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Are you dropping splitters/mergers in the middle of belts? It doesn't remove the belt piece it replaces, which causes the belts to slow down a bit because they try to fill the belt while the splitter/merger tries also.
If so, place mergers/splitters, then connect the belts. Or if you have to place the merger first, then place it and deconstruct the belts it's on and reconnect them.
I noticed it on 1.0 release trying to merge 2x 600 items belts into 1x 1200 belt but it's not possible, the merger chokes the 2 incoming belts and output is only around 1150..... if you cannot trust the numbers the game tells you, you can't build an efficient functional factory
Once you get to the MK4, 5 and 6 belts, your math will be good, your design will be good but it still might not give you that craved 100% efficiency. Because these belts (and MK2 pipes) don't always seem to deliver what FICSIT wrote on the tin.
If you reach endgame and go full alternative recipes it becomes a bit of a moot point anyway because very rarely will you ever saturate any of the belt types.
Edit:
Sorry about the earlier post. I kind of hit that post before I could finish writing.
Back to the topic. I think I encountered the problem OP said. But TBH, the product from all those factories still counts as 270 on my mk.2 belts (mostly from 9 Smelters). Even if some of the smelters did stop working, it still outputs 270 ingots and my whole supply chain can still make all the products at 100% efficiency.
There are known bugs, however. Especially with Merger and Splitter that you built ON the belt. Instead of build on anything else (including on top of each other). The output from those Merger and Splitter will be lower than expected, ex. from 600+600 down to 1100 instead of 1200. The quick way to solve this is to delete the connected belt and rebuild it. Or rebuilt the bugged Merger and Splitter entirely.
This kind of solves why some items went to the sink that should have been on the belt instead
And yes, I don't place in-line mergers and splitters directly on belts. There were some issues with that during EA, I think, not sure. So I just got into a habit of building mergers and splitters first and then attaching belts to them. Maybe there is something to that?
Pipes Mk2, on the other hand, are known to carry less than 600m³ though, more like 580m³. This is an old issue. And this still seems to be true in 1.0 as I can't keep a fully overclocked reactor full of water at 600m³ even with a full large tank buffer that was pre-filled before the reactor was turned on. The devs don't consider this a bug but a side effect of their fluid mechanics, so "working as intended".
I am telling you: Build 20 well fed quickwire constructors and make that run 100% efficient with a single MK6 output belt. Hah! One step easier, build 13 fully fed quickwire constructors and make that run 100% efficent on a MK5. These builds will most likely choke on the wire sooner than later.
This isn't really a bug in the game.
The problem isn't the belt. The problem is getting your items ON THE BELT. The room is there, in theory. But in praxis, when the engine ticks, when it is time for the merger to move the item, there might be no room. And the next engine tick, the belt has already moved so far, there is now a one item gap. So no more 1200/m, only 1199.9/m. And this adds up.
Same thing happens with the MK5 and 4 belts, just not as often.
All I am really saying is: If you want to avoid a terrible headache, do not use a belts full capacity. If your build produces 775 items per minute, instead of using a single MK5, I suggest you use two MK4. Is all I am saying. It will prevent so much headache.