Sensor Storage Mat for FIFO Buffering on Production Lines
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In production lines, asynchronisms such as machine breakdowns or different operational cadences between upstream and downstream stations lead to desynchronization of production flows, causing accumulation of objects and forced shutdowns, which disrupt efficiency and require manual intervention to maintain order and classification of objects during desynchronization.
Innovation Solution
A temporary storage system with a control unit and sensors that records object deposits and determines a removal sequence, allowing automatic and orderly retrieval of objects, maintaining upstream station operation and replenishing downstream stations without operator intervention, using a FIFO method to reintegrate objects into the production flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If objects are stored in a buffer zone with simple counting, then storage capacity is provided, but automatic ordering and classification of objects cannot be maintained during desynchronization
Solution Approach 1:
The patent introduces a temporary storage system with sensors and control units as an intermediary between upstream and downstream production zones. This intermediary automatically tracks object positions, maintains arrival order, and manages retrieval sequences, eliminating the need for manual intervention while providing buffer storage capacity.
Solution Approach 2:
The patent replaces manual tracking and ordering mechanisms with an automated sensor-based detection system. Sensors detect object presence and position, while control units automatically manage storage and retrieval sequences, substituting mechanical/manual operations with electronic detection and control.
2Productivity
If upstream station continues operation during desynchronization, then productivity is maintained, but objects accumulate and require manual intervention to maintain order
Solution Approach 1:
The temporary storage system operates autonomously to maintain object order during desynchronization. The control unit automatically detects object arrivals, tracks positions, determines retrieval sequences, and signals removal locations without operator intervention, allowing the system to self-manage the buffering process while upstream production continues.
Solution Approach 2:
The system uses sensors to continuously monitor object presence and position in the temporary storage zone, providing feedback to the control unit. This feedback enables automatic adjustment of retrieval operations to maintain proper sequencing, allowing continuous upstream operation without manual intervention.
3Device complexity
If simple buffer storage is used, then device complexity is low, but automatic management of sequencing from storage to downstream station cannot be achieved
Solution Approach 1:
The patent divides the temporary storage system into discrete sensor zones that detect object presence at specific locations. This segmentation allows the control unit to track individual object positions and manage retrieval sequences automatically, achieving complex automation through modular, distributed sensing elements.
Solution Approach 2:
The temporary storage system performs multiple functions: it provides buffer storage capacity, automatically tracks object positions, maintains arrival order, determines retrieval sequences, and signals removal locations. This multi-functionality achieves automatic sequencing management while keeping the physical system relatively simple through integrated sensor and control unit operations.
Data Source
Figure 1~2B
Figure 3A~4
Figure 5
AI summary
A temporary storage system (20) comprises a temporary storage mat (10), a control unit (21) and signalling means (22). The temporary storage mat (10) comprises a plurality of regularly distributed sensors. In a loading phase, the control unit (21) receives information from at least one of the sensors when an item is deposited on the temporary storage mat (10) and records a trace of the deposition of the item in association with a reference to each of the sensors activated by the deposition. In an unloading phase, the control unit (21) determines a removal sequence of the items and, for each item to be removed, identifies the referenced sensors, transmits signalling information identifying the position of the item to the signalling means (22), and receives information from at least one of the sensors when the item is removed.