CN111670447B - Method for identifying and using recycled products in a mixing cycle - Google Patents
Method for identifying and using recycled products in a mixing cycle Download PDFInfo
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- CN111670447B CN111670447B CN201980010874.6A CN201980010874A CN111670447B CN 111670447 B CN111670447 B CN 111670447B CN 201980010874 A CN201980010874 A CN 201980010874A CN 111670447 B CN111670447 B CN 111670447B
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- 238000002156 mixing Methods 0.000 title description 13
- 238000004519 manufacturing process Methods 0.000 claims abstract description 118
- 238000010074 rubber mixing Methods 0.000 claims abstract description 4
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- 239000000203 mixture Substances 0.000 claims description 34
- 230000000694 effects Effects 0.000 claims description 11
- 238000010058 rubber compounding Methods 0.000 claims description 7
- 238000013439 planning Methods 0.000 claims description 6
- 238000010276 construction Methods 0.000 claims description 5
- 238000011049 filling Methods 0.000 claims description 3
- 238000012384 transportation and delivery Methods 0.000 claims description 2
- 239000000047 product Substances 0.000 description 175
- 238000012546 transfer Methods 0.000 description 18
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- 238000001125 extrusion Methods 0.000 description 5
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Classifications
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q10/00—Administration; Management
- G06Q10/30—Administration of product recycling or disposal
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q10/00—Administration; Management
- G06Q10/08—Logistics, e.g. warehousing, loading or distribution; Inventory or stock management
- G06Q10/087—Inventory or stock management, e.g. order filling, procurement or balancing against orders
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W90/00—Enabling technologies or technologies with a potential or indirect contribution to greenhouse gas [GHG] emissions mitigation
Abstract
In the field of tire production, the present invention relates to a method of identifying and using a recycled product according to a production plan of a rubber mixing method using the identified recycled product.
Description
Technical Field
The present invention relates generally to rubber mixtures and the production of vehicle tires produced therefrom. More particularly, the present invention relates to the identification, management and re-incorporation of recovered products as initial products for use in a mixing process.
Background
In the field of tyre manufacturing, there are a number of machines for producing semifinished products. These machine-produced products consist of at least two rubber mixtures (known as "complex products") with different properties. The machine performs various processes including an extrusion process, an assembly process, and a peeling process, in which some manufactured products are notCan be used directly to manufacture tires (e.g., during dimensional changes, startup, etc.). During start-up, shut-down, dimensional changes, and other known steps, these machines typically produce products that are not used downstream (e.g., on an assembly machine). Also, in these tire building machines (for example, under the trade name VMI MAXX TM The machines) the products used by these machines cannot be used immediately on the production line. For example, dimensional tolerances have not been achieved.
Tire building involves a number of different complex products. It is desirable to use complex products during the building of the tyre, as doing so reduces the number of product laying operations that need to be performed. There is a trend towards increasing amounts of different rubber compounds for manufacturing individual tires, so that the properties of these compounds can be optimized according to the region in which they are located in the tire.
In general, complex products that are not used as such but are recycled after being treated (hereinafter referred to as "recycled products" or "validated products") are generally stored without any special consideration (e.g., on a tray with a partition). Thus, complex products of various nature and origin may be on the same tray.
The present invention relates to optimizing the use of recycled product in rubber mixtures by utilizing a separate recycled product identifier to store and re-incorporate the recycled product. Although several types of rubber mixtures are envisaged in the tyre production process, there is an opportunity to recover unused complex products for reuse downstream.
Disclosure of Invention
The present invention relates to a method of identifying and using a recycled product according to a production plan of a rubber mixing method using the identified recycled product. The method of identifying and using recycled products includes the steps of:
-generating at least one production plan to implement at least one rubber mixing method;
-identifying recycled products meeting at least one generated production plan;
-filling the container with a complex product originating from at least one manufacturing system, to obtain a container filled with the complex product;
-storing the containers filled with the complex products in a container subsystem having a storage device, identifying the containers filled with the complex products as containers filled with the recovered products and storing them with the storage device of the container subsystem;
-booking the construction of at least one tray comprising containers filled with identified recycled products satisfying at least one generated production plan;
-identifying a container filled with the identified recycled product in a container filled with the recycled product in the container subsystem;
-automatically retrieving the container identified in the previous step;
-automatically building reserved pallets according to an ongoing production schedule.
In certain embodiments, the method further comprises the steps of: the constructed pallet is stored in a pallet subsystem having a storage means, and the constructed pallet is identified as a pallet satisfying at least one generated production plan by the storage means of the pallet subsystem and stored.
In certain embodiments, the method further comprises at least one of the following steps, each step being performed prior to the step of subscribing to the build of at least one tray:
-determining a storage time for a container filled with recycled product to be stored in the container subsystem;
-verifying the availability of recycled products in the container subsystem and the availability of fresh mixtures meeting the ongoing production schedule.
In certain embodiments, the step of subscribing to the construction of at least one tray comprises: a step of booking containers in the container subsystem having the longest storage time duration.
In certain embodiments, after the step of verifying the availability of the recycled product in the container subsystem and the availability of the fresh mix that meets the ongoing production schedule, the step of re-incorporating the recycled product into the fresh mix is further included.
In certain embodiments, the step of generating at least one production plan comprises: a step of predicting the time required between the step of identifying the container filled with the recycled product in the container subsystem and the step of automatically retrieving the identified container.
In certain embodiments, the method further comprises: a step of recording the arrival date of each container in the container subsystem to obtain the time that each container has been stored in the container subsystem; and a step of recording the arrival date of each tray in the tray subsystem to obtain the time that each tray has been stored in the tray subsystem.
In certain embodiments, the method further comprises the steps of:
-identifying a pallet meeting an ongoing production plan;
-automatically retrieving the identified tray for transferring the identified tray to a downstream system of the tray subsystem.
In certain embodiments, the system downstream of the tray system comprises at least one mixer.
In certain embodiments, the method further comprises the step of performing at least one planning activity necessary to satisfy at least one generated production plan.
In certain embodiments, the step of performing at least one planning activity comprises at least one of the following steps:
-determining an estimated level of storage in the container subsystem and the tray subsystem at the end of the ongoing plan;
-determining the status of the ongoing plan;
-predicting the mixture obtained by the upcoming generated production schedule;
-determining the nature of the recycled product to be used in the upcoming generated production plan.
In certain embodiments, the identified and removed containers and trays are recorded to update the storage level of the containers in the container subsystem and the storage level of the trays in the tray subsystem.
In certain embodiments, the method further comprises: a step of emptying the container filled with the recovered product and a step of emptying the constructed pallet.
In certain embodiments, the method further comprises at least one of the following steps:
-stacking empty containers on an empty tray;
-building a tray comprising empty containers to be sent to one or more sources of complex products.
In certain embodiments, the step of identifying the container filled with the recycled product is performed by one or more RFID tags indicating the location where the container is to be removed.
Other aspects of the invention will become apparent from the detailed description that follows.
Drawings
The nature and various advantages of the present invention will become more apparent upon reading the following detailed description and studying the drawings, wherein like reference numerals refer to like parts throughout, and wherein:
FIG. 1 depicts a schematic diagram of a system of the present invention that performs a method of identifying and utilizing a recycled product according to at least one production plan of a rubber compounding process utilizing the identified recycled product.
Fig. 2 depicts a front perspective view of a container for receiving a corresponding recycled product, and fig. 3 depicts a bottom perspective view of the container of fig. 2.
Fig. 4 depicts a partial perspective view of the container subsystem and tray transfer area.
Fig. 5 and 6 depict partial perspective views of the container subsystem of fig. 4 with a stacking device.
Fig. 7 depicts steps of the method of the present invention performed by the system of fig. 1.
Fig. 8 depicts a simulated density plot of a process according to the prior art.
Fig. 9 depicts a simulated density plot of a process according to the present invention.
Detailed Description
Unused complex products (or "complex products") are identified as being of various types and grades, each type and grade specifying a particular complex product whose attributes are known. Each property of the complex product has specific properties that can be controlled to obtain a recycled product. To ensure that the recycled product has controlled properties, complex products of various nature will be used later in the rubber mixture used in the mixing process. In the remainder of this description, various types, grades, batches of complex products will be designated by the term "nature" of complex products.
The present invention relates to systems and methods for generating production plans for an ongoing or likely phase to ensure execution of the planned future phase. "stage" means the duration of operation of a mixer or mixing apparatus using the same recipe. By utilizing the disclosed invention, it is known that products will deliver with consistent and stable characteristics. The product obtained will be used as a starting material in a mixing line used in the tyre manufacturing cycle.
Referring now to the drawings, in which like numerals represent like elements, FIG. 1 depicts one example of a system 100, the system 100 implementing a method of identifying and using recycled product according to at least one production plan using a rubber compounding method of identified recycled product. The system 100 allows for the identification, management and re-incorporation of unused complex products that are recycled products that can be used in a tire manufacturing cycle.
Future production plans are generated as expected for future phases of the plan in which a specified number of recycled products are required for a specified period of time. The specified time period depends on the completion of the production plan in progress and also on the upcoming production plan.
To meet the production plan, the system of the present invention generates one or more production plans. Each production plan contains one or more phases. For example, in some embodiments, current requirements of phases are met and execution of an ongoing phase is indicated, and then individual production plans are generated that will meet the requirements of one or more subsequent phases according to a specified schedule for executing the phases, so that possible phases can be identified.
The system of the present invention determines the likelihood (feasility) of a mixture associated with the use of a production plan that implements an ongoing phase. "possibility of a mixture" means the ability to meet the technical standards of each material used in the mixture. "possibility of mixture" also means the ability to obtain technical end results of the mixture (i.e. the recycled product used retains its own technical characteristics while at the same time contributing to the desired characteristics of the mixture into which the recycled product used is incorporated). In some embodiments, the production plans may be categorized using a self-learning approach where some production plans are preferable over others. The system may then sort the different production plans based on the likelihood of the relevant mixture.
The system 100 is located downstream of a system or machine for manufacturing complex products (e.g., a system or machine that performs an extrusion process, an assembly process, a stripping process, or some other process in which some manufactured products cannot be used directly to shape tires). It is envisioned that the system 100 is capable of producing rubber compounds having varying properties, as determined by the performance requirements of the resulting tire. Thus, the system 100 utilizes equipment that enables production yields by managing the entry, identification, transfer, storage, and exit of groups of recycled products, thereby enabling the creation of processes for recycling unused complex products. Thus, in a given mixing cycle, recycled products having the desired attributes in an ongoing manufacturing cycle can be easily located by the system 100.
The complex product is identified as a recycled product that has been identified for use in at least one rubber compounding production program generated by the method of the present invention. The complex products are stored in corresponding containers. The container serves as a removable storage device capable of identifying, storing and transporting complex products that become identified recycled products. Each complex product is characterized by a unique identification (e.g., using a number, code, RFID tag, hypertext link, or equivalent means) that allows the extruder or mixer (or equivalent device) to learn of the complex product in the process of being manufactured according to a predetermined recipe.
To control these particular attributes, each recycled product is placed in a container, and each container contains only one recycled product at a time. Referring also to fig. 2 and 3, the container (or "tub") 10 has a pair of long sides 10a, a pair of short sides 10b, and a bottom 10c that together form a space to receive a particular recycled product for reuse. Each container 10 includes a pair of legs 12 extending from a bottom 10c so that the containers can be stacked on a tray or on itself. It should be appreciated that corresponding structures or equivalent structures (e.g., one or more tabs) may be employed along at least a portion of the top perimeter of the container 10. All references to "container" or "containers" refer to the container 10 described. A full container is a container filled with recycled product for reuse that is stored on a corresponding tray. The fully loaded containers are stored on trays according to the nature of the recovered product, as required by the stage in progress.
In one embodiment of the container 10, the inner surface 10a' of each long side 10a is inclined (e.g., up to an angle of 5 °) with respect to the bottom 10c to facilitate release of the recycled product from the fully loaded container. An optional non-stick coating may be applied to the inner surface 10a' to facilitate removal of the complex product from the corresponding container.
To control these particular attributes, each recycled product is placed in a corresponding container 10 designated to receive it. The container 10 and its contents (i.e., recycled products having known properties) are identified, learned, and managed by identification means integrated into the container 10. Thus, the system 100 is able to transfer and store each container 10 according to the identity of each container 10. The identification of the container 10 is performed manually (e.g., using at least one visual and/or tactile identifier) or automatically (e.g., using a number, code, RFID identification, hypertext link, or equivalent means). The present invention is described with respect to RFID tags integrated into containers 10, but it should be understood that other equivalent identification means may be used.
The identification of the recycled product is closely related to the identification of the container such that the management system 100 automatically identifies the nature of the recycled product within the container by identifying the particular container. The filling of the container 10 takes place in a manner that its volume is more or less constant and weight is predictable.
Referring again to fig. 2 and 3, in one embodiment of the container 10, the bottom 10c of the container may include several optional apertures 10c' aligned along the length of the bottom. The aperture 10c' is capable of receiving a corresponding stripper device (not shown) having telescoping fingers aligned with the aperture of the container. The stripping apparatus and container 10 construct a container-stripping system downstream of system 100.
Referring again to fig. 2 and 3, each short side 10b of the container 10 includes identification means cooperating with automated handling means (e.g. grippers). The identification means comprises an RFID tag 10e located on the container 10, the RFID tag 10e enabling an RFID reader located on the automated handling device to identify the container.
In one embodiment, a square recess 10f and a triangular recess 10g are also built into each short side 10b of the container 10. The automated handling device may include corresponding lugs such that the recesses and lugs enable the container 10 to be properly positioned by realigning the lugs in the corresponding recesses. Of course, the geometry of the recesses and projections is not limited to square and triangular.
Referring again to fig. 1 and 4, 5, and 6, the system 100 includes a container storage subsystem (or "container subsystem") 110 in which unused complex products (or "complex products") originating from at least one manufacturing system are stored in respective containers 10. In one embodiment, the container subsystem 110 may include a storage device selected from known automated devices (e.g., one or more automated systems and equivalents thereof) or known manual devices. As described herein, the present invention relates to a storage device 120 that is an automated storage system (e.g., an "automated warehouse system" system or "ASRS").
When stored in the container subsystem 110, these complex products are considered to be usable (or "recycled") for at least one tire manufacturing stage. The container 10 filled with the complex product is identified and stored in the storage device 120. When complex products arrive at the storage, the system 100 makes these recovered products available to meet the production schedule.
Referring again to fig. 4, 5 and 6, the system 100 may also include a tray storage subsystem (or "tray subsystem") 200 in which trays of containers of recycled product from the container subsystem 110 are stored until a phase from the generated production plan is initiated. The tray subsystem 200 may also include storage devices (not shown) selected from known automated devices (e.g., one or more automated systems and equivalents thereof) or known manual devices. As described herein, the present invention relates to a storage device for a tray subsystem 200 that is an automated storage system (e.g., "ASRS").
In one embodiment, each tray used in tray subsystem 200 is capable of storing several full or empty containers (e.g., tray P to tray subsystem 200 with full containers 10 and tray P' from tray subsystem 200 with empty containers 10, see fig. 1). When the trays are stored in the tray subsystem 200, these trays are considered satisfactory for feeding the mixing mill with recycled product stored in the container 10 (which is stacked on the tray). Thus, with recycled products already associated with the trays, it is possible to guarantee a mixture recipe defined by the stage in progress. This phase is programmed to meet at least one production plan for performing the rubber compounding method.
The tray subsystem 200 enables a method of managing trays of containers of recycled products to be performed in which the availability of the trays is also optimized. The tray is complete or incomplete depending on the recipe corresponding to the stage being performed. In one embodiment, the tray 210 used in the system 100 is capable of storing and carrying several (full or empty) containers 10 (see fig. 1). In one embodiment, the tray 220 used in the system 100 is capable of storing and carrying one (full or empty) container 10 (see again fig. 1). Regardless of the number of containers carried by the associated tray, the container 10 is designed to be stored in the storage device 120.
The identification of the tray may be performed manually (e.g., using at least one visual, audible, and/or tactile identifier) or automatically (e.g., using a number, code, RFID identification, hypertext link, or equivalent means) by known identification means such that the identification of the tray may be closely related to the identification of the container 10 stored on the tray (and thus the identification of the recycled product). The trays from the tray subsystem 200 with the containers filled with recycled product may be fed to a mixer or some other system.
In one embodiment, the tray may include one or more placement indicators (not shown) covering at least a portion of the surface of the tray. Placement indicators may be used to ensure proper positioning of the containers on the tray (as described above). In certain embodiments, the placement indicator may work with a corresponding sensor (not shown) on the container that detects the placement indicator for automatic placement of the container on the tray. In certain embodiments, the placement indicators need not be integrated into the tray (e.g., they may be provided on a removable mat that may be placed on the tray if desired). The sensor on the container may use a placement indicator for guiding and placement of the container on the tray (either directly on the tray surface or on a movable mat).
Referring also to fig. 4, 5 and 6, and through the illustrative examples of using the present invention disclosed in connection with the method of using recycled products, two subsystems are serviced by a transfer area 300 that they share. Pallets with (full or empty) containers 10 are placed in the area 300 either manually (e.g., using a known forklift 500) or automatically and removed from the area 300. In transfer region 300, movable gripper 400 is capable of placing and retrieving containers 10 relative to container subsystem 110 and also relative to tray subsystem 200. The use of shared transfer areas eliminates redundancy and also helps to reduce costs by effectively utilizing recycled products.
To facilitate placement and removal of containers relative to the container subsystem 110, the transfer region 300 receives trays filled with containers filled with complex products from at least one manufacturing system. Fig. 1, which shows a complex product from three different processes I, II, III, is given by way of example. It should be appreciated that system 100 (and in particular container subsystem 110) may accommodate complex products from one, two, or several systems and/or machines that produce portions of the product that cannot be directly utilized.
Depending on the nature of the complex product, a full container may be dispensed to a location in the container subsystem 110. For example, it should be appreciated that the containers may be placed in sections that are allocated according to the needs of an ongoing phase and/or according to the needs of an upcoming phase. The zones for recycling the product can be established from products of the same nature or from combinations of products intended to be included in a given rubber mixture. In either case, the containers may be placed on respective trays for transfer to the tray subsystem 200. Thus, the number and composition of trays can be arbitrarily selected and changed according to the stage of the pre-establishment.
Also in the transfer area 300, the full containers remain armed in the transfer area until the gripper 400 removes the full containers to place them in place in the storage device 120. The storage device 120 has a machine (or equivalent) that is capable of selectively placing and selectively removing at least one container 10 relative to the container subsystem 110. The selective placement and removal is performed based on predictions of the recovered product that are intended for a generated production plan containing one or more given phases. A machine selected from the commercially available machines is depicted as a stacking device 150 having a shuttle 152, the shuttle 152 running on a track 154 within the storage device 120. It should be understood that stacking device 150 may be replaced with equivalent devices known to those skilled in the art.
The stacking device 150 places and removes containers according to at least one production plan generated to meet an ongoing production plan and an upcoming production plan. In the example of fig. 6, the storage device 120 of the container subsystem 110 may include a dedicated section 120A for storing recycled products of a specified nature. Section 120A includes a plurality of locations, each of which is assigned to a single container 10. The manufacturing system upstream of the container subsystem 110 indicates that it requires an empty container 10V that is dispensed to be filled with recycled product having the same particular properties. The stacking device 150 removes the empty containers 10V from the section 120A by the shuttle 152 to transfer them to the transfer area 300. In the transfer zone, empty containers 10V may be stacked on trays of similar empty containers (i.e., empty containers associated with trays and also associated with recycled products of the same nature). Trays filled with empty containers may be sent to an upstream manufacturing system. At the same time, the full container 10P from section 120A is still available to the tray subsystem 200. The system 100 may update the empty containers 10V and the full containers 10P present, thereby also updating the ongoing production plan.
Referring again to fig. 1 and 7, one embodiment of the present invention for performing a method of satisfying a production plan will now be described.
In one embodiment of a method of satisfying a production schedule, the method includes the step of generating at least one production schedule to perform at least one rubber compounding process. In some of these embodiments, several production plans may be generated based on selections made by the user.
A recycled product that will meet the generated production plan is identified. The system 100 can identify the container based on the minimum time allotted to achieve mixing, taking into account the time required to combine the recycled products (which are required to make the selected mixture). Further, the system 100 can identify the container based on criteria related to the composition of the trays of recycled product to be supplied at a determined time in the future. The units of time used may be seconds, minutes, hours, days, weeks and months. The units of time used may be equivalent units of these units of time, for example, the remaining time until the system 100 can create a production schedule for mixing rubber for a number of products based on the selected rubber.
Referring again to fig. 1 and 7, the container 10 arrives at the system 100 either on the tray 210 or on the tray 220. Specifically, the container 10 reaches a container subsystem 110 filled with complex products derived from various processes.
The method includes the step of identifying recycled products that meet at least one of the generated production plans. Each container 10 is identified by its complex product. As each complex product reaches the container subsystem 110, the complex product has been deemed to be usable in the mixing process (i.e., the complex product has been deemed to be usable as an identified recycled product that meets the ongoing production schedule). Thus, as each complex product reaches subsystem 110, it becomes a recycled product. The system 100 may record the date of arrival (date, time, etc.) of each container 10 to manage the time each container resides in the container subsystem 110.
The containers 10 are stored in the storage device 120 using known equipment (e.g., the stacking device 150). The storage device 120 may include defined sections for different recycled products (as described above). The containers and/or their locations in the storage device 120 may be visually or otherwise identified by one or more known means (e.g., one or more RFID tags) to indicate the sections from which the containers are to be removed.
The method may comprise the step of performing at least one planning activity necessary to achieve an ongoing production plan and/or at least one upcoming production plan. The planning activity may include one or more steps including at least a portion of the following:
determining the projected storage levels of the container subsystem 110 and the tray subsystem 200 at the end of the ongoing production schedule;
-determining the status of an ongoing production plan;
-predicting the mixture to be obtained by the upcoming production schedule;
determining the nature of the recycled product to be used in the upcoming production plan (including determining the length of time that the recycled product will be stored prior to its use).
These determinations may be affected based on one or more factors including, but not limited to: completion of one or more production plans (and final storage of the recycled product remaining in the system 100), generation of future production plans, current storage levels of container and tray subsystems, and flow of production activities.
The method comprises the following steps: construction of at least one (complete or incomplete) pallet with containers filled with identified recycled products meeting the ongoing production schedule is ordered. In this step, the tray subsystem 200 sends an order to the container subsystem 110 to remove containers 10 from the storage 120 according to the ongoing production plan.
The method further includes the step of automatically retrieving containers filled with the identified recycled product that meets the ongoing production schedule. In one embodiment, to ensure that recycled products that have not exceeded the expiration date are used, an order to build the tray is performed after the length of time the container is stored is determined. For this embodiment, the order is placed to remove containers that have been stored for the longest time, which are identified as meeting the ongoing production schedule. These identified containers are removed before the containers have been stored for a short period of time.
In one embodiment, an order to build a tray is performed in order to obtain a mixture of recycled product and at least one fresh (fresh) mixture. "fresh mix" means a mix composed of virgin starting materials without added recycled product. The method enables the re-incorporation of the withdrawn recycled product into the fresh mixture after checking the availability of the "recycled" type of product and the "fresh" type of mixture. The method is particularly capable of reducing any imbalance between the production of complex products and the ability to recycle such complex products.
In generating the production schedule, an actual delivery date for the reserved recovery product may be determined for the production schedule. If the recycled product stored in the container subsystem 110 does not meet the first production schedule, then the next production schedule that will use the available recycled product is prioritized. Thus, each current parameter in the container subsystem 110 and the inventory provided in the container subsystem 110 are dynamically monitored to dynamically rank the production plans so that there is always at least one production plan that can be executed.
The method includes the step of automatically building a reserved pallet according to an ongoing production schedule. Containers 10 removed from the storage device 120 are sent to the transfer area 300 to build a tray. In fig. 1 and 4, up to 9 containers per tray are used to construct the tray. It should be understood that the number of containers on the tray is limited only by the capacity of the tray. It should also be appreciated that the tray may be "complete" (i.e., the tray carries the largest possible number of containers) or "incomplete" (i.e., the tray carries less than the largest possible number of containers). In embodiments where a mixture of "recycled" type products and "fresh" type products are used to meet an ongoing production schedule, the containers of both types of products may be placed on the same tray. All of the constructed trays are sent from the transfer area 300 to the tray subsystem 200 for storage (see tray P of fig. 1).
The method includes the step of storing the constructed pallet in the pallet subsystem 200. For example, the storage of the tray subsystem 200 may include a section assigned to a tray constructed to meet at least one generated production plan (e.g., by the nature of the containers on the tray, by the planned mixing time, etc.). The system 100 may record the arrival date of each tray to manage the time each tray is stored in the tray subsystem 200.
In one embodiment, the method includes the step of identifying a tray that will meet an ongoing production plan. These trays are identified along with the associated containers (and thus the associated recycled products). It is envisioned that system 100 manages a production schedule to be able to produce rubber compounds having varying properties, as determined by the performance requirements of the produced tire. Thus, during a given production schedule, trays of recycled products having desired attributes can be easily found by the tray subsystem 200.
In one embodiment, the method comprises the steps of: the reservation automatically retrieves an identified tray having a container filled with an identified recycled product that meets the ongoing production schedule. In this step, the tray subsystem 200 sends an order to the container subsystem 110 to remove the containers 10 from the storage device according to the recipe of the created mixture at the end of the ongoing production plan. In one embodiment, to ensure that the recycled product that has not exceeded the expiration date is used, the order is executed after the tray storage time is determined. For this embodiment, the tray that has been stored for the longest time and the tray having the property of the recycled product that meets the production schedule are taken out prior to the tray that was most recently placed in the storage.
In one embodiment, the method comprises the steps of: the reserved trays are removed to transfer them to a mixer or another system downstream of the tray subsystem 200. Thus, the order is performed tray by tray, rather than container by container. Thus, the method ensures that the removed trays and associated recycled products will meet the ongoing production schedule.
The system 100 may record the removal of the reserved trays and recycled products. The system 100 is capable of updating the storage of containers in the subsystem 110 and the storage of trays in the tray subsystem 200. If desired, the system 100 may order containers and/or trays filled with recycled products to meet at least one upcoming production schedule.
In one embodiment of the method, the method comprises the step of emptying the tray and the container. In this embodiment, the trays may be emptied by known handling means (e.g., grippers) that remove each container 10 from the associated tray. In this embodiment, the emptying of the containers may be performed by a system (not shown) for managing trays of containers of recycled products located downstream of the system 100. The management system is used for supplying recycled products to the mixer. In one embodiment, the recovered product is weighed and then introduced into a mixer.
After the trays and containers have been emptied, the empty containers are stacked on an empty tray (see tray P' of fig. 1). The system 100 may return empty containers to the transfer area 300 (see fig. 1). Through the transfer area 300, the trays may be filled with empty containers 10 so that they may be sent to one or more sources of complex products (see fig. 1). If desired, empty containers 10 may be placed in the storage device 120 to meet upcoming production plans. Therefore, by reducing the stroke required to reload the tray, efficiency can be improved.
In certain embodiments, the recovery product that can be used for several generated production plans cannot be used to meet the upcoming production plan until a threshold level of recovery product in the container subsystem 110 is reached. For example, for a recycled product (or a pallet of related recycled products) that is often used in large quantities in a frequently performed production plan, the recycled product cannot be used in small quantities in a production plan that is performed relatively infrequently until there is sufficient inventory of the recycled product to satisfy at least one execution of the most frequently performed production plan. The purpose of this is to give production priority based on the demand for recycled product, the remaining amount of recycled product, the scarcity of recycled product, and related factors.
Example
For example, by verifying the simulation of the change in viscosity (Mooney) change, the control method (i.e., the "first in first out" or "FIFO" method) is compared with the method of the present invention, and the following comparison result is obtained. The mooney index (also referred to as viscosity index or plasticity index) characterizes solid substances in a known manner. An oscillating consistometer as described in standard ASTM D1646 (1999) is used. The plasticity measurement is performed according to the following principle: samples that were analyzed in the green state (i.e., prior to curing) were molded (shaped) in a cylindrical chamber heated to a given temperature (e.g., 35 ℃ or 100 ℃). After preheating for 1 minute, the rotor was rotated at 2 revolutions per minute (rpm) within the test specimen, and the working torque for maintaining this movement was measured during 4 minutes of rotation. The mooney viscosity (ML 1+4) is expressed in "mooney units" (MU, 1 mu=0.83 Nm) and corresponds to the value obtained at the end of 4 minutes.
In the analog FIFO method, containers are allocated in stages in the order in which the containers are presented in the simulation. In the method of the invention, the aim is to minimize the variation of the average value of the properties under investigation by selecting one or more receptacles per tray. It should be understood that any mixing properties (including, but not limited to, viscosity or "mooney index", fluidity, and scorch time) may be studied.
In this example, the unused complex product is generated by two different manufacturing operations: tire building operations and extrusion operations. Each complex product was identified and a production plan was generated that lasted 28 days. The complex product is placed in an associated container.
Tire building operations produce containers of complex products (about 1 or 2 containers per hour) at a known frequency and with a known distribution. However, during the conversion of the nature of the complex product, the squeezing operation generates 3 or 4 containers. The average fluidity values of the trays are calculated and compared to find the difference between one tray and another.
For both simulations, two phases were performed. The first stage is indicated by the numeral "1" in the following table and fig. 8 and 9. The second stage is indicated by the following table and the numeral "2" in fig. 8 and 9. The results are summarized in the following table:
table 1: result induction
Reminding attention effect quantity: the effector is a tool for solving the differences between groups without being affected by the sample size. A significant effect is indicated by an effector value of greater than 0.3 (cf. Cohen 1988).
Fig. 8 and 9 show that the mooney variation of the FIFO method is larger compared to the method of the invention. Although the average value of the trays does not vary between the two methods, the variation in the Mooney properties from one tray to another, without the method of the present invention, has a significant impact on the industrial operation in which the recycled product is used. For example, the process of the present invention smoothes the variation between recovered products used in rubber compounding. The method of the present invention therefore limits the need for new extrusion dies to accommodate the changes required, thereby ensuring extrusion consistency for complex products.
One cycle of the method may be performed under control of one or more PLCs and may include pre-programming of management information. For example, the total number of containers required (when provided with a certain number of properties), the total number of empty trays available, the number of trays on standby, the determined storage time of the containers or trays, etc. The PLC controls the list of reserved containers, reserved trays, and the list of containers associated with each tray.
The PLC may be configured to arrange containers in the container subsystem 110 and trays in the tray subsystem 200. The PLC can identify the arranged containers so that a particular container can be found and retrieved at any time. Groups of containers 10 are created and placed in respective sections such that the average of the desired attributes falls within a predefined tolerance range (referred to as "chunking"). The PLC can arrange the containers so that the identified containers can be found and retrieved at any time, thereby constructing a pallet. Thus, the system allows for the conversion of unused complex products to recycled products. For example, the space required for yield prediction and storage of trays can be improved.
The system 100 may be part of a tire production apparatus. The system 100 may be part of several identical systems supplied to the same device. The same system may be placed in other devices, with the containers of one device stored in the system of another device to meet their production requirements (e.g., they may be located in devices that are geographically remote from each other). In this case, the steps of the method may be performed in different devices. For example, the container subsystem 110 may receive containers filled with complex products from geographically remote devices. Further, the container subsystem 110 of the first device may supply containers filled with recycled products to build trays ordered by one or more of the tray subsystems 200 in one or more geographically remote devices. The system thus provides a solution that is adaptive according to the level of production activity.
The terms "at least one" and "one or more" are used interchangeably. The ranges given between "a and b" include values of "a" and "b".
Although particular embodiments of the disclosed apparatus have been shown and described, it should be understood that various changes, additions and modifications can be made without departing from the spirit or scope of the present invention. Accordingly, no limitation should be imposed on the scope of the invention as described, except as specified in the appended claims.
Claims (15)
1. A method of identifying and using a recycled product according to a production plan of a rubber mixing method using the identified recycled product, the method comprising the steps of:
generating at least one production plan to effect at least one rubber compounding process;
identifying a recycled product that meets at least one of the generated production plans;
filling the container (10) with a complex product originating from at least one manufacturing system, to obtain a container filled with the complex product;
storing the containers filled with the complex products in a container subsystem (110) with a storage device (120), and identifying the containers filled with the complex products as containers filled with the recovered products and storing the containers by utilizing the storage device (120) of the container subsystem (110);
subscribing to the construction of at least one tray comprising containers filled with identified recycled products satisfying at least one generated production plan;
identifying a container filled with the identified recycled product among the containers filled with the recycled product in the container subsystem (110);
automatically taking out the container identified in the previous step;
the reserved pallets are automatically built according to the ongoing production schedule.
2. The method of claim 1, further comprising the step of: the constructed trays are stored in a tray subsystem (200), the tray subsystem (200) having storage means, the constructed trays being identified as trays satisfying at least one generated production plan by the storage means of the tray subsystem (200) and stored.
3. The method of claim 1 or 2, further comprising at least one of the following steps, each step being performed before the step of subscribing to the build of at least one tray:
determining a storage time for a container filled with the recycled product to be stored in the container subsystem (110);
the availability of recycled product in the container subsystem (110) and the availability of fresh mix meeting the ongoing production schedule are verified.
4. A method according to claim 3, wherein the step of subscribing to the construction of at least one tray comprises: a step of booking containers in the container subsystem (110) having the longest duration of storage time.
5. A method according to claim 3, further comprising the step of re-incorporating the recycled product into the fresh mixture after the step of verifying the availability of the recycled product in the container subsystem (110) and the availability of the fresh mixture to meet an ongoing production schedule.
6. A method according to claim 3, wherein the step of generating at least one production plan comprises: a step of predicting a time required between the step of identifying a container filled with the recycled product in the container subsystem (110) and the step of automatically retrieving the identified container.
7. The method as recited in claim 2, further comprising: a step of recording the arrival date of each container in the container subsystem (110) to obtain the time that each container has been stored in the container subsystem (110); and a step of recording the arrival date of each tray in the tray subsystem (200) to obtain the time that each tray has been stored in the tray subsystem.
8. The method of claim 2, further comprising the step of:
identifying a tray that meets an ongoing production plan;
the identified trays are automatically retrieved for delivery to a downstream system of the tray subsystem (200).
9. The method of claim 8, wherein a system downstream of the tray subsystem comprises at least one mixer.
10. The method of claim 2, further comprising the step of performing at least one planning activity necessary to satisfy at least one generated production plan.
11. The method of claim 10, wherein the step of performing at least one planning activity comprises at least one of:
determining an estimated level of storage in the container subsystem (110) and the tray subsystem (200) at the end of the ongoing plan;
determining a status of an ongoing plan;
predicting a mixture obtained from an upcoming generated production schedule;
the nature of the recycled product to be used in the upcoming production plan is determined.
12. The method of claim 11, wherein the identified and retrieved containers and trays are recorded to update the storage level of the containers in the container subsystem (110) and the storage level of the trays in the tray subsystem (200).
13. The method as recited in claim 1, further comprising: a step of emptying the container filled with the recovered product and a step of emptying the constructed pallet.
14. The method of claim 13, further comprising at least one of:
stacking the empty containers on an empty tray;
a tray is constructed that includes empty containers that are to be sent to one or more sources of complex products.
15. The method of claim 1, wherein the step of identifying a container filled with recycled product is performed by one or more RFID tags indicating a location from which the container is to be removed.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| FR1851018 | 2018-02-07 | ||
| FR1851018 | 2018-02-07 | ||
| PCT/EP2019/051980 WO2019154657A1 (en) | 2018-02-07 | 2019-01-28 | Method for identifying and for using recovered products in a mixing cycle |
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| Publication Number | Publication Date |
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| CN111670447A CN111670447A (en) | 2020-09-15 |
| CN111670447B true CN111670447B (en) | 2023-12-22 |
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| CN201980010874.6A Active CN111670447B (en) | 2018-02-07 | 2019-01-28 | Method for identifying and using recycled products in a mixing cycle |
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| EP (1) | EP3750117A1 (en) |
| CN (1) | CN111670447B (en) |
| MX (1) | MX2020008102A (en) |
| WO (1) | WO2019154657A1 (en) |
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- 2019-01-28 WO PCT/EP2019/051980 patent/WO2019154657A1/en unknown
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| US7650297B1 (en) * | 2003-12-04 | 2010-01-19 | Honda Motor Co., Ltd. | System and method for managing returnable containers |
| JP2005208772A (en) * | 2004-01-20 | 2005-08-04 | Aisin Seiki Co Ltd | Returnable container delivery management method and device equipped with production progress management function |
| WO2008096016A1 (en) * | 2007-02-09 | 2008-08-14 | Nv Engineering Systems | Configurable system, method and associated software for managing the manufacturing and processing of high valued goods in high volume |
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Also Published As
| Publication number | Publication date |
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| EP3750117A1 (en) | 2020-12-16 |
| MX2020008102A (en) | 2020-09-25 |
| WO2019154657A1 (en) | 2019-08-15 |
| CN111670447A (en) | 2020-09-15 |
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