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Nikhil T avatar image
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Nikhil T asked Jeff Nordgren commented

Alternate destination on conveyor full condition

This is for all the conveyors connected to the sink. I am creating different product types and diverting them down these conveyors based on label types. All that seems to work well. What I want to configure, in case of a full line condition on the conveyor, I need to check if the next paired conveyor is not full. If so, then divert to the next line, if not I want the box to recirculate.

e.g. Conveyors connected to sink 7 and 8 forms a pair- if conveyor 58 is full, check conveyor 57 and if conveyor 57 is not full-divert to conveyor 57. Same condition if conveyor 57 is full, divert to conveyor 58. If both are full-then keep recirculating.

Similar conveyor pairs are for-

  • Conveyors connected to sinks 5 and 6
  • Conveyors connected to sinks 3 and 1
  • Conveyors connected to sinks 4 and 2

Any help will be appreciated. Thank you.

FlexSim 20.1.3
flexsim 20.1.3coveyor full - alternate destination or recirc
model2.fsm (13.7 MiB)
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Jeff Nordgren avatar image Jeff Nordgren commented ·

@nikhil.t,

I'm confused about a couple of things in your model. First, in your Photo Eyes, you reference motors that do not exist in the model, so I added them (see attached model). In your PF, I renamed the Source blocks so I could see where the errors in the System Console were coming from. With all named the same "Source", it's hard to tell which block is causing the error. So, in Source1, Source2 and Source5, you make an invalid name (object) for the sources to listen to. I'm not sure how to fix those because I don't know what your intentions were.

As far as the lines becoming full, in your model, they never will become full. The reason being is that the Sink takes flowitem immediately so there will never be a backup on the conveyor leading to that Sink. So I'm not sure what your intensions are there either.

A little more information on how things are supposed to work would be helpful.

Thanks.

Nikhil-model2-JN1.fsm

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nikhil-model2-jn1.fsm (13.7 MiB)
Nikhil T avatar image Nikhil T Jeff Nordgren commented ·

Model3.fsm @jeff.nordgrenJeff, Thank you for your reply and I apologize for not sending a simplified version of what my needs are.

This new model is a simplified version of what I am looking for. Basically 4 item types are created and go down each divert. So all reds go down one lane, green boxes go down another lane, and so on.

I have put a photo eye on each lane, when the conveyor gets full, I want the case to go down straight in the sink

I have tried multiple ways of programming the ‘Block’ logic for the photo eye, but had no success so far.

An additional requirement that has come up, if there are 3 consecutive cases of the same color generated, I need to send only 2 through the respective divert and the 3 rd one will go straight in the sink.

Hope this makes sense. Let me know in case of any questions. Thank you.

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Jeff Nordgren avatar image Jeff Nordgren Nikhil T commented ·

@nikhil.t,

Could you please send the model again? I'm getting an error trying to download the one attached to your reply.

Thanks.


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Jeff Nordgren avatar image Jeff Nordgren commented ·

@nikhil.t,

Attached is your model with the changes that I've made. Take a look at the model and see if it is now doing what you are needing it to do.

I just added center port connections from DP1 to the photo eye on each of the lines. And then added code to the On Arrival trigger of DP1 to check to see if the lane is blocked (PE blocked state). If it's not blocked, the flowitem is sent to that conveyor. If it is blocked, it just continues on down the main conveyor to Sink1.

If you have any problems or questions, please don't hesitate to ask.

Thanks.

Nikhil-model3-JN1.fsm

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nikhil-model3-jn1.fsm (45.9 KiB)
Nikhil T avatar image Nikhil T Jeff Nordgren commented ·

@jeff.nordgren That works great. Thanks. Also, I had posted an additional requirement for the same model in the previous post. An additional requirement that has come up, if there are 3 consecutive cases of the same color generated, I need to send only 2 through the respective divert and the 3 rd one will go straight in the sink. This is a choke logic that is used in sortation systems. Can you help me configure this? Thank you and appreciate your help.

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Jeff Nordgren avatar image Jeff Nordgren Nikhil T commented ·

@nikhil.t,

Attached is your model with the changes that I've made to it.

I added two labels to Source1 that are used to keep track of multiple same type items. In the On Creation trigger, I create a label on each flowitem called "Choke" and initialize it to zero. Then in the Code Snippet of the OnCreation trigger is where I change the "Choke" label on the flowitem to 1 if multiple types have been created and I also color the item gray.

Then in ExitTransfer1 (end of conveyor before Sink1) is where I have code to send the items to their proper queue. The fist column of 4 queues are where Overflow items (lane blocked) are sent. If the item is a "Choke" item, then it is sent to the proper queue in column 2. I also reset it to the original color.

Take a look at the model and see if this is what you had in mind? If you have any questions or problems, please don't hesitate to ask.

Thanks.

Nikhil-model3-JN2.fsm

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Jeff Nordgren avatar image
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Jeff Nordgren answered

@nikhil.t,

Attached is your model with the changes that I made. I moved the "logic" of the choke from Source1 to DP1. Everything else should be the same. Take a look at the model and see if it is now doing what you are needing it to do. If you have any problem(s)/question(s), please let us know.

Thanks.

Nikhil-model3-JN3.fsm


nikhil-model3-jn3.fsm (49.2 KiB)
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Nikhil T avatar image Nikhil T commented ·

@jeff.nordgren . That works as I wanted to. Thank you so much. I have learnt a few things along the way. I appreciate your help.

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