Buffering Containers with Adaptive Motion Profiles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing container treatment systems face challenges in adapting to different types of containers and optimizing operations during various states, leading to inefficiencies in container handling and potential damage during storage and retrieval.
Innovation Solution
A method and device that control shuttles and conveyor belts based on specific container formats and materials, optimizing motion profiles to prevent back pressure and tilting, using open-loop and closed-loop controllers to adjust acceleration, deceleration, and speed according to container properties and operational modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If containers are moved quickly into storage and removed from storage, then productivity is improved, but containers may fall over or be damaged due to excessive acceleration and deceleration
Solution Approach 1:
The system dynamically adjusts acceleration and deceleration rates based on container type and operational mode. Different container formats (e.g., bottles, cans, boxes) receive customized motion profiles that optimize both speed and stability. The control system continuously adapts motion parameters to prevent containers from falling over while maintaining high productivity.
Solution Approach 2:
The invention changes motion parameters (acceleration, deceleration, speed) according to container properties and operational modes. The control system stores specific parameter sets for different container types and operational states, adjusting these parameters to balance quick handling with container safety. This allows the system to move containers quickly while preventing damage through controlled motion profiles.
2Productivity
If the system is optimized for specific container types, then handling efficiency is improved, but adaptability to different container formats decreases
Solution Approach 1:
The system achieves universality by implementing a single buffer device that can handle multiple container formats through programmable control. The shuttles and conveyor belts are configured to accommodate different container types by adjusting motion parameters, eliminating the need for separate dedicated buffers for each container format. This multi-functional design maintains high handling efficiency across diverse container types.
Solution Approach 2:
The control system dynamically adapts to different container types by receiving format information and automatically adjusting motion profiles. When a new container type is introduced, the system can be reconfigured through software without physical modifications, maintaining both efficiency and adaptability. The dynamic adjustment capability allows the same hardware to optimize performance for each container format independently.
3Loss of time
If acceleration ramps and deceleration ramps are increased, then the time for entering and removing containers from storage is reduced, but the risk of containers falling over increases
Solution Approach 1:
The system changes acceleration and deceleration parameters based on container properties and operational mode. For fragile or tall containers, the system uses gentler ramps to prevent tilting, while for robust containers, steeper ramps are applied to minimize handling time. This parameter adaptation allows the system to reduce time loss without increasing the risk of containers falling over.
Solution Approach 2:
The motion profiles are dynamically adjusted during operation based on real-time detection of container types and operational states. The system continuously monitors container response and adapts acceleration/deceleration rates accordingly, optimizing the balance between handling speed and stability. This dynamic control prevents containers from falling over while minimizing the time they spend in handling positions.
Data Source
AI summary
A method and a device for buffering containers in a container treatment system are disclosed. The containers enter into storage on an infeed conveyor belt in the infeed direction, are moved in a single row onto a transversely adjoining buffer area by rail-guided and individually driven shuttles with row pushers in a buffering direction running transverse to the infeed direction, and are removed from storage on an outfeed conveyor belt transversely adjoining in the buffering direction. The shuttles and the infeed/outfeed conveyor belts are controlled in dependence of target positions, target speeds and/or target accelerations stored specifically for the container type, and/or the shuttles are controlled in dependence of target positions, target distances and/or target speeds stored specifically for modes of operation for initializing and reading out the shuttles, for following preceding shuttles, and for moving to route positions.