Anomaly prediction device and automated warehouse

Abstract

Before positional accuracy deteriorates after the system has stopped, abnormal behavior should be appropriately detected. [Solution] The abnormality prediction device comprises a trolley, at least one detection unit for outputting a detection identifier, a control unit for controlling the drive of the trolley, and a determination unit for determining abnormal predictive operation of the interlocking member. The control unit starts stopping control of the trolley when a detection identifier is output, and the determination unit determines abnormal predictive operation of the interlocking member based on whether or not a detection identifier is output between the start of the stopping control and the completion of the stopping of the drive source.

Description

Technical Field

[0001] The technology disclosed in this specification relates to a technology for determining an abnormal precursor operation.

Background Art

[0002] In an automated warehouse, a cart having wheels can travel between storage shelves to store or retrieve items from the storage shelves (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In a cart that drives wheels via an interlocking member such as a belt, the accuracy of the stop position may decrease due to belt loosening or the like. In order to suppress such a case, it is desirable to grasp a precursor of an abnormality before the position accuracy after the stop is degraded.

[0005] The technology disclosed in this specification has been made in view of the problems described above, and is a technology for grasping a precursor of an abnormality before the position accuracy after the stop is degraded.

Means for Solving the Problems

[0006] An abnormality prediction device, which is a first aspect of the technology disclosed in this specification, comprises a trolley capable of traveling on a roadway, comprising a drive source, a wheel linked to the drive source via an interlocking member, at least one detection unit for outputting a detection identifier when the current position of the trolley corresponds to the stopping position of the trolley on the roadway, a control unit for controlling the drive of the trolley, and a determination unit for determining abnormality prediction behavior of the interlocking member, wherein the control unit starts stopping control of the trolley when the detection identifier is output, and the determination unit determines the abnormality prediction behavior of the interlocking member based on whether or not the detection identifier is output between the start of the stopping control and the completion of stopping of the drive source. [Effects of the Invention]

[0007] According to a first aspect of the technology disclosed in this specification, abnormal behavior can be detected and signs of abnormality can be identified before the positional accuracy deteriorates after the stopping is complete.

[0008] Furthermore, the purposes, features, aspects, and advantages related to the technology disclosed in this specification will become even clearer from the detailed description and accompanying drawings provided below. [Brief explanation of the drawing]

[0009] [Figure 1] Figure 1 is a schematic side view showing an example of the configuration of an automated warehouse according to an embodiment. [Figure 2] Figure 2 is a schematic plan view showing an example of the configuration of an automated warehouse according to an embodiment. [Figure 3] Figure 3 is a perspective view showing an example of the configuration of a trolley that travels in an automated warehouse. [Figure 4] Figure 4 shows an example of the body structure of a bogie. [Figure 5] Figure 5 is a perspective view showing an example of the configuration of one of a pair of rails on a track. [Figure 6] Figure 6 is a flowchart showing an example of the operation of the trolley. [Figure 7]Figure 7 shows an example of trolley stopping control. [Figure 8] Figure 8 shows another example of trolley stopping control. [Figure 9] Figure 9 is a flowchart showing an example of a method for controlling retry operations. [Figure 10] Figure 10 shows another example of trolley stopping control. [Modes for carrying out the invention]

[0010] The embodiments will be described below with reference to the attached drawings. In the following embodiments, detailed features will be shown for the purpose of explaining the technology, but these are illustrative, and not all of them are necessarily essential features for the embodiments to be implementable.

[0011] Please note that the drawings are for illustrative purposes only, and for the sake of clarity, some components may be omitted or simplified as appropriate. Furthermore, the relative sizes and positions of components shown in different drawings are not necessarily accurately represented and may be modified as appropriate. In addition, hatching may be used in drawings other than cross-sectional views, such as plan views, to facilitate understanding of the embodiment.

[0012] Furthermore, in the following explanations, similar components will be denoted by the same symbols, and their names and functions will also be the same. Therefore, detailed explanations of them may be omitted to avoid redundancy.

[0013] Furthermore, in the descriptions contained in this specification, when a certain component is described as "equipped with," "includes," or "has," unless otherwise specified, it is not an exclusive expression that excludes the existence of other components.

[0014] In addition, in the descriptions set forth in the specification of the present application, even if ordinal numbers such as "first" or "second" are used, these terms are used for convenience to facilitate understanding of the content of the embodiments, and the content of the embodiments is not limited to the order or the like that may be caused by these ordinal numbers.

[0015] In addition, in the descriptions set forth in the specification of the present application, when it is described as "A or B", this description shall include, as long as there is no contradiction, the case where only one of A and B is indicated and the case where both A and B are indicated.

[0016] In addition, in the descriptions set forth in the specification of the present application, expressions such as "the positive direction of the... axis" or "the negative direction of the... axis" shall take the direction along the arrow of the... axis shown in the figure as the positive direction and the direction opposite to the arrow of the... axis shown in the figure as the negative direction.

[0017] In addition, in the descriptions set forth in the specification of the present application, even if terms meaning specific positions or directions such as "above", "below", "left", "right", "side", "bottom", "front", or "back" are used, these terms are used for convenience to facilitate understanding of the content of the embodiments and have no relation to the positions or directions when the embodiments are actually implemented.

[0018] <Embodiments> Hereinafter, an abnormality prediction determination device and an automated warehouse according to the present embodiment will be described.

[0019] <Regarding the configuration> FIG. 1 is a side view schematically showing an example of the configuration of an automated warehouse according to the present embodiment. Further, FIG. 2 is a plan view schematically showing an example of the configuration of an automated warehouse according to the present embodiment. Further, FIG. 3 is a perspective view showing an example of the configuration of a carriage traveling in the automated warehouse.

[0020] The receiving conveyor 16 is an example of an external conveying device that transports goods 10 from an external position to a position closer to the storage shelves 50. The outbound conveyor 18 is an example of an external conveying device that transports goods 10 from a position close to the storage shelves 50 to an external position further away from the storage shelves 50. The receiving conveyor 16 and the outbound conveyor 18 are, for example, roller conveyors or belt conveyors.

[0021] The storage rack 50 is provided on at least one side of the travel path 48 of the trolley 40, which is a transporter that transports objects horizontally. In this embodiment, a pair of storage racks 50 are provided on both sides of the travel path 48. The storage rack 50 has multiple shelves 52 that are supported at intervals in the vertical direction (the Z-axis direction corresponding to the vertical direction). Each shelf 52 can support and store objects 10. Each shelf 52 in each level can also support multiple objects 10. Therefore, when viewed as a whole, the storage rack 50 stores multiple objects 10 arranged vertically and horizontally. In the storage rack 50, the space in which the objects 10 are stored is the storage space. Therefore, the storage rack 50 has multiple storage spaces arranged along the direction of movement of the trolley 40 traveling on the travel path 48. Each storage space may be continuous without partitions or may be partitioned. Note that there may be only one shelf 52 instead of multiple shelves.

[0022] The travel path 48 is provided along the extending direction (X-axis direction) of the storage rack 50, specifically between a pair of storage racks 50, along the extending direction between them. The travel path 48 extends along the extending direction of the storage rack 50 and extends to the transfer device 60. The travel path 48 is provided corresponding to each of the multiple upper and lower levels of racks 52. Each travel path 48 may be configured, for example, with a pair of rails. The rails may also serve as the lateral frames of the storage rack 50, or they may be configured separately from the storage rack 50.

[0023] The trolley 40, also known as a picker or dolly, is configured to travel back and forth along a travel path 48 extending in the X-axis direction. The trolley 40 is equipped with an object loading / unloading mechanism 42 for loading and unloading objects 10 to and from the storage racks 50 and the transfer device 60.

[0024] A lifting device 30 and a transfer device 60 are provided in a portion of the storage rack 50 in the direction of its extension. In this embodiment, a transfer device 60 for receiving goods, a lifting device 30 for receiving goods, and a conveyor 16 for receiving goods are provided at one end of each of the pair of storage racks 50. In addition, a transfer device 60 for shipping goods, a lifting device 30 for shipping goods, and a conveyor 18 for shipping goods are provided at the other end of each of the pair of storage racks 50. A transfer device, a lifting device, and a conveyor for receiving and shipping goods may also be provided in the middle of the longitudinal direction of the pair of storage racks 50. The transfer device, lifting device, and conveyor do not need to be separated into receiving and shipping types, and may be used for both receiving and shipping goods.

[0025] The transfer device 60, also known as the temporary storage shelf, is a device that relays objects between the lifting device 30 and the trolley 40. The transfer device 60 is equipped with multiple support bases 62, each corresponding to one of the multiple shelves 52. The multiple support bases 62 are located next to the storage shelf 50 and at the same height as the corresponding shelf 52. The support bases 62 are, for example, roller conveyors with rollers. By rotating a motor built into the roller, objects 10 can be moved along the transport direction. The objects 10 on the support bases 62 may also be pushed along the transport direction by a pusher driven by an actuator such as a cylinder, which is provided separately. The trolleys 40, provided corresponding to each shelf 52, can transfer objects 10 to the support bases 62 and shelves 52.

[0026] The lifting device 30 is a lifting device that directly or indirectly passes or receives objects 10 to or from a trolley 40, or to an external transport device, such as an inbound conveyor 16 or an outbound conveyor 18. In this embodiment, the inbound lifting device 30 directly receives objects 10 from the inbound conveyor 16. The lifting device 30 indirectly passes objects 10 to the trolley 40 via an inbound transfer device 60. The outbound lifting device 30 also indirectly receives objects 10 from the trolley 40 via an outbound transfer device 60. The outbound lifting device 30 directly passes objects 10 to or from the outbound conveyor 18. The lifting device 30 may also directly pass or receive objects 10 to or from the transfer device 60.

[0027] The lifting device 30 is a device that lifts and lowers an object 10, and is also called a reservoir. The lifting device 30 comprises a column 31 extending in the vertical direction (Z-axis direction) and a lifting platform 32 that lifts and lowers while supporting the object 10 by the drive of a lifting drive unit (not shown here). The lifting drive unit comprises, for example, a motor and a transmission mechanism that transmits the rotational driving force of the motor to the lifting platform 32. The transmission mechanism may include, for example, a chain (or rotating belt) that is circulatingly supported by sprockets (or pulleys) supported above and below the column 31. In this case, the rotation of the motor is transmitted to the chain (or rotating belt), and the lifting platform 32 is moved up and down by the circulating rotation of the chain (or rotating belt). The lifting platform 32 is, for example, a roller conveyor having rollers. Multiple rollers are rotatably supported in a parallel arrangement by, for example, a frame. The object 10 can be moved along the transport direction by rotating a motor built into the roller. The object 10 on the lifting platform 32 may also be moved along the transport direction by a pusher driven by an actuator such as a cylinder, which is provided separately. The lifting platform 32 moves vertically (in the Z-axis direction) along the column 31 by the drive of the lifting drive unit. As a result, the lifting platform 32 moves up and down to a position corresponding to each of the multiple support platforms 62 at a position adjacent to the transfer device 60. When the lifting platform 32 is positioned at a height corresponding to any of the support platforms 62, the object 10 can be moved horizontally between the lifting platform 32 and the support platform 62 and transferred. In addition, the lifting platform 32 moves up and down to a position corresponding to the receiving conveyor 16 or the shipping conveyor 18 at a position adjacent to the end of the receiving conveyor 16 or the shipping conveyor 18 that is closest to the storage rack 50. By positioning the lifting platform 32 at a height corresponding to the receiving conveyor 16 or the shipping conveyor 18, the object 10 can be moved horizontally between the lifting platform 32 and the receiving conveyor 16 or the shipping conveyor 18.

[0028] The control unit 100 controls the transport operations of the receiving conveyor 16 and the outgoing conveyor 18, the lifting and lowering operations of the lifting device 30, the transfer operations, the transfer operations of the transfer device 60, the travel operations of the trolley 40, and the loading and unloading operations of the goods 10. In the automated warehouse 20, the goods 10 are loaded and unloaded under the control of the control unit 100.

[0029] The control unit 100 may include, for example, a storage device including a memory (recording medium) such as a hard disk drive (i.e., HDD), random access memory (i.e., RAM), read-only memory (i.e., ROM), flash memory, volatile or non-volatile semiconductor memory, magnetic disk, flexible disk, optical disk, compact disk, minidisc, or DVD; a processing circuit such as a central processing unit (i.e., CPU) that executes programs stored in the storage device, an external CD-ROM, an external DVD-ROM, or an external flash memory; an input device that can input information such as a mouse, keyboard, touch panel, or various switches; and an output device that can output information such as a display, liquid crystal display, or lamp.

[0030] In the automated warehouse 20, when an item 10 is received, a database is generated and updated that associates the item 10's identification information (item identification code or name) with its storage location. When an item 10 is received, the available space on the storage shelf 50 is identified by referring to this database, and one of these available spaces is selected as the planned storage location. When an item 10 is released, its storage location is identified by referring to the database. The database may be stored in the storage unit of the control unit 100, or it may be stored in another storage unit.

[0031] As shown in Figure 3, the trolley 40 comprises a body 41 and an item loading / unloading mechanism 42. The trolley 40 is an example of a device for loading or unloading items 10 to or from the storage rack 50.

[0032] The vehicle body 41 is configured to move the loading / unloading mechanism 42 between positions corresponding to the shelves 52 or support bases 62. The vehicle body 41 also incorporates a drive unit 141, which includes a motor and gears. Driven by the drive unit 141, wheels 41a and 41b of the wheels 41a, 41b, 41c, and 41d attached to the vehicle body 41 rotate, allowing the vehicle body 41 to travel along the travel path 48. At each level, the vehicle body 41 moves back and forth along the travel path 48, causing the loading / unloading mechanism 42 to move to a position opposite one of the shelves 52 at that level (specifically, a position opposite the position on the shelf 52 where an object 10 is placed or an empty space where an object should be placed) or to a position opposite the support base 62. The vehicle body 41 is also equipped with a detection unit 53 for detecting position markers, which will be described later.

[0033] The trolley 40 is equipped with a transfer control unit 341, and the control unit 100 provides the transfer control unit 341 with a control signal to control the operation of the trolley 40. Based on this control signal, the transfer control unit 341 controls the operation of the travel drive unit 141, the arm drive unit 241, etc. In addition, data indicating the state of the trolley 40 acquired by the trolley 40 is output to the outside through the transfer control unit 341.

[0034] The object loading / unloading mechanism 42 is a device that takes in an object 10 from the outside into itself, or sends an object 10 from the inside into itself out. The object loading / unloading mechanism 42 comprises a loading platform 45 on which the object 10 is placed, a pair of arms 43 that can move in and out in the Y-axis direction relative to the storage shelf 50 and the transfer device 60, and a pair of claws 44 provided on the leading end of the pair of arms 43 in the direction of extension and in front of the leading end. The upper surface of the loading platform 45 is formed as a plane that is the same as or larger than the bottom surface of the object 10, and spreads along the horizontal direction.

[0035] The pair of arms 43 are driven forward and backward by an arm drive unit 241, which includes a motor. The claws 44 can change their orientation between a state where they are tilted so as to protrude from the ends of the arms 43 by the drive of the motor, etc., and a state where they are aligned vertically along the ends of the arms 43.

[0036] The pair of claws 44 at the leading edge of the pair of arms 43 and the pair of claws 44 closer to the front of the leading edge can be reversed if the direction of extension of the pair of arms 43 is reversed. With the pair of claws closer to the front of the leading edge protruding, the pair of arms 43 are extended, pushing the object 10 on the mounting platform 45 towards the storage shelf 50 or transfer device 60. With the pair of arms 43 extended, the pair of claws 44 at the leading edge are protruding, and then the pair of arms 43 are retracted. This pulls the object 10 on the storage shelf 50 or transfer device 60 side onto the mounting platform 45. As a result, the object 10 is moved between the trolley 40 and the storage shelf 50 or transfer device 60. The object 10 is loaded and unloaded from the storage shelf 50 from the travel path 48 side. The trolley 40 traveling on the travel path 48 can load and unload the object 10 to both of the pair of storage shelves 50.

[0037] Figure 4 shows an example of the configuration of the body section 41 of the bogie 40. As shown in the example in Figure 4, the body section 41 houses a motor 141a, a pulley 141b that transmits the rotation of the motor 141a, and a belt 141c, which is an interlocking member that rotates in conjunction with the pulley 141b, as a driving unit 141. A rotating shaft 41e that interlocks the wheels 41a and wheels 41b attached to the body section 41 is provided passing through the body section 41. The belt 141c is wrapped around the pulley 141b and also around a pulley 41f attached to the rotating shaft 41e, thereby transmitting the rotation of the pulley 141b to the rotating shaft 41e via the pulley 41f. In other words, the belt 141c transmits the rotation of the motor 141a to the wheels 41a and 41b via the rotating shaft 41e. The belt 141c suppresses the transmission of vibrations and other forces between the motor 141a and the wheels 41a and 41b, and also expands the tolerance range for their alignment. In addition to the belt 141c, other interlocking members such as gears, chains, and pulleys can be envisioned to link the rotation of the motor 141a with the drive of the wheels 41a and 41b. The rotating shaft 41e is fixed to the vehicle body 41 so as to be rotatable by a bearing holder set 41g.

[0038] Here, the tension of the belt 141c wrapped around pulleys 141b and 41f may decrease due to aging or deterioration of the belt 141c. If this occurs, a misalignment may occur in the interlocking of pulleys 141b and 41f via the belt 141c.

[0039] On the other hand, even if the above-mentioned discrepancy occurs, it may not be detected as an abnormality in the operation of the trolley 40. For example, when the motor 141a of the trolley 40 is stopped by stop control, even if the pulley 41f rotates too much due to inertia before the motor 141a has finished stopping, causing the above-mentioned discrepancy, the elasticity of the belt 141c may correct (recover) the above-mentioned discrepancy by the time the motor 141a has finished stopping.

[0040] An action that indicates a future malfunction of the trolley 40 is called a malfunction warning action. In the example above, a shift in the stopping position of the trolley 40 at the time the motor 141a finishes stopping corresponds to a malfunction (action) of the trolley 40 (belt 141c), and a shift occurring before the motor 141a finishes stopping corresponds to a malfunction warning action of the trolley 40 (belt 141c).

[0041] In this embodiment, the objective is to take measures such as maintenance before an abnormality occurs in the trolley 40 by recognizing the above-mentioned abnormality warning behavior.

[0042] Figure 5 is a perspective view showing an example of the configuration of one of the pair of rails 48a provided on the track 48.

[0043] The rail 48a comprises a side plate portion 148a, an upper plate portion 148b, a lower plate portion 148c, and a hanging piece 148d. The upper plate portion 148b extends from the upper edge of the side plate portion 148a, and the lower plate portion 148c extends from the lower edge of the side plate portion 148a in the same direction as the upper plate portion 148b. In addition, the hanging piece 148d extends downward from the edge of the upper plate portion 148b opposite to the side plate portion 148a. The vertical dimension (Z-axis direction) of the hanging piece 148d is shorter than the vertical dimension of the side plate portion 148a, and in this case, it is about half the vertical dimension of the side plate portion 148a. Therefore, a narrow gap 148s is formed between the lower side edge of the hanging piece 148d and the leading edge of the lower plate portion 148c, along the extending direction of the rail 48a.

[0044] The rail 48a is supported horizontally on the storage rack 50 with its side plate portion 148a facing the storage rack 50 and its gap 148s facing the space between the pair of storage racks 50. The wheels 41a, 41b, 41c, and 41d attached to the body portion 41 can run on the upper plate portion 148b of the rail 48a.

[0045] Furthermore, the rail 48a is fitted with multiple position markers 49. The position markers 49 are markers that enable the bogie 40 to detect its position on the running track 48. Here, the position markers 49 are the partially recessed portions of the lower edge of the hanging piece 148d. The position markers 49 are formed, for example, by partially cutting out the lower edge of the hanging piece 148d.

[0046] The detection unit 53 provided on the vehicle body 41 is composed of, for example, an optical sensor, and by detecting the position marker 49, the current position of the bogie 40 on the travel path 48 can be detected. The detection unit 53 may consist of a single sensor, or, as shown in the example in Figure 3, detection units 53a, 53b, and 53c, each corresponding to a single sensor, may be arranged along the X-axis direction, which is the travel direction of the bogie 40. The width of one of the sensors is, for example, several millimeters.

[0047] The configuration of the position marker 49 and the detection unit 53 is not limited to the above example. The configuration may involve detecting a protruding portion of the rail 48a as a position marker 49 with an optical sensor or the like provided on the vehicle body 41 as a detection unit 53. Alternatively, the protruding portion of the rail 48a may be deformed when it comes into contact with a part corresponding to the detection unit 53 on the bogie 40, and this deformation may be detected as an identifier. Alternatively, the vehicle body 41 passing the installation position of a sensor (detection unit) attached to the rail 48a may be detected. Alternatively, a permanent magnet attached to the rail 48a may be detected with a magnetic sensor or the like. Any configuration that allows the position marker partially attached to the rail 48a to be detected, for example, electrically or hardware-wise, by the detection unit 53 provided on the bogie 40 or the rail 48a side is acceptable.

[0048] The position marker 49 is intended to indicate the position of the trolley 40 on the running track 48, but here the position marker 49 is used to indicate the position where the trolley 40 is loading or unloading objects 10 from the storage rack 50 and the support base 62.

[0049] The control unit 100 stores the position (distance) of each position marker 49 from one end of the entire travel track 48. The control unit 100 uses one end of the entire travel track 48 as the initial position and, when moving away from the initial position, increments the count of each position marker 49 detected. When moving towards the initial position, it decrements the count of each position marker 49 detected. In this way, the control unit 100 can determine the travel position of the trolley 40 on the travel track 48 based on the position markers 49. When the trolley 40 approaches the target position (stopping position), the control unit 100 can make the trolley 40 travel at a slow speed.

[0050] As shown in Figure 5, each detection unit is equipped with a support portion 153a. The support portion 153a is formed in a U-shape with a bottom portion and two wall portions. With the lower edge of the hanging piece 148d of the rail 48a positioned between the two wall portions of the support portion 153a, the trolley 40 travels along the running track 48 in the positive and negative directions of the X axis.

[0051] When the detection unit 53 is located at a position other than where the position marker 49 is provided, the light emitted from one of the two walls of the support unit 153a is blocked by the hanging piece 148d. On the other hand, when the detection unit 53 is located at the position where the position marker 49 is provided, the light emitted from one of the two walls of the support unit 153a passes through the position marker 49 and is received by the other wall, thereby enabling detection of the position marker 49.

[0052] <About operation> Next, the operation of the trolley 40 in the automated warehouse will be described. In the following, the case in which detection units 53a, 53b, and 53c, shown in Figure 3, are provided will be described with reference to Figure 6. Here, Figure 6 is a flowchart showing an example of the operation of the trolley 40. In the following, it will not be mentioned whether or not the trolley 40 is transporting an object 10, but it can be controlled similarly whether or not the object 10 is being transported.

[0053] The trolley 40's operation is controlled by the transfer control unit 341, which receives control signals from the control unit 100. Specifically, the transfer control unit 341 controls the operation of the travel drive unit 141 and the arm drive unit 241, causing the trolley 40 to transport objects 10 while moving between multiple shelves 52 in the storage shelf 50.

[0054] When the trolley 40 is to stop at a desired position (for example, the position where the object 10 is stored), the trolley 40 is controlled to travel at a low speed from a position a predetermined distance ahead of the desired stopping position, and to stop smoothly at the desired stopping position.

[0055] Next, the stopping operation of the trolley 40 will be explained further. The stopping operation described below is performed when the trolley 40 has determined its desired stopping position and is traveling at a low speed.

[0056] First, detection units 53a, 53b, and 53c all detect a position marker 49 corresponding to the stopping position of the trolley 40 (step ST01). Then, detection units 53a, 53b, and 53c output a detection signal, which is an identifier indicating that a position marker 49 has been detected, to the transfer control unit 341. Here, the width of one position marker 49 in the X-axis direction is assumed to correspond to the sum of the widths of detection units 53a, 53b, and 53c in the X-axis direction.

[0057] Next, when detection signals from all three detection units 53a, 53b, and 53c are transmitted from the transfer control unit 341 to the control unit 100, the control unit 100 outputs a stop control signal to the transfer control unit 341 instructing the trolley 40 to stop moving (step ST02).

[0058] Next, the transfer control unit 341, having received the stop control signal, controls the drive of the travel drive unit 141. Specifically, the transfer control unit 341 starts controlling the motor 141a to stop its rotation (step ST03).

[0059] Next, the transfer control unit 341 determines whether detection signals indicating the detection of the position marker 49 have been output from all of the detection units 53a, 53b, and 53c (step ST04). If detection signals have been output from all of the detection units 53a, 53b, and 53c (corresponding to YES), the process proceeds to step ST06. On the other hand, if no detection signal has been output from at least one of the detection units 53a, 53b, and 53c (corresponding to NO), the process proceeds to step ST05, where the transfer control unit 341 outputs a warning signal to the control unit 100 indicating an abnormal premonitory operation of the trolley 40, or more specifically, an abnormal premonitory operation of the belt 141c. The process then proceeds to step ST06. The control unit 100, upon receiving the warning signal, issues a warning if necessary. The warning is expected to be issued (output) to the worker by sound or screen display. Furthermore, the warning signal may include information on the number of detection units that did not output a detection signal. In this case, the warning signal may be different (for example, different volume or screen display content) to indicate a higher degree of abnormality as the number of detection units that did not output a detection signal increases. This allows for a decision on whether or not to continue operation based on the degree of abnormality. The timing of the warning signal may be the timing of receiving the warning signal, or it may be timed to coincide with the timing of issuing the abnormality warning described later.

[0060] As described above, it is possible to determine abnormal behavior of the trolley 40 (specifically, the belt 141c) between the start of stop control for the trolley 40 and the completion of the stop. In other words, the trolley 40, detection unit, control unit 100, and transfer control unit 341 in the automated warehouse configuration function as an abnormal behavior determination device.

[0061] Next, the transfer control unit 341 determines whether or not the stop control of the motor 141a has been completed (step ST06). Specifically, the transfer control unit 341 determines the completion of the stop control by checking whether or not the rotational speed of the motor 141a is below a predetermined rotational speed. If the stop control is completed (YES), the process proceeds to step ST07; if the stop control is not completed (NO), the process returns to step ST04.

[0062] In step ST07, the transfer control unit 341 determines whether detection signals indicating the detection of the position marker 49 have been output from all of the detection units 53a, 53b, and 53c. If detection signals have been output from all of the detection units 53a, 53b, and 53c (YES), the operation ends, indicating that the stop control of the trolley 40 has been successfully completed. On the other hand, if no detection signal has been output from at least one of the detection units 53a, 53b, and 53c (NO), the process proceeds to step ST08.

[0063] In step ST08, the transfer control unit 341 performs a fine adjustment (retry operation) of the stopping position of the trolley 40. Details of the retry operation will be described later.

[0064] Next, the transfer control unit 341 determines again whether detection signals indicating the detection of the position marker 49 have been output from all of the detection units 53a, 53b, and 53c (step ST09). If detection signals are output from all of the detection units 53a, 53b, and 53c (YES), the operation ends, indicating that the position of the trolley 40 has been adjusted to the appropriate stopping position. On the other hand, if no detection signal is output from at least one of the detection units 53a, 53b, and 53c (NO), the transfer control unit 341 outputs an abnormal signal indicating abnormal operation to the control unit 100 (step ST10) and ends the operation.

[0065] Furthermore, the control unit 100, upon receiving an abnormal signal, will issue an abnormal warning as necessary. The method of issuing (outputting) the abnormal warning is expected to be to the operator, such as by sound or on a screen display.

[0066] Figure 7 shows an example of stop control for the trolley 40. In Figure 7, the positional relationships of the detection units 53a, 53b, and 53c of the trolley 40 with respect to the position marker 49 are shown at different timings. The top row of Figure 7 shows the position of the detection unit at the start timing of the stop control of the trolley 40, the middle row shows the position of the detection unit at the timing between the start and completion of the stop control of the trolley 40, and the bottom row shows the position of the detection unit at the completion timing of the stop control of the trolley 40.

[0067] First, as shown in the upper diagram, the transfer control unit 341 causes the trolley 40 to move at a low speed prior to stopping control. Then, as shown in the middle diagram, when all of the detection units 53a, 53b, and 53c detect the corresponding position marker 49 (step ST01), the transfer control unit 341 starts stopping control of the trolley 40 based on the stop control signal output from the control unit 100 (steps ST02, ST03).

[0068] Next, the transfer control unit 341 monitors that detection signals are being output from all of the detection units 53a, 53b, and 53c (step ST04), and determines that the stop control is complete based on the rotational speed of the motor 141a (step ST06).

[0069] Then, as shown in the lower diagram, after the stop control is completed, the transfer control unit 341 determines that detection signals have been output from all of the detection units 53a, 53b, and 53c (step ST07). In this way, the stop control of the trolley 40 is completed successfully.

[0070] Figure 8 shows another example of stop control for the trolley 40. In Figure 8, the positional relationships of the detection units 53a, 53b, and 53c of the trolley 40 with respect to the position marker 49 are shown at different timings. The first row from the top in Figure 8 shows the position of the detection unit at the start timing of the stop control of the trolley 40, the second and third rows from the top show the position of the detection unit at the timing between the start and completion of the stop control of the trolley 40, and the fourth row from the top shows the position of the detection unit at the completion timing of the stop control of the trolley 40.

[0071] First, as shown in the first diagram from the top, the transfer control unit 341 causes the trolley 40 to move at a low speed prior to stopping control. Then, as shown in the second diagram from the top, when all of the detection units 53a, 53b, and 53c detect the corresponding position marker 49 (step ST01), the transfer control unit 341 starts stopping control of the trolley 40 based on the stop control signal output from the control unit 100 (steps ST02, ST03).

[0072] Next, the transfer control unit 341 determines whether detection signals are being output from all of the detection units 53a, 53b, and 53c (step ST04). In this embodiment, the output of the detection signals is continuously monitored, and at the timing when the detection signal from any one of the detection units 53a, 53b, and 53c is interrupted (the third timing from the top), the transfer control unit 341 outputs a warning signal indicating abnormal operation to the control unit 100 (step ST05).

[0073] Next, it is determined that the stop control has been completed based on the rotational speed of the motor 141a (step ST06).

[0074] Then, as shown in the fourth diagram from the top, after the stop control is completed, the transfer control unit 341 determines that no detection signal has been output from the detection unit 53a (step ST07), and performs a retry operation of the trolley 40 (step ST08).

[0075] Figure 9 is a flowchart showing an example of a method for controlling a retry operation. As shown in the example in Figure 9, first, the transfer control unit 341 identifies the detection unit 53a that is not outputting a detection signal (step ST11). In this embodiment, since the detection units 53a, 53b, and 53c are arranged in this order in the positive X-axis direction, the detection unit 53a is the detection unit located furthest towards the negative X-axis direction, and the detection unit 53c is the detection unit located furthest towards the positive X-axis direction.

[0076] Next, the transfer control unit 341 controls the drive of the motor 141a so as to shift the position of the trolley 40 in the positive X-axis direction, which is the direction opposite to the direction in which the detection unit 53a, which is not outputting a detection signal, is located (step ST12). If, in addition to the detection unit 53a, the detection unit 53b is also not outputting a detection signal, the transfer control unit 341 controls the drive of the motor 141a so as to shift the position of the trolley 40 further in the positive X-axis direction.

[0077] On the other hand, although different from the case shown in Figure 8, if the detection unit 53c does not output a detection signal, the transfer control unit 341 controls the drive of the motor 141a to shift the position of the trolley 40 in the negative X-axis direction, which is the direction opposite to the direction in which the detection unit 53c is located. If neither the detection unit 53c nor the detection unit 53b outputs a detection signal, the transfer control unit 341 controls the drive of the motor 141a to further shift the position of the trolley 40 in the negative X-axis direction.

[0078] As described above, the transfer control unit 341 performs a retry operation of the trolley 40.

[0079] Next, the transfer control unit 341 determines that detection signals are output from all of the detection units 53a, 53b, and 53c (step ST09). In this way, the stopping control of the trolley 40 is successfully completed.

[0080] However, in the case shown in Figure 8, since a warning signal indicating abnormal operation is output, the control unit 100 can issue a warning to the operator indicating abnormal operation by sound or screen display.

[0081] Figure 10 shows another example of stop control for the trolley 40. In Figure 10, the positional relationships of the detection units 53a, 53b, and 53c of the trolley 40 with respect to the position marker 49 are shown at different timings. The first row from the top in Figure 10 shows the position of the detection unit at the start timing of stop control for the trolley 40, the second and third rows from the top show the position of the detection unit at the timing between the start and completion of stop control for the trolley 40, and the fourth row from the top shows the position of the detection unit at the completion timing of stop control for the trolley 40.

[0082] First, as shown in the first diagram from the top, the transfer control unit 341 causes the trolley 40 to move at a low speed prior to stopping control. Then, as shown in the second diagram from the top, when all of the detection units 53a, 53b, and 53c detect the corresponding position marker 49 (step ST01), the transfer control unit 341 starts stopping control of the trolley 40 based on the stop control signal output from the control unit 100 (steps ST02, ST03).

[0083] Next, the transfer control unit 341 outputs a warning signal indicating an abnormal operation to the control unit 100 at the timing when the detection signal from any one of the detection units 53a, 53b, and 53c is interrupted (the third timing from the top) (steps ST04 and ST05).

[0084] Next, it is determined that the stop control has been completed based on the rotational speed of the motor 141a (step ST06).

[0085] Then, as shown in the fourth diagram from the top, after the stop control is completed, the transfer control unit 341 determines that no detection signal has been output from the detection unit 53a (step ST07), and performs a retry operation of the trolley 40 (step ST08).

[0086] Next, the transfer control unit 341 determines again whether detection signals are being output from all of the detection units 53a, 53b, and 53c (step ST09). If it determines that no detection signal has yet been output from the detection unit 53a, the transfer control unit 341 outputs an abnormal signal indicating abnormal operation to the control unit 100 (step ST10).

[0087] According to this embodiment, if the trolley 40 deviates from its stopping position before the motor 141a has finished stopping, this can be determined as a warning sign of an abnormality. Therefore, even if the trolley 40 returns to its stopping position after the stopping is complete and the stopping control of the trolley 40 is completed normally, despite the presence of warning signs of an abnormality, it can still be determined as a warning sign of an abnormality. This allows for the recognition of warning signs of an abnormality before an abnormal signal is output due to a failure to complete the stopping control normally (before the stopping position accuracy deteriorates), thus providing sufficient time for maintenance and enabling efficient maintenance.

[0088] Furthermore, because there are relatively few disturbances during the short time from the start to the completion of stop control, it is possible to maintain a high accuracy in detecting abnormal predictive operation.

[0089] In this embodiment, as shown in steps ST03, ST04, and ST05 of Figure 6, abnormal warning operation is determined based on whether or not detection signals are continuously output from all detection units from the start of motor 141a stop control to the completion of motor 141a stop (whether or not the detection signal from any detection unit is interrupted). However, abnormal warning operation may be determined by detecting the output of a detection signal at any timing between the start of motor 141a stop control and the completion of motor 141a stop. In other words, the output of a detection signal from a detection unit does not have to be detected for the entire period from the start of motor 141a stop control to the completion of motor 141a stop.

[0090] In this embodiment, it is stated that the control unit 100 issues a warning when it receives a warning signal. However, the control unit 100 may also be configured to issue a warning when it receives a warning signal at a frequency exceeding a predetermined threshold while the trolley 40 is being repeatedly stopped.

[0091] <Modifications of the embodiments described above> In the embodiments described above, the material, dimensions, shape, relative arrangement, or implementation conditions of each component may also be described, but these are all examples and not limiting.

[0092] Therefore, countless variations and equivalents not shown are envisioned within the scope of the art disclosed in this specification. For example, these include modifications, additions, or omissions of at least one component.

[0093] <Note> This disclosure discloses the following aspects:

[0094] An abnormality prediction device according to the first embodiment comprises a trolley capable of traveling on a roadway, comprising a drive source, wheels linked to the drive source via an interlocking member, at least one detection unit for outputting a detection identifier when the current position of the trolley corresponds to the stopping position of the trolley on the roadway, a control unit for controlling the drive of the trolley, and a determination unit for determining abnormality prediction behavior of the interlocking member, wherein the control unit starts stopping control of the trolley when the detection identifier is output, and the determination unit determines the abnormality prediction behavior of the interlocking member based on whether or not the detection identifier is output between the start of the stopping control and the completion of the stopping of the drive source.

[0095] According to the first embodiment, if the trolley moves away from its stopping position before the drive source has finished stopping, this can be determined as a warning sign of an abnormality. Therefore, even if the trolley returns to its stopping position after the stopping is complete despite the presence of warning signs of an abnormality, determining it as a warning sign of an abnormality allows for sufficient time for maintenance and enables efficient maintenance.

[0096] The configurations relating to the second and subsequent embodiments may be adopted as optional configurations that are not mandatory.

[0097] In the abnormality prediction determination device according to the second embodiment, if the detection identifier is not output after the start of the stop control and before the stop of the drive source is completed, and the detection identifier is output after the stop of the drive source is completed, the determination unit determines that the interlocking member has performed the abnormality prediction operation.

[0098] According to the second embodiment, even if there are signs of an abnormality, the vehicle may still return to the stopping position after the stop is completed, and this can still be determined as a sign of an abnormality.

[0099] An abnormality prediction device according to the third embodiment further comprises an alarm unit for issuing a warning indicating an abnormality when the determination unit determines that an abnormality is occurring.

[0100] According to the third embodiment, an abnormal warning can be issued to inform the operator of an abnormal behavior.

[0101] The abnormality prediction device according to the fourth embodiment is an abnormality prediction device according to the third embodiment in which the control unit repeatedly performs the stop control of the trolley, and when the determination unit determines that an abnormality prediction operation has occurred at a frequency of a predetermined first threshold or higher, the alarm unit issues the prediction warning.

[0102] According to the fourth embodiment, a warning can be issued only when abnormal predictive behavior occurs with a relatively high frequency, and the operator can be notified only when necessary.

[0103] The abnormality prediction device according to the fifth embodiment is configured such that, in the abnormality prediction device according to the third or fourth embodiment, if the detection identifier is not output after the drive source has finished stopping, the alarm unit issues an abnormality warning indicating abnormal operation of the trolley.

[0104] According to the fifth embodiment, different warnings can be issued for abnormal warning behavior and abnormal behavior.

[0105] An abnormality prediction determination device according to the sixth embodiment is an abnormality prediction determination device according to any one of the first to fifth embodiments, wherein a plurality of the detection units are provided along the direction of travel of the trolley, the control unit starts the stop control of the trolley when the detection identifier is output from all of the detection units, and the determination unit determines that the interlocking member has performed the abnormality prediction operation if the detection identifier is not output from at least one of the detection units between the start of the stop control and the completion of the stop of the drive source.

[0106] According to the sixth aspect, the accuracy of the determination can be improved by using multiple detection units to make the determination.

[0107] An abnormality prediction determination device according to the seventh embodiment is an abnormality prediction determination device according to the sixth embodiment, wherein the abnormality prediction operation includes a first abnormality prediction operation and a second abnormality prediction operation in which the degree of abnormality of the interlocking member is higher than that of the first abnormality prediction operation, and the determination unit determines it to be the first abnormality prediction operation if the number of detection units in which the detection identifier was not output after the start of the stop control until the stop of the drive source was completed is 1 or more and less than a predetermined second threshold, and the determination unit determines it to be the second abnormality prediction operation if the number is equal to or greater than the second threshold.

[0108] According to the seventh embodiment, by determining different abnormal warning operations depending on the number of detection units that do not detect the stopping position, the content of the abnormal warning operation can be recognized in detail.

[0109] An abnormality prediction device according to the eighth embodiment is an abnormality prediction device according to the sixth or seventh embodiment, wherein the direction along the travel direction of the trolley is defined as the first direction, and the direction opposite to the first direction is defined as the second direction, and the plurality of detection units include a first detection unit located furthest toward the first direction and a second detection unit located furthest toward the second direction, and the control unit controls the drive of the trolley so that the trolley shifts toward the second direction if the first detection unit does not output the detection identifier after the drive source has finished stopping, and the control unit controls the drive of the trolley so that the trolley shifts toward the first direction if the second detection unit does not output the detection identifier after the drive source has finished stopping.

[0110] According to the eighth aspect, the direction of the retry operation can be determined according to the position of the detection unit that does not detect the stop position.

[0111] The automated warehouse according to the ninth embodiment comprises an abnormality prediction device according to any one of the first to eighth embodiments, and a storage section provided on the side of the travel path for storing goods, wherein the trolley is provided with a loading and unloading mechanism for loading and unloading goods into and from the storage section.

[0112] According to the ninth aspect, even if there are signs of an abnormality, if the vehicle returns to the stopping position after the stop is completed, it is determined to be an abnormal warning operation, thereby securing a grace period for maintenance and enabling efficient maintenance. [Explanation of Symbols]

[0113] 10 things 20 Automated Warehouse 28 Road 40 bogies 41a wheels 41b Wheel 41c wheels 41d wheels 42. Mechanism for loading and unloading items 48 Roads 53 Detection unit 53a Detection unit 53b Detection unit 53c Detection unit 100 Control Unit 141a Motor

Claims

1. A trolley comprising a drive source and wheels that are interlocked with the drive source via an interlocking member, and capable of traveling on a roadway, At least one detection unit for outputting a detection identifier when the current position of the trolley corresponds to the stopping position of the trolley on the travel path, A control unit for controlling the drive of the trolley, The system includes a determination unit for determining abnormal predictive operation of the interlocking member, The control unit starts stopping the trolley when the detection identifier is output. Based on whether or not the detection identifier is output between the start of the stop control and the completion of the stop of the drive source, the determination unit determines the abnormal predictive operation of the interlocking member. Abnormal sign determination device.

2. An abnormality prediction device according to claim 1, If the detection identifier is not output after the stop control is initiated and before the drive source is stopped, and the detection identifier is output after the drive source has been stopped, the determination unit determines that the interlocking member is exhibiting the abnormal predictive operation. Abnormal sign determination device.

3. An abnormality prediction device according to claim 1 or 2, The determination unit further comprises an alarm unit for issuing a warning indicating the abnormal behavior when the determination unit determines that an abnormal behavior has occurred. Abnormal sign determination device.

4. An abnormality prediction device according to claim 3, The control unit repeatedly performs the stop control of the trolley, If the determination unit determines that an abnormal predictive operation occurs at a frequency equal to or greater than a predetermined first threshold, the alarm unit will issue the predictive warning. Abnormal sign determination device.

5. An abnormality prediction device according to claim 3, If the detection identifier is not output after the drive source has finished stopping, the alarm unit will issue an abnormal warning indicating abnormal operation of the trolley. Abnormal sign determination device.

6. An abnormality prediction device according to claim 1 or 2, Multiple detection units are provided along the direction of travel of the trolley, The control unit starts the stop control of the trolley when the detection identifier is output by all of the detection units. If, after the stop control is initiated and before the drive source is stopped, the detection identifier is not output by at least one of the detection units, the determination unit determines that the interlocking member is exhibiting the abnormal premonitory behavior. Abnormal sign determination device.

7. An abnormality prediction device according to claim 6, The abnormality warning action includes a first abnormality warning action and a second abnormality warning action in which the degree of abnormality of the interlocking member is higher than that of the first abnormality warning action. If the number of detection units that did not output the detection identifier after the start of the stop control and before the stop of the drive source was completed is one or more and less than a predetermined second threshold, the determination unit determines that it is the first abnormal warning operation, and if it is equal to or greater than the second threshold, the determination unit determines that it is the second abnormal warning operation. Abnormal sign determination device.

8. An abnormality prediction device according to claim 6, The direction along the direction of travel of the trolley is defined as the first direction, and the direction opposite to the first direction is defined as the second direction. The plurality of detection units include a first detection unit located furthest to the first direction and a second detection unit located furthest to the second direction. If the detection identifier is not output by the first detection unit after the drive source has finished stopping, the control unit controls the drive of the trolley so that the trolley shifts in the second direction. If the detection identifier is not output by the second detection unit after the drive source has finished stopping, the control unit controls the drive of the trolley so that the trolley shifts in the first direction. Abnormal sign determination device.

9. An abnormality prediction device according to claim 1 or 2, It is provided on the side of the aforementioned travel path and includes a storage section for storing objects, The trolley is provided with an object loading / unloading mechanism for loading and unloading objects into and from the storage compartment. Automated warehouse.

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