METHOD FOR PREVENTIAL MAINTENANCE OF AN AUTOMATED CONVEYOR SYSTEM AND CORRESPONDING CONVEYOR SYSTEM

Description

[0001] The invention relates to a method for monitoring the function of an automated conveyor system having at least one conveyor line for maintenance of the conveyor system, wherein conveyor devices comprised by the conveyor line are equipped with sensors and actuators which are used for controlling and / or regulating the movement of the conveyor devices, and wherein the sensors and actuators of the conveyor devices are coordinated via one or more control devices.

[0002] Furthermore, the invention relates to a corresponding automated conveyor system.

[0003] Processes and systems of the type in question from the field of intralogistics have been known in practice for years. Intralogistics aims at organizing, controlling, implementing, and optimizing the internal flow of materials, information, and goods handling in industry, commerce, and public institutions. Enterprise Resource Planning (ERP) systems are often used in intralogistics for the fundamental, overarching planning and control of a company.

[0004] In addition to managing personnel and capital, ERP systems can also manage material requirements planning and thus the necessary storage and retrieval processes for the intralogistics system. The ERP system transmits this information to a warehouse management system (WMS), which stores the storage location for a specific item. Using this information, the material flow controller (MFC), which is subordinate to the WMS, can coordinate the various machines or conveyor systems in a warehouse in such a way that a desired item is transported to a desired location at a desired time.

[0005] The MFC controls data and information flows in an automated intralogistics / conveyor system between the existing conveyor systems and issues specific "control orders" at the "right" time and in the "right" sequence to a central programmable logic controller (PLC) that is assigned to individual machines serving as conveyor systems in the automated conveyor system. These machines can be, for example, conveyor systems on a conveyor line or a storage and retrieval machine (SRM).

[0006] The central PLC then coordinates the individual sensors and actuators in a machine, thus executing a "control task." The central PLC ultimately transforms the specification, for example, that a storage and retrieval machine should retrieve a specific crate at position "xy," into an actual coordinated movement. This movement is ultimately executed by motors (often electric motors in intralogistics), which are usually controlled via a servo drive or frequency converter and can be supplied with power directly. The servo drive or frequency converter, in combination with a subordinate, moving PLC, executes the movement depending on the permissible machine parameters, such as speed.

[0007] Using an example application scenario, namely an online order from a mail-order company, this conveying process can be illustrated as follows: A customer orders a pair of shoes on a website. This order is managed and processed in the ERP system. As soon as administrative tasks such as payment terms have been clarified, the ERP system releases the shipment. The WMS determines that the ordered shoes are stored in warehouse 3, aisle 5. The material flow controller sends a "control order" to the AS / RS responsible for aisle 5, which, depending on capacity utilization, is either processed immediately by the central PLC responsible for the AS / RS in aisle 5 or placed at the back of an order list.As soon as it's the pair of shoes' turn, the central PLC controls the drive of the RGB with a servo converter and a moving, subordinate PLC in conjunction with an absolute encoder, executing the movement of the RGB—for example, a movement of 17.25 m forward and 5.82 m upward in aisle 5. As soon as this position is precisely reached, the central PLC controls the pick-up of the crate by the load handling device. After the successful pick-up, the PLC controls the movement of the AS / RS to a drop-off point, where the shoes are transferred. This drop-off point usually consists of an automatic conveyor system, which in turn is controlled by the MFC. More precisely, the MFC only triggers a "control command," which is then converted by a central PLC and possibly a downstream decentralized control module into a specific movement of a motorized roller as a conveyor device.

[0008] The MFC tracks material flow using various scanners, allowing the MFC to control various motors via a central PLC so that the container containing the shoes arrives at the desired picking station. There, an employee usually manually packs the shoes from the container into a shipping carton. The MFC ultimately ensures that this carton is transported to a delivery truck.

[0009] Extensive data traffic is already taking place to coordinate the various machines and conveyor systems, usually based on bus systems such as CAN bus. This data traffic serves to ensure the automated operation of the automated conveyor system.

[0010] However, existing conveyor systems also face the demands of the intralogistics market, which represent a conflict of objectives, making it virtually impossible to achieve all of them. The availability of the conveyor technology must continually increase, reaching almost 100%. At the same time, warehouse throughput and thus the dynamics of the conveyor systems in automated conveyor systems must continually increase. Doubling the dynamics typically means not just halving the service life of wear parts, but reducing their service life many times over. This results in higher maintenance costs and downtime, which, however, must also be reduced. This can have significant negative consequences, such as the downtime of an assembly line if individual parts are not available at the assembly site in time.

[0011] However, the problem with an automated conveyor system known from practice is that maintenance is carried out reactively. This means that analysis of the problems and, if necessary, troubleshooting measures are only carried out after any errors and / or malfunctions have already occurred. This results in significant disruption and downtime for the conveyor system.

[0012] Document WO 2008 / 070678 A2 discloses a remote conveyor monitoring system for monitoring the operation of conveyor belts at a first location. A local human-machine interface (HMI) can be operated to collect and store data representing the states and operating characteristics of the conveyor belts. Multiple computers at different locations can retrieve the data via an internet connection. Thus, data related to the operating states of the conveyor belts can be remotely consolidated and monitored by human users via computers at different global locations.

[0013] Document EP 3 187 948 A1 discloses an automated system and method for managing product quality in container processing plants.

[0014] Document EP 3 121 664 A1 relates to a computer-implemented method and system for monitoring a motor-driven conveyor belt, which is described using the example of a seed drill.

[0015] Document EP 2 375 302 A1 discloses a vehicle system with a transport path and a plurality of transport vehicles configured to move along the transport path, as well as a self-diagnosis method for such a vehicle system. Each of the transport vehicles comprises a communication unit that enables communication with a system controller or a zone controller. Each of the transport vehicles also comprises its own on-board control device that controls the movement of the respective transport vehicle.

[0016] Document US 2013 / 0293160 A1 discloses a system and method for controlling automated electromechanical systems comprising a number of electrical rotating machines, such as motors, generators, or the like. The document is based on known control schemes in which a central control unit receives sensor data and user inputs, processes the data, and then distributes commands to the various components, including the electrical rotating machines. Given the associated long signal propagation times, which negatively impact the performance, reliability, and safety of the system, particularly in large systems, a decentralized control scheme is proposed in which programmable logic controllers are directly coupled to or integrated into the rotating machines of a machine system.

[0017] Document EP 2 807 096 B1 discloses a system and method for monitoring the condition of a conveyor belt, wherein the conveyor belt rotates around a drive drum driven by an electric motor and at least one deflection drum. At least one sensor unit is provided, which detects at least one sensor signal representing at least one operating variable of the electric motor. A control unit processes the sensor signals and, by means of a processing unit, generates corresponding control signals for controlling the movement of the electric motor.

[0018] Document WO 2005 / 124488 A1 discloses an intelligent electric drive for controlling axes within technical processes. The drive comprises a drive controller, an electric motor, and a control device for detecting and monitoring threshold values ​​of axis-relevant electrical / mechanical operating state variables. The control device includes additional monitoring with analysis of the operating state variables for early detection of possible deviations from target specifications and processing of the analysis results.

[0019] The document DE 20 2016 008 397 U1 discloses a system and method for computer-aided prediction of future operating states of machine components.

[0020] The document WO 2017 / 220281 A1 discloses a transport device and a method for controlling and monitoring a transport device.

[0021] The document WO 2017 / 220281 A1 discloses a system and a method for monitoring the function of an engine system.

[0022] The present invention is based on the object of designing and developing a method for monitoring the function of an automated conveyor system of the type mentioned above in such a way that any downtimes of the conveyor system are reduced or minimized as much as possible, while preferably enabling improved and more efficient maintenance of the conveyor system. Furthermore, a corresponding automated conveyor system is to be specified.

[0023] According to the invention, the above object is achieved by the features of claim 1.

[0024] The above object is further achieved by an automated conveyor system having the features of claim 14.

[0025] Advantageous embodiments of the teaching according to the invention are specified in the dependent claims.

[0026] According to the invention, it was first recognized that it is significantly advantageous to implement proactive maintenance and servicing of the conveyor technology with a view to reducing potential downtimes of the conveyor system. The invention further recognized that the acquisition costs, which should be kept low on a regular basis, would increase significantly if a large number of additional sensors, data transmission units, and evaluation units had to be integrated into the conveyor system.

[0027] The present invention therefore proposes a method in which conveyor system states are determined to monitor the function of the conveyor system. System parameter data is provided by recording sensor and / or actuator data from the conveyor systems. The sensor and / or actuator data can also be acquired from hardware already present or required for the functionality of the conveyor system, namely from sensors and / or actuators that serve to control and / or regulate the movement of the conveyor system. According to the invention, the system parameter data is transmitted to a central evaluation unit for determining and / or evaluating the conveyor system states.

[0028] Consequently, the method according to the invention and the automated conveyor system according to the invention make it possible to reduce conveyor system downtimes. It is precisely by evaluating acquired system parameter data that conveyor system conditions can be determined, and various necessary maintenance measures can be initiated in a timely manner. This enables improved and more efficient maintenance of the conveyor system.

[0029] The conveyor systems can advantageously include motorized rollers, lifters, belt conveyors, chain conveyors, timing belt conveyors, and / or link belt conveyors. Furthermore, support rollers connected to the motorized roller via belts can also be considered. Furthermore, the conveyor systems can include support rollers that are coupled to a large motor, for example, for a length of 30 m. This allows monitoring of important components of a conveyor line where any disruption and / or malfunction could impair the availability of the entire conveyor system or even lead to a failure of the entire conveyor system. This can now be counteracted in a timely manner.

[0030] Advantageously, the control devices can comprise at least one central control device in addition to the decentralized control modules. Both the central control device and the decentralized control modules can be designed as programmable logic controllers. The decentralized control modules can be installed directly at the individual motor rollers or close to the respective motor rollers of a conveyor line and can control them if necessary.

[0031] In a further advantageous manner, the decentralized control modules can be designed such that an autonomous and / or a non-autonomous operating mode is implemented on the decentralized control modules. The decentralized control modules can thus support two operating modes. It is conceivable that a decentralized control module can be connected to a predefined number of light barriers and a predefined number of motorized rollers. Several decentralized control modules could then be connected to one another via a bus system (e.g., CAN bus). This allows for ingenious control either via a PLC as the central control device or in autonomous operating mode, in which the decentralized control modules communicate with one another and can control the conveyor line independently.In non-autonomous operating mode, the control module can thus be controlled via a higher-level central control device, for example a PLC, so that a PLC relay mode is implemented. In concrete terms, it is conceivable that in PLC relay mode the control module acts as a relay of a higher-level central PLC. The control module executes, for example, the commands received via a bus system (for example the CAN bus) and reports back the status of the inputs. Autonomous operation is also possible. In autonomous operating mode, the control modules of a conveyor line can map conveyor functions such as an accumulation conveyor without external control (for example by a higher-level central PLC). In one advantageous embodiment, the control modules can be connected in series for this purpose. Each control module could, for example, map up to two accumulation locations.A buffer zone evaluates a (configurable) stop light barrier and controls a motor. A start light barrier could also be configured. The transfer from upstream or downstream conveyor technology could be implemented via digital I / O or CAN bus. Start / stop and system error states could be implemented via digital I / O of a control module or via the CAN bus. Furthermore, the status of each decentralized control module could be retrieved via a bus interface (e.g., a CAN bus interface). Consequently, the control modules can communicate with each other, and the conveyor line can be controlled at least partially independently in autonomous operation.

[0032] According to the invention, the sensor and / or actuator data are acquired by the decentralized control modules. The sensor and / or actuator data, or system parameter data derived therefrom, can then be provided and / or stored by the decentralized control modules, enabling the determination and / or evaluation of conveyor system states.

[0033] Furthermore, it is also conceivable that the sensor and / or actuator data are recorded by the central control device, wherein the sensor and / or actuator data or system parameter data derived therefrom are then provided and / or stored by the central control device.

[0034] Advantageously, the decentralized control modules and / or the central control device can process the sensor and / or actuator data in such a way that the acquired sensor and / or actuator data are provided and / or stored as system parameter data in a processed, pre-filtered, reduced and / or concentrated form.

[0035] In an advantageous embodiment, the sensor and / or actuator data or the system parameter data can be sent directly from the decentralized control modules to the central evaluation unit. It is conceivable that the decentralized control modules are equipped with a separate, preferably wireless, communication interface via which the system parameter data is transmitted directly to the central evaluation unit. Furthermore, it is conceivable that the sensor and / or actuator data or the system parameter data are transmitted indirectly from the decentralized control modules to the central evaluation unit. This could be done, for example, via the higher-level, central control device and / or via one or more additional decentralized control modules.

[0036] Advantageously, one or more of the decentralized control modules can function as an edge gateway, with the system parameter data being sent to the central evaluation unit via the edge gateway. At this point, it should be noted that the term edge gateway can be understood as an edge device in edge computing. An edge gateway can be viewed as a node at the transition between two networks. It can be a connection node between a local network and a metropolitan area network (MAN), or the transition computer between a wide area network and an access network. Functionally, the gateway connects corporate networks to the core network. Edge gateways can support a wide variety of mobile networks, local networks, radio networks, and landline networks to which they have interfaces. Edge gateways can use WiFi and Ethernet, via which they can communicate, and can also, if necessary,Aggregate and convert industrial protocols such as CAN bus, Modbus, BACnet, SCADA, or ZigBee. The term "edge gateway" or "edge computer" can also be used to describe a device that is a form of programmable logic controller (PLC) in which the processing elements are positioned closer to the sensor, allowing the sensor data to be quickly analyzed and filtered. As a local controller, the device is thus able to reduce data volume in decentralized data centers. The edge gateway differs from conventional PLCs primarily in its greater data processing capability, which is ensured by the use of multi-core processors with higher computing power.

[0037] In an advantageous embodiment, the system parameter data of the conveyor systems can include information regarding operating time, switching cycles, and / or power consumption. Thus, values ​​for the operating time, switching cycles, and / or power consumption are stored and evaluated. This system parameter data can thus be accessed as easily recorded data, since this data can usually be obtained without significant effort or, in most cases, without additional complex hardware.

[0038] Advantageously, the sensor and / or actuator data of the conveyor systems or the system parameter data of the conveyor systems can be recorded in a load-dependent manner. Load-dependent recording can mean that the conveyor system is operated at a predefined (possibly different) load and / or dynamic (e.g., faster or slower) during recording, and this is taken into account in the evaluation. This makes it possible to determine how the conveyor system reacts at a certain, predefined (possibly increased) load or dynamic. Furthermore, predefined containers to be conveyed (possibly with different weights) could be taken into account in the recording. Consequently, suitable and meaningful results regarding the conveyor system states to be determined can be achieved within the framework of an evaluation.

[0039] In an advantageous embodiment, predeterminable process parameter data can be transmitted to the central evaluation unit to determine the conveyor system status. The process parameters can advantageously be retrieved from a warehouse management system, a material flow computer, and / or a central control unit. Thus, process parameter data can include, for example, information regarding container weight, previous maintenance intervals, last maintenance, maintenance frequency, material flow, and / or overload control.

[0040] In an advantageous embodiment, predefined environmental parameter data relating to the environment of the conveyor systems can be recorded – if necessary with additional and / or if necessary with already existing separate sensors – whereby the environmental parameter data is transmitted to the central evaluation unit to determine the conveyor system status. Additional sensors or separate sensors can be understood here to include sensors that are not or not directly used for the movement control and / or regulation of the conveyor systems. Rather, it is conceivable that additional sensors are installed here that measure environmental parameter data such as temperature, humidity, dust, etc. The recording and consideration of environmental influences on an automated conveyor system allows for more efficient calculation and / or correction of sensor data or system parameter data. Automatic intralogistics systems orConveyor systems are rarely systems that operate independently of their environment. They are frequently integrated into agile environments that are subject to changing environmental influences. Manual storage locations, i.e., operated by humans, are also common – for example, with forklifts, hand pallet trucks, electric pallet trucks, etc. Human behavior varies in such environments and cannot be predicted (forklifts take a different route, drive further to the right or left, move faster, slower, have to swerve, etc.). In addition to humans, nature also influences the conveyor system, particularly through temperature influences (summer, winter), light influences (UV radiation blinds sensors), wind influences (e.g., wind load on shelving structures), etc. Therefore, by recording changing environmental influences, any distortions in the acquired system parameter data can be eliminated or taken into account during the evaluation and analysis of this system parameter data.

[0041] It is therefore conceivable that the external influences could be measured separately and independently and then analyzed / evaluated in the central evaluation unit. This allows for important conclusions to be drawn for the conveyor system in a sophisticated manner, as outlined below: At an outside temperature of 35°C, with no wind, and forklift traffic near the storage and retrieval machine, increased vibrations of the mechanical structure occur, shortening the service life of certain components by "x" months. If all forklifts pass the rack on the right instead of the left, the error rate can be reduced by "x"%. If, in the summer, starting in June, the blinds on window "xyz" are lowered by 50%, the conveyor system sensors are no longer blinded, and availability increases by "x"%.

[0042] In an advantageous embodiment, it is conceivable that environmental parameter data could be accessed via a corresponding interface to the building's technology (if present). This allows a wide range of existing information to be accessed in a simple and efficient manner.

[0043] According to the invention, a parallel, preferably wireless, communications network is used to transmit parameter data to the central evaluation unit. This is conceivable, for example, for the system parameter data, the process parameter data, and / or the environmental parameter data. Consequently, a parallel, radio-based network could advantageously be used in order not to overload the network structure required for operation with diagnostic and analysis data. The diagnostic and analysis data, which may include the system parameter data, process parameter data, and / or environmental parameter data, are not as time-critical as the actual control data of the automated conveyor system. With regard to the diagnostic and analysis data, it is conceivable that this data is sent multiple times if the connection is not stable enough and packets are possibly lost. This is not conceivable for the controlling control data of the conveyor system.With a view to a cost-effective solution, it is conceivable that the parallel wireless communication network be implemented as a mesh network or using Bluetooth Low Energy technology. This allows a cost-effective parallel communication network to be created in a sophisticated way for non-critical communication. The mesh network design is particularly advantageous, as each additional module increases the wireless range and allows a very extensive conveyor system to be covered with as little central infrastructure as possible.

[0044] Advantageously, the central evaluation unit can determine, evaluate, and / or assess the conveyor states of the conveyors based on the received parameter data using an analysis function that takes physical relationships in the parameter data into account, wherein a predeterminable maintenance measure is initiated depending on an analysis result calculated by the analysis function. The parameter data received and taken into account by the central evaluation unit can include, for example, system parameter data, process parameter data, and / or environmental parameter data. Depending on the analysis result determined by the analysis function, a controlling influence on the conveyor system can be exerted within the framework of the predeterminable maintenance measure. Consequently, a controlling and thus active influence of the central evaluation unit on the automated conveyor system is possible.The following maintenance measures are conceivable in an advantageous manner: . Limit throughput / dynamics if disruptions (e.g. due to breakdowns) are to be expected at higher throughputs. Another option is to predict a disruption before the next possible (possibly planned) maintenance appointment. Automatic adjustment of maintenance intervals. Partially or completely bypass route sections at risk of failure by selecting an alternative route in the conveyor system. Recognise that some route sections are more heavily used than others and therefore require maintenance more frequently. If the route allows, the central evaluation unit could redistribute the load and achieve even capacity utilization. Display failure probabilities in order to intervene automatically or to give an operator notifications to make changes. Material flow control based on remaining time until maintenance (dynamic setting or route profile).

[0045] In an advantageous embodiment, the condition of the conveyor systems can be recorded, their condition compared, and the conveyor systems of the conveyor system can be diagnosed. Continuous conveyor systems - continuous conveyors - can often run continuously or be ready for use at any time, so that an incoming data packet is immediately forwarded automatically via a decentralized control module. Therefore, continuous monitoring of the conveyor systems of the conveyor system is recommended. In addition to the recording and evaluation of system and component data as parameter data such as temperature, vibration, malfunctions, and power consumption, which are part of the scope of delivery of the conveyor system provider, temperature sensors from an existing heating system of the conveyor system operator could also be integrated. The condition comparison represents the comparison of the actual condition with a specified reference value.This reference value can be either a target value to be maintained or a limit value that must not be exceeded. Depending on the parameter being examined, the target value can be determined during machine acceptance and / or defined using predefined variables. Continuous conveyors are a mass product for which extensive data from various projects can be available, which could also be used as a reference value. During diagnostics, the results of the condition comparison can be used to locate any errors as early as possible and determine their cause, so that necessary maintenance measures can be planned in good time. The diagnosis can, for example, be carried out on a local computer as the central evaluation unit in a logistics hall. The parameter data can, for example, be transferred from the conveyor systems to the local computer as the central evaluation unit via ProfiNet and a switch, or via WLAN.Further processed data and / or results can then be stored in the cloud.

[0046] Advantageously, the central evaluation unit can be implemented in the form of one or more software components, wherein the software components provide the central evaluation unit via a central computer and / or via a cloud platform.

[0047] In an advantageous embodiment, time-synchronized data acquisition and recording of the parameter data can be carried out. Automatic conveyor systems consist of many individual components and many different controllers and machines / conveyor devices. Within the scope of advantageous embodiments of the invention, as much data as possible from these components or conveyor devices can be acquired and processed using a central evaluation unit or a cloud platform for predictive maintenance and / or condition monitoring. From the fusion of the various parameter data, conclusions can be drawn regarding the condition of the conveyor system. For suitable analysis, the respective components of the conveyor system can report their events with a synchronized timestamp, so that suitable data analysis can be implemented using algorithms for machine learning and / or artificial intelligence.In reality, events that occur simultaneously do not arrive at the analysis function with different timestamps. A central time service can be advantageously used for this purpose, providing synchronous and appropriate timestamps to all connected components. This could be a time server on the Internet, the central analysis unit itself, and / or a time server in the conveyor system's network that synchronizes with an external time server at regular intervals.

[0048] Advantageously, the components to be synchronized can include, for example, the following: controllers, decentralized control modules, motor controllers, warehouse management software, material flow computers, visualization systems, fault messages.

[0049] The invention and / or advantageous embodiments of the invention may provide one or more of the following advantages: Increased availability of the conveyor system Reduction of maintenance costs Product improvements Demand-oriented provision of spare parts Demand-oriented deployment of service personnel, for example for repairs and / or troubleshooting Digital support for service and maintenance personnel

[0050] There are now various possibilities for advantageously embodying and developing the teaching of the present invention. For this purpose, reference is made, on the one hand, to the claims subordinate to claim 1 and, on the other hand, to the following explanation of preferred embodiments of the invention with reference to the drawing. In conjunction with the explanation of the preferred embodiments of the invention with reference to the drawing, generally preferred embodiments and developments of the teaching are also explained. The drawing shows: Fig. 1 shows a schematic view of a possible data exchange between individual components of an automated conveyor system within the scope of an embodiment of the invention, Fig. 2 shows a schematic view of an automated conveyor system according to an embodiment of the invention, Fig. 3 shows a schematic view of a decentralized control module for two motor rollers of an automated conveyor system according to an embodiment of the invention, and Fig. 4 shows a schematic view of several decentralized control modules for several motor rollers of an automated conveyor system according to an embodiment of the invention.

[0051] Fig. 1 shows a schematic view of a possible data exchange between individual components of an automated conveyor system within the framework of an embodiment of the invention.

[0052] For the coordination and control of the various conveyor devices of the automated conveyor system, extensive data traffic, usually based on bus systems such as CAN bus, takes place - similar to conventional conveyor systems. This data traffic serves to ensure the automated operation of the conveyor system. In contrast to conventional automated conveyor systems, Fig. 1 illustrated conveyor system according to an embodiment of the invention, this data is additionally stored and processed, if necessary in conjunction with other measurement data, for evaluation with regard to predictive maintenance of the conveyor system.

[0053] Modern ERP systems can partially combine the functions of a warehouse management system (WMS) and a material flow computer (MFC) in one software.

[0054] Fig. 1 shows that there is a constant exchange of data between warehouse orders and feedback from sensors. This existing data flow is selectively transmitted in sections to a central evaluation unit and stored there in order to monitor the condition of the conveyor system, especially the individual conveyor devices, in combination with additional measurement data.

[0055] In concrete terms, Fig. 1 the mutual communication between the following components: Enterprise Resource Planning System (ERP), warehouse management system (WMS), material flow computer (MFC), central control device in the form of a programmable logic controller (PLC), and decentralized control module (DS).

[0056] Furthermore, communication with a central evaluation unit (ZA) can take place to enable predictive maintenance for the automated conveyor system. Data exchange is thus possible between the MFR and ZA, between the PLC and ZA, and between the DS and ZA.

[0057] The central evaluation unit (ZA) can be a software component implemented on a central computer in the logistics hall of the conveyor system. Furthermore, the central evaluation unit can be a software component provided via / on / in a cloud platform. Finally, it is conceivable that the central evaluation unit consists of several software components implemented in a distributed form both on a central computer in the logistics hall and on the cloud platform, and that these software components communicate with each other. This allows, for example, complex analysis and evaluation functions to be relocated to the cloud platform. Furthermore, recorded parameter data and / or analysis results can be outsourced to the cloud, if necessary so that they can be accessed in later use cases.

[0058] Furthermore, the central evaluation unit can Fig. 1 Create control instructions. For example, the MFR could be instructed to make greater use of unused alternative routes. Furthermore, the central control device in the form of a central PLC could be instructed to use heavily worn components of a conveyor system with lower dynamics. In any case, in the embodiment according to Fig. 1 a connection of the conveyor system to a central evaluation unit is realized.

[0059] In the embodiment according to Fig. 1 The material flow control is based on a PLC database that can store up to 1,000 data records. Access times to the transport data are therefore on average less than 100 ms (PLC cycle time); there are no delays or waiting times on the conveyor system. This structure minimizes data traffic between the MFC and PLC, as communication is not required at every decision-making point. Transport confirmations and status messages are thus decoupled from the material flow and reported to the MFC from the conveyor process without time-critical delays.

[0060] Fig. 2 shows a schematic view of an automated conveyor system according to a further embodiment of the invention. Fig. 2 illustrates an overall system 1 that includes both an automated conveyor system 2 with a conveyor line and an automated warehouse system 3 with a rack storage system and storage and retrieval machines (SRMs). The SRMs are used to store and / or retrieve goods from the rack storage system.

[0061] Fig. 3 shows a schematic view of a decentralized control module 4 for controlling two motor rollers 5 and 6 as conveyor devices of an automated conveyor system according to an embodiment of the invention. The decentralized control module 4 coordinates or controls the two motor rollers 5 and 6 via the actuators 7 and 8. The signal from the light barriers 9 and 10 is detected by the sensors 11 and 12. The support rollers 13 are coupled to the first motor roller 5 by means of a belt drive 14. The support rollers 15 are correspondingly coupled to the second motor roller 6 by means of a belt drive 16. Furthermore, the control module 4 has a data processing device with a communication interface 17, which provides a direct connection to the central evaluation unit.

[0062] Fig. 4 shows a schematic view of several decentralized control modules according to Fig. 3 which are provided for controlling motor rollers as conveyor devices of an automated conveyor system according to an embodiment of the invention.

[0063] The entire conveyor system is controlled by the material flow controller (MFC). The individual conveyor elements, such as motorized rollers and lifts, are controlled by central PLCs as central control units. Individual motorized rollers can be controlled centrally via a central PLC or locally via the decentralized control module. The decentralized control module can independently perform simpler control tasks, such as evaluating a light barrier and activating a motorized roller for a specific time, without integrating the central PLC.

[0064] The decentralized control module records the sensor and actuator data available from the sensors and / or actuators. This allows for the provision, storage, and forwarding of measurable values ​​such as switching cycles, operating time, and power consumption. This is easily memorized system parameter data that can be obtained without extensive additional hardware and forwarded to the central evaluation unit.

[0065] Decentralized control modules - as in Fig. 3 and Fig. 4 shown as an example - could collect the following data and make it available to the central evaluation unit: Operating hours of the motor rollers Number of switching operations on and off Increased power consumption

[0066] The following information or parameter data could be made available to the central evaluation unit via LVS, MFR and PLC: Container weight (exact number of heavy containers) Environmental influences (temperature, humidity, dust, etc.) Previous maintenance intervals, last maintenance Material flow from barcode scanner, overload control

[0067] The data received by the central evaluation unit can be combined using a suitable algorithm so that the following measures can be implemented: Predictive Maintenance Preference for less busy alternative routes on conveyor lines Planning of suitable maintenance times Planned shutdown of a line without congestion

[0068] Furthermore, a decentralized control module - as in Fig. 3 and Fig. 4 As shown by way of example, they act as an edge gateway that performs data reduction. This enables edge computing in the decentralized control modules of the motorized rollers, for example, running on a slimmed-down mini-computer with a slimmed-down Linux system. Since measuring the operating hours, power consumption, and clock speeds of a single motorized roller can result in several thousand data points per hour, it is conceivable that the system parameter data could be preprocessed in a central edge gateway (or several central gateways) to keep the data volume low.

[0069] Furthermore, it is conceivable that each decentralized control module of the motor roller - as in Fig. 3 and Fig. 4 As shown in the example, this task is taken over and only the processed data is forwarded, for example, directly to the central evaluation unit or indirectly to the central evaluation unit via the central PLC control. This allows, where appropriate, only concentrated data to be sent to the central evaluation unit. A suitable data transmission would therefore, for example, consist of the following information: "XXXX" switching on and off processes, fluctuation in current consumption during idle operation "X.X" %, max. current consumption "X.XX" A, switching-on time during the measuring period "XX" %, duration of the measuring period "X" h.

[0070] A decentralized control module can serve as a "small" data collection point for one or more motorized rollers and one or more sensors. Power supplies and other motors not installed in the support rollers are also connected to this module, whose information can also be recorded and sent to the central evaluation unit for analysis there or, if necessary, in the cloud.

[0071] With regard to further advantageous embodiments of the method according to the invention and the conveying system according to the invention, reference is made to the general part of the description and to the appended claims in order to avoid repetition.

[0072] Finally, it should be expressly pointed out that the above-described embodiments of the method according to the invention and of the conveying system according to the invention serve only to explain the claimed teaching, but do not limit it to the embodiments. Bezugszeichenliste

[0073] 1Overall system 2Conveyor system 3Warehouse system 4Control module 5Motor roller 6Motor roller 7Actuator / Motor 8Actuator / Motor 9Light barrier 10Light barrier 11Sensor 12Sensor 13Support roller 14Belt 15Support roller 16Belt 17Communication interface

Claims

1. Method for function monitoring of an automated conveyor system having at least one conveyor path for maintaining the conveyor system, wherein conveyor devices which the conveyor path comprises are provided with sensors (11, 12) and actuators (7, 8) which are used for controlling and / or regulating the movement of the conveyor devices, wherein the sensors (11, 12) and actuators (7, 8) of the conveyor devices are coordinated by means of a plurality of control devices, wherein the control devices comprise decentralised control modules (4), wherein for function monitoring of the conveyor system conveyor device states are determined, wherein sensor and / or actuator data of the conveyor devices are detected by the decentralised control modules (4) and wherein system parameter data derived from the sensor and / or actuator data are provided by the decentralised control modules (4), and wherein the system parameter data in order to determine and / or evaluate the conveyor device states are transmitted to a central evaluation unit, wherein there is used in order to transmit the system parameter data to the central evaluation unit a communication network which is constructed parallel with a network structure which is required for the operation of the conveyor system.

2. Method according to claim 1, characterised in that the conveyor devices comprise motor rollers (5, 6), lifters, belt conveyors, chain conveyors, toothed belt conveyors and / or apron conveyors.

3. Method according to claim 1 or claim 2, characterised in that the control devices in addition to the decentralised control modules (4) comprise at least one central, preferably storage-programmable, control device.

4. Method according to claim 3, characterised in that the decentralised control modules (4) and / or the central control device carries out a processing of the sensor and / or actuator data in such a manner that the sensor and / or actuator data detected are provided and / or stored as system parameter data in prepared, prefiltered, reduced and / or concentrated form.

5. Method according to claim 3 or claim 4, characterised in that the sensor and / or actuator data or the system parameter data are transmitted from the decentralised control modules (4) directly and / or indirectly to the central evaluation unit.

6. Method according to any one of claims 1 to 5, characterised in that one or more of the decentralised control modules (11) act as an edge gateway, wherein the system parameters are transmitted via the edge gateway to the central evaluation unit.

7. Method according to any one of claims 1 to 6, characterised in that the system parameter data of the conveyor devices comprise information items relating to duration of operation, switching cycles and / or power consumption.

8. Method according to any one of claims 1 to 7, characterised in that the sensor and / or actuator data of the conveyor devices or the system parameter data of the conveyor devices are detected in a load-dependent manner.

9. Method according to any one of claims 1 to 8, characterised in that predeterminable process parameter data, preferably from a storage management system, a material flow processor and / or a central control device, in order to determine the conveyor device states, are transmitted via the communication network to the central evaluation unit.

10. Method according to any one of claims 1 to 9, characterised in that predeterminable environmental parameter data with respect to the environment of the conveyor devices are detected, wherein the environmental parameter data in order to determine the conveyor device states are transmitted via the communication network to the central evaluation unit.

11. Method according to any one of claims 1 to 10, characterised in that the communication network is constructed as a wireless radio-based network, in particular as a mesh network.

12. Method according to any one of claims 1 to 11, characterised in that the central evaluation unit determines and / or evaluates the conveyor device states based on the parameter data received by means of an analysis function, wherein, depending on an analysis result calculated by the analysis function, a predeterminable maintenance measure is introduced.

13. Method according to any one of claims 1 to 12, characterised in that the central evaluation unit is implemented in the form of one or more software components, wherein the software components provide the central evaluation unit by means of a central processor and / or by means of a cloud platform.

14. Automated conveyor system comprising at least one conveyor path, a plurality of control devices and a central evaluation unit, in particular for carrying out a method according to any one of claims 1 to 13, wherein the conveyor path comprises conveyor devices which are provided with sensors (11, 12) and actuators (7, 8) for controlling and / or regulating the movement of the conveyor devices, wherein the control devices comprise decentralised control modules (4) and serve to coordinate the sensors (11, 12) and actuators (7, 8) of the conveyor devices of the at least one conveyor path, wherein the conveyor system is constructed in such a manner that for function monitoring of the conveyor system conveyor device states are determined, wherein the decentralised control modules (4) are configured to detect sensor and / or actuator data of the conveyor devices and to provide system parameter data derived from the sensor and / or actuator data, and wherein a communication network via which the system parameter data in order to determine and / or evaluate the conveyor device states are transmitted to the central evaluation unit is provided, wherein the communication network is constructed parallel with a network structure which is required for the operation of the conveyor system.