While using gap optimizing merge controller, gap maintained on release is inconsistent and there is an error message. And if gap error is ignored, I notice one of the slug lane (right most) is not being released in a consistent manner. The model behaves well when the flow item induction rate is low. I am attaching conveyor tutorial model showing this odd behavior. Any support on identifying the issue is highly appreciated.
Model:
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The process flow that controls the lane releases does not take into account items that are added to a slug after it has been released. This occurs if the conveyor is completely full with one or more additional items pending in the source. (See pictures below)
To circumvent this, you could set a small gap for items entering the conveyor so they are not added to already releasing slugs.
Or set a maximum count for slugs so they can't extend to the end of the conveyor.
Hi @Felix Möhlmann . Thanks for your response and solution. The reasoning about items added to slug after releasing makes sense. Unfortunately the solution does not work in my actual model. I tried entry length + distance and max item count. Is the issue any different in this model? Model attached : Gap_Optimizing_Merge_Example_II.fsm
In this case the gapping at the photo eye causes the flow on the conveyor to back up and delays the items from clearing the merging decision point. Because of this, the calculated clearing time is wrong and subsequent slugs are released too early.
To fix this you can adjust the process flow by adding the gaps that will be created to the "lastItemOffsetTime" calculation. This way, the back up is taken into account for the needed gap between releases.
(The rank of the last item is synonymous with the number of items in the slug. Multiplied by the gap introduced by the photo eye, this adds the total extra distance of the added gaps.)
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