Smart packaging wall

{
  "publication_number": "US10647454B2",
  "country": "US",
  "kind": "B2",
  "title": "Smart packaging wall",
  "abstract": "A packaging system for high flexibility and speed box-last packaging comprises one or more dimensional scanning sensors that are configured to scan a group of one or more target products that are to be boxed and gather dimension information describing physical dimensions of the group of one or more target products. The system also comprises one or more packaging-production machines that are configured to generate custom-made packaging templates that conform to a pre-determined set of packaging template types. Additionally, the system comprises a packaging template buffer that comprises physically divided sections that contain multiple packaging templates selected from the pre-determined set of packaging template types that are generated by the one or more packaging-production machines. Each of the packaging templates are organized within the physically divided section based upon packaging template type.",
  "claims": [
    "1. A packaging system for high flexibility and speed box-last packaging, comprising: one or more scanning sensors that are configured to scan a group of one or more target products that are to be boxed and gather dimension information describing physical dimensions of the group of one or more target products; one or more packaging-production machines that are configured to generate custom-made packaging templates that conform to a pre-determined set of packaging template types, wherein the one or more packaging-production machines are configured to generate the packaging templates based upon the dimension information gathered by the one or more scanning sensors; a physical packaging template buffer that comprises physically divided sections that contain multiple packaging templates selected from the pre-determined set of packaging template types that are generated by the one or more packaging-production machines, wherein each of the packaging templates are organized within a physically divided section based upon packaging template type; and a packaging system control unit that triggers the one or more packaging-production machines to generate a first physical packaging template that corresponds with a particular template type, wherein the particular template type comprises interior dimensions that are greater than or equal to the physical dimensions of the group of one or more target products, and concurrently triggers a visual indicator that is associated with a second physical packaging template that also corresponds with the particular template type, wherein the visual indicator indicates a location of the second physical packaging template within the physical packaging template buffer.",
    "2. The packaging system as recited in claim 1, wherein the one or more scanning sensors comprise a light curtain.",
    "3. A method for high flexibility and speed box-last packaging, comprising: receiving, from one or more dimensional scanning sensors, dimension information describing physical dimensions of a group of one or more target products that are to be boxed; accessing, from a packaging database, a packaging inventory that comprises a listing of an available number of each respective packaging template type within a physical packaging template buffer, wherein the physical packaging template buffer comprises physical packaging templates that are already manufactured and ready to be folded into boxes; selecting a particular packaging template type that is associated with interior dimensions that are greater than or equal to the physical dimensions of the group of one or more target products; communicating to a packaging-production machine a template creation command that directs the packaging-production machine to create a first physical packaging template that corresponds with the particular packaging template type; communicating to the physical packaging template buffer a template identification command that provides a visual indicator indicating which physical packaging template should be selected from the physical packaging template buffer, wherein: the physical packaging template buffer contains a second physical packaging template that also corresponds with the particular packaging template type, and the template identification command causes the physical packaging template buffer to display to a user that the second physical packaging template should be constructed into a box.",
    "4. The method as recited in claim 3, further comprising: when the physical packaging template buffer already includes a packaging template that corresponds with the particular packaging template type, delaying the communication of the template creation command to the packaging-production machine until another group of one or more target products is scanned by the one or more dimensional scanning sensors; and generating a second template creation command that directs the packaging-production machine to create two packaging templates concurrently, wherein the two packaging templates include the particular packaging template type.",
    "5. The method as recited in claim 3, further comprising: calculating a production time associated with an amount of time required to generate a potential packaging template type with the packaging-production machine; and when the production time exceeds a threshold, associating the particular packaging template type with a pre-manufactured packaging template that is associated with particular interior dimensions that are greater than or equal to the interior dimensions of the particular packaging template.",
    "6. The method as recited in claim 3, further comprising: receiving, from one or more weight sensors, weight information describing a weight of the group of one or more target products; and selecting the particular packaging template type that is associated with strength characteristics that exceed the weight of the group of one or more target products.",
    "7. The method as recited in claim 3, wherein the one or more dimensional scanning sensors comprise light curtains.",
    "8. The method as recited in claim 3, further comprising: receiving, from one or more group-scanning sensors, group information describing order information associated with the group of one or more target products.",
    "9. The method as recited in claim 8, further comprising: identifying invalid information within either the group information or the dimension information; and upon identifying the invalid information, redirecting the group of one or more target products towards a secondary conveyor belt.",
    "10. A computer system for high flexibility and speed box-last packaging, comprising: one or more processors; and one or more computer-readable media having stored thereon executable instructions that when executed by the one or more processors configure the computer system to perform at least the following: receive, from one or more dimensional scanning sensors, dimension information describing physical dimensions of a group of one or more target products that are to be boxed; access, from a packaging database, a packaging inventory that comprises a listing of an available number of each respective physical packaging template type within a physical packaging template buffer, wherein the physical packaging template buffer comprises physical packaging templates that are already manufactured and ready to be folded into boxes; access, from the packaging database, an order queue that comprises information about currently pending orders that need to be boxed; receive, from one or more packaging-production machines, takt information, wherein the takt information describes an amount of time required to complete one or more pending orders within the order queue; and automatically optimize a boxing of the group of one or more target products by selecting a particular physical packaging template type based upon the packaging inventory, the order queue, and the takt information, wherein: selecting the particular physical packaging template type comprises displaying a visual indicator that is associated with a particular physical packaging template that also corresponds with the physical particular template type, wherein the visual indicator indicates a location of the particular physical packaging template within the physical packaging template buffer the particular physical packaging template type is associated with a particular production line selected from one or more production lines, the one or more production lines including: a first production line that is associated with pre-manufactured physical packaging templates, and a second production line that is associated with the physical packaging templates that are produced by the one or more packaging-production machines and stored within the physical packaging template buffer.",
    "11. The computer system as recited in claim 10, wherein the pre-manufactured physical packaging templates are generated using a die-cut machine.",
    "12. The computer system as recited in claim 10, wherein automatically optimizing the boxing of the group of one or more target products comprises: selecting the physical particular template type that is associated with the first production line when the takt information indicates that a takt value is exceeding a takt threshold.",
    "13. The computer system as recited in claim 10, wherein the one or more packaging-production machines generate custom-made physical packaging templates that conform to a pre-determined set of packaging template types.",
    "14. The computer system as recited in claim 10, wherein the executable instructions include instructions that are executable to configure the computer system to: calculate an available-template-packaging excess associated with the group of one or more target products and available physical packaging templates, wherein the available-template-packaging excess comprises a total volume by which the interior dimensions of the pre-manufactured physical packaging templates and the physical packaging templates stored within the physical packaging template buffer exceed the dimensions of the group of one or more target products that are to be boxed; and when the available-template-packaging excess exceeds a second threshold, automatically optimize the boxing of the group of one or more target products by selecting a particular physical packaging template type that is associated with a third production line, wherein the third production line is associated with custom-made physical packaging templates that are generated on-demand based upon the physical dimensions of the group of one or more target products.",
    "15. The computer system as recited in claim 13, wherein the physical packaging template buffer comprises physically divided sections that contain the physical packaging templates that are organized within physically divided section based upon packaging template type.",
    "16. The computer system as recited in claim 10, wherein automatically optimizing the boxing of the group of one or more target products comprises: selecting the physical particular template type that is associated with the second production line when the physical packaging template buffer comprises a physical packaging template with dimensions that are greater than or equal to the physical dimensions of the group of one or more target products.",
    "17. The computer system as recited in claim 16, wherein automatically optimizing the boxing of the group of one or more target products comprises: calculate a packaging excess associated with the group of one or more target products and the pre-manufactured physical packaging templates, wherein the packaging excess comprises a total volume by which the interior dimensions of the pre-manufactured physical packaging templates exceed the dimensions of the group of one or more target products that are to be boxed; and when the packaging excess exceeds a first threshold, selecting a particular physical packaging template type that is associated with the second production line.",
    "18. The computer system as recited in claim 10, wherein the executable instructions include instructions that are executable to configure the computer system to: when the particular physical packaging template type is associated with the second production line: communicate a template creation command to a packaging-production machine that directs the packaging-production machine to create a first physical packaging template that corresponds with the particular physical packaging template type; communicating to the physical packaging template buffer a template identification command that indicates which physical packaging template should be selected from the physical packaging template buffer, wherein: the physical packaging template buffer contains a second physical packaging template that also corresponds with the particular physical packaging template type, and the template identification command displays to a user that the second physical packaging template should be constructed into a box.",
    "19. The computer system as recited in claim 18, wherein the executable instructions include instructions that are executable to configure the computer system to: when the physical packaging template buffer already includes a physical packaging template that corresponds with the particular physical packaging template type, delay the communication of the template creation command to the packaging-production machine until another group of one or more target products is scanned by the one or more dimensional scanning sensors; and generating the template creation command that directs the packaging-production machine to create two physical packaging templates concurrently, wherein the two physical packaging templates include the particular physical packaging template type."
  ],
  "description_excerpt": "Shipping and packaging industries frequently use paperboard and other fanfold material processing equipment that converts fanfold materials into box templates. One advantage of such equipment is that a shipper may prepare boxes of required sizes as needed in lieu of keeping a stock of standard, pre-made boxes of various sizes. Consequently, the shipper can eliminate the need to forecast its requirements for particular box sizes as well as to store pre-made boxes of standard sizes. Instead, the shipper may store one or more bales of fanfold material, which can be used to generate a variety of box sizes based on the specific box size requirements at the time of each shipment. This allows the shipper to reduce storage space normally required for periodically used shipping supplies as well as reduce the waste and costs associated with the inherently inaccurate process of forecasting box size requirements, as the items shipped and their respective dimensions vary from time to time.\n\nIn addition to reducing the inefficiencies associated with storing pre-made boxes of numerous sizes, creating custom sized boxes also reduces packaging and shipping costs. In the fulfillment industry it is estimated that shipped items are typically packaged in boxes that are about 40% larger than the shipped items. Boxes that are too large for a particular item are more expensive than a box that is custom sized for the item due to the cost of the excess material used to make the larger box.",
  "cpc": [
    "B65B 57/12",
    "B31B 50/00",
    "B31B 50/006",
    "B31B 50/26",
    "B31B 50/94",
    "B65B 2210/04",
    "B65B 43/00",
    "B65B 43/08",
    "B65B 5/02",
    "B65B 5/024",
    "B65B 59/00",
    "B65B 59/001",
    "B65B 59/003",
    "B65B 65/003",
    "B65G 1/16",
    "G05B 19/188",
    "G05B 2219/23261",
    "G05B 2219/45048",
    "G06Q 10/08",
    "G06Q 10/083",
    "G06Q 10/087",
    "G06Q 50/04",
    "Y02P 90/02",
    "Y02P 90/30"
  ],
  "ipc": [
    "B65B 43/00",
    "B65B 43/08",
    "B65B 5/02",
    "B65B 57/12",
    "B65B 59/00",
    "B65B 65/00",
    "G05B 19/18",
    "G06Q 10/08"
  ],
  "assignees": [
    "Packsize LLC"
  ],
  "inventors": [
    "Thomas Lamb",
    "David Iverson",
    "Adam de Laveaga",
    "Ryan Osterhout",
    "John McCracken",
    "Gary Moe",
    "Niklas Pettersson"
  ],
  "filing_date": "2017-07-18",
  "publication_date": "2020-05-12",
  "grant_date": "2020-05-12",
  "priority_date": "2016-07-22",
  "application_number": "US-201715652518-A",
  "family_id": "60989800",
  "cited_by_count": 1,
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}