Systems and methods for assembling unpacked merchandise in containers

Patent metadata

Field	Value
Publication number	US-2022355963-A1
Application number	US-202117308689-A
Country	US
Kind code	A1
Filing date	May 5, 2021
Priority date	May 5, 2021
Publication date	Nov 10, 2022
Grant date	—

Abstract

There are provided systems and methods relating to assembling unpacked merchandise in containers. In one form, the system includes an order of merchandise items to be assembled in containers, and a predetermined set of containers defining different sizes and including at least two different types of containers. The system also includes a control circuit configured to: receive notification of the order, select a first type of container, determine a first subset of the plurality of merchandise items to be received in the selected type of container, select a size of the selected type of container to receive the first subset of merchandise items, and instruct the disposition of the first subset of merchandise items within the selected type and size of container.

First claim

What is claimed is:

1 . A system for assembling merchandise orders in containers, the system comprising:
an order including a plurality of merchandise items to be assembled in at least one container; a predetermined set of containers defining different sizes and including at least two different types of containers, a first type of container comprising boxes and a second type of container comprising deformable bags, each of a plurality of types of merchandise items corresponding to one of the at least two different types of containers and corresponding to a level of protection for transport of the type of merchandise item; a control circuit configured to:
receive notification of the order including the plurality of merchandise items;
select a first type of container from the at least two types of containers to receive a first subset of the plurality of merchandise items;
determine the first subset of the plurality of merchandise items to be received in the selected type of container, each of the merchandise items in the first subset corresponding to the selected type of container;
select a size of the selected type of container to receive the first subset of the plurality of merchandise items; and
instruct the disposition of the first subset of the plurality of merchandise items within the selected type and size of container.

2 . The system of claim 1 , wherein the control circuit is configured to determine an arrangement of the first subset of the plurality of merchandise items within the selected type of container comprising:
iteratively applying a best fit decreasing algorithm involving reverse sorting the plurality of merchandise items from a largest volume merchandise item to a smallest volume merchandise item; iteratively calculating a plurality of virtual packing arrangements based on the algorithm, the virtual packing arrangements being applied to the selected type of container in order of increasing size; and selecting the arrangement in which the first subset of the plurality of items occupies a selected type of container with the smallest size.

3 . The system of claim 1 , wherein the control circuit is configured to:
select a second type of container from the at least two types of containers to receive a second subset of the plurality of merchandise items; determine the second subset of the plurality of merchandise items to be received in the second selected type of container, each of the merchandise items in the second subset corresponding to the second selected type of container; select a size of the second selected type of container to receive the second subset of the plurality of merchandise items; and instruct the disposition of the second subset of the plurality of merchandise items within the second selected type and size of container.

4 . The system of claim 1 , wherein the control circuit is configured to:
receive an input set of flat bags, each flat bag having two dimensions; calculate deformation of each flat bag to generate a set of deformable bags of different volumes for each flat bag, each deformable bag in the set having an associated volume; and select a deformable bag in the set to receive the first subset of the plurality of merchandise items.

5 . The system of claim 1 , wherein the deformable bags comprise at least one of polybags and jiffy bags.

6 . The system of claim 1 , wherein:
the first subset of the plurality of merchandise items are all the same type of merchandise item; and the control circuit is configured to select boxes as the container type and to instruct creation of a customized box that form fits the first subset of the plurality of merchandise items.

7 . The system of claim 1 , where the control circuit is configured to:
receive an indicator that a first merchandise item has a cavity defining a space therein; determine that a second merchandise item has a size that is less than the space defined by the cavity; and instruct that the second merchandise item be disposed within the cavity.

8 . The system of claim 1 , wherein the control circuit is configured to:
receive an indicator that a merchandise item is to be disposed in protective packaging occupying a predetermined amount of space; calculate a new size of the merchandise item when disposed in the protective packaging; and instruct packing of the protectively packaged merchandise item in a container selected from the predetermined set of containers.

9 . The system of claim 1 , wherein the control circuit is configured to:
receive an indicator that a merchandise item is to be arranged in a container in a predetermined orientation; calculate a plurality of virtual packing arrangements in which the merchandise item is arranged in the container in the predetermined orientation; and select one of the plurality of the virtual packing arrangements.

10 . The system of claim 1 , wherein the control circuit is configured to:
cause the display of the arrangement of the first subset of the plurality of merchandise items within the selected type and size of container on a virtual reality framework.

11 . A computer implemented method for assembling merchandise orders in containers, the method comprising:
receiving notification of an order including a plurality of merchandise items to be assembled in at least one container; receiving input of a predetermined set of containers defining different sizes and including at least two different types of containers, a first type of container comprising boxes and a second type of container comprising deformable bags, each of the plurality of types of merchandise items corresponding to one of the at least two different types of containers and corresponding to a level of protection for transport of the type of merchandise item; selecting a first type of container from the at least two types of containers to receive a first subset of the plurality of merchandise items; determining the first subset of the plurality of merchandise items to be received in the selected type of container, each of the merchandise items in the first subset corresponding to the selected type of container; selecting a size of the selected type of container to receive the first subset of the plurality of merchandise items; and instructing the disposition of the first subset of the plurality of merchandise items within the selected type and size of container.

12 . The method of claim 11 , further comprising, by the control circuit, determining an arrangement of the first subset of the plurality of merchandise items within the selected type of container comprising:
iteratively applying a best fit decreasing algorithm involving reverse sorting the plurality of merchandise items from a largest volume merchandise item to a smallest volume merchandise item; iteratively calculating a plurality of virtual packing arrangements based on the algorithm, the virtual packing arrangements being applied to the selected type of container in order of increasing size; and selecting the arrangement in which the first subset of the plurality of items occupies a selected type of container with the smallest size.

13 . The method of claim 11 , further comprising:
selecting a second type of container from the at least two types of containers to receive a second subset of the plurality of merchandise items; determining the second subset of the plurality of merchandise items to be received in the second selected type of container, each of the merchandise items in the second subset corresponding to the second selected type of container; selecting a size of the second selected type of container to recei

Assignees

• Walmart Apollo Llc

Inventors

• Chakravarthy Sunada Sn
• Siew Hew Sam Rei E

Classifications

• B65B2210/04

  Customised on demand packaging by determining a specific characteristic, e.g. shape or height, of articles or material to be packaged and selecting, creating or adapting a packaging accordingly, e.g. making a carton starting from web material · CPC title

• B65B59/003 Primary

  Arrangements to enable adjustments related to the packaging material · CPC title

• B65B2210/02

  Plurality of alternative input or output lines or plurality of alternative packaging units on the same packaging line for improving machine flexibility · CPC title

• B65B59/001 Primary

  Arrangements to enable adjustments related to the product to be packaged · CPC title

• B65B2220/18

  the primary packaging being bags the subsequent secondary packaging being rigid containers, e.g. cardboard box · CPC title