Item sizing guide for a packing machine

A dimensioning tool for a packing machine is provided. The dimensioning tool is configured to allow insertion of an item into the packing machine when the item satisfies one or more criteria. The dimensioning tool includes a first gauge and a second gauge separate from the first gauge. The first gauge is configured to restrict a first set of dimensions of the item that can be inserted into the packing machine, according to the one or more criteria. The second gauge is configured to restrict a second set of dimensions of the item that can be inserted into the packing machine, according to the one or more criteria.

BACKGROUND

The present invention relates to a dimensioning tool (or guide) for sizing and placing items within a semi-automated packing machine.

Many facilities (e.g., warehouses, plants, distribution centers, storehouses, factories, etc.) perform various tasks to prepare items for shipment. For example, an item being prepared for shipment may transition through an inventory area, sorting area, picking area, packing area, staging area, etc., before being shipped to a customer. Facilities typically use semi-automated equipment to aid with these various tasks. For example, a facility can use a semi-automated packing machine to form packaging around an item, resulting in a package that can be shipped. In some cases, the efficiency and reliability of these semi-automated packing machines may depend in part on the size, orientation, and placement of the items within the machines.

DETAILED DESCRIPTION

Embodiments describe a dimensioning tool (or guide) that can be used for placing items within a semi-automated packing machine. For example, a semi-automated packing machine within a facility may be configured to form packaging around items of various sizes and dimensions. In some cases, however, one or more items that are improperly sized for the semi-automated packing machine (e.g., the item has at least one dimension outside of an acceptable range) may transition to the semi-automated packing machine from upstream operations within the facility. In these cases, attempting to form a package around an item that is improperly sized for a semi-automated packing machine and/or improperly placed within the semi-automated packing machine can result in a defective package (e.g., the package may not be fully sealed, which can lead to damaged or missing items), impacting the efficiency of facility operations.

In one embodiment described in more detail below, a dimensioning tool is disposed in proximity to the semi-automated packing machine and is utilized to determine acceptable item sizes and/or item placements for the semi-automated packing machine. For example, the dimensioning tool can be utilized to determine if a given item has unacceptable dimensions (e.g., the item has at least one dimension outside of a predefined range) for the semi-automated packing machine. In another example, the dimensioning tool can be used to determine correct placement (or position) of an item (that has acceptable dimensions) for the semi-automated packing machine. By using the dimensioning tool described herein to determine acceptable item sizes and/or item placements for a semi-automated packing machine, embodiments can significantly reduce the occurrence of defective packages, improving the efficiency of facility operations.

Many of the following embodiments use a fulfillment center as a reference example of an environment in which the dimensioning tool described herein can be utilized to aid in the packing of items. Note that the dimensioning tool described herein is not limited to these type of environments and that the dimensioning tool can be utilized in a variety of environments (e.g., retail centers, grocery stores, food distribution centers, etc.) and for a variety of devices/apparatuses. For example, in some embodiments, the dimensioning tool can be used to aid sizing and/or placement of items for other semi-automated operations within a facility, such as sorting, staging, shipping etc. Further note that, as used herein, a dimensioning tool may also be referred to as an item sizing guide, a dimensioning guide, a two-part dimensioning gauge, a direct measurement guide, a dimensioning device, a dimensioning gauge, etc.

FIG.1is a block diagram illustrating an example facility100that utilizes one or more dimensioning tools for semi-automated packing machines, according to one embodiment. In one embodiment, the facility100is a fulfillment center that performs various operations (e.g., sorting, singulation, picking, packing, etc.) in order to ship items to customers.

In the depicted embodiment, the facility100includes a management system110and an equipment (or machine) area120. The equipment area120is representative of various phase(s) of facility operations known to a person of ordinary skill in the art. In one example, the equipment area120can include one or more receiving stations to singulate disparate items as they are initially received into the facility100. In another example, the equipment area120can include a sorting station to route singulated items to different packing stations (e.g., for order fulfillment). Other examples of facility operations that may take place within the equipment area120include, but are not limited to, staging at loading zones or other predefined regions within a facility, loading onto and/or off vehicles, and so forth.

In this particular embodiment, the equipment area120includes one or more junction segments1021-K, junction segments1121-K, junction segments1141-K, and packing stations1041-K (also referred to as packing systems). The junction segments102,112, and114generally represent sections of the facility100in which items (e.g., individual items, items within totes or containers, items within packages, etc.) are moved (or transitioned) within and/or out of the equipment area120. The junction segments102,112, and114can have a variety of different configurations (e.g., shape, material, angle, height (or elevation), etc.) suitable for a given equipment area120within a facility. For example, one or more of the junction segments102,112, and114can be oriented horizontally (e.g., without an inclination) or tilted (e.g., with an inclination). In some examples, the junction segment(s)102,112, and114may be at a different height (or elevation) than other junction segment(s). In some examples, the junction segment(s)102,112, and114can have a surface shape that is substantially planar, crowned, domed, concave, convex, irregular, or any other shape or combination of shapes. Additionally, the material(s) that forms the top surface of the junction segment(s)102,112, and114may be formed of one or more of a variety of materials (e.g., metal, plastic, rubber, fabric, foam, carpet, wood, tile, etc.). In some examples, the junction segment(s)102,112, and114can include a conveyor belt or a series of conveyor belts (that may have different configurations). In general, the junction segment(s)102,112, and114can have any form factor suitable for transitioning and/or holding items, packages, totes, containers, etc.

Here, one or more items may transition to the packing stations1041-K on junction segments1021-K from other areas of the facility100. Each packing station1041-K includes a respective packing machine1081-K, which is a semi-automated device (or machine or apparatus) that can create a package containing an item by forming packaging material (also referred to as packing material) around the item and sealing the packaging material. The packing machine108can form packaging material around items of varying sizes, and thus has the ability to create packages of varying sizes. The packing machine108can be configured with roller(s) that have packaging material wrapped around them. In some embodiments, the roller(s) (e.g., motorized roller(s)) can be configured to form (or wrap) packaging material around different sides of an item. The packing machine108may also be equipped with heat sealers (also referred to as heat sealing device(s), heat sealing equipment, etc.) that seal the packaging material on one side of the item to the packaging material on another side of the item using heat and/or pressure, in order to create a sealed package that includes the item. In one embodiment, the packing machine108forms flexible bubble-wrap packaging around one or more items. Note that this is merely an example and that the packing machine108can use a variety of materials (e.g., plastic, bubble wrap, paper, rubber, foam, fabric, etc.) for the packaging material.

In some embodiments, each packing machine1081-K may accept and process items that satisfy a (predefined) set of dimensions configured for the packing machine108. For example, each packing machine1081-K may have a predefined maximum volume (e.g., predefined value (or range of values) along each dimension (x, y, and z)) that it can accept for packing an item. In one embodiment, the predefined set of dimensions for each packing machine108is associated with a maximum size of an item that can be packed by the packing machine108without resulting in a defective package caused in part by the size of the item. For example, the predefined set of dimensions configured for a packing machine108may be associated with a threshold level of seal quality of a package output by the packing machine108.

Additionally or alternatively, in one embodiment, the predefined set of dimensions for each packing machine108is associated with a particular place (or location) within the packing machine108where the item can be inserted without resulting in a defective package caused in part by the placement of the item. For example, the placement location configured for a packing machine108may be associated with a threshold level of seal quality of a package output by the packing machine108.

In one embodiment, the management system110may route a given item to one of the packing stations1041-K (e.g., via a respective junction segment102) based in part on information associated with the item. Such information can include, for example, the type of item, the item's destination, the item's dimensions (and volume), the item's orientation, etc. In some cases, the management system110can receive the information associated with an item from one or more devices within the facility100that are located upstream from the packing station(s)104-1. These upstream devices can include, for example, cameras, dimensioning cameras, barcode readers, and the like. In a particular embodiment, identifying information (e.g., barcode) on the item may be scanned and transmitted to the management system110. The management system110can then use the identifying information to determine the type of item and the item's dimensions (e.g., in a database), and route the item to one of the packing stations1041-K, based in part on the item's dimensions.

In some cases, one or more of the items that are routed to a given packing station104may be improperly sized (e.g., have at least one dimension outside of an acceptable range) for the packing machine108at that packing station104. In one example, this can occur due to incorrect information (e.g., item type, dimensions, weight, etc.) for the item being stored in a database and retrieved by the management system110. In another example, the improper routing of an item can occur due to missing information for the item (e.g., identifying information for the item may not have been scanned upstream). In yet another example, the improper routing of an item can occur due to an error that occurred at one or more upstream stations (e.g., the item may have been accidently picked and routed to the wrong packing station).

In some cases, a user (or associate) that receives an improperly sized item at a packing station104may attempt to feed the item into the packing machine108at the packing station104, which in turn can reduce the quality of a package formed (or created) by the packing machine108. For example, if an associate attempts to pack an item that cannot fit into the packaging material (e.g., the item's volume is outside of an acceptable volume), this can result in a defective package seal. The defective package seal can be caused by at least one of a misalignment, a crimp error, incomplete heat seal marks, item exceeding a maximum size, etc. In some cases, even if an item is correctly sized (e.g., has acceptable dimensions and volume), the improper placement of the item into the packing machine108can cause a defective package to be formed. For example, items that are irregularly shaped, such as obtuse and elongated items may have to placed into the packing machine108in a certain orientation and/or position in order for the packing machine108to create a successful package seal (e.g., meeting a threshold level of seal quality).

In embodiments described herein, each packing station1041-K within the facility100is equipped with a respective dimensioning tool1061-K. The dimensioning tool106at a packing station104is configured to constrain the dimensions of items to those that can be safely and successfully packaged by the packing machine108at the packing station104. That is, the dimensioning tool106can exclude items whose dimensions will lead to a package seal failure by the packing machine108.

In one embodiment, the dimensioning tool106allows insertion of an item into the packing machine when the item satisfies a predefined set of dimensions associated with a threshold level of seal quality (configured for the packing machine). In some cases, the threshold level of seal quality for a given packing machine108may be defined as a level of seal quality of a package output by the package machine, such that the package does not include at least one of a predefined set of seal defects (e.g., horizontal seal defect, crimp error, misalignment, etc.).

As described below, in one particular embodiment, the dimensioning tool106includes two two-dimensional (2D) gauges that collectively constrain the length, width, and height of items that can be packed into the packing machine in accordance with one or more criteria (e.g., a set of maximum dimensions associated with a predefined threshold of seal quality). In some embodiments, each dimensioning tool106at a packing station104is installed (or mounted) in a fixed position optimized for the packing machine108at that packing station104. In other embodiments, the dimensioning tool106can be placed in different locations for a packing machine108, e.g., if the packing machine108is modified to process different sized items.

A user at a given packing station104can use the dimensioning tool106at the packing station104to determine whether to feed an item into the packing machine108at the packing station104and/or the manner (e.g., orientation and/or placement) in which to feed the item into the packing machine108. If an item can fit within the dimensioning tool106, then this indicates that the item can be packed by the packing machine108(e.g., without resulting in a defective package due to a defective seal). As shown inFIG.1, items that are fed into the packing machines1081-K may exit the packing machines1081-K as packages (or packed items). The packages can then transition away from the packing stations1041-K via junction segments1121-K.

On the other hand, if an item cannot fit within the dimensioning tool106, then this indicates that the item should not be packed by the packing machine108(e.g., since packing that item can lead to a defective package). As shown inFIG.1, items that cannot fit into the packing machine can be set aside and transitioned away (or diverted) from the packing stations1041-K via junction segments1141-K. The diverted items may be sent to another station in the facility100for (re)processing, which can include, for example, flagging the items to indicate they have been rejected, (re)scanning the items, updating the dimensions for the items, updating packing recommendations for the items, etc.

FIGS.2A-2Cdepict different views of an example dimensioning tool106, according to one embodiment. In particular,FIGS.2A-2Cshow a front perspective view, a top perspective view, and a side perspective view, respectively, of the dimensioning tool106. The dimensioning tool106includes a (first) gauge202and a (second) gauge204, each of which can indicate whether an item is improperly sized (e.g., oversized) for a packing machine108and/or improperly placed within a packing machine108, in order to reduce (or even prevent) package seal failures.

In the embodiment shown inFIGS.2A-2C, the gauge202is a single-piece structure with portions (or members)202A,202B, and202C. Portion202C is a horizontal (or flat) portion of the gauge202(e.g., in the x-y plane) and includes a slot206for mounting (or attaching) (e.g., via screws, bolts, brackets, etc.) the gauge202to a location of the packing machine108. As described below in one embodiment, the gauge202is mounted to a (first) fixed location at the in-feed of the packing machine108. Portions202A and202B are parallel to each other in a vertical plane and extend downward (e.g., in the vertical (z) direction) from an end of portion202C towards gauge204. Here, portions202A and202B have a pronged structure. Note, however, that the gauge202may have a different structure in other embodiments. The gauge202can be formed of one or more of a variety of materials (e.g., metal, plastic, foam, rubber, wood, tile, etc.).

Note that althoughFIGS.2A-2Cshow the gauge202as a single-piece structure, in other embodiments, the gauge202can be formed with multiple pieces. For example, the gauge202can include a two-piece structure with portion202C as a first piece and portions202A and202B as a second piece. In another example, the gauge202can include a three-piece structure with portion202C as a first piece, portion202A as a second piece, and portion202C as a third piece. The gauge202can be built using a variety of tools and methods known to those of ordinary skill in the art, including, for example, 3D printing.

As also shown inFIGS.2A-2C, the gauge204is a single-piece structure with portions (or members)204A and204B. The gauge204also includes a slot208for mounting (or attaching) (e.g., via screws, bolts, brackets, etc.) the gauge204to a location of the picking machine108. As described below, in one embodiment, the gauge204is mounted to a (second) fixed location at the in-feed of the picking machine108. The portions204A and204B are parallel to each other in the horizontal (x-y) plane and extend towards the gauge202in the x direction from an end of the gauge204. Similar to gauge202, portions204A and204B of gauge204have a pronged structure. Note, however, that in other embodiments, the gauge202may have a different structure.

The gauge204can be formed of one or more of a variety of materials (e.g., metal, plastic, foam, rubber, wood, tile, etc.). The gauge204can be formed with the same set of materials as the gauge202or formed with a different set of materials. Similar to gauge202, note that althoughFIGS.2A-2Cshow the gauge204as a single-piece structure, in other embodiments, the gauge204can be a multi-piece structure. The gauge204can be built using a variety of tools and methods known to those of ordinary skill in the art, including, for example, 3D printing.

In one embodiment, the gauge202and the gauge204collectively constrain what a user (or associate) can put into a three-dimensional (3D) space. For example, the gauge202and the gauge204can define the maximum dimensions (e.g., height, width, and length) of an item that can go inside of the packing machine108. As noted, these dimensions may be the maximum dimensions of an item that can be packed by the packing machine108without resulting in a defective package (e.g., due to a seal failure). That is, the maximum dimensions may be associated with a threshold level of seal quality configured for the packing machine108. Additionally, the gauge202and the gauge204define the manner (e.g., placement) in which an item can be loaded into the packing machine108(e.g., for items that satisfy the maximum dimensions). Here, the placement location configured for the packing machine108may also be associated with a threshold level of seal quality configured for the packing machine108.

The gauge204is configured to constrain the dimensions of an item along two dimensions (e.g., in the x-y plane). In particular, the gauge204defines a maximum dimension D1(along the y-axis) that corresponds to a width across the surface of gauge204. As shown, D1extends from an outer end of portion204A to an outer end of portion204B (FIG.2A). Although not shown inFIGS.2A-2C, the gauge204also defines a maximum dimension D2(along the x-axis) that corresponds to a distance between a first location along a length (x-axis) of gauge204and a second location along a same (x) axis as the gauge204. Note D2is described in more detail below with respect toFIG.3. The gauge202defines a maximum dimension D3(along the y-axis) that corresponds to a width between portions202A and202B of gauge202. As shown inFIG.2A, D3extends between ends of portions202A and202B of the gauge202(FIG.2A). The gauge202also defines a maximum dimension D4(along the z-axis) that extends between portion202C of gauge202and a surface of gauge204(FIG.2C).

Note that the maximum dimensions D1and D2can correspond to different dimensions of an item depending on how a given item is oriented with respect to the dimensioning tool106. For example, the maximum dimension D1can correspond to the item's width and the maximum dimension D2can correspond to the item's length, or vice versa. Similarly, the maximum dimensions D3and D4can correspond to different dimensions of an item depending on how a given item is oriented with respect to the dimensioning tool106. For example, the maximum dimension D3can correspond to an item's height and the maximum dimension D4can correspond to an item's width, or vice versa.

The gauges202and204may be mounted in different fixed locations on a packing machine108in order to configure the maximum dimensions D1, D2, D3, and D4for the dimensioning tool106. In the embodiment depicted inFIGS.2A-2C, the gauge202and the gauge204may be mounted in different fixed locations, such that the gauge204and the gauge202are vertically and horizontally offset from each other. For example, the gauges202and204are mounted to the packing machine108in different locations (e.g., in a vertical (x-z) plane) in order to create a vertical offset (VOffset) between the ends of the portions202A and202B of the gauge202and a surface of the gauge204(FIG.2C). Similarly, the gauges202and204are mounted to the packing machine108in different locations (e.g., in a horizontal (x-y) plane) in order to create a horizontal offset (HOffset) between gauge204and gauge202.

FIG.3illustrates an example of a dimensioning tool106located at a packing machine108of a packing station104, according to one embodiment. As shown, the packing machine108includes an in-feed tray310for loading (or feeding or placing) items into the packing machine108. The in-feed tray310includes a bottom surface310A, an in-feed bracket (or guide)310B, and an in-feed bracket (or guide)310C. Here, when an item is placed into the in-feed tray310, the packing machine108can form packaging material around different sides of the item. The packing machine108may use heat sealers to seal the packaging material on one side of the item to the packaging material on the other side of the item to create a sealed package.

In this embodiment, the gauge202of the dimensioning tool106is disposed above the in-feed tray310(e.g., mounted to a first fixed position of the packing machine108) and the gauge204is disposed on the bottom surface310A of the in-feed tray310(e.g., mounted to a second fixed position of the packing machine108).

As noted, the dimensioning tool106depicted inFIG.3can constrain the dimensions of an item that can be put into the packing machine108(via the in-feed tray310) in order to reduce the likelihood of a defective package (e.g., due to a package seal failure). Here, for example, gauge204of the dimensioning tool106constrains the item's length and width (e.g., to below D1and D2) and gauge202of the dimensioning tool106constrains the item's height and width (e.g., to below D3and D4). In this embodiment, D2extends (along the x-axis in a horizontal (x-y) plane) from a first location (or junction)324between portions204A and204B to a second location326along the x-axis of the in-feed tray310. Here, the second location326corresponds to the intersection of bar320of the packing machine108with the in-feed tray310. The bar320may define an outer (e.g., bottom) seal of a package formed by the packing machine108.

Note that whileFIGS.2and3illustrate maximum dimensions D1and D2for gauge204, the gauge204may define different maximum dimensions (of an item that can be packed by the packing machine108) along the same respective axes as D1and D2. For example, the gauge204can define different maximum dimensions (along the same (y) axis as D1) between the ends of portions204A and204B for different points within D2. Similarly, the gauge204can define different maximum dimensions (along the same (x) axis as D2) between the locations324and326for different points within D1. Note that D1may be the same as D3or different than D3.

Likewise, whileFIGS.2and3illustrate maximum dimensions D3and D4for gauge202, the gauge202may define different maximum dimensions (of an item that can be packed by the packing machine108) along the same respective axes as D3and D4. For example, the gauge202can define different maximum dimensions (along the same (y) axis as D3) between portions202A and202B for different points within D4. Similarly, the gauge202can define different maximum dimensions (along the same (z) axis as D4) between portion202C and the surface of gauge204for different points within D3.

FIGS.4A-4Dillustrate an example sequence for using a dimensioning tool106to place an item in a packing machine108, according to one embodiment. Referring toFIG.4A, the packing machine108is configured to accept items from a user and form packaging material402around the item(s) to create a package with the item (e.g., for shipping to a customer). As shown, the packing machine108can form packaging material402around different sides of the in-feed tray310where an item would be placed. In some embodiments, the packaging material402may wrap around the bar320, forming a U-shaped channel that defines the bottom of a package created by the packing machine108. Here, a user (or associate) may initially check that the in-feed tray310is clear and that the packing machine108is ready to receive an item for processing.

As shown inFIG.4B, at a subsequent point in time, the user can retrieve an item420from the junction segment102, scan the item420, and place the item420on the in-feed tray310. Here, the item420has dimensions ID1, ID2, and ID3. Assuming the item420was laying flat on a surface, ID1may refer to the height of the item420, ID2may refer to the (draw) length of the item420, and ID3may refer to the width of the item420. InFIG.4B, the item420is placed on the in-feed tray310, such that ID1is along the same axis (e.g., y-axis) as D1and D3, ID2is along the same axis (e.g., x-axis) as D2, and ID3is along the same axis (e.g., z-axis) as D4. With the item420in this orientation, the user may attempt to slide the item420into the packing machine108via the in-feed tray310.

However, as shown inFIG.4C, when the user attempts to place the item420into the packing machine, the item420does not clear the bottom gauge204(e.g., the item420overlaps a portion of the gauge204). In particular, the item dimension ID2is not within a maximum dimension defined by the gauge204(e.g., along the same (x) axis as D2) for the item dimension ID1(along the same (y) axis as D1). Because the item420does not clear the bottom gauge204, this indicates that the item420is improperly sized and/or improperly placed within the packing machine108in order for the packing machine108to successfully create a package (e.g., without a seal failure). Based on this indication, the user may can attempt to re-orient the item420(e.g., by re-aligning the dimensions of the item with respect to the dimensioning tool106).

For example, as shown inFIG.4D, the user re-orients the item420, such that ID1is along the same (y) axis as D1and D3, ID2is along the same (z) axis as D4(as opposed to D2), and ID3is along the same (x) axis as D2(as opposed to D4). Here, with the item420in this orientation, the item420does not clear the gauge202and the gauge204. For example, the item dimension ID1is not within a maximum dimension defined by the gauge204(e.g., along the same (y) axis as D1) for the item dimension ID3(along the same axis as D2), and the item dimension ID2is not within a maximum dimension defined by the gauge202(e.g., along the same (z) axis as D4) for the item dimension ID1(along the same (y) axis as D3). Based on this indication, the user can determine that placing the item420into the packing machine108may result in a defective package, and may divert the item420via junction segment114for re-processing.

FIGS.5A-5Billustrate another example sequence for using a dimensioning tool106to place an item in a packing machine108, according to one embodiment. Here, inFIG.5A, a user places the item520onto the in-feed tray310, such that ID1is along the same (y) axis as D1and D3, ID2is along the same (x) axis as D2, and ID3is along the same (z) axis as D4. However, the item520does not clear gauge204, e.g., due in part to the item dimension ID1being outside a maximum dimension defined by the gauge204(e.g., along the same (y) axis as D1) for the item dimension ha (along the same (x) axis as D2).

Based on this indication, as shown inFIG.5B, the user re-orients the item520, such that ID2is along the same (z) axis as D4(as opposed to D2) and ID3is along the same (x) axis as D2(as opposed to D4). Here, in this orientation, the item520clears both gauges202and204, indicating that the packing machine108can process the item520without forming a defective package.

Note that whileFIGS.4A-4DandFIGS.5A-5Ddepict items420and520being boxed-shape, the dimensioning tool106described herein can gauge items of a variety of configurations and shapes.FIGS.6A-6B, for example, illustrate a sequence for using a dimensioning tool106to place an irregularly shaped item(s) in a packing machine108, according to one embodiment. Here, the user may retrieve one or more flexible and soft items620(e.g., plastic wrapped items) to place into the packing machine108(through the dimensioning tool106) (FIG.6A). After placing the item(s)620into the packing machine108, the user confirms that the item(s)620clear both gauges202and204, indicating that the packing machine108can process the item(s)620without forming a defective package.

FIG.7illustrates an example packing station700(also referred to as a packing system), according to one embodiment. The packing station700may be similar to packing station104described above. For example, the packing station700may be included within a facility (e.g., facility100) and used to process items, by packing the items in packaging material in preparation for shipment. As shown, the packing station700includes packing machine108and dimensioning tool106, which are described in more detail above. The packing machine108includes in-feed tray310and bar320, which are also described in more detail above. In one embodiment, the dimensioning tool106is used to determine whether items are improperly sized for the packing machine108. Additionally or alternatively, in one embodiment, the dimensioning tool106is used to determine proper placement of item(s) into the packing machine108. For items that do not fit within the dimensioning tool106(e.g., due to being improperly sized and/or improperly placed), the items may be diverted for re-processing via junction segment114. On the other hand, items that do fit within the dimensioning tool106may be packed by the packing machine108, and subsequently transitioned via junction segment112.