Breaking start up harmonics

Is when operation centers fail over and over to fall into synchronisation, the result is the line fails to start even though all machines centers are operational. Nothing is wrong, still the line fails to start due to lack of harmonics.

Each process in a packing or filling line has its own startup characteristics. They can be different in startup speeds or how they handle products while ramping up. For example, where one slowly accelerates to its desired running speed, producing products the whole time, another process starts idle and only starts processing at full speed. One needs permanent product feeding when starting, while the other handles items as they come.

Accumulation systems can help break startup harmonics by ensuring each machine can start up with its own optimal curve. The accumulator does this by collecting the products from the upstream machine, while the downstream machine is in the process of starting. This can be to let the upstream machine slowly ramp up production while the next machine is coming up to speed.

Another way the accumulator can help is by always holding a certain amount of products in its buffer. Then, if the process is stopped, its will have enough products to feed the downstream machine when startup is initiated again.

A dynamic accumulator can compensate for the different ramp-up/acceleration times of two machines as this type of accumulator can adjust its own speed on the fly. This way, products will keep the necessary spacing required by the next machine for a flawless operation.

Any mismatches in machine characteristics are quickly solved, increasing the total efficiency of the line.