Multi-Belt Buffer Control for Stable Container Flow During Line Faults
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Solution Overview
Problem
Existing buffer systems are unable to react independently to malfunctions in a filling line to optimize buffer capacity and increase line efficiency, and the quantity of containers dispensed is not constant or defined.
Innovation Solution
A method and apparatus for automatically controlling at least two drivable belts by detecting the operating states of upstream and downstream machines, determining the speed of each belt based on these states, and controlling the belts accordingly, which can include closed-loop control and simulation of container positions without the need for light barriers or cameras.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If buffer systems use conventional control methods, then the system structure is simple, but the system cannot react independently to malfunctions to optimize buffer capacity or increase line efficiency
Solution Approach 1:
The buffer system is equipped with sensors, processors, and control mechanisms that enable it to autonomously detect malfunctions, calculate optimal speeds, and adjust belt operations without external intervention. The system serves itself by independently monitoring its own state and making real-time adjustments to maintain productivity during malfunctions.
Solution Approach 2:
The control system continuously receives feedback from sensors monitoring belt positions, container locations, and machine operating states. This feedback loop enables the processor to calculate optimal speeds and adjust belt operations in real-time, allowing the system to react dynamically to malfunctions and optimize buffer capacity.
2Quantity of substance
If the quantity of containers dispensed is controlled by pushing behavior on the line, then the control method is simple, but the quantity of containers dispensed is not constant or defined
Solution Approach 1:
The patent replaces the mechanical pushing behavior control method with an automated electronic control system. Sensors detect container positions and belt states, while a processor calculates optimal speeds to achieve precise, constant container delivery quantities, eliminating the imprecision of manual pushing control.
Solution Approach 2:
The system dynamically adjusts belt speeds as a controllable parameter to maintain constant container delivery quantities. By changing the speed parameter based on real-time system state and desired delivery quantities, the system achieves precise control over the number of containers dispensed.
3Measurement precision
If light barriers or cameras are used to monitor container positions, then monitoring accuracy is high, but the system complexity and cost increase
Solution Approach 1:
Instead of using complex optical monitoring systems like light barriers or cameras, the patent creates a simulated representation of container positions based on sensor data and physical models. This simulation copy provides sufficient monitoring accuracy for control purposes while avoiding the complexity and cost of optical detection systems.
Solution Approach 2:
The patent introduces a simulation model as an intermediary between physical sensors and control decisions. Rather than directly using complex optical sensors to monitor container positions, the system uses simple sensors combined with a simulation model to infer positions, reducing overall system complexity while maintaining adequate measurement precision.
Data Source
AI summary
The invention relates to a method for automatically controlling at least two drivable belts in a system. The belts are each configured to transport containers in a first or second direction. The system comprises a machine that is upstream of the belts and/or a machine that is downstream of the belts. The method comprises: detecting a first operating state of the upstream machine and/or detecting a second operating state of the downstream machine; furthermore determining a speed to be selected for each of the belts based on the first and/or second operating state; and controlling the belts in accordance with the speed to be selected. The invention also relates to an apparatus for carrying out the method, wherein the system comprises a machine that is upstream of the belts and/or a machine that is downstream of the belts.