Method for predicting the replacement timing of a conveying device, system for predicting the replacement timing of a conveying device, and parts feeder

Abstract

Predict the replacement timing for the conveying equipment. [Solution] The method for predicting the replacement time of the transport device includes the steps of detecting the thickness of the coating layer in the inspection transport path 71 provided in a part of the transport path 30 at predetermined intervals, and predicting the replacement time of the parts feeder 100 based on the thickness of the coating layer detected at predetermined intervals, wherein the initial thickness of the coating layer in the inspection transport path 71 is different from the initial thickness of the coating layer in the other parts of the transport path 30 excluding the inspection transport path 71.

Description

[Technical Field]

[0001] The present invention relates to a method for predicting a replacement timing of a conveying device, a system for predicting a replacement timing of a conveying device, and a parts feeder. [Background Art]

[0002] Patent Document 1 discloses a conveying device provided with a bowl for a parts feeder in which a conveying path, along which loaded parts move while coming into contact with each other due to vibration, is formed along the circumferential direction. [Prior Art Literature] [Patent Literature]

[0003] [Patent Document 1] Japanese Unexamined Patent Publication No. 2005-343601 [Summary of the Invention] [Problem to be Solved by the Invention]

[0004] In a conveying device as described in Patent Document 1, the surface of the conveying path is worn when a plurality of parts move while contacting each other on the conveying path, and conveying efficiency decreases due to a change in friction coefficient and the like. Although a conveying device with reduced conveying efficiency can exhibit the same performance as before by replacing components or the like on which the conveying path is formed, in order to avoid a decrease in factory operation rate caused by stopping the operation of the conveying device, it is desirable to be able to grasp the replacement timing before replacement of components or the like of the conveying device becomes necessary.

[0005] The present invention has been made in view of the above problems, and an object of the present invention is to predict the replacement timing of a conveying device provided with a conveying path along which parts move while coming into contact with each other. [Means for Solving the Problem]

[0006] The present invention relates to a method for predicting the replacement time of a conveying device, which has a conveying path formed in which parts that are brought in move while in contact with each other, and includes the steps of detecting the thickness of a coating layer in an inspection conveying path provided in a part of the conveying path at predetermined intervals, and predicting the replacement time of the conveying device based on the thickness of the coating layer detected at predetermined intervals, wherein the initial thickness of the coating layer in the inspection conveying path is different from the initial thickness of the coating layer in other parts of the conveying path excluding the inspection conveying path.

[0007] Furthermore, the present invention relates to a system for predicting the replacement time of a conveying device, which has a conveying path formed in which parts are transported and move in contact with each other, and comprises: a storage unit that stores the results of detecting the thickness of the coating layer in an inspection conveying path provided in a part of the conveying path at predetermined intervals; an analysis unit that predicts the replacement time of the conveying device based on the results stored in the storage unit; and a communication unit that notifies the replacement time of the conveying device predicted by the analysis unit.

[0008] Furthermore, the present invention relates to a parts feeder in which an inspection transport path is provided in a portion of the transport path in which the transported parts move while in contact with each other, wherein the initial thickness of the coating layer in the inspection transport path is different from the initial thickness of the coating layer in the other portion of the transport path excluding the inspection transport path. [Effects of the Invention]

[0009] According to the present invention, it is possible to predict when a conveying device equipped with a conveying path in which parts move while in contact with each other will need to be replaced. [Brief explanation of the drawing]

[0010] [Figure 1] This is a diagram showing the configuration of a parts feeder according to an embodiment of the present invention. [Figure 2] This is a perspective view of a bowl for a parts feeder according to an embodiment of the present invention. [Figure 3] This is a plan view of a bowl for a parts feeder according to an embodiment of the present invention. [Figure 4] This is a cross-sectional view along line AA in Figure 3. [Figure 5] This is a block diagram of a system for predicting the replacement timing of a transport device according to an embodiment of the present invention. [Figure 6] This graph illustrates a method for predicting the replacement timing of a conveying device according to an embodiment of the present invention. [Modes for carrying out the invention]

[0011] Hereinafter, with reference to the drawings, a method for predicting the replacement timing of a conveying device, a system for predicting the replacement timing of a conveying device, and a parts feeder according to an embodiment of the present invention will be described.

[0012] The conveying device replacement timing prediction system according to an embodiment of the present invention predicts the replacement timing of a conveying device in which a conveying path is formed, in which multiple parts that are brought in move while in contact with each other, based on the wear condition of the conveying path.

[0013] The following describes the case where the conveying device whose replacement time is predicted by the replacement time prediction system 90 is a parts feeder 100, as shown in Figures 1 and 2, which includes a parts feeder bowl 20 (hereinafter referred to as "bowl 20") into which parts are fed from an inlet 21, and a vibrator 10 that vibrates the bowl 20 in the circumferential direction with a predetermined amplitude. Figure 1 is a side view showing the configuration of the parts feeder 100, and Figure 2 is a perspective view showing the bowl 20. Note that the conveying device whose replacement time is predicted by the replacement time prediction system is not limited to the parts feeder 100, but can be any type of conveying device that has a conveying path in which the fed-in parts move while in contact with it, for example, a linear feeder that conveys parts in a straight line.

[0014] The parts feeder 100 is a conveying device that vibrates the bowl 20 with a vibrator 10, thereby transporting the parts placed inside the bowl 20 in the direction of vibration, aligning them to a predetermined position, and then discharging them from the outlet 22 of the bowl 20.

[0015] The vibrator 10 includes an unillustrated electromagnet, and transmits vibration of a predetermined cycle generated by an alternating current supplied to the electromagnet to the bowl 20. Note that the vibration generation source is not limited to an electromagnet, and may be a piezoelectric element, or may be one that converts displacement of a solenoid actuator or a fluid pressure actuator into vibration via a mechanism such as a cam.

[0016] As shown in FIG. 2, the bowl 20 is a bottomed cylinder having a bottom surface 20a and a cylindrical portion 20b, and is formed of a metal material with good castability and machinability, for example, an aluminum alloy. The bowl 20 is fixed to the vibrator 10 via an unillustrated bolt inserted through an insertion hole 24 formed substantially at the center, and vibrates at a predetermined cycle and a predetermined amplitude in the circumferential direction about a central axis O. Note that the vibration cycle and amplitude of the bowl 20 are adjusted by an unillustrated control device that controls the alternating current supplied to the vibrator 10.

[0017] The cylindrical portion 20b is provided with a carry-in port 21 through which parts are carried in and a carry-out port 22 through which parts are carried out, so that the two ports are adjacent to each other in the circumferential direction. The carry-in port 21 and the carry-out port 22 are each formed to extend radially outward from the cylindrical portion 20b so that parts can be easily transferred between devices of a preceding process and a subsequent process.

[0018] The bottom surface 20a has the highest height at the central portion where the insertion hole 24 is formed, and is inclined so as to gradually descend from the central portion toward the cylindrical portion 20b to prevent parts from staying at the central portion of the bottom surface 20a.

[0019] Further, the bowl 20 is provided with a conveyance path 30 along the circumferential direction, along which parts carried in from the carry-in port 21 move toward the carry-out port 22. The conveyance path 30 is formed in a range shorter than one full circumference in the circumferential direction so as to connect the carry-in port 21 and the carry-out port 22.

[0020] Since the conveyance path 30 is not helical, it is not provided with a gradient and is formed substantially horizontally from the start end to the terminal end. Therefore, compared with a case where the conveyance path for parts is formed in a helical shape, since there is no gradient on the conveyance path 30, only a small thrust is required to move the parts, which makes it possible to smoothly move the parts toward the carry-out port 22.

[0021] It should be noted that the conveyance path 30 may be formed helically over one or more circumferential turns to connect the carry-in port 21 and the carry-out port 22. In this case, the conveyance path 30 forms an inclined surface with a slight gradient that rises gently from the start end to the terminal end.

[0022] Further, the bowl 20 is provided with a selecting section 40 that allows only movement of parts in a predetermined posture among the parts moving along the conveyance path 30, and a slope 50 that receives the parts excluded by the selecting section 40 and returns them to the conveyance path 30.

[0023] As shown in FIG. 3, the selecting section 40 includes a sorting surface 41 provided on the same plane as the conveyance path 30, and a support surface 42 that supports the parts moving on the sorting surface 41. The sorting surface 41 and the support surface 42 are planes orthogonal to each other in a radial cross-section, and the inclination of the sorting surface 41 relative to the horizontal plane is set smaller than that of the support surface 42. Specifically, the angle of the sorting surface 41 relative to the horizontal plane is approximately 30 degrees, while the angle of the support surface 42 relative to the horizontal plane is approximately 60 degrees. Therefore, the sorting surface 41 supports the lower side of the parts moving along the conveyance path 30, and the support surface 42 supports the side of the parts moving along the conveyance path 30. It should be noted that the angle formed between the sorting surface 41 and the support surface 42 is not limited to 90°, and may be appropriately changed according to the shape of the parts and other factors.

[0024] Furthermore, the width of the sorting surface 41 is set to be smaller than the smallest dimension among the dimensions such as height, width, and thickness of the parts. Therefore, among the parts moving along the conveyance path 30, parts in a predetermined posture are supported by the sorting surface 41 and the support surface 42, while parts not in the predetermined posture fall off from the sorting surface 41.

[0025] On the other hand, the slope 50 is a recess provided radially inward from the selection section 40, and has a receiving surface 51 provided in the part where the part falls, a confluence surface 53 formed on the same plane as the transport path 30, and an inclined surface 52 that slopes upward at a predetermined angle from the receiving surface 51 toward the confluence surface 53.

[0026] Therefore, the parts that fall onto the receiving surface 51 move up the inclined surface 52 to the confluence surface 53, where they merge with the parts that have moved along the sorting surface 41 and the support surface 42 in a predetermined orientation.

[0027] The selected section 40 and the slope 50, as described above, are formed by cutting a transport path 30 that has the same width as the confluence surface 53.

[0028] Furthermore, the bowl 20 is provided with a final selection section 45 that allows only parts in a predetermined orientation to move along the transport path 30 toward the discharge port 22, a buffer section 61 that drops the parts excluded by the final selection section 45 onto the receiving bottom surface 20a, and a re-loading section 62 that merges the parts that have fallen onto the bottom surface 20a with the parts being loaded from the entrance port 21.

[0029] The final selection unit 45, like the selection unit 40, has a sorting surface 41 provided on the same plane as the transport path 30, a support surface 42 for supporting parts moving on the sorting surface 41, and a turning surface 43 formed continuously with the support surface 42, the inclination with respect to the horizontal plane gradually decreasing toward the outlet 22.

[0030] The buffer section 61 is a stepped section with a horizontal plane, provided to prevent parts excluded in the final selection section 45 from falling directly onto the bottom surface 20a. The re-loading section 62 is an upward sloping surface connecting the bottom surface 20a to the starting end of the transport path 30, and the gradient of the re-loading section 62 is set to a size that allows parts that have fallen onto the bottom surface 20a to climb up.

[0031] In the final selection section 45, similar to the selection section 40, parts that are in a predetermined position among the parts moving along the transport path 30 are supported by the sorting surface 41 and the support surface 42, and parts that reach the turning surface 43 are discharged from the outlet 22 with the surface in contact with the turning surface 43 as the bottom surface.

[0032] Meanwhile, parts that are not in the prescribed orientation fall from the sorting surface 41 and reach the bottom surface 20a via the buffer section 61. The parts that fall to the bottom surface 20a climb up the re-in section 62 and are returned to the transport path 30.

[0033] Although Figure 3 shows an example where there are three selection units 40 and three slopes 50, the number of selection units 40 and three slopes 50 is not limited to three; there may be four or more, or there may be one or two.

[0034] Although the bowl 20, which has a transport path 30 in which the parts move while in contact with each other, is made of an aluminum alloy or the like, which is relatively resistant to rust, it is still made of metal, and therefore, depending on the environment in which it is used, corrosion may occur and rust may develop.

[0035] If slight irregularities caused by rust or the like form on the transport path 30, they will create resistance to the movement of the parts, hindering the smooth transport of the parts. Furthermore, if slight irregularities caused by rust or the like form on the sorting surface 41 or support surface 42, for example, parts in a predetermined position that should be allowed to move may get caught on the irregularities and fall onto the receiving surface 51 or bottom surface 20a, potentially resulting in a significant decrease in the efficiency of transporting the parts.

[0036] Therefore, in order to prevent slight irregularities caused by rust or other factors from forming on the transport path 30, a coating with excellent rust prevention properties is provided on the surface of the transport path 30 as the parts move in contact with it.

[0037] For example, the coating is a ceramic coating formed by a room-temperature impact solidification phenomenon using the aerosol deposition method, which is formed by spraying an aerosol containing ceramic fine particles dispersed in a gas onto the surface of the transport path 30.

[0038] The aerosol is generated by dispersing ceramic powder with a particle size of 0.08 to 5 μm in an inert gas such as air, nitrogen, or helium, and is ejected at a speed of 150 to 400 m / s from a nozzle located inside a container of a film deposition apparatus (not shown) capable of housing a bowl 20 (base material), perpendicular to the surface of the transport path 30 of the bowl 20. When the aerosol is ejected towards the bowl 20, the pressure inside the container of the film deposition apparatus is controlled to a predetermined reduced pressure state in order to improve the aerosol ejection speed, but the temperature inside the container is not specifically controlled and remains at room temperature. Note that the particle size of the ceramic powder and the aerosol ejection speed described above are examples and are not limited to them. The temperature inside the container may also be controlled to a constant temperature (for example, 25°C).

[0039] The nozzle that sprays the aerosol has a structure that allows the spray direction to be adjusted. For example, when forming a coating on the sorting surface 41 of the selection section 40 and when forming a coating on the support surface 42 of the selection section 40, the angle of the nozzle is adjusted to a different angle so that the aerosol is sprayed in a direction perpendicular to the sorting surface 41 and the support surface 42, respectively. By spraying the aerosol while moving the nozzle along the sorting surface 41 and the support surface 42 at a predetermined pitch speed, a ceramic coating of a predetermined thickness is formed on the sorting surface 41 and the support surface 42. When spraying the aerosol toward the bowl 20, the movement may be directed toward the bowl 20 rather than the nozzle.

[0040] The ceramic coating formed by this room-temperature impact solidification phenomenon is a thin film with a thickness of about 1 to 6 μm (preferably 2 to 4 μm), but it has a high hardness of 1000 to 1400 HV, high adhesion to metal surfaces, and exhibits relatively high rust prevention and wear resistance. When forming a ceramic coating on the conveying path 30 of a bowl 20 made of aluminum alloy or the like, in order to further improve the adhesion of the ceramic coating to the material and the wear resistance of the ceramic coating, a nickel coating with a thickness of about 4 to 6 μm is formed on the surface of the conveying path 30 by electroless nickel plating before forming the ceramic coating.

[0041] Here, the coating formed on the transport path 30, where multiple parts move while in contact with each other, that is, the coating formed on the selection section 40 having the sorting surface 41 and support surface 42, the receiving surface 51, the slope 50 having the inclined surface 52 and confluence surface 53, the turning surface 43 formed continuously with the support surface 42, etc., will gradually wear down as multiple parts move along the transport path 30 while in contact with each other, as described above. For this reason, the transport efficiency may gradually decrease due to changes in the coefficient of friction in the transport path 30.

[0042] While the parts feeder 100, whose transport efficiency has decreased in this way, can be restored to its original performance by replacing the bowl 20 on which the transport path 30 is formed, it is desirable to be able to determine the replacement timing before the bowl 20 needs to be replaced in order to avoid a decrease in the factory's operating rate due to the shutdown of the parts feeder 100.

[0043] Therefore, in this embodiment, an inspection transport path 71 for detecting the thickness of the coating layer is provided in a portion of the transport path 30, and by understanding how the thickness of the coating layer in this inspection transport path 71 changes over time, the timing for replacing the bowl 20 on which the transport path 30 is formed is predicted.

[0044] As shown in Figures 3 and 4, the inspection transport path 71 is provided in the middle of the transport path 30 and is formed in an arc shape on the inspection piece 70 which is detachably formed from the bowl 20.

[0045] The inspection transport path 71 is flush with the transport path 30, as the inspection piece 70 is fixed to the bowl 20 by fastening members such as bolts (not shown), and forms part of the transport path 30, in which multiple parts move while in contact with each other.

[0046] Furthermore, the inspection piece 70 has a support surface 72 that supports parts moving along the inspection transport path 71. The support surface 72 becomes flush with the support surface 42 formed on the bowl 20 when the inspection piece 70 is fixed to the bowl 20.

[0047] In this way, the inspection piece 70 is fixed to the bowl 20, and its shape allows for the smooth transport of parts. In other words, the bowl 20 is able to transport parts because the inspection piece 70 of the above shape is fixed to it. The inspection piece 70, like the bowl 20, is made of aluminum alloy, and the ceramic coating described above is formed on the surfaces of the inspection transport path 71 and the support surface 72.

[0048] Furthermore, the inspection piece 70 is provided with a mounting portion 73 to which a bracket 74 for fixing a coating sensor 81 for detecting the thickness of the coating layer on the surface of the inspection transport path 71 is attached. The mounting portion 73 is continuous with the cylindrical portion 20b formed in the bowl 20 when the inspection piece 70 is fixed to the bowl 20.

[0049] The coating sensor 81 and bracket 74 are attached to the inspection piece 70 only when detecting the thickness of the coating layer on the surface of the inspection transport path 71, and are removed while the parts feeder 100 is in operation. This prevents the coating sensor 81 and bracket 74 from being damaged by vibrations of the bowl 20. In the example shown in Figure 4, the coating sensor 81 is positioned so that its detection surface 81a faces the inspection transport path 71, but the coating sensor 81 may also be fixed by the bracket 74 to detect the thickness of the coating layer on the surface of the support surface 72.

[0050] The coating sensor 81 is a sensor capable of detecting the amount of reflected light reflected from the surface of a ceramic coating formed on the inspection transport path 71, and is, for example, a reflective photoelectric sensor having a light-emitting element and a light-receiving element. The coating sensor 81 may have a light-emitting part and a light-receiving part provided separately, and may be composed of, for example, an illumination device such as a light source and an imaging device such as a camera. In addition, the coating sensor 81 may be fitted with a lens to limit the detection range, that is, the range in which light is irradiated.

[0051] Measurement by the coating sensor 81 is performed at predetermined operating intervals, for example, every 100 to 200 hours, when the parts feeder 100 is stopped, for example, when the parts feeder 100 is in inspection status.

[0052] The detection value from the coating sensor 81 is amplified or converted by the amplifier 82 and then transmitted via the communication unit 82a built into the amplifier 82 to the server 90 (replacement timing prediction system 90), described later, each time a measurement is taken. The amplifier 82 may be provided integrally with the coating sensor 81, and the communication unit 82a may be provided separately from the amplifier 82.

[0053] The data transmitted from the communication unit 82a to the server 90 includes time information such as the measured date and time, along with the identification ID of the bowl 20 and the identification ID of the parts feeder 100 to which the bowl 20 is attached.

[0054] Specifically, the communication unit 82a accesses a network such as the Internet via a repeater, access point, personal computer, portable terminal, etc., using short-range wireless communication means such as Wi-Fi (registered trademark) or Bluetooth (registered trademark), and transmits data to a predetermined server 90. The data transmitted to the server 90 may have a timestamp added indicating the date and time the communication unit 82a accessed the repeater or access point. In addition, the measured value of the coating sensor 81 may not be automatically transmitted to the server 90, but rather the operator may manually input the value displayed on the amplifier 82 into a portable terminal, etc., that can be connected to the server 90, and then transmit it to the server 90.

[0055] Next, referring to Figure 5, we will describe a replacement timing prediction system 90 that predicts the replacement timing of the bowl 20 of the parts feeder 100 using the detection results of the coating sensor 81.

[0056] The replacement timing prediction system 90 is a system comprising a server 90 equipped with a storage unit 92 that stores the results of detection of the thickness of the coating layer in the inspection transport path 71 provided in a part of the transport path 30 at predetermined operating time intervals by a coating sensor 81; an analysis unit 93 that predicts the replacement timing of the bowl 20 of the parts feeder 100 based on the operating time interval results stored in the storage unit 92; and a communication unit 91 that notifies a pre-registered terminal 86 of the replacement timing of the bowl 20 predicted by the analysis unit 93. By using such a replacement timing prediction system 90, administrators can notify customers (users) of the replacement timing of the bowl 20 and provide services to inspection companies to encourage maintenance and inspection. In other words, it becomes possible to provide a business model that replaces consumables instead of the conventional business of selling transport equipment.

[0057] The replacement timing prediction system 90 may be configured using an on-premise server, a cloud-based server, or multiple servers in which the storage unit 92 and the analysis unit 93 are distributed. Furthermore, some or all of the multiple servers constituting the replacement timing prediction system 90 may be installed in a country other than the country in which the parts feeder 100 is used.

[0058] Furthermore, the replacement timing prediction system 90 is not limited to a server, but may be a personal computer equipped with a storage unit 92, an analysis unit 93, and a communication unit 91, or a portable terminal such as a tablet.

[0059] The communication unit 91 can communicate with the communication unit 82a of the coating sensor 81 via a network such as the Internet, and has the function of receiving the detection value of the coating sensor 81 transmitted from the communication unit 82a and transmitting it to the storage unit 92.

[0060] The storage unit 92 stores the results of the thickness of the coating layer in the inspection transport path 71 detected by the coating sensor 81, as well as information about the user of the parts feeder 100, such as the purchase date, the type of parts being transported, the operating environment, etc., and information about the inspection company that performs maintenance and inspection of the parts feeder 100, all of which are stored in association with an identification ID.

[0061] In the analysis unit 93, using the data stored in the storage unit 92, the relationship between the detected value of the coating sensor 81, for example, luminance indicating light intensity, and the operating time is determined, as shown in Figure 6. Based on this relationship, the replacement timing of the bowl 20 of the parts feeder 100 is determined using a known regression analysis method. If the correlation between light intensity and the thickness of the coating layer is known in advance, the relationship between the thickness of the coating layer and the operating time is determined. Furthermore, the light intensity is not limited to that indicated by luminance; other parameters that can directly or indirectly indicate light intensity may be used.

[0062] Specifically, the analysis unit 93 predicts the replacement timing of the bowl 20 of the parts feeder 100 by determining when the regression line obtained by the least squares method intersects with the replacement judgment threshold pre-stored in the storage unit 92, as shown in the graph in Figure 6. Note that regression analysis is not limited to the least squares method. Also, the regression equation is not limited to a linear function but may be a function of degree two or higher. Furthermore, for predicting the replacement timing, for example, a machine learning algorithm may be used, which learns past data patterns and predicts the replacement timing of the bowl 20 based on the learning results.

[0063] Here, if the initial thickness of the coating layer in the inspection transport path 71 is set to be the same as the initial thickness of the coating layer in the other parts of the transport path 30 excluding the inspection transport path 71, it is considered that the timing for replacing the bowl 20 of the parts feeder 100 can be accurately predicted based on the change in the thickness of the coating layer in the inspection transport path 71.

[0064] However, measuring the change in the thickness of a ceramic coating with the aforementioned wear resistance is difficult. Even when measuring the change in light intensity using the coating sensor 81, which is a photoelectric sensor, as described above, it is difficult to grasp the trend of thickness change from the change in light intensity if the decrease in the thickness of the coating layer is slight.

[0065] Therefore, in this embodiment, the initial thickness of the coating layer in the inspection transport path 71 is made sufficiently thinner than the initial thickness of the coating layer in other parts of the transport path 30 excluding the inspection transport path 71, so that the change in thickness due to wear is more easily observed in the coating formed on the inspection transport path 71 than in other parts of the transport path 30 excluding the inspection transport path 71.

[0066] Specifically, the initial thickness of the coating layer in the inspection transport path 71 is set to about one-third of the initial thickness of the coating layer in the other parts of the transport path 30 excluding the inspection transport path 71. For example, if the initial thickness of the coating layer (ceramic coating) in the other parts of the transport path 30 excluding the inspection transport path 71 is 3 μm, then the initial thickness of the coating layer (ceramic coating) in the inspection transport path 71 is set to about 1 μm.

[0067] By setting the initial thickness of the coating layer in the inspection transport path 71 to be thin in this way, even if the change in the thickness of the coating layer in the inspection transport path 71 is slight, the amount of light reflected by the aluminum alloy material of the inspection piece 70 will easily change in response to the change in the thickness of the coating layer.

[0068] As a result, in the other parts of the transport path 30, excluding the inspection transport path 71, the initial thickness of the coating layer is kept at the normal thickness to improve wear resistance, while in the inspection transport path 71, the initial thickness of the coating layer is made significantly thinner than usual to allow for assessment of the wear state of the coating layer.

[0069] Generally speaking, nickel has a higher light absorption rate and lower light reflectivity than the aluminum alloy material used for the inspection piece 70. In other words, the inspection piece 70 made of aluminum alloy has a lower light absorption rate and higher light reflectivity than nickel. Therefore, when a ceramic coating of a predetermined thickness is directly formed on the inspection piece 70 made of aluminum alloy, the relatively high light reflectivity of the aluminum alloy results in a relatively small change in the amount of reflected light in response to a change in the thickness of the ceramic coating layer, i.e., a change in the amount of light reflected from the surface of the aluminum alloy. Consequently, if the change in the thickness of the ceramic coating layer is slight, it becomes difficult to detect the change. In contrast, when a nickel coating is formed on the surface of the inspection transport path 71 of the inspection piece 70 as a first coating with a predetermined thickness (for example, about 4 to 6 μm), and then a ceramic coating of a predetermined thickness is formed as a second coating, the light reflectivity of nickel is relatively low. As a result, the change in the amount of reflected light in response to a change in the thickness of the ceramic coating layer (second coating), that is, the change in the amount of light reflected by the nickel coating (first coating), becomes relatively large. Therefore, even if the change in the thickness of the ceramic coating layer is slight, it becomes easier to detect the change.

[0070] Therefore, in order to accurately determine the wear state of the coating layer in the inspection transport path 71, it is preferable to pre-form a nickel coating on the surface of the inspection transport path 71.

[0071] Furthermore, by replacing the inspection piece 70 when wear in the inspection transport path 71 has progressed to a certain extent, it is possible to continue operating the parts feeder 100 without reducing transport efficiency until it is time to replace the bowl 20. Since the inspection transport path 71 is only a part of the transport path 30, if the wear in the inspection transport path 71 has little impact on transport efficiency, the inspection piece 70 may be used as is without replacement.

[0072] As described above, the timing for replacing the bowl 20 of the parts feeder 100, as predicted by the analysis unit 93, is transmitted via the communication unit 91 to a terminal 86 that has been pre-registered with an identification ID.

[0073] Terminal 86 is a personal computer or portable terminal of a user who uses the parts feeder 100, or a personal computer or portable terminal of an inspection company that performs maintenance and inspection of the parts feeder 100. Information regarding the replacement timing of the bowl 20 received by the communication unit 86a of terminal 86 is displayed on the display unit 86b, allowing the user or inspection company to know when the bowl 20 needs to be replaced.

[0074] In this way, the replacement time for the bowl 20 of the parts feeder 100 is notified to the user of the parts feeder 100 and the inspection company that performs maintenance and inspection of the parts feeder 100 through the following steps: detecting the thickness of the coating layer in the inspection transport path 71 provided in a part of the transport path 30 at predetermined intervals; predicting the replacement time of the parts feeder 100 based on the thickness of the coating layer detected at predetermined intervals; and notifying the predicted replacement time.

[0075] This makes it possible to set the shutdown period for the parts feeder 100 to coincide with the replacement time of the bowl 20, and as a result, it is possible to avoid a decrease in the factory's operating rate due to the shutdown of the parts feeder 100.

[0076] Furthermore, if the detection results of the coating sensor 81 are not stored in the storage unit 92 periodically (for example, every predetermined operating time), it becomes difficult for the analysis unit 93 to accurately predict when the bowl 20 needs to be replaced. For this reason, a message may be sent to the terminal 86 indicating that it is time to detect the thickness of the coating layer using the coating sensor 81 when a predetermined operating time is expected to be reached, prompting the user or inspection company to attach the coating sensor 81 to the inspection piece 70 and perform the detection work to detect the thickness of the coating layer.

[0077] The above embodiments produce the following effects.

[0078] The method for predicting the replacement timing of the conveying device includes the steps of detecting the thickness of the coating layer in the inspection conveying path 71, which is provided in a part of the conveying path 30, at predetermined intervals, and predicting the replacement timing of the parts feeder 100 based on the thickness of the coating layer detected at predetermined intervals. The initial thickness of the coating layer in the inspection conveying path 71 is different from the initial thickness of the coating layer in other parts of the conveying path 30 excluding the inspection conveying path 71, as it is formed to be thinner.

[0079] By making the initial thickness of the coating layer in the inspection transport path 71 significantly thinner than the initial thickness of the coating layer in other parts of the transport path 30 excluding the inspection transport path 71, the change in coating thickness due to wear becomes easier to observe.

[0080] Therefore, by understanding the change in the thickness of the coating formed on the inspection transport path 71, it is possible to predict when the parts feeder 100, which is equipped with a transport path 30 in which parts move while in contact with each other, needs to be replaced.

[0081] Furthermore, the replacement timing prediction system 90 includes a storage unit 92 that stores the results of detecting the thickness of the coating layer in the inspection transport path 71 provided in a part of the transport path 30 at predetermined operating time intervals using a coating sensor 81; an analysis unit 93 that predicts the replacement timing of the bowl 20 of the parts feeder 100 based on the operating time interval results stored in the storage unit 92; and a communication unit 91 that notifies a pre-registered terminal 86 of the replacement timing of the bowl 20 predicted by the analysis unit 93.

[0082] By notifying a pre-registered terminal 86 of the predicted replacement time for the bowl 20 based on the change in the thickness of the coating formed on the inspection transport path 71 provided in a part of the transport path 30, it becomes possible to set the downtime of the parts feeder 100 in accordance with the replacement time for the bowl 20. As a result, it is possible to avoid a decrease in the factory's operating rate due to the downtime of the parts feeder 100.

[0083] Next, a modified example of the above embodiment will be described.

[0084] In the above embodiment, the inspection transport path 71 is formed on an inspection piece 70 that is detachably formed on the bowl 20. Alternatively, the inspection transport path 71 may be formed directly on the bowl 20 as part of the transport path 30. That is, the inspection transport path 71 may be formed by making the initial thickness of the coating layer on a part of the transport path 30 thinner than on other parts. In this case, the inspection transport path 71 is inseparable from the bowl 20, but since the inspection transport path 71 is only a part of the transport path 30, the effect of wear on the inspection transport path 71 on the transport efficiency is suppressed.

[0085] Furthermore, in the above embodiment, the inspection transport path 71 is provided at one location on the transport path 30. Alternatively, the inspection transport path 71 may be provided at multiple locations on the transport path 30.

[0086] Furthermore, in the above embodiment, the coating formed on the transport path 30, including the inspection transport path 71, is a ceramic coating. The coating formed on the transport path 30 is not limited to a ceramic coating, and any coating that can be formed on the transport path 30 by known surface treatments may be used, for example, a titanium nitride coating or a DLC (diamond-like carbon) coating.

[0087] Furthermore, in the above embodiment, the conveying device whose replacement time is predicted is a parts feeder 100 equipped with a bowl 20. The conveying device whose replacement time is predicted is not limited to such a parts feeder 100, but can be any type of conveying device that has a conveying path in which the transported parts move while in contact with it, for example, a linear feeder that transports parts in a straight line.

[0088] Furthermore, in the above embodiment, the parts feeder 100 is configured to consist only of a bowl 20. However, the parts feeder 100 may also include, in addition to the bowl 20, a chute (not shown) connected to the outlet 22 for transferring parts that have been aligned to a predetermined position and discharged from the outlet 22 to a device for a subsequent process. In this case, it is preferable to also provide the aforementioned ceramic coating to the transport path formed in the chute. The chute may also be a linear feeder configured in combination with a vibration exciter.

[0089] Furthermore, although the above embodiment described the case where the material of the bowl 20 is an aluminum alloy, the material of the bowl 20 is not limited to an aluminum alloy. Any material can be used as long as the above-mentioned ceramic coating can be formed to the desired thickness, such as stainless steel or carbon steel.

[0090] The configuration, operation, and effects of the embodiments of the present invention will be described below.

[0091] The method for predicting the replacement timing of the conveying device includes the steps of detecting the thickness of the coating layer in the inspection conveying path 71 provided in a part of the conveying path 30 at predetermined intervals, and predicting the replacement timing of the parts feeder 100 based on the thickness of the coating layer detected at predetermined intervals, wherein the initial thickness of the coating layer in the inspection conveying path 71 is different from the initial thickness of the coating layer in the other parts of the conveying path 30 excluding the inspection conveying path 71.

[0092] In this configuration, the initial thickness of the coating layer in the inspection transport path 71 is made sufficiently thinner than the initial thickness of the coating layer in other parts of the transport path 30 excluding the inspection transport path 71, making it easier to see the change in coating thickness due to wear.

[0093] Therefore, by understanding the change in the thickness of the coating formed on the inspection transport path 71, it is possible to predict when the parts feeder 100 equipped with the transport path 30 needs to be replaced.

[0094] Furthermore, the inspection transport path 71 is formed to be detachable from the transport path 30.

[0095] In this configuration, since the inspection transport path 71 is formed to be detachable from the transport path 30, the parts feeder 100 can be kept running without reducing transport efficiency until it is time to replace the bowl 20 by replacing the inspection piece 70 on which the inspection transport path 71 is formed when wear on the inspection transport path 71 has progressed to a certain extent.

[0096] Furthermore, the replacement timing prediction system 90 includes a storage unit 92 that stores the results of detecting the thickness of the coating layer in the inspection transport path 71 provided in a part of the transport path 30 at predetermined operating time intervals using a coating sensor 81; an analysis unit 93 that predicts the replacement timing of the bowl 20 of the parts feeder 100 based on the operating time interval results stored in the storage unit 92; and a communication unit 91 that notifies a pre-registered terminal 86 of the replacement timing of the bowl 20 predicted by the analysis unit 93.

[0097] In this configuration, the replacement time for the bowl 20 is predicted based on the detection result of the thickness of the coating layer of the inspection transport path 71 stored in the storage unit 92, and the predicted replacement time for the bowl 20 is notified to a pre-registered terminal 86.

[0098] This makes it possible to set the shutdown period for the parts feeder 100 to coincide with the replacement time of the bowl 20, and as a result, it is possible to avoid a decrease in the factory's operating rate due to the shutdown of the parts feeder 100.

[0099] Furthermore, in a parts feeder 100 in which an inspection transport path 71 for detecting the thickness of the coating layer is provided in a portion of the transport path 30 as the transported parts move in contact with each other, the initial thickness of the coating layer in the inspection transport path 71 is different from the initial thickness of the coating layer in the other portions of the transport path 30 excluding the inspection transport path 71.

[0100] In this configuration, the initial thickness of the coating layer in the inspection transport path 71 is made sufficiently thinner than the initial thickness of the coating layer in other parts of the transport path 30 excluding the inspection transport path 71, making it easier to see the change in coating thickness due to wear.

[0101] Therefore, by understanding the change in the thickness of the coating formed on the inspection transport path 71, it is possible to predict when the parts feeder 100 equipped with the transport path 30 needs to be replaced.

[0102] Although embodiments of the present invention have been described above, these embodiments only represent a part of the application examples of the present invention, and are not intended to limit the technical scope of the present invention to the specific configurations of the above embodiments. [Explanation of Symbols]

[0103] 100...Parts feeder (transport device), 20...Bowl for parts feeder, 30...Transport path, 70...Inspection piece, 71...Inspection transport path, 81...Coated sensor, 86...Terminal, 90...Server (replacement timing prediction system), 91...Communication unit, 92...Storage unit, 93...Analysis unit

Claims

1. A method for predicting the replacement timing of a conveying device, which predicts the replacement timing of a conveying device in which a conveying path is formed in which parts that have been brought in move while in contact with each other, A step of detecting the thickness of the coating layer in an inspection transport path provided in a portion of the transport path at predetermined intervals, The process includes predicting the replacement time of the transport device based on the thickness of the coating layer detected at predetermined intervals, A method for predicting the replacement timing of a transport device, characterized in that the initial thickness of the coating layer in the inspection transport path is different from the initial thickness of the coating layer in other parts of the transport path excluding the inspection transport path.

2. The method for predicting the replacement timing of a conveying device according to claim 1, characterized in that the inspection conveying path is formed to be detachably attached to the conveying path.

3. A system for predicting the replacement timing of a conveying device, which predicts the replacement timing of a conveying device in which a conveying path is formed where parts that have been brought in move while in contact with each other, A storage unit is provided in a portion of the transport path, which stores the results of detecting the thickness of the coating layer in the inspection transport path at predetermined intervals. An analysis unit predicts the replacement timing of the transport device based on the results stored in the storage unit, A system for predicting the replacement timing of a transport device, characterized by comprising: a communication unit that notifies the replacement timing of the transport device predicted by the analysis unit; and a transport device replacement timing prediction system.

4. A parts feeder in which an inspection transport path for detecting the thickness of the coating layer is provided in a portion of the transport path through which the transported parts move while in contact with each other, A parts feeder characterized in that the initial thickness of the coating layer in the inspection transport path is different from the initial thickness of the coating layer in other parts of the transport path excluding the inspection transport path.

5. The parts feeder according to claim 4, characterized in that the inspection transport path is formed to be detachable from the transport path.

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