Conveyor

Abstract

The present invention addresses the problem of providing a conveyance device capable of reducing the frequency of stoppages.　In the present invention, a conveyance path 7 is formed by connecting a plurality of conveyance units. The conveyance units each have a drive device, which drives the conveyance unit, and an individual control device which controls the conveyance unit. The individual control devices each have a high-level control device 46 in a conveyance device that drives the conveyance unit when specific drive conditions are met. The high-level control device 46 communicates with the individual control device, and the high-level control device 46 has a state of movement monitoring means 35 for monitoring the state of movement of an actual conveyed article on the conveyance path 7. A correction operation for driving the conveyance units is carried out on the basis of a specific state of the surroundings of the conveyed article irrespective of the drive conditions if the conveyance unit, on which the conveyed article has been placed, has stopped even though the conveyed article can be moved.

Description

[Technical Field]

[0001] The present invention relates to a transport device such as a conveyor device. [Background technology]

[0002] A distributed control type conveying device is known as one type of conveying device (Patent Document 1). Distributed control involves arranging multiple conveying units called zone conveyors in a linear or branched configuration to form a continuous conveying path, with each conveying unit having its own independent drive motor (drive device). Each conveying unit is also equipped with a load sensor. The load sensor is a sensor that detects whether or not there is an object being conveyed on the conveying unit. Each conveying unit is equipped with a control device called a zone controller. The control device has a built-in CPU and memory means, and the memory means stores a computer program that configures a logic circuit (control circuit).

[0003] In a distributed control type transport device, each transport unit forms one zone, and the zones are connected to each other. When certain driving conditions are met, for example, there is an object being transported in the own zone (transport unit) and there is no object being transported in the downstream zone, the drive motor of the own zone (transport unit) is started and the object is sent to the downstream zone. Specifically, when the conditions are met that the load sensor in the own zone detects a transported item in the own zone (hereinafter referred to as load sensor ON) and the load sensor in the downstream zone does not detect a transported item (hereinafter referred to as load sensor OFF), the drive motor of the own zone (transport unit) is started and the transported item is sent to the downstream zone. The driving conditions are not limited to the above-mentioned operation logic. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2005-231745 [Patent Document 2] Japanese Patent Application Laid-Open No. 2013-230914 Summary of the Invention [Problem to be solved by the invention]

[0005] A problem with prior art transport devices is that they can be stalled for extended periods of time. For example, if there is an item being transported in the own zone and the load sensor is ON, and the load sensor in the downstream zone is OFF, the own zone (transport unit) will operate, but if there is an item being transported in the own zone but the load sensor detects it incorrectly and the load sensor is OFF, the zone will not operate. If the cause of the stoppage is a malfunction of the load sensor, the zone in question will be permanently stopped. When one zone stops, the zones upstream of that zone will be congested, and as a result, the entire conveyor system will stop. There may also be other reasons that force the transport device to be stopped. SUMMARY OF THE INVENTION The present invention focuses on the above-mentioned problems of the prior art, and has as its object to provide a conveying device that can reduce the frequency of stops. [Means for solving the problem]

[0006] An aspect for solving the above-mentioned problem is a conveying device in which a conveying path is formed by connecting a plurality of conveying units, the conveying units having a drive device that drives the conveying units and an individual control device that controls the conveying units, and the individual control device drives the conveying units when specific drive conditions are met, the conveying device has a host control device, the host control device communicates with the individual control devices, the host control device has a movement status monitoring means that monitors the actual movement status of the conveyed object on the conveying path, and when the conveying unit on which the conveyed object is placed is stopped even though the surrounding conditions of the specific conveyed object indicate that the conveyed object is capable of moving, a corrective operation is executed to drive the conveying unit by command of the host control device regardless of the drive conditions.

[0007] In many cases, an individual control device is provided for each transport unit, but there are also cases where one individual control device controls a plurality of transport units.

[0008] In the above-mentioned aspect, information regarding the destination of the transported object is exchanged between the individual control devices, and the transported object is transported to a predetermined destination, and the upper control device has a movement path estimation means for estimating a movement path for the transported object, and if a specific transported object is about to deviate from the movement path estimated by the movement path estimation means, it is desirable that a corrective operation be performed to guide the transported object to the path estimated by the movement path estimation means, taking priority over the information regarding the destination exchanged between the individual control devices.

[0009] According to this aspect, the frequency of incorrect delivery of the transported item is reduced.

[0010] Another aspect for solving a similar problem is a conveying device in which a conveying path is formed by connecting multiple conveying units, the conveying units having a drive device that drives the conveying unit and an individual control device that controls the conveying unit, and the individual control device drives the conveying unit when specific drive conditions are met, information regarding the destination of the conveyed object is exchanged between the individual control devices, and the conveying device in which the conveyed object is conveyed to a predetermined destination has a host control device that communicates with the individual control devices, the host control device has a movement path estimation means that estimates the movement path of the conveyed object and a movement status monitoring means that monitors the actual movement status of the conveyed object on the conveying path, and if a specific conveyed object is about to deviate from the movement path estimated by the movement path estimation means, a corrective operation is performed to guide the conveyed object to the path estimated by the movement path estimation means, taking priority over the information regarding the destination exchanged between the individual control devices.

[0011] According to this aspect, the frequency of incorrect delivery of the transported item is reduced.

[0012] Another aspect for solving a similar problem is a conveying device in which a conveying path is formed by connecting multiple conveying units, and the conveying units have a drive device that drives the conveying units and an individual control device that stores individual programs that operate the conveying units according to a certain operating logic, and the conveying device has a higher-level control device, and the higher-level control device communicates with the individual control devices and has an operation status monitoring means that individually monitors the operating status of each conveying unit, a desired operation storage means that stores desired operations of the conveying device, and / or a desired operation assumption means that virtually executes the desired operations of the conveying device, and the desired operation of the conveying device is compared with the actual operation of the conveying device obtained by the operation status monitoring means, and if a predetermined deviation occurs between the two, a corrective operation is executed that takes priority over the individual program to execute an operation that is closer to the desired operation.

[0013] In each of the above aspects, when any of the corrective actions is performed, it is desirable that the circumstances at that time be recorded.

[0014] In each of the above aspects, it is desirable that any one of the transport units is a roller conveyor, and that the tangential force of the roller is 100 Newtons or less.

[0015] The conveying device has a junction where multiple conveying paths converge, and when there are multiple conveying paths and there are simultaneously conveying items in conveying units just before the junction, it is desirable that a priority be determined in advance as to which conveying unit will convey the items to the junction.

[0016] It is desirable that the host control device stores the order in which each of the articles is transported. [Effects of the Invention]

[0017] The transport device of the present invention stops less frequently than the conventional one. [Brief explanation of the drawings]

[0018] [Figure 1] 1 is a block diagram of a layout of a conveyor device and a host control device according to a first embodiment of the present invention. FIG. [Figure 2] FIG. 2 is a perspective view of a transport unit that constitutes a linear transport zone. [Figure 3] FIG. 2 is a perspective view of the vicinity of a conveying direction changing zone formed by a conveying direction changing device. [Figure 4] A block diagram of a zone controller and a circuit diagram showing the relationship between each zone controller and a higher-level control device. [Figure 5] 1(a) is an explanatory diagram showing the conveyance route of an article A, and FIG. 1(b) is an explanatory diagram showing the conveyance route of an article B. FIG. [Figure 6] 10A shows a state in which the transported article A has stopped in zone 7 and is unable to move, and FIG. 10B shows a state in which the stop has been forcibly released. [Figure 7]1A shows a state in which an article A is about to deviate from its original conveying path, and FIG. 1B shows a state in which the conveying path has been corrected. [Figure 8] FIG. 10A shows a state in which conveyed goods A and B have stopped just before the junction and are no longer moving, and FIGS. 10B and 10C are explanatory diagrams showing a state in which the stop has been forcibly released. [Figure 9] FIG. 10 is a block diagram of a layout of a conveyor device and a host control device according to a second embodiment of the present invention. [Figure 10] FIG. 10 is a block diagram of a layout of a conveyor device and a host control device according to a third embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0019] Hereinafter, an embodiment of the present invention will be described. The conveying device 1 of this embodiment is a conveyor having a layout as shown in Fig. 1, in which the conveying path 7 is branched and there are multiple destinations and routes for conveying the objects. The conveying device 1 also has a host control device 46. The straight portion of the conveying path 7 of the conveying device 1 is divided into multiple short zones. That is, in the conveying device 1, the straight portion of the conveying path 7 is configured by multiple straight conveying zones connected in series. The conveying device 1 also includes multiple conveying direction changing zones, which configure the branched conveying path 7. The conveying device 1 is intended to convey objects of roughly fixed size, such as pallets, containers, and trays, and each zone has a length sufficient to accommodate at least one object.

[0020] Each zone is provided with one transport unit 2, 20. The transport units 2, 20 are formed by integrating a mechanical structure and a zone controller 10. The transport unit 2 installed in the linear transport zone is a zone conveyor as shown in Fig. 2. The transport unit 20 installed in the transport direction changing zone is a transfer device as shown in Fig. 3.

[0021] The transport unit 2 is a short roller conveyor, and the transport rollers 5 consist of a freely rotating driven roller 5b and a motorized roller 5a. In this embodiment, there is only one motorized roller 5a, and all the others are driven rollers 5b that rotate connected by a transmission belt 6. The motorized roller 5a has a built-in drive motor 15 as its drive device. The drive motor 15 has the function of outputting a pulse signal in response to rotation. The same applies to the drive motors of the other motorized rollers.

[0022] 2, the transport unit 2 is provided with a load sensor S. The load sensor S is provided on the side frame 3.

[0023] The load sensor S detects whether or not an article is present on the transport unit 2.

[0024] A photoelectric sensor can be used as the load sensor S, and a light-emitting element (not shown), such as a light-emitting diode or infrared diode, is provided on the opposing side frame 3. When an object is conveyed, the light from the light-emitting element is blocked and an ON (H level) signal is output, and when there is no object being conveyed, an OFF (L level) signal is output. In this way, the load sensor S is turned ON / OFF, making it possible to detect that the object has been conveyed to the specified position. Note that the cargo presence sensor is not essential, and it is also possible to consider a configuration in which, for example, a camera is used to capture an image of part or all of the conveying device 1, and the position of the transported goods and the transport status are detected by analyzing the image.

[0025] Next, the conveying direction changing zone will be described. The conveying unit 20 installed in the conveying direction changing zone is a transfer device as shown in Figure 3. The conveying unit 20 has a direction changing mechanism that switches the conveying direction or the carry-in direction. As shown in FIG. 3, the transport unit 20 is composed of a main transport conveyor 21, a sub-transport conveyor 22, and an elevator (not shown). The main transfer conveyor 21 of the transfer unit 20 is a belt conveyor in which a plurality of thin belts 25 are arranged at regular intervals. The main transfer conveyor 21 is driven by a drive motor (drive device) not shown.

[0026] When the transported item M placed on the transport unit 20 is to be moved in a straight line, the main transport conveyor 21 is extended above the sub-transport conveyor 22 by a lifting device (not shown), and the motor-integrated roller 28 of the main transport conveyor 21 is driven to run the belt 25. When the transported object M placed on the transport unit 20 is to be discharged laterally, after the transported object is pulled onto the main transport conveyor 21, an elevator device (not shown) raises the sub-transport conveyor 22 and lowers the main transport conveyor 21, causing the sub-transport conveyor 22 to protrude above the main transport conveyor 21, and then drives the motorized rollers of the sub-transport conveyor 22 to rotate each transport roller 26. The motorized rollers of the sub-transport conveyor 22 also have drive motors (drive devices). The transport unit 20 is also provided with a load sensor S (not shown). The transport unit 20 is also equipped with a zone controller (not shown).

[0027] The conveying units 2 and 20 are all low-load specifications, and the maximum tangential force of the conveying rollers 5, 26, and belt 25 is 100 Newtons or less. Therefore, even if a worker is caught in the conveying units 2 and 20, no serious accident will occur.

[0028] In the transport device 1, a plurality of transport units 2, 20 are connected to form a transport path 7. The layout of the transport device 1 is as shown in FIG. Each zone is assigned a unique address. For convenience, the addresses are numbered 1 to 19 as shown in FIG. 1. In this embodiment, the address of the first zone is 1, the address of the second zone is 2, and so on. Addresses are assigned sequentially thereafter. The address of each zone is stored in the zone controller 10 of each zone. In Figure 1, the arrows attached to each zone model the functions of the transport units 2 and 20 in each zone, and indicate the transport direction. The transport device 1 uses only the straight transport unit 2 and the branching transport unit 20. In other words, the straight arrows indicate the zone conveyors, which are the transport units 2 in the straight transport zone. The arrows that branch out indicate the transfer device that is the transfer unit 20 in the transfer direction changing zone. The fifth and ninth zones are transfer units (transfer devices) 20, and the other zones are straight-traveling transfer units 2.

[0029] As mentioned above, each zone has a zone controller 10 and a load sensor S. The zone controller 10 supplies power to the drive motors 15 (drive devices) of the transport units 2, 20 in each zone, and drives and stops the drive motors 15 of the transport units 2, 20 in each zone. As shown in FIG. 4, the zone controller 10 is an individual control device having a control circuit 40 that controls the transport units 2 and 20 individually. That is, the zone controller 10 includes a drive circuit 42 for driving the drive motor 15 as shown in FIG.

[0030] The zone controller 10 has a control circuit 40 (control means) that controls the drive circuit 42. The control circuit 40 has a memory (not shown) that stores individual programs for operating the drive equipment according to a certain operating logic. The control circuit 40 operates the drive circuit 42 according to a predetermined control logic, and drives and stops the drive motor 15 (drive device). That is, the transport units 2 and 20 operate in accordance with a predetermined control logic when specific operating conditions are met. Although there are no limitations on the driving conditions, the cases can be broadly divided into two: when the transported article is discharged from the own zone to a downstream zone, and when the transported article is introduced from the upstream zone.

[0031] The driving conditions when discharging an item from one's own zone to a downstream zone are not limited, but for example, it is possible that the load sensor in the own zone is in the ON state and the load sensor in the downstream zone is in the OFF state. In addition, if the load sensor of the own zone is ON and the downstream zone is operating, the own zone will also be operated.

[0032] The driving conditions when introducing an item from an upstream zone are not limited, but for example, it is possible that the load sensor in the own zone is in the OFF state and the load sensor in the upstream zone is in the ON state.

[0033] The zone controller 10 also includes a transport destination storage member (transport destination storage means) 47 and a transmitter / receiver (communication means) 41 built therein. The destination storage member 47 is a memory that functions as a destination storage means for temporarily storing destination information. Note that the "destination information" here refers to the destination on the conveying device 1 and is information including the address mentioned above. The transmitter / receiver 41 exchanges signals with the zone controller 10 of the adjacent zone, and functions as an information receiving means for receiving destination information from the upstream zone and as an information transmitting means for transmitting the destination information to the downstream zone. The zone controller (individual control device) 10 can also communicate with a higher-level control device 46 via a transmitter / receiver (communication means) 41. The zone controller (individual control device) 10 also operates according to commands from the higher-level control device 46. That is, a signal from the higher-level control device 46 can operate the drive circuit 42 and drive or stop the drive motor 15 (drive device).

[0034] A zone controller 10 is provided in every zone, and adjacent zone controllers 10 are connected to each other by signal lines 43. In addition, each zone controller 10 receives a signal from the inventory sensor S of the respective zone. Furthermore, all the zone controllers 10 and the host control device 46 are connected by a communication network 27 and communicate with each other.

[0035] In this embodiment, one zone controller (individual control device) 10 is provided for each zone, but one zone controller (individual control device) may control multiple zones.

[0036] In the conveying device 1 of this embodiment, a conveyed article identification device 45 is installed in the first zone, which is the start position. The conveyed article identification device 45 is specifically a barcode reader.

[0037] The upper control device 46 has an operation instruction means 30, a transfer destination selection means 31, a transfer destination instruction means 32, a movement route estimation means 33, a transfer order storage means 48, a movement status monitoring means 35, a surrounding information confirmation means 36, a route comparison means 37, a priority determination means 58, a forced drive / stop means 38, a history recording means 50, and a communication means 56. The upper control device 46 also has a display device 60. The operation instruction means 30 instructs the start and stop of the entire conveyance device 1 and the individual zone controllers 10 to start and stop the conveyance units 2 and 20 to be controlled.

[0038] The destination selection means 31 determines the destination of each article. The information read from the above-mentioned item identification device 45 is sent to the upper control device 46. The destination selection means 31 of the upper control means identifies the item from the information written on the barcode and inquires about the destination (destination) of the item. Furthermore, the movement path assumption means 33 determines the movement path of the transported article, and stores the determined movement path for each transported article. Then, the destination instruction means 32 transmits the address of the destination location to the zone controller 10 of the second zone, and inputs it into the destination storage member 47 of the zone controller 10 of the second zone. The destination information input to the destination storage member 47 is sent to the downstream zone controller 10 in sequence along with the transport of the object.

[0039] The conveyance order storage means 48 stores the order in which the articles are conveyed.

[0040] In this embodiment, each zone controller 10 and the upper control device 46 are connected via a communication network 27 to communicate with each other and exchange information. Information from the inventory sensor S and information about the goods being transported in the zone are input from each zone controller 10 to the upper control device 46 via the communication network 27 .

[0041] The movement status monitoring means 35 monitors the current operation status of the transport device 1 based on information obtained through the communication network 27 . That is, the movement status monitoring means 35 monitors whether or not there is an article in each zone, what the article is, the operating status of each zone, and the like. In this embodiment, the movement status monitoring means 35 displays the layout of the conveying device 1 on the display device 60, and further displays in which zone the transported article M is located. In addition, the display device 60 displays a moving image of the movement status of the transported article M.

[0042] When an article stops due to some abnormality, the peripheral information confirmation means 36 confirms the driving status of the zone in which the article is placed and the zones before and after it, as well as the presence or absence of the article.

[0043] The route comparison means 37 compares the movement route determined by the movement route assumption means 33 with the route along which the transported article is actually going to move.

[0044] The priority order determining means 58 determines the order of priority for conveying the articles to the junction from which conveyance unit when there are articles simultaneously in conveyance units before the junction.

[0045] The forced drive / stop means 38 sends a signal to a specific zone via a communication means to forcibly drive or stop the specific zone. That is, even if the drive conditions are not met, the specific zone is forcibly driven by the signal from the forced drive / stop means 38. Conversely, even if the drive conditions are met, the specific zone is forcibly stopped by the signal from the forced drive / stop means 38.

[0046] The forced drive / stop means 38 transmits a signal from the upper control device 46 and causes each zone controller 10 to perform an operation (corrective operation) different from the control logic of the individual program. The history recording means 50 records the history when the forced drive / stop means 38 functions and the operation of a zone is corrected. In other words, when a corrective operation is performed, the history recording means 50 records the situation before and after the correction.

[0047] Next, the operation of the transport device 1 will be described. In the conveying device 1 of this embodiment, an object to be conveyed is placed in the first zone, which is the start position. A barcode or the like (not shown) is attached to the object to be conveyed. The bar code attached to the transported item is read by the transported item identification device 45, and the signal is sent to the upper control device 46. The upper control means identifies the transported item from the information written on the barcode, inquires about the destination (destination) of the transported item, transmits the address of the destination to the zone controller 10 of the second zone, and inputs it into the destination memory member 47 of the zone controller 10 of the second zone.

[0048] On the other hand, when an object is placed in the first zone, the presence sensor for the first zone turns ON. If there are no objects in the second zone, the driving conditions for the zone controller of the first zone are met and the zone controller is driven. The driving conditions for the zone controller of the second zone are also met and the zone controller is driven. As a result, the second zone is also driven, and the object moves from the first zone to the second zone. The next zone, the third zone, also meets the driving conditions and is driven. The transported article moves from the second zone to the third zone. In this embodiment, information regarding the destination of the article is also passed on from the second zone to the third zone. Thereafter, the goods move sequentially downstream, and the information on the destinations is also sent in order. Then, the goods move to the predetermined destination.

[0049] Meanwhile, the communication network 27 notifies the upper control device 46 of the fact that the transported items are moving sequentially from the first zone to the second zone, the third zone, etc., and the movement status monitoring means 35 monitors the movement status of each transported item and the current operating status of the transport device 1.

[0050] If the article stops and stops moving for some reason, the surrounding information confirmation means 36 automatically checks the driving status of the zone where the article is placed and the zones before and after it, as well as the presence or absence of the article (hereinafter referred to as the situation confirmation operation). For example, if it is detected that the article has remained in the same zone for a certain period of time, the situation confirmation operation is automatically executed. As a result, if it is acceptable to move the transported article, the forced drive / stop means 38 sends a signal to the stopped zone and the zone downstream thereof to forcibly drive the zone (hereinafter referred to as the forced drive operation). In other words, even if the drive conditions are not met, the stopped zone and the zone downstream thereof are forcibly driven by the signal from the forced drive / stop means 38. When a stopped zone or a zone downstream thereof is forcibly driven by the host control device 46, the history recording means 50 records the situation before and after the correction.

[0051] If two transported objects simultaneously arrive at the zone just before the junction and stop moving in this state, a collision will occur at the junction if the transport units in the two zones are driven simultaneously. In this embodiment, the host controller 46 is provided with a transport order storage means 48 and a priority order determination means 58 as means for avoiding collisions. The conveyance order storage means 48 stores the order in which the articles are conveyed. When the transported articles simultaneously arrive at a zone just before the junction and stop and become unable to move in this state, the preceding transported article stored in the transport order storage means 48 is carried into the junction first.

[0052] Furthermore, the priority determination means 58 issues a command to the junction and the transport unit before it to introduce one of the transported items into the junction and then bring the other transported item into the junction, regardless of the destination or transport order of the transported items.

[0053] When two transported objects simultaneously arrive at the zone just before the junction and stop and become unable to move in this state, if the transport order of the objects is stored in the transport order storage means 48, the object that is earlier in the transport order will be transported to the junction first in response to a command from the upper control device 46. If the transport order of the transported objects is not stored in the transport order storage means 48, the transport units are driven in the order determined by the priority order determination means 58 in response to a command from the host control device 46.

[0054] In this embodiment, the movement path of the transported article is determined by the movement path assumption means 33 of the upper control device 46 separately from the operation of each zone controller, and the transport path is stored for each transported article. Furthermore, in this embodiment, the movement status monitoring means 35 monitors the drive status of each zone and predicts the zone to which each transported article will move next. The next predicted direction of movement is then compared with the path determined by the movement path prediction means 33 by the path comparison means 37.

[0055] Here, the destination based on the destination information sent sequentially through communication between adjacent zones and the discharge destination according to the record of the moving route estimating means 33 may differ for some reason. If the two are different, the forced drive / stop means 38 sends a signal to the zone where the transported object is placed and to the zone downstream of it, forcibly stopping or driving the zone. In other words, the destination of the transported object is corrected by the signal from the forced drive / stop means 38. When the destination of the article is corrected by the upper level control device 46, the history recording means 50 records the situation before and after the correction.

[0056] The above functions will be specifically described below. Figure 5(a) shows the original transport route for item A. That is, item A is an item that should be transported in a straight line from zone 1 to zone 10. Figure 5(b) shows the original transport route for item B. That is, item B is an item that should change course in zone 5, go from zone 11 to zone 19, and join the straight section in zone 9.

[0057] If the zone downstream of the current zone is empty, the article A moves from the first zone to the tenth zone without stopping, as shown by the arrow in FIG. 5(a). However, as shown in FIG. 6(a), there are cases where, for example, conveyed article A stops in zone 7 and cannot move any further. When such a situation occurs and the movement status monitoring means 35 detects that this state has continued for a certain period of time, the surrounding information confirmation means 36 performs a situation confirmation operation and checks whether there is a transported item in the 8th zone, which is downstream of the 7th zone where the transported item is placed. If there is no article in the downstream eighth zone as shown in Figure 6(a), a signal is sent from the upper control device 46 to the seventh zone, which is stopped by the forced drive / stop means 38, and to the eighth zone downstream of that, as shown in Figure 6(b), to forcibly drive those zones. That is, even if a corrective action is performed and the drive conditions are not met, the seventh and eighth zones are driven by the signal from the forced drive / stop means 38, and article A moves downstream.

[0058] As described above, the article A is to be conveyed linearly from the first zone to the tenth zone. Therefore, when the article A reaches the fifth zone, the sixth zone downstream of the fifth zone is driven, and the eleventh zone on the detour route must be stopped. However, as shown in FIG. 7(a), for example, when the transported article A reaches the fifth zone, the sixth zone through which the article should proceed may stop, and the eleventh zone through which the article should not proceed may start operating. When the movement status monitoring means 35 detects that such a situation has occurred, the surrounding information confirmation means 36 checks whether there are any transported items in the sixth zone, which is downstream of the fifth zone where the transported item is placed. If there is no article being conveyed in the downstream zone 6 as shown in Figure 7(a), the forced drive / stop means 38 sends a signal to the downstream zone 6 and the detour zone 11 as shown in Figure 7(b), driving the zone 6 and stopping the zone 11. That is, even if the drive conditions are not met, the zone 6 is driven by a signal from the upper control device 46 by the forced drive / stop means 38. Also, even if the drive conditions are met, the zone 11 is stopped by a signal from the forced drive / stop means 38.

[0059] The conveyance device 1 shown in FIG. 1 has a straight path that goes through zones 5, 6, 7, 8, and 9, and a detour path that goes through zones 5, 11, 12, . . . 9, with zone 9 being a junction. As shown in Figure 8(a), when transported items A and B arrive at the same time in zones 8 and 19 just before the junction, the system is programmed to let one of them pass first, but there are cases where the transport device 1 stops in the state shown in Figure 8(a). When the movement status monitoring means 35 detects that such a situation has occurred, the surrounding information confirmation means 36 checks whether there is a transported item in the 9th zone, which is downstream of the 8th and 19th zones where the transported item is placed.

[0060] If there are no articles in the downstream ninth zone as shown in FIG. 8(a), the preceding article stored in the transport order storage means 48 is carried into the junction first. For example, if article A is to pass first, as shown in Figure 8(b), the forced drive / stop means 38 sends a signal to the 8th zone where article A is stopped and to the 9th zone downstream of that, forcing the zones to move. In other words, even if the drive conditions are not met, the 8th and 9th zones are driven by the signal from the forced drive / stop means 38, and article A moves downstream. Next, a signal is sent to zone 19, where article B is stopped, and to zone 9 downstream thereof, to forcibly drive those zones. In other words, even if the drive conditions are not met, zone 19 and zone 9 are driven by the signal from the forcible drive / stop means 38, and article B moves downstream.

[0061] If the transport order of the transported objects is not stored in the transport order storage means 48, the transport units are driven in the order determined by the priority order determination means 58 in response to a command from the host control device 46. For example, a signal is sent to zone 8 and zone 9 downstream of it to forcibly drive those zones.

[0062] 6, 7, and 8 are carried out, the history recording means 50 records the situation before and after the correction, making it possible to verify the cause of the malfunction.

[0063] In the embodiment described above, the upper control device 46 has a movement status monitoring means 35, which monitors the current position and movement status of each transported object, and if the transport unit on which the transported object is placed is stopped even though the conditions around the transported object indicate that the transported object is capable of moving, a forced drive operation is performed to discharge the transported object from the zone. In the embodiment described above, the current position and movement status of each transported object are monitored, but it is also possible to monitor the overall movement of the transport device 1 from a bird's eye view, and if there is a malfunction, to temporarily change the driving conditions of the zone.

[0064] For example, there is no branch point between zones 1 and 4 in Figure 1. Therefore, when an item is carried into zone 1, it should be carried to zone 4 without any delay. The transfer device 1 of this embodiment employs a distributed control system, so that the first to fourth zones are always stopped, and only the zones that satisfy the drive conditions are driven. However, for example, if there is a problem with the load sensor S, the transported goods may be delayed in a specific zone. In such a case, it is recommended to configure the system so that the driving conditions for that zone are changed.

[0065] This configuration will be described below. As shown in Figure 9, the upper control device 57 used in the conveying device 100 of this embodiment has an operation instruction means 30, a destination selection means 31, a destination instruction means 32, a desired operation storage means 51, an operation status monitoring means 52, an operation comparison means 53, a program rewriting means 55, a history recording means 50, and a communication means 56. Here, the functions of the operation instruction means 30, the transport destination selection means 31, the transport destination instruction means 32, the history recording means 50, and the communication means 56 are the same as those in the above-described embodiment.

[0066] In this embodiment, the desired operation of the conveying device 100 is stored in the desired operation storage means 51. For example, as described above, it is stored as a desired operation that when an article is carried into the first zone, it is carried into the fourth zone without any delay. The operating status monitoring means 52 monitors the operating status of each zone from information obtained by the communication means 56 .

[0067] The operation comparison means 53 compares the current operation status of the transport device 100 obtained by the operation status monitoring means 52 with the desired operation of the transport device 100 stored in the desired operation storage means 51 . If a predetermined deviation occurs between the two as a result of the comparison, the program rewriting means 55 rewrites or replaces the program of the zone controller 10, and the program takes priority over the individual program up to that point, causing the zone controller 10 to execute an operation closer to the desired operation.

[0068] For example, there may be cases where the presence sensor of a particular zone downstream is OFF, but the presence sensor of that zone does not turn OFF, and the presence sensor of the upstream zone of that zone is ON, but the upstream zone remains stopped. Such situations can be detected by the operation status monitoring means 52. The above situation differs from the desired operation of the transport device 100 stored in the desired operation storage means 51 by more than a certain amount.

[0069] In such a case, the program of the zone controller 10 is changed by the program rewriting means 55. For example, the control logic of the individual programs up until now has been to start the drive motor 15 (drive device) of the own zone when the conditions are met that the load sensor of the own zone is ON and the load sensor of the downstream zone is OFF, but this can be changed to a program that constantly rotates the drive motor 15. Alternatively, the program can be changed to match the start and stop of the drive motor 15 to the preceding and following zones. As a result, the operation of the transport apparatus 100 is closer to the desired operation.

[0070] The desired operation stored in the desired operation storage means 51 described above is a rough example such as "when an item is brought into the first zone, it is brought into the fourth zone without delay," but it may also be more detailed and specific. For example, software (simulation software) that faithfully simulates the operation of the conveying device 100 may be used, and the desired operation of the conveying device 100 when moving the transported item A or the transported item B may be envisioned on the software, and this may be stored in the desired operation memory means 51.

[0071] The simulation software stores, but is not limited to, the layout of the conveying device 100, the length of each zone, the mechanical structure, the rotation speed of the drive motor, the generated torque, the position of the load sensor, etc. The simulation software also stores the control circuit 40 of the zone controller 10, individual programs, various settings, etc., and can faithfully realize the operation of the conveying devices 1, 100 in virtual space.

[0072] For example, a number of transported items including transported item A and transported item B are simultaneously transported by a conveyor device in a virtual space of the simulation software, and the desired operation of the transport device 100 is executed in the virtual space, and the situation at that time is stored in the desired operation memory means 51. The current operating status of the conveying device 100 obtained by the operating status monitoring means 52 is compared with the desired operation of the conveying device 100 stored in the desired operation storage means 51, and if there is a difference between the two that exceeds a certain level, the program of the zone controller 10 is changed by the program rewriting means 55.

[0073] In the above embodiment, the operation executed by the simulation software is stored in the desired operation storage means 51. However, as shown in FIG. 10, a desired operation assumption means 70 equipped with simulation software may be provided in the upper control device 57, and the transport device 100 may be operated in virtual space simultaneously and in parallel with the real transport device 100. If there is a difference between the two that exceeds a certain level, the program of the zone controller 10 may be changed by the program rewriting means 55.

[0074] The desired operation assumption means 70 operates the transport device 100 in a virtual space independently of the actual transport device 100, and virtually moves the transported object. In the virtual space, virtual cargo presence sensors turn on and off, and this information is input to each zone controller in the virtual space, which controls the drive motors in the virtual space and moves the transported goods in the virtual space.

[0075] The simulation software and the desired operation assumption means 70 can also be employed in the embodiment shown in FIG. That is, instead of or in addition to the surrounding information confirmation means 36, the desired operation assumption means 70 is employed, and when it is detected that the transported object has remained in the same zone for a certain period of time, the desired operation assumption means 70 checks whether there is a transported object in the surrounding zones. Assuming that the transport device 1 has been operating normally up until that point, the desired operation assumption means 70 can estimate the driving status of the zone in which the transported object is placed and the zones before and after it, as well as the presence or absence of the transported object.

[0076] Alternatively, the actual movement status of each transported item confirmed by the movement status monitoring means 35 may be compared with the virtual movement status assumed by the desired operation assumption means 70 or simulation software. [Explanation of symbols]

[0077] 1. Conveyor device 10 Zone controller (individual control device) 15 Drive motor (drive device) 20 Transport unit 30 Operation instruction means 31 Destination selection method 32 Delivery destination instruction means 33 Estimated travel route and means 35. Means of monitoring movement status 36 Means of checking surrounding information 37 Route Comparison Method 38 Forced drive and stop means 40 Control circuit 41 Transmitter / Receiver 42 Drive circuit 46,57 Upper control device 47 Destination memory member 48 Transport order storage means 50 History Recording Means 51 Desired action storage means 52 Operation status monitoring means 53 Operation comparison means 55 Program rewriting method 58 Priority Determination Methods 60 Display device 100 conveying device S inventory sensor

Claims

1. A conveying device in which a conveying path is formed by connecting a plurality of conveying units, the conveying units each having a drive device that drives the conveying unit and an individual control device that controls the conveying unit, the individual control device driving the conveying unit when a specific drive condition is satisfied, a host control device, the host control device communicating with the individual control devices; the host control device has a movement status monitoring means for monitoring the actual movement status of the transported object on the transport path, A conveying device characterized in that, when the surrounding conditions of a specific transported item indicate that the transported item is capable of being moved but the transport unit on which the transported item is placed is stopped, a corrective operation is executed to drive the transport unit by command from the upper control device regardless of the drive conditions.

2. Information regarding the destination of the transported goods is exchanged between the individual control devices, and the transported goods are transported to the predetermined destination, the host control device has a movement path estimation means for estimating a movement path of the transported object, The conveying device according to claim 1, characterized in that, when a specific object is about to deviate from the movement path assumed by the movement path assumption means, a corrective operation is performed to guide the object to the path assumed by the movement path assumption means, taking priority over information regarding the destination exchanged between the individual control devices.

3. A conveying device in which a conveying path is formed by connecting a plurality of conveying units, each of the conveying units having a drive device for driving the conveying unit and an individual control device for controlling the conveying unit, the individual control device driving the conveying unit when a specific drive condition is satisfied, information regarding the destination of the conveyed object is exchanged between the individual control devices, and the conveying device conveys the conveyed object to a predetermined destination, a host control device, the host control device communicating with the individual control devices; the host control device has a movement path estimation means for estimating a movement path of the transported object, and a movement status monitoring means for monitoring the actual movement status of the transported object on the transport path; A conveying device characterized in that, when a specific transported object is about to deviate from the movement path assumed by the movement path assumption means, a corrective operation is performed to guide the transported object to the path assumed by the movement path assumption means, taking priority over information regarding the destination exchanged between the individual control devices.

4. In a conveying device in which a conveying path is formed by connecting a plurality of conveying units, and the conveying units each have a drive device that drives the conveying unit and an individual control device that stores an individual program that operates the conveying unit according to a certain operating logic, a host control device, the host control device having an operation status monitoring means that communicates with the individual control devices and monitors the operation status of each transport unit individually, a desired operation storage means that stores a desired operation of the transport device, and / or a desired operation assumption means that virtually executes the desired operation of the transport device; A conveying device characterized in that the desired operation of the conveying device is compared with the actual operation of the conveying device obtained by an operation status monitoring means, and if a predetermined discrepancy occurs between the two, a corrective operation is executed to execute an operation closer to the desired operation in priority to the individual program.

5. 5. The conveying apparatus according to claim 1, wherein when any of the corrective actions is performed, the situation at that time is recorded.

6. 6. The conveying device according to claim 1, wherein any one of the conveying units is a roller conveyor, and the tangential force of the roller is 100 Newtons or less.

7. The conveying device according to any one of claims 1 to 6, characterized in that it has a junction where multiple conveying paths converge, and when there are multiple conveying paths and there are simultaneously conveying items in conveying units before the junction, a priority is predetermined as to which conveying unit will convey the conveying items to the junction.

8. 8. The conveying device according to claim 1, wherein the host control device stores a conveying order for each of the objects.

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