Buffer Load Sequencing with Recirculation to Prevent Blockage
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Solution Overview
Problem
Buffer storage and load sequencing systems face challenges in managing the flow rate of sequenced loads and reducing the risk of blockage, particularly in selecting loads and destination levels while ensuring compliance with sequential order rules and optimizing recirculation.
Innovation Solution
An iterative management method for the entrance elevator that prioritizes loads in recirculation and optimizes the selection of destination levels and recirculation levels, using a management unit to detect loads, select loads based on priority conditions, and assign recirculation status to loads, thereby improving sorting capacity and reducing blockage risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the system prioritizes increasing the exit flow rate of sequenced loads, then productivity is improved, but the risk of blockage in the buffer storage unit increases
Solution Approach 1:
The management unit performs preliminary actions by detecting loads at exits of entrance conveyor and recirculation level before making selection decisions. It proactively assigns recirculation status to loads and pre-selects destination levels or recirculation levels, preventing blockage conditions before they occur while maintaining high throughput
Solution Approach 2:
The management unit continuously monitors the buffer storage unit status, detecting loads at various exits and using this feedback information to dynamically adjust load selection and recirculation decisions. This closed-loop control enables the system to respond to changing conditions and prevent blockage while optimizing exit flow rate
2Reliability
If the system increases the number of entrance levels to reduce blockage risk, then device complexity increases, but the buffer storage capacity increases
Solution Approach 1:
Instead of changing the structural parameter of adding more entrance levels, the system changes operational parameters by implementing recirculation of loads. The management unit dynamically adjusts load flow patterns through recirculation, effectively increasing buffer capacity without adding physical levels or increasing device complexity
Solution Approach 2:
The recirculation level acts as an intermediary element that allows loads to return to the entrance conveyor and re-enter the buffer storage unit. This intermediary mechanism provides additional buffering capacity without requiring additional entrance levels, thus reducing blockage risk without increasing device complexity
3Manufacturing precision
If the system implements strict sequential order rules for load sequencing, then manufacturing precision is improved, but the sorting capacity decreases
Solution Approach 1:
The management unit implements dynamic load selection based on priority conditions rather than static sequential processing. It can adaptively choose between selecting loads from the entrance conveyor or recirculation level exits, and dynamically determine destination levels or recirculation assignments, maintaining sequential order while maximizing sorting capacity
Solution Approach 2:
The system segments the load flow into different paths: loads can be directed to entrance levels in sequential order or assigned to recirculation. This segmentation allows the system to maintain strict sequencing for loads proceeding through the normal path while using recirculation as an alternative path that doesn't disrupt the sequential order, thereby preserving manufacturing precision while improving sorting capacity
Data Source
AI summary
A method for managing a buffer storage and load sequencing system, receiving non-sequenced loads, providing a sequence of loads, and including a buffer storage unit (having entrance levels, at least one recirculation level, and an entrance elevator facing entrances and an exit elevator facing exits of the levels. A management unit iteratively manages the entrance elevator by, at each iteration (even if there are loads to be recirculated in the system): selecting a load at exit from an entrance conveyor or at exit from the recirculation level; if the selection of one of the entrance levels is completed, generating a task for the entrance elevator of transferring the selected load to the entrance of the selected level; if not, selecting a level of loads to be recirculated and assigning the load(s) on this level a “load(s) to be recirculated” status without generating a task of transfer for the entrance elevator.