Product Flow Regulator Buffer Elevator Throughput
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Solution Overview
Problem
Existing product flow regulators are unable to meet increasing demands for processing speed due to inefficiencies in input and output speeds, leading to potential production backups and waste, especially in foodstuff production.
Innovation Solution
The implementation of buffer devices upstream and downstream from elevators in product flow regulators, allowing for a prebuffer function that increases the work cadence of elevators and reduces lift height, thereby enhancing production throughput by optimizing the use of time and space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the packaging device operates at high speed to prevent product backups, then packaging output increases, but the production device cannot keep up leading to operational disruptions
Solution Approach 1:
The system is divided into separate functional zones: production device, infeed-side buffer device, infeed-side elevator, intermediate storage with multiple levels, discharge-side elevator, and discharge-side buffer device. This segmentation allows each component to operate independently at optimized speeds, enabling the packaging device to run faster while the production device maintains its own rhythm.
Solution Approach 2:
The infeed-side buffer device and infeed-side elevator perform preliminary actions by accumulating products before they reach the intermediate storage. This pre-positioning of products ensures that even if the production device temporarily stops, the packaging device can continue operating using products already prepared in the buffer zones.
2Loss of substance
If the production device is switched off during packaging interruption, then product backup is prevented, but substantial delay occurs due to removing products in process
Solution Approach 1:
Products are preliminarily grouped into formations by the infeed-side buffer device and elevator before reaching the intermediate storage. This preliminary organization allows for rapid loading/unloading operations, minimizing the time the production device needs to be stopped while preventing product waste through efficient transfer mechanisms.
Solution Approach 2:
The intermediate storage with multiple levels acts as an intermediary between production and packaging operations. It can accumulate products at different levels, allowing the production device to be switched off quickly without causing backups, while the packaging device continues operating from stored products.
3Volume of stationary object
If the elevator lift height is increased to reach higher intermediate storage levels, then storage capacity increases, but transfer time increases reducing throughput
Solution Approach 1:
The intermediate storage is divided into multiple levels that can be independently accessed. The discharge-side elevator can service different levels separately, allowing products to be transferred to lower levels more quickly while maintaining overall storage capacity. This segmentation reduces the average lift height required for frequent operations.
Solution Approach 2:
The system transitions from a single vertical elevator shaft to a multi-level structure with horizontal distribution. Products can be moved to intermediate levels and then distributed horizontally to different discharge points, reducing vertical travel distance and transfer time while maintaining storage volume.
4Productivity
If the work cadence of the elevator is increased to meet higher throughput demands, then productivity increases, but transfer precision and reliability may deteriorate
Solution Approach 1:
The transfer system is segmented into multiple independent elevators (infeed-side and discharge-side) that can operate in parallel. This allows the system to handle higher throughput by distributing the load across multiple units, each maintaining precise control at manageable speeds, rather than overloading a single elevator.
Solution Approach 2:
The intermediate storage with its multiple levels acts as a mediator that buffers between the high-speed packaging operation and the precision requirements of product transfer. It allows elevators to operate at optimized cadences while maintaining precision through controlled, staged transfers rather than rapid single-step movements.
Data Source
AI summary
The product flow regulator is used for decoupling an incoming flow of piece-goods from a downstream device for further processing. It comprises a stationary intermediate storage with a plurality of store levels, an infeed-side elevator with one or more transport levels for taking products arriving on conveyors to intermediate storage and a discharge-side elevator for removing the temporarily stored products and delivering them to forwarding conveyors. A buffer device is arranged upstream from these elevators on the infeed side and downstream from these elevators on the discharge side.