Collector Conveyor Injection Timing for FIFO Aisle Flow Merging
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Solution Overview
Problem
Logistics warehouses face inefficiencies in optimizing the flow of incoming loads onto a collector conveyor, leading to suboptimal throughput due to empty spaces and uncontrolled disruptive flows, which hinder the mechanical capacity of the collector and result in slowed outflow processes.
Innovation Solution
A method is proposed to calculate and control the injection dates of loads onto the collector conveyor, ensuring a feasible final sequence that maximizes throughput by minimizing empty spaces and managing both experienced and controlled disruptive flows, using a formula-based approach to determine optimal injection times based on the position and sequence of loads along the aisles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If loads are injected sequentially onto the collector conveyor, then the final sequence of loads can be controlled, but empty spaces are created between injection zones that reduce throughput
Solution Approach 1:
The control system calculates and determines the injection dates for all loads before actual injection occurs. By预先 computing the optimal injection schedule that accounts for aisle positions, load sequences, and collector capacity, the system eliminates empty spaces between injection zones while maintaining the required final sequence. This preliminary planning allows multiple loads to be injected in parallel without creating gaps in the collector flow.
2Productivity
If the collector conveyor operates at maximum mechanical capacity, then throughput is maximized, but disruptive flows cause obstructions that reduce efficiency
Solution Approach 1:
The control system continuously monitors the collector conveyor for obstructions and disruptive flows. When an obstruction is detected, the system dynamically recalculates injection dates and adjusts the injection schedule in real-time. This feedback mechanism allows the collector to operate at maximum capacity while automatically adapting to disruptions, maintaining both high throughput and flow stability by redistributing loads around obstructions.
3Productivity
If injection dates are calculated to minimize empty spaces, then throughput increases, but the complexity of scheduling and control increases
Solution Approach 1:
The patent replaces complex manual scheduling and mechanical coordination with an automated control system that uses algorithms to calculate optimal injection dates. The control system processes aisle positions, load sequences, and collector capacity parameters computationally, substituting intricate mechanical timing mechanisms with software-based scheduling. This reduces operational complexity while achieving optimized throughput through formula-based date calculation.
Data Source
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AI summary
A method for merging k incoming payload flows, transported respectively by k aisles ai with i ∈ {1, ..., k}, into an outgoing payload flow transported by a collector, within a logistics warehouse. The k aisles are FIFO type, distributed along the collector and numbered from a1 to ak in the direction of collector movement. Δi is a time distance between aisles ai and ak. The method, executed by a control system, comprises: obtaining (461) a set L comprising n payloads distributed across the k aisles and to be injected onto the collector to form an output sequence; calculating (462) a time t0 at which the first payload of the output sequence passes aisle ak; calculating (463) n injection times for the n payloads onto the collector, as a function of t0; command (464) of the collector and the k aisles, for injection of payloads in accordance with the injection dates.