Article processing device

Abstract

To provide an article processing device capable of stably securing capacity of article processing and accuracy at the time of resuming article supply, while suppressing energy consumption by operation restriction in the case where article supply is interrupted temporarily.SOLUTION: In an article processing device, when an article detection signal on a preceding stage side exceeds carrying-in standby time and is not inputted in a control part 50, a motion restriction operation for restricting an article conveyance speed Vrj is restricted on a subsequent stage side, and when the article detection signal is inputted, the motion restriction operation is cancelled and the article conveyance speed on the subsequent stage side is accelerated to the setting speed. The control part 50 includes: acceleration pattern storage means which stores whether or not to complete acceleration of the article conveyance speed in a subsequent stage side conveyance operation part 20 when cancelling the motion restriction operation before starting carrying-in of a workpiece W from a preceding stage side conveyance operation part 10, or to continue further acceleration after completing carrying-in in the case of completing acceleration after starting carrying-in, as a plurality of acceleration patterns; and pattern determination means for selectively determining the acceleration pattern according to workpiece carrying-in situation.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to an item processing apparatus, and more particularly to an item processing apparatus having an idling function that, when the supply of items to be processed such as inspection or sorting is temporarily interrupted, transitions to a standby state in which specific operations related to the processing are stopped, and returns from the standby state when the supply of items is resumed. [Background technology]

[0002] 2. Description of the Related Art There are known article processing apparatuses that perform processes such as article inspection and sorting, in which articles conveyed along a predetermined conveying path are sequentially handled in a predetermined operating manner.

[0003] In this article processing device, if a heavy load is placed on the main mechanisms and functional parts related to a specified article processing when the device is started up or begins operation, there is a risk that the article processing capacity and accuracy will decrease. Therefore, when the device is started up, the main mechanisms and functional parts may be placed in an operating state where the load is reduced or some of them are stopped (hereinafter referred to as an idling state).

[0004] Furthermore, the main mechanisms and functional units that handle the articles to be processed often consume a lot of energy, for example, electricity, so it is required to reduce the energy consumption of the main mechanisms and functional units in an article processing apparatus.

[0005] Conventional item processing equipment of this type, for example, operates in a normal operation mode in which multiple devices work together to pack multiple items into an outer box in sequence when the input wait time for an item supply signal notifying the supply of items from an external conveyor is within a predetermined time, and operates in a standby operation mode in which some of the equipment that is controlled to be in a constant operating state in the normal operation mode is stopped when the input wait time exceeds the predetermined time (see, for example, Patent Document 1).

[0006] In addition, depending on whether the input waiting time of a detection signal indicating the supply of items from the upstream conveyor exceeds a predetermined monitoring time, if the input waiting time is within the predetermined monitoring time, the system is controlled to a normal operation mode in which the downstream aligning conveyor aligns multiple items in the item conveying direction and then packs them into an outer box, and if the input waiting time exceeds the predetermined monitoring time, the system is controlled to a pause mode in which the item processing device is temporarily stopped (see, for example, Patent Document 2).

[0007] As an example of an item processing device that includes a weighing device that weighs items on a conveyor, there is a device that slows down or temporarily stops the weighing conveyor that constitutes the weighing section when no items are transported from the upstream conveyor, and resumes it when an item is transported (see, for example, Patent Document 3 and Patent Document 4). [Prior art documents] [Patent documents]

[0008] [Patent Document 1] Patent Publication No. 2021-116100 [Patent Document 2] JP 2012-140166 A [Patent Document 3] JP 2010-038563 A [Patent Document 4] Japanese Utility Model Application Publication No. 54-161168 Summary of the Invention [Problem to be solved by the invention]

[0009] However, in the above-mentioned conventional article processing equipment, when article supply is temporarily interrupted, it is expected that energy consumption can be reduced by temporarily suspending operation of the equipment, including the transport conveyor in the article processing section, but it was found that there is a problem with restarting the process when article supply is resumed.

[0010] For example, when the conveyor in the article processing section is resumed, it takes time to resume stable conveyance at a predetermined conveying speed from a paused state, and the speed difference or change between the conveyor in the article processing section and the conveyor upstream of the conveyor may cause the conveying state of the article after the detection of the article to fluctuate, causing the timing of the predetermined article processing to be shifted. Various processing conditions are set in the article processing device on the premise that the conveyor is operated at a constant speed, and the temporary suspension and resumption of the conveyor adds a variable element. In other words, the operation control to reduce energy consumption leads to a deterioration in the quality of the article processing itself, such as the capacity and accuracy of the predetermined article processing, so there is a problem in achieving both reduction in energy consumption and maintenance of the quality of the article processing.

[0011] The present invention has been made to solve the conventional problems described above, and aims to provide an item processing device that can sufficiently reduce the energy consumption of the item processing device when item supply from the upstream side is temporarily interrupted, while stably ensuring the specified item processing capacity and accuracy when item supply is resumed. [Means for solving the problem]

[0012] In order to achieve the above-mentioned object, the article processing apparatus of the present invention comprises: (1) an upstream conveying operation unit that conveys an article through an upstream conveying section; a downstream conveying operation unit that conveys the article through a downstream conveying section adjacent to the upstream conveying section on the downstream side; an article detection sensor that detects an article passing through a predetermined detection position in the upstream conveying section and outputs an article detection signal to notify that the article will be conveyed into the downstream conveying section; a processing operation unit that performs a predetermined processing operation in a preset manner on an article that has been conveyed into the downstream conveying section and has reached a predetermined operation start position; and a control unit that controls the downstream conveying operation unit and the processing operation unit in accordance with the input status of the article detection signal from the article detection sensor; and when the article detection signal is not input to the control unit for a predetermined input wait time, an operation limiting operation is performed that limits the article conveying speed in the downstream conveying operation unit, while when the article detection signal is input to the control unit during the operation limiting operation, This is an item processing apparatus that releases the operation restriction operation and accelerates the item conveying speed in the downstream conveying operation unit to a predetermined operating speed, wherein the control unit has an acceleration pattern memory means that stores as multiple acceleration patterns when conveying is resumed, whether the acceleration of the item conveying speed in the downstream conveying operation unit when the operation restriction operation is released is completed before the item begins to be conveyed from the upstream conveying operation unit to the downstream conveying operation unit, or whether the acceleration is completed after the item begins to be conveyed and then continues after the conveying is completed, and a pattern determination means that determines which acceleration pattern to select from the multiple acceleration patterns when conveying is resumed depending on the item conveying status, and is characterized in that the control unit performs time correction control for the time from when the item detection signal is input to the control unit to when the operation restriction operation is released and the processing operation unit performs the predetermined processing operation based on the determination result of the pattern determination means and the stored information of the acceleration pattern memory means.

[0013] With this configuration, in the present invention, when an item detection signal is input to the control unit during operation restriction, it is determined which of the multiple acceleration patterns at the time of resuming loading corresponds to the loading status of the item. Therefore, fluctuations in the item transport state after item detection and shifts in the timing of the operation of a predetermined processing operation unit due to differences in transport speed between the rear stage transport operation unit that forms the item processing section as the rear stage transport section and the upstream front stage transport operation unit, or changes therein, are effectively suppressed. As a result, an item processing device is obtained that can stably ensure the specified item processing capacity and accuracy when item supply is resumed while sufficiently reducing energy consumption by the operation restriction of the item processing device.

[0014] (2) In a preferred embodiment of the present invention, the acceleration pattern storage means may store a plurality of acceleration patterns for resuming carrying-in in association with product type information including the length of the article in the conveying direction and the conveying speed of the article. In this way, it is possible to accurately determine the carrying-in status of the article when the operation restriction operation is released based on the product type information, and it is possible to quickly and accurately select an acceleration pattern for resuming carrying-in according to the carrying-in status of the article.

[0015] (3) In a preferred embodiment of the present invention, the item detection sensor is provided so as to be able to change the predetermined detection position in the upstream conveying section where the item is detected in the conveying direction, and the pattern determination means may be configured to determine which of a plurality of acceleration patterns to select when the loading is resumed, based on the product type information stored in the acceleration pattern storage means and the predetermined detection position of the item detection sensor. In this case, it is possible to more accurately determine the loading status of items when the operation restriction operation is released, based on the product type information and information on the predetermined detection position of the item detection sensor.

[0016] (4) In a preferred embodiment of the present invention, the control unit may be configured to stop article transport in the downstream transport operation unit when the article detection signal is not input to the control unit for a period exceeding the predetermined carry-in waiting time. In this case, the effect of reducing energy consumption can be enhanced by limiting the operation of the article processing device through the operation limiting operation.

[0017] (5) In a preferred embodiment of the present invention, at least one of the multiple acceleration patterns at the time of resuming carrying-in stored in the acceleration pattern storage means may include a pre-carry-in start stage until carrying-in of the item to the downstream transport operation section starts, a transit carry-in stage corresponding to a transit carry-in period from the start of carrying-in of the item to the completion of carrying-in, and a final stage from the time the item transport speed is accelerated to the predetermined operation speed until the item reaches the predetermined operation start position in the downstream transport section, and the item transport speed in the downstream transport operation section may be accelerated in stages in the multiple stages. In this way, the item transport speed can be accelerated in stages at an appropriate timing while accelerating under conditions close to a suitable speed change rate.

[0018] (6) In a preferred embodiment of the present invention, at least one of the plurality of stages may further include a post-transfer acceleration stage from the time when the loading of the article is completed until the article conveying speed in the downstream conveying operation section is accelerated to the predetermined operation speed. In this way, the article conveying speed can be accelerated stepwise at an appropriate timing while accelerating at a suitable and relatively large speed change rate.

[0019] (7) In a preferred embodiment of the present invention, a transfer correction sensor is provided to detect the item during a transfer carry-in period from the start of the carry-in of the item to the rear stage conveying operation section until the carry-in is completed, and the front stage conveying operation section and the rear stage conveying operation section are respectively composed of a front stage conveyor and a rear stage conveyor, and the control section calculates an average speed during the transfer carry-in period based on the product type information and detection information of the transfer carry-in period to detect slippage of the item during the transfer carry-in period, and detects slippage of the item during the transfer carry-in period. The apparatus may further include a free-running slippage detection means for detecting slippage of the article in the free-running section where the conveying driving force of the upstream stage conveying operation unit is reduced, based on the upstream conveying time from the time the item detection signal is output by the item detection sensor to the time the transfer correction sensor outputs an item detection signal at the start of conveying to the downstream stage conveying operation unit, and a free-running slippage detection means for detecting slippage of the article in the free-running section where the conveying driving force of the upstream stage conveying operation unit is reduced, based on the detection information from the transfer slippage detection means and the free-running slippage detection means, and may be configured to perform time correction control for the time from when the item detection signal is input to the control unit to when the operation restriction operation is released and the processing operation unit performs the specified processing operation.

[0020] In this case, when an article detection signal is input to the control unit during operation restriction, the carrying-in status of the article can be calculated with high accuracy taking into consideration slippage during transfer between conveyors and free running slippage when carrying-in to the downstream side carrying operation unit begins, and the accuracy of selecting and determining the acceleration pattern when carrying-in is resumed according to the carrying-in status of the article can be improved. Note that the conveyor referred to here is one having an endless carrying member such as a belt conveyor or a chain conveyor, but can also include a carrying operation unit such as in a carrier sorter described later.

[0021] (8) In a preferred embodiment of the present invention, the acceleration pattern storage means stores a predetermined precondition for the processing unit to operate stably under a set condition of an idling function or an operation timing based on the product type information, and the control unit further includes an operation request means for displaying an acceleration pattern selection screen that displays the plurality of acceleration patterns including the current acceleration pattern as options and requesting a selection operation of an acceleration pattern on the operation stability side that satisfies the predetermined precondition when the pattern determination means determines that the processing unit cannot operate stably based on the predetermined precondition. In this case, although the operation of the processing unit is not stabilized by the acceleration of the downstream transport operation unit based on the predetermined acceleration pattern when releasing the operation restriction of an operation restriction, for example, an idling state, the selection operation of switching to a more stable acceleration pattern is made possible in a timely manner by requesting a selection operation of an acceleration pattern on the operation stability side that satisfies the predetermined precondition by the operation request means.

[0022] (9) In a preferred embodiment of the present invention, when the pattern determination means determines that the processing operation unit cannot operate stably based on the predetermined preconditions at the time of the product type registration, the operation request means displays and outputs a setting screen on which setting conditions for the idling function or operation timing are displayed and the acceleration pattern selection screen, and outputs a selection operation request for the acceleration pattern on the operation stability side, and the control unit can be configured to adjust the setting value displayed on the setting screen to a setting value corresponding to the selected acceleration pattern when the selection operation for the acceleration pattern on the operation stability side is performed by the operation request means, and when the selection operation for the acceleration pattern on the operation stability side is requested by the operation request means and the selection operation for the acceleration pattern is performed by the user, the setting value displayed on the setting screen is adjusted to a setting value corresponding to the selected acceleration pattern, thereby enabling stable operation of the processing operation unit with a stable acceleration pattern.

[0023] (10) In a preferred embodiment of the present invention, the processing operation unit may be configured to perform a predetermined sorting operation or item inspection using a pre-set sorting method or item inspection method on an item that has been transported into the downstream conveying section and reached the predetermined operation start position. In this case, fluctuations in the conveying state of an item after item detection or shifts in the timing of the operation of the predetermined sorting processing operation unit due to differences in conveying speed between the downstream conveying operation unit that forms the sorting processing operation section as the downstream conveying section and the upstream upstream conveying operation unit, or changes therein, are effectively suppressed. As a result, while sufficiently reducing energy consumption by the operation restriction operation of the sorting processing operation unit, the capacity and accuracy of the predetermined sorting process or predetermined item inspection process can be stably ensured when item supply is resumed. Effect of the Invention

[0024] According to the present invention, it is possible to provide an item processing device that can sufficiently reduce the energy consumption of the item processing device when the supply of items from the upstream side is temporarily interrupted, while stably ensuring a specified item processing capacity and accuracy when the supply of items is resumed. [Brief description of the drawings]

[0025] [Figure 1] 1 is a schematic configuration diagram of a carrier sorting type article sorting system including an article processing apparatus according to a first embodiment of the present invention. [Diagram 2] 1 is an external perspective view of an item sorting system according to a first embodiment of the present invention. [Diagram 3] FIG. 1 shows the display screen of the operating state in the item sorting system of the first embodiment of the present invention, where (a) shows the display screen of the normal operating state, (b) shows the display screen of the operating state when the time interval between item supply exceeds a predetermined time and transitions to an idle state, and (c) shows the display screen of the operating state immediately after returning from the idle state of (b). [Figure 4] 4 is a time chart showing the operation timing of each part in an operation check mode that enables a state transition to an idle state in the item selection system according to the first embodiment of the present invention. [Diagram 5] This is an explanatory diagram of the loading acceleration patterns when an incoming item is detected in an idle state in the item sorting system of the first embodiment of the present invention and the loading acceleration pattern is resumed, and is divided into (a) a first loading acceleration pattern P1 in which acceleration of the downstream conveying operation section from the idle state is completed before the loading of the item to the downstream conveying operation section begins, (b) a second loading acceleration pattern P2 in which acceleration is completed after the loading of the item begins and before the loading is completed, and (c) a third loading acceleration pattern P3 in which acceleration is completed after the loading of the item begins and acceleration continues after the loading of the item is completed. [Figure 6] This is an explanatory diagram of the loading process, showing the process of resuming item delivery when an item to be delivered to the downstream conveying operation section is detected while in an idle state in the item sorting system of the first embodiment of the present invention, divided into the stage (a) when an item to be delivered is detected while in an idle state, the stage (b) when item transport by the upstream conveying operation section is resumed for delivery of the item to the downstream conveying operation section, the transfer delivery stage (c) after item delivery to the downstream conveying operation section has started, the stage (d) of completion of transfer delivery for delivery of items to the downstream conveying operation section, and the transport stage (e) after completion of item delivery to the downstream conveying operation section. [Figure 7] This is an acceleration correction pattern explanatory diagram showing the acceleration correction patterns of the transport drive of the rear stage transport operation unit, which is resumed in response to the output of an item detection signal that detects an incoming item while in an idle state in the item sorting system of the first embodiment of the present invention, divided into a first transport acceleration pattern P1, in which the acceleration of the rear stage transport operation unit from the idle state is completed before the item delivery to the rear stage transport operation unit begins, a second transport acceleration pattern P2, in which acceleration is completed after the item delivery starts and before the delivery is completed, and a third transport acceleration pattern P3, in which acceleration is completed after the item delivery starts and acceleration continues after the delivery is completed. [Figure 8]As an example of an item type registration screen in the item sorting system according to the first embodiment of the present invention, a screen is shown on which conditions related to the idling function and conditions related to the sorting operation can be set together with item type information, and this is an explanatory diagram of an entry acceleration pattern that can be automatically set by calculation in accordance with the registered conditions. [Figure 9] A flowchart showing an outline of the processing procedure for determining the acceleration pattern after lifting operational restrictions in an idling state, in addition to the type registration that is performed when the device is in an operation-stopped state after being powered on in the item sorting system according to the first embodiment of the present invention. [Figure 10] 5 is a flowchart showing an outline of a processing procedure for implementing operational restrictions on an idling function in the item selection system according to the first embodiment of the present invention. [Figure 11] This is a flowchart showing the remainder of the general processing procedure for releasing the idle operation state that restricts the operation of the downstream transport operation unit and resuming normal operation of the processing operation unit in the item sorting system of the first embodiment of the present invention, as the processing following connector A in Figure 10. [Figure 12] This is an explanatory diagram of a first loading acceleration correction pattern P1, which is one of the acceleration correction patterns for the transport drive of the downstream transport operation unit that is resumed in response to the output of an incoming item detection signal in the item sorting system according to the first embodiment of the present invention, in which the acceleration of the downstream transport operation unit from an idle state is completed before the start of item transport into the downstream transport operation unit. [Figure 13] This is an explanatory diagram of an acceleration correction pattern showing a third loading acceleration pattern P3-1, which is one of the acceleration correction patterns for the transport drive of the downstream transport operation section that is resumed in response to the output of an incoming item detection signal in the item sorting system of the first embodiment of the present invention, and which involves multiple stages of gradual acceleration and a case in which acceleration is completed after the start of the item loading, and acceleration is further continued after the loading is completed. [Figure 14]This is an explanatory diagram of a third loading acceleration pattern P3-2, which is one of the acceleration correction patterns of the transport drive of the downstream transport operation section that is resumed in response to the output of an incoming item detection signal in the item sorting system of the first embodiment of the present invention, in which the speed at the start of loading starts from the minimum speed limit, acceleration is completed after the start of loading of the item, and acceleration continues further after the loading is completed. [Figure 15] This is an explanatory diagram of an acceleration correction pattern showing a second loading acceleration pattern P2-1, which is one of the acceleration correction patterns for the transport drive of the downstream transport operation section that is resumed in response to the output of an incoming item detection signal in the item sorting system of the first embodiment of the present invention, and which involves multiple stages of gradual acceleration and a case in which acceleration is completed after the start of the loading of items and before the loading is completed. [Figure 16] This is an explanatory diagram of a second loading acceleration pattern P2-2, which is one of the acceleration correction patterns of the transport drive of the downstream transport operation section that is resumed in response to the output of an incoming item detection signal in the item sorting system of the first embodiment of the present invention, in which the speed at the start of loading starts from the minimum speed limit and acceleration is completed after the start of loading of the item, and before the loading is completed. [Figure 17] 1(a) is an explanatory diagram of transfer slippage, which means that when an item is transported from an upstream conveying operation section to a downstream conveying operation section, the actual item movement speed becomes slower than the ideal speed due to the speed difference between the upstream and downstream sides or a sudden acceleration in the item movement speed in an item sorting system according to the first embodiment of the present invention; (b) is an explanatory diagram of free-running slippage, which means that when an item is transported from an upstream conveying operation section to a downstream conveying operation section, the actual item movement speed becomes slower than the ideal speed because part of the bottom surface of the item is not in contact with any of the conveying sections. [Figure 18] 10 is a schematic configuration diagram of an article inspection system including an article inspection device and a pusher-type sorting device as an article processing device according to a second embodiment of the present invention. FIG. [Figure 19] FIG. 11 is a schematic configuration diagram of an article inspection system including a weighing device as an article processing device according to a third embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0026] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0027] (First embodiment) 1 to 16 show the configuration and operation of an article sorting system including an article processing apparatus according to a first embodiment of the present invention.

[0028] First, the configuration will be described.

[0029] (Overall composition) As shown in Figures 1 and 2, the item sorting system 1 according to the first embodiment of the present invention comprises an upstream side conveying operation unit 10 which sequentially conveys a work W, which is an item to be inspected, in a predetermined conveying direction (to the right in Figure 1) at a speed Vc by a first belt conveyor 11, a downstream side sorting conveying operation unit 20 which, when a work W being conveyed in the predetermined conveying direction by the upstream side conveying operation unit 10 is brought into the upstream end side, sequentially conveys the work W in the predetermined conveying direction at a speed Vrj and operates according to a predetermined sorting method in which the work W being transported in the downstream side conveying section Z2 is gradually moved in a direction perpendicular to the predetermined conveying direction, a downstream side conveying operation unit 30 which forms multiple parallel sorted item conveying paths L1, L2, L3 arranged downstream of each of the specific sorting directions d1, d2 and d3 by the downstream side sorting conveying operation unit 20, and a control device 50 which controls the downstream side sorting conveying operation unit 20.

[0030] The front stage transport operation unit 10 is a front stage transport operation unit that transports the work W to pass through the front stage transport section Z1, and the rear stage sorting transport operation unit 20 is a rear stage transport operation unit that transports the work W to pass through the rear stage transport section Z2 adjacent to the downstream side of the front stage transport section Z1. Note that in this embodiment, the front stage transport section Z1 and the rear stage transport section Z2 are arranged relatively upstream with respect to the multiple sorted product transport paths L1, L2, L3 on the downstream side and adjacent to each other in the transport direction, but it goes without saying that they may be adjacent transport sections in any transport area in the transport path.

[0031] The upstream side conveying operation section 10 is provided with an object detection sensor 15 such as a photocell that detects a work W passing through a predetermined detection position pd within the upstream side conveying section Z1, which is a distance Lc upstream from the upstream end of the downstream side sorting conveying operation section 20, and an object detection signal from this object detection sensor 15 is input into the control device 50, thereby notifying the control device 50 that a work W is about to be transported into the downstream side conveying section Z2.

[0032] The downstream side sorting and conveying operation section 20 has a carrier sorting mechanism 22 (processing operation section; sorting operation section of a predetermined sorting operation method) that performs a predetermined processing operation on the work W that has been transported into the downstream side conveying section Z2 and reached a predetermined operation start position pd.

[0033] A detailed description of the configuration of the carrier sorting mechanism 22 of the rear-stage sorting transport operation section 20 will be omitted, but as described, for example, in Japanese Patent Laid-Open Publication No. 54-131258 and Japanese Patent Publication No. 58-39729, the carrier sorting mechanism 22 comprises a plurality of parallel bars each extending in a direction perpendicular to the article transport direction and supported and driven at both ends by endless chains, a plurality of article transport plates respectively fitted to the parallel bars in a slidable manner, and a plurality of sorting members each arranged in the spatial region between the aforementioned left and right endless chains and shaped to be engageable with the inner protruding portions of the plurality of article transport plates. The system has a number of guide rails extending in the circumferential direction, a movable sorting gate member arranged on the upstream end side of the multiple guide rails and engaging the inward protruding portion of each article transport plate with any one of the guide rails at a predetermined transport start position (a predetermined position in the circumferential direction), and a drive mechanism that indexes the sorting gate member to a predetermined angular position in response to a sorting command input signal (corresponding to the aforementioned article inspection result OK / NG and sorting operation command signal RJ) to a sorting control unit 26 having sorting operation means such as solenoids 23L, 23R.

[0034] The downstream transport operation section 30 is configured with a known conveyor capable of transporting the products along a plurality of sorted product transport paths L1, L2, L3 in the respective downstream transport directions D1, D2, D3.

[0035] The control device 50 is composed of a display operation unit 51, an allocation judgment unit 52 that judges the sorting direction corresponding to the sorting command signal and operates the aforementioned sorting gate member, a statistical processing unit 53 that accumulates the judgment results of the allocation judgment unit 52 and performs statistical processing, an external input / output control unit 54 having an interface function that takes in external inputs that serve as command inputs for allocation control and outputs the judgment results of the allocation judgment unit 52 and the processing result information of the statistical processing unit 53 to the outside, a sorting / transport control unit 55 that outputs a sorting control signal that indicates the timing and sorting direction of the sorting operation to the control unit 26 of the downstream sorting transport operation unit 20 in accordance with the command input taken in by the external input / output control unit 54, and a memory device 52M equivalent to an internal memory that stores setting values ​​and conditions necessary for the processing operations of each unit.

[0036] This control device 50 is configured to control the operation of the downstream sorting transport operation unit 20 (processing operation unit) using the carrier sorting method depending on the input status of the item detection signal from the item detection sensor 15, and as shown in Figure 4, when the loading wait time during which an item is not detected exceeds a predetermined loading wait time and becomes the idling start time Tdl, and the continuous non-detection time of the work detection sensor becomes Tpitch, that is, when the item detection signal is not input to the control device 50 beyond the predetermined loading wait time, an operation limiting operation is performed to limit the item transport speed Vrj in the downstream transport operation unit 20, for example, an idling state (standby operation state) that limits Vrj to 0 (m / s). When the vehicle enters this idling state with operational restriction, the display operation unit 51 transitions from the operating state display screen 51ap shown in FIG. 3(a) to the idling state display screen 51bp shown in FIG. 3(b), and when the vehicle returns from the operational restriction due to the generation of an object detection signal, the display operation unit 51 transitions from the idling state display screen 51bp shown in FIG. 3(b) to the operating state display screen 51cp shown in FIG. 3(c).

[0037] In addition, when an item detection signal from the item detection sensor 15 is input to the control device 50 during operation restriction operation, the control device 50 immediately releases the operation restriction operation and accelerates the item conveying speed in the downstream sorting conveying operation section 20 to a predetermined operating speed.

[0038] Although the detailed hardware configuration of the control device 50 is not shown, it is configured to include, together with the sorting control unit 26, for example, a CPU, ROM, RAM, an input / output interface circuit, a drive circuit, etc., and serves as a controller that executes a plurality of control programs, such as a predetermined conveying control program, a sorting control program, and an acceleration pattern selection control program, stored in the ROM that constitutes the memory device 52M and other memory devices, to perform various functions that will be described later.

[0039] In addition, the memory device 52M of the control device 50 has the function of an acceleration pattern storage means for storing, for example, three (multiple) acceleration patterns P1, P2, P3 shown in Figures 6 and 7 so that when the operation restriction operation is released, the acceleration of the item conveying speed Vrj in the rear stage sorting conveying operation section 20 is completed before the work W starts to be conveyed from the front stage conveying operation section 10 to the rear stage sorting conveying operation section 20, as shown in Figure 5(a), or after the work W starts to be conveyed, as shown in Figures 5(b) and 5(c), the acceleration is completed so that it differs whether or not the acceleration is continued after the conveying is completed.

[0040] Here, the multiple acceleration patterns P1, P2, and P3 are divided into three patterns according to the value of the acceleration completion time Ta from when the work W starts to be carried into the rear-stage conveying section Z2 until the acceleration to the set conveying speed Vrj of the rear-stage sorting conveying operation unit 20 is completed after the operation restriction is released (in FIG. 7, Ta2 and Ta3 facing right are positive, and Ta1 facing left is negative (acceleration is completed before carrying in)). In addition, the predetermined sorting operation of the rear-stage sorting conveying operation unit 20 is more stable when acceleration is performed with the acceleration pattern P2 than when acceleration is performed with the acceleration pattern P3 in which the position of the work W at the time of acceleration completion is closest to the start position pe of the predetermined sorting operation of the rear-stage sorting conveying operation unit 20, and the predetermined sorting operation of the rear-stage sorting conveying operation unit 20 is more stable when acceleration is performed with the acceleration pattern P1 in which the position of the work W at the time of acceleration completion is farthest from the start position pe of the predetermined sorting operation of the rear-stage sorting conveying operation unit 20 than when acceleration is performed with the acceleration pattern P2.

[0041] The distribution determination unit 52 of the control device 50 has a function of a pattern determination means for determining which of the multiple acceleration patterns P1, P2, and P3 to select when resuming the carrying-in of the workpiece W is selected based on the stored information of the memory device 52M, depending on the carrying-in status of the workpiece W. The distribution / transport control unit 55 of the control device 50 is configured to execute a time correction control for the time from when the operation restriction operation in the idling state is released and the product transport speed Vrj in the rear-stage distribution transport operation unit 20 is accelerated to a preset normal operation speed when an article detection signal is input to the control device 50 from the article detection sensor 15 during the operation restriction operation, based on the determination result of the distribution determination unit 52, which is a pattern determination means, and the stored information of the memory device 52M, which is an acceleration pattern storage means. This control corresponds to a control for correcting the time from when the article detection signal is input to the control device 50 to when the rear-stage distribution transport operation unit 20 starts performing the processing operation of the predetermined distribution transport due to the release of the operation restriction operation. In addition, the loading status of the work W here means at least the loading status of the goods based on the input status of the goods detection signal from the goods detection sensor 15, and corresponds to the loading conditions of the goods to the downstream sorting conveying operation section 20, which are determined from the input status of the goods detection signal as well as the work length and conveying speed in the conveying direction corresponding to the set variety, the detection position of the goods detection sensor 15, etc.

[0042] As shown in Figure 8, the memory device 52M stores multiple acceleration patterns P1, P2, and P3 when the operation restriction operation is released and the transport of the work W to the downstream sorting transport operation section 20 is resumed, in association with product registration information including the work length Lw, which is the length of the work W in the transport direction, and the transport speeds Vc, Vrj of the upstream and downstream sides.

[0043] In addition, the item detection sensor 15 is arranged so that its predetermined detection position pd in the upstream conveying section Z1 where it detects the work W can be changed to a different position in the conveying direction, and the allocation determination unit 52 is able to determine which of the multiple acceleration patterns P1, P2, P3 to select when loading is resumed by performing a predetermined theoretical calculation described below that takes into account other predetermined setting values ​​under the current setting conditions, depending on the type information stored in the memory device 52M and the predetermined detection position pd of the item detection sensor 15.

[0044] Furthermore, when an item detection signal from the item detection sensor 15 is not input for longer than a predetermined loading wait time and the continuous non-detection time Tpitch of the work detection sensor is equal to or longer than the preset idling start time Tdl (see Figure 4), the control device 50 exerts an idling function that stops item transport in the carrier sorting mechanism 22 of the downstream side sorting transport operation unit 20, which is the downstream side transport operation unit, just before the start position pe of the predetermined sorting operation, so that when item transport is interrupted beyond the predetermined loading wait time, an operation restriction operation is performed that reduces the energy consumption per unit time of the downstream side sorting transport operation unit 20 compared to normal operation.

[0045] At least one of the multiple acceleration patterns at the time of resumption of loading stored in the acceleration pattern memory means includes multiple acceleration stages, including a pre-loading stage until the loading of the work W into the downstream transport operation section begins, as shown in Figures 6(a) to 6(b), a transfer loading stage corresponding to the transfer loading time from the start of loading of the work W to the completion of loading (see TR1, TR2, and TR3 in Figure 7) as shown in Figures 6(c) to 6(d), and a final stage from the time the item transport speed is accelerated to a predetermined operating speed to the time the work W reaches a predetermined operation start position in the downstream transport section, as shown in Figure 6(e), and the item transport speed Vrj is accelerated in accordance with these multiple acceleration stages, as shown in Figures 12 to 16.

[0046] The multiple acceleration stages, in acceleration pattern P3 in Figure 7, further include a post-transfer acceleration stage corresponding to the post-transfer acceleration time (Ta3-TR3) obtained by subtracting the above-mentioned transfer delivery time TR3 from the acceleration time Ta3 from the time t2 when the work W begins to be transported into the rear stage conveying section Z2 to the time t6 when acceleration to the set conveying speed Vrj3 of the rear stage sorting conveying operation section 20 is completed, i.e., a post-transfer acceleration stage from the end of the transfer delivery time TR3, which is the time when the transport of the work W is completed, to the time t6 when the item conveying speed Vrj in the rear stage sorting conveying operation section 20 is accelerated to the predetermined operating speed Vrj3.

[0047] The rear-stage sorting and conveying operation unit 20 may also be provided with a transit correction sensor 25 that detects the work W during transit carry-in periods TR3, TR1, TR2 from the start time t2, t4, t5 (corresponding to the elapsed time Tc3, Tc1, Tc2 from the item detection time in FIG. 7) of carrying the work W into the rear-stage conveying section Z2 until the completion of carrying in. Furthermore, the front-stage conveying operation unit 10 and the rear-stage sorting and conveying operation unit 20 are each composed of a front-stage belt conveyor 11 and a rear-stage carrier-type conveyor 21.

[0048] Based on such a configuration, the control device 50 executes a predetermined control program stored in the memory device 52M, thereby performing the function of a transfer slippage detection means 56 that calculates the average speed during the transfer delivery period TR based on the product type information and the detection information during the transfer delivery period TR1, TR2 or TR3 (hereinafter simply referred to as TR) and detects slippage in the transport direction of the work W during the transfer delivery period TR (for example, the difference between the travel distance during the transfer delivery period TR at the average speed and the work length Lw).

[0049] The slippage parameter t shown on the product type setting screen 51t in Fig. 8 is a value that is manually set or is automatically calculated from the detection results by the transfer slippage detection means 56. There is a limit to the settable range, with typical values ​​being between 0 and 2. Furthermore, if the slippage parameter t is obtained by automatic calculation and does not fall within the settable range, it is possible to perform the calculation without using correction.

[0050] In addition, the control device 50 also functions as an idle slippage detection means 57 that detects slippage in the conveying direction of the work W in the idle slippage section near the downstream end where the conveying driving force of the upstream conveying operation unit 10 decreases, based on the conveying direction length of the upstream conveying section Z1, the conveying speed Vc of the upstream conveying operation unit 10, and the upstream conveying time (Tc3, Tc1 or Tc2 in Figure 7) from the time t0 when the item detection signal is output from the item detection sensor 15 to the time (t2, t4 or t5 in Figure 7) when a detection signal is output from the transfer correction sensor 25 that detects the leading edge of the work W at the start of conveying into the downstream conveying section Z2.

[0051] 8 is a value that is manually set or is automatically calculated from the detection result by the free running slip detection means 57, and can be set to a value greater than 0 to represent the speed ratio with respect to the case where there is no acceleration / deceleration due to free running slip. If the value obtained by automatic calculation is 0 or less, it is possible to perform the calculation without using correction.

[0052] The control device 50 is further configured to cancel the operation restricted operation when an article detection signal is output from the article detection sensor 15 during the operation restricted operation, and executes time correction control for accelerating the article conveying speed Vrj in the downstream conveying operation section 20 to a predetermined operation speed (Vrj3, Vrj1 or Vrj2 in FIG. 7) based on detection information from the transfer slippage detection means 56 and the free-running slippage detection means 57. Note that in FIG. 8, for convenience of illustration, the conveying speeds Vrj1, Vrj2, Vrj3 are shown as different conveying speeds, but it goes without saying that they may be equal to each other.

[0053] The memory device 52M, which is an acceleration pattern storage means, stores predetermined prerequisites for the downstream side sorting and conveying operation unit 20 (processing operation unit) to operate stably under the setting conditions of the idling function or operation timing based on the product type information, and calculation formulas for the setting values ​​Lcmin1, Lcmin2, Vsmin of the stable operation limits described below, and the control device 50 further has an operation request means 58 which displays and outputs an acceleration pattern selection screen 51ps which displays a plurality of acceleration patterns P1, P2 and P3 including the current acceleration pattern as options when the sorting determination unit 52, which is at least a pattern determination means, determines that the carrier selection mechanism 22 of the downstream side sorting and conveying operation unit 20 cannot operate stably based on the predetermined prerequisites, and requests the selection operation of an acceleration pattern on the stable operation side which satisfies the predetermined prerequisites.

[0054] In addition, when the distribution judgment unit 52 registers a product type, the control device 50 uses the function of the operation request means 58 to display and output setting screens 51r, 51f, and 51t that display the setting conditions for the idling function or operation timing, as shown in Fig. 8, and also displays and outputs an acceleration pattern selection screen 51ps when a pattern detail display is requested, and outputs a selection operation request for the acceleration pattern on the stable operation side by a message, voice, etc. Also, the control device 50 displays and outputs the setting screens 51r, 51f, and 51t and the acceleration pattern selection screen 51ps when the distribution judgment unit 52 judges that the downstream side distribution transport operation unit 20 cannot operate stably based on a predetermined prerequisite.

[0055] The control device 50 selects the corresponding acceleration pattern according to the settings made at the time of product registration. The work length (L), rear stage conveying speed (Vrj), and front stage conveying speed (Vc) are set on the production information setting screen 51r, and a number of main setting values ​​that affect the idling function and the acceleration pattern of the rear stage conveying when released are displayed and output on the setting screen 51f so that they can be manually adjusted (increased or decreased by moving the cursor, operating the operation direction mark, etc.). In this setting screen 51f, underlined portions such as the idling time (Tdl), the distance Lc (previous stage sensor position (Lc) in Figure 8) to the installation position of the previous stage item detection sensor 15 based on the detection position of the transfer correction sensor 25 corresponding to the start position of the delivery of items to the subsequent stage conveying section Z2, and the distance Lp to the operation start position pe of the subsequent stage sorting conveying operation unit 20 based on the detection position by the transfer correction sensor 25 of the delivery of items to the subsequent stage conveying section Z2 are set, and the minimum speed required for stable delivery of items to the subsequent stage conveying section Z2 (minimum delivery speed limit (Vsmin) in Figure 8) and pattern status are displayed.

[0056] Also, in the setting screen 51t, the delay time T3 (hereinafter simply referred to as delay time T3) from the time when the operation restriction in the idling state is released, that is, the time when the next work W is detected by the object detection sensor 15 to the time when the work W reaches the start position pe of the sorting and conveying operation by the downstream side sorting and conveying operation unit 20, and a value corresponding to the slip parameter t for calculating the operation timing by correcting (for example, correcting 10 times) the slip in the conveying direction of the work W during the transfer delivery period TR (for example, the difference between the travel distance during the transfer delivery period TR at the average speed and the work length Lw), and A value corresponding to a free run parameter α for correcting slippage in the transport direction of the work W in the free running section near the downstream end (the section where the transport belt surface separates from the work W near the conveyor rollers) before the work W starts being transported into the rear stage transport section Z2 and where the transport driving force of the front stage transport operation unit 10 decreases, and calculating the operation timing, and a sorting operation time T4 for the time when the next work W reaches the operation start position pe of the sorting transport by the carrier sorting mechanism 22 of the rear stage sorting transport operation unit 20 and the sorting transport operation (carrier sorting operation) continues are each displayed and can be manually adjusted.

[0057] Although there are limitations on the settable ranges of the slip parameter t and the free-run parameter α, any values ​​may be used for the values ​​displayed and manually adjusted on screen 51t as long as the slip parameter t and the free-run parameter α are uniquely determined. For example, even if the calculated range of the slip parameter t is 0 or more and 2 or less (0≦t≦2), when displaying on screen 51t or manually setting it, it is possible to set it to "0 to 200" or "-50 to 50" in advance, and then perform appropriate processing such as "dividing by 100" or "+50 and then dividing by 50" internally before calculation for the set value to calculate the range of the parameter.

[0058] Here, the automatic setting values ​​for each setting are automatically selected as acceleration patterns based on, for example, the type information of the workpiece W, the rear stage conveying speed (Vrj), the front stage conveying speed (Vc), the mounting position (Lc) of the front stage object detection sensor 15, etc. The automatic setting values ​​are the values ​​on the side of the range of setting values ​​that can be calculated as the setting values ​​corresponding to the selected acceleration pattern that provide higher stability of the sorting conveying operation, or the central value. The manual setting values ​​can be increased or decreased and the pattern can be changed by, for example, moving the cursor and operating the operation direction mark, as well as by mechanical adjustment operations using an adjustment mechanism for the mounting position of the object detection sensor 15.

[0059] The control device 50 has the functions of the aforementioned distribution determination unit 52, statistical processing unit 53, external input / output control unit 54 and distribution / transportation control unit 55, as well as the functions of transfer slippage detection means 56, free-running slippage detection means 57 and operation request means 58, and also has the function of calculation means 59 for calculating a number of setting values, and in this embodiment, each setting value and pattern is calculated by theoretical calculation based on product information and manual selection and setting conditions.

[0060] More specifically, the acceleration completion time Ta, which indicates how much time is left to complete the required acceleration when the workpiece W starts to be carried into the rear-stage conveying section Z2, is the time Twa (hereinafter referred to as acceleration completion time Twa) from the time when the workpiece W is detected by the front-stage object detection sensor 15 to the time when the acceleration is completed, minus the front-stage conveying time Tc from the time when the workpiece W is detected by the front-stage object detection sensor 15 to the time when the workpiece W starts to be carried into the rear-stage conveying section Z2. The front-stage conveying time Tc is calculated from the distance Lc to the front-stage object detection sensor 15 based on the detection position of the transfer correction sensor 25, which corresponds to the start position of the conveying of the goods to the rear-stage conveying section Z2, and the conveying speed Vc of the front-stage conveying operation unit 10, according to the following formula (1): Ta=Twa - Tc = Twa - Lc / Vc (1) It can be calculated.

[0061] In addition, among the acceleration patterns P1, P2, and P3 that have different acceleration completion timings, the acceleration pattern P1 satisfies the following formula (1-1): Ta<0 (1-1) The work length Lw is selected and set under the condition that it is equal to or less than the distance Lp from the detection position of the transfer correction sensor 25, which is the start position of carry-in to the rear-stage conveying section Z2, to the operation start position pe of the rear-stage sorting conveying operation unit 20, that is, the following formula (4-1) is satisfied: Lw ≦ Lp (4-1) The acceleration pattern P2 is determined under the condition that the above formula (4-1) is satisfied for the work length Lw, and the following formula (2-1) is satisfied using the average speed Va during the transfer delivery period TR and the work length Lw. 0 ≦ Ta < Lw / Va (2-1) The selection is set.

[0062] In addition, the acceleration pattern P3 is as follows: (Lw / Va) < Ta (3-1a) Ta ≦ (Lw / Va)+(Lp - Lw) / Vd (3-1b) The work length Lw is selected and set under the condition that both of the above are satisfied. Lw ≦ Lp-(Ta-(Lw / Va)) Vd ≦ Lp (4-2) The above will be limited to the range in which the above formula is valid.

[0063] The condition equations for the mounting position (Lc) of the upstream object detection sensor 15 corresponding to the acceleration patterns P1, P2, and P3, which have different acceleration completion timings, are as follows: for acceleration pattern P1, the following equations (1-5), for acceleration pattern P2, the following equations (2-5a) and (2-5b), and for acceleration pattern P3, the following equations (3-5a) and (3-5b).

[0064] Twa Vc ≤ Lc (1-5) (Twa-Lw / Va)·Vc≦Lc···(2-5a) Lc <Twa·Vc ···(2-5b) (Twa-Lw / Va―(Lp-Lw) / Vd)·Vc≦Lc···(3-5a) Lc<(Twa-Lw / Va)·Vc···(3-5b) In addition, the above-mentioned sorting delay time T3 (the time from the time t0 when an object is detected on the upstream side to the time when the operation start position pe is reached) corresponding to the acceleration patterns P1, P2, and P3, which have different acceleration completion timings, is expressed by the following formula (1-2) for acceleration pattern P1, by the following formula (2-2) for acceleration pattern P2, and by the following formula (3-2) for acceleration pattern P3: T3=Tc + Lw / Vm + Lrj / Vrj ···(1-2) T3=Tc+Ta+(Lw-Ta·Va) / Vm +Lrj / Vrj ···(2-2) T3 = Tc + Ta + Lrj / Vrj (3-2) are calculated respectively.

[0065] Here, Vm is the transfer speed when the acceleration of the rear stage conveying speed Vrj is completed at the time the work W begins to be transported into the rear stage conveying section Z2, Vd is a tentative speed equivalent to the average speed when the acceleration of the conveying speed in the rear stage sorting conveying operation section 20 after the work W is transported is a constant acceleration, Va is the average speed of the tentative speed Vd and the front stage conveying speed Vc, and Lrj / Vrj is the time it takes for the work W to pass through the rear stage conveying section Z2 at the set speed Vrj (steady speed) during operation.

[0066] In addition, the elapsed time Tc from the point of object detection on the upstream side, which identifies the start point of transport into the downstream transport section Z2, the transfer speed Vm when the acceleration of the downstream transport speed Vcl is completed at the time the work W starts to be transported into the downstream transport section Z2, and the average speed Va of the provisional speed Vd of the downstream transport speed during acceleration when transferring to the downstream sorting transport operation section during acceleration from when the leading edge of the work W reaches the detection position of the transfer correction sensor 25 until the rear end of the work W passes that detection position, can be calculated respectively by the following equations (5-1), (5-2), (5-3), and (5-4).

[0067] Tc = Lc / Vc (5-1) Vm = (Vrj + Vc) / 2 (5-2) Va = (Vd+Vc) / 2 (5-3) Vd = (Vrj + Vs) / 2 (5-4) The speed at the start of loading, Vs, is calculated using the following formula: Vs = Vrj / Tacc × (Lc / Vc-Twt) =Vrj / Tacc×(Tc-Twt) ···(5-5) is required from.

[0068] The above formula is based on the above-mentioned preconditions for stably executing the sorting and conveying operation of the tier-side sorting and conveying operation unit 20 after the operation restriction operation (idling) is released, and includes the following three conditions.

[0069] (Precondition 1) When the workpiece W reaches the operation start position pe of the rear-stage sorting and transporting operation unit 20, the acceleration of the rear-stage sorting and transporting operation unit 20 is completed. (Precondition 2) When the work W reaches the operation start position pe of the rear-stage sorting and transporting operation unit 20, the transfer of the work W into the rear-stage transport section Z2 (transfer to the rear-stage sorting and transporting operation unit 20) is completed (conditional formula (4-1)), and (Precondition 3) The acceleration of the transport speed of the downstream-side sorting transport operation section 20 is approximately constant.

[0070] If these preconditions are not met, the following measures will be necessary:

[0071] (Measure 1) When Precondition 1 is not satisfied, in order to make the acceleration to the set speed of the conveying speed Vrj in time, in order to lengthen the time Tc from the object detection by the upstream object detection sensor 15 to the start of conveying the work W into the downstream conveying section Z2, the distance Lc from the object detection position pd of the upstream object detection sensor 15 to the detection position of the transfer correction sensor 25, which is the start position of conveying the work W into the downstream conveying section Z2, is increased to a degree that satisfies the following formula (4-4): Lc ≧ (Twa- (Lp-Lw) / Vd -Lw / Va)·Vc = Lcmin1 (4-4) For example, by coarsely and finely adjusting the installation position Lc of the upstream object detection sensor 15 in the conveying direction using its position adjustment mechanism and shortening the acceleration completion time Ta (from positive to negative), the acceleration pattern can be changed from acceleration pattern 3 to acceleration pattern 2 and then to acceleration pattern 1.

[0072] (Measure 2) If precondition 2 is not met, the distance Lp may be specific to the device and may not be changeable, and the work length Lw is determined by the type of product produced, so if neither of these can be changed, the operation restriction in the idling state cannot be applied. Alternatively, precondition 2 may be removed, and the upstream transport distance Lc may be added to the transport distance Lp after the start of loading, and an approximate correction may be performed to determine whether the transfer has been completed, and the operation speed of the downstream sorting transport operation unit 20 may be corrected.

[0073] (Measure 3) In the acceleration patterns P2 and P3, when the work W starts to be carried into the rear-stage conveying section Z2, the conveying speed Vrj of the rear-stage sorting conveying operation unit 20 may become excessively slow (for example, when the distance Lc is short). Therefore, a minimum speed limit is added to the speed Vs at the start of carrying-in, Vsmin, and the minimum value Lcmin of the distance Lc from the item detection position pd of the front-stage item detection sensor 15 to the detection position of the transfer correction sensor 25 is set based on the following formula (4-3).

[0074] Lc ≧((Vsmin / Vrj)·Tacc + Twt)·Vc = Lcmin2 (4-3) Here, Tacc is the acceleration time of the transport speed in the downstream side sorting transport operation unit 20 in the following equation (4-5) (the time from the elapse of Twt to the acceleration completion time Twa).

[0075] Tacc = Twa - Twt (4-5) Using these prerequisites and the measures to be taken when the prerequisites are not met, the control device 50 selects a corresponding acceleration pattern (either acceleration patterns P1, P2, P3, or no corresponding pattern) from multiple set values ​​as shown in Fig. 8, and executes a display output to encourage manual adjustment to a more preferable acceleration pattern by changing the set value or the front-stage sensor position Lc. Note that if there is no corresponding acceleration pattern, an error display output is given stating "no corresponding pattern".

[0076] The above formula is for the case where the slip parameter t and the free-running parameter α are fixed to 1. In this case, the effects of slip during transfers and free-running slip are not flexibly taken into account.

[0077] In contrast, in other cases where the slippage parameter t and the free-run parameter α are used, more accurate calculations are possible for the item movement speeds Va and Vm during transfers, the elapsed time Tc from the time the item is detected in the previous stage, and values ​​using these values. For example, equations (5-1), (5-2), and (5-3) can be transformed into the following equations (6-1), (6-2), and (6-3) for calculation.

[0078] Tc = (Lc-Lgap) / Vc + Lgap / (α·Vc) ···(6-1) Vm =((2-t)·Vrj + α·t·Vc ) / 2 ···(6-2) Va =((2-t)·Vd + α·t·Vc ) / 2 ···(6-3) Here, Lgap is the idling section during transfer shown in FIG. 17(b), and is a distance equivalent to the sum of the gap distance Ls between the front and rear conveyor rollers and the diameters of the front and rear conveyor rollers.

[0079] Furthermore, the distance Lc from the upstream object detection sensor position to the transfer detection position can be set based on the above formula (4-3) when the speed Vs (transfer start speed) at the time when the object starts to be carried into the downstream conveying section Z2 is equal to or greater than the lower limit Vsmin for stable operation. However, it can of course be modified using the slip parameter t, the free run parameter α, the conveyor roller diameter, etc.

[0080] In addition, if a subsequent workpiece W is detected by the upstream object detection sensor 15 before the acceleration of the conveying speed Vrj to the set speed is completed after the operation restriction operation is released, the acceleration completion monitoring timer Twa20 for that subsequent workpiece W is timed, and the acceleration completion monitoring timer Twa20 is included in the upstream conveying time Tc for the subsequent workpiece W, and a similar correction calculation is performed.

[0081] Next, the operation will be described.

[0082] (Product registration and acceleration pattern determination process) In the item sorting system according to the first embodiment of the present invention, as shown in the outline procedure in FIG. 9, when the device is in a stopped state after being powered on, a production information screen including a variety registration screen 51r as shown in FIG. 8 can be displayed, and variety information is set, input, and registered, while a predetermined calculation process is executed by the control device 50 (step S1), and the initial values ​​of each parameter are displayed on the setting screens 51r, 51f, 51t, etc. (step S2).

[0083] Next, when the necessary input or change is prompted and executed for parameters Vc (preceding stage conveying speed), Vrj (steady conveying speed), Lw (work length), Lc (preceding stage conveying distance after object detection), Tdl (idling start time), etc. (step S3), it is determined whether each parameter is set within a specified range (step S4). If each parameter is not within the specified range (NO in step S4), the process returns to the previous step, and if each parameter is within the specified range (YES in step S4), the predetermined parameters Tc, Ta, Vs, Vd, and Vm are internally calculated based on various detection information and setting information (step S5).

[0084] Next, it is determined whether the parameter Lc satisfies both equations (4-4) and (4-3), and if not, an alarm is output indicating that there is an installation position error in the upstream object detection sensor 15, and if the acceleration pattern needs to be changed (step S17), the process returns to the parameter input / change step S3.

[0085] On the other hand, if the parameter Lc satisfies both equations (4-4) and (4-3), then it is determined whether or not it satisfies equations (1-1) and (4-1). If it satisfies equation (1-1) (YES in step S7), a pattern flag 1 corresponding to the acceleration pattern P1 is set, and then the sorting delay time T3 is calculated by equation (1-2) (step S9).

[0086] Furthermore, if equation (1-1) or equation (4-1) is not satisfied (NO in step S7), it is determined whether equations (2-1) and (4-1) are satisfied (step S11), and if equation (2-1) is satisfied (YES in step S11), pattern flag 2 corresponding to acceleration pattern P2 is set, and then selection delay time T3 is calculated using equation (2-2) (step S13).

[0087] If equation (2-1) is not satisfied (NO in step S11), then it is determined whether equations (3-1a), (3-1b) and (4-2) are satisfied (step S14). If equation (3-1) is satisfied, pattern flag 3 corresponding to acceleration pattern P3 is set, and then selection delay time T3 is calculated by equation (3-2) (step S16).

[0088] If the formulas (3-1a), (3-1b) and (4-2) are not satisfied, an error message "No applicable acceleration pattern" is displayed (NO in step S14), and the process returns to inputting / changing the setting value (step S3).

[0089] Then, parameter information such as the set acceleration pattern P1, P2 or P3, the calculated sorting delay time T3, and the sorting operation time T4 after the workpiece arrives at the downstream sorting transport operation unit 20 is displayed (step S10).

[0090] (Operation restrictions after operation starts and their release) In the article selection system of this embodiment, as shown in FIG. 10, the system is in an operation standby state when the operation starts, and first, the idling flag is set to 1 to enter the operation standby state (step S21).

[0091] Next, after a timer for the non-detection continuous time Tpitch of the workpiece detection sensor is started (step S22), it is determined whether or not the delivery of the workpiece W has been detected by the article detection sensor 15 on the upstream side (step S23).

[0092] At this time, if the delivery of the work W is not detected by the upstream object detection sensor 15 (NO in step S23), it is determined whether the continuous undetected time Tpitch of the work detection sensor has become equal to or longer than a certain idling start time Tdl due to the continued undetected time (step S24).

[0093] Then, when the undetected continuous time Tpitch becomes equal to or greater than the idling start time Tdl (YES in step S24), the idling flag corresponding to the operation standby state is set to 1 (step S25), or if the undetected continuous time Tpitch is not equal to or greater than the idling start time Tdl (NO in step S24), the idling flag is not set and the process returns to the workpiece loading determination step S23.

[0094] Next, when a workpiece is carried in (YES in step S23), the non-detection continuous time Tpitch of the workpiece detection sensor is cleared (step S26), and then the idling flag state is determined (step S27).

[0095] At this time, if the idling flag = 1, idling mode = 2, which is a transition mode from standby to operation, is set (step S30), and if the idling flag = 3, then the operation mode is switched to (steps S28, S29), and normal device operation is performed, while the sorting delay time T3 is calculated by equation (1-2) and calculations are performed according to automatic calculation or manual adjustment of each setting value related to the sorting operation of the carrier sorting mechanism 22, and a sorting operation time T4 specific to the carrier sorting mechanism 22 is set (step S29).

[0096] When idling mode=2 is set (step S30), as shown in FIG. While the acceleration completion monitoring timer Twa20 starts (step S31), the pattern flag is determined (step S32), and depending on the pattern flag that has been set, a sorting delay time T3 is calculated from equation (1-2) if the pattern flag = 1, from equation (2-2) if the pattern flag = 2, or from equation (3-2) if the pattern flag = 3. Calculations are then performed according to automatic calculation or manual adjustment of each setting value related to the sorting operation of the carrier sorting mechanism 22, and after a sorting operation time T4 specific to the carrier sorting mechanism 22 is set (step S36), the sorting operation of the carrier sorting mechanism 22 of the downstream sorting conveying operation unit 20 is executed (step S37).

[0097] During this time, whether or not acceleration to the set speed of the conveying speed Vrj of the downstream side sorting conveying operation unit 20 after the operation restriction has been completed is checked by checking whether the count value of the acceleration completion monitoring timer Twa20, which is started when the restriction operation is released, has reached or exceeded the acceleration completion time Twa (step S38). If acceleration has been completed (YES in step S38), then the timer Twa20 is cleared (step S39), and then the idling flag = 3 is set to switch from standby to operating mode (step S40).

[0098] On the other hand, if the acceleration is not complete (NO in step S38), then it is repeatedly determined whether the next workpiece W is being delivered or not until the next workpiece W is delivered (step S41). If the next workpiece W is delivered (YES in step S41), the timer Twa20 shifts the elapsed time Tc for the next workpiece W to determine the acceleration completion time Ta (step S42). Then, an acceleration pattern that satisfies the conditions is reset in the pattern classification process using equations (1-1), (2-1), and (3-1) (step S43), and the process returns to the pattern flag determination step (S32).

[0099] (Idling function and timing correction for an example of the first loading acceleration pattern P1) As shown in Figure 12, in the case of pattern 1, in which the acceleration is completed before the work W transfers to the rear stage, the work W is transported at the transport speed Vc of the front-stage transport operation unit 10 during the drive delay time Twt and during the subsequent acceleration time Tacc for which a constant acceleration a (= Vrj / Tacc) is required, and during the transfer time Tm from the start of entry into the rear-stage transport section Z2 to the completion of the transfer, the work W is transferred and transported at a transfer speed Vm that is approximately halfway between the set transport speed Vrj of the rear-stage sorting transport operation unit 20 and the transport speed Vc of the front-stage transport operation unit 10, and once the transfer is completed, the work W is transported to the operation start position pe (the operation start point in the same figure) before the rear-stage transport time Trj at the set transport speed Vrj has elapsed.

[0100] In this case, as shown in Figure 7, the acceleration pattern P1 at the time of resumption of loading stored in the memory device 52M includes a pre-loading stage P1a until the loading of the work W into the downstream sorting transport operation section 20 begins, a transfer loading stage P1b corresponding to the transfer loading period from the start of loading of the work W to the completion of loading, and a final stage P1c from the point at which the item transport speed is accelerated to a predetermined operating speed Vrj1 to the time at which the work W reaches a predetermined operation start position pe in the downstream transport section Z2, and in these multiple stages, the item transport speed Vrj is accelerated in stages, as shown in Figure 7.

[0101] When starting from an operating state when starting operation from a stopped state, operation can be started by changing idling plug = 1 in step S21 of FIG. 10 to idling plug = 2 and changing the judgment condition from step S27 to step S30 from idling plug = 1 to idling plug = 2.

[0102] (Idling function and timing correction for an example of the third loading acceleration pattern P3) Figure 13 shows an example of an acceleration pattern for pattern 3, in which the acceleration completion timing occurs after the work W transfers to the rear stage, and the timing correction conditions are that the acceleration completion time Ta is greater than the work length Lw / transfer average speed Va, and the front-stage conveying speed Vc is less than or equal to the speed Vs at the start of loading into the rear-stage conveying section Z2.

[0103] In this case, during the drive delay time Twt and thereafter until the workpiece W starts to be transported into the rear-stage transport section Z2, the workpiece W is transported at the transport speed Vc of the front-stage transport operation unit 10, and during the acceleration completion time Ta from the start of transport into the rear-stage transport section Z2 to the completion of the transfer acceleration, the speed is gradually switched from the transfer average speed Va to a provisional speed Vd of the accelerating workpiece transport speed of the rear-stage transport operation unit, which is greater than the transfer average speed Va, and the actual speed change is that the workpiece is transported into the transfer station at an acceleration close to a constant acceleration Vrj / Tacc from the start of transport, and when the transfer is completed, the workpiece is transported to the operation start position pe (operation start point in the same figure) within the time the rear-stage transport time Trj at the set transport speed Vrj has elapsed.

[0104] That is, as shown in Figure 7, the acceleration pattern P3 when loading is resumed includes a pre-loading stage P3a until the loading of the work W into the downstream sorting conveying operation section 20 begins, a transfer loading stage P3b corresponding to the transfer loading period from the start of loading of the work W to the completion of loading, and a final stage P3c from the point at which the item conveying speed is accelerated to a predetermined operating speed Vrj3 until the work W reaches a predetermined operation start position pe in the downstream conveying section Z2, and in these multiple stages, while the item conveying speed Vrj is accelerated in stages, an actual acceleration that is substantially close to a constant acceleration a = Vrj / Tacc is performed.

[0105] (Idling function and timing correction of another example of the third loading acceleration pattern P3) Figure 14 shows an example of an acceleration pattern for pattern 3 in which the acceleration completion timing occurs after the work W transfers to the rear stage, and the timing correction conditions are that the acceleration completion time Ta is greater than the work length Lw / transfer average speed Va, and the speed Vs at the start of loading into the rear stage transport section Z2 is the minimum speed Vsmin.

[0106] In this case, during the drive delay time Twt and thereafter until the workpiece W starts to be transported into the rear stage transport section Z2, the workpiece W is transported at the transport speed Vc of the front stage transport operation unit 10, and during the acceleration completion time Ta from the start of transport into the rear stage transport section Z2 to the completion of acceleration, the speed is switched from the transfer average speed Va to the provisional speed Vd of the workpiece being transported during acceleration by the rear stage transport operation unit, and in terms of actual speed change, at the start of the transfer, slippage occurs and the workpiece drops to the rear stage transport speed Vs (≒ minimum speed Vsmin) at the start of transport, and then as the transfer progresses, acceleration close to a substantially constant acceleration Vrj / Tacc occurs, and when the transfer is completed, the workpiece is transported to the operation start position pe (operation start point in the same figure) before the rear stage transport time Trj at the set transport speed Vrj has elapsed.

[0107] (Idling function and timing correction for an example of the second carry-in acceleration pattern P2) Figure 15 shows an example of an acceleration pattern for pattern 2, in which the acceleration completion timing occurs in the middle of the work W transferring to the rear stage, and the conditions for timing correction are that the acceleration completion time Ta is less than or equal to the work length Lw / transfer average speed Va, and the front-stage conveying speed Vc is less than or equal to the speed Vs at the start of loading into the rear-stage conveying section Z2.

[0108] In this case, during the drive delay time Twt and thereafter until the workpiece W starts to be transported into the rear stage transport section Z2, the workpiece W is transported at the transport speed Vc of the front stage transport operation unit 10, and from the start of transport into the rear stage transport section Z2 to the completion of the transfer, the workpiece W is accelerated gradually at the transfer average speed Va during the transfer time Ta during acceleration, and at the transfer speed Vm after acceleration is completed, while the actual speed change is such that the workpiece W is accelerated close to a constant acceleration Vrj / Tacc from the start of transport, and when the transfer is completed, the workpiece W is transported to the operation start position pe (operation start point in the same figure) until the rear stage transport time Trj at the set transport speed Vrj has elapsed.

[0109] (Idling function and timing correction of another example of the second carry-in acceleration pattern P2) Figure 16 shows an example of an acceleration pattern for the case of pattern 2, in which the acceleration completion timing occurs in the middle of the work W transferring to the rear stage, and the conditions for timing correction are that the acceleration completion time Ta is less than or equal to the work length Lw / transfer average speed Va, and the speed Vs at the start of loading into the rear stage transport section Z2 becomes the minimum speed Vsmin. In this case, during the drive delay time Twt and thereafter until the workpiece W starts to be transported into the rear stage transport section Z2, the workpiece W is transported at the transport speed Vc of the front stage transport operation unit 10, and from the start of transport into the rear stage transport section Z2 until acceleration is completed, the workpiece W is accelerated in stages at the transfer average speed Va during acceleration, and after acceleration is completed, at the transfer speed Vm after acceleration is completed.In terms of actual speed change, at the start of the transfer, slippage occurs and the speed drops to the rear stage transport speed Vs (≒ minimum speed Vsmin) at the start of transport, and then the workpiece W is transported at the transfer speed in a state where it is accelerated at a constant acceleration close to Vrj / Tacc from the start of transport to the completion of acceleration, and after acceleration is completed, the workpiece W is transported to the operation start position pe (operation start point in the same figure) before the rear stage transport time Trj at the set transport speed Vrj has elapsed.

[0110] Next, the operation will be described.

[0111] (During normal operation) In the item sorting system 1 of this embodiment configured as described above, an instruction to start a predetermined sorting and conveying operation by the carrier sorting mechanism 22 of the downstream sorting and conveying operation unit 20 and one of the sorting directions d1, d2, or d3 is input from the outside to the external input / output control unit 54 of the control unit 50, and each time the supply of each work W is detected by the upstream item detection sensor 15, the control unit 50 controls the sorting and conveying operation of the downstream sorting and conveying operation unit 20, and each work W is sorted and conveyed to a plurality of different sorted item conveying paths L1, L2, L3 depending on the item inspection results performed upstream, etc.

[0112] (Restriction on operation of downstream transport operation part due to interruption of work supply) During such operation, if the supply of the workpieces W is interrupted due to some abnormality occurring upstream of the workpieces W, and the article detection signal from the upstream article detection sensor 15 is not input to the control device 50 for a period exceeding a predetermined carry-in waiting time, an operation restriction operation is executed to restrict the article conveying speed Vrj in the downstream conveying operation unit 20, for example, to a stopped state of Vrj=0, and to put the unit in an idling state. Therefore, the energy consumption in the article sorting system 1, in particular the energy consumption of the downstream conveying operation unit 20 having the carrier sorting mechanism 22, can be reduced.

[0113] (Recovery control from operation restriction due to resumption of work supply) Furthermore, during this operation restriction, when the work supply is resumed and a new work W is detected by the upstream article detection sensor 15 and the article detection signal is input to the control device 50, the operation restriction of the downstream transport operation unit 20 by the control device 50 is released, and immediately after the release, the article transport speed Vrj of the downstream transport operation unit 20 is accelerated from the speed limit value (e.g., 0 m / s) to a predetermined operation speed that is a set speed. This allows the downstream transport operation unit 20 to quickly return from the operation restriction.

[0114] (Acceleration pattern switching control according to recovery conditions) In this embodiment, when an article detection signal is input to the control device 50 during the operation restriction operation in which the downstream side sorting conveying operation unit 20 is in an idling state, it is determined which of the multiple acceleration patterns P1, P2, and P3 to select when the carrying-in is resumed according to the carrying-in status of the work W. Therefore, the transport state of the work W after the article detection is changed or the timing of the operation of the carrier sorting mechanism 22 is shifted due to the difference in transport speed between the downstream side sorting conveying operation unit 20 that forms the article processing section as the downstream side conveying section Z2 and the upstream side upstream conveying operation unit 10 or the change in the transport speed is effectively suppressed. As a result, the article sorting system 1 can stably ensure the capacity and accuracy of the predetermined sorting conveying operation of the downstream side sorting conveying operation unit 20 when the supply of articles is resumed while sufficiently reducing the energy consumption by the operation restriction operation of the article sorting system 1 including the downstream side sorting conveying operation unit 20.

[0115] In addition, in this embodiment, the memory device 52M, which is an acceleration pattern storage means, stores multiple acceleration patterns P1, P2, P3 at the time of resuming loading in association with product type information including the conveying direction length Lw and conveying speed Vrj of the work W. Therefore, the allocation determination unit 52, which is a pattern determination means, can accurately determine the item loading status at the time the operation restriction operation is released based on the product type information, and the acceleration pattern selection at the time of resuming loading in accordance with the work W loading status can be quickly and accurately performed.

[0116] Furthermore, in this embodiment, the upstream article detection sensor 15 is provided so that the predetermined detection position pd in the upstream conveying section Z1 for detecting the workpiece W can be changed in the conveying direction, and the allocation determination unit 52, which is a pattern determination means, can determine which of the multiple acceleration patterns P1, P2, P3 to select when carrying-in is resumed, according to the product type information stored in the memory device 52M and the predetermined detection position pd of the article detection sensor 15. Therefore, the article carrying-in status when the operation restriction operation is released can be more accurately determined based on the product type information and the distance Lc that specifies the predetermined detection position pd of the article detection sensor 15.

[0117] In addition, in this embodiment, when an item detection signal from the item detection sensor 15 on the upstream side is not input to the control device 50 for a period exceeding a predetermined input waiting time Tdl, the control device 50 executes an operation restriction operation that stops item transport in the downstream sorting conveying operation section 20, thereby effectively reducing the energy consumption of the item sorting system 1.

[0118] In this embodiment, as shown in Fig. 7, Fig. 12 or Fig. 16, at least one of the multiple acceleration patterns P1, P2, P3 stored in the memory device 52M at the time of resumed loading includes a loading pre-start stage P1a, P2a or P3a until the loading of the work W to the downstream sorting transport operation unit 20 starts, a transit loading stage P1b, P2b or P3b corresponding to the transit loading period from the loading start point of the work W to the loading completion point, and a final stage P1c, P2c or P3c from the point at which the item transport speed is accelerated to a predetermined operation speed until the work W reaches a predetermined operation start position in the downstream transport section Z2, and the item transport speed Vrj is accelerated in stages in these multiple stages. Therefore, while accelerating the item transport speed Vrj in stages at an appropriate timing, the acceleration of the actual item transport speed can be performed under conditions close to a suitable speed change rate (a = Vrj / Tacc).

[0119] In addition, in this embodiment, the aforementioned multiple stages further include post-transfer acceleration stages P2b, P3b from the time the work W is completed being delivered until the item conveying speed Vrj in the downstream sorting conveying operation section 20 is accelerated to a predetermined operating speed, as in acceleration patterns P2, P3.Therefore, as shown in Figure 13 or Figure 16, it is possible to perform effective acceleration at an appropriate and relatively large speed change rate while accelerating the item conveying speed Vrj in stages at the appropriate timing.

[0120] Furthermore, in this embodiment, the control device 50 calculates the average speed Va during the transfer delivery period based on the product type information and the detection information of the transfer delivery period, and detects slippage of the work W during the transfer delivery period (for example, the section where the running state is as shown in Figure 17(a)) by using a transfer slippage detection means 56, and detects slippage of the work W during the transfer delivery period (for example, the section where the running state is as shown in Figure 17(a)) by using the transfer direction length of the upstream side conveying section Z1, the conveying speed Vc of the upstream side conveying operation unit 10, and the upstream side conveying time Tc from the time when the upstream side item detection sensor 15 outputs an item detection signal to the upstream side when the transfer correction sensor 25 outputs a delivery start detection signal to the downstream side. The control unit 50 further includes a free running slippage detection means 57 that detects slippage of the work W in the free running section (for example, the section where the running state is as shown in Figure 17(b)) where the conveying driving force of the upstream side conveying operation unit 10 is reduced, and performs control of the operation delay time T3 for accelerating and correcting to the ideal speed based on the detection information of the transfer slippage detection means 56 and the free running slippage detection means 57.

[0121] Therefore, when an item detection signal from the item detection sensor 15 on the upstream side is input to the control device 50 during operation restriction operation, the loading status of the work W can be accurately calculated taking into account the slippage during transfer between belt conveyors and free running slippage when loading begins into the downstream sorting conveying operation section 20, and the accuracy of selecting and determining the acceleration pattern when loading is resumed in accordance with the loading status of the work W can be sufficiently improved.

[0122] In this embodiment, the memory device 52M, which is an acceleration pattern storage means, stores the preconditions for stable operation of the rear-stage sorting transport operation unit 20, and when the control device 50 determines that the rear-stage sorting transport operation unit 20 cannot operate stably based on the predetermined preconditions, it further has an operation request means 58 that displays an error message "No corresponding acceleration pattern" on the setting screen 51f and displays and outputs the acceleration pattern selection screen 51ps, and requests a change operation of the acceleration pattern on the stable operation side that satisfies the preconditions of the predetermined acceleration pattern. Therefore, when releasing the operation restriction, although the sorting transport operation of the rear-stage sorting transport operation unit 20 is not stable with acceleration based on the predetermined acceleration pattern, by changing the change operation to the acceleration pattern on the stable operation side that satisfies the predetermined preconditions by the operation request means 58 using the setting value, the front-stage sensor position Lc, etc., a change operation to switch to a more stable acceleration pattern is possible in a timely manner.

[0123] Furthermore, in this embodiment, when it is determined that the downstream-side sorting transport operation unit 20 cannot operate stably, the operation request means 58 displays and outputs the setting screens 51f, 51t and the acceleration pattern selection screen 51ps on which the setting conditions of the idling function or operation timing are displayed, and outputs a selection operation request for the acceleration pattern on the operation stability side, and when the acceleration pattern selection operation is performed, the setting values ​​displayed on the setting screens 51f, 51t can be automatically or manually adjusted to the setting values ​​corresponding to the selected acceleration pattern. Therefore, stable operation of the processing operation unit with a stable acceleration pattern is possible.

[0124] In addition, in this embodiment, the rear-stage sorting and conveying operation unit 20 executes a predetermined sorting operation by a preset sorting method for the work W that has been carried into the rear-stage conveying section Z2 and reached the predetermined operation start position pe, so that the difference in conveying speed between the rear-stage sorting and conveying operation unit 20 that forms the sorting processing operation section as the rear-stage conveying section Z2 and the upstream front-stage conveying operation unit 10 on the upstream side, or a change in the conveying speed, can be effectively suppressed from causing a change in the conveying state of the work W after the detection of the item or a shift in the timing of the operation of the predetermined sorting processing operation unit. Therefore, while sufficiently reducing the energy consumption by the operation limiting operation of the rear-stage sorting and conveying operation unit 20, the ability and accuracy of the predetermined sorting process by the rear-stage sorting and conveying operation unit 20 can be stably ensured when the supply of items is resumed.

[0125] In this way, in this embodiment, it is possible to provide an item sorting system 1 including a downstream sorting conveying operation unit 20 that can sufficiently reduce the energy consumption of the item sorting system 1 including the downstream sorting conveying operation unit 20 when the supply of items from the upstream side is temporarily interrupted, while stably ensuring the capacity and accuracy of a specified sorting conveying operation when the supply of items is resumed.

[0126] Second embodiment FIG. 18 shows an article inspection system 100 including an article inspection device and a sorting device as an article processing device according to the second embodiment of the present invention.

[0127] As shown in Figure 18, the item inspection system 100 of the second embodiment includes a conveying operation unit 110 that sequentially conveys the inspected item, work W, in a predetermined conveying direction (rightward in Figure 18) using multiple belt conveyors 111, 112, 113, an item inspection device 120 that performs item inspection using a predetermined inspection method on the work W that has reached the item detection position pd1 on the upstream end, a pusher sorting device 130 arranged downstream of the item inspection device 120, and a control device 150 that controls the item inspection device 120 and the pusher sorting device 130.

[0128] The item inspection device 120 is configured to inspect the work W being conveyed by the conveying operation unit 110 for suitability of the quality and physical quantities required for the product, for example, by performing a specified X-ray inspection, such as the presence or absence of foreign matter, the presence or absence of missing parts, the suitability of the shape, size, storage condition, etc. of the contents, the distribution of density, thickness, volume or mass, etc.

[0129] The item inspection device 120 includes an X-ray generator (not shown), which can generate X-rays that can penetrate the workpiece W and irradiate the workpiece W on the conveyor 111 in a fan beam shape that is approximately perpendicular to the conveying direction of the conveying operation section 110, an X-ray detector 121 such as an X-ray line sensor camera arranged directly below the upper running section of the conveyor 112, and a processing unit 122 that performs predetermined signal processing to convert the detection signal of the X-ray detector 121 into X-ray image data.

[0130] The pusher sorting device 130 constitutes a sorting device that selectively sorts and discharges the workpieces W being transported in accordance with the inspection results of the article inspection device 120.

[0131] This pusher sorting device 130 has a push member 131 that can push the work W in the sorting area Z3 (predetermined conveying section, item processing operation section) from the conveyor 113 of the conveying operation section 110 outward (lower side in Figure 18) onto the discharged item receiving platform conveyor 180, and a drive mechanism 132 that drives the push member 131 in the approaching direction and the retreating direction (hereinafter referred to as the advancing and retreating directions) toward the sorting area Z3.

[0132] The push-out member 131 also has a distribution function for switching the transport path downstream from the sorting zone Z3, which is the transport path after inspection. The drive mechanism 132 includes, for example, an air cylinder 133, an electromagnetic valve unit 134 that controls the supply and exhaust of air (compressed air) to the air cylinder 133 in response to a control signal input, and a guide mechanism 135 (not shown in detail) that handles the lateral load (side pressure) of the air cylinder 133. The drive mechanism 132 pneumatically drives the air cylinder 133 in the extension / retraction direction by controlling the supply and exhaust of air from an air source 140 including an air compressor or the like.

[0133] 18, the air cylinder 133 is, for example, of a double-acting type, and a piston 142 is slidably housed in the air cylinder 133, and the inside of the air cylinder 133 is divided into a pair of pressure chambers 144A and 144B by this piston 142, and supply and discharge ports 145a and 145b communicating with the pair of pressure chambers 144A and 144B are formed. In addition, a piston rod 143 is fixed to the piston 142, and a pusher member 131 is attached to the tip side of the piston rod 143 protruding outward from the air cylinder 133.

[0134] The pusher sorter 130 has a sorting control unit 136 that generates sorting control signals RJ1 and RJ5 in the backward direction to control the solenoid valve unit 134 in response to input of a sorting command signal RJ and an OK / NG signal, which is an inspection judgment result signal, from a sorting control unit 156 of the control device 150. Then, in response to input of a sorting command signal RJ and an OK / NG signal, which is an inspection judgment result signal, compressed air from the air source 140 side is supplied to the pressure chamber 144A or 144B through the corresponding one of the supply and discharge ports 145a or 145b, while air can be exhausted from the pressure chamber 144B or 144A through the other one of the supply and discharge ports 145b or 145a. The air cylinder 133 moves the piston rod 143 to one side in the forward / backward movement direction so as to cause the push-out member 131 to enter the sorting area Z3 on the conveyor 113 and push the work W being transported outward from the conveyor 113, and conversely, moves the push-out member 131 back out of the sorting area Z3 on the conveyor 113.

[0135] The control device 150 is configured to include a display operation unit 151, an inspection processing unit 152 that executes inspection processing required for each functional unit of the X-ray inspection device 120 in response to an article detection signal from the upstream article detection sensor 115, a statistical processing unit 153 that accumulates and statistically processes the inspection judgment results in the inspection processing unit 152, an external input / output control unit 154 that has an interface function for taking in external inputs that serve as command inputs for the X-ray inspection and outputting the inspection processing results of the inspection processing unit 152 and the processing result information of the statistical processing unit 153 to the outside, a sorting control unit 156 that outputs an operation control signal for the pusher sorter 130 in response to the command input taken in by the external input / output control unit 154 and the processing results of the inspection processing unit 152, a transport control unit 157 that controls the transport operation of the downstream conveyor 113 corresponding to the pusher sorter 130 based on detection signals from the downstream article detection sensor 128 and the transfer correction sensor 129, and a memory device 152M equivalent to an internal memory that stores setting values ​​and conditions required for the processing operation of each unit.

[0136] In the object inspection system 100 of this embodiment configured as described above, the external input / output control unit 154 of the control device 150 receives detection signals from the upstream object detection sensor 115 and the transfer correction sensor 125, as well as detection signals from the downstream object detection sensor 128 and the transfer correction sensor 129. Each time the upstream object detection sensor 115 detects the supply of each work W, the control device 150 controls the restart operation of the specified X-ray inspection process by the object inspection device 120, and depending on the inspection results, the work is sorted into one of several different sorting directions by the pusher sorting device 130.

[0137] If the supply of workpieces W to the article inspection device 120 is interrupted due to an abnormality occurring upstream while the system is operating to perform such article inspection and sorting operations, and an article detection signal from the upstream article detection sensor 115 is not input to the control device 150 for a specified waiting time for loading, an operation restriction operation is executed to restrict the article conveying speed Vrj in the article inspection section Z2 by at least the article inspection device 120 of the article inspection device 120 and the pusher sorting device 130, for example, to a stopped state of Vrj=0, and to an idling state. Therefore, energy consumption in the article inspection system 100 can be reduced.

[0138] Alternatively, if the transport of the workpieces W is interrupted due to the occurrence of some abnormality in the article inspection device 120, and the article detection signal from the downstream article detection sensor 128 is not input to the control device 150 for a period exceeding a predetermined carry-in waiting time, an operation restriction operation is executed to restrict the article transport speed Vrj in the article sorting section Z3 by at least the pusher sorting device 130 of the article inspection device 120 and the pusher sorting device 130, for example, to a stopped state of Vrj=0, and to an idling state. Therefore, the energy consumption in the article inspection system 100 can be reduced.

[0139] If the supply of work W to the item inspection device 120 is interrupted due to the occurrence of some kind of abnormality upstream, and the item detection signals from the upstream item detection sensor 115 and the downstream item detection sensor 128 are not input to the control device 150 for a period exceeding a specified input waiting time, it becomes possible to operate both the item inspection device 120 and the pusher sorting device 130 in an idling state, thereby reducing energy consumption in the item inspection system 100.

[0140] Furthermore, during any of the operation restricted operations, when workpiece transport is resumed and a new workpiece W is detected by the upstream article detection sensor 115 or the downstream article detection sensor 128, and the article detection signal is input to the control device 150, the operation restricted operation of the article inspection device 120 and the pusher sorting device 130 by the control device 150 is released, and immediately after the release, the article transport speed Vrj in the article inspection device 120 and the pusher sorting device 130 is accelerated from the speed limit value (e.g., 0 m / s) to a predetermined operation speed, which is the set speed. This allows the article inspection system 100 to quickly return from the operation restricted operation.

[0141] In this embodiment, when an article detection signal from the upstream or downstream side is input to the control device 150 during operation restriction operation in which at least one of the article inspection device 120 and the pusher sorting device 130 is in an idling state, a determination is made as to which of a plurality of acceleration patterns preset for resuming loading should be selected depending on the loading status of the workpiece W. Therefore, while the energy consumption is sufficiently reduced by the operation restriction operation of the article inspection system 100 including the article inspection device 120 and the pusher sorting device 130, the capacity and accuracy of the specified X-ray inspection and sorting operation of the article inspection device 120 and the pusher sorting device 130 can be stably ensured when the supply of articles is resumed, and the same effect as in the first embodiment can be obtained.

[0142] Third embodiment FIG. 19 shows an article inspection system 200 including a weighing device as an article processing device according to a third embodiment of the present invention.

[0143] As shown in FIG. 19, the article inspection system 200 according to the third embodiment includes a front-stage transport operation unit 210 that sequentially transports a work W in a predetermined transport direction (rightward in FIG. 19) by a plurality of belt conveyors 211, 212, and 213, a front-stage article detection sensor 215 that detects the work W that has reached an article detection position pd on the belt conveyor 211, a transition correction sensor 225 that detects the work W that has passed the article detection position pd and reached a predetermined run-up start position pp, and a downstream transport unit 226 that transports the work W detected by the transition correction sensor 225 to a downstream conveyor 212 by the belt conveyor 212. The system is equipped with an approach transport operation section 220 (rear stage transport operation section) which allows the work W to run up to the entry start position pe within a predetermined conveying speed range, an item weighing detection sensor 226 which detects the work W which has been approach-transported by the belt conveyor 212 and passed the entry start position pe, and a load detection means such as a load cell which receives the weight of the work W as a vertically downward load while being transported by the belt conveyor 213, and which weighs the work W at a predetermined weighing operation timing determined by the weighing device, and a control device 250 which controls the approach transport operation section 220 and the weighing device 230.

[0144] Here, the control device 250 includes a display operation unit 251, an inspection processing unit 252 that executes the run-up transport and weighing processing required for each functional unit of the weighing device 230 in response to an article detection signal from the upstream article detection sensor 215, a statistical processing unit 253 that accumulates and statistically processes the inspection judgment results in the inspection processing unit 252, an external input / output control unit 254 having an interface function for taking in an external input that serves as a command input for the X-ray inspection and outputting the inspection processing results of the inspection processing unit 252 and the processing result information of the statistical processing unit 253 to the outside, and a command input and detection processing unit 254 that are taken in by the external input / output control unit 254. It is composed of a sorting control unit 256 that outputs an operation control signal (RJ, OK / NG in Figure 19) for a sorting device not shown in the figure depending on the processing result of the inspection processing unit 252, a conveying control unit 257 that controls the conveying operation of the pre-run conveying operation unit 220 in response to an item detection signal from the item detection sensor 215 on the upstream side, and controls the conveying operation of the conveyor 213 of the weighing device 230 in response to an item detection signal from the pre-run conveying operation unit 220 and the weighing device 230, and a memory device 252M equivalent to an internal memory that stores setting values ​​and conditions necessary for the processing operation of each unit.

[0145] In the item inspection system 200 of this embodiment, detection signals from the upstream item detection sensor 215 and the transfer correction sensor 225 are input into the external input / output control unit 254 of the control device 250, and each time an item detection signal is input from the upstream item detection sensor 215, the control device 250 executes control to cause the work W that has reached the predetermined approach start position pp to approach by the approach transport operation unit 220, and further, each time the supply of each work W is detected by the item weighing detection sensor 226, which detects the work W to be weighed passing through the loading start position pe, the control device 250 executes predetermined control related to the predetermined weighing operation by the weighing device 230.

[0146] If the supply of workpieces W to the approach transport operation section 220 is interrupted due to some abnormality occurring upstream while the system is operating to perform such article inspection, and the article detection signal from the upstream article detection sensor 215 is not input to the control device 250 for a period exceeding a predetermined carry-in waiting time Tdl, an operation restriction operation is executed to restrict the article conveying speed Vrj in the approach conveying operation of the approach transport operation section 220 and the weighing device 230 and the article conveying speed V in the weighing conveying operation, for example, to a stopped state of Vrj=0, and to an idling state. Therefore, energy consumption in the article inspection system 200 can be reduced.

[0147] During the operation restricted, when workpiece transport is resumed and a new workpiece W is detected by the upstream article detection sensor 215 and the article detection signal is input to the control device 250, the operation restricted operation of the approach transport operation section 220 and the weighing device 230 by the control device 250 is released, and immediately after the release, the article transport speed Vrj in the approach transport operation section 220 and the weighing device 230 and the article transport speed V in the weighing transport operation are accelerated from the limited speed value (e.g., 0 m / s) to the predetermined operation speed, which is the set speed. This allows the article inspection system 200 to quickly return from the operation restricted.

[0148] In this embodiment, when an article detection signal from the upstream side is input to the control device 250 during operation restriction operation in which the approach transport operation section 220 and the weighing device 230 are in an idling state, a determination is made as to which of a plurality of acceleration patterns set in advance for resuming loading should be selected according to the loading status of the workpiece W. Therefore, while the energy consumption is sufficiently reduced by the operation restriction operation of the article inspection system 200 including the approach transport operation section 220 and the weighing device 230, the predetermined approach transport operation capacity and weighing accuracy of the approach transport operation section 220 and the weighing device 230 can be stably ensured when the supply of articles is resumed, and the same effects as in the first embodiment can be obtained.

[0149] In each of the above-mentioned embodiments, a predetermined sorting operation, item inspection, or a preparatory transport operation for said inspection is performed in the item transport section of the downstream transport operation section. However, it goes without saying that the processing operation is not limited to those described above, so long as a predetermined processing operation is carried out on the downstream side in response to item detection on the upstream side.

[0150] As described above, the present invention can provide an item processing apparatus that can sufficiently reduce the energy consumption of the item processing apparatus when the supply of items from the upstream side is temporarily interrupted, while stably ensuring the specified item processing capacity and accuracy when the supply of items is resumed.The present invention is useful for item processing apparatuses and item processing systems equipped with the same that have an idling function that switches to a standby state in which specific operations related to the processing are stopped when the supply of items that are to be processed, such as inspection or sorting, is temporarily interrupted, and returns from the standby state when the supply of items is resumed. [Explanation of symbols]

[0151] 1. Item sorting system 10 Front stage transport operation section 11, 41 Conveyor belt 15, 115, 215 Item detection sensor (item detection sensor on the front stage) 20 Rear stage sorting transport operation unit (rear stage transport operation unit) 21 Carrier type conveyor 22 Carrier selection mechanism (processing operation unit) 23L, 23R solenoid 25, 125, 225 Transit correction sensor 26, 136 Sorting control unit (sorting control unit) 30 Downstream transport section 50, 150, 250 Control device (control unit) 51, 151, 251 Display operation section 51ap, 51bp, 51cp display screen (transition screen) 51f, 51r, 51t setting screen 51ps Pattern selection screen (acceleration pattern selection screen) 52 Sorting judgment section 52M, 152M, 252M memory device (acceleration pattern storage means) 53, 153, 253 Statistical processing unit 54, 154, 254 External input / output control section 55 Sort / Transport Control Unit 56 Means for detecting slippage during transfer 57 Means for detecting slippage during free running 58 Operation request means 59 Calculation means 100, 200 Item Inspection System 110 Transport operation section 111, 211 Belt conveyor (front conveyor) 112, 222 Belt conveyor (rear stage conveying section or front stage conveying section) 113, 213 Belt conveyor (rear stage conveying section, rear stage conveyor) 120 Item inspection device (predetermined processing operation unit) 121 X-ray detector 122 Processing Units 128 Rear-stage object detection sensor 129 Rear-stage transition correction sensor 130 Pusher sorting device (predetermined processing operation unit) 131 Extrusion member 132 Drive mechanism 133 Air Cylinder 134 Solenoid valve unit 135 Guide mechanism 140 Air source 142 Piston 143 Piston rod 144A, 144B Pressure chamber 144a, 144b Supply and exhaust ports 152, 252 Inspection processing section 156, 256 Sorting control section 157, 257 Transport control section 180 Discharge receiving tray conveyor 210 Front stage transport operation section 220 Approach transport operation section 226 Item weighing detection sensor 230 Measuring device (prescribed processing operation part) d1, d2, d3 Allocation direction D1, D2, D3 Downstream transport direction L1, L2, L3 Sorted product transport route Lc distance (distance to the previous sensor position based on the loading start position) Lp distance (distance to the operation start sensor position based on the loading start position) Lw Work length P1, P2, P3 acceleration patterns P1a, P2a, P3a Pre-delivery stage P1b, P2b, P3b Transit loading stage P1c, P2c, P3c Final stage Pd Upstream object detection position Pe: Starting position of rear stage Vc Transport speed of the upstream transport section Vd Virtual speed of workpiece loading speed during acceleration of the downstream transport operation part t Slip parameter t0: Time when an object is detected (time when the object detection signal is output from the previous stage) t2, t4, t5 Start of loading t3, t6, t7 At the end of acceleration T3 Sorting delay time T4 Sorting operation time (operating time) Ta: The time from the detection of an object at the upstream side to the start of carrying it into the downstream side conveying section Ta2 acceleration time Tc, Tc1, Tc2, Tc3: Pre-stage transport time (transport time from the object detection position on the pre-stage side to the start of loading position) TR, TR1, TR2, TR3 Transit Carry-in Period Twa, Twa1, Twa2, Twa3 acceleration completion time Twa20 Acceleration completion monitoring timer Twt drive delay time Va average transfer time Transfer speed after VM acceleration is complete Vrj conveying speed (conveying speed of the rear conveying section) Vrj1, Vrj2, Vrj3 Conveyor speed (predetermined operating speed, set speed) Vs, Vs1, Vs2, Vs3 Speed ​​when entering the rear stage transport section W Work (item, item to be processed) Z1 Front-stage transport section Z2 Rear transport section Z3 Item sorting area α Free-run parameter

Claims

1. a front stage conveying operation section (10) that conveys an article so as to pass through a front stage conveying section; a rear stage conveying operation section (20) that conveys the article so as to pass through a rear stage conveying section adjacent to the downstream side of the front stage conveying section; an article detection sensor (15) that detects an article passing through a predetermined detection position in the upstream conveying section and outputs an article detection signal notifying that the article is being carried into the downstream conveying section; a processing operation unit (22) that executes a predetermined processing operation in a preset manner on an article that has been carried into the downstream conveying section and has reached a predetermined operation start position; a control unit (50) that controls the downstream transport operation unit and the processing operation unit in response to an input state of the object detection signal from the object detection sensor, an article processing device which, when the article detection signal is not input to the control unit beyond a predetermined carry-in waiting time, executes an operation restriction operation which restricts the article conveying speed in the downstream transport operation unit, and, when the article detection signal is input to the control unit during the operation restriction operation, releases the operation restriction operation and accelerates the article conveying speed in the downstream transport operation unit to a predetermined operation speed, The control unit is an acceleration pattern storage means (52M) for storing, as a plurality of acceleration patterns at the time of resuming carrying-in, whether or not the acceleration of the article conveying speed in the rear stage conveying operation section when the operation limiting operation is released is completed before the article starts being carried in from the front stage conveying operation section to the rear stage conveying operation section, or if the acceleration is completed after the article starts being carried in, whether or not the acceleration is continued after the carrying-in is completed; and a pattern determination means for determining which of a plurality of acceleration patterns to select when the loading is resumed according to the loading status of the article, This article processing apparatus is characterized in that, based on the judgment result of the pattern judgment means and the stored information of the acceleration pattern memory means, it performs time correction control for the time from when the article detection signal is input to the control unit to when the processing operation unit performs the specified processing operation due to the release of the operation restriction operation.

2. 2. The article processing apparatus according to claim 1, wherein the acceleration pattern storage means stores a plurality of acceleration patterns for when the loading is resumed in association with product type information including the length of the article in the conveying direction and the conveying speed of the article.

3. the object detection sensor is provided so as to be able to change the predetermined detection position in the upstream transport section where the object is detected in the transport direction, The item processing apparatus according to claim 2, characterized in that the pattern determination means determines which of a plurality of acceleration patterns to select when the loading is resumed, based on the item type information stored in the acceleration pattern memory means and the specified detection position of the item detection sensor.

4. 4. The article processing apparatus according to claim 1, wherein the control unit stops article transport in the downstream transport operation unit when the article detection signal is not input to the control unit beyond the specified input waiting time.

5. An item processing apparatus as described in any one of claims 1 to 3, characterized in that at least one of the multiple acceleration patterns at the time of resumption of loading stored in the acceleration pattern memory means includes a pre-loading stage until the loading of the item into the downstream transport operation section begins, a transfer loading stage corresponding to a transfer loading period from the start of the loading of the item to the completion of the loading, and a final stage from the point at which the item transport speed is accelerated to the specified operation speed until the item reaches the specified operation start position within the downstream transport section, and in the multiple stages, the item transport speed in the downstream transport operation section is accelerated in stages.

6. 6. An article processing apparatus as described in claim 5, characterized in that at least one of the multiple stages further includes a post-transfer acceleration stage from the time when the article is completely loaded until the article conveying speed in the downstream conveying operation section is accelerated to the predetermined operating speed.

7. A transit correction sensor is provided to detect the article during a transit delivery period from the start of delivery of the article to the downstream side transport operation unit to the completion of delivery, the front stage-side transport operation section and the rear stage-side transport operation section are respectively constituted by a front stage-side conveyor and a rear stage-side conveyor, The control unit is a transfer slippage detection means for detecting slippage of the article during the transfer period by calculating an average speed during the transfer period based on the product type information and the detection information of the transfer period; and a free-running slippage detection means for detecting slippage of the article in a free-running section in which the conveying driving force of the upstream conveying operation section is reduced, based on the length of the upstream conveying section in the conveying direction, the conveying speed of the upstream conveying operation section, and the upstream conveying time from the time when the article detection signal is output from the article detection sensor to the time when the detection signal of the article at the start of conveying to the downstream conveying operation section is output from the transfer correction sensor, An item processing device as described in any one of claims 1 to 3, characterized in that, based on detection information from the transfer slippage detection means and the free-running slippage detection means, time correction control is performed for the time from when the item detection signal is input to the control unit to when the processing operation unit performs the specified processing operation due to the release of the operation restriction operation.

8. the acceleration pattern storage means stores a predetermined prerequisite for the processing operation unit to stably operate under a set condition of an idling function or an operation timing based on the product type information, The item processing device described in claim 2, characterized in that the control unit further has an operation request means for displaying and outputting an acceleration pattern selection screen that displays the multiple acceleration patterns including the current acceleration pattern as options when the pattern determination means determines that the processing operation unit cannot operate stably based on the specified preconditions, and for requesting the selection operation of an acceleration pattern on the stable operation side that satisfies the specified preconditions.

9. when the pattern determination means determines that the processing operation unit cannot operate stably based on the predetermined precondition at the time of the product type registration, the operation request means displays and outputs a setting screen on which setting conditions for the idling function or the operation timing are displayed and the acceleration pattern selection screen, and outputs an operation request for selecting the acceleration pattern on the operation stable side; The article processing apparatus according to claim 8, wherein the control unit adjusts the setting value displayed on the setting screen to a setting value corresponding to the selected acceleration pattern when the acceleration pattern is selected.

10. An item processing apparatus as described in any one of claims 1 to 3, characterized in that the processing operation unit performs a predetermined sorting operation or item inspection using a preset sorting method or item inspection method on items that have been transported into the downstream transport section and reached the predetermined operation start position.

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