Transfer Line Pitch Control for Boxing Buffer Saturation
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Solution Overview
Problem
Existing boxing systems face inefficiencies due to buffer saturation during temporary stops or slowdowns of the boxing machine, leading to production line inefficiencies as the production machine must slow down to empty the buffer, resulting in lost productivity.
Innovation Solution
A system and method that dynamically varies the pitch between products on the transfer line to create empty spaces, allowing periodic emptying of the buffer without production machine slowdowns by using conveyors with variable speeds and manipulators to place products from the buffer into these spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the boxing machine operates at high speed, then productivity is improved, but the buffer reaches saturation state causing production machine to stop
Solution Approach 1:
The system dynamically adjusts the speed of the transfer line conveyor based on buffer saturation level. When the buffer approaches saturation, the transfer line speed is reduced to allow buffer emptying, preventing production stops. This dynamic speed adjustment resolves the contradiction between maintaining high productivity and ensuring continuous operation.
Solution Approach 2:
The system implements feedback control by monitoring the buffer saturation state and using this information to adjust the transfer line speed. The control unit receives information about buffer saturation and automatically modifies conveyor speed to prevent buffer overflow, thereby maintaining both high productivity and continuous operation.
2Reliability
If the production machine slows down to empty the buffer, then buffer saturation is prevented, but system efficiency is reduced
Solution Approach 1:
Instead of permanently slowing down the production machine, the system dynamically adjusts only the transfer line speed when buffer saturation is detected. This allows the production machine to maintain high speed while the transfer line temporarily slows to empty the buffer, preserving overall system efficiency while managing buffer levels.
Solution Approach 2:
The system separates the control of the production machine from the transfer line. The production machine operates independently at high speed, while the transfer line speed is independently controlled based on buffer status. This segmentation allows buffer management without compromising production machine efficiency.
3Ease of operation
If the transfer line maintains constant speed, then operation simplicity is maintained, but buffer saturation cannot be prevented during boxing machine stops
Solution Approach 1:
The transfer line transitions from constant speed operation to dynamic speed adjustment based on real-time buffer saturation monitoring. The control unit automatically modifies transfer line speed in response to buffer conditions, preventing saturation while maintaining operational simplicity through automated control.
Solution Approach 2:
The system implements feedback control where the buffer saturation state is continuously monitored and fed back to the control unit, which automatically adjusts transfer line speed. This feedback mechanism prevents buffer saturation while keeping the operation simple through automated response to buffer conditions.
Data Source
AI summary
A system for boxing products, including a transfer line configured to transfer products from a product output section of a production machine to a product input section of a boxing machine, and a device for varying a pitch between products on the transfer line so as to form empty spaces having respective lengths in the transport direction equal to or greater than a length of said products.