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Abstract

A continuous processing system for performing production operations on a plurality of unit products using at least two discrete processing machines including: an upstream processing machine; a downstream processing machine; an accumulator for transferring unit products between the upstream machine and the downstream machine and for accumulating unit products in tightly packed continuously touching relationship in a variable length area starting at a position adjacent the downstream machine and extending toward the upstream machine, the number of unit products in the tightly packed continuously touching relationship defining a continuous-fill-accumulation; a count-in sensor for sensing each unit product entering the accumulator; a count-out sensor for sensing each unit product exiting from the accumulator; a computer software accumulator model for operating on data derived from the sensor signals and from physical characteristics of the accumulator for continuously predicting the continuous-fill-accmulation; and machine speed control apparatus for continuously variably controlling the speed of the upstream machine and/or the downstream machine based on the predicted continuous-fill-accumulation.

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First Claim