question

David,

What you are seeing at 600 sec is actually the result of a slug transfer that begins at approximately 555 sec. This is when six red boxes (lets call them SB1, SB2... SB6) are released from Slug_Type1 at the same time that two additional boxes (lets call them AB1, AB2) are traveling down the same conveyor. As the last of the six boxes (SB6) is traversing on to StraightConveyor17 the first of the two additional boxes (AB1) reaches the end of the Slug_Type1 conveyor. At 561.38 sec AB1 initiates a traversal onto StraightConveyor17 when it should not because it has not been released by the MergeController. AB1 never appears to actually do or start the traversal but it does create a node in the traversals variable of StraightConveyor17. I believe that this is why you see the green boxes stopped in front of the traversal point for the red boxes at 600 sec.

I do not have an answer that will solve your model without making any changes to it. I think that this error is either a bug in the MergeController or an issue where you may not be using the MergeController 100% correctly.

I tried placing a small buffer conveyor between Slug_Type1 and StraightConveyor17 as well as between Slug_Type1 and StraightConveyor17 and this appears to have solved the problem. I don't believe that it stops the exact issue that caused your problem but it does eliminate the need for slugs released up stream to have to stop because of it. This is because the traversal is not onto StraightConveyor17 but onto the small buffer conveyor.

I attached the version of the model I edited.

I hope this helps,

Brandon

@anthony.johnson @phil.bobo