Display Manufacturing Line Control for Storage Filling Rate
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Solution Overview
Problem
The challenge of managing the filling rate of a storage unit in a manufacturing process to prevent overflow and maintain efficiency in the production of display apparatuses, particularly in processes where the storage capacity is limited.
Innovation Solution
Implementing a controller that simulates and adjusts the operational states of processors in a digital twin environment to maintain a designated filling rate below a certain threshold, ensuring efficient operation by converting processors to a down state as needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the storage capacity is increased to handle higher production volume, then the productivity is improved, but the device complexity and cost increase
Solution Approach 1:
The patent implements dynamic control of processor operational states based on real-time storage filling rate. The controller adjusts the number of active processors against down processors according to storage capacity, creating a dynamic system that adapts to varying production demands without requiring permanently oversized storage infrastructure.
Solution Approach 2:
The system changes the operational parameter of processors from a fixed state to a variable state. Processors can switch between operational and down states based on storage filling rate thresholds, allowing the production system to flexibly adjust output capacity without physical expansion of storage resources.
2Productivity
If more processors are kept in operational state to maintain high productivity, then the production output is improved, but the storage filling rate exceeds the designated value causing overflow risk
Solution Approach 1:
The controller continuously monitors the storage filling rate and uses this feedback to adjust processor operational states. When the filling rate approaches the designated threshold, the controller automatically converts operational processors to down processors, preventing overflow while maintaining optimal productivity within safe boundaries.
Solution Approach 2:
The system proactively converts processors to down states before storage overflow occurs. By monitoring filling rates and acting in advance when thresholds are approached, the system prevents harmful overflow conditions rather than reacting after problems arise.
3Reliability
If processors are converted to down state to reduce storage filling rate, then the storage overflow is prevented, but the productivity decreases
Solution Approach 1:
The controller periodically assesses storage filling rates and adjusts processor states accordingly. This periodic control creates a rhythm of operational adjustment where processors are converted to down states temporarily when needed, then can be reactivated when storage capacity permits, maintaining overall productivity while ensuring storage reliability.
Data Source
AI summary
A controller includes a simulator configured to simulate a final model for converting at least one of 1-1st processors and 1-2nd processors into a down state, in a virtual space that is a virtual space, so that a filling rate, which is a ratio of a used capacity of the storage to a total capacity of the storage, is equal to or less than a first value, and a process controller configured to control a first process line according to the final model.