Conveyor Equipment

Abstract

To provide a conveyor device that can significantly reduce the number of information readout devices and is easy to install.SOLUTION: A conveyance object identification device 45 is installed in a first zone. The conveyance object identification device 45 is a bar code reader. Information read from the bar code reader is sent to an upper-level control unit 46. The upper-level control unit 46 identifies a conveyance object from the information written in the bar code, inquires a conveyance destination of the conveyance object, sends an address of a target place to a zone controller 10 of a second zone, and inputs the information into conveyance destination storage means of the zone controller 10 of the second zone. The conveyance destination information entered into the conveyance destination storage means is sequentially forwarded to the zone controller 10 on the downstream side together with conveyance of the conveyance object.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention provides The present invention also relates to a conveyor device. The present invention relates to a method for manufacturing a conveyor device such as a roller conveyor or a belt conveyor. Related inventions of The present invention relates to a method for manufacturing a conveyor device in which a conveying path is divided into a plurality of short zones and the conveying path is branched into a plurality of paths, so that there are a plurality of destinations for conveying the conveyed objects. Related inventions of teeth ,Ko This relates to conveyor systems. The present invention also relates to a zone controller for controlling the zones of the conveyor system. The present invention also relates to a transport module. The present invention also relates to a CAD device for use in designing a conveyor system. [Background technology]

[0002] Conveyor systems are often installed in delivery areas, collection points, warehouses, etc. For example, at delivery areas, it is necessary to sort transported items according to their delivery destinations, so conveyor systems installed at delivery areas have many branched conveying paths. In other words, conveyor systems installed at delivery areas often have multiple delivery destinations. In a conveyor device installed at a delivery site, a plurality of sub-branch conveyance paths branch off from a main conveyance path, and the branch conveyance paths further branch off to form grandchild branch conveyance paths and great-grandchild branch conveyance paths. In addition, the conveyor device installed at the delivery site has multiple straight conveying paths that constitute a main conveying path, a child branch conveying path, and a grandchild branch conveying path, and a conveying direction changing device that changes the conveying direction, and the conveying direction changing device is located at the branching point.

[0003] When transporting objects using a conventional conveyor system, a storage medium such as a barcode or IC tag containing information about the destination (destination) is attached to each object. An information reader is installed at each branch point, which reads the destination of the object and operates a conveying direction changer to send the object to the specified conveying path.

[0004] Also known is a conveyor system in which a series of conveyor systems is composed of multiple zones (Patent Document 2). In the conveyor device disclosed in Patent Document 2, a zone controller is provided for each zone, and the motor for each zone is controlled by the respective zone controller. A conveyor device including a zone having a branching function is also known (Patent Document 3). In the prior art, a zone having a branching function receives a signal from the outside and performs a branching operation. That is, a zone having a branching function has a function of, for example, making the conveyed article go straight or discharging the conveyed article laterally. These operations are performed by operating a plurality of motors in a predetermined order, and in the prior art, the plurality of motors are operated sequentially by an external signal. Specifically, a programmable logic controller (PLC) controlled the zones with branching functions. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Laid-Open No. 2005-231745 [Patent Document 2] Japanese Patent Application Laid-Open No. 2012-211015 [Patent Document 3] Japanese Patent Application Laid-Open No. 2013-230914 Summary of the Invention [Problem to be solved by the invention]

[0006] Conventional conveyor systems require an information readout device at each branch point. This means that conventional conveyor systems have a large number of components. Furthermore, changing the layout of a conveyor system or installing a new one requires complicated construction work. Furthermore, conventional conveyor systems require multiple programmable logic controllers (PLCs). The present invention focuses on the above-mentioned problems of the prior art, and aims to provide a conveyor device that can significantly reduce the number of information readout devices and PLCs and that is easy to install. [Means for solving the problem]

[0007] The aspect for solving the above problem is as follows: A conveyor system that transports an object from a start position to a destination, the conveyor system transporting the object across multiple zones, the multiple zones including a linear transport zone that transports the object in a linear manner and a transport direction changing zone that selects the transport direction of the object and sends it out, the conveyor system further comprising at least one object identification device and initial information transmission means that transmits destination information regarding the destination of the object to one of the zones, and a destination selection means, the destination selection means identifying the destination of the object identified by the object identification device, and information regarding the identified destination is transmitted to one of the zones by the initial information transmission means, the destination selection means having a route determination means that determines a transport route, and the information regarding the transport route is transmitted to one of the zones by the initial information transmission means. The above-described aspect preferably has a zone controller that controls one or more zones, and the zone controller has destination storage means that temporarily stores the destination information, information receiving means that receives the destination information from an upstream zone, and information transmitting means that transmits the destination information to a downstream zone, and as the article is moved, the destination information is passed from the zone controller that controls the upstream zone to the zone controller that controls the downstream zone. In the above aspect, when there are a plurality of transport routes, it is preferable that the transport destination selection means is capable of searching for the shortest transport route from among the transport routes. In the above aspect, when there are a plurality of transport routes, it is preferable that the transport destination selection means is capable of searching for a transport route that can reach the destination in the shortest time from among the transport routes. In the above-described aspect, when there are many articles passing through the shortest route, it is preferable to search for a detour route that is a route that can reach the destination in the shortest time. Another aspect for solving the same problem is: A method for manufacturing a conveyor device that is divided into a plurality of zones, transports objects across the zones, and transports the objects from a start position to a destination, the method comprising: a step of manufacturing a conveyor module that integrates a control device having a writable memory with the mechanical structure of each zone; an information writing step of writing information written in a CAD device that designs the conveyor device into the memory of the conveyor module, the information written in the CAD device including the speed of each zone of the conveyor device; and an on-site assembly step of transporting the conveyor module with the information written in the control device to a construction site and combining the zones according to the layout designed in the CAD device, characterized in that the information writing step is performed on a plurality of the conveyor modules in a state where they are not combined prior to the on-site assembly step. In the above-described embodiment, it is preferable that the address of the zone adjacent to the transport module is outputted and stored from the CAD device directly or via another device. The above-mentioned aspect makes it possible to output addresses determined by a layout drawn on the conveying module directly from the CAD device or via another device, and corresponding operation programs corresponding to the functions of each zone, and it is preferable that the operation programs corresponding to the functions of each zone include a control program that executes operations when introducing the conveyed item, a control program that operates the direction change mechanism, and a control program that executes operations to discharge the conveyed item. In the above aspect, it is preferable that a unique address is automatically set for each zone by creating a layout using the CAD device. Another aspect that solves the same problem is a conveyor device manufactured by the above-mentioned conveyor device manufacturing method, wherein the multiple zones include a linear conveying zone that conveys the objects in a linear manner and a conveying direction changing zone that selects the conveying direction of the objects and sends them out, and the conveyor device has a number adjustment function that waits until a specified number of objects are collected in the multiple zones and sends the objects out downstream when the specified number is collected. Another aspect that solves the same problem is a conveyor device manufactured by the above-mentioned conveyor device manufacturing method, wherein the multiple zones include a linear conveying zone that conveys the transported objects in a linear manner and a conveying direction changing zone that selects the conveying direction of the transported objects and sends them out, there are multiple destinations to which the transported objects may be sent, and the conveyor device has a ratio branching function that allocates the number of transported objects to the destinations. Another aspect that solves the same problem is a conveyor system that includes a conveyor manufactured by the above-mentioned conveyor manufacturing method and other equipment, and that has a display device that is capable of displaying information on the operating status, cargo status, abnormal status, and transported items of the conveyor device on the display device. A related aspect of the present invention is a conveyor system for transporting an object from a start position to a destination, the conveyor system being divided into a plurality of zones and transporting the object across the zones, the plurality of zones including a linear transport zone for transporting the object in a linear manner and a transport direction changing zone for selecting the transport direction of the object and sending it out, the conveyor system further comprising at least one object identification device and initial information transmission means for transmitting destination information regarding the destination of the object to one of the zones, each zone having destination storage means for temporarily storing the destination information, information receiving means for receiving the destination information from an upstream zone, and information transmission means for transmitting the destination information to a downstream zone, the conveyor system being characterized in that the destination information is passed from the upstream zone to the downstream zone as the object is moved across the zones.

[0008] Another aspect of a related invention of the present invention is a conveyor system for transporting an article from a start position to a destination, the conveyor system being divided into a plurality of zones each long enough to accommodate at least one article, and transporting the article across the zones, the plurality of zones including a linear transport zone for transporting the article in a linear manner and a transport direction changing zone for selecting the transport direction of the article and sending it out, the conveyor system further comprising at least one article identification device and initial information transmission means for transmitting the destination information to one of the zones, each zone having destination storage means for temporarily storing the destination information, information receiving means for receiving the destination information from an upstream zone, and information transmission means for transmitting the destination information to a downstream zone, the conveyor system being characterized in that the destination information is passed from the upstream zone to the downstream zone as the article is moved across the zones.

[0009] Here, "linear conveying zones that convey objects in a linear manner" refers to zones that have one inlet and one outlet for the objects. Linear conveying zones may also have the ability to switch the inlet and outlet by reversing the motor or other mechanism. "Linear conveying zones that convey objects in a linear manner" does not matter whether the planar shape of the conveying path is straight or curved. A linear conveying zone is a zone that does not have the ability to select the outlet direction of the objects, either left / right or up / down. In contrast, a conveying direction changing zone is a zone that can discharge conveyed materials in multiple directions or can receive conveyed materials from multiple directions. The discharge direction and the carry-in direction of the conveying direction changing zone may be perpendicular or oblique. The conveying direction changing zone may also change the conveying direction vertically. In other words, in a three-dimensional conveyor device with upper and lower conveying paths, the conveyed article may be raised to the upper conveying path or lowered to the lower conveying path. The conveyor device of this aspect includes a linear conveying zone for conveying an object in a linear manner, and a conveying direction changing zone for selecting a conveying direction and sending the object out, and the conveying path is branched into a plurality of paths. The conveyor system of this aspect has at least one object identification device and can identify the object. The conveyor system of the present invention also has an initial information transmission means for transmitting the destination information to one of the zones. Therefore, the initial information transmission means transmits information on the destination of the identified object to one of the zones. The initial information transmission means may transmit information to multiple zones. In this conveyor system, each zone has a destination storage means, an information receiving means, and an information transmitting means. As the transported article moves across zones, the destination information is passed from the upstream zone to the downstream zone. Therefore, when the article reaches the transport direction changing zone, the destination information is also transmitted to the transport direction changing zone. The transport direction changing zone operates based on the transmitted destination information and can send the article in the desired direction. In some cases, multiple zones are controlled by a single control device. In this case, the destination information is transferred within the control device from a memory in charge of an upstream zone to a memory in charge of a downstream zone. A conveyor system may have portions that are not divided into zones, for example, a portion of the conveyor system may have a long straight path. It is desirable that information be passed between adjacent zones, but information may be passed by skipping intermediate zones. In other words, "as the transported item is moved across zones" is not limited to cases where the transported item crosses adjacent zones, but also includes cases where there is an intermediate zone and the transported item crosses over that zone.

[0010] Another aspect of a related invention of the present invention is a conveyor system for transporting articles from a start position to a destination, the conveyor system having an area divided into a plurality of zones and transporting articles across the zones, the plurality of zones including a linear transport zone for transporting articles in a linear manner and a transport direction changing zone for selecting a transport direction for the articles and having a zone controller for controlling one or more zones, the zone controller having destination storage means for temporarily storing destination information regarding the destination of the articles, information receiving means for receiving the destination information from an upstream zone, and information transmitting means for transmitting the destination information to a downstream zone, and further having at least one article identification device and initial information transmitting means for transmitting the destination information to one of the zones, the conveyor system being characterized in that as the articles are moved, the destination information is passed from the zone controller controlling the upstream zone to the zone controller controlling the downstream zone.

[0011] It is desirable for information to be passed between adjacent zones, but if there is no branch point in the middle, information may be passed from the upstream zone to a downstream zone several zones away, skipping the middle zone. Furthermore, when a zone controller controls multiple zones, it is desirable that information be passed between adjacent zone controllers. However, if there is no intermediate branch point, information may be passed from the upstream zone controller zone to a downstream zone controller several zones away, skipping the intermediate zone controller.

[0012] In each aspect of the related inventions described above, it is desirable that each linear conveying zone has its own individual power source and can be driven and stopped independently of the other zones, and that each linear conveying zone has a load sensor that detects whether or not there is an article being conveyed thereon, and that the destination information stored in the destination memory means is erased and / or rewritten based on whether or not the linear conveying zone has been driven and whether or not the load sensor has detected the presence of an article being conveyed.

[0013] In this type of conveyor device, the destination information stored in the destination memory means is erased and / or rewritten based on whether the linear conveying zone has been driven or not, and whether the load sensor has detected the presence of an item being conveyed or not, so there is little risk of malfunction.

[0014] In each aspect of the related inventions described above, it is desirable that each linear conveying zone has its own individual power source and can be driven and stopped independently of the other zones, and that each linear conveying zone has a load sensor that detects whether or not there is an item being conveyed thereon, and that the destination information stored in the destination memory means be rewritten when the linear conveying zone itself is driven and the load sensor changes from a state in which it does not detect the presence of an item to a state in which it detects the presence of an item.

[0015] In each of the aspects of the related inventions described above, it is desirable that a unique address be set for each zone.

[0016] In each of the above-described aspects of the related invention, it is desirable that the unique address can be automatically set.

[0017] In each of the above-described aspects of the related invention, it is desirable to have a display device that displays the layout of the conveyor system.

[0018] In each aspect of the related invention described above, it is desirable to be able to import drawing information created on another device and create a layout to be displayed on the display device.

[0019] In each aspect of the related inventions described above, it is desirable that the multiple zones have presence sensors that detect whether or not there is an article being transported thereon, that a zone controller is provided that controls one or more zones, that the zone controller has built-in destination storage means, information receiving means, and information transmitting means, and that the signal from the presence sensor is input to the zone controller.

[0020] In each aspect of the related invention described above, it is desirable that the invention has at least one of the following functions. (1) A quantity adjustment function that waits until a specified number of transported items are collected in multiple zones, and then sends the transported items downstream when the specified number is collected. (2) A ratio branching function in which there are multiple destinations to which the transported items may be transported and the number of transported items is allocated to the destinations. (3) A congestion avoidance function that detours the transported goods when there is congestion at the destination.

[0021] In each aspect of the related inventions described above, it is desirable to have a destination selection means, which identifies the destination of the item identified by the item identification device, and for information regarding the identified destination to be transmitted to one of the zones by an initial information transmission means.

[0022] In each aspect of the related invention described above, it is desirable that the transport destination selection means has route determination means for determining a transport route, and that information regarding the transport route is transmitted to one of the zones by the initial information transmission means.

[0023] In each aspect of the related invention described above, when there are a plurality of transport routes, it is desirable that the transport destination selection means be able to search for the shortest transport route from among the transport routes.

[0024] In each aspect of the related invention described above, when there are a plurality of transport routes, it is desirable that the transport destination selection means be able to search for a transport route that can reach the destination in the shortest time from among the transport routes.

[0025] In each aspect of the related invention described above, it is desirable that the information regarding the destination include the following information. (1) Information about the zone where the conveying direction is to be changed and the conveying direction in that zone.

[0026] It is desirable that the zone has a length sufficient to accommodate at least one article.

[0027] It is desirable that some or all of the linear conveying zones be capable of conveying the articles in both forward and reverse directions.

[0028] It is desirable to have a total length measuring device for measuring the total length of the transported object.

[0029] A related aspect of the invention relating to a conveyor system is a conveyor system including the above-mentioned conveyor device and other equipment, or a conveyor system including a plurality of the above-mentioned conveyor devices, characterized in that it has individual control devices that individually control each of the conveyor devices and equipment included in the conveyor system, and an integrated controller that comprehensively controls the individual control devices included in the conveyor system.

[0030] In the above-described embodiment, it is desirable that the integrated controller also serves as an individual control device for individually controlling the conveyor devices.

[0031] Another aspect of the related invention is a conveyor system that is divided into a plurality of zones and transports objects across the zones, the conveyor system having motors in the plurality of zones and load sensors that detect whether or not an object is present in the zone, and the zone controller is used in the conveyor system and has the function of controlling one or more zones and supplying power to the motors, and the zone controller is equipped with destination storage means that can input signals from the load sensors and temporarily stores destination information regarding the destination of the object, information receiving means that receives the destination information from an upstream zone, and information transmitting means that transmits the destination information to a downstream zone, This zone controller is characterized by rewriting the destination information stored in the destination storage means when the motor of the zone it controls is driven and the load sensor changes from a state in which it does not detect the presence of an item to a state in which it detects the presence of an item.

[0032] Another aspect of the related invention is a conveying module that integrates a mechanical structure on which an object to be conveyed is placed and that conveys the object, and a controller that controls the mechanical structure, wherein the mechanical structure has a direction changing mechanism that switches the conveying direction or the carry-in direction, and is capable of bringing in the object from one or more carry-in directions and unloading the object in one or more conveying directions, and the controller has a control means that executes an operation to introduce the object to be conveyed, a control means that operates the direction changing mechanism, and a control means that executes an operation to unload the object to be conveyed.

[0033] In the above-mentioned aspect, it is desirable that the controller has an information receiving means for receiving destination information regarding the destination of the transported item from the controller of another transport module, and is capable of operating the direction changing mechanism based on the information received by the information receiving means.

[0034] Another aspect of a related invention is a CAD device for designing the above-mentioned conveyor system, comprising: layout creation means for creating a layout of the conveyor system composed of a plurality of the zones; layout display means for displaying the layout; information input means for writing at least the following information; and information output means for outputting the information: (1) Information about the location of the zone (2) Information about the operation of the zone

[0035] In the above aspect, the information preferably includes information identifying adjacent zones.

[0036] Another aspect of the related invention is a method for manufacturing a conveyor device having the above-mentioned configuration, which includes a step of manufacturing a conveying module in which a control device having a writable memory and the mechanical structures of each zone are integrated, and an information writing step of writing information written in the above-mentioned CAD device into the memory of the conveying module, and an on-site assembly step of transporting the conveying module with the information written in the control device to a construction site and joining each zone according to the layout designed in the CAD device. [Effects of the Invention]

[0037] The conveyor device and conveyor system of the present invention have a small number of parts and are easy to install. Related inventions The conveyor manufacturing method simplifies the work involved in designing and constructing a conveyor. The use of the zone controller and transport module of the related invention significantly reduces the number of information readout devices, simplifying the construction of the conveyor. Furthermore, the CAD manufacturing method of the related invention simplifies the work involved in designing and constructing a conveyor. [Brief explanation of the drawings]

[0038] [Figure 1]1 shows a layout of a conveyor device and a display screen of a display device according to a first embodiment of the present invention. [Figure 2] FIG. 10 is an explanatory diagram illustrating symbols indicating the functions of transport modules installed in each zone of the conveyor device. [Figure 3] FIG. 1 is a perspective view of a zone conveyor that constitutes a linear transport zone. [Figure 4] This is a perspective view of a straight conveying path to which three zone conveyors are connected. [Figure 5] FIG. 2 is a perspective view illustrating an example of a conveying direction changing device. [Figure 6] FIG. 6 is an exploded perspective view of the direction changer of FIG. 5. [Figure 7] 6 is a perspective view of the vicinity of a conveying direction changing zone configured by the conveying direction changing device of FIG. 5. FIG. [Figure 8] FIG. 2 is a block diagram of a zone controller and a circuit diagram showing the relationship between adjacent zone controllers. [Figure 9] 10A and 10B are perspective views showing another example of a conveying direction changing device, in which FIG. 10A shows a state in which the conveyed object is made to travel straight, and FIG. 10B shows a perspective view showing a state in which the conveyed object is diverged in an oblique direction. [Figure 10] FIG. 1 is a perspective view of a zone conveyor that forms a curved path. [Figure 11] 10 is a diagram illustrating a layout of a conveyor device and a display screen of a display device according to a second embodiment of the present invention. [Figure 12] 3 is a table showing the configuration of a control system for a conveyor device according to the present embodiment. [Figure 13] 1 is a configuration diagram illustrating a control system for a conveyor device according to an embodiment of the present invention. [Figure 14] FIG. 2 is a block diagram of an integrated controller employed in the conveyor device of the present embodiment. [Figure 15] 2 is a layout of a conveyor apparatus obtained by changing the layout of the conveyor apparatus shown in FIG. 1. [Figure 16] (a) is a CAD screen according to an embodiment of the present invention, and (b) and (c) are enlarged views of a portion of the screen. [Figure 17]10 shows a layout of a conveyor device and a display screen of a display device according to a third embodiment of the present invention. [Figure 18] FIG. 10 is a front view of a monitor screen showing an example of a monitor display displayed on a display device of a host control device, in which a layout of a conveyor device according to a fourth embodiment of the present invention is displayed. [Figure 19] 13 is a diagram illustrating a layout of a conveyor device and a display screen of a display device according to a fifth embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0039] Further embodiments of the present invention will be described below. The conveyor device 1 of the first embodiment is a conveyor having a layout as shown in FIG. 1, in which a conveying path branches into a plurality of paths and there are a plurality of destinations to which an object is conveyed. In the conveyor system 1 of the first embodiment, the straight portion of the conveying path is divided into multiple short zones. That is, in the conveyor system 1, the straight portion of the conveying path is configured by multiple straight conveying zones connected in series. The conveyor system 1 also includes multiple conveying direction change zones, forming a branched conveying path. The conveyor device 1 is intended to transport objects of roughly a fixed size, such as pallets, containers, and trays, and each zone has a length sufficient to accommodate at least one object.

[0040] Each zone is provided with a transfer module, which is an integrated unit of a mechanical structure and a zone controller 10. The transport module installed in the linear transport zone is a zone conveyor 2 as shown in Fig. 3. The transport module installed in the transport direction changing zone is a transfer device 20 as shown in Fig. 5.

[0041] The zone conveyor 2 is a roller conveyor, and is configured by supporting a plurality of conveying rollers 5 at predetermined intervals in the conveying direction between a pair of parallel-arranged left and right side frames 3, 3, which convey the object W. The conveying rollers 5 consist of freely rotating driven rollers 5b and motorized rollers 5a incorporating a drive motor (not shown). In this embodiment, there is only one motorized roller 5a, and all the others are driven rollers 5b.

[0042] Adjacent conveyor rollers 5 in the zone conveyor 2 are wound with a transmission belt 6. This allows the rotational driving force of the motorized roller 5a to be transmitted to all of the driven rollers 5b. In this embodiment, the motorized roller 5a is located in the center. The zone conveyor 2 can change the loading direction and conveying direction by rotating the motorized roller 5a forward or backward, but it does not have the function of branching off the destination or introducing conveyed items from multiple loading routes.

[0043] As shown in Figure 3, the zone conveyor 2 is provided with a load sensor S. The load sensor S is provided on the side frame 3. The load sensor S is located near the downstream end.

[0044] 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 photoelectric sensor is turned ON / OFF, making it possible to detect that the object has been conveyed to the specified position.

[0045] The straight section of the conveyor path of the conveyor device 1 is made up of zone conveyors 2, which are conveying modules, connected in series, as shown in Figure 4. One side frame 3 of each zone conveyor 2a, 2b, 2c, etc. is equipped with a zone controller 10 for controlling the drive of the motor inside each motorized roller 5a, as shown in Figure 4. The zone controller 10 is attached integrally to the zone conveyor 2, which is a mechanical structural part, and is part of the conveying module. The function of the zone controller 10 will be described later.

[0046] Next, the conveying direction changing zone will be described. The conveying module installed in the conveying direction changing zone is a transfer device 20 as shown in Figures 5, 6, and 7. The transfer device 20 has a direction changing mechanism that switches the conveying direction or the loading direction. As shown in FIG. 6, the transfer device 20 is composed of a main transfer conveyor 21, a sub-transfer conveyor 22, and an elevator device 23. The main transport conveyor 21 of the transfer device 20 is a belt conveyor in which a plurality of thin belts 25 are arranged at regular intervals. The main transport conveyor 21 is driven by a motorized roller 28 provided at the end.

[0047] The sub-conveyor 22 of the transfer device 20 is a roller conveyor. The sub-conveyor 22 has multiple rollers 26 arranged in parallel, which are linked by a belt 27. One of the multiple rollers 26 that make up the sub-conveyor 22 is a motorized roller, and all of the rollers 26 rotate when the motorized roller is driven. The secondary conveyor 22 is arranged so that rollers 26 are present between the belts 25 of the main conveyor 21 as shown in FIG.

[0048] The lifting device 23 has a linear cam 29 and lifts and lowers the main transfer conveyor 21 and the sub-transfer conveyor 22 . When the transported object placed on the transfer device 20 is to be moved in a straight line, the main transport conveyor 21 is extended above the sub-transport conveyor 22 by the lifting device 23, and the motorized roller 28 of the main transport conveyor 21 is driven to run the belt 25. When the transported object placed on the transfer device 20 is to be discharged laterally, after the transported object is pulled into the main transport conveyor 21, the sub-transport conveyor 22 is raised by the lifting device 23 and the main transport conveyor 21 is lowered, causing the sub-transport conveyor 22 to protrude above the main transport conveyor 21, and the motor-integrated rollers of the sub-transport conveyor 22 are driven to rotate each roller 26. The transfer device 20 is also provided with a load sensor (not shown). The transfer device 20 is also equipped with a zone controller (not shown). The zone controller 10 is integrally attached to a transfer device 20, which is a mechanical structural part, and is a part of the transport module.

[0049] The layout of the conveyor system 1 of the first embodiment is as shown in Figure 1, and has a complexly branched conveying path. Unlike the second and third embodiments described below, the conveyor system 1 of the first embodiment does not have a detour route or the like. Each zone is assigned a unique address. For convenience, addresses are assigned from 1 to 88 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. The arrows attached to each zone model the function of the transport module in each zone. The meaning of the arrows is as shown in Figure 2. The conveyor system 1 of the first embodiment uses only the straight and branching modes shown in Figure 2. In other words, the straight arrows indicate the zone conveyor 2, which is the transport module of the linear transport zone. The branched arrow indicates a transfer device 20 which is a transport module in the transport direction changing zone. In the conveyor device 1 of the first embodiment, the zones at addresses 3, 5, 18, 20, 22, 25, 29, 35, 38, 40, 46, 50, 53, 61, 64, 67, 71, 75, 77, and 82 are conveying direction changing zones. The conveying module of the conveying direction changing zone is the transfer device 20. The other zones are linear conveying zones, and the conveying module is the zone conveyor 2.

[0050] As mentioned above, each zone has a zone controller 10 and a presence sensor S. The zone controller 10 supplies power to the motors of the conveying modules of each zone and drives and stops the motors of the conveying modules of each zone. That is, the zone controller 10 has a built-in drive circuit that drives the motors, as shown in Figure 8. Specifically, the zone controller 10 has a built-in drive circuit that drives the motors built into the motor-incorporated rollers. The zone controller 10 also includes a transport destination storage member (transport destination storage means) 40 and a transmitter / receiver 41 built therein. The destination storage member 40 is a memory that functions as a destination storage means for temporarily storing the destination information. Note that the "destination information" here refers to the destination on the conveyor system 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 the destination information from the upstream zone and as an information transmitting means for transmitting the destination information to the downstream zone.

[0051] 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.

[0052] In the conveyor system 1 of the first embodiment, an article identification device 45 is installed in the first zone, which is the start position. The article identification device 45 is specifically a barcode reader. Information read by the barcode reader is sent to a higher-level control device (conveyor controller or integrated controller (ICS)). In this embodiment, an integrated controller (ICS) is used as the higher-level control device 46. The upper control device 46 identifies the item from the information written on the barcode, checks the destination (destination) of the item, and transmits the address of the destination to the zone controller 10 of the second zone (initial information transmission means), which then inputs it into the destination storage member 40 of the zone controller 10 of the second zone. The destination information input to the destination storage member 40 is sent to the downstream zone controller 10 in sequence along with the transport of the object.

[0053] Although not adopted in the conveyor system 1 of the first embodiment, the address of the destination can also be transmitted from the host control device 46 to the destination storage member 40 of another zone. That is, the address of the destination can also be transmitted to the zone controllers 10 of multiple zones. Specifically, the address of the destination can be transmitted to the destination storage member 40 of the upstream zone, and then the address of the destination can also be transmitted to the destination storage member 40 of the downstream zone. For ease of explanation, the information input to the destination storage member 40 of the zone controller 10 of the second zone will be referred to as first initial information, and the information input to the downstream zone will be referred to as second initial information.

[0054] The above-mentioned upper control device 46 is a known personal computer, and includes a CPU and a memory (not shown). The host controller 46 functions as an article selection means, a transport route determination means, a special transport command means, and an initial information transmission means. In this embodiment, the destination information is input to the upper control device 46 from an even higher-level control device and stored in an internal memory. For example, destination information is input that an item A is destined for Fujita Shoten, and an item B is destined for Daiminami Store. This destination information is then stored in an internal memory.

[0055] Furthermore, a signal from the article identification device 45 is input to the upper control device 46. That is, information for identifying the article read by the barcode reader is input.

[0056] In this embodiment, the upper control device 46 functions as a destination selection means, and compares the item identification information input from the item identification device 45 with the shipping destination information stored in memory to determine the destination of the item on the conveyor device 1. The host controller 46 also has the function of determining the transport route of the object on the conveyor device 1. That is, a CPU (not shown) searches for a route from the first zone, which is the starting position, to the final destination. For example, when there are multiple transport routes, such as in the conveyor system 60 of the second embodiment and the conveyor system 8 of the third embodiment, which will be described later, the shortest route is searched for as a general rule. Note that the conveyor system 1 of the first embodiment does not use this function, since it has only one transport route. When there are multiple transport routes, such as in the conveyor system 60 of the second embodiment and the conveyor system 8 of the third embodiment, it is possible to search for the transport route that will reach the destination in the shortest time. For example, if there are multiple routes from the first zone, which is the start position, to the final destination, but the shortest route among them has many objects passing through it, a detour route is searched for.

[0057] Then, the optimum transport route is determined and transmitted to the zone controller 10 of the second zone. That is, in this embodiment, the upper control device 46 functions as an initial information transmitting means. The initial information sent to the zone controller 10 of the second zone is the first initial information, which is the destination of the transported article. In principle, the first initial information is the final destination of the transported article, but depending on the transported article, an intermediate passing position may become the first initial information. For example, when performing the "number-matching operation" described later, a zone on the way to the final destination is designated as the first initial information.

[0058] As described above, the host control device 46 has the function of transmitting second initial information to the zone controller 10 of the downstream zone. The second initial information includes information indicating the further direction in which a specific conveyed article that has arrived at the zone should proceed. That is, a specific article arrives at a specific zone based on the first initial information. Then, second initial information is input from the higher-level control device 46 to the zone controller 10 of the zone where the article has arrived based on the first initial information, and the article then proceeds toward the destination of the second initial information.

[0059] In this embodiment, each zone controller 10 is connected to the upper control device 46 via a communication means. Information from the inventory sensor S and information about the transported goods in the zone are input from each zone controller 10 to the upper control device 46 via the communication means. On the other hand, the above-mentioned communication means allows the host control device 46 to send a signal to each zone controller 10 to stop the individual zone. In this embodiment, the information transmitted from each zone controller 10 to the upper control device 46 (information from the cargo sensor S and information on the transported goods in the zone) and the signal to stop the individual zone transmitted from the upper control device 46 to each zone controller 10 can be used to perform special transport such as "quantity matching operation," "ratio branching operation," "congestion avoidance operation," and "merging operation."

[0060] Here, "number-matching operation" refers to an operation in which a specified number of transported articles are waited for in multiple zones, and when the specified number of articles are gathered, the articles are sent downstream. Specifically, in normal operation, an article is carried into a zone, and if there is no article in the downstream zone, the article is sent to the downstream zone. In "quantity matching operation," when a specific item arrives at a specific zone, the first zone is stopped until several items of the same type are gathered in the adjacent zone upstream. Once the desired number of items have accumulated in the adjacent zone upstream, they are gathered and transported downstream all at once. In the "quantity matching operation," the zone where the transported article is to wait is specified as the first initial information, and the specific transported article is led to the zone where it is to wait. When a predetermined number of articles accumulate in the standby zone and the zone upstream of it, and this fact is confirmed by information sent from the zone controller 10 to the higher-level control device 46, the higher-level control device 46 sends a release signal to release the suspension of the zone, and also instructs the zone controller 10 as second initial information which zone the articles will ultimately be transported to. The articles are then moved to the destination zone.

[0061] In addition, the same operation can be achieved by instructing the zone to which the transported item will ultimately be transported as first initial information, sending a stop signal from the upper control device 46 to the zone where the transported item is to wait, temporarily stopping the transported item, and once a predetermined number of transported items have accumulated, sending a release signal from the upper control device 46 to release the stop of the zone.

[0062] The "proportional distribution operation" is an operation in which there are multiple destinations to which the transported articles may be transported, and the number of transported articles is distributed among the destinations. For example, there may be two trucks or containers available for transporting goods to the same destination (for example, Fujita Shoten), and goods may be loaded onto either truck or container. In such cases, the goods should be transported onto multiple trucks etc. in the same amount. In such cases, the operation of distributing the goods to multiple trucks etc. in the same amount is called "ratio distribution operation." Specifically, when a specific article arrives at a specific zone, the final destination of the article is changed, for example, alternately. In the "ratio branch operation," a branch point zone is specified as the first initial information, and a specific transported article is led to the branch point zone. When the article reaches the branching point zone, second transport information is sent to the zone controller, and the article is moved alternately to multiple zones. That is, multiple zones are alternately designated as the second transport information, and the article is moved alternately to multiple zones.

[0063] In this embodiment, as described above, in addition to the "alternate method" in which the final destination of the transported items is alternately changed, it is also possible to select a "priority method" in which priorities are set and when a predetermined number of items have accumulated at a destination with a higher priority, the items are sent to a destination with a lower priority. You can also set a distribution ratio and select the "proportional method," which allocates destinations according to that ratio.

[0064] In the above-mentioned "proportion branch operation," when the transported item reaches the branch point, the final transport destination is input to the zone controller 10 as second transport information, but the destination may also be allocated from the beginning. That is, the same operation can be realized even if the final destination of the transported article is allocated at the stage of transmitting the first initial information.

[0065] "Traffic congestion avoidance operation" refers to an operation that detours the transported article when there is congestion at the transport destination. In this operation, when goods accumulate in a zone in a specific area and this fact is discovered by information sent from the zone controller 10 to the upper control device 46, the upper control device 46 sends a signal to the zone connected to the detour route to temporarily change the direction of conveyance, and the goods are diverted to the detour route.

[0066] Furthermore, if an article remains in the same zone for a certain period of time, a signal to temporarily change the conveying direction may be sent from the upper controller 46 to the zone connected to the circuit, and the article may be diverted to a detour.

[0067] It is also possible to adopt a configuration in which the transported article is diverted to a detour route when the above two conditions are met.

[0068] "Merge operation" is an operation that controls the merging portion of the transport paths, and in this embodiment, two methods can be selected: "alternate merging" and "lot merging." "Alternate merging" is a method in which two upstream conveying paths merge and converge into one downstream conveying path, and objects are transported downstream alternately from one upstream conveying path and the other upstream conveying path. The number of pieces transported at one time is not limited to one piece at a time, but may be multiple pieces at a time. Also, the numbers of pieces introduced may be different, such as two pieces at a time from one upstream transport path and one piece at a time from the other.

[0069] "Lot merging" is a method similar to the "piece-matching operation" described above, in which a certain number of items are waited for to accumulate on one of the upstream conveying paths, and once that number is reached, the items are conveyed downstream.

[0070] In this embodiment, the host controller 46 is connected to a display device 33, and the zone in which each transported article is currently located is displayed on the display device 33 as a monitor.

[0071] The function of the conveyor device 1 of the first embodiment will be specifically described below. As described above, the conveyor system 1 of the first embodiment is divided into multiple small zones, and the transport modules of each zone have their own transport motors. Therefore, the conveyor system 1 of the first embodiment can drive and stop each zone individually. In the conveyor system 1 of this embodiment, the motors (transport motors) of the transport modules of each zone are always stopped and are driven only when necessary. The cases where it is necessary are when an article should be received from an upstream zone and when an article should be discharged to a downstream zone. The former is when there is an article in the upstream zone (immediately before) but no article in the own zone. Specifically, if the load sensor in the upstream zone detects the presence of an article but the load sensor in the own zone does not detect an article, and the transport module in the own zone is currently stopped transporting, the own transport module will be activated to accept the article.

[0072] In addition, even if there is an article in the upstream zone and the downstream zone is operating, the article can be accepted from the upstream zone. Specifically, even if the cargo presence sensor in the upstream zone detects the presence of an article and the downstream zone is operating, the own conveying module will be activated to accept the article.

[0073] Furthermore, when an article should be discharged to the downstream zone, it means that there is an article in the own zone and there is no article in the downstream zone. Specifically, when the load sensor in the own zone detects the presence of an article and the load sensor in the downstream zone does not detect an article, the own conveying module is activated and the article is discharged downstream. Furthermore, even if there is an article in the own zone and the downstream zone is operating, the article can be discharged to the downstream zone. Specifically, even if the load sensor in the own zone detects the presence of an article and the downstream zone is operating, the own conveying module is activated to discharge the article to the downstream zone.

[0074] In the conveyor device 1 of this embodiment, when an object is carried into its own zone from an upstream zone, the destination information is transmitted from the upstream zone to its own transceiver unit 41. The destination information is then stored in the destination storage member 40. When the transported article is discharged from its own zone, the transport destination information stored in its own transport destination storage member 40 is erased. To explain the relationship between the movement of transported goods and the movement of information, when a transported goods is brought into a zone from an upstream zone and moves across zones, the destination information is also passed from the upstream zone to the downstream zone.

[0075] Specifically, when the conveying module in its own zone operates and its own load sensor S detects an item from a state in which it was not detecting any, the destination information is sent from the upstream zone to its own transceiver unit 41, the information in the destination memory member 40 is rewritten, and the destination information is stored in its own destination memory member 40.

[0076] Furthermore, when the transport module of the own zone is activated and the transport sensor S of the own zone is changed to a state where it is not detecting the transported item, and a certain period of time has passed since then, the transport destination information stored in the transport destination memory member 40 of the own zone is erased. That is, the destination information stored in the destination memory member 40 is erased or rewritten based on whether or not the conveying module in the linear conveying zone has been driven and whether or not the load sensor S has detected the presence of an item. More specifically, when the conveying module of the linear conveying zone is activated and the load sensor S changes from a state in which it does not detect the presence of an item to a state in which it detects the presence of an item, the destination information stored in the destination memory member 40 is rewritten.

[0077] In the conveyor system 1, a barcode is attached to the transported object, and the object is placed in the first zone, which is the starting position. As described above, an object identification device 45 is installed in the first zone, and information identifying the object read by the object identification device 45 is sent to a higher-level control device 46. Information on the address of the object's destination (destination) and the transport route is then sent from the higher-level control device 46 to the zone controller 10 of the second zone, and input into the destination storage means of the zone controller 10 of the second zone.

[0078] Here, the information on the conveying route is information indicating the zone where the route is changed and the route after the change. As described above, the conveyor system 1 of this embodiment is composed of a straight conveying zone and a conveying direction changing zone. Here, the straight conveying zone only has the function of sending the conveyed object downstream, so it does not contribute to the selection of the conveying destination. In this embodiment, only the conveying direction changing zone contributes to the selection of the conveying destination. Therefore, in this embodiment, the information on the conveying path includes the address of the conveying direction changing zone and the discharge direction from the conveying direction changing zone. More specifically, the information on the conveying path includes the address of the conveying direction changing zone where the direction should be changed and the discharge direction from the conveying direction changing zone, but does not include the address of the conveying direction changing zone where the conveying direction is not changed.

[0079] In this embodiment, the upper control device 46 functions as an initial information transmitting means, and transmits the destination information to the zone controller 10 of the second zone. The article is transported downstream without stopping, and as the article moves, the information stored in the destination storage member 40 of the zone that received the article is rewritten, and the information about the destination is sent in order.

[0080] When the transported article reaches the transport direction changing zone (zone with addresses 3, 5, 18, 20, 22, 25, 29, 35, 38, 40, 46, 50, 53, 61, 64, 67, 71, 75, 77, and 82), the contents of the transport destination memory member 40 of the zone controller 10 of the transport direction changing zone are checked, and the sending direction is determined. For example, when an article reaches a zone with address 3, the address of the destination (destination) is transmitted from the upstream second zone to the zone controller 10 of the third zone, and the information stored in the destination storage member 40 of the zone controller 10 of the third zone (conveyance direction change zone) is rewritten. That is, when the article moves from the second zone to the third zone and is transported across zones, the destination information is passed from the upstream second zone to the downstream third zone as the article moves across zones.

[0081] The information is then read, and if the destination address is one of 4 to 8, the direction change mechanism functions. Specifically, after the object is pulled onto the main conveyor 21, the auxiliary conveyor 22 is caused to extend above the main conveyor 21, and the motorized rollers of the auxiliary conveyor 22 are driven to discharge the object to the addresses 4 to 8 (the fourth to eighth zones). At this time, the address of the destination (destination) is sent from the third zone (conveyance direction change zone) to the zone controller 10 of the fourth zone, and the information stored in the destination memory member 40 of the zone controller 10 of the fourth zone (linear conveyance zone) is rewritten. In this way, even at the branching section, the destination information is passed from the third zone on the upstream side to the fourth zone on the downstream side as the object moves across zones.

[0082] In this embodiment, as described above, the information on the transport path includes the address of the transport direction changing zone where the direction should be changed and the discharge direction from the transport direction changing zone. If the destination address is 4 to 8, address 3 is included as the address of the transport direction changing zone where the direction should be changed, and further information on the discharge direction being "right" is included. In this embodiment, the zone controller 10 of the third zone (conveying direction change zone) corresponding to address 3 receives information about the conveying route from the upstream second zone, and if its own address (address 3) is included in the information, it operates in accordance with the information and discharges the conveyed item to the addresses 4 to 8 side. Thereafter, the designation of the own zone is deleted from the information on the transport route, and the information after designation of the own zone is transmitted to the zone controllers 10 of the third zone (transport direction changing zone) and the fourth zone.

[0083] If the address of the destination (destination) sent to the third zone together with the transported item is 9 to 88, the transported item travels on the main transport conveyor 21 and is discharged to the ninth zone (address 9). The address of the destination (destination) is also sent from the third zone (transport direction change zone) to the zone controller 10 of the ninth zone, and the information stored in the destination memory member 40 of the zone controller 10 of the ninth zone (linear transport zone) is rewritten. In this case, as the article moves across zones, the destination information is passed from the upstream third zone to the downstream ninth zone.

[0084] As mentioned above, the transport route information does not include the address of the transport direction change zone, which does not change the transport direction, so if the address of the destination (destination location) sent to the third zone is 9 to 88, the direction change mechanism of the transport direction change zone will not react.

[0085] The same applies when the transported article reaches another transport direction changing zone, where the address of the destination is confirmed and the transported article is discharged in that direction. The address of the destination is also transmitted together with the transported article. As a result, the transported item is transported from the start position to the destination.

[0086] As described above, in this embodiment, the address of the transport direction change zone is included in the transport route information, so the direction change mechanism operates if the address of the own zone is included in the received transport route information, and does not operate if the address of the own zone is not included in the received transport route information.

[0087] In the embodiment described above, the conveying direction changing zones (zones with addresses 3, 5, 18, 20, 22, 25, 29, 35, 38, 40, 46, 50, 53, 61, 64, 67, 71, 75, 77, and 82) employ conveying modules that discharge conveyed objects at right angles, but they may also employ modules that oscillate bars 50 as shown in Figure 9 to discharge conveyed objects at an angle. Also, as shown in Figure 10, a conveying module 51 with a curved path may be employed.

[0088] It is recommended that the conveyor device 1 of this embodiment be combined with other devices such as a plurality of conveyor devices, an automated warehouse, a self-propelled transport device, etc. to form a series of conveyor systems. For example, a control system such as that shown in FIGS. 11 and 12 is constructed, and an integrated controller (WCS) controls a conveyor controller that controls the conveyor device 1 and controllers of many devices such as displays. Furthermore, it is recommended to combine it with a warehouse management system that manages warehouse inventory and orders, as shown in Figures 11 and 12. The conveyor system shown in Figures 11 and 12 is a conveyor system including a conveyor device 1, and has individual control devices such as a conveyor controller and a display controller that individually control each conveyor device and piece of equipment included in the conveyor system, and an integrated controller that performs overall control of the individual control devices included in the conveyor system.

[0089] The conveyor system 60 shown in Fig. 11 has two independent conveyor systems 61 and 62. The conveyor system 60 shown in Fig. 11 is controlled by a single upper control system 46 (integrated controller WCS) as shown in Fig. 11.

[0090] It is also recommended that the integrated controller also function as a conveyor controller for controlling the conveyor device 1.

[0091] Furthermore, the conveyor device 1 of this embodiment and conveyor devices 60 and 8 described below have the following special functions, which will be explained below. Note that the reference numerals of the conveyor devices will be represented by 1 to represent the conveyor devices 1, 60 and 8. About CAD equipment In this embodiment, the conveyor device 1 can be designed using a CAD device. The CAD device will be explained below. (1) A layout for the monitor can be created using a CAD drawing as an outline. In order to check the operating status of each part of the conveyor system 1 and to know whether or not there is a delay in the transported goods, a display device 33 is provided in the upper control device 46, and the display device 33 displays a layout diagram as shown in Figure 1. On the other hand, the conveyor system 1 of this embodiment is a combination of modularized devices. When constructing the conveyor system 1, construction drawings are naturally created. In many cases, CAD is used to create the construction drawings. The conveyor system 1 of this embodiment can import this CAD information and create a layout for monitoring. That is, since the components of the conveyor system 1 of this embodiment are standardized, a layout for monitoring can be created by tracing the construction drawings, etc.

[0092] FIG. 16(a) shows an example of a display screen 30 of a CAD device. The CAD device of this embodiment has a known drawing function. The CAD device also stores a model diagram showing the function as shown in FIG. 2. An operator creates a layout diagram of the conveyor systems 1 and 60 using the CAD device and specifies and fits the model diagram of FIG. 2 into each zone. The function of each zone is determined by specifying the model diagram. The operator also inputs the speed for each zone. Speed ​​levels are predefined, such as SPEED 1 and SPEED 2, and the operator specifies the speed level.

[0093] (2) The address of the zone controller can be set automatically. In this embodiment, when a monitor layout is created, the addresses of the zones can be automatically set by software. Of course, it is also possible to set the address manually.

[0094] Specifically, when you draw a layout as shown in Figure 16(a), numbers and symbols are automatically assigned to each zone. Also, if you change an existing layout, insert a new zone between zones, or delete an existing zone, new addresses are assigned.

[0095] (3) The layout can be rotated to any angle, such as 90°, 180°, or 270°, depending on the location of the monitor screen.

[0096] (4) The layout can be freely enlarged or reduced within a specified range on the monitor screen.

[0097] (5) The addresses determined by the layout can be output in correspondence with the operation programs corresponding to the functions of each zone. The operating programs corresponding to the functions of each zone include a control program that executes operations when introducing the transported items, a control program that operates the direction change mechanism, and a control program that executes operations when discharging the transported items. The addresses of adjacent zones are also output.

[0098] Next, the functions of the host controller 46 and the display device 33 connected to the host controller 46 will be described.

[0099] (1) The operating status, inventory status, abnormality status (details of the abnormality and how to deal with it), and information on the transported items of the conveyor system 1 can be displayed on the display device 33. In other words, the zone in which each transported item is currently located can be monitored and displayed on the display device 33. (2) The display device 33 monitors and displays the zone in which each transported article is currently located.

[0100] (3) The operator can freely specify the range of "start / stop" and "emergency stop" of the conveyor device while looking at the display device 33. For example, it is possible to stop only the 21st zone and onwards (address 21 and below) in FIG. 1 and allow other parts to be driven, or to stop only the branch path on the 62nd zone side branched off from the 61st zone. For example, in the case where there is a transport route that passes through the picking area and a transport route that bypasses the picking area as shown in FIG. 11, the transport route that passes through the picking area may be stopped and the transported items may be transported directly to the shipping area. In addition, in the conveyor device 60 shown in Figure 11, the conveyor path branches off in the 12th zone (address 12) into one heading towards the storage area and one heading towards the shelves in the picking area, but it is also possible to stop the conveyor path heading towards the storage area and transport the entire quantity to the shelves in the picking area. Furthermore, when an emergency stop button (not shown) is operated, it is possible to stop only the zone in the vicinity of the button, and the stop area in this case can be determined in advance.

[0101] (3) The operator can instruct "number matching operation," "ratio branching operation," "traffic jam avoidance operation," and "merging operation" while looking at the display device 33.

[0102] (4) The starting point (start) name and destination (goal) name can be registered to create a transport command. In the first embodiment, the start position is only the first zone (address 1), but the name of this position can be determined arbitrarily. Also, in the first embodiment, there are multiple destinations (destinations) for the transported items (addresses 6, 8, 23, 27, 30, 41, 44, 51, 54, 65, 72, 73, 78, 79, 83, 86, 88, 90). These can be given arbitrary names. For example, if it is a conveyor device installed in a distribution center, names such as Fujita Shoten and Daiminami Store can be given depending on the destination.

[0103] (5) Branching / merging conditions can be set. For example, there may be multiple rows of shipping zones in a shipping area, as shown in Figure 11. In the example shown in Figure 11, there is a first shipping zone from zones 76 to 78, a second shipping zone from zones 79 to 81, and a third shipping zone from zones 82 to 84. When there are multiple shipping zones in this way, there are cases where you want to send out transported goods preferentially to a specific shipping zone (first come, first served), cases where you want to allocate the goods so that the number of goods currently accumulated in each shipping zone remains the same even when they are discharged from the shipping zone (equal distribution), cases where you want to make the number of goods sent to each shipping zone equal (alternate control), etc. In this embodiment, these conditions can be set.

[0104] (6) It has a branching / merging operation algorithm. Standard patterns such as "first come, first served," "equal distribution," and "alternate control" are stored in the upper control device 46.

[0105] (7) A completion report for the command can be sent to the upper system (WMS). It has the function of reporting to the upper system (WMS) that the transported goods have arrived at their destination. In this embodiment, the host controller 46 is further connected to a warehouse management system (WMS) as shown in Fig. 13. In this embodiment, information that the transported item has arrived at its destination is automatically input to the integrated control system (ICS) and the warehouse management system (WMS).

[0106] (8) It also supports layout changes. For example, the layout of the conveyor device 1 shown in FIG. 1 is changed to that shown in FIG. As described above, an address is assigned to each zone that constitutes the conveyor system 1. In this embodiment, the layout can be changed by swapping the zones while keeping the addresses assigned. The layout shown in Figure 15 is obtained by moving the entire zone of addresses 21 to 30 in Figure 1 downstream, i.e., by inserting the zone of addresses 21 to 30 in Figure 1 between addresses 33 and 34 in Figure 1. In this embodiment, even after the layout has been changed, the same input means can be used to make the transported article arrive at the desired zone.

[0107] The following is an explanation. In this embodiment, as described above, the information on the transport path includes the address of the transport direction changing zone where the direction should be changed and the discharge direction from the transport direction changing zone, but does not include the address of the transport direction changing zone where the transport direction is not changed. If the destination address is 21 to 30, the location where the direction is changed is replaced with a straight conveyance zone (address 31) in the original layout position. The zone with address 31 is not included in the conveyance route information, so the conveyed item goes straight through the zone with address 31. Then, when the conveyed item reaches the zone with address 20, the direction changing mechanism of conveyance direction changing zone 20 functions, and the conveyed item is discharged to the side of the zone with address 21. In this way, in this embodiment, even after changing the layout, the transported article can be made to arrive at the desired zone using the same input means.

[0108] (9) During construction, it notifies you of any errors in the placement (wiring) of the actual transport unit, etc. In a preferred manufacturing method for the conveyor system 1 of this embodiment, an address is assigned to each module at the factory, as will be described later. In this case, the transport modules are connected together at the construction site, and any wiring errors made during this process are displayed on the display screen of the host control device 46.

[0109] In addition, the conveyor device 1 has the following functions. (1) When an automatic recognition device such as a bar code reader is connected to the control device of the conveyor device, the control device of the conveyor device automatically recognizes the bar code reader, etc., and allows the necessary settings to be made interactively.

[0110] (2) If the transported item is a tray or container, an individual ID is assigned to the tray, etc., and the destination (destination) of the transported item is linked to information obtained from a barcode reader, etc. This function has been described above.

[0111] (3) Transport instructions can be created based on instructions from the upper system (WMS). For example, a control system like the ones shown in Figures 12 and 13 can be constructed, with an integrated controller (WCS) controlling the conveyor controllers, display devices, and other controllers for many other devices. The conveyor controllers are also connected to zone controllers, which monitor the operating status of each zone. Transport commands can then be created based on commands from the warehouse management system (WMS), which is the higher-level system of the integrated controller (WCS).

[0112] (4) The ID and destination information of the tray, etc. can be sent to the zone controller. This function has been described above.

[0113] (5) The control device of the conveyor device (host control device 46) has an interface function with other system components (DPS display, printer, weighing machine, robot, etc.).

[0114] In the embodiment described above, the transported article identification device 45 is provided in the first zone, which is the start position, but the position of the transported article identification device 45 may be any position upstream of the transport direction changing zone. Also, the transported article identification device 45 may be provided at multiple locations.

[0115] In the embodiment described above, the information read by the transported item identification device 45 is sent to the upper control device (46), which identifies the transported item and queries the destination (destination) of the transported item, and transmits the address to the zone controller 10 of the second zone (initial information transmission means). However, the present invention is not limited to this configuration, and an IC tag or the like that identifies the destination may be attached to the transported item itself, and the transported item identification device 45 may read information about the destination stored in the IC tag or the like, and transmit this information to the zone controller 10 of the first zone or any subsequent zone (initial information transmission means). The address may also be transmitted to a zone controller 10 downstream of the second zone.

[0116] One example of a conveyor system layout is one with a circulation route 35, such as conveyor system 8 shown in Figure 17. As shown in Figure 17, circulation route 35 connects zone 33 and zone 3, and returns transported items in zone 33, which is located near the end of the layout, to zone 3, which is near the beginning. 17 can transport an article via multiple routes. For example, when transporting an article to Zone 36 at the end, there is an outer route that goes from Zone 1 to Zone 36 via Zones 12 and 23, and an inner route that goes from Zone 1 to Zone 46, turns right at Zone 7, merges with Zone 28, and then reaches Zone 36.

[0117] In addition, some of the linear conveying zones of the conveyor device 8 shown in Figure 17 can be operated in both forward and reverse directions. Specifically, in zones 65, 66, and 67, by operating a manual switch, the conveyed article can be returned from zone 67 toward zone 65.

[0118] The conveyor device 8 shown in FIG. 17 is configured to perform "quantity matching operation," "ratio branching operation," "congestion avoidance operation," and "merging operation."

[0119] In this embodiment, "ratio split operation" is performed in Zone 13. "quantity matching operation" is performed in Zone 26. "traffic jam avoidance operation" is performed in Zone 33. "merging operation" is performed in Zone 28.

[0120] The "ratio branch operation" will now be described. In the conveyor device 8 of this embodiment, zones 57, 59, and 61 are destinations for articles to be loaded onto trucks or containers for transport to the same destination (for example, Fujita Shoten), and it does not matter which zone the articles are brought into. In this embodiment, the first arrival position of all the transported objects to be transported to zones 57, 59, and 61 is zone 13, which is located just before the branch point. Specifically, address 13 is specified as the first initial information in the destination storage member 40 of the zone controller 10 of zone 2. Furthermore, any one of addresses 57, 59, and 61 is transmitted from the higher-level control device 46 to the zone controller 10 in the 13th zone (address 13) as second initial information. That is, in this embodiment, the higher-level control device 46 transmits the second initial information to the zone controller 10 in the 13th zone. For example, addresses 57, 59, and 61 are transmitted in order to the zone controller 10 in the 13th zone.

[0121] The article arrives at the zone at address 13 according to the first initial information sent to the zone controller 10 of the second zone. When information that the transported article has reached the 13th zone (address 13) is returned from the zone controller 10 of the 13th zone to the upper control device 46, second initial information is sent from the upper control device 46 to the zone controller 10 of the 13th zone. The transported article is transported sequentially to the zones with addresses 57, 59, and 61 in accordance with the second initial information.

[0122] As described above, in the "proportional branch operation", the "alternate method", "priority method" and "proportional method" can be selected.

[0123] Next, the "numbering operation" will be described. For example, there may be a case where two items are to be carried into the 64th zone (address 64). In this case, the "number matching operation" is performed. Specifically, when the upper level control device 46 receives information from the zone controller 10 in the 26th zone (address 26) that an object destined for the 64th zone has arrived, the upper level control device 46 issues a temporary stop command to the zone controller 10 in the 26th zone. As a result, one object destined for the 64th zone stops in the 26th zone. When another transported object whose final destination is Zone 64 arrives at Zone 25, the zone immediately before Zone 25, the temporary stop command is cancelled by the host controller 46. As a result, two transported objects whose final destination is Zone 64 are transported consecutively downstream.

[0124] Next, "traffic congestion avoidance driving" will be described. In this embodiment, as described above, each zone controller 10 and the upper control device 46 are connected by a communication means, and information on the inventory sensor S and information on the transported goods in the zone are input from each zone controller 10 to the upper control device 46. In this embodiment, if information from each zone controller 10 indicates that the most downstream zones 34, 35, and 36 are clogged with transported articles and cannot proceed further, and if this state continues for a certain period of time, the upper control device 46 sends a command to the zone controller 10 at address 33 to forcibly change the discharge direction toward the circulation route 35.

[0125] As a result, the transported goods flow into the circulation route 35 and return to the third zone at the front, eliminating the congestion. In this embodiment, the circulation route 35 is inserted in the middle, but the destination information is passed from the 33rd zone on the upstream side in the transport direction to the third zone on the downstream side. That is, when the transported article moves from zone 33 to zone 3 and is transported across zones, the destination information is passed from the upstream zone controller 10 in zone 33 to the downstream zone controller 10 in zone 3 as the transported article moves across zones.

[0126] Furthermore, regardless of whether or not the transported goods are jammed in a specific area, if the transported goods remain in a specific zone for a long period of time, a command is sent from the upper control device 46 to the zone controller 10 of the 33rd zone to forcibly change the discharge direction toward the circulation route 35. As a result, the transported goods flow into the circulation route 35, and the transported goods return from the 33rd zone to the zone with address 3 on the leading side, thereby eliminating the congestion.

[0127] Next, "merging driving" will be described. In the conveyor device 8 of this embodiment, the article conveyed via the 46th zone and the article conveyed via the 8th zone join together in the 28th zone. As described above, in this embodiment, two methods can be selected: "alternate merging" and "lot merging." The "alternate merging" is executed as a function of the zone controller 10 of the 28th zone. That is, the zone controller 10 of the 28th zone has a program for the "alternate merging" stored in advance, and the "alternate merging" is executed in response to a command from the upper control device 46.

[0128] On the other hand, when "lot merging" is performed, a temporary stop command is sent from the upper controller 46 to the zones upstream of the 28th zone (zones 27 and 55). Then, the 28th zone is controlled by the command from the upper controller 46, and when a predetermined number of transported articles accumulates upstream of the 28th zone, the transported articles are sent downstream.

[0129] A preferred method of manufacturing the conveyor systems 1, 8, and 60 will now be described. In the conveyor devices 1, 8, and 60 of this embodiment, the conveying modules are manufactured separately, and the zone controller 10 of each conveying module stores the address of its own zone, the address of the adjacent zone, and a program that controls the operation of the motor and direction change mechanism of each module.In this state, the devices are transported to the construction site and assembled. That is, in this embodiment, a transfer module is manufactured separately. The transfer module is an integrated unit of a mechanical mechanism and the zone controller 10. The transfer module can be standardized and is highly versatile.

[0130] When manufacturing the conveyor devices 1, 8, and 60, the layout is determined using the CAD device described above. Then, directly from the CAD device or via another device, a program for controlling the operation of the motors and direction changing mechanisms of each module is stored in the zone controller 10 of the separately manufactured transport module. More specifically, the CAD device or the like outputs addresses determined by the layout, addresses of adjacent zones, and operation programs corresponding to the functions of each zone, and these are stored in the zone controller 10 of the transport module.

[0131] In this case, the transport modules are not combined with each other, but are separated into individual transport modules or into multiple groups, and an address and an operation program are output to the zone controller 10 of the transport module in this state, and are stored in the memory of the zone controller 10. For example, a transport module constituting a transport direction changing zone has, as a mechanical structure, a direction changing mechanism that switches the transport direction or the carry-in direction as shown in Figures 5 and 9. The transport module can carry in the transported object from one or more carry-in directions and can carry out the transported object in one or more transport directions.

[0132] In the conveying module that constitutes the conveying direction change zone, the associated zone controller stores, in addition to the address, a control program that executes operations when introducing the conveyed item, a control program that operates the direction change mechanism, and a control program that executes operations when discharging the conveyed item.

[0133] The conveying module constituting the conveying direction changing zone is a conveying module that integrates a mechanical structure on which an article is placed and conveyed, and a zone controller that controls the mechanical structure. The mechanical structure has a direction changing mechanism that switches the conveying direction or the carry-in direction, and can carry the article in from one or more carry-in directions and can carry the article out in one or more conveying directions. The zone controller of the conveying direction changing zone also has a control means that executes an operation to introduce the article, a control means that operates the direction changing mechanism, and a control means that executes an operation to discharge the article.

[0134] In the conveying modules that make up the linear conveying zone, the zone controller 10 stores addresses as well as a control program that executes operations when introducing the conveyed item and a control program that executes operations when discharging the conveyed item.

[0135] Each transport module is manufactured individually, and each transport module with an individual program written into the zone controller 10 is packaged and transported to the construction site. At the construction site, the transport modules are lined up according to the layout and connected mechanically and electrically. As a result, the conveyor apparatus 1, 60, 8 as shown in Figures 1, 11, 17 can be assembled at the construction site. According to the manufacturing method of this embodiment, there is no need to assemble the conveyor devices 1, 60, 8 in the manufacturing factory. Therefore, even if the manufacturing factory is small, large conveyor devices 1, 60, 8 can be manufactured.

[0136] In the conveyor device of each of the above-described embodiments, the display device 33 is connected to the host control device 46 as described above, and the zone in which each transported article is currently located is displayed on the monitor of the display device 33. FIG. 18 shows an example of the monitor display. In the figure, "A" and "B" indicate the items being transported. In this embodiment, the straight portion of the conveying path is divided into a plurality of straight conveying zones, but in this embodiment, two straight conveying zones are combined into a set and controlled by one zone controller. Therefore, the conveying module of the linear conveying zone is a roller conveyor having a length that allows two articles to be placed on it. Two sets of presence sensors S are provided on the roller conveyor.

[0137] In the above embodiment, the destination information is basically passed between adjacent zones, but the information may be transmitted by skipping intermediate portions. For example, in the case of the conveyor device 1 shown in Figure 1, information regarding the destination may not be passed between the 10th zone and the 17th zone, and the destination information may be passed from the 10th zone to the 18th zone when the item being transported in the 10th zone reaches the 18th zone. In this configuration, when the transported item moves from zone 10 to zone 18 and is transported across zones, the destination information is passed from zone 10 on the upstream side to zone 18 on the downstream side as the transported item moves across zones.

[0138] In the above-described embodiment, each zone has a length sufficient to accommodate at least one article, but an embodiment will be described in which an article exceeding the length of a zone can be transported. A conveyor system 63 of the fifth embodiment shown in Figure 19 has the same layout as the conveyor system 1 of the first embodiment described above, and is provided with a total length measuring device 65 for measuring the total length of a conveyed object at the start of the conveyor system 1. The total length measuring device 65 is, for example, an optical length measuring device attached to a conveyor system 66.

[0139] The total length measuring device 65 measures the total length of the transported object by, for example, stopping the transported object on the conveyor device 66. Alternatively, the conveyor device 66 is operated at a constant speed, and the total length of the transported object is measured by the time it takes to pass a certain position or the number of rotations of the motor. The conveyor device 63 has a zone with address 0, and an article is placed in this zone. The zone with address 0 conveys the article to the total length measuring device 65, which measures the total length of the article.

[0140] The measured data is sent from the total length measuring device 65 to the host control device 46. If the total length of the transported object measured by the total length measuring device 65 is shorter than the length of each zone, the object will be placed one by one in each zone and transported downstream, as described above. In addition, in the conveyor device 63 of this embodiment, information regarding the length of the transported item is sent from the upper control device 46 to the zone controller 10 of the second zone along with the destination information, and is input into the destination memory member 40 of the zone controller 10 of the second zone.

[0141] The following zones receive information about the length of the conveyed article from the upstream zone controller 10 and can stop the conveyed article at a fixed position in each zone. For example, if the load sensor S is installed near the center of the length of each zone, the zone conveyor can be stopped a certain time after the load passes the load sensor S based on information regarding the length of the load, thereby stopping the load at a certain position (e.g., the center) on the zone conveyor.

[0142] If the total length of the article measured by the total length measuring device 65 is longer than the length of each zone, the article is stopped in the following zone, straddling the adjacent zone. That is, even if the total length of the transported article is longer than the length of each zone, information regarding the length of the transported article as well as the destination information is sent from the upper control device 46 to the zone controller 10 of the second zone. Then, for that transported article, each zone operates in pairs.

[0143] Furthermore, in the conveyor system 1 of the first embodiment, all of the linear conveying zones convey the objects in only one direction, whereas in the conveyor system 63 of the fifth embodiment, the linear conveying zones in many areas can move the objects in either the forward or reverse direction. Specifically, as shown in FIG. 19, zones 21 to 30 can all be operated in both forward and reverse directions, allowing transported articles to be moved in either direction. [Explanation of symbols]

[0144] 1,8,60,63 Conveyor equipment 2-Zone Conveyor (Straight-Line Zone Conveying Module) 10 Zone Controller 20 Transfer device (transport module in the transport direction change zone) 33 Display device 40 Destination storage member (destination storage means) 41 Transmitting and receiving unit (information receiving means, information transmitting means) 45 Transported goods identification device 46 Upper control device (initial information transmission means) 51 Transfer module S inventory sensor

Claims

1. A conveyor device that transports an object from a start position to a destination, the conveyor device transporting the object across a plurality of zones, The plurality of zones include a linear conveying zone for conveying the object linearly and a conveying direction changing zone for selecting a conveying direction of the object and sending it out, The system further comprises at least one item identification device and an initial information transmitting means for transmitting destination information regarding the destination of the item to any one of the zones, a destination selection means for selecting a destination of the object identified by the object identification device, and information relating to the identified destination, which is included in destination information relating to the destination of the object, is transmitted to one of the zones by an initial information transmission means; The transport destination selection means has a route determination means for determining a transport route, and information regarding the transport route is transmitted to any one of the zones by the initial information transmission means; Furthermore, ratio branching operation control is possible, In the ratio branch operation control, The initial information transmission means transmits information regarding the transport route and the specified transport destination, The linear conveying zone is provided with an address of the conveying direction changing zone, which is a linear conveying destination of the conveyed object, and In the conveying direction changing zone, one of the addresses, which is a sending destination of the conveying direction of the conveyed object, is sequentially A conveyor device characterized by transmitting.

2. 2. The conveyor system according to claim 1, further comprising a zone controller for controlling one or more zones, the zone controller having destination storage means for temporarily storing the destination information, information receiving means for receiving the destination information from an upstream zone, and information transmitting means for transmitting the destination information to a downstream zone, and the destination information is passed from the zone controller controlling the upstream zone to the zone controller controlling the downstream zone as the article is moved.

3. 3. The conveyor system according to claim 1, wherein when there are a plurality of transport routes, the transport destination selection means is capable of searching for the shortest transport route from among the transport routes.

4. 4. The conveyor system according to claim 1, wherein when there are a plurality of transport routes, the transport destination selection means is capable of searching for a transport route that can reach the destination in the shortest time from among the transport routes.

5. 5. The conveyor system according to claim 4, wherein when there are many articles passing through the shortest route, a detour route is searched for, which is a route that can reach the destination in the shortest time.

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