Buffer Storage Decouples Passport Production Lines
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Solution Overview
Problem
Existing systems for producing book-shaped identification, value, or security documents face delays in cycle time and throughput due to faults in individual devices, as subsequent devices are impaired, leading to inefficiencies in production.
Innovation Solution
The implementation of a buffer storage system that decouples production flows between devices, allowing for flexible processing and redundancy in key stages such as sewing, gluing, and printing, ensuring continuous operation even if faults occur, along with redundant devices for critical processes like sewing and gluing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fault occurs in a first device in the system, then subsequent or parallel devices in the system are impaired in their further production, but the cycle time and throughput are delayed
Solution Approach 1:
The production system is segmented into multiple independent production lines (first production line with first sewing device, second production line with second sewing device). Each line can operate independently, so a fault in one line does not impair the other line's productivity, resolving the contradiction between reliability and cycle time
Solution Approach 2:
The system changes the operational parameter from single-line production to multi-line parallel production. By introducing a second sewing device and corresponding production line, the system maintains production continuity (reliability) while preventing cycle time delays when faults occur, as the unaffected line continues operating
2Reliability
If subsequent devices are impaired due to faults in previous devices, then the entire production flow is delayed, but individual device independence is reduced
Solution Approach 1:
The system divides the production process into separate segmentable lines, each with its own sewing device and associated components. This segmentation allows independent operation of each line, maintaining production stability while managing system complexity through modular architecture
Solution Approach 2:
The system prepares multiple production lines in advance (first and second sewing devices, respective buffer storage units) so that when a fault occurs in one line, the other line is already positioned to continue production without interruption, maintaining stability without requiring complex real-time coordination
Data Source
Figure 1~2b
Figure 2c~2f
Figure 3a
AI summary
The invention relates to a system (150) for the production and processing of a book-shaped identification, valuables, or security document (100). The system (150) comprises: a receiving device (250) for receiving the data card (106); a recognition device (208); an attachment device (200); a passport book page device (300); an adhesive device (400); a sewing device (500); a dispensing device (600) for dispensing the cover (102); an adhesive and folding device (700); an edge processing device (800); a finishing device (850); and one or more holding and transport devices (950, 952, 954, 1000) for transporting the data card (106), the passport book block (104), the passport book blank (128), and/or an identification, valuables, or security document (100) between the devices.A first buffer storage unit (902) is provided, which is connected on the buffer input side to the passport page device (300), the attachment device (200), and the adhesive device (400), and on the buffer output side to the sewing device (500) for decoupling a first production flow (904) from a second production flow (924). The invention also relates to a corresponding method for producing the identification, value, or security document (100).