Buffer Load Sequencing With Recirculation to Prevent Blockage
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Buffer storage and load sequencing systems face challenges in optimizing the flow rate of sequenced loads and reducing the risk of system blockage, particularly in selecting loads and destination levels while ensuring compliance with sequential order rules and managing recirculation levels.
Innovation Solution
The system employs an iterative management approach for the entrance elevator, prioritizing the selection of loads and destination levels based on sequential order numbers and recirculation status, with rules that delay transfer tasks until recirculation loads are processed, and assign 'to be recirculated' status to optimize load placement and reduce blockage risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the system increases the number of entrance levels to improve sequencing capacity, then the buffer storage capacity increases, but the system complexity and footprint increase
Solution Approach 1:
The patent introduces a recirculation level that operates in a different dimensional space (vertical recirculation path) rather than simply adding more horizontal entrance levels. Loads that cannot be sequenced immediately are redirected to the recirculation level, which loops back to the entrance, effectively adding storage capacity without proportionally increasing system complexity.
Solution Approach 2:
The recirculation level serves multiple functions: it acts as additional buffer storage, provides an alternative path for loads that cannot be sequenced immediately, and maintains system throughput by preventing blockages. This multi-functional element increases capacity without requiring separate dedicated components for each function.
2Productivity
If the system prioritizes sequencing loads to improve exit flow rate, then productivity increases, but the risk of system blockage increases
Solution Approach 1:
The management unit proactively identifies loads that cannot be sequenced immediately and redirects them to the recirculation level before they can block the main sequencing path. This preliminary action prevents blockages from forming in the first place, maintaining both high throughput and system reliability.
Solution Approach 2:
The recirculation level acts as an intermediary buffer between the entrance levels and the exit conveyor. When the main sequencing path is full or blocked, loads are diverted to this intermediate zone, which temporarily holds them without disrupting the overall flow. This mediator prevents complete system blockage while maintaining productivity.
3Area of stationary object
If the system implements recirculation to increase storage capacity without adding entrance levels, then the footprint is reduced, but the device complexity increases
Solution Approach 1:
The recirculation level is integrated with the existing entrance and exit elevators, merging multiple functions into shared infrastructure. The same elevators that serve the entrance levels also service the recirculation level, reducing the need for additional dedicated components and minimizing the increase in device complexity.
Solution Approach 2:
The recirculation level is positioned vertically within the existing system footprint, nesting the recirculation path within the space already occupied by the entrance and exit levels. This nested arrangement increases storage capacity without requiring additional horizontal space, effectively reducing the footprint per unit of storage capacity.
Data Source
AI summary
A method for managing a buffer storage and load sequencing system. The system receives non-sequenced loads and provides at least one sequence of loads, and includes a buffer storage unit having entrance levels, at least one recirculation level, an entrance elevator facing entrances and an exit elevator facing exits of the levels. A management unit iteratively manages the entrance elevator. At each iteration the entrance elevator: has a “waiting for recirculation” status for a load to be recirculated in the system; holds this elevator until the load to be recirculated has been transferred to the recirculation level, else selects a load at exit from an entrance conveyor or at exit from the recirculation level; if the selection of the entrance level is completed, generates a task, for the entrance elevator, of transferring the selected load to the selected level; if not assigns this load the “awaiting recirculation” status.