Pre-Dosed Container Store Control for Immediate Order Start
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Solution Overview
Problem
Current store control methods for processing lines that handle pre-dosed containers with fluid products lack automation for starting production orders immediately, managing container storage at entry and exit points, and prioritizing orders dynamically, leading to inefficiencies and operator intervention.
Innovation Solution
A control method and system that uses identifying codes on containers to automate the storage and retrieval process, dynamically manage production orders, and prioritize based on customer specifications and product requirements, allowing for parallel execution of orders and real-time management of production lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated store control methods are implemented to compute container numbers and determine filling state, then productivity is improved, but the system cannot immediately start production orders when sufficient containers are stored without operator intervention
Solution Approach 1:
The control system continuously monitors the store's filling state by receiving signals from detection devices that count containers. When the predetermined number of containers is reached, the system automatically receives feedback and triggers the production order without operator intervention, resolving the contradiction between automation and immediate order execution.
Solution Approach 2:
The system pre-establishes the predetermined number of containers needed for each production order in advance. This preliminary configuration allows the automated system to immediately initiate production orders when the pre-defined container threshold is reached, eliminating the need for operator discretion and achieving both high automation and immediate order execution.
2Ease of operation
If manual operator verification is used to check container storage status, then production orders can be started when sufficient containers are available, but this reduces productivity and increases operational time
Solution Approach 1:
The patent replaces manual operator verification with automated detection devices that use sensors or vision systems to count and verify container storage status. This substitution maintains operational accuracy while dramatically improving productivity by eliminating manual checking time and enabling immediate order initiation when containers are sufficient.
3Adaptability or versatility
If stores are designed to store containers for multiple production orders, then adaptability is improved, but the complexity of managing and tracking containers for different orders increases
Solution Approach 1:
The control system segments container tracking by creating separate virtual zones or logical groupings within the store for different production orders. Each order's containers are tracked independently through identification codes or positioning systems, allowing the system to manage multiple orders simultaneously without increasing physical store complexity, thus resolving the contradiction between adaptability and control complexity.
Data Source
AI summary
A method automatically controls stores for a processing line for containers pre-dosed with fluid products. The identifying code for each container is determined and then checked whether the container is necessary for production orders received. The container is introduced into a first store and the quantity and identifying codes of the containers in the first store are recorded. Production orders are checked for products yet to be started. The containers are picked up and sent towards a first manipulation station and at least one production order of a product is processed and the containers are sent towards different stations. Quality control inspection is conducted and if the product is compliant, introduced into a second store. Containers with non-compliant product are introduced into a control line. The quantity of containers in the second store is recorded and the containers are sent towards a packaging station to fulfill production orders.