Void Fill Solution | CMES Robotics
                       Case 
Vstuodyid Fill 
Solution
Case study - Void Fill 
Solution
  
1. SU2. MMARY
CH·DAeLcLreEaNsGedE efficiency of packaging work due to high SO· SLoUftTwIaOrN PATENT
dmepaennudaeln ce on e- 3D measurement 
·Clahbaollrenge in measuring the void of the packaging box a- lBgooxr isthizme recognition 
a·Icnccureraatseeldy the cost burden as when the volume of the a- lGgroarpithhimcal User Interface 
pgarcokwaging box -(G RUeIc) ipe tool for custom 
s ·Hseatrtdinwgare: 3D scanner 
& PC
3. RESULTS
· Accurately calculates the void of the packaging box
·Fills the void of the box with an appropriate amount of cushioning 
material
·Improves cushioning material use efficiency leading to a 
significant cost saving
·Short cycle times (min. 2 sec. including processing, It can 
be changed  depending on the operating enviroment.)
·ROI within 6 months (1 production line)
*Customer’s requirement
  
1. BACKGROUND CHALLENGE
Efforts to build an automated packing system
& Challenge in calculating the appropriate amount of cushioning material
With more than a 50% market share, Korea's largest logistics service company i modernizing its op rating system  and  
leading various logistics businesses by introducing an automated packing system using cutting-edge IT technology.
Fo  examp e,l   it was le ss effic ei nt to fill the void with the cushioning material ni th p or duct box packaging stage, as it  
performed manually. The company tried to change the system to an automated one to increase production efficiency. It was  
challenging to accurately calculate the appropriate amount of cushioning material ot fill the packaging box's void.
2. CHALLENGE
Product protection in the packaging box by filling with a cushioning material
When packing a product in a box, filling the empty sp  ce inside the box with cushioning material is nec ary to limit 
product  movement inside the box during shipping that can cause damage and protect the products. The packers carefully 
check the  size and type of the box and its shape and put an appropriate amount of cushioning material in the box.
Necessary to calculate the volume of the void of the box accurately
How  ver, s   ce the existing product p  ckaging operation has relied manual work, the packaging operati n had o be  
efficient. It is difficult to accurately measure the volume of the box's void, excluding the space occupied by goods, so it was 
 chall nging to suffic ei ntly fi ll the empty internal space with cushioning material. Also, as the box's volume increases, more 
 packers are required, which adds to the cost burden.
Accurately measure the volume of the box's void through CMES Void Fill Solution
CMES Void Fill S  lution offers more efficie    y in coping w h critical problems in the packaging process by accurately measur- 
 ing the volume of the empty inner space in a box containing a product.

Case study - Void Fill 
Solution
  
1. PACKAGE SOLUTION
CO1M) PSoOftNwEarNeTPSATENT 2) Hardware
3D measurement · 3D scanner & 
·Baolgxo sriizthe mrecognition algorithm P*C 3D vision application model differs by box size
i.e. Box sizes used in mass production line
Box size (W.D.H) 3D SCANNER 
MODEL
Min 195/ 180/ 135
Photoneo M
Max 310/ 235/ 210
Min 275/ 170/ 120
Photoneo L
Max 480/ 360/ 295
Graphical User Interface (GUI)
Recipe tool for custom 
setting
2. OPERATION SETTING
M asurable box thickness: Min. 2.5mm
·Height between the sensor and the bottom of the product box to be measured: 700mm(Medium box), 1,250mm(Large box) 
 Sensor post is installed considering  tsi am t  re ali dn atcol noi
to me   usa ter eh b ateylcurcadiovsx'o
·Prevents laser reflection by removing obstructions from conveyor rollers and box guides
Measurable box 
thickness
Min. 2.5mm

Case study - Void Fill 
Solution
3. WORKFLOW
Ⓒ Barcode 
Data
Vision PC PLC
Ⓒ Box ⑥ Amount of Filling 
Data Material
Ⓒ 3D Volume 
Data
Barcode Reader Ⓒ 3D Scanning 3D Vision Sensor
Data Filling  
Ⓒ Capturing Trigger Machine
Signal
step step 2 step 3
1
BOX Reading BOX Scanning BOX Filling void
barcode box
① arcode re er scans the barcode on the packaging box,   nd the barcode data is transmitted to the PLC.
② The box information (type, loaded goods) from the barcode data is transferred from the PLC to the vision PC.
③ When the 3D vision sensor located above the packaging box receives the capture trigger signal from the vision 
PC,  it scans the inside of the packaging box containing the product to measure the box's void accurately.
④ The mea us red 3D anned data is transmitted t   the Vision PC.
⑤ Vision PC transmits the measured volume data of the box's void to PLC.
⑥ PLC ca cl ulates the amount of cushioning material based on the transmitted data and transfers the result to the filling 
 machine.
4. FUNCTIONS
1) 3D measurement algorithm
·Accurately measures the volume of the box's void by dividing the area inside the packaging box
·Able to set the grid level suitable for various cushioning material sizes
[Grid 10] [Grid 20]

Case study - Void Fill 
Solution
2) Box size recognition algorithm
·Able to identify the size of the boxes delivered from the conveyor belt
3) Graphical User Interface (GUI)
·Able to immediately check the measurement status of the packaging box's void through the graphical user  
interface, thus improving convenience for the operator.
5. ADVANTAGES
·High accuracy with a solution that integrates high-resolution 3D vision sensors, and software in combination with 
 vision algorithms (Error 10% *)
Sho   cycle t mi es (min. 2 sec. including processing, It can be changed depending o  the operating enviroment.)
·Improves the measurement limitation issues according to the material of the existing loaded 
product  Accurate yl cal uc lates ht e vo d of boxes loaded w th products of various materials
·Calculates the box void of different sized packaging boxes with one 3D scanner
·Patented solution (products packaging device and packaging method)
* Customer’s requirement
  
Previously, a certain number of pack s got involv d in the void filling of th  packaRgingE boxS. ThUe mLanuTal oSperation  
had limitations in production efficiency because putting an appropriate amount of cushioning material was  
highly challenging, and it was also challenging to calculate the box's void volume. However, with CMES Void 
Fill  solution, the box's void can be accurately measured, leading to the use of an 
appropriate amount of cush-  ion ni g material. So, filling the void with appropriate 
cushioning ma et rial becomes easy and fast. Also, we  expect a cost reduction effect by 
improving the efficiency of using the cushioning mate rial.
-packing engineer -
Global logistics company applies the solution in mass 
pro-  duction lines.
The client deploys CMES Void F l Solution in mass production lines for the contract 
 logistics businesses which provide services to a global health food company having 
 an Asian logistics hub in Incheon and the largest healthcare goods company 
in  Korea.
Improved cushioning material use efficiency & high 
price  competitiveness
Void Fill Solution allows the adjustment of  the cycle time request by the 
custom-  er to align with the overall process speed. The solution enables the 
packaging  process   ot realize the full automa it on by ca cl ulating the appr  
priate amount   of cushioning material according to the packaging box. The 
solution results in a high
t-saving effect with improved cu hs oi ning mater ai l use efficiency and price  
competitiveness within six Wmeobnstihtes  o f ROI(For onwew mwa.csms epsr3odd.cuocmtion line).
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