Roller conveying device, roller conveying method, and roller conveying program

Abstract

To facilitate the determination of a malfunctioning condition with respect to the conveyance of a conveyed object.SOLUTION: A roller conveying device of the present invention comprises: a motor; a conveying roller driven by the motor and conveying a conveyed object; a rotary encoder for measuring a rotational displacement amount of the conveying roller; and control means. The control means includes rotational displacement amount acquiring means for acquiring a rotational displacement amount from the rotary encoder, speed calculating means for calculating a conveying speed of the conveyed object based on the rotational displacement amount, dispersion calculation means for calculating the dispersion of the conveying speed, malfunction determination means for determining whether or not the conveying roller is malfunctioning based on the dispersion, and outputting means for outputting the determination result at least when the conveying roller is determined to be malfunctioning.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to a roller conveyor device, a roller conveying method, and a roller conveying program.

Background Art

[0002] Patent Document 1 discloses a stepping motor driving device that determines the deterioration over time of a component that is driven by a stepping motor.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In a printer, there is a period during which an abnormal state continues before an actual failure such as paper jamming occurs. Since the business stops when a failure occurs, it is desirable to replace the component in the abnormal state before the failure occurs. Therefore, it is desired to determine the abnormal state.

[0005] An object of the present disclosure is to provide a roller conveyor device or the like that facilitates determination of an abnormal state regarding the conveyance of an object to be conveyed.

Means for Solving the Problems

[0006] In one embodiment of the present disclosure, a roller conveyor device includes a motor, a conveyor roller driven by the motor to convey an object, a rotary encoder that measures the rotational displacement amount of the conveyor roller, a rotational displacement amount acquisition means that acquires the rotational displacement amount from the rotary encoder, a speed calculation means that calculates the conveyance speed of the object based on the rotational displacement amount, a variance calculation means that calculates the variance of the conveyance speed, a malfunction determination means that determines whether the conveyor roller is malfunctioning based on the variance, and an output means that outputs the determination result when at least the conveyor roller is determined to be malfunctioning, and a control means.

[0007] In one embodiment of the present disclosure, a roller conveying method is such that a roller conveyor device including a motor, a conveyor roller driven by the motor to convey an object, and a rotary encoder that measures the rotational displacement amount of the conveyor roller acquires the rotational displacement amount from the rotary encoder, calculates the conveyance speed of the object based on the rotational displacement amount, calculates the variance of the conveyance speed, determines whether the conveyor roller is malfunctioning based on the variance, and outputs the determination result when at least the conveyor roller is determined to be malfunctioning.

[0008] In one embodiment of the present disclosure, a roller conveyor program causes a roller conveyor device including a motor, a conveyor roller driven by the motor to convey an object, and a rotary encoder that measures the rotational displacement amount of the conveyor roller to execute a process of acquiring the rotational displacement amount from the rotary encoder, a process of calculating the conveyance speed of the object based on the rotational displacement amount, a process of calculating the variance of the conveyance speed, a process of determining whether the conveyor roller is malfunctioning based on the variance, and a process of outputting the determination result when at least the conveyor roller is determined to be malfunctioning.

Advantages of the Invention

[0009] According to the present disclosure, it is possible to achieve the effect of facilitating the determination of a malfunctioning state regarding the conveyance of an object.

Brief Description of the Drawings

[0010]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Embodiments for Carrying Out the Invention

[0011] The roller conveyor device according to the embodiment in the present disclosure will be described with reference to the drawings. However, the roller conveyor device is not limited to the description in the drawings.

[0012] <First Embodiment> FIG. 1 is a block diagram showing an example of the configuration of the roller conveyor device 10. FIG. 2 is a diagram showing an example of the outer shape of the roller conveyor device 10. FIG. 3 is a diagram showing an example of the internal structure of the roller conveyor device 10. The roller conveyor device 10 includes a control unit 100, a conveyor roller 310, a motor 320, and a rotary encoder 330. However, the number of components shown in FIG. 3 is an example. For example, in FIG. 3, the roller conveyor device 10 includes three sets of conveyor rollers 310. However, the roller conveyor device 10 may include less than three sets of conveyor rollers 310, or may include more than three sets of conveyor rollers 310.

[0013] The roller conveyor device 10 conveys the conveyed object 400 by the conveyor rollers 310 provided inside. For example, the roller conveyor device 10 conveys the conveyed object 400 inserted into the insertion port 360. Alternatively, the roller conveyor device 10 may convey the conveyed object 400 stored inside. The roller conveyor device 10 is, for example, a device incorporated in a card reader that reads and writes information from / to a card and conveys the card as the conveyed object 400. Alternatively, the roller conveyor device 10 is a device incorporated in a printer that prints paper and conveys the paper as the conveyed object 400. However, the roller conveyor device 10 is not limited to these, and may be other devices.

[0014] The motor 320 drives the conveyor roller 310 using the belt 323. In FIG. 3, the motor 320 includes a shaft 321 and a pulley 322 provided on the shaft 321. The motor 320 rotates the pulley 322 to move the belt 323 hung on the pulley 322. The belt 323 is driven by the pulley 322 of the motor 320 and drives the pulley 312 of the conveyor roller 310. In this way, the motor 320 rotates the pulley 322 to move the belt 323 hung on the pulley 322 and drives the pulley 312 of the conveyor roller 310. In FIG. 3, the motor 320 drives three conveyor rollers 310 using the belt 323, but this is just an example. The motor 320 may drive one or two conveyor rollers 310, or may drive more than three conveyor rollers 310. The motor 320 may use a driving force transmission mechanism different from the belt 323. For example, the motor 320 may use a gear, a chain, a cam, or a link, etc. as the transmission mechanism. Alternatively, the motor 320 may use a plurality of transmission mechanisms.

[0015] The conveying roller 310 conveys the conveyed object 400. In FIG. 3, two upper and two lower conveying rollers 310 located at the same distance from the insertion port 360 are each connected by a shaft 311. Further, the upper and lower shafts 311 are connected via a gear box 313. In this way, in FIG. 2, the four conveying rollers 310 constitute one set. However, the conveying rollers 310 may constitute less than four sets, more than four sets, or may operate independently without constituting a set. When the motor 320 drives the belt 323, the upper conveying roller 310 is driven by a pulley 312 provided on the shaft 311 to convey the conveyed object 400. When the shafts 311 of the two upper conveying rollers 310 rotate, the gear box 313 drives the shafts 311 of the two lower conveying rollers 310 to rotate in a direction opposite to the rotation direction of the shafts 311 of the two upper conveying rollers 310. Therefore, the lower conveying roller 310 rotates in the opposite direction to the upper conveying roller 310 and cooperates with the upper conveying roller 310 to convey the conveyed object 400. In this way, the conveying roller 310 is driven by the motor 320 to rotate and conveys the conveyed object 400. However, the driving force transmission mechanism between the conveying rollers 310 is not limited to the belt 323 and the gear box 313, and other transmission mechanisms such as a chain, a cam, or a link may be used.

[0016] The rotary encoder 330 outputs the amount of rotational displacement of the conveying roller 310. The amount of rotational displacement is, for example, a relative rotational angle or an absolute value of the rotational angle, but is not limited thereto. In FIG. 3, a pulley 332 is provided on the shaft 331 of the rotary encoder 330, and the rotary encoder 330 outputs the amount of rotational displacement corresponding to the rotation of the pulley 332. Since the pulley 332 is driven by the belt 323 by which the motor 320 drives the rotary encoder 330, the amount of rotational displacement output by the rotary encoder 330 is a value proportional to the amount of rotational displacement of the conveying roller 310. When the amount of rotational displacement output by the rotary encoder 330 is made the same as the amount of rotational displacement of the conveying roller 310, the diameter of the pulley 332 of the rotary encoder 330 may be made the same as the diameter of the pulley 312 of the conveying roller 310. In this way, the rotary encoder 330 outputs the amount of rotational displacement of the conveying roller 310 or a rotational displacement proportional to the amount of rotational displacement. In the following description, for the sake of convenience of explanation, it is assumed that the amount of rotational displacement output by the rotary encoder 330 is the same as the amount of rotational displacement of the conveying roller 310. The rotary encoder 330 may be directly attached to any one of the conveying rollers 310 without passing through the belt 323. The rotary encoder 330 may be attached to a plurality of conveying rollers 310 instead of one.

[0017] FIG. 4 is a diagram showing an example of the rotary encoder 330. In the rotary encoder 330 of FIG. 4, a rotating disk provided with slits is provided on the shaft 331. The light receiving portion of the optical sensor is provided to face the light emitting portion of the optical sensor with the rotating disk interposed therebetween. Then, the light receiving portion outputs data of a binary pulse train corresponding to a state in which light is received from the light emitting portion at the slit and a state in which no light is received at the shielding portion as the rotating disk rotates. This data is data indicating the amount of rotational displacement of an incremental encoder. However, the rotary encoder 330 is not limited to the incremental type as shown in FIG. 4, and may be an absolute type encoder. The rotary encoder 330 is not limited to the optical type, and may be an encoder of another type such as a magnetic type.

[0018] The control unit 100 includes a rotational displacement amount acquisition unit 110, a speed calculation unit 120, a variance calculation unit 130, a malfunction determination unit 140, and an output unit 150.

[0019] The rotational displacement amount acquisition unit 110 acquires the rotational displacement amount from the rotary encoder 330. For example, the rotational displacement amount acquisition unit 110 may acquire, as the rotational displacement amount, data of a binary pulse train corresponding to the slits and shielded portions of the rotary disk from the rotary encoder 330.

[0020] The speed calculation unit 120 calculates the conveyance speed of the conveyed object 400 based on the rotational displacement amount. For example, the slits and shielded portions on the rotary disk of the rotary encoder 330 have a constant width and the corresponding angles are determined. Therefore, the speed calculation unit 120 can obtain the rotational angle from the number of pulses of the data acquired from the rotary encoder 330. In the following description, the unit of the rotational angle is degree. Further, when the conveyance roller 310 makes one revolution, the conveyed object 400 is conveyed by the length of the circumference of the conveyance roller 310. Therefore, the conveyance distance of the conveyed object 400 is "the length of the circumference of the conveyance roller 310 × rotational angle / 360". And the conveyance speed of the conveyed object 400 is the conveyance distance of the conveyed object 400 divided by time. Therefore, the speed calculation unit 120 may calculate, as the conveyance speed, a value obtained by dividing the conveyance distance obtained from the rotational angle by time. For example, the speed calculation unit 120 may calculate, as the conveyance speed, the conveyance distance obtained from the rotational angle per unit time. For example, the speed calculation unit 120 may calculate the conveyance distance per second or per minute as the conveyance speed.

[0021] The position of the conveyed object 400 may move slightly due to the influence of vibration or the like. On the other hand, when conveying the conveyed object 400, the conveyance roller 310 rotates for a certain period. Therefore, the speed calculation unit 120 may not use the rotational displacement amount generated in a period shorter than the period of conveying the conveyed object 400.

[0022] The dispersion calculation unit 130 calculates the dispersion of the conveyance speed. Dispersion is an index representing the degree of data scatter, and the larger the value, the more scattered the data is. Specifically, dispersion is the mean of the squares of the deviations, which are the differences between the mean value of the data and each data point. The dispersion of the conveyance speed is given by the following formula. Dispersion = (Σ (Conveyance speed - Average conveyance speed) 2 ) / Number of conveyance speeds) To calculate the dispersion, a plurality of conveyance speeds are required. Therefore, the dispersion is calculated using the conveyance speeds over a certain period. Thus, the dispersion calculation unit 130 calculates the dispersion of the conveyance speed for each predetermined period for calculating the dispersion. Hereinafter, the period for calculating the dispersion is referred to as the "dispersion calculation period". That is, the dispersion calculation unit 130 calculates the average conveyance speed, which is the average of all the conveyance speeds calculated by the speed calculation unit 120 during that dispersion calculation period, for each dispersion calculation period. Hereinafter, "all the conveyance speeds calculated by the speed calculation unit 120 during that dispersion calculation period" is simply referred to as "all the conveyance speeds included in that dispersion calculation period". Further, the dispersion calculation unit 130 calculates the deviation (= Conveyance speed - Average conveyance speed) for all the conveyance speeds included in that dispersion calculation period. Then, the dispersion calculation unit 130 counts the number of conveyance speeds included in that dispersion calculation period, and substitutes the counted number of conveyance speeds and the deviation into the above formula to calculate the dispersion.

[0023] In this way, the dispersion calculation unit 130 calculates the dispersion of the conveyance speeds included in each dispersion calculation period for each dispersion calculation period. For example, the dispersion calculation unit 130 may use several hours, several days, one week, one month, or several months as the dispersion calculation period. However, the dispersion calculation unit 130 is not limited to these, and may use a period calculated based on the material and usage frequency of the conveyance roller 310, etc. The deterioration of the conveyance roller 310 often progresses over a certain period. Therefore, the dispersion calculation unit 130 may calculate the dispersion of the conveyance speed using a dispersion calculation period of a certain length, such as one month or several months. The dispersion calculation unit 130 is not limited to one, and may calculate the dispersion in a plurality of dispersion calculation periods.

[0024] The malfunction determination unit 140 determines whether the conveyance roller 310 is malfunctioning based on the variance. Malfunction does not mean a non-operating state, but rather a state where the performance or function has deteriorated. For example, in a normal state, the conveyance roller 310 conveys the conveyed object 400 at a substantially constant conveyance speed. FIG. 5 is a diagram showing an example of the conveyance speed during normal operation. Therefore, the variance of the conveyance speed becomes small. FIG. 6 is a diagram showing an example of the variance during normal operation.

[0025] However, for example, when a part of the outer periphery of the conveyance roller 310 is damaged, slipping or the like occurs, so the rotation speed of the conveyance roller 310 becomes non-uniform. As a result, the conveyance speed of the conveyed object 400 does not become constant and becomes non-uniform. Alternatively, when some of the conveyance rollers 310 are worn and the diameter changes, slipping or the like occurs in some of the conveyance rollers 310, so the rotation speed of the conveyance roller 310 becomes non-uniform. As a result, the conveyance speed of the conveyed object 400 fluctuates. Thus, when deterioration occurs in the conveyance roller 310 and the conveyance of the conveyed object 400 becomes malfunctioning, the variance of the conveyance speed becomes larger than during normal operation. FIG. 7 is a diagram showing an example of the variance during malfunction.

[0026] Therefore, the malfunction determination unit 140 determines whether the conveyance roller 310 is malfunctioning based on the variance of the conveyance speed. For example, the malfunction determination unit 140 may determine that there is a malfunction when the value of the variance exceeds the variance threshold. Alternatively, the malfunction determination unit 140 may determine whether the value of the variance exceeds the variance threshold for each variance calculation period, count the number of variance calculation periods in which the value of the variance exceeds the variance threshold, and determine that there is a malfunction when the count number exceeds the count threshold.

[0027] However, fluctuations in the conveying speed may occur even during normal operation. Therefore, even when the normal state continues, the number of dispersion calculation periods in which the value of the dispersion exceeds the dispersion threshold may exceed the count threshold during the counting period. Thus, the malfunction determination unit 140 may count the number of dispersion calculation periods in which the value of the dispersion exceeds the dispersion threshold for each period in which the count value is counted, and determine that there is a malfunction when the count number exceeds the count threshold. Hereinafter, the period in which the dispersion calculation periods in which the value of the dispersion exceeds the dispersion threshold are counted is referred to as the "counting period". The counting period may be, for example, one day, one week, one month, half a year, or one year, but is not limited thereto, and may be determined based on the usage frequency or the like.

[0028] The causes of malfunction of the conveying roller 310 were described using partial damage to the outer circumference and deformation of the roller diameter. However, the causes of malfunction of the conveying roller 310 are not limited to these, and member deterioration, swelling failure, or deposits can also be assumed.

[0029] The output unit 150 outputs the determination result at least when it is determined that at least the conveying roller 310 is malfunctioning. For example, when it is determined that the conveying roller 310 is malfunctioning, the output unit 150 may output and display a malfunction message such as "The conveying roller 310 is malfunctioning. Please replace it." as the determination result on the display 350. Alternatively, the output unit 150 may output the determination result to another device (not shown). The determination result output by the output unit 150 and the output destination may be appropriately determined by the designer. The output unit 150 may also output the determination result even when it is determined that the conveying roller 310 is not malfunctioning.

[0030] In FIG. 2, the roller conveying device 10 further includes a sensor 340, a display 350, and an insertion port 360.

[0031] Sensor 340 detects the presence or absence of the conveyed object 400. The sensor 340 is, for example, a proximity sensor, an ultrasonic sensor, or a reflective photosensor, but is not limited thereto. In FIG. 3, the sensor 340 detects whether there is a conveyed object 400 above the sensor 340. For example, when the leftmost sensor 340 detects the conveyed object 400 and the other sensors 340 do not detect the conveyed object 400, the conveyed object 400 is located above the leftmost sensor 340. Thus, the position of the conveyed object 400 can be determined based on the detection result of the sensor 340. The output of the sensor 340 is used, for example, to control the operation of the motor 320. For example, the motor 320 may be controlled to operate based on the position of the sensor 340 that has detected the conveyed object 400.

[0032] The display 350 displays information regarding the roller conveyor device 10. For example, when a malfunction of the conveyor roller 310 is detected, the display 350 displays that the conveyor roller 310 is malfunctioning. When no malfunction of the conveyor roller 310 is detected, the display 350 may display that the conveyor roller 310 is not malfunctioning. The display 350 may also display other information such as the conveying state of the conveyed object 400, an error message, and an operation method. In FIG. 2, the display 350 is provided above the roller conveyor device 10. However, the installation position of the display 350 is not limited to FIG. 2 and may be other positions such as the front of the roller conveyor device 10.

[0033] The insertion port 360 is an opening used to insert the conveyed object 400. The insertion port 360 may also serve as an outlet for the conveyed object 400.

[0034] However, the roller conveyor device 10 may not be provided with at least one of the sensor 340, the display 350, and the insertion port 360. For example, the roller conveyor device 10 may not be provided with the display 350. Alternatively, the roller conveyor device 10 may be provided with a different number of components than those shown in FIG. 2 as these components. For example, the roller conveyor device 10 may be provided with less than 4 sensors 340, or may be provided with more than 4 sensors 340. Alternatively, the roller conveyor device 10 may be provided with a plurality of insertion ports 360. Alternatively, the roller conveyor device 10 may be provided with a configuration different from the configuration shown in FIG. 2. For example, the roller conveyor device 10 may be provided with a discharge port for the conveyed object 400 at a position different from the insertion port 360.

[0035] FIG. 8 is a flowchart showing an example of the operation of the control unit 100 of the roller conveyor device 10. The rotational displacement amount acquisition unit 110 acquires the rotational displacement amount from the rotary encoder 330 (step S201). The speed calculation unit 120 calculates the conveyance speed of the conveyed object 400 based on the rotational displacement amount (step S202). The variance calculation unit 130 calculates the variance of the conveyance speed (step S203). The malfunction determination unit 140 determines whether or not the conveyor roller 310 is malfunctioning based on the variance (step S204). The output unit 150 outputs the determination result when at least the conveyor roller 310 is determined to be malfunctioning (Yes in step S205) (step S206). When the conveyor roller 310 is not determined to be malfunctioning (No in step S205), the roller conveyor device 10 ends the operation. Alternatively, the roller conveyor device 10 may return to the operation of step S201.

[0036] The roller conveyor device 10 includes a motor 320, a conveyor roller 310 driven by the motor to convey the conveyed object 400, a rotary encoder 330 that measures the rotational displacement amount of the conveyor roller 310, and a control unit 100. The control unit 100 includes a rotational displacement amount acquisition unit 110, a speed calculation unit 120, a variance calculation unit 130, a malfunction determination unit 140, and an output unit 150. The rotational displacement amount acquisition unit 110 acquires the rotational displacement amount from the rotary encoder 330. The speed calculation unit 120 calculates the conveyance speed of the conveyed object 400 based on the rotational displacement amount. The variance calculation unit 130 calculates the variance of the conveyance speed. The malfunction determination unit 140 determines whether the conveyor roller 310 is malfunctioning based on the variance. The output unit 150 outputs the determination result when at least the conveyor roller 310 is determined to be malfunctioning. With such a configuration, the roller conveyor device 10 outputs a malfunction state regarding the conveyance of the conveyed object 400. Since the roller conveyor device 10 determines and outputs the malfunction of the conveyor roller 310, the user can know the malfunction of the conveyor roller 310 without visually checking the conveyor roller 310 or the like. In this way, the roller conveyor device 10 can facilitate the determination of the malfunction state regarding the conveyance of the conveyed object.

[0037] <Modification example> FIG. 9 is a block diagram showing an example of the configuration of a roller conveyor device 11 which is a modification example. The roller conveyor device 11 identifies at least one of the conveyor roller 310 that actually conveys the conveyed object 400 and the set of conveyor rollers 310, and determines the malfunction of the identified conveyor roller 310 and at least one of the set of conveyor rollers 310. The roller conveyor device 11 includes a control unit 101 in place of the control unit 100 with respect to the configuration of the roller conveyor device 10. And the control unit 101 includes a roller identification unit 160 in addition to the configuration of the control unit 100. In the control unit 101 of the roller conveyor device 11, since the rotational displacement amount acquisition unit 110 and the speed calculation unit 120 operate in the same manner as the roller conveyor device 10, detailed description thereof is omitted.

[0038] The roller specifying unit 160 specifies at least one of the conveying roller 310 that conveys the conveyed object 400 and the set of the conveying rollers 310 based on the position of the conveying roller 310, the length of the conveyed object 400, and the conveyance amount of the conveyed object 400. The position of the conveying roller 310 is fixed. The length of the conveyed object 400 is predetermined as the specification of the roller conveying device 11. Therefore, the roller specifying unit 160 stores in advance the position of the conveying roller 310 and the length of the conveyed object 400. For example, at the time of factory shipment, the manufacturer may set it in the roller specifying unit 160. Then, the roller specifying unit 160 calculates the conveyance amount of the conveyed object 400 based on the rotational displacement amount. For example, when the rotational displacement amount is an angle, the conveyance amount of the conveyed object 400 is "the length of the outer circumference of the conveying roller 310 × angle / 360". Then, the roller specifying unit 160 specifies at least one of the conveying roller 310 that conveys the conveyed object 400 and the set of the conveying rollers 310 based on the conveyance amount, the position of the conveying roller 310, and the length of the conveyed object 400.

[0039] When the conveyed object 400 is inserted to the conveyance roller 310 closest to the insertion port, the conveyance roller 310 starts to convey the conveyed object 400. And it is the user, not the conveyance roller 310, that inserts the conveyed object 400 to the position of the conveyance roller 310 closest to the insertion port. Therefore, in the following description, the position where the conveyed object 400 is inserted to the position of the conveyance roller 310 closest to the insertion port is defined as "conveyance amount = 0". And, for example, the conveyance roller 310 closest to the insertion port conveys the conveyed object 400 in the range where the conveyance amount changes from "0" to "the length of the conveyed object 400". Thus, for example, in the range where the conveyance amount changes from "0" to "the length of the conveyed object 400", the roller specifying unit 160 specifies the conveyance roller 310 closest to the insertion port as the conveyance roller 310 that conveys the conveyed object 400. The other conveyance rollers 310 convey the conveyed object 400 in the range where the conveyance amount changes from "the position of that conveyance roller 310" to "the position of the length obtained by adding the length of the conveyed object 400 to the position of that conveyance roller 310". That is, also for the other conveyance rollers 310, the roller specifying unit 160 can specify the conveyance roller 310 that conveys the conveyed object 400 from the conveyance amount of the conveyed object 400, the position of the conveyance roller 310, and the length of the conveyed object 400. This relationship holds even when a plurality of conveyance rollers 310 convey the conveyed object 400 at the same time.

[0040] With reference to the drawings, the operation of specifying the conveyance roller 310 in the roller specifying unit 160 will be described. FIG. 10 is a diagram showing an example of the relationship between the conveyance amount and the conveyance roller 310 that conveys the conveyed object 400. Hereinafter, for convenience of explanation, as shown in FIG. 10, each conveyance roller 310 is called conveyance roller A, conveyance roller B, and conveyance roller C from the left. Further, for clarity of the figure, the upper conveyance roller 310 is omitted. And conveyance roller A, conveyance roller B, and conveyance roller C convey the conveyed object 400 inserted into the insertion port to the discharge port. It is assumed that the intervals between the conveyance rollers 310 are the same. Further, it is assumed that the length of the conveyed object 400 is longer than the interval between the conveyance rollers 310. That is, there are cases where a plurality of conveyance rollers 310 convey the conveyed object 400.

[0041] When the conveyed object 400 is inserted from the insertion port and the right end of the conveyed object 400 is inserted up to the position of the conveying roller A, the conveying roller A starts conveying the conveyed object 400. As described above, this position is set as the initial position of the conveyance amount (conveyance amount = 0). In the following description, the right end of the conveyed object 400 is used as the position of the conveyed object 400.

[0042] (1) When the conveyed object 400 is inserted up to the initial position, the conveying roller A starts conveying the conveyed object 400. Therefore, at the initial position of the conveyance amount, the roller specifying unit 160 specifies the conveying roller A as the conveying roller 310 that conveys the conveyed object 400.

[0043] (2) When the conveyed object 400 is conveyed up to the position of the conveying roller B, the set of the conveying roller A and the conveying roller B conveys the conveyed object 400. Therefore, in the range where the conveyance amount is from the "initial position" to the "position of the conveying roller B", the roller specifying unit 160 specifies the conveying roller A as the conveying roller 310 that conveys the conveyed object 400. And when the conveyance amount exceeds the "position of the conveying roller B", the roller specifying unit 160 specifies the set of the conveying roller A and the conveying roller B as the conveying roller 310 that conveys the conveyed object 400.

[0044] (3) When the conveyed object 400 is further conveyed and the conveyance amount exceeds the "position of the conveying roller A plus the length of the conveyed object 400", the conveying roller A can no longer convey the conveyed object 400, so the conveying roller B conveys the conveyed object 400 alone. Therefore, in the range where the conveyance amount is from the "position of the conveying roller B" to the "position of the conveying roller A plus the length of the conveyed object 400", the roller specifying unit 160 specifies the set of the conveying roller A and the conveying roller B as the conveying roller 310 that conveys the conveyed object 400. And when the conveyance amount exceeds the "position of the conveying roller A plus the length of the conveyed object 400", the roller specifying unit 160 specifies the conveying roller B as the conveying roller 310 that conveys the conveyed object 400.

[0045] (4) Further, the conveyed object 400 is conveyed. When the conveyed object 400 is conveyed to the position of the conveying roller C, the set of the conveying roller B and the conveying roller C conveys the conveyed object 400. Therefore, in the range where the conveyance amount is from "the position obtained by adding the length of the conveyed object 400 to the position of the conveying roller A" to "the position of the conveying roller C", the roller specifying unit 160 specifies the conveying roller B as the conveying roller 310 that conveys the conveyed object 400. And when the conveyance amount exceeds "the position of the conveying roller C", the roller specifying unit 160 specifies the set of the conveying roller B and the conveying roller C as the conveying roller 310 that conveys the conveyed object 400.

[0046] (5) Further, the conveyed object 400 is conveyed. When the conveyance amount exceeds "the position obtained by adding the length of the conveyed object 400 to the position of the conveying roller B", the conveying roller B cannot convey the conveyed object 400, so the conveying roller C conveys the conveyed object 400 alone. Therefore, in the range where the conveyance amount is from "the position of the conveying roller C" to "the position obtained by adding the length of the conveyed object 400 to the position of the conveying roller B", the roller specifying unit 160 specifies the set of the conveying roller B and the conveying roller C as the conveying roller 310 that conveys the conveyed object 400. And when the conveyance amount exceeds "the position obtained by adding the length of the conveyed object 400 to the position of the conveying roller B", the roller specifying unit 160 specifies the conveying roller C as the conveying roller 310 that conveys the conveyed object 400.

[0047] (6) Further, when the conveyed object 400 is conveyed, a part of the conveyed object 400 is discharged from the discharge port. And when the conveyed object 400 is further conveyed and the conveyance amount becomes "the position obtained by adding the length of the conveyed object 400 to the position of the conveying roller C", the conveying roller C cannot convey the conveyed object 400. Therefore, in the range where the conveyance amount is from "the position obtained by adding the length of the conveyed object 400 to the position of the conveying roller B" to "the position obtained by adding the length of the conveyed object 400 to the position of the conveying roller C", the roller specifying unit 160 specifies the conveying roller C. And when the conveyance amount becomes "the position obtained by adding the length of the conveyed object 400 to the position of the conveying roller C", the roller specifying unit 160 determines that there is no conveying roller 310 that conveys the conveyed object 400 and the conveyance of the conveyed object 400 is completed.

[0048] In this way, the roller identification unit 160 identifies at least one of the conveying rollers 310 that convey the conveyed object 400 and the set of the conveying rollers 310 based on the conveying amount.

[0049] However, the roller identification unit 160 is not limited to the conveying amount calculated from the rotational displacement amount output by the rotary encoder 330, and may identify at least one of the conveying roller 310 and the set of the conveying rollers 310 with reference to information from other sensors. For example, the roller identification unit 160 may identify at least one of the conveying roller 310 that conveys the conveyed object 400 and the set of the conveying rollers 310 by using the output of a sensor 340 that detects the conveyed object 400, such as the sensor 340 shown in FIG. 2. An example of the operation when the roller identification unit 160 uses the sensor 340 will be described. For the sake of convenience of explanation, the side where the conveyed object 400 is conveyed to the conveying roller 310 is referred to as the upstream side, and the side where the conveyed object 400 is conveyed away from the conveying roller 310 is referred to as the downstream side.

[0050] The roller identification unit 160 may identify at least one of the conveyance roller 310 and the set of conveyance rollers 310 using the output of the sensor 340 on the side (upstream side) where the conveyed object 400 is conveyed. For example, when the sensor 340 located on the upstream side detects the conveyed object 400, the roller identification unit 160 may identify the conveyance roller 310 on the downstream side of the sensor 340 as the conveyance roller 310 that conveys the conveyed object 400. Specifically, for example, when the sensor 340 at the left end of FIG. 2 detects the conveyed object 400, the roller identification unit 160 may identify the leftmost conveyance roller 310 as the conveyance roller 310 that conveys the conveyed object 400. Alternatively, when the sensor 340 immediately adjacent to the right of the leftmost sensor 340 detects the conveyed object 400, the roller identification unit 160 may identify the conveyance roller 310 immediately adjacent to the right of the leftmost conveyance roller 310 as the conveyance roller 310 that conveys the conveyed object 400. When the leftmost sensor 340 and the sensor 340 immediately adjacent to the right detect the conveyed object 400, the roller identification unit 160 may identify the set of the leftmost conveyance roller 310 and the conveyance roller 310 immediately adjacent to the right as the conveyance roller 310 that conveys the conveyed object 400.

[0051] Alternatively, the roller identification unit 160 may identify the conveyor roller 310 that conveys the conveyed object 400 by using the outputs of both the sensor 340 on the side (upstream side) where the conveyed object 400 is conveyed and the sensor 340 on the side (downstream side) where the conveyed object 400 is conveyed. For example, the roller identification unit 160 may identify, as the conveyor roller that conveys the conveyed object 400, the conveyor roller 310 that is detected by both the upstream sensor 340 and the downstream sensor 340. Alternatively, the roller identification unit 160 may identify the conveyor roller 310 sandwiched between the upstream and downstream sensors 340 during the period from when the upstream sensor 340 detects the conveyed object 400 until the downstream sensor 340 stops detecting the conveyed object 400. For example, during the period from when the leftmost sensor 340 detects the conveyed object 400 until the adjacent sensor 340 on the right stops detecting the conveyed object 400, the roller identification unit 160 may identify the leftmost conveyor roller 310 as the conveyor roller 310 that conveys the conveyed object 400. When three or more sensors 340 detect the conveyed object 400, the roller identification unit 160 may identify, as the conveyor roller 310 that conveys the conveyed object 400, a set of a plurality of conveyor rollers 310 sandwiched between those sensors 340.

[0052] The dispersion calculation unit 130 calculates the dispersion of at least one of the identified conveyor roller 310 and the set of conveyor rollers 310. For example, the dispersion calculation unit 130 may classify the conveyance speeds acquired from the speed calculation unit 120 for each of the conveyor roller 310 or the set of conveyor rollers 310 identified by the roller identification unit 160, and calculate the dispersion for each of the classified conveyance speeds.

[0053] The malfunction determination unit 140 determines the malfunction of at least one of the identified conveyor roller 310 and the set of conveyor rollers 310 based on the dispersion of at least one of the identified conveyor roller 310 and the set of conveyor rollers 310. For example, based on the dispersion calculated by the dispersion calculation unit 130 for at least one of the identified conveyor roller 310 and the set of conveyor rollers 310, it may be determined whether at least one of the conveyor roller 310 and the set of conveyor rollers 310 is malfunctioning.

[0054] In this way, even when there are a plurality of conveying rollers 310, the roller conveying device 11 identifies and outputs at least one of the malfunctioning conveying roller 310 and the set of conveying rollers 310. Therefore, the user can know at least one of the malfunctioning conveying roller 310 and the set of conveying rollers 310 without individually checking at least one of the conveying roller 310 and the set of conveying rollers 310. In this way, the roller conveying device 11 facilitates the determination of malfunction of the conveying roller 310 even when there are a plurality of conveying rollers 310.

[0055] <Hardware Configuration> Next, the hardware configurations of the control units 100 and 101 will be described. Each component of the control units 100 and 101 may be constituted by a hardware circuit. In the control units 100 and 101, a plurality of components may be constituted by one piece of hardware. Alternatively, the control units 100 and 101 may be realized as a computer including a processor, a memory, and an interface. The processor is, for example, a central processing unit (CPU: Central Processing Unit), but is not limited thereto. The memory is a read-only memory (ROM: Read Only Memory) and a random access memory (RAM: Random Access Memory), but is not limited thereto. The interface is an input / output interface for connecting a bus to which the processor is connected and other components, and a network interface for connecting the computer and an external network, but is not limited thereto.

[0056] FIG. 11 is a block diagram showing the configuration of a computer 600 which is an example of the hardware configuration of the control units 100 and 101. The computer 600 includes a processor 610, a ROM 620, a RAM 630, a storage device 640, an input / output interface 650, and a network interface 660.

[0057] The processor 610 reads a program from at least one of the ROM 620 and the storage device 640. Then, based on the read program, the processor 610 controls the RAM 630, the storage device 640, the input / output interface 650, and the network interface 660. And the computer 600 including the processor 610 controls these components to realize the functions of the rotational displacement amount acquisition unit 110, the speed calculation unit 120, the variance calculation unit 130, the malfunction determination unit 140, the output unit 150, and the roller identification unit 160. In this way, the computer 600 may realize functions as a combination of hardware and software.

[0058] The processor 610 may read a program included in a recording medium 690 storing a computer-readable program using a recording medium reading device (not shown). Alternatively, the processor 610 may receive a program from a configuration (not shown) via the input / output interface 650, store it in the RAM 630 or the storage device 640, and operate based on the stored program. Alternatively, the processor 610 may receive a program from another device via the network interface 660.

[0059] The ROM 620 stores programs and fixed data executed by the processor 610. The ROM 620 is, for example, a programmable ROM (P-ROM) or a flash ROM. The RAM 630 temporarily stores programs and data executed by the processor 610. The RAM 630 is, for example, a dynamic RAM (D-RAM). The storage device 640 stores data and programs that the computer 600 stores long-term. Also, the storage device 640 may operate as a temporary storage device for the processor 610. The storage device 640 is, for example, a hard disk device or a solid state drive (SSD).

[0060] The ROM 620 and the storage device 640 are non - transitory recording media. On the other hand, the RAM 630 is a transitory recording media. And the processor 610 is operable based on the programs stored in the ROM 620, the storage device 640, and the RAM 630. That is, the processor 610 is operable using either the non - transitory recording media or the transitory recording media. When realizing each function, the processor 610 may use at least one of the RAM 630 and the storage device 640 as a temporary storage medium for programs and data.

[0061] The input / output interface 650 relays the data exchange between the processor 610 and the rotary encoder 330. The input / output interface 650 may also relay the data exchange between the processor 610 and the display 350. The input / output interface 650 is, for example, a PCI (Peripheral Component Interconnect) card.

[0062] The network interface 660 relays the data exchange between the processor 610 and other devices. The network interface 660 is, for example, a LAN (Local Area Network) card or a wireless LAN card.

[0063] The computer 600 configured as described above executes the operations of each component in the control units 100 and 101 to realize the functions as the control units 100 and 101.

[0064] Some or all of the above - described embodiments can also be described as follows in the appended claims, but are not limited thereto.

[0065] (Appended Claim 1) A motor, A conveying roller driven by the motor to convey an object, A rotary encoder that measures the rotational displacement amount of the conveying roller, Rotation displacement amount acquisition means for acquiring the rotation displacement amount from a rotary encoder, speed calculation means for calculating the conveyance speed of the conveyed object based on the rotation displacement amount, variance calculation means for calculating the variance of the conveyance speed, malfunction determination means for determining whether the conveyance roller is malfunctioning based on the variance, output means for outputting the determination result when at least the conveyance roller is determined to be malfunctioning, control means comprising the above, a roller conveyance device comprising the above.

[0066] (Appendix 2) The variance calculation means calculates the variance of the conveyance speeds included in the variance calculation period for each variance calculation period, and the malfunction determination means determines that the motor is malfunctioning when the value of the variance exceeds the variance threshold value. The roller conveyance device according to Appendix 1.

[0067] (Appendix 3) The malfunction determination means counts the number of variance calculation periods in which the value of the variance exceeds the variance threshold value, and determines that the motor is malfunctioning when the count number exceeds the count threshold value. The roller conveyance device according to Appendix 2.

[0068] (Appendix 4) The malfunction determination means counts the number of variance calculation periods in which the value of the variance exceeds the variance threshold value in each count period, and determines that the motor is malfunctioning when the count number exceeds the count threshold value. The roller conveyance device according to Appendix 3.

[0069] (Appendix 5) The variance calculation means calculates the average conveyance speed from all the conveyance speeds included in the variance calculation period in each variance calculation period, calculates the deviation of all the conveyance speeds included in the variance calculation period, and calculates the variance from the number of conveyance speeds and the deviation included in the variance calculation period. The roller conveyance device according to any one of Appendices 2 to 4.

[0070] (Appendix 6) Further provided with roller specifying means for specifying at least one of the conveying rollers for conveying the conveyed object and the set of conveying rollers based on the position of the conveying rollers, the length of the conveyed object, and the conveying amount of the conveyed object. The dispersion calculation means calculates the dispersion of the conveying speed of at least one of the specified conveying rollers and the set of conveying rollers. The malfunction determination means determines the malfunction of at least one of the conveying rollers and the set of conveying rollers based on the dispersion of at least one of the specified conveying rollers and the set of conveying rollers. The roller conveying device according to any one of Appendices 1 to 5.

[0071] (Appendix 7) The roller specifying means calculates the conveying amount of the conveyed object based on the rotational displacement amount. The roller conveying device according to Appendix 6.

[0072] (Appendix 8) Equipped with a sensor for detecting the conveyed object. The roller specifying means specifies at least one of the conveying rollers for conveying the conveyed object and the set of conveying rollers by using the output of the sensor. The roller conveying device according to Appendix 6 or 7.

[0073] (Appendix 9) The roller specifying means specifies at least one of the conveying rollers and the set of conveying rollers by using the output of the sensor on the side where the conveyed object is conveyed. The roller conveying device according to Appendix 8.

[0074] (Appendix 10) The roller specifying means further specifies at least one of the conveying rollers and the set of conveying rollers by using the output of the sensor on the side where the conveyed object is conveyed. The roller conveying device according to Appendix 9.

[0075] (Appendix 11) A motor, A transport roller driven by a motor to transport an object, a rotary encoder that measures the rotational displacement amount of the transport roller, A roller transport device comprising: obtains the rotational displacement amount from the rotary encoder, calculates the transport speed of the object based on the rotational displacement amount, calculates the variance of the transport speed, determines whether the transport roller is malfunctioning based on the variance, and outputs the determination result when at least the transport roller is determined to be malfunctioning. Roller transport method.

[0076] (Appendix 12) A motor, a transport roller driven by the motor to transport an object, a rotary encoder that measures the rotational displacement amount of the transport roller, In a roller transport device comprising: a process of obtaining the rotational displacement amount from the rotary encoder, a process of calculating the transport speed of the object based on the rotational displacement amount, a process of calculating the variance of the transport speed, a process of determining whether the transport roller is malfunctioning based on the variance, a process of outputting the determination result when at least the transport roller is determined to be malfunctioning, A roller transport program to be executed.

[0077] Also, part or all of the configurations described in Appendices 2 to 10 subordinate to the above-described Appendix 1 (roller transport device) may be subordinate to Appendix 11 (roller transport method) and Appendix 12 (roller transport program) in the same subordinate relationship as Appendices 2 to 10. Furthermore, not limited to Appendix 1, Appendix 11, and Appendix 12, within the scope not departing from the above-described embodiments, various hardware, software, various recording means for recording software, or a system may similarly have part or all of the configurations described as appendices subordinate thereto.

[0078] The present invention has been described with reference to the embodiments, but the present invention is not limited to the above embodiments. Various changes that can be understood by those skilled in the art can be made to the configuration and details of the present invention within the scope of the present invention.

Industrial Applicability

[0079] The roller conveyor is not limited to cards and paper, and is applicable to all devices that convey objects using rollers.

Explanation of Signs

[0080] 10 Roller conveyor 11 Roller conveyor 100 Control unit 101 Control unit 110 Rotational displacement amount acquisition unit 120 Speed calculation unit 130 Dispersion calculation unit 140 Malfunction determination unit 150 Output unit 160 Roller identification unit 310 Conveyor roller 311 Shaft 312 Pulley 313 Gearbox 320 Motor 321 Shaft 322 Pulley 323 Belt 330 Rotary encoder 331 Shaft 332 Pulley 340 Sensor 350 Display 360 Insertion port 400 Object to be conveyed 600 Computer 610 Processor 620 ROM 630 RAM 640 Storage device 650 Input / output interface 660 Network Interface 690 Recording Medium

Claims

1. A motor, a conveying roller driven by the motor to convey an object to be conveyed, a rotary encoder for measuring the rotational displacement amount of the conveying roller, a rotational displacement amount acquisition means for acquiring the rotational displacement amount from the rotary encoder, a speed calculation means for calculating the conveying speed of the object to be conveyed based on the rotational displacement amount, a variance calculation means for calculating the variance of the conveying speed, a malfunction determination means for determining whether the conveying roller is malfunctioning based on the variance, an output means for outputting a determination result when at least the conveying roller is determined to be malfunctioning, a control means comprising the above, A roller conveyor device comprising the above.

2. The variance calculation means calculates the variance of the conveying speed included in the variance calculation period for each variance calculation period, The malfunction determination means determines that the motor is malfunctioning when the value of the variance exceeds a variance threshold value. The roller conveyor device according to Claim 1.

3. The malfunction determination means counts the number of variance calculation periods in which the value of the variance exceeds the variance threshold value, and determines that the motor is malfunctioning when the count number exceeds a count threshold value. The roller conveyor device according to Claim 2.

4. The malfunction determination means counts the number of variance calculation periods in which the value of the variance exceeds the variance threshold value in each count period, and determines that the motor is malfunctioning when the count number exceeds a count threshold value. The roller conveyor device according to Claim 3.

5. The distributed calculation means calculates an average conveyance speed from all the conveyance speeds included in the distributed calculation period in each of the distributed calculation periods, calculates a deviation of all the conveyance speeds included in the distributed calculation period, and calculates the variance from the number of the conveyance speeds and the deviation included in the distributed calculation period. The roller conveyor device according to any one of claims 2 to 4.

6. The roller conveyor device further includes roller specifying means for specifying at least one of the conveying rollers that convey the conveyed object and a set of the conveying rollers based on the position of the conveying rollers, the length of the conveyed object, and the conveyance amount of the conveyed object. The distributed calculation means calculates the variance of the conveyance speed of at least one of the specified conveying rollers and the set of the conveying rollers. The malfunction determination means determines a malfunction of at least one of the conveying rollers and the set of the conveying rollers based on the variance of at least one of the specified conveying rollers and the set of the conveying rollers. The roller conveyor device according to any one of claims 1 to 4.

7. The roller specifying means calculates the conveyance amount of the conveyed object based on the rotational displacement amount. The roller conveyor device according to claim 6.

8. The roller conveyor device includes a sensor for detecting the conveyed object. The roller specifying means specifies at least one of the conveying rollers that convey the conveyed object and a set of the conveying rollers using the output of the sensor. The roller conveyor device according to claim 6.

9. A motor, Conveying rollers driven by the motor to convey a conveyed object, A rotary encoder for measuring the rotational displacement amount of the conveying rollers, A roller conveyor device comprising: acquiring the rotational displacement amount from the rotary encoder, Calculate the conveyance speed of the conveyed object based on the rotational displacement amount, Calculate the variance of the conveyance speed, Determine whether the conveying roller is malfunctioning based on the variance, Output the determination result when at least the conveying roller is determined to be malfunctioning. Roller conveying method.

10. A motor, A conveying roller driven by the motor to convey a conveyed object, A rotary encoder that measures the rotational displacement amount of the conveying roller, In a roller conveying device comprising: A process of acquiring the rotational displacement amount from the rotary encoder, A process of calculating the conveyance speed of the conveyed object based on the rotational displacement amount, A process of calculating the variance of the conveyance speed, A process of determining whether the conveying roller is malfunctioning based on the variance, A process of outputting the determination result when at least the conveying roller is determined to be malfunctioning, A roller conveying program to be executed.

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