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 (12); a downstream processing machine (22); an accumulator (32) for transferring unit products (11) between the upstream machine and downstream machine and for accumulating unit products in tightly packed continuously touching relationship (62) in a variable length area starting at a position (36) adjacent the downstream machine and extending toward (34) the upstream machine, the number of unit products in the tightly packed continuously touching relationship defining a continuous-fill-accumulation; account-in center (52) for sensing each unit product entering the accumulator; account-out center (54) for sensing each unit product exiting from the accumulator; a computer software accumulator model (200) for operating on data derived from the sensor signal and from physical characteristics of the accumulator for continuously predicting the continuous-fill-accumulation; and machine speed control apparatus (40) for continuously bearably controlling the speed of the upstream machine and/or the downstream machine based on the predicted continuous-fill-accumulation.