Abstract:
A simulation program that determines a packaging configuration for placement of any math-based part/assembly into a selected shipping container(s) for transfer of the product to customer plants. The simulation program determines either automatically or manually an efficient packaging configuration for placement of any part/assembly into any appropriate shipping container.

Description:
TECHNICAL FIELD  
         [0001]    This application relates to a method and apparatus for determining and providing a user with a packaging configuration based upon a user provided input.  
         BACKGROUND  
         [0002]    Currently, production-part packaging configurations are manually determined using “best guess” method and manual alignment of physical parts/assemblies by industrial and packaging engineering group members. This process is labor-intensive and generally is only applicable on a part-by-part basis thus the process must be repeated for each unique part/assembly.  
           [0003]    A simulation program that determines optimum and efficient packaging configurations for placement of any math-based part/assembly into its appropriate shipping container(s) for transfer of the product to customer plants.  
           [0004]    A simulation program that determines either automatically or manually an efficient packaging configuration for placement of any part/assembly into any appropriate shipping container.  
           [0005]    The simulation program also allows the user to modify the output in order to select containers based upon other criteria including but not limited to the following: customer preference, size, weight, amount of containers per eight hour shift and other manufacturing requirements.  
           [0006]    The above-described and other features and advantages of the present invention will be appreciated and understood by those skilled in the art from the following detailed description, drawings, and appended claims. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0007]    [0007]FIG. 1 is a schematic illustration of the packaging optimization process of the present application;  
         [0008]    [0008]FIG. 2 is a diagrammatic illustration of portions of a control algorithm for the packaging optimization method of the present application;  
         [0009]    [0009]FIG. 2A is a diagrammatic illustration of portions of an automatic mode portion of the control algorithm for the packaging optimization method of the present application;  
         [0010]    [0010]FIG. 2B is a diagrammatic illustration of portions of a manual mode portion of the control algorithm for the packaging optimization method of the present application;  
         [0011]    [0011]FIG. 2C is a diagrammatic illustration of portions of a retrieval mode portion of the control algorithm for the packaging optimization method of the present application;  
         [0012]    FIGS.  3 - 7  illustrate an automatic mode of the packaging optimization method illustrated in FIG. 2;  
         [0013]    FIGS.  8 - 9  illustrate a manual mode of the packaging optimization method illustrated in FIG. 2;  
         [0014]    FIGS.  10 - 15  illustrate a 3D nesting method illustrated in FIG. 2 and FIG. 3; and  
         [0015]    FIGS.  16 - 20  illustrate options available for the control algorithm. 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0016]    Referring now to FIG. 1, the method for optimizing a packaging configuration for an item to be shipped is illustrated generally. In exemplary embodiment of the present invention, an executable simulation program  10  is run from a computer workstation  12 . In response to a request for an input of the item to be used in the simulation, the program runs in either a manual, automatic or retrieval mode.  
         [0017]    The item inputted is a computer aided design (CAD) model representation  14  of the physical part/assembly to be shipped. This computer model is selected from a product database  16 . For example, model  14  can be a CAD representation of an automotive part such as a window regulator motor.  
         [0018]    The simulation arranges model  14  (primary) with a duplicate model (secondary) in a variety of configurations for both the primary and the secondary. Here, these two configured parts serve as the unit of measure for the development of part/container layouts. These unit patterns are oriented into six unique pattern orientations, which are considered for each packaging container. These six orientations relate to movement of the configured patterns about the x, y and z axis. Each of these pattern orientations is considered for each packaging container available from a container database  18 . Accordingly, program  10  analyzes many arrangements of the model and numerous configurations for comparison to multiple containers in order to provide the most efficient configuration.  
         [0019]    Upon completion of the simulation the most efficient packaging configuration is determined with reference to the container size, the number of parts incorporated into the container, the overall weight of the container and efficiency of the pack configuration.  
         [0020]    Referring now to FIG. 2. the operation of program  10  is illustrated schematically. The program user executes step  20  to open the file for a CAD model  14  from the product database  16 . The program user selects the packaging simulation program  21  from a database  16 .  
         [0021]    The simulation program prompts the user to select the packaging mode option to be used by the program, either step  22 ,  23  or  24 . In this embodiment there are three options; step  22  is the option for the automatic mode (FIG. 2A), step  23  is the option for the manual mode (FIG. 2B), and step  24  is the option for the retrieval mode (FIG. 2C).  
         [0022]    A saved pack layout is opened from a database  16  with the selection of the retrieval mode  24 . And the packaging simulation program  21  advances to step  31 , where the program user can interact with the saved data through display and printout options.  
         [0023]    The simulation program will run faster with a simplified CAD part model, (i.e., a simplified CAD model representation of the original CAD model), than say that of the actual CAD part model that is available from the product database. Therefore, pack layouts can be created (and saved) using the simplified CAD part model. And these pack-layouts are then retrieved after the original CAD part model has been opened, with the intent of “fine-tuning” the two-part pattern. This allows for improved pack-layout efficiencies when using the Manual mode of the simulation program.  
         [0024]    If either the manual or automatic mode is selected, the simulation program advances to step  26 . The program user is then prompted to enter packaging parameters, which include but are not limited to the following items; part weight, part ship rate, part to part clearance, part to container clearance, and part orientation options (or limitations).  
         [0025]    Once the packaging parameters are inputted at step  26 , the simulation program advances to step  28 . And the program user is prompted to select a customer container database that includes the listing of available containers for multiple customers. Each customer container database in  28  has the listing of available containers and the selection criteria (if applicable) for choosing the appropriate container. With selecting the ‘CUSTOM’ option in step  28 , the program user can create a new container database in step  29 . The ‘CUSTOM’ option  29  includes: creating a unique list of containers by selecting any number of customer databases and/or by individually defining container sizes; saving and retrieving the newly created container list; and display options for listing and clearing the container list.  
         [0026]    If the manual mode is selected in step  23  (FIG. 2), then step  32  provides the program user with a plurality of part/container pack design options. These options include but are not limited to the following; adjustment of the pattern, adjustment of the repeat distance, lists packs, display packs, displays of the work pattern, available options, parameters, information and of course an exit prompt. All of these options in step  32  are interactive and can be continuously selected until the exit option is selected. Additionally, the options of steps  32  are presented to the program user in the recommended order of usage. Although these options are in the order of recommended usage the order of their usage may vary.  
         [0027]    Referring now to FIGS.  3 - 7 , portions of the simulation run by the automatic mode, which can be selected in step  22 , are illustrated. FIGS.  3 - 7  illustrate just one example of a simulation run with a particular model  38 . Referring in particular to FIG. 3, the development of a two-part pattern about the xy plane is illustrated. Here, a primary part  38  is fixed at the origin of a principal plane  40 . Primary part  38  corresponds to the CAD model selected in step  20  of FIG. 2. In this Figure principal plane  40  is configured about the xy axis. During execution of the simulation program, primary part  38  is compared with a plurality of secondary part locations  42 ; and are arranged in an array about primary part  38  in principal plane  40  (FIG. 3).  
         [0028]    For purposes of illustration, twelve positions of secondary part  42  are arranged in an array about primary part  38 . It is, of course, contemplated that more or less locations of the secondary part  42  may be arranged in an array about primary part  38 . However, for purposes of this illustration twelve positions are used.  
         [0029]    In addition, four unique orientations of the primary part are also investigated with each of the secondary part locations. Three primary part orientations are illustrated by bracket  44 . The fourth configuration being the primary part  38  orientation that is currently being investigated by the simulation program and is illustrated at the origin of principal plane  40 .  
         [0030]    Accordingly, FIG. 3 illustrates that 48 two-part pattern configurations in the xy plane are available for comparison by the simulation program.  
         [0031]    Referring now to FIG. 4, the analysis of a two-part pattern for the same CAD model selected in step  20  is illustrated about the xz plane. Here, a primary part  38  is fixed at the origin of a principal plane  46 . In this Figure principal plane  46  is configured about the xz axis. Similar to the comparison of FIG. 3, and during execution of the simulation program, primary part  38  is compared with a plurality of secondary parts  42  which are arranged in an array about principal plane  40  (FIG. 3).  
         [0032]    In addition, four unique orientations of the primary part are also investigated with each of the secondary part locations. Three primary part orientations are illustrated by bracket  44 . The fourth configuration being the primary part  38  orientation that is currently being investigated by the simulation program and is illustrated at the origin of principal plane  46 . Accordingly, FIG. 4 illustrates that 48 two-part pattern configurations in the xz plane are available for comparison by the simulation program.  
         [0033]    Referring now to FIG. 5, the analysis of a two-part pattern for the same CAD model selected in step  20  is illustrated about the yz plane. Here, a primary part  38  is fixed at the origin of a principal plane  50 . In this Figure principal plane  50  is configured about the yz axis. During execution of the simulation program primary part  38  is compared with a plurality of the secondary parts  42  which are arranged in an array about principal plane  50  (FIG. 5).  
         [0034]    In addition, four unique orientations of the primary part are also investigated with each of the secondary part locations. Three primary part orientations are illustrated by bracket  44 . The fourth configuration being the primary part  38  orientation that is currently being investigated by the simulation program and is illustrated at the origin of principal plane  50 . Accordingly, FIG. 5 illustrates that  48  two-part pattern configurations in the yz plane are available for comparison by the simulation program.  
         [0035]    [0035]FIG. 6 illustrates several ( 54 ,  56 ,  58 ,  60 ,  62 ,  64  and  66 ) of many two-part pattern configurations between primary part  3   8  and secondary part  42  which are utilized by the packaging optimization simulation system. For purposes of illustration, and referring now to FIGS. 3 and 6, the two-part configurations illustrated in FIG. 6 represent the configurations of primary part  38  when it has the initial configuration illustrated as  68  in FIG. 3 and it is being configured with secondary part  42  having the configuration illustrated by ( 70 - 84 ) in FIG. 3. The configuration of secondary part  42  with respect to primary part  38 , namely configurations ( 70 ,  72 ,  74 ,  76 ,  78 ,  80 , and  82 ) corresponds to the configurations illustrated in FIG. 6 by items ( 54  and  70 ), ( 56  and  72 ), ( 58  and  74 ), ( 60  and  76 ), ( 62  and  78 ), ( 64  and  80 ) and ( 66  and  82 ), respectively.  
         [0036]    Accordingly, one hundred and twenty, two-part patterns are determined from FIGS.  3 - 5 . This number is based upon a twelve point array of secondary part  42 , which as previously mentioned may be modified to include more or less positions, and the factoring out of redundant patterns which may be determined (twenty four in all) from the simulation run in FIGS.  3 - 5 . Of course, and if the number of positions in the array varies this number will also vary.  
         [0037]    Referring now to FIG. 7, each two-part pattern orientation is considered in six orientations  84 ,  86 ,  88 ,  90 ,  92  and  94 ; corresponding to orientations of the two-part patterns about the x, y and z axis. And the coordinate system (x, y and z) is understood to be fixed to one of the inside corners of the packaging container during simulation. Accordingly, each orientation is considered for each packaging container available from the database.  
         [0038]    Accordingly, the simulation calculates seven hundred and twenty possible configurations (or part layouts) of the developed two-part patterns. Here, a part layout can be understood to be the unbounded three dimensional array of a two-part pattern. These seven hundred twenty part layouts or configurations are then compared to each of the containers selected from the database in order to generate the part/container layouts. If any of the calculated part/container layouts do not meet the customers&#39; packaging requirements, then these layouts are not considered as a valid (or potential) packaging design and (by default) will not be displayed to the program user as such. All of the valid part/container layouts are organized in a list and presented to the program user as an on-screen display printout (illustrated as box  19 , FIG. 1).  
         [0039]    Box  30  (FIG. 2) summarizes the execution of the simulation program in the automatic mode. Item (A) in box  30  summarizes the run of the simulation program that develops the one hundred and twenty possible configurations of the two-part pattern described in FIGS.  3 - 6 . Item (B) in box  30  summarizes the run of the simulation program that executes the calculations used to develop the part layouts described in FIGS. 7. Item (C) in box  30  summarizes the run of the simulation program that develops the part/container layouts.  
         [0040]    Referring now to FIGS.  8 - 10 , portions of the manual mode of program  10  are illustrated. The manual mode is selectable from box  23  (FIG. 2). During manual mode the user obtains the CAD part model from the database and is illustrated in box  100  as the primary part. The simulation program prompts the user to develop the pattern by selecting the pattern direction from the options available in the box  102 . In an exemplary embodiment, the default pattern direction in box  102  coincides with the smallest dimension of the primary part. Of course, and as an alternative the default direction may vary. In addition, the user may select any pattern direction available in box  102 .  
         [0041]    Once the pattern direction is selected, the simulation program creates a copy (secondary part) of the primary part and is located in the pattern direction as chosen in box  102 . This is illustrated in box  104 .  
         [0042]    After the pattern direction is selected, the simulation prompts the user with a menu of options, illustrated in box  32  (FIG. 2). The first option listed (recommended) is to adjust the part-pattern and is illustrated in box  106 . Adjustment of the part-pattern consists of configuring the secondary part relative to the primary part which is fixed in position. The part-pattern adjustment options illustrated in box  106  consists of the following; 3D translation of the secondary part in the six axial directions, translation distance value setting (illustrated in FIG. 107), re-orienting the secondary part 180 degrees about an axis, change of the pattern direction, and nesting options. For example, box  108  illustrates the 180 degrees flipping of the secondary part along the z-axis.  
         [0043]    After accepting the position of the secondary part, selecting the Nest option in box  106  (FIG. 8) allows the program user to select the dimensional control for nesting. This is illustrated in box  1   10  (FIG. 9). For example, box  110  provides the user with nesting options in either one dimension (along the XC, YC or ZC axis), or two dimensional (in the XY, YZ, or XZ plane), or three-dimensional indicated as full (box  1   12 ).  
         [0044]    Referring now to FIGS.  10 - 15 , the nesting process method is illustrated two dimensionally for simplicity and understanding. During this process an initial clearance gap (between the primary and secondary part) is provided from the user input for the desired part-to-part clearance (FIG. 2, Box  26 ); and stored as a calibration constant. The primary part is fixed in location at an origin location and then the secondary part is positioned at any non-intersecting location. The minimum distance between the primary part and the secondary is measured and stored in memory as the clearance vector. In addition, the dimensions (x, y, and z) of a boundary box  114  around both parts is measured and recorded.  
         [0045]    During operation of the nesting process the minimum distance is measured between parts and is compared to the user defined clearance gap. If the minimum distance is greater than the desired part-to-part clearance, then the secondary part is translated along a clearance vector toward the primary part and to the location where the minimum distance between parts is now equal to the clearance gap (FIG. 11, Box  116 ). And if the dimensions of this new boundary box  116  decreases, the secondary part is translated incrementally and perpendicularly to the clearance vector until the minimum distance between the parts is reached which will provide the smallest possible dimensions of the boundary box  118  (FIG. 14).  
         [0046]    For example, and referring now to FIG. 15 portions of a control algorithm  120  for performing the nesting process method is illustrated. The steps of the control algorithm  120  are also illustrated sequentially in FIGS.  10 - 14 .  
         [0047]    Box  122  represents the request for a clearance gap input for the two parts. Box  124  represents the positioning of the primary part at an origin point. Box  126  represents the manual positioning of the secondary part at any non-intersecting location. Box  128  represents the logic for measuring the minimum distance between the parts and the assignment of a value to a variable defined as the clearance vector.  
         [0048]    Box  130  represents the measurement of the dimensions of the boundary box defining or enclosing both the secondary and primary parts. This value is stored in memory.  
         [0049]    A decision node  132  determines whether the minimum distance is equal to the clearance gap. If not, a decision node  134  determines whether the minimum distance is greater than the clearance gap. If not, then the minimum distance is less than the clearance gap. And with box  136 , the secondary part is translated along the clearance vector to the location where the length of the clearance vector is equal to that of the clearance gap. Here, the secondary part moves away from the primary part and in the direction of the clearance vector. And the logic of box  128  is repeated.  
         [0050]    If however, the minimum distance measured is greater than the clearance gap, box  138  instructs the secondary part to be moved along the clearance vector in the direction toward the primary part to the location where the length of the clearance vector is equal to that of the clearance gap.  
         [0051]    After this process is performed box  140  represents the remeasurement of the boundary box around both parts and the new value is assigned to a new boundary box measurement stored in memory.  
         [0052]    Alternatively, and if the minimum distance is equal to the clearance gap, box  142  represents the instruction to translate the secondary part along a line perpendicular to the clearance vector. After this process is performed box  140  represents the remeasurement of the boundary box defined around both parts and this value is assigned to new boundary box measurement stored in memory.  
         [0053]    After the commands of box  140  are executed, a decision node  144  determines whether any of the edge dimensions (x, y or z) of the boundary box decreased over the previously recorded dimensions, (i.e., comparison of new measurement vs. previous measurement).  
         [0054]    If there was no measured decrease in any of the dimensions of the boundary box, box  146  instructs the secondary part to be translated back to its previous position. Then box  148  stores that positional information of the two-part pattern to be used.  
         [0055]    Alternatively, and if any of the dimensions of the boundary box decreased, the logic of box  128  is repeated. This process will continue until the minimum boundary box dimensions are obtained.  
         [0056]    Referring now to FIG. 16, the option for adjusting the repeat distance of the two-part pattern is illustrated. Here a command prompt  150  provides a user with selections for allowing independent control (x, y and z directions) of the clearance between the two-part patterns. This is particularly useful for interpreting the thickness of dunnage required for packaging the considered part. Command prompt  150  allows the user to manually set the value for the (two-part) pattern repeat distance by translating the repeated (second) two-part pattern either away or closer to the initial two-part pattern. The magnitude for translating the two-part pattern can be set by the user with the ‘Move Distance’ option. One dimensional nesting (in the direction of ‘Set Axis’ of the two two-part patterns is available with the ‘Auto’ option.  
         [0057]    Referring now to FIG. 17, the options for the listing pack command of box  32  (FIG. 2) is illustrated as dialog box or prompt  152 . And each option in box  152  has its own menu of options, (i.e., prompts  154 ,  156 ,  158 ,  160  and  162 ). Box  164  represents the information obtained after the containerization optimization method has been performed. It is noted that here this option is available for all packaging modes, (e.g., automatic, retrieve and manual). Box  164  provides the user with necessary information in order to select the most efficient packaging container. For example, outlined in box  164  a line of text reveals that twelve parts with an overall (packed container) weight of 28.9 pounds and overall efficiency of 0.3475 is obtained from pack No. 66. Prompt  158  allows the user the option to list results by container style, (e.g., Totes, Bulk Packs, All Styles, Single Container and Auto). The ‘Auto’ container style is the default setting which selects the container style based on the customer&#39;s requirements; that is, if a customer database was selected in Box  28  (FIG. 2).  
         [0058]    Prompt  160  allows the user to input the maximum weight limit for the container to be used. Prompt  162  allows the user to input a shift limit, (i.e., maximum amount of containers to be shipped during an eight hour work period). Both prompts  160  and  162  have an on/off toggle feature that allows the weight and shift limit control feature to be either considered or ignored by the simulation program. Prompt  154  allows either all the pack results to be listed or to consider only the most efficient results for each unique container size. All of these features allow the user to modify the output for display purposes. Prompt  156  provides data sorting options that allows the user to sort the column data in Box  164 , (e.g., container volume, total number of parts per container, containers per shift, efficiency, etc.).  
         [0059]    Referring now to FIG. 18, the display pack option of box  32  (FIG. 2) is illustrated by dialog boxes and or command prompts  166 ,  168   170 ,  172  and  174 . Prompts  166  and  168  provide the user with the selections settings and the options for allowing the program user to display the individual pack designs with three different pack-layout options; namely, between parts, around outside edge and don&#39;t distribute identified as information boxes  170 ,  172  and  174 , respectively. It is noted that this option is available for all packaging modes selected, (e.g., automatic, retrieve and manual).  
         [0060]    Referring now to FIG. 19, the display work pattern option of box  32  (FIG. 2) is illustrated by box  176 . This action allows the part pattern to be displayed. This is useful for editing the two-part pattern. The pack options in box  32  are illustrated by box  177 . This action allows the pack-layout design to be saved (for use in retrieval mode), cleared, retrieved and/or calculated. The ‘Calculate’ option is useful if changes are made to the original two-part pattern, when using the ‘Display Work Pattern’ option (box  176 ).  
         [0061]    Referring now to FIG. 20, the ‘Parameters’ display and information option of box  32  (FIG. 2) are illustrated by dialog box  178  and box  180 . The parameter option allows the packaging and manufacturing parameters to be edited by the user. The information option displays positioning information regarding the considered two-part pattern.  
         [0062]    While the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.