Dynamic Buffer for Conveyor Line Synchronization
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Solution Overview
Problem
Conventional conveyor systems are rigid and lack flexibility to handle temporary machine faults or pauses, leading to article damage due to unsuitable storage conditions and inefficient buffering, especially when the downstream machine resumes operation at a faster speed than the upstream machine.
Innovation Solution
A dynamic buffer system with a ring-shaped storage conveyor and flexible transmission organs, managed by a command and control unit, allows for temporary storage and ordered retrieval of articles between machines, ensuring articles are stored and reintroduced in the same order, accommodating varying machine speeds and product types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a rigid conveyor system is used to transfer articles between machines, then the system structure is simple, but the system lacks flexibility to handle temporary machine faults or pauses
Solution Approach 1:
The patent implements a dynamic buffer system that can adapt its operation based on machine status. The buffer conveyor can store articles when the downstream machine is halted, and dynamically control the release of articles when the machine resumes operation. This dynamic behavior allows the system to handle temporary machine faults without requiring complex reconfiguration, resolving the contradiction between adaptability and complexity.
Solution Approach 2:
The buffer acts as an intermediary element between the upstream and downstream machines. It receives articles from the upstream machine and stores them temporarily, then releases them to the downstream machine when ready. This intermediary function provides flexibility to handle machine faults while maintaining a relatively simple overall system structure.
2Adaptability or versatility
If articles are stored in a buffer to accommodate machine speed differences, then flexibility is improved, but article damage occurs due to unsuitable storage conditions and prolonged storage time
Solution Approach 1:
The buffer conveyor maintains continuous movement of articles through its ring-shaped design with multiple compartments. Articles are constantly in motion rather than stationary, which prevents damage from prolonged storage conditions. The continuous circulation allows articles to be stored temporarily while maintaining suitable conditions, resolving the contradiction between flexibility and article preservation.
Solution Approach 2:
The system dynamically adjusts the buffer operation based on downstream machine availability. When the downstream machine is operational, articles are quickly transferred through the buffer to avoid prolonged storage. When halted, articles are stored in the buffer's multiple compartments which maintain suitable conditions. This dynamic control minimizes storage time while providing flexibility for speed variations.
3Productivity
If the downstream machine operates at a faster speed than the upstream machine, then productivity is improved, but the buffer must manage varying article flow rates to prevent accumulation and damage
Solution Approach 1:
The buffer conveyor is divided into multiple compartments that can independently hold articles. This segmentation allows the buffer to manage varying article flow rates by distributing articles across multiple segments rather than accumulating them in a single location. The segmented structure prevents excessive accumulation while maintaining flexibility for speed variations between machines.
Solution Approach 2:
The ring-shaped buffer conveyor maintains continuous circulation of articles, ensuring that articles are constantly moving rather than stationary. This continuous motion prevents accumulation even when the downstream machine operates at higher speeds, as articles are continuously processed through the buffer rather than stagnant in storage.
4Ease of operation
If a simple conveyor line is used for article transfer, then the system is easy to operate, but it cannot cope with temporary unforeseen functioning faults or brief halts without affecting the other machine
Solution Approach 1:
The buffer serves as an intermediary that decouples the upstream and downstream machines. When a fault or halt occurs in one machine, the buffer absorbs the disruption and allows the other machine to continue operating. This intermediary function enhances system reliability while maintaining ease of operation, as the buffer automatically manages article flow without requiring complex control interventions.
Solution Approach 2:
The buffer is designed to provide beforehand cushioning against machine faults. By having the buffer capacity pre-configured and ready to receive articles, the system can cope with temporary unforeseen functioning faults or brief halts without affecting the other machine. This prior cushioning approach enhances reliability while keeping the system simple to operate.
Data Source
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AI summary
A dynamic buffer (1) is associated to two consecutive conveyor lines (L1, L2), respectively belonging to a first machine (M1) and a second machine (M2) and comprises: a storage conveyor (20), in which an operating station (P) for inlet and outlet of articles is defined, situated in proximity of an unloading position (A) of the first line (L1); handling organs (40) for transferring the articles (2) from the unloading position (A) to the second line (L2), in a condition of normal functioning of the second machine (M2), or to the operating station (P) of the storage conveyor (20), in a halted condition of the second machine (M2). On restarting, the second machine (M2) is accelerated and the handling organs (40) pick up the articles (2) stored in the storage conveyor (20) from the operating station (P), in the same order of insertion and in alternation with the articles (2) supplied towards the unloading position (A); this stage proceeds up to the emptying of the storage conveyor (20).