At the load distribution station 14, a gap 120 (around the one or more articles 16 in the container is created to minimize or prevent movement of the articles during transport or to protect them from damage. (See FIG. 7) Dispensing a controlled amount of loading material. Each loading material distribution station 14 includes a loading material supply section or is connected to the loading material supply section. A specific example of a loading material distribution station is disclosed in International Patent Application Publication No. 2003/089163. In the present invention, any kind of loading material distribution device or loading material distribution means can be applied.

  The containers 20 may be sent randomly to the load distribution material distribution station 14 or may be sent to the load distribution material distribution station 14 based on one or more routing criteria. The criteria for specifying the route include, for example, the size of the container, the weight of the container, the packing priority, the destination of shipment, the type of packing material, the shipping method, the shipping company, the outer shape of the gap, the packing density of the gap, and the article. Fragility, efficiency of packing material distribution station, etc.

  Similar to the packing station 12, and as shown in FIG. 1, in the embodiment of the present invention, the packing material distribution station 14 may be arranged in series, for example, the packing material distribution stations 14f and 14g. . When a plurality of stations are arranged in a line, the loading material can be sequentially supplied to the container. For example, one or more types of loading materials may be supplied, or one or more types of loading materials may be supplied. Further, the packing material may be supplied to a group of containers at the same time, or one or a plurality of types of packing materials may be supplied.

  In addition, the packing material distribution station 14 may be arranged in parallel like the packing material distribution stations 14a to 14e, for example. With such an arrangement, the loading material can be supplied to a plurality of containers almost simultaneously (at substantially the same time). Also, the packing material can be supplied to a plurality of containers independently of each other. Thereby, for example, for the maintenance and refilling of the loading material distribution station 14, the loading material distribution station 14 can be taken offline without affecting the entire system. Furthermore, each of the load distribution material distribution stations 14 may be dedicated to a particular container 20 based on routing criteria as described below.

  The packing material distribution unit 14 may supply a single type of packing material, or may supply a plurality of types of packing material, and each station may include one or a plurality of packing materials. Packing materials with different properties may be supplied. For example, the container 20 may be filled with different density packing materials. Note that this also includes filling different regions of one container with different density packing materials. In addition, when the shape characteristic, geometry, or outer shape of the gap volume is known, more or less packing material may be supplied to different regions based on the information. .

  The source of loading material at each station 14 may include a loading material distributor such as a hopper or other storage container. In addition to the above configuration or in place of the above configuration, the load distribution material distributor is a load distribution material conversion device that converts a stored material into a lower density load distribution material as shown in FIG. 52 may be sufficient. In addition, the load distribution material may be distributed from a common supply source to a plurality of load distribution material distributors, or each distribution unit 14 may include a supply source.

  In the case of the packing material converting machine 52, the packing material is generated on the spot. This is because the area occupied by the load converting device 52 and the storage material is generally smaller than storing the same amount of the load covering material. In addition, the loading material conversion machine may include a suitable mechanism for moving the loading material in the direction of the container or into the container. For example, mechanically supplying and transporting mechanisms (conveyors, pushers, screws, rollers, movable supports, etc.), air-driven devices that are powered by electromagnetic or gravity, etc. .

[Packing material]
Any material can be used as the packing material as long as it can be disposed in the gap in the container 20. For example, different types of packing material include continuous strip packing material, discrete pad-like packing material, expandable dunnage, and fluidized packing material. Including wood.

  One or more elongate packing materials can be used to fill the gap volume. As this kind of packing material, for example, made of paper, twisted to take a volume larger than the area and thickness of the material, or formed in a three-dimensional shape, A soft or stiff, elongate foam, elongate airbag having a predetermined width and / or a predetermined constant length, or various lengths, having a predetermined cross-sectional area, and having a predetermined range of length. Airbag “tubes”, generally a pair of plastic sheets bonded together and an elongated bubble pack enclosing an air “foam” pocket between them, extruded-in-place, outlet A long or tubular foam that has a shape as it exits, and a connected load in which parts of the packing material are joined together or connected in a sausage shape The flooring load can be mentioned.

  Linked consignment materials include relatively low density parts to which higher density materials are connected and generally occupy a larger volume than comparable unequipped sizes and numbers of uncoupled low density consignment materials. it can. The connected loading material includes, for example, an airbag in which a high density portion and a low density portion are connected.

  A continuous strip of material may be fed directly into the space in the container using a chute with a rotating member to “fire” the strip into the container or relay container, The piece may be pushed, dropped or moved into the container from another support position. Moreover, the said elongate piece may be wound in the shape of a spiral, and each part may be made to draw out from the said spiral as needed.

  A piece of consignment material or a separate unit of consignment material is a section of the consignment material. In general, when using separate pad-shaped load material, one or more load material pads having a common length or different lengths are placed in the interstitial volume. Then, the pad-shaped packing material may be similar in shape to the above-described elongated packing material. As a typical packing material pad, for example, one or a plurality of papers are twisted or formed into a three-dimensional shape to take up a volume larger than the area and thickness of the material. Or a soft or rigid foam consisting of separate or connected parts, an airbag having a predetermined size and shape, an airbag having a predetermined cross-sectional area and capable of being formed to a predetermined length Examples include “tubes” and bubble pack sheets having a predetermined length. Further, if necessary, the paper may be coated to increase the mass, and / or part of the paper may be cut or removed to reduce the mass.

  The separate pad-shaped packing material may be disposed in the container by changing the direction by the take-out robot. That is, the take-out robot may push the separate pad-shaped packing material into the container from the support position, drop it, or supply it directly from the hopper or the packing material conversion machine. . In addition, in a typical pad-generating packing material distributor disclosed in US Pat. No. 5,123,889, a storage material sheet (such as kraft paper) in which one or more sheets are stacked has a lower density. It has been converted into a packing material.

  The expansion material is expanded to fill a predetermined range of volume. An example of an extended packing material is a chemical foam placed in a sealed bag, typically formed of several types of polymers suitable for controlled activation. Foam-in-a-bag, and inflate-in-place air pillows. The inflatable air pillow expands inside the container to fill the interstitial volume, as described, for example, in US Pat. No. 6,253,806. In foam-in-a-bag packing material, the foam swells in the bag to fill the bag itself or the volume enclosed by a void in a closed volume. The swelled foam solidifies in the same shape as the gap volume. The bag may be placed in a container, and after the container is closed, the foam may fill the volume of the closed space, and particularly if the gap volume shape is known, It may be hardened into a desired shape before placement.

  Fluid load material includes a plurality of relatively small load material products that flow into gaps within the container. For example, the fluid packing material includes foam “peanuts”, paper peanuts, airbags “ravioli” formed from small airbags, and the like.

  The product of the fluid packing material may have various sizes inside the supply source. The fluid packing material is generally first distributed to a hopper for storage and then fed to the container via a tube or chute. An example of a fluid packing material distributor is disclosed in US Pat. No. 6,672,037. Further, a vibrating table may be used in order to securely store the fluid loading material in the gap volume in the container.

  The type of the packing material distributor or converter 52 to be used generally depends on the packing material. In addition to the examples described here, various methods for delivering and arranging the packing material in the container 20 can be applied to each of the packing material products. Further, the load distribution material distributor 52 may have a characteristic of self-control, that is, a characteristic of stopping distribution of the load distribution material by a trigger of the sensor. For example, a sensor such as an electromagnetic sensor, a mechanical trigger, or a back pressure sensor can be applied. Further, for example, a restriction plate may be provided so as to cover the opening of the container so that the loading material passes through the restriction plate. And you may provide the gate valve which permits passage of the above-mentioned restriction | limiting board of a fluid loading material, a butterfly valve, or another valve | bulb. The plate closes the top of the container, but allows the container to be filled with the load until one or more sensors indicate that the container is full. . An example of this is disclosed in US Provisional Patent Application No. 60 / 624,348, filed on November 2, 2004, and can be combined here with reference thereto.

  The load material supplied at each load material distribution station 14 may be placed in the container 20 entirely manually. The packing material is arranged by a packer starting or controlling one or more steps performed by one or more devices (such as a take-out robot) that arrange the packing material on the container 20. May be. Furthermore, instead of the above, the loading material may be disposed in the container without external control. In this example, for example, when the controller 26 controls one or more devices, the packing material can be automatically placed in the gap volume in the container 20 without any work by the packer. .

[Closed station]
At the closing station 102, the container is closed and ready for shipment. After dispensing the loading material, the container 20 is transported to a closure station 102 for closing the container 20. As an apparatus for automatically closing the container 20, an apparatus generally called a “box closing machine” is known. This device can be used in the final step of the packaging process where the container is automatically closed and sealed for loading. In the case of an RSC container, the container 20 may be automatically sealed using an automatic flap folding device that is essential to or associated with an automatic box sealing device. Examples of the box sealing device include, but are not limited to, a sealer, a taper, and a string binding device. Further, when using a shoe box type container 20, the container 20 uses a hot glue or a string tying device to fix the lid portion to the upper part of the container, for example, using hot glue, tape or string. The container 20 is closed and fixed for shipment. In addition, shipping labels may be automatically attached, which in many cases minimizes or eliminates operator interaction with the packaging process, resulting in operator incompatibility defects. Allows release from state handling and / or placement of articles into more containers.

  Alternatively, the packer may close and seal the container 20 using tape, string, or adhesive. Further, instead of the above, the packer may perform some steps such as folding the flap downwards or placing a lid on the container, and the other steps may be performed by a closure mechanism. . Finally, the container 20 is sent to the loading station 104. Therefore, the container 20 may be stored according to the destination, the transportation method, and the like, and may be collected for shipping as necessary.

[Example of operation method]
FIG. 8 shows an example of the method of the automatic packing system. The illustrated steps or blocks represent functions, operations, or events that are performed in the system. When implemented in software, each block may be represented by a module, segment, or a portion of code that includes one or more executable instructions for performing a particular logical function (s). Good. Further, when implemented in hardware, each block may be represented by one or more circuits or other electronic device for performing a specific logical function (group). Computer software applications generally perform dynamic and flexible processing. For example, functions, operations, or events performed by software and / or hardware may be performed in other sequences than those shown.

  The example system shown in FIGS. 3 and 8 can be operated in the following manner. That is, in step 200, one or more containers 20 are assembled by the container assembler 32 at one of the one or more packing stations 12, and the one or more articles 16 are sequentially turned into shipping containers. Be placed. Next, in step 202, the container 20 is sent to a selected one of a plurality of gap determination stations 70 that determine the gap volume when a gap volume is required. This step is not essential and may be omitted as described above. In step 204, the container identifier may be detected as necessary. Then, at step 206, the container 20 is inspected to be suitable for receiving the covering material, i.e., for a defect state. Here, if an incompatible defect condition exists, the container 20 is redirected in step 208 for special handling by the operator. On the other hand, if there is no incompatible defect state, the required amount of the covering material for filling the gap volume is determined in step 210. Subsequently, in step 212, the container 20 is sent to one of the plurality of loading material distribution stations 14. Then, in the packing material distribution station 14, the packing material is distributed and arranged in the gap volume in step 214.

  Further, based on the determined gap volume, a specified amount of the covering material may be automatically distributed. The container 20 may be automatically arranged at the discharge port of the loading material distributor 14a, and the loading material may be automatically distributed to the container 20 automatically without an operator. Moreover, although it distributes automatically, it can also be said that it does not distribute directly to the container 20, and you may distribute according to the next position of the container 20 which an operator shows. The container 20 may be further processed after a defined amount of load material has been dispensed and the dispensed load material has been dispensed directly into the container 20 or dispensed into the container 20 in the next step. For example, in step 216, the container is routed to pass the container closer of the closure station 130, the container 20 is closed in step 218, and then shipped in step 220 for further transportation to a distant location. Route the container 20 to the station 132.

  Returning now to FIG. The figure shows an example of an embodiment of the packaging system 300. System 300 includes a plurality of packing stations 12a, 22b; a transport network 24 having a plurality of transport lines (eg, 68b, 68c, 68f, 68g, 68h, 68m, 68n, 68o and 68t); Convertor lines 68aa, 68bb, 68cc; routing gates 302a and 302b; intermediate station 22a; and load distribution material distribution stations 14a, 14b, 14c and 14d. During normal operation, articles (not shown) are placed within the container group 20 at parallel packing stations 12a and 12b. The article may be placed manually or via an automated system. The container 20 advances to the intermediate station 22a via either the transport line 68b or 68c, or a combination thereof.

  The transport line 68 is illustrated as a plurality of conveyors. That is, the transport lines 68b, 68c, 68f, 68g, 68h, 68m, 68n, 68o and 68t. However, the transport network 24 may include any means that can transport the container group 20 between two or more stations. For example, one or more conveyors and one or more chutes driven by motor, gravity, air, or manually. Further, the transportation network 24 may include any combination of different types of transportation lines. Also, the length of each transport line generally depends on the distance between stations. Here, the sensors and elements described as being associated with different or separate stations may be integrated into one station. For example, the sensor for determining whether or not a container that can automatically be filled with packing material has been described as being associated with an intermediate station, but the packing stations 12a and 12b or the dispensing stations 14a, 14b and 14c It may be integrated into. In this case, the distance of the transport line between the sensor and the station can be a very short distance, for example less than 1 foot.

  In the intermediate station 22a, data or information on the container 20 and / or the contents of the container are acquired. The data is acquired via one or more sensors (not shown). Examples of the data include the shape characteristics of the contents of the container 20, the size of the container 20, the arrangement of the contents, and the like. The controller 26 uses the data obtained at the intermediate station 22a (as a function of the data) to determine whether or not the loaded container 20 is appropriate for automatically loading a load material. If the loaded container 20 is not suitable for automatic loading, for example, when the contents of the container 20 are above the top of the container 20, the container 20 is redirected by the container redirector 301 to the redirection line 68aa. Moved to. Embodiments are possible where the container redirector 301 is an air operated piston that pushes the container 20 into the redirect line 68aa. The container direction changing machine 301 only needs to change the direction of the container 20 to the direction changing line 68aa, and any means can be applied. For example, a switching bar, a trap door, a take-out robot, and the like can be given. Also possible is an embodiment in which the container diverter 301 does not physically remove the container 20 from the transport line that leads to the loading material distribution station 14. Instead of physically removing, the controller 24 instructs the load distribution material distribution station 14 to pass through the load distribution material distribution station 14 without placing the load material in the container 20, thereby causing the transport line to pass. The container 20 is indirectly removed from the container. In this case, if necessary, the container 20 may be removed from the system after passing through the packing material distribution station 14.

  Returning now to the illustrated embodiment. The direction change line 68aa is a means for physically removing the container 20 from the transportation line that continues to the automatic loading material distributors 14a, 14b, and 14c. If desired, turnaround line 68aa may include a transport line to turnaround station 14d that resolves the non-compliant defect condition. Further, the packing material may be arranged in the container at the direction changing station 14d, or the container 20 may be reintroduced into the transport lines 68f, 68g or 68h leading to the automatic packing material distribution stations 14a, 14b and 14c. Alternatively, it may be sent to a loading material distribution station (not shown) outside the transport network 24.

  If the container 20 is suitable for packaging (eg, there is no non-conforming defect state), the controller 26 controls the series of routing gates 302a and 302b that can be controlled by the controller 26 to select the container. May be directed to the provided load distribution material distribution station 14. The first routing gate 302a designates the route of the container 20 to the loading material distribution station 14a or designates the route of the container 20 to the second routing gate 302b, thereby loading the route of the container 20. Used to designate one of the floor covering distribution stations 14b and 14c. Each of the routing gates 302a and 302b includes air-operated swing arms 304a and 304b. When the first swing arm 304a is enabled or in a closed state, the container 20 is first sent to the first transport line 68f and then sent to the automatic loading material distributor 14a. Also, if the first swing arm 304a is opened and the second swing arm 304a is enabled or closed, the container 20 is sent to the transport line 68g and the automatic loader distributor 14b. Further, if both swing arms 304a and 304b are opened, the container is sent to the transport line 68h and sent to the automatic load distribution machine 14c. The routing gates 302a and 302b may include any means for routing the container 20 to the selected automatic loading material distribution station 14a, 14b or 14c or the like. Examples of this means include a single arm, a robot arm, a bush bar, a turntable, and a plate.

  The controller 26 uses the data obtained at the intermediate station 22a to determine the amount of loading material to be placed in the container 20. The controller 26 supplies a signal to the selected loading material distribution station 14a, 14b or 14c, thereby supplying a necessary amount of loading material to the loading material distribution machine such as a loading material conveyor (not shown). Instruct to dispense. Then, in the automatic loading material distribution stations 14a, 14b and 14c, the container 20 is automatically filled with the determined amount of loading material.

  The container 20 emerging from the load distribution material distribution station 14a moves on the transportation line 68m, moves to the closing station 102a that closes the container, and then moves to the loading station 104a through the transportation line 68t. From the stock distribution stations 14b and 14c, transport lines 68n and 68o, respectively, leave the containers to a common closure station 102b. In the illustrated example, the convertible load distribution station 14d transports containers to the closure station 102c via the transport line 68bb, and then the transport line 68cc is shared by the automatic load distribution stations 14b and 14c. Transport the above containers.

  Although a preferred embodiment of the present invention has been shown and described herein, it will be apparent to those skilled in the art who have read and understood the present specification and the accompanying drawings that equivalent changes and modifications can be devised. It is. In particular, with respect to the various functions performed by components as described above, the terms used to describe the elements (including references to “means”) perform the functions of the elements described above (ie functionally). Is equivalent) if not suggested, and is structurally equivalent to the disclosed structure for performing the above functions in the embodiments of the invention shown herein. If not, it means that they are equivalent. Further, attention may be paid to only one of the embodiments, and only certain features of the invention may be disclosed, and if desired or advantageous for known or specific uses, such A feature may be combined with one or more features of other embodiments.

It is the schematic of the packaging system of this invention. It is a top view which shows one Embodiment of the packaging system of this invention. It is a side view which shows the outline of the path | route which a container passes by a packing system. FIG. 2 is a perspective view of a standard rectangular expansion container (RSC) used in the system of FIG. FIG. 2 is a side view of a gap volume scanner used in the system of FIG. 1. 6 is a cross-sectional view taken along line 6-6 in the gap volume scanner of FIG. It is a cross-sectional view of a container in which a plurality of article groups are arranged in a state where a gap shown by shading remains. It is a flowchart which shows the packing process of one Embodiment of this invention.

Claims (15)

A plurality of loading material distribution stations each having at least one loading material distribution machine capable of distributing the loading material;
Transporting a plurality of containers to at least two loading material distribution stations for placing the packing material in the containers, and a transport network for transferring the plurality of containers from the packing material distribution station,
The packaging system, wherein the transport network includes a mechanism for sending each container to a specific loading material distribution station based on the characteristics of the container.   The packaging system according to claim 1, wherein the mechanism includes a sensor that identifies a characteristic of the container.   The packing system according to claim 1 or 2, wherein the packing material distributor includes a packing material conversion machine capable of converting a storage material into a lower density packing material.   The load distribution machine includes at least one of air bags, crumpled paper, foam strips, foam peanuts, and paper strips. The packaging system according to claim 1, further comprising: a supply source of a packing material comprising:   5. One or more packing stations for placing one or more articles in one or more shipping containers, according to any one of the preceding claims. Packing system.   6. Packing according to any one of the preceding claims, comprising an intermediate station upstream of at least one loading material distribution station and comprising a sensor for detecting a characteristic of the gap volume in the container. system.   The intermediate station comprising at least one device for determining whether the container meets a predetermined standard upstream of at least one loading material distribution station. 7. The packaging system according to any one of items 6. The packaging system according to claim 7, wherein the transportation network includes a path for turning a nonconforming container that does not satisfy the predetermined standard. Shipping containers from a plurality of load distribution stations to selected load distribution stations based on routing criteria, including container characteristics;
And supplying the packing material to the container at the packing material distribution station.   The shipping step is based on one or more criteria for specifying a route, including characteristics of the packing material, characteristics of a gap in the container, and characteristics of an article to be shipped in the container. The packing method according to claim 9, further comprising a shipping step.   The packing method according to claim 9 or 10, wherein the sending step includes a step of determining a type of a covering material to be distributed.   The packing method according to any one of claims 9 to 11, further comprising a step of determining a gap volume in the container.   13. A packaging method according to any one of claims 9 to 12, including the step of assigning an identifier to each container and tracking the container as the container moves through the packaging system.   The packaging method according to any one of claims 9 to 13, further comprising a step of redirecting a container that does not conform to a predetermined standard. A plurality of packing stations for packing containers;
A plurality of packing material distribution stations;
A transport network connecting the packing station and the plurality of packing material distribution stations for transporting the group of containers from the plurality of packing stations to one or more packing material distribution stations;
A controller for automatically shipping containers to the selected distribution material distribution station via the transport network;
Upstream of at least one loading material distribution station, comprising information indicating a gap volume in the container, and a gap volume detection device for supplying the acquired information to the controller,
The controller determines the amount of loading material to be distributed at the loading material distribution station using information indicating the gap volume, and automatically distributes the determined amount of loading material. An automatic packing system for filling a space in a container, characterized by managing a dispensing station.

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