Warehouse Conveyor Merge Timing for FIFO Throughput
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Solution Overview
Problem
Logistical warehouses face inefficiencies in optimizing the flow of incoming loads onto a collector conveyor, leading to suboptimal throughput due to vacant spaces and the impact of disturbing flows, which hinder the mechanical capacity of the conveyor system.
Innovation Solution
A control system that calculates and manages the injection dates of loads onto the collector conveyor to minimize vacant spaces and accommodate disturbing flows, ensuring a First-In-First-Out (FIFO) sequence and optimal throughput by determining the precise timing of load injection based on the position and sequence of loads on the conveyor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If loads are injected sequentially onto the collector conveyor, then the FIFO sequence is maintained, but vacant spaces are created reducing throughput
Solution Approach 1:
The control system pre-calculates optimal injection dates for each load before injection occurs. By determining the precise timing in advance based on load position, sequence number, and conveyor speed, the system prepares the injection schedule proactively, allowing loads to be injected at optimal moments that minimize vacant spaces while maintaining FIFO compliance.
Solution Approach 2:
The system dynamically adjusts injection timing based on real-time parameters including load position, sequence number, and conveyor speed. The injection dates are not fixed but are calculated dynamically to optimize throughput while respecting FIFO constraints, allowing the system to adapt to varying operational conditions.
2Productivity
If the collector conveyor runs at maximum mechanical capacity, then throughput is maximized, but disturbing flows cause imbalances and vacant spaces
Solution Approach 1:
The control system continuously monitors load positions, sequence numbers, and conveyor speed, using this feedback to recalculate and adjust injection dates. This closed-loop control ensures that even when disturbing flows occur, the system can adaptively maintain optimal injection timing to minimize vacant spaces and maintain flow balance at maximum throughput.
Solution Approach 2:
The system changes operational parameters dynamically, specifically adjusting injection timing based on load sequence numbers and positions. By modifying the injection date parameter for each load according to its specific characteristics and real-time system state, the system optimizes throughput while compensating for disturbing flows.
3Productivity
If injection timing is optimized for maximum throughput, then vacant spaces are minimized, but complex calculation and control are required
Solution Approach 1:
The patent replaces complex mechanical timing mechanisms with a computational control system. Instead of using mechanical devices to physically schedule and time load injections, the system uses algorithms to calculate optimal injection dates and electronic control to execute them, simplifying the physical system while achieving optimized throughput.
Data Source
AI summary
Method for merging, within a logistical warehouse, k incoming flows of payloads, transported respectively by k FIFO conveyor lanes αi with i∈{1, . . . , k} into one outgoing flow of payloads transported by a collector conveyor. The k lanes are distributed along the collector and numbered a1 to ak. Δi is a time-related distance between the lanes ai and ak. A control system obtains a set L having n payloads distributed on the k lanes and having to be injected into the collector to form an exit sequence; computes a date t0 at which the first payload σ1 of the exit sequence σ passes in front of the lane ak; and computes n dates of injection of the n payloads into the collector, as a function of t0; and commands the collector and the k alleys, for an injection of the n payloads into the collector in compliance with the injection dates.