US20150379462A1

US20150379462A1 - Protective packaging system consumable resupply system

Info

Publication number: US20150379462A1
Application number: US14/749,940
Authority: US
Inventors: Thomas D. Wetsch; George Bertram; Edward Eisenberger
Original assignee: Pregis Innovative Packaging Inc
Current assignee: PREGIS INTELLIPACK LLC
Priority date: 2014-06-27
Filing date: 2015-06-25
Publication date: 2015-12-31
Also published as: WO2015200863A1; US10160177B2; CN106715274B; CN106715274A; US20150375882A1; EP3160851A4; EP3160853A1; US10926507B2; EP3160852B1; EP3160852A4; WO2015200911A1; EP3160851B1; CN107074389B; CN107074388A; US20150375469A1; CN107074388B; CN107074389A; EP3160851A1; EP3160853A4; US20150378352A1

Abstract

The present disclosure is related to methods and machines for creating packaging materials and reordering supply materials. As one example, a machine of the present disclosure includes a supply material input for receiving raw supplies, one or more machine components configured to convert the raw supplies into completed packaging materials, a material output for outputting completed packaging materials created using the raw supplies, and a processing element configured to receive data corresponding to the one or more machine components. The processing element determines using at least one of an initial raw supply level, a completed packaging materials level, one or more current packaging material orders, and/or historical operating parameters of the one or more machine components to determine if additional raw supplies are required.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to U.S. provisional patent application No. 62/018,267 entitled “Computerized Controller for Packaging Materials”, the entirety of which is incorporated herein by reference. The present application is related to U.S. application Ser. No. 14/749,866, entitled “Protective Packaging Device Queue Control,” U.S. application Ser. No. 14/749,911, entitled “Integrated Protective Packaging Control,” U.S. application Ser. No. 14/750,736, entitled “Self-Contained Computational Device for Protective Packaging Systems,” and U.S. application Ser. No. 14/750,813, entitled “Protective Packaging Machines Demonstrative Content”, all of which are hereby incorporated by reference herein in their entireties.

TECHNICAL FIELD

The present invention relates generally to packaging devices, and more specifically, to a computerized controller for packaging devices.

BACKGROUND

Packaging machines are used to create packaging materials, such as cushioning elements, that may be used to surround or contain items in a predetermined volume (e.g., box) to allow the item to be shipped, transported, stored, and the like with a reduced risk of damage. Examples of packaging machines include foam-in-bag machines that inflate bags with expandable foam where the foam provides the cushioning support, air-bag machines that inflate bags with air or other similar gases to provide the cushioning support, and dunnage machines that shred materials such as paper where the shredded elements provide cushioning for the items.
Operational control of packaging machines often requires manual input by a user or machine administrator. For example, for a foam-in-bag machine, such settings can include, bag dimensions, the percentage of foam that should be inserted into the bag, and the number of bags desired. Other types of machines include related types of input requirements. These manual inputs can be some limited, as well as time consuming, confusing or difficult to follow, and may result in issues due to human error (e.g., typographical errors, etc.). Furthermore, users of conventional packaging machines may be required to manually enter inputs to make numerous packaging elements, cumbersomely waiting for each packaging element to be created before entering an input for a subsequent packaging element. This can result in an inefficient use of the user's time, as well as the user's employer's resources.
Additionally, often packaging machines may run through an inventor of raw materials without a user being aware of the current inventory levels. This may cause an inventory of raw materials to be exhausted without new supplies having been ordered. This causes delays in producing packaging materials, delay completion of orders and cause packaging material companies to lose money or customers.

SUMMARY

In one embodiment, a method for maintaining an inventory of packaging supplies is disclosed. The method includes receiving by a processing element an initial level of packaging supplies, e.g., supplies that are used to create packaging materials. Once the initial level is received, the method includes receiving by the processing element packaging data corresponding to current supply use by one or more packaging machines over a predetermined time period, determining by the packaging machine whether a current level of packaging supplies is below a predetermined threshold and when the current level of packaging supplies is below a predetermined threshold, activating by the processing element a new order process.
In another embodiment, a machine for creating packaging materials and reordering supply materials is disclosed. The machine includes a supply material input for receiving raw supplies, one or more machine components configured to convert the raw supplies into completed packaging materials, a material output for outputting completed packaging materials created using the raw supplies and a processing element configured to receive data corresponding to one or more machine components. The processing element determines using at least one of an initial raw supply level, a completed packaging materials level, one or more current packaging material orders, or historical operating parameters of the one or more machine components to determine if additional raw supplies are required.
In yet another embodiment, a foam-in-bag packaging system is disclosed. The foam-in-bag packaging system includes a foam-in-bag machine and a portable computing device in electrical communication with the foam-in-bag machine. The portable computing device including at least one processing element, a touch sensitive display in communication with the at least one processing element and a network/communication interface in communication with the at least one processing element. The processing element transmits a new order message via the network/communication interface to a user device to reorder raw supplies for use by the foam-in-bag machine based on at least one of a number of bags created by the foam-in-bag machine over a predetermined time period, an initial inventory of raw supplies, one or more current bag orders, and a prediction of future bag orders.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a block diagram of a packaging system including a packaging machine and a controller.

FIG. 1B is a block diagram illustrating raw supplies being received into an input of a packaging machine and the machine outputting at an output packaging materials.

FIG. 2A is a block diagram of the packaging system of FIG. 1A including additional machines.

FIG. 2B is a block diagram of the packaging system of FIG. 1A including additional controllers and machines.

FIG. 2C is a diagram illustrating the system of FIG. 2A with various types of machines.

FIG. 3 is a simplified block diagram of the controller of FIG. 1A.

FIG. 4A is a rear isometric view of an example of a packaging assembly including foam precursor or other chemical supplies.

FIG. 4B is a side isometric view of the packaging assembly of FIG. 4A with the material supplies hidden for clarity.

FIG. 4C is an enlarged view of FIG. 4A.

FIG. 4D is a perspective view of a mounting assembly for the packaging system of FIG. 4A.

FIG. 5A is an image of an example of a custom element graphical user interface for the controller.

FIG. 5B is an image of an example of a custom sequence graphical user interface for the controller.

FIG. 6 is an image of an example of a queue graphical user interface.

FIG. 7A is an image of the queue graphical user interface of FIG. 6 with a sequence and an item added to a queue pathway.

FIG. 7B is an image of the queue graphical user interface of FIG. 6 with two items and a sequence added to the queue pathway.

FIG. 8 is a flow chart illustrating a method for adding items to a queue for the machine of the packaging assembly of FIG. 4A.

FIG. 9 is a flow chart illustrating a method for using the controller to monitor and reorder supplies for the packaging system of FIG. 4A.

DETAILED DESCRIPTION

In some embodiments herein, a packaging system including a controller and a packaging machine is disclosed. The packaging machine is typically a device for making protective packaging, although in other embodiments it can be other types of manufacturing machines. Embodiments of machines create packaging material, including protective packaging materials and other packaging products. Exemplary protective packaging materials include foam-in-bag cushions, foam-in-place protective packaging, inflated pillows and cushions, inflatable bags, paper dunnage, and the like, for example for impact protection, stabilizing products within a box or other container, or void fill. In some embodiments, the controller can be any type of suitable processor, computer, or electronic module associated with or in the machine.
In some embodiments, the controller can be a computer. The computer may be a portable computer, such as a tablet, smart phone, gaming device, or the like, and is placed into communication with the packaging device as well as one or more sensors that may be connected to or integrated with the packaging device. As will be described in more detail below, the controller may control and/or vary one or more components of the packaging machine (e.g., settings, machine selections, cushioning characteristics, etc.) and may sense and control input materials provided to the packaging machine (e.g., sheets of plastic used to create the inflatable bags). Further, the controller may also be in communication with one or more other controllers and/or machines, so as to allow the controller to communicate with and control an entire warehouse or other grouping of packaging machines, where the group of machines may be located in a single location or in two or more locations.
The controller may be configured to reorder supplies (e.g., consumables by the machine) for the packaging machine. For example, the controller may monitor the current status of the input or raw materials (e.g., through one or more sensors on the packaging machine, inventory databases, the controller, and/or materials) and when the raw materials reach a particular level the controller may place an order or send a notification that new supplies are required. In another example, the controller may estimate the materials or consumables remaining based on the queue history of the matching. In this example, the controller can review the types and number of cushioning elements created over a set time period and using that data determine the amount of materials that may be remaining. In examples the controller can predict when new raw supplies will be needed and automatically alert a user and/or automatically place orders from a vendor for the raw supplies, the packaging materials manufacturer may eliminate delays due to exhaustion of raw supplies, increasing production times, and products.
In some embodiments, the controller may receive an input indicating a desired cushioning element to be created and/or a packaged item for which the cushioning element is needed. Based on the input, the controller may adjust the machine parameters to create the desired cushioning element. The input may be a user input (e.g., selection of an icon or entered data), may be sensed by the controller or machine (e.g., first type of material corresponds to a first type of bag), or may be a combination of a sensed and user input. Additionally, the controller may adjust components of the machine based on other users or states of the machines. As one example, during a maintenance setting the controller may provide power to certain components, while withholding power from others. In this example, a user can repair and/or test a machine with a reduced risk of injury to himself and/or the machine. As another example, during a cleaning setting the controller may activate components to operate a cleaning cycle for the machine. Depending on the packaging machine and user preferences, the controller may be configured to selectively modify, control, monitor, and/or activate each component of the packaging machine and may do these actions either based on a user input, automatically (e.g., through sensed data), or a combination thereof.
As briefly discussed above, the controller may include a display either integrated therewith (e.g., a tablet) or a display that is separate from the controller but in communication therewith. The display may be used to display a graphical user interface (GUI) that allows a user to select and modify the machine and to instruct the machine to create a desired cushioning element or elements in a desired order and with a particular set of characteristics. The GUI may include icons that mirror or mimic characteristics of particular cushioning elements (e.g., image that matches an image of a particular bag). This allows a user to quickly visually identify the desired input without requiring additional knowledge of the machine. The icons may indicate selected characteristics and parameters of packaging element or elements, and changes to the parameters may be reflected by the icons. The icons may be selected by a user to provide instructions to the machine based on the desire cushioning element or elements to be created by the machine.
The controller may receive user input that loads the selected cushioning element to be created into a manufacturing queue for the packaging machine. Alternatively or additionally, the icons or other input components for the controller may be configured to set a sequence of bags or other cushioning elements that can then be added as a group to the queue of the machine. For example, when the user selects a particular icon on the GUI, a first sequence of cushioning elements may be programmed into the machine in order to be manufactured in the order of the sequence. The cushioning elements within the sequence may then be added to the machine's queue to create those elements. The cushioning elements within the queue may thus be added either via a particular sequence or may be added individually. This allows the queue of the machine to be dynamically tailored to the specific needs of the user. Also, the order of items within the queue may be selected. For example, when adding a new item or sequence to the queue the user or the controller may assign the item or sequence a priority, where the priority may determine the item or sequence's placement within the queue. This allows certain cushioning elements to be made before others, depending on the priority. Also, the order of items within the queue may be varied. For example, while or after a queue is created, a user may modify the order. The order of the items within the queue and changes made thereto may be represented by the GUI. For example, the icons representing items or sequences may be presented on the GUI according to the order of the represented items or sequences within the queue.
In some embodiments, the controller may control production steps relating to how the machine produces packaging elements. For example, the controller may also be configured to insert pauses into the queue of the packaging machine. For example, between each cushioning element and/or sequence, the controller may instruct the machine to enter into a pause state or otherwise not proceed to the next element in the sequence until a set period of time has elapsed. This may help to ensure that the machine does not overheat, that the cushioning elements are made correctly, or that the downstream processes (e.g., removing of the cushioning elements from the machine) can be done before the next cushioning element is created. As another example, the controller may be configured to insert a cleaning step into the queue of the packaging machine. For example, the cleaning step may cause the packaging machine to administer a cleaning fluid to one or more components of the machine. For example, for a foam-in-bag machine, a solvent may be administered to prevent buildup of the foam precursor.
In one example, the controller may receive data (e.g., input by a user, from a sensor such as a bar code scanner, or the like) regarding an item to be packaged using the packaging elements created by the machine or machines. In this example, the controller may preload a desired item or queue of items to be created based on the packaged item into the machine, as well as may display steps or operations that may be performed by other machines or by the user. In this example, the controller may be used to provide instructions (to the machine and/or user) regarding the entirety of, or a portion of, the packaging flow for the item. This allows customized packaging to be more easily created and integrated into an automated process.
The various features provided by the controller may be set to various access levels. For example, an administrator may be able to access and modify features that a user may not be able to access. This allows a manufacturer to prevent some settings on the packaging machine from being modified by a user, while still allowing those features to be modified by a person having the correct access levels.
Turning now to the figures, a system for controlling one or more manufacturing machines will now be discussed. It should be noted that although the below examples are discussed with respect to packaging material manufacturing machines, the present disclosure may be applied to substantially any suitable type of manufacturing machine. FIG. 1A is a block diagram illustrating a manufacturing and control system with a single machine and controller. FIG. 1B illustrate the input and outputs for a packaging machine. FIG. 2A is a block diagram illustrating a system with multiple machines. FIG. 2B is a block diagram illustrating a system with multiple machines with their own controllers. With reference to FIG. 1A, the manufacturing and control system 100 may include a machine 102 having one or more sensors 108 and a controller 104. The controller 104, and optionally the machine 102, may be in communication with a network 106 which allows the controller 104 and/or machine 102 to receive and transmit data to and from other controllers, machines, and/or computing devices, as will be discussed in more detail below. The controller 104 and/or machine 102 may communicate with an external database, such as a cloud database 122 that runs on a cloud computing platform.
With reference to FIG. 1B, the machine 102 receives raw supplies 105 (e.g., foam precursors, paper products, plastic films, etc.) that can be used to create packaging materials at an input 103. As the raw supplies 105 are input into the machine 102, the machine components (e.g., motors, pumps, conveyors, etc.) convert the raw supplies 105 into packaging materials 111. In other words, after the machine components process the raw supplies 105, an output 109 of the machine outputs the formed or generated packaging materials 111. As a first example, in instances where the machine 102 is a paper dunnage machine, the raw supplies 105 may be one or more paper products and the machine components convert the paper products into paper dunnage, which is transmitted to the output 109 for a user to insert into a package. As a second example, in instances where the machine 102 is a foam-in-bag machine, the raw supplies 105 may include foam precursors and/or films to create foam-in-bag packing materials. As a third example, in instances where the machine 102 is a pillow machine, the raw materials 105 may be films and/or compressed air or other gases that are used to inflate the pillows which are output as the packaging materials 111. The type of raw materials 105 depends on the type of packaging materials 111 desired to be created by the machine 102.
The controller 104 is in electrical communication with the machine 102 and the network 106. With reference to FIG. 2A, in a multiple machine system 110, the controller 104 may be in communication with other machines 112, 116, 120, 125. This allows the controller 104 to receive and send data to each of the machines 102, 112, 116, 120, 125 and allows a single controller to control the operations and operating settings of the machines. As one example, the controller 104 may send and receive instructions to each of the machines, allowing a single controller 104 to operate multiple machines. In these embodiments, the machines may not include a display or other user interface or may have a simplified user interface and the operation and programming of the machine may be done via the controller 104 (e.g., through communication through the network 106).
With reference to FIG. 2B, in a multiple machine system 110, each controller 104, 114, 118, 122 may be in communication with at least one another controller, or as shown in FIG. 2B every controller (either directly or indirectly) within the system 110. This allows each of the controllers 104, 114, 118, 122 to send and receive data between each other and receive and send data about each machine 102, 112, 116, 120 within the system 110.
In the system 110 shown in FIGS. 2A and 2B, each machine 102, 112, 116, 120 may be in a similar physical location (e.g., in a single warehouse, campus, or station) or may be in a variety of different locations spatially separated from one another (e.g., across multiple states, countries, or the like). The system 110 may allow each controller 104, 114, 118, 122 to control one or more of the machines 102, 112, 116, 120. The multiple machine system 110 of FIGS. 2A and 2B may include the same components as the system 100 of FIG. 1A and as such, for ease of explanation, the following discussion is made with respect to the single machine system 100 of FIG. 1A, but may be understood to apply to the components of the system 110. That is, each of the controllers 114, 118, 122 and machines 112, 116, 120 of system 110 that are not discussed below may be substantially the same as controller 104 and machine 102, respectively, of the system 100 discussed below, with the exception being that any of the machines and/or controllers may be different from one another within the system 110. As shown in FIG. 2C, the machines may be grouped in packaging “stations” where a controller 104 may control different types of machines that a user can operate simultaneously or separately.
With reference to FIG. 2C, in this embodiment, the system 110 may include three different types of machines, such that the first machine 102 may be a foam-in-bag machine, the second machine 112 may be an inflated air pillow machine, and the third machine 116 may be a paper dunnage machine. In this example the controller 104 may control the queues and/or sequences (discussed in more detail below) for each of the machines 102, 112, 116 although the machines may each make different cushioning elements. Additionally, in this example the system 110 may include an external sensor 133, such as a barcode scanner, that may be used to receive data and transmit data to the controller 104. In the embodiment shown in FIG. 2C, each of the machines, the controller 104, and/or the external sensor 133 may be in communication with the controller 104 and/or each other, e.g., through a WiFi network, Bluetooth, or the like.
In some embodiments, using the system 110 shown in FIG. 2C, the user may scan a packaging item 135 (i.e., an item to be packed and cushioned using cushioning materials) using the external sensor 133. The external sensor 133 may scan a barcode, serial number, color, quick response (QR) code, or the like, and transmit the item data to the controller 104. Based on the data, the controller 104 determines the type of cushioning elements needed for the item 135 and transmits the items into the queues for each of the machines 102, 112, 116, which either substantially simultaneously or sequentially, create the cushioning elements.
With reference again to FIG. 1A, the controller 104 and the machine 102 will now be discussed in more detail. FIG. 3 is a simplified block diagram of the controller. FIG. 4F is an enlarged view of the controller connected to the machine. With reference to FIGS. 1 and 3, the controller 104 may be substantially any type of electronic or computing device. Some non-limiting examples include a tablet computer, a smartphone, a digital music player, portable gaming station, laptop computer, microcomputer, processor or processing chip, or the like. In many embodiments the controller 104 may be a portable computing device with an integrated touch sensitive display, such as a tablet computer or smart phone.
The controller 104 may include one or more processing elements 130, one or more sensors 132, one or more memory components 134, a display 132, a networking/communication interface 138, and an input/output interface 140. Each of the components may be in communication either directly or indirectly with one another via one or more systems busses and each will be discussed in turn below. It should be noted that FIG. 3 is meant as exemplary, and in other examples, the controller 104 may include fewer or more components than those shown in FIG. 3.
With reference to FIGS. 4A-4C, in embodiments where the controller is a portable computing device with an integrated touch sensitive screen (e.g., a tablet or smart phone), the controller may include a device enclosure 113 that encloses at least a portion of the select components. For example, the enclosure 113 may define a housing for the components of the controller 104, while still providing access to the components, such as one or more cameras 117, ports 115, and/or input/output buttons 119. Additionally, the enclosure 113 may only enclose a portion of the display 136 to allow the display to be visible and accessible to the user.
With reference again to FIG. 3, the one or more processing elements 130 may be substantially any suitable electronic device cable of processing, receiving, and/or transmitting instructions. For example, the processing element 130 may be a microprocessor or a microcomputer. Additionally, it should be noted that the processing element 130 may include more than one processing member. For example, a first processing element may control a first set of components of the controller 104 and a second processing element may control a second set of components of the controller 104, where the first and second processing elements may or may not be in communication with each other. Additionally, each processing element 130 may be configured to execute one or more instructions in parallel.
The sensors 132 may provide substantially any type of input to the controller 104. For example, the sensors 132 may be one or more accelerometers, microphones, global positioning sensors, gyroscopes, light sensors, image sensors (such as a camera), force sensors, and so on. The type, number, and location of the sensors 132 may be varied as desired and may depend on the desired functions of the system 100. In some examples, the sensors 132 may include at least a camera 117 and a microphone 127 that capture images and sound, respectively.
The memory 134 stores electronic data that may be utilized by the controller 104. For example, the memory 134 may store electrical data or content e.g., audio files, video files, document files, and so on, corresponding to various applications. The memory 134 may be, for example, non-volatile storage, a magnetic storage medium, optical storage medium, magneto-optical storage medium, read only memory, random access memory, erasable programmable memory, flash memory, or a combination of one or more types of memory components.
The display 136 provides a visual output for the controller 104. The display 136 may be substantially any size and may be positioned substantially anywhere on the controller 104. In some embodiments, the display 136 may be a liquid display screen, plasma screen, light emitting diode screen, and so on. The display 136 may also function as an input device in addition to displaying output from the controller 104. For example, the display 136 may include capacitive touch sensors, infrared touch sensors, or the like that may capture a user's input to the display 136. In these embodiments, a user may press on the display 136 in order to provide input to the controller 104. In other embodiments, the display 136 may be separate from or otherwise external to the electronic device, but may be in communication therewith to provide a visual output for the electronic device.
The networking/communication interface 138 receives and transmits data to and from the controller 104. The networking/communication interface 138 may be transmit and send data to the network 106, other machines, and/or other computing devices. For example, the networking/communication interface may transmit data to and from other computing devices through the network 106 which may be a wireless network (WiFi, Bluetooth, cellular network, etc.) or a wired network (Ethernet), or a combination thereof.
As a specific example, the networking/communication interface 138 may be configured to allow the controller 104 to communicate with the machine 152 and control various components within the machine. The networking/communication interface 138 may translate messages from the controller 104 into a form that the machine 104 can understand and receive. For example, with reference to FIG. 4F, the networking/communication interface 138 may include an input port 115 that is defined through the device enclosure 113. In this example, the input port 115 may be a micro universal serial bus port, but many other types of ports are envisioned. The input port 115 may receive a connector, such as the male end of a cable and when connected transmits data to and from the machine 102 from the controller 104.
The input/output interface 140 allows the controller 104 to receive inputs from a user and provide output to the user. For example, the input/output interface 140 may include a capacitive touch screen, keyboard, mouse, stylus, or the like. The type of devices that interact via the input/output interface 140 may be varied as desired. In one example, one or more buttons 119 may be included in the input/output interface 140. The buttons 119 allow a user to provide in input to the controller 104 such as returning to a home screen, selecting a particular function, or the like.
The controller 104 may also include a power supply 142. The power supply 142 provides power to various components of the controller 104. The power supply 142 may include one or more rechargeable, disposable, or hardwire sources, e.g., batteries, power cord, or the like. Additionally, the power supply 142 may include one or more types of connectors or components that provide different types of power to the controller 104. In some embodiments, the power supply 142 may include a connector (such as a universal serial bus) that provides power to the controller 104 or batteries within the controller 104 and also transmits data to and from the controller 104 to the machine 102 and/or another computing device.
With reference again to FIG. 1A, the machine 102 may be substantially any type of manufacturing machine. However, in many embodiments the machine 102 may be a packaging machine that produces packaging materials or cushioning elements, such as, but not limited to, dunnage, foam-in-bag pillows, air or gas filled pillows, bubble wrap, or the like. Examples of sheet-fed paper dunnage machines that may be used with the system 100 of FIG. 1A include machines such as those described in U.S. Pat. No. 8,267,848 entitled “Dunnage Device and Handler Disengagement,” which is incorporated by reference herein in its entirety. Examples of center-fed paper dunnage machines include those described in U.S. Pat. No. 8,641,591 entitled “Center-Fed Dunnage System,” and U.S. Publication No. 2012/0165172 entitled, “Center Fed Dunnage System and Cutter.” Examples of air inflation sealing device machines include U.S. Pat. No. 8,061,110 entitled “Inflation and Sealing Device with Disengagement Mechanism,” U.S. Pat. No. 8,128,770 entitled, “Inflation and Sealing Device for Inflatable Air Cushions,” U.S. Publication No. 2011/0172072 entitled, “Packaging pillow device with upstream components,” and U.S. application Ser. No. 13/844,741 entitled “Replaceable Blade,” each of which is incorporated by reference herein in its entirety. Examples of foam based protective packaging machines include U.S. Publication No. 2013/0047554 entitled, “Spindle Mechanism for Protective Packaging Device,” U.S. Provisional Application No. 61/944,030 and U.S. Nonprovisional application Ser. Nos. 14/630,642 and 14/630,643 entitled, “Inflation and Sealing Device and Methods,” and U.S. Non-provisional application Ser. No. 14/630,586 entitled, “Recipe Controlled Device for Making Packaging Materials,” each of which is incorporated by reference herein in its entirety.
FIGS. 4A-4C illustrate various views of an example of a foam-in-bag (FIB) machine incorporating the controller 104. With reference to FIGS. 4A-4C, the FIB machine 152 includes a control panel 160 and a mounting assembly 162 for the controller 104. Additionally, the machine 152 may be supported on a stand 154 anchored to a base 156 having a set of wheels 158. The stand 154 may allow the machine 152 to be telescoping to allow the machine 152 to be positioned at various heights relative to the base 156.
The FIB machine 152 may be substantially similar to the machine described in U.S. Publication No. 2013/0047552 entitled “Foam-in-Bag Apparatus with Power Failure Protection,” and incorporated by reference herein in its entirety.
The FIB machine 152 may include one or more pumps 171 that are fluidly connected to one or more foam precursor supply chemicals, Fill Material A and Fill Material B, such as chemical canisters that are used to create a cushioning foam. One or more nozzles or hoses may be used to connect the pumps 171 to the respective fill material supply containers and connect the pumps 171 to the machine 152, allowing the supply containers to be positioned in locations separate from the FIB machine 152. The machine 152 may also include a solution pump 173 connected to its base 156. The solution pump 173 may be fluidly connected to a cleaning solution reservoir that may be attached to or separate from the machine. The machine 152 may also include a roll reception assembly 176 that extends outward from the machine 152. The roll reception assembly 172 may include a dowel or other roll support that receives a roll of film material, such as the material used to form the bag in which the foam is injected into.
The mounting assembly 162 is configured to support the controller 104 on the FIB machine 152. The mounting assembly 162 may include a back plate 164, an enclosure 166, a hinge 168, and a latch 170 (see FIG. 4B). The back plate 164 forms a support bracket that is connected to a housing of the FIB machine 152. The back plate 164 may form a recessed cavity in which the controller 104 may be secured. The hinge 168 is connected to the controller 104 and the back plate 164 and allows the controller 104 to extend outwards from the back plate 164 and be rotatable relative thereto. For example, the hinge 168 may allow the controller 104 to rotate on its pivot point to angles between 0 and 180 degrees, or over another suitable angular range, relative to the back plate 164 and also allows the controller 104 to rotate at different angles so that the display 136 can be oriented by a user to a desired viewing angle. The rotatable features of the hinge 168 allow each user to position the display 136 of the controller 104 at an angle he or she desires, and also allows the controller 104 to be stored in a recessed position against the back plate 164 and parallel thereto. The stored position helps to prevent the controller 104 from being damaged when not in use (e.g., transportation of the machine 152 and/or storage of the machine). In other words, the hinge 168 may have a horizontal axis of rotation and/or a vertical or other axis of rotation to allow the controller 104 to be positioned at a variety of different locations. Alternative mounts can enable other positions of the controller 104.
In one embodiment, the hinge 168 may be configured so that the controller 104 may be rotated by a user's hand. For example, the hinge 168 may include a hinge pin that exerts a frictional torque against the rotation of the enclosure 166. The friction may be adjustable, e.g., by turning a lock nut, but generally the friction may be set so that the torque will be high enough so that the hinge 168 will not rotate when the controller 104 is tapped (e.g., such as by a user touching the display 136), but low enough so that the angle of the controller 104 can be adjusted by hand.
The enclosure 166 of the mounting assembly 162 may enclose a portion of the controller 104 to secure the controller 104 to the machine 152. For example, the enclosure 166 may surround the sides of the display 136 and the backside of the controller 104, which allows the display 136 to be viewable by the user and allows the sensors 132, such a camera, to also have a field of view. The enclosure 166 can help to protect the controller 104 from debris, fluids, and secures the controller 104 to the machine 152 to help prevent the controller 104 from being removed. For example, the enclosure 166 may be connected to the controller 104 with specialized fasteners so that only an authorized user can remove the controller 104 from the machine 152 to help prevent theft and damage to the controller 104. Alternative mounting assemblies can be more open allow easy placement and removal of the controller 104.
In this embodiment, the latch 170 secures the controller 104 to the back plate 164 when in the stored position. The latch 170 may be a magnetic fastener that magnetically attaches to the backside of the enclosure 166 to secure the controller 104 adjacent the back plate 164, or substantially any other type of fastener that can selectively secure the controller 104 in a desired position.
FIG. 4D is an enlarged view of the mounting assembly 162 with a top cover of the enclosure hidden for clarity. With reference to FIG. 4D, the mounting assembly 162 may include multiple fasteners that secure the controller 104 to the enclosure 166. For example, the mounting assembly 162 may include brackets 161 a, 161 b that clamp around a front side of the controller 104 to secure it against the back wall of the enclosure 166. Additionally, the mounting assembly 162 may include a plurality of shock absorbers 165 a, 165 b, 165 c that dampen vibrations from the machine 152 and/or mounting assembly 162 to help protect the controller 104. In other words, the shock absorbers help to reduce damage to the controller 104.
For a FIB machine, in operation, one or more foam precursors are fluidly connected to the pump 174, and a film roll is loaded on the roll reception assembly 176. For example, the film may be fed through the machine 152 and the machine 152 seals the edges of two sheets of film together and the foam precursor is sprayed or deposited between the sheets of film. When a desired fill supply has been inserted into the chamber defined by the sheets, and the film is a desired length, the machine 152 seals the ends of the sheets to seal foam precursor within the chamber. The film is then cut to a desired length by a cutting element and the cushioning element is created. Other known types of foam-in-bag machines can also or alternatively be used.
For a machine that makes paper or other crumpled or folded dunnage machine, the machine can use suitable stock materials, such as individual, separate, e.g. pre-cut, sheets, tubes, or a continuous sheet or other material that is cut to length, typically after or during its being formed into dunnage. Continuous type stock material examples include a long strip of sheet material fed from the interior or exterior of one or more supply rolls or fanfolded material stacks. The converter can be configured to crumple the sheets in a desired direction, such as cross-crumpling with folds and creases extending transversely to the feed direction of the sheets, or longitudinal crumpling, with folds and crease extending longitudinally along the direction in which the sheet(s) are fed through the converter, although a combination of directions or other directions can be used.
In an example of a cross-crumpling device, the dunnage converter may include entry-side crumpling rollers or other elements that move a portion of the sheet with which they interact at a faster rate, and exit-side crumpling rollers or other elements that move a portion of the sheet that they interact with at a slower rate. These rollers can be arranged to define a crumpling zone therebetween. A sheet of material is moved through the entry rollers along a longitudinal path at the faster rate. Since the exit-side rollers move at the slower rate, the material is compressed into the crumpling zone and thus crumpled into dunnage. In some embodiments, entry-side and exit-side crumpling rollers may be displaced transversely along the path with respect to each other to cause shearing effect in the material within the crumpling zone, to form tighter and more offset creases in the transverse region that is disposed longitudinally downstream from the crumple zone. Such devices are disclosed, for instance in U.S. Pat. No. 8,267,848 entitled “Dunnage Device and Handler Disengagement,” the entirety of which is incorporated herein by reference. The control panel 160 and/or the controller 104 may include means for adjusting the speed and/or position of the crumpling rollers to adjust the crumpling of the material. The control panel 160 and/or the controller 104 may include means for controlling a cutting element to cut a predetermined length of the material so to create dunnage of a desired size.
In a longitudinal crumpling machine, typically, long, continuous strips of paper of other material are fed into a converting station. In devices that feed from the inside of a roll, the material may twist along a longitudinal axis as a helix, forming a tube or coil. A drum can be driven to draw the tube or coil through the converting station. A roller can be positioned and biased against the drum to flatten the tube or coil. The biased drum can grip the tube or coil, pull it along the feed path so to pinch the material of the tube or coil so that the material bunches ahead of the pinched portion, and is crumpled so to form dunnage. Such devices are disclosed, for instance in U.S. Application Publication No. 2012/0165172 entitled “Center-Fed Dunnage System Feed and Cutter,” and U.S. Application Publication No. 2014/0038805 entitled “Dunnage Supply Daisy Chain Connector,” the entireties of which is incorporated herein by reference. The control panel 160 and/or the controller 104 may include means for adjusting the speed and/or position of the roller relative to adjust the crumpling of the material. Adjusting the speed and/or position of the roller relative to the drum may also create creases of a desired tightness. The control panel 160 and/or the controller 104 may include means for controlling a cutting feature to cut a predetermined length of the material so to create dunnage of a desired size.
In devices that feed from the outside of a roll, the device may crumple the material in a generally longitudinal pattern, thereby putting a series of longitudinal folds and/or pleats within the sheeting. The device may include a rake having tines and spaces therebetween, over which paper is fed to create waves within the sheeting. The sheeting may then pass through a space between a drum and a guide roller, so that the waves form folds and/or pleats within the paper sheeting. Such devices are disclosed, for instance, in U.S. Pat. No. 8,016,735 entitled “Apparatus for Crumpling Paper Substrates,” the entirety of which is incorporated herein by reference. The control panel 160 and/or the controller 104 may include means for adjusting the positions of the tines and spaces to adjust the size of the waves and thus adjust the configuration of the folds and/or pleats. The control panel 160 and/or the controller 104 may include means for adjusting the speed and/or positions of the drum and guide roller to adjust the folding and/or pleating of the material. The control panel 160 and/or the controller 104 may include means for controlling a cutting feature to cut a predetermined length of the material so to create dunnage of a desired size.
In other devices that feed from the outside of a roll, the device may include a throat section and a pair of crumpling rollers. As material is pulled through the throat section, it may gather or pleat. The gathered or pleated material may be fed between the pair of crumpling rollers, which may press the gathered or pleated material together to form dunnage. Such devices are disclosed, for instance, in U.S. Pat. No. 6,910,997 entitled “Machine and Method for Making Paper Dunnage,” the entirety of which is incorporated herein by reference. The control panel 160 and/or the controller 104 may include means for adjusting the size of the throat, and/or the speed and/or position of the crumpling rollers to adjust the crumpling of the material. The control panel 160 and/or the controller 104 may include means for controlling a cutting element to cut a predetermined length of the material so to create dunnage of a desired size.
With reference to FIG. 4C, the control panel 160 will now be discussed in more detail. The control panel 160 includes a plurality of input buttons 180 a-180 g, 184 a-184 c that may be used to control aspects of the machines 152. The functions of the input buttons 180 a-180 g, 184 a-184 c may be the same as some of the functions that are adjustable via the controller 104 or may be different from those adjustable by the controller 104. In embodiments where the input buttons 180 a-180 g, 184 a-184 c of the control panel 160 control functions that are adjustable by the controller 104, the machine 152 may include duplicative controls which may assist in teaching new users how to use the functionality of the controller 104 and may provide a backup control system for the machine 152.
The first set of input buttons 180 a, 180 b, 180 c, 180 d, 180 e, 180 f 180 g can be programmed to correspond to the dimensions of the bag produced by the FIB machine 152. For example the first button 180 a may correspond to the smallest default size bag, the seventh button 180 f may correspond to the largest default size bag, and the eighth button 180 g may correspond to the previous size bag that was used. It should be noted that the input buttons may be programmed for substantially any task or input to the machine, such as, but not limited to, item creation sequences, queues, and different sizes or characteristics that may not necessarily correspond to the external markings on the input buttons.
With reference to FIG. 4C, in addition to the bag dimension input buttons 180 a-180 g, the control panel 160 may include a secondary control panel 182. The secondary control panel 182 includes a stop button 184 a, a film roll button 184 b, and a height button 184. The stop button 184 a stops the operation of the FIB machine 152, the film machine 184 b loads additional film into the machine 152, and the height button 184 c adjusts the height of the stand 154 to raise and lower the machine 152.
In some embodiments, the control panel 160 may form part of a machine control system for controlling various components of the machine 152 to form packaging elements. For example, buttons 180 a-180 g, which corresponding to the dimensions of the bag, may cause the machine control system to control one or more drive mechanisms that output certain amounts of web material to form bags of a particular size. In doing so, when a user activates (e.g., pushes on) a button 180 a-180 g, data is sent to the drive mechanisms, to thereby activate and control the drive mechanisms.

Controller Operation

The controller 104 may send data to the machine 102 to activate and control the drive mechanisms, similarly to the control panel 160. In some embodiments, the controller 104 communicates with the control panel 160. For example, the controller 104 may send data to the control panel 160, and based on the data, the control panel 160 may send data to the drive mechanisms for activating and controlling the drive mechanisms. In some embodiments, the controller 104 may communicate directly to the components of the machine themselves. For example, the controller 104 may send data directly to the drive mechanisms to activate and control the drive mechanisms. In some embodiments, the control panel 106 may be omitted and/or varied as the controller 104 may include functionality of the control panel 106. Additionally, it should be noted that the buttons and their functions as shown in FIGS. 4A-4C are illustrative and may be varied as desired.
As discussed in more detail below, the controller 104 can control the operation, characteristics, and parameters of these machines. For example, the controller 104 may be used to operate the machine 102, track data regarding the machine, the cushioning elements, user inputs, and the like, and may also be used to communicate between machines, users, and the network 106. In one example, the controller 104 may track data corresponding to the usage of the machine (e.g., number of cushioning elements created, the amount of fill materials, time of peak usage, and so on), the location of the machine (e.g., through global positioning system or beacon) and may then provide this data to another computing device through the network 106 and/or through a direct connection means (e.g., cable, removable memory, etc.). This allows a manufacture to track the operation of its machines and ensure that the machines are operating as desired. Additionally, the data tracking and transmission may allow a manufacture to better service its machines and clients as it can better track customer needs, trends, common issues, and so on.
As the controller 104 can operate the machine, it is able to modify settings of certain components within the machine, and can tailor the components and operation of the machine to particular customers, types of cushioning elements, operating environment, and other factors.
As one example, the controller 104 may selectively provide power to certain components within the machine 152. For example, during a maintenance setting, the controller 104 may restrict power to the film-cutting device (such as a heating element) but may provide power to the feed roller. The components may be selectable by a user or may be predetermined based on a setting or the like.
The controller 104 may allow a user to manually vary certain machine parameters. For example the controller 104 may allow a user to adjust the film feed rate, the heating time or temperature, the fill material (e.g., foam-precursor or air) percentage or the like. However, in some embodiments the features that may be modified by a user may be restricted to various levels of user access. For example, a typical user may not be able to modify certain components below or above threshold levels. As another example, certain components may be restricted to typical users. The number of access levels and components that are restricted may be varied as desired.

Sequence and Queues

The controller 104 can set the characteristics for packaging elements (e.g., pillows, paper dunnage) that are created by the machine 102 and can also determine the order in which packaging elements with certain characteristics are created (i.e., a manufacturing queue). In embodiments where the controller 104 is used with the FIB machine 152, the controller 104 may be used to control the length of each cushioning pillow, the amount of fill material deposited into the pillow, the type of fill material used, and the order and number of cushioning pillows that are created. Additionally, it should be noted that the features controlled by the controller 104, such as the sequences and queues, may be assigned to manual inputs to the machine 152 as well. For example, a foot pedal and/or the control panel 160 buttons may be assigned to match one or more buttons for the controller 104 so that the functionality of the manual inputs to the machine may correspond to the functionality of certain electronic inputs from the controller 104.
FIG. 5A is an illustrative image of a graphical user interface 200 for the controller 104 that allows a user to create a custom cushioning element. With reference to FIG. 5B, in this embodiment, the individual element GUI 200 may include a bag icon 202 having a fill material graphic 204, as well as fill adjustment inputs 206, length adjustment inputs 210, and editing inputs 208. The bag icon 202 may be configured to correspond to the type of cushioning element being created. For example, a foam-in-bag element and the fill material graphic 204 correspond to the percentage of fill material to be deposited. In this example, the fill material for the bag is set to 20% and so the fill material graphic 204 is shown as another color filling about 20% of the bag icon 202. This provides a visual indicator for the user that directly corresponds to the amount of fill material that will be used to inflate the bag. Additionally, although not shown in this example, the graphic selected for the fill material graphic 204 may include additional features depending on the type of bag, such as any connection points or columns defined in the bag (e.g., sealed portions that define different pillow configurations within the bag).
With continued reference to FIG. 5A, the fill adjustment inputs 206 allow a user to provide input to the controller 104 to vary the percentage fill for the bag. For example, a user may press the up arrow as displayed on the display 136 of the controller 104 to increase the fill percentage and the down arrow to decrease the fill percentage. It should be noted that the controller 104 may include minimum and/or maximum values for the fill percentage, so as to prevent a user from over or under filling a particular bag. However the minimum and maximum values may be adjusted or removed by a user with a desired access level (e.g., administrator, or the like).
Similarly, the length adjustment inputs 210 allow the user to increase or decrease the length of the bag. The length adjustment inputs 210 may corresponds to the length of the film that is cut by the cutting device (see machine 152). The length adjustment inputs 210 may be similar to the fill adjustment inputs 206 and a user may provide input to the controller 104 in a similar manner, but correspond to a different component of the machine 152. As with the fill adjustment inputs, the length adjustment inputs 210 may have minimum and/or maximum values that a typical user may not be able to exceed. Additionally, in some embodiments, the minimum and maximum values of the fill adjustment and the length adjustment may be tied together, i.e., as the bag length increases, the maximum fill percentage may increase and vice versa. As such, the minimum and maximum values for both the fill adjustment inputs 206 and the length adjustment inputs 210 may be dynamically variable.
The editing or control icons 208 allow the user to save the custom bag he or she has created by varying the fill percentage and length, cancel the custom bag operation, and/or delete the custom bag he or she has created or modified. The editing tasks and corresponding icons 208 may be varied as desired.
The custom bag settings created using the individual element GUI 200 may be saved and used by the controller 104 to upload to a queue and/or sequence of the machine 152 as will be discussed in more detail below.
An illustrative GUI for creating a sequence for the machine 152 will now be discussed. FIG. 5B is a screen shot of a custom sequence GUI 212. With reference to FIG. 5B, the custom sequence GUI 212 may include one or more item icons 214, 218, editing icons 208, a title 217, and delay icons 216. The item icons 214, 218 correspond to items, such as bag configurations, custom bag settings, and optionally non-bag items (e.g., cleaning settings, film feed settings, and calibration). The item icons 214, 218 may include the bag icon 202 (or other icon corresponding to the selected item) and select information about the item, as shown in FIG. 5B, the length, fill percentage, and number of columns or pockets within each item. For example, a bag icon representing a larger bag may have a larger configuration than a bag icon representing a smaller bag. A bag icon may show a bag's programmed fill percentage, for example, with a line across the bag (e.g., a line extending across the width of the bag and located 70% at the height of the bag to represent a bag with a 70% fill percentage), shading (e.g., shading extending across 70 of the bag's height to represent a bag with a 70% fill percentage), etc. In some instances, such as standard items or for non-bag items, the item icon 214, 218 may not include the bag icon 202.
The title 217 of the custom sequence GUI 212 allows a user to edit or input a title or name that corresponds to the custom sequence of items that he or she creates using the GUI 212. For example, the title 217 may allow a user to input a name and then using the editing buttons 208, the user can save the particular sequence of items in the controller 104 memory 134.
The sequence GUI 212 may also include adding icons 221, 223 that allow a user to add additional items to the sequence, such as custom bags, standard bags, or the like. The adding icons 221, 223 may lead the user to another menu page that allows to select the features of the item to be added and/or select an item with previously stored characteristics (e.g., standard item or the item created via the item element GUI 200). After one of the adding icons 221, 223 is selected, the item icon 214, 218 corresponding to the selected item is added into the sequence order.
A custom sequence may be created using the custom sequence GUI 212 and when the user has arranged the items and delays as he or she wishes, the sequence can be stored in the memory 134 of the controller 104. As will be discussed below, the sequence may be selected and provided to the machine 152 as part of a queue for making cushioning elements, where the machine goes through the sequence and creates the listed items and introduces delays between each item based on the sequence.
A queue GUI for arranging the manufacturing queue for the machine 152 will now be discussed in more detail. FIG. 6 is a screen shot illustrating a queue GUI used to determine the order that cushioning items and some machine functions are completed. With reference to FIG. 6, the queue GUI 220 may include a plurality of queue element icons 222 a-222 h. The queue element icons 222 a-222 h correspond to items and/or sequences that may be added to the queue for the machine 152. For example, the queue element icons 222 a-222 h may be assigned to a particular item (either custom or standard) or may be assigned to a sequence (custom or standard). As will be explained in more detail below, by selecting one of the queue element icons 222 a-222 h, a user may determine the types of cushioning elements and the order in which they are manufactured by the machine 152. Additionally the queue element icons 222 a-222 h are configured to correspond to the control panel 160 buttons and the functions of the queue element icons and the control panel buttons 160 may correspond to one another, i.e., the first control panel button may be a XXS bag, which may be the same type of bag characteristics selected when a user selects the first queue item icon 222 a. In some embodiments the graphics of the GUI may be modified based on the assigned function for a particular icon. For example the queue element icons may change in color based on whether they have been assigned to a sequence, an item, or a default setting. Also, the icons may be editable by a user, so that a user can change the text displayed, the color, and optionally the shape.
The queue GUI 220 may also include a menu button 226 that allows a user to return to a home screen or previous menu screen. In other words, the menu button 226 exits the queue GUI 220 to allow a user to access other features of the controller 104.
The queue GUI 220 may also include one or more control buttons, such as a clear queue button 228, enable continuous mode 238, and an enable editing button 240. These buttons control the queue and the machine. For example, when the clear queue button 228 is selected, the queue that has been created is deleted and the items of the queue are removed from the line of the machine 152. When the enable continuous mode button 238 is selected, the queue selected by the user may be repeated for a predetermined number of loops. The enable editing button 240 may be selected to allow a user to make modifications to a queue that he or she has already created or may remove the editing ability to a specific queue.
The queue GUI 220 also includes an activation button 224. The icon displayed in the activation button 224 varies based on the state of the queue and the machine. When in “play” mode the queue is provided to the machine 152 which then manufactures the various items and within “pause” or “stop” mode, the machine 152 is stopped from manufacturing the items in the queue.
The queue GUI 220 may include a film feed button 230, a calibration bag button 232, an agile bag button 234, and a run tip cleaning cycle button 234. Each of these buttons 230, 232, 236 may be added as items to a queue. The calibration bag button 232 activates a particularly configured bag that is used to calibrate the machine 152. The agile bag button 234 may be similar to the item buttons 222 a-222 h and may allow a user to customize a bag for the queue instantaneously. For example, rather than entering into the item GUI 200, the user can define the features of a bag while in the queue GUI 220.
The queue GUI 220 may also include a plurality of production step buttons, such as a pause icon 216 and a run tip cleaning cycle button 234, which may be added to the queue. The pause icons 216 may be positioned between each item icon 214, 218. The pause icons 216 may be similar to the length and fill icons 206, 210 of the item GUI 200, but may correspond to a pause or time delay. For example, the pause icons 216 may include a numeric display and a set of arrows that allow a user to adjust the numeric display. The pause icons 216 correspond to a pause that is introduced into the machine 152 between each item. The pauses may be beneficial to allow the previous bag to be properly created, the components to be cooled/heated, cleaned, or the like. In instances where a pause is not required or desired, the pause may be set to 0.0 (as shown in FIG. 5B) and no pause may be part of the sequence.
When the run tip cleaning cycle button 236 is selected, a cleaning fluid, such as a solvent, may be administered (e.g., to the tips that administer the foam precursor) to remove debris from the tips. The tip cleaning cycle is run by the machine 152 in the order it is presented in the queue and is similar to other items in the queue, but rather than selecting characteristics of a bag, the tip cleaning cycle activates other components of the machine 152.
As will be discussed in more detail below, as items are added to the queue, the item icons are added to the queue pathway 243 on the queue GUI 220. This allows a user to view the order of the items within the queue and vary them if desired. For example, FIGS. 7A and 7B illustrate screen shots of the queue GUI 220 with items added into the queue. With reference to FIG. 7B, a first sequence 244 including two items 246, 250 and a delay of 1.0 seconds between each of the items is positioned closest to a first edge of the screen, a delay 256 is then added between the sequence 244 and the next items 256 in the queue. As shown in FIG. 7A, each of the items 246, 250, 252 in the queue, including the items 246, 250 in the sequence 244, include the item icon with relative information about each of the bags. Additionally, it should be noted that the items 246, 250 in the sequence are added to the queue pathway 243 in a set whereas the item 256 is added individually. When running this queue, the machine 152 would create the first item 246 in the sequence 244, pause for 1.0 seconds, create the second item 250 in the sequence, pause for 1.0 seconds and then create the last item 252 within the queue.
With reference to FIG. 7B, in this example, the first two items 260, 262 within the queue pathway 243 are custom bag items created using the item GUI 200 and include the user titled name “trial.” The two items are separated by delays 256 of 1.0 seconds and a sequence including a third item 264 is added to the queue pathway 243 after the second item 262.
An illustrative method for using the controller 104 to determine one or more queues for items for the machine will now be discussed in more detail. FIG. 8 is a flow chart illustrating a method for setting the queues for the machine 152. With reference to FIG. 8, the method 300 may begin with operation 302 and the controller 104 determines whether the operation of the machine will be queue based or instant. For example, the packaging assembly 100 may allow a user to select a button on the control panel 160 of the FIB machine 152 to activate the machine 152 to manufacture the selected item alternatively or additionally the controller 104 may include a button on the home screen or the queue GUI 220 which when selected to instruct the machine 152 to make an item, outside of the queue or rather than going through the queue process. This allows a user to choose to use the queue process or if a certain item is needed out of order or the like the user can select the instant process.
With continued reference to FIG. 8, if the queue process is not selected and the user wishes to use the instant process, the method 300 may proceed to operation 316. In operation 316, the machine 152 receives instructions from the controller 104 corresponding to the selected item. For example, the controller 104 provides the machine 152 with settings for certain components (e.g., pumps, rollers, cutting elements, and so on) that correspond to the item selected. Once the controller 104 has provided the machine 152 with the item selection data, the method 300 may proceed to operation 318 and the machine 152 runs to manufacture the item. For example, as described above, in the example of the FIB machine 152, the film is received into the machine where it is filled with sealed material and sealed in the desired locations to create a cushioning element. After the item has been created, the method 300 may proceed to an end state 320.
If in operation 302, the queue process is selected, the method 300 may proceed to operation 304. In operation 304, the controller 104 determines whether a sequence is to be added to the queue. For example, the user may select one of the item icon buttons 222 a-222 h that may be assigned to a sequence or the user may select a custom sequence he or she has created. If a sequence is selected, the method 300 proceeds to operation 308 and the controller 104, in particular, the processing element 130, adds the items from the sequence into the queue for the machine 152. Additionally, with reference to FIG. 7A, the processing element 130 may instruct the display 136 to add the sequence icon 244 corresponding to the selected sequence to the queue pathway 243 to provide visual confirmation to the user that the selected sequence (and the items corresponding to that sequence have been added to the queue). Additionally, the queue pathway 243 provides visual feedback to the user regarding the position of the selected sequence within the queue for the machine 152.
If in operation 304 the sequence is not selected, the method 300 proceeds to operation 306. In operation 306, the processing element 130 adds the selected item (rather than sequences) to the queue for the machine and causes the corresponding item to be displayed in the queue pathway 243 on the queue GUI 220. As shown in FIG. 7B, the sequences GUI 220 will then display the corresponding item button 260 within the pathway in the order that they have been added to the queue. As discussed above, the film feed button 230, the calibration bag button 232, the agile bag button 234, and/or the tip cleaning cycle button 236 may also be added as items to the queue and may be displayed with a corresponding icon within the queue pathway 243.
With reference again to FIG. 8, after the corresponding items from either the sequence or the individual items have been added to the queue, the method 300 may proceed to operation 310. In operation 310, the processing element 130 receives input regarding a delay. For example the user may select the delay icon 256 by providing input to the controller 104 (e.g., touching the display 136) to increase or decrease the delay that will follow the recently added sequence or item. Once the user input has been received, the delay for the queue is set and is displayed in the queue pathway 243.
After the delay is set, the method 300 may proceed to operation 312. In operation 312, the controller 104 determines whether the user wishes to add another item to the queue. The controller 104 determines whether the user has hit the clear queue 228 or the activate button 224 to either delete the queue or run the queue, respectively. If neither of those inputs have been received, the method 300 may return to operation 304 and the controller 304 may determine whether a sequence button has been selected to add another sequence to the queue or whether an item button has been selected to add another item to the queue.
With continued reference to FIG. 3, if another item or sequences is not to be added to the queue, the method may proceed to operation 314. In particular, if the controller 104 receives input from the user to run the queue, such as by selecting the activation button 224, the queue will be sent to the machine 152 which will begin to create the items within the queue, in order. For example with reference to FIG. 7A, in this example, the queue includes a first sequence 244 having two items 246, 250 separated by a delay 248 and so the first item 246 will be created first, then the machine will pause for 1.0 second per the delay 248 and then proceed to make the next item 250. After the sequence has completed, the queue will advance to the delay 256, and then move to the next item in the queue 252. If the continuous mode button 238 is selected, the queue will repeat on a loop until the number of loops, number of items, or predetermined time has been reached. Alternatively, if the continuous mode is not selected the queue will run through each of the items in the queue pathway 243 until each has been created. Once the queue has completed, the method 300 may proceed to an end state 320 and the method may complete.
It should be noted that although the queues and sequences have been discussed with respect to the GUIs on the controller 104, in other embodiments the queues (and corresponding items/sequences) may be programmed to correspond to certain input buttons on the control panel 106 of the machine 102. This allows a user to automatically select a predetermined queue by selecting an input button on the controller panel 106, which means that the controller 104 may be used to program the machine and certain queues but may not be required for daily operation of the machine.
In operation, the controller 104 and/or a control panel 106 for a machine 102 may receive user input corresponding to one or more parameters for forming a plurality of packaging elements in a particular order. Based on this user input, the controller 104 and/or control panel 106 may create and store a queue. The controller 104 and/or the control panel 106 may use the stored queue to cause the machine 102 to create the plurality of packaging elements in the particular order.
A user may enter input corresponding to parameters for forming packaging elements. For example, if the machine is a FIB machine 102 and the user wants to create one first bag of a first size and having a first density, and two second bags of a second size and having a second density, the user may input parameters corresponding to the bags' sizes, fill percentages, and quantities. For example, the user may input data corresponding to one first bag having a first size and having a first fill percentage and data corresponding to a sequence of second bags, for example, two second bags having a second size and second fill percentages. The user may store these parameters as icons (e.g., icon 222 c for the bag having the first size and icon 222 d for the sequence of the two bags having the second size). For cases in which the user uses controller 104 to create queues, the user may activate these icons to add items and/or sequences to a queue. For example, the user could activate button 222 c for adding the first bag and button 222 d for adding the sequence of second bags to the queue. The user may also add a customized bag to the queue. For example, user may activate the agile bag button 234 to create a customized bag for the queue. The queue GUI 212 may include buttons allowing a user to select a quantity and/or spacing of secondary seals within the bag, to create a series of adjoining chambers filled with the foam.
This input may cause the controller 104 and/or control panel 106 to create a queue containing instructions for forming each of the packaging elements (e.g., first instructions for forming one first bag having the first size and fill percentage, and second instructions for forming the sequence of two second bags having the second size and the second fill percentage). The queue may indicate the order of forming the first bag and then the two second bags. For example, the queue may include information indicative of the order of forming the first and second bags (e.g., information that indicates: form the first bag, and then form the two second bags), and/or the manner in which the first and second instructions are stored in the queue may indicate the order of forming them (e.g., the first instructions may be written prior to the second instructions). Any suitable type and number of parameters corresponding to any suitable type and number of packaging elements may be added to the queue.
The queue may contain a stored set of instructions for creating a plurality of packaging elements having selected parameters, and the queue may indicate an order for forming the plurality of elements and/or timing parameters (e.g., pauses) associated with the packaging element creation. The queue may be used by the controller 104 and/or by the control panel 106 to cause the machine to create the plurality of packaging elements having the selected parameters. In some embodiments, the controller 104 and/or the control panel 106 may receive information that runs or activates the queue.
While discussion has been directed on selecting the length and/or fill percentage of packaging cushions, the queue may include instructions for controlling any suitable type of machine. The queue GUI 212 may include buttons corresponding to various types and configurations of packaging elements for controlling various types of machines (e.g., FIB machines, inflatable air cushion machines, paper dunnage machines, etc.). For example, the queue GUI 212 may include buttons corresponding to air cushions, and a user may select the size of bag, the amount of air to be inserted therein, whether the bag includes a seal of a valve, etc. The queue GUI 212 may include buttons allowing a user to select a quantity and/or spacing of secondary seals within an inflatable air cushion, to create a series of adjoining air chambers.
For example, the queue GUI 212 may include buttons for causing a paper dunnage machine to create paper dunnage. For example, the queue GUI 212 may include buttons for controlling parameters of one or more paper dunnage machines, such as a cutting mechanism to control the size of material to be cut, the speed and/or positions of one or more crumpling rollers and/or drums, etc. As such, a user can use the queue GUI 212 to cause one or more paper dunnage machines to create paper dunnage elements, similarly to the discussion on packaging elements.
When the queue is activated, the controller 104 and/or the control panel 106 may cause the instructions contained within the queue to be read so to create the plurality of packaging elements having the selected parameters. In some embodiments, the queue may be stored in the control panel 106. In some embodiments, the queue may be stored in the controller 104 and/or in external storage (e.g., cloud 122), and when the queue is triggered, the queue is sent to the control panel 106. The control panel 106 may parse the queue and read the instructions contained therein, causing the machine components to form the packaging elements according to the instructions.
The queue may be stored in the controller 104, the control panel 106 of the machine 102, and/or in an external database (e.g., cloud database 122). In some embodiments, the queue is stored in the control panel 106 and/or in external storage (e.g., cloud 122), and when the queue is activated, the queue is sent to the control panel 104. In some embodiments, the queue is stored in the controller 104, which may activate the queue. Upon activating the queue, the controller 104 may parse the queue and read the instructions contained therein. Based thereon, the controller 104 may communicate with the machine according to the timing and order associated with the queue. For example, in the scenario for creating a first FIB bag and then two second FIB bags, when the controller 104 activates the queue, the controller 104 may read the queue to determine the first instructions, the second instructions, and their order (e.g., first and then second). Thus, the controller 104 may send to the machine 102 (to the control panel 106 and/or to the drive mechanisms and/or other components of the machine 102) the first instructions, and then the second instructions. In some embodiments, the controller 104 may read the pause instructions, and based thereon, may wait a predetermined amount of time before sending the second instructions. In some embodiments, the pause instructions may be read by the control panel 106. For example, the pause instructions may cause the control panel 106 to pause between sending information to the drive mechanisms and/or other components of the machine 102.
These queues may be stored and later retrieved and used by the machine 102. For example, if a packaging facility packs on a regular basis similarly shaped items with a particular set of packaging elements, a user may store a queue associated with the set of packaging elements. The user may enter input that associated the stored queue with one or more buttons controller 104 and/or control panel 106. Thus, when a user desires to pack an item using the set of packaging elements, the user can simply activate the button on the controller 104 and/or control panel 106, which may cause trigger the queue. The queue instructions may be read and used to cause the machine 102 to create the set of packaging elements.
As explained above, the queue may contain instructions for controlling any suitable number and type of packaging machines 102. For example, a user may add to the queue third instructions for forming an air filled cushion by an air pillow machine 112, having a selected size and/or containing a selected amount of air. For cases in which the queue is run by the controller 104, in some embodiments, the controller may determine, for each set of instructions within the queue, which machine (e.g., 102, 112) is to receive the instructions. In some embodiments, the controller 104 may send all of the instructions to all of the machines. For cases in which the queue is run by a machine (e.g., 102, 112), in some embodiments, a machine (e.g., 102) may parse the queue and send instructions contained in the queue to one or more other machines (e.g., 112).
Stored queues may be updated, for example, via network. For example, a packaging facility may employ several queues that contain instructions for a small FIB element that is filled 40% with foam. It may become known that the functionality of the cushion is not noticeably diminished if it is filled only 35% with foam precursor, and/or the chemical composition of the foam precursor may be altered so that less chemical substance is needed. Thus, a user may update some or all of the queues (e.g., within network) having instructions for a creating a small FIB element filled 40% so that the instructions instead cause the machine 102 to produce a small FIB element that is 35% filled with foam precursor. For example, in cases when the queues are stored in an external database (e.g., cloud database 122) the instructions contained in the queues may be changed and/or modified. As such, the queues may be controlled an updated, for example, as analytics data develops, or as new technology is introduced. The queues may allow different levels of access by different users. For example, a first user (e.g., an upper level employee) may be allowed to create, program, update and/or modify the queues, while a second user (e.g., a lower level employee, such as an operator of a packaging device) may not be allowed to modify the queues, but may only be allowed to run particular queues.

Material Monitoring and Reordering

As briefly mentioned above, in some embodiments the packaging assembly 100 may monitor the supplies used to create the cushioning material and may automatically reorder to the supplies or provide a notification regarding the remaining amount of supplies. FIG. 9 is a flow chart illustrating a method for monitoring and/or ordering supplies. With reference to FIG. 9, the method 400 may begin with operation 402. In operation 402, the ordering monitor process may be activated. For example, the user may select an option on the controller 104 to initiate the monitor process or alternatively, in some embodiments the controller 104 may automatically activate the monitoring processing when it is turned on.
After operation 402, the method 400 may proceed to operation 404 and the controller 104 may determine the supply data. For example, the processor 130 may receive data from one or more machine sensors, the controller sensors 132 or other sensors (e.g., barcode scanner in communication with the controller 104), where the supply data corresponds to the types of supplies being used by the machine 152. Examples of the supply data may include, but are not limited to, serial number, brand name, size or quantity, density, material type, thickness and other material characteristics, and so on. In some instances the data may be retrieved from the memory 134 which may store the supply data when the supplies are newly added or refilled into the machine 152. As another example, the controller 104 may use one or more sensors to scan the packaging of the supplies (e.g., bar code, serial number, etc.) or the material itself to determine a portion of or the entire supply data. The supply data may assist the controller 104 in determining the status of the supplies (e.g., a higher density foam as the fill material may be used more quickly than a lower density foam), but in some embodiments may not be needed and in those embodiments operation 404 may be omitted. The supply date may also include an initial inventory level (e.g., the volume or level of supplies that are in stock), history or order information for supplies, and so on.
After operation 404, the method 400 may proceed to operation 406. In operation 406 the controller 104 determines whether an estimate of the supply levels will be used. For example, in some embodiments the controller 104 may be able to track the actual level of the supplies, such as by using one or more sensors and/or user input and in other examples, the controller 104 may provide an estimate of the number of supplies based on usage and other data. It should be noted that although operation 406 may be a user selectable option, in some embodiments, this option may be previously programmed into the controller 104 and may be based on the type of supplies used, the type of sensors included within the controller 104 and/or machine 152, and other types of factors.
If in operation 406, an estimate is not selected, the method 400 may proceed to operation 408. In operation 408, the processing element 130 of the controller 104 may receive data corresponding to the supplies. The data may include sensor data from the sensors or may include supply data from the machine or other components. For example, the processing element 130 may receive sensor data such as, but not limited to, a float sensor on the fill supply materials that determines the fill level within the container, a weight sensor that determines the weight of the film roll on the roll reception assembly 176 and/or fill supply containers, a sensor that measures the diameter of the film roll, a camera that captures images of the supplies, a determination of how many items (e.g., bags or packaging materials) created during a predetermined time period, the number of orders that have been fulfilled, the number of sequences or queues completed, and so on. Once the supply data has been received, the method 400 may proceed to operation 414, which will be discussed below. Other supply data may include the number of cycles a pump has run, the time of operation of a motor, the temperature of a heating element, or the like.
With continued reference to FIG. 9, if in operation 406 the supply levels are to be estimated, the method 400 may proceed to operation 410. In operation 410, the processing element 130 analyzes the queue and/or item history of the machine 152. In particular, the processing element 130 analyzes the number and characteristics of the items created by the machine 152 since the last refill (or another point in time selected by the user). For example, the memory 134 of the controller 104 may store data corresponding to the bag lengths, percentage fill of teach bag, for each item made by the machine 152. This data may then be analyzed by the processing element 130.
After the historical data of the machine 152 and/or controller 104 is analyzed, the method 400 may proceed to operation 412. In operation 412, the processing element 130 uses the historical data and the initial supply data to estimate the supplies remaining. For example, if the machine 152 has created 10 bags each having a length of 20 inches, the processing element 130 may determine that 80 feet of film is remaining by determining how much film has been used and compare that to how much film was initially included with the original supply. As another example, the processing element may use the supply data to determine approximately the amount of fill materials within each container and then use the historical data to estimate how much fill (e.g., foam creating chemicals) have been used based on the number of cushions, bags, and the percentage of fill used for each. It should be noted that the above examples are meant as illustrative and many other types of estimates based on the type of supplies used for the machine may be used.
After operation 412, or after operation 408 the method 400 proceeds to operation 414. In operation 414, the processing element 130 using either the supply sensor data from operation 408 or the estimated supply levels from operation 412, predicts the future supply usage. For example, the processor 130 may analyze the historical usage of the machine 152 over a predetermined time period (e.g., last hour or two, past two weeks, previous year) and/or may analyze data received from another computing device (e.g., pending orders, sales predictions, etc.) to predict the future supply usage of the machine 152.
After operation 414, the method 400 may proceed to operation 416. In operation 416, the processing element 130 determines whether the current supplies for the system 100 will be sufficient for a predetermined time period. The time period may be based on a typically delivery time for new supplies, a threshold set that when crossed automatically requires new supplies, or another metric that may be used. In examples where the processing element 130 may predict the future use of the machine 152, the processing element 130 may use the future estimate in comparison to the typical shipping time for new supplies to determine if the supplies are sufficient or insufficient for the time period. Alternatively, in instances where the controller 104 may not predict the future use, operation 416 may involve an analysis of whether the remaining supplies have fallen below a predetermined threshold.
With continued reference to FIG. 9, if in operation 416 the supplies are sufficient for the time period or above a threshold level for reordering supplies, the method 400 may proceed to operation 420. In operation 420, the controller 104 may wait for a predetermined time period and then return to operation 402. The wait period may be determined by the user and optionally may be dynamically determined based on the supplies remaining and/or estimated future use. For example, if the processing element 130 determines in operation 414 that the system has one month of supplies remaining the wait time may be set to 3 weeks or alternatively if the system has 1 week of supplies remaining, the wait time may be one day or less. In this manner the controller 104 can maintain the monitor on the supply levels, but may selectively use resources (e.g., processing and sensor resources) based on an educated determination as to when the supplies may run low. After operation 420, the method 400 may return to operation 402.
If in operation 416, new supplies are needed, i.e., the current supplies are below a threshold and/or not predicted to be sufficient for the predetermined time frame, the method 400 may proceed to operation 418. In operation 418, the controller 104 may activate a new order. In one example, the controller 104 may communicate via the network 106 to place an order or submit an order to a supplier. The order details may be preset by the user, may be automatically determined based on an analysis of new orders or sales information, or may be based on the previously ordered supplies. In another example, during operation 418 the controller 104 may send a notification to a user (e.g., email, text message, or the like) that alerts the user that supplies are low and should be reordered. In this example, the user can respond with instructions to the controller 104 to order the supplies or the user can reorder the supplies using another computing device or method. After operation 418, the method 400 may proceed to end state 422.
The foregoing description has broad application. For example, while examples disclosed herein may focus on packaging machines, it should be appreciated that the concepts disclosed herein may equally apply to substantially any other type of machine that is used for manufacturing elements or components. Similarly, although the controller may be discussed with respect to a tablet computing device, the devices and techniques disclosed herein are equally applicable to other types of computing devices. Accordingly, the discussion of any embodiment is meant only to be exemplary and is not intended to suggest that the scope of the disclosure, including the claims, is limited to these examples.

Claims

What is claimed is:

1. A method for maintaining an inventory of packaging supplies comprising:

receiving by a processing element an initial level of packaging supplies;

receiving by the processing element packaging data corresponding to current supply use by one or more packaging machines over a predetermined time period;

determining by the packaging machine whether a current level of packaging supplies is below a predetermined threshold; and

when the current level of packaging supplies is below a predetermined threshold, activating by the processing element a new order process.

2. The method of claim 1, wherein the new order process comprises transmitting by the processing element a message to a user device.

3. The method of claim 2, wherein the new order process comprises transmitting by the processing element a new order submission to a packaging supply company.

4. The method of claim 1, further comprising predicting by the processing element a future supply use for the one or more packaging machines and using the future supply use and the current supply to determine whether based on at least the current level of packaging supplies and a future predicted level of supplies the new order process should be initiated.

5. The method of claim 4, further comprising analyzing by the processing element a typical time frame for order fulfillment to determine whether the new order process should be initiated.

6. The method of claim 1, wherein the packaging data corresponding to current supply use during the predetermined time period by one or more packaging machines comprises at least one of number of packaging materials created, size of the packaging materials created, temperature of the one or more machines, a number of pump cycles for the one or more machines, and/or a number of motor activations for the one or more machines.

7. The method of claim 1, wherein the new order process comprises displaying on a display screen a new order alert.

8. The method of claim 1, wherein the current level of packaging supplies is estimated based on operating data over the predetermined time period.

9. The method of claim 1, wherein, based on the new order process, packaging supplies are shipped.

10. A machine for creating packaging materials and reordering supply materials comprising:

a supply material input for receiving raw supplies;

one or more machine components configured to convert the raw supplies into completed packaging materials;

a material output for outputting completed packaging materials created using the raw supplies; and

a processing element configured to receive data corresponding to one or more machine components, wherein the processing element determines using at least one of an initial raw supply level, a completed packaging materials level, one or more current packaging material orders, or historical operating parameters of the one or more machine components to determine if additional raw supplies are required.

11. The machine of claim 10, wherein when additional raw supplies are required the processing element transmits a new order alert to one or more user devices.

12. The machine of claim 10, wherein when additional raw supplies are required the processing element outputs a new order alert via an output device connected to the machine.

13. The machine of claim 12, wherein the output device is a display screen.

14. The machine of claim 12, wherein when additional supplies are required the processing element transmits a new order request to a raw supply vendor.

15. The machine of claim 12, wherein the raw supplies comprise at least one of foam precursors, paper, plastic film, or compressed air.

16. The machine of claim 12, wherein the historical operating parameters comprise at least one of number of completed packaging materials created in a predetermined time frame, operating time of the one or more components, a number of queues of items produces in a predetermined time frame.

17. The machine of claim 12, wherein the machine is a foam-in-bag machine and the raw supplies comprise one or more foam precursors.

18. The machine of claim 12, wherein the machine is a dunnage machine and the raw supplies comprise a paper product.

19. The machine of claim 12, wherein the machine is an inflated pillow machine and the raw supplies comprise plastic film.

20. The machine of claim 12, further comprising a controller connected to the machine and in communication with one or more sensors connected to the one or more components, wherein the processing element is incorporated into the controller.

21. A foam-in-bag packaging system comprising:

a foam-in-bag machine; and

a portable computing device in electrical communication with the foam-in-bag machine, the portable computing comprising:

at least one processing element;

a touch sensitive display in communication with the at least one processing element; and

a network/communication interface in communication with the at least one processing element; wherein

the at least one processing element transmits a new order message via the network/communication interface to a user device to reorder raw supplies for use by the foam-in-bag machine based on at least one of number of bags created by the foam-in-bag machine over a predetermined time period, an initial inventory of raw supplies, one or more current bag orders, and a prediction of future bag orders.

22. The foam-in-bag packaging system of claim 21, wherein the user device is a supplier ordering system.

23. The foam-in-bag packaging system of claim 22, wherein the display outputs a new order alert notification when the processing element transmits the new order message.