Processing Line with Model Based Speed and Backlog Control and Method

A control system for a processing line, wherein the processing line includes a conveyor adapted and configured to convey a product type from upstream processing equipment upstream of the conveyor to downstream processing equipment downstream of the conveyor, the control system comprising:

• a product sensor for the conveyor, the product sensor being adapted and configured to generate signals representative of a number of the product type moving on the conveyor from the upstream processing equipment past the sensor to the downstream processing equipment;
• a conveyor speed sensor for the conveyor, the conveyor speed sensor being adapted and configured to generate signals representative of a speed of the conveyor;
• and
• a controller including a processor and memory, the controller being adapted and configured to:
• (i) process information representative of a backlog set point, the backlog set point being representative of the product to be processed on the processing line;
• (ii) store a plurality of data structures in the memory of the controller of the control system, wherein the data structures include a plurality of data items associated together as the backlog set point and the product type;
• (iii) determine a backlog measurement for the conveyor based upon the product sensor signals and the conveyor speed sensor signals;
• (iv) compare the backlog measurement to the backlog set point to determine a difference in backlog;
• and (v) generate signals for controlling the processing line based upon the difference in backlog.