Automated Load Sequencing Reducing Manifold Disturbance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Automated load distribution systems face inefficiencies in forming outgoing flows from incoming flows, particularly in maintaining optimal sorting and rate, with existing solutions imposing strong constraints on sources and collectors, leading to suboptimal manifold filling rates and increased waiting times.
Innovation Solution
A control system constructs a collection list to reduce disorder in charges based on destination order numbers, allowing charges to be collected and transported out of order while ensuring compliance with weak constraints, thereby optimizing the collection process and reducing the complexity of buffer storage and sequencing systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If strong constraints are imposed on sources and collectors to maintain sorting order, then destination order compliance is improved, but manifold filling rate deteriorates
Solution Approach 1:
The control system performs preliminary sequencing of loads in source buffers before they reach the collector. By pre-organizing loads in increasing destination order in the FIFO buffers, the system reduces the need for strict real-time constraints during collection, allowing more flexible and efficient manifold filling while maintaining destination order compliance.
Solution Approach 2:
FIFO source buffers act as intermediary elements between sources and the collector. These buffers temporarily store and pre-sort loads, mediating between the unsorted incoming flows and the collector. This intermediary sorting function allows the collector to operate with fewer constraints while still ensuring proper destination ordering.
2Manufacturing precision
If strict sorting constraints are applied during collection, then pre-sorting quality is improved, but waiting times increase
Solution Approach 1:
The system performs preliminary sorting actions in the source buffers before loads enter the collector. By pre-sequencing loads in destination order within each FIFO buffer, the sorting work is done in advance rather than during collection, eliminating waiting times caused by real-time sorting constraints while maintaining high pre-sorting quality.
3Reliability
If complex buffer storage and sequencing systems are used to maintain order, then destination sequencing accuracy is improved, but system complexity increases
Solution Approach 1:
The sequencing function is segmented and distributed across multiple independent FIFO source buffers, each handling a portion of the sorting task. Instead of one complex centralized sequencing system, the problem is divided into simpler parallel buffer operations, reducing overall system complexity while maintaining sequencing accuracy through the combined output of all buffers.
Solution Approach 2:
The FIFO source buffers serve multiple functions: they act as temporary storage, perform preliminary sorting, and regulate flow to the collector. This multi-functionality eliminates the need for separate dedicated sequencing devices, reducing system complexity while maintaining destination sequencing accuracy through the buffers' inherent FIFO properties and control system management.
Data Source
Figure 1A~1C
Figure 2
Figure 3~4
AI summary
A method for sequencing loads in an automated load distribution system comprising: k sources, with k≥2; at least one destination; k source buffer devices, of the FIFO type, each receiving loads from one of the k sources; a collector collecting the loads exiting the k source buffer devices and transporting them to at least one destination, the collector comprising k successive nodes, each configured to collect the loads exiting one of the k source buffer devices; and a control system configured to process commands, each command listing loads for a given destination and each associated with a destination order number.The control system performs the following steps: construction (31) of a collection list containing n charges to be collected and reducing a disorder of the n charges with respect to an increasing order of destination order numbers, the n charges being contained in the source buffer devices, n=∑i=1i=kpi, with p(i) a number of charges to be collected in the ith source buffer device; and control (32) of the collector and the source buffer devices for a collection of charges on the collector conforming to the collection list.