Conveyor system

Abstract

A conveyor system according to the present invention comprises a roller with a built-in conveyor motor (roller with a built-in C-M) and a switching device. The roller with a built-in C-M comprises a control unit inside a roller tube, the control unit controlling the motor according to control details contained in a control signal received by a communication unit. The control details contained in the control signal received by the communication unit are outputted to the switching device, and the switching device stores the control details. Upon determining a communication anomaly, the roller with a built-in C-M outputs the communication anomaly to the switching device, and in response, the switching device causes the control unit to control the motor according to the stored control details.

Description

Conveyor System

[0001] The present invention relates to a conveyor system including a motorized roller for a conveyor used in a conveyor device and a switching device for switching a control source.

[0002] Conveyor devices are widely used to transport objects, for example, in production sites and distribution sites. Conveyor devices can be broadly categorized into roller conveyor devices and belt conveyor devices. A roller conveyor device includes multiple rollers arranged side by side in one direction and moves (conveys) objects (transported objects) along a path (conveyance path) on the multiple rollers. A belt conveyor device includes multiple rollers arranged side by side in one direction and a conveyor belt stretched over the multiple rollers and moves objects along the conveyor belt. The rollers in these roller conveyor devices and belt conveyor devices include motorized rollers (drive rollers) that incorporate a motor and rotate by the driving force generated by the motor, and rollers (driven rollers, free rollers) that rotate via, for example, a suspended belt or a moving object in accordance with the rotation of the motorized roller. The motor of the motorized roller is driven by a motor drive device (motor control device) attached to the outside of the motorized roller, for example, on a conveyor frame (see, for example, Patent Documents 1 and 2). Furthermore, by incorporating the motor drive device into the motorized roller, the conveyor device can be simplified.

[0003] Meanwhile, in recent years, the Internet of Things (IoT) has enabled a variety of things to be connected to communication networks. IO-Link is known as one method for connecting these things to communication networks. IO-Link is an I / O connection technology standardized by IEC 61131-9 for communication with devices, and is a technology that provides the device with a communication interface that complies with the IO-Link standard, enabling bidirectional communication signals between the device and a higher-level system. A device that has a communication interface that complies with the IO-Link standard is called an IO-Link device. This IO-Link device has a hub function, is connected to an IO-Link master that is connected to a communication network, and communicates with the higher-level system via the IO-Link master and the communication network.

[0004] By using the motor drive device as an IO-Link device, it is possible to centrally control the motor drive device in a higher-level system via an IO-Link master and a communication network. In this case, if a communication abnormality (communication failure) occurs in the communication network, there is a risk that the conveyor device will stop or operate in an uncontrolled state.

[0005] JP 2014-068501 A JP 2018-177441 A

[0006] The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a conveyor system that can operate a conveyor device in a predetermined control mode even when a communication abnormality occurs.

[0007] A conveyor system according to the present invention includes a motorized conveyor roller and a switching device. The motorized conveyor roller includes a control unit within a roller tube that controls the motor in accordance with control content contained in a control signal received by a communication unit. The control content contained in the control signal received by the communication unit is output to the switching device, which stores the control content. When the motorized conveyor roller detects a communication abnormality, it outputs the communication abnormality to the switching device. When the switching device receives the signal abnormality, it causes the control unit to control the motor in accordance with the stored control content. This conveyor system can operate the conveyor in a predetermined control mode even when a communication abnormality occurs.

[0008] These and other objects, features and advantages of the present invention will become apparent from the following detailed description and accompanying drawings.

[0009] 5 is a plan view of a conveyor device in an embodiment. FIG. 6 is a partial cross-sectional view illustrating the configuration of a motorized conveyor roller used in the conveyor device. FIG. 7 is a block diagram illustrating the configuration of a communication control processing unit and a switching device of the motorized conveyor roller. FIG. 8 is a circuit diagram illustrating the circuit configuration of the communication control processing unit as an example. FIG. 9 is a diagram illustrating Level Shifters 54, 55 in the circuit diagram shown in FIG. 4. FIG. 10 is a flowchart illustrating the operation of the communication control processing unit. FIG. 11 is a first sequence diagram illustrating the operations of a hub (IO-Link master) MS / conveyor management device SV, the communication control processing unit 4, and the switching device CD. FIG. 12 is a second sequence diagram illustrating the operations of a hub (IO-Link master) MS / conveyor management device SV, the communication control processing unit 4, and the switching device CD. FIG. 13 is a plan view of a conveyor device in a first modified embodiment.

[0010] Hereinafter, one or more embodiments of the present invention will be described with reference to the drawings. However, the scope of the invention is not limited to the disclosed embodiments. In addition, components with the same reference numerals in each drawing indicate the same components, and their description will be omitted as appropriate. In this specification, when referring to a general term, a reference numeral without a subscript is used, and when referring to an individual component, a reference numeral with a subscript is used.

[0011] A conveyor system according to an embodiment includes a motorized conveyor roller and a switching device. In this embodiment, the conveyor system further includes a roller conveyor device. The motorized conveyor roller includes a communication unit, a roller tube, a pair of support shafts facing each other and rotatably supporting the roller tube, a motor disposed inside the roller tube and generating a driving force to rotate the roller tube, a control unit disposed inside the roller tube and controlling the motor in accordance with control content contained in a control signal received by the communication unit, and a first processing unit disposed inside the roller tube and outputting the control content contained in the control signal received by the communication unit to the switching device. The switching device includes a memory unit and a second processing unit that stores the control content in the memory when the control content is input from the motorized conveyor roller. The first processing unit further determines whether a communication abnormality exists, and if the first processing unit determines that a communication abnormality exists, outputs the communication abnormality to the switching device. The second processing unit further causes the control unit to control the motor according to the stored control content when the communication abnormality is input from the motorized roller for the conveyor. The conveyor device of the roller conveyor device includes a plurality of rollers arranged side by side in one direction, and an object moves along a movement path on the plurality of rollers. The plurality of rollers includes one or more of the motorized rollers for the conveyor. Below, the conveyor system will be described in more detail by describing the motorized roller for the conveyor, the switching device, and the conveyor device in more detail.

[0012] FIG. 1 is a plan view of a conveyor device according to an embodiment. FIG. 2 is a partial cross-sectional view illustrating the configuration of a motorized conveyor roller used in the conveyor device. FIG. 3 is a block diagram illustrating the configuration of a communication control processing unit and a switching device of the motorized conveyor roller. Note that the configuration of a second modified embodiment, which will be described later, is indicated by dashed lines in FIG. 3. FIG. 4 is a circuit diagram showing the circuit configuration of the communication control processing unit, as an example. FIG. 5 is a diagram illustrating Level Shifters 54 and 55 in the circuit diagram shown in FIG. 4. FIG. 5A is a diagram illustrating Level Shifter 54, with the horizontal axis representing input voltage and the vertical axis representing output voltage corresponding to the set rotation direction (target rotation direction (forward rotation CW, reverse rotation CCW)). FIG. 5B is a diagram illustrating Level Shifter 55, with the horizontal axis representing input voltage and the vertical axis representing set speed (target speed) [min －１ ] (set rotation speed (target rotation speed) [rpm]).

[0013] The conveyor device CS in the embodiment is, for example, a roller conveyor device CS including a plurality of rollers MR, FR arranged side by side in one direction, and moving an object (object to be conveyed) Ob on a moving path (conveying path) over the plurality of rollers MR, FR, as shown in Fig. 1. In Fig. 1, the object Ob is indicated by a two-dot chain line.

[0014] More specifically, the roller conveyor device CS includes a pair of first and second conveyor frames CFa and CFb, one or more conveyor motor-incorporating rollers MR, one or more driven rollers FR, and one or more belts BT.

[0015] The first and second conveyor frames CFa and CFb are elongated members that rotatably support motorized conveyor rollers (motorized rollers, hereinafter referred to as "CM-incorporated rollers") MR and driven rollers (free rollers) FR. They face each other at a predetermined distance (first distance) perpendicular to the first distance and are arranged parallel to each other in the first distance. The first distance is an appropriate distance depending on the size of the object Ob to be conveyed by the roller conveyor device CS, and the lengths of the CM-incorporated rollers MR and driven rollers FR are set according to the first distance. The first and second conveyor frames CFa and CFb have a generally U-shaped cross section (an E-shape with the center "-" removed) to increase strength, and are made of an iron-based metal (including alloys) such as SPC (Steel Plate Cold). The first and second conveyor frames CFa and CFb are each formed with a plurality of through-holes (not shown) at predetermined intervals (second intervals) along the one direction for inserting first and second support shafts 2a and 2b of the C-M built-in roller MR and first and second support shafts AXa and AXb of the driven roller FR, which will be described later. The first and second support shafts 2a and 2b of the C-M built-in roller MR are inserted into the respective through-holes in the first and second conveyor frames CFa and CF, and are fixed to the first and second conveyor frames CFa and CF, respectively, by respective fixing brackets (not shown). The first and second support shafts AXa and AXb of the driven roller FR are, for example, inserted into the respective through openings in the first and second conveyor frames CFa and CFb, and are fixed to the first and second conveyor frames CFa and CFb, respectively, by screwing respective nuts (not shown) into the respective screw grooves formed in the first and second support shafts AXa and AXb.

[0016] Multiple C-M rollers MR are arranged side by side in one direction, with two driven rollers FR arranged side by side in that direction. That is, a predetermined number of C-M rollers MR are arranged side by side in that direction, every three rollers in the example shown in FIG. 1 , and two driven rollers FR are arranged side by side in that direction between two adjacent C-M rollers MR. Therefore, these multiple C-M rollers MR and multiple driven rollers FR are parallel to each other in a direction perpendicular to the one direction. Of these multiple C-M rollers MR and multiple driven rollers FR, each C-M roller MR is connected to each of the two driven rollers FR adjacent to it in that direction by a belt BT wrapped around one end of the roller. When the C-M roller MR rotates, the rotation of the single C-M roller MR is transmitted to each of the two driven rollers FR by the belt BT, causing each of the two driven rollers FR to rotate. This allows an object (object to be conveyed) Ob placed on the plurality of CM-incorporated rollers MR and the plurality of driven rollers FR to be movable (conveyed).

[0017] The motorized conveyor roller MR used in such a roller conveyor device CS is configured, for example, as shown in FIG. 2 . More specifically, the motorized conveyor roller MR includes a cylindrical roller tube 1 having a predetermined length (first length) and made of, for example, an iron-based metal (including alloys), such as carbon steel for mechanical construction. A first cap member 7a, which serves as a member for closing the one end of the roller tube 1, is fixedly attached to the other end, and a second cap member 7b, which serves as a member for closing the other end, is fixedly attached to the other end. A first bearing (not shown) is provided within the first cap member 7a, and the first bearing rotatably supports a first support shaft 2a via a cylindrical connecting member 9, which is made of, for example, an iron-based metal (including alloys), such as carbon steel for mechanical construction (e.g., S45C). The connecting member 9 is inserted through the first support shaft 2a and fixedly attached to the first support shaft 2a. The first cap member 7a has a through-hole that penetrates along the central axis of the roller tube 1 and through which the first support shaft 2a is inserted via the connecting member 9. Similarly, a second bearing (not shown) is provided within the second cap member 7b, and the second bearing rotatably supports the second support shaft 2b. The second cap member 9b has a through-hole that penetrates along the central axis and through which the second support shaft 2b is inserted. The first support shaft 2a is made of, for example, an iron-based metal (including an alloy), and is a hollow columnar member through which a cable CB that is connected to the communication control processing unit 4 (described later) is inserted. The second support shaft 2b is a cylindrical member.

[0018] With this configuration, the roller tube 1 is rotatably supported by the first and second support shafts 2a and 2b that stand upright from the first and second conveyor frames CFa and CFb, respectively.

[0019] The C-M built-in roller MR has a motor 3 built into a roller tube 1. More specifically, the motor 3 is housed in a cylindrical internal frame 8 of a predetermined length (second length) that is smaller in diameter than the roller tube 1 and made of a metal (including an alloy) such as aluminum, and the internal frame 8 is housed within the roller tube 1 with a gap from the inner peripheral surface of the roller tube 1 so that the roller tube 1 can rotate relative to the internal frame 8.

[0020] A reducer 5 composed of a planetary gear or the like is fixedly housed within the inner frame 8 in the other part on the other side of the inner frame 8, and a cylindrical intermediate plate 6 is fixedly connected to the output shaft of the reducer 5, with the outer circumferential surface of the intermediate plate 6 fixedly connected to the inner circumferential surface of the roller tube 1. A motor 3, fixedly housed within the inner frame 8, is disposed on one side of the reducer 5, and the output shaft of the motor 3 is connected to the input portion of the reducer 5. With this configuration, when the output shaft of the motor 3 rotates, the intermediate plate 6 rotates via the reducer 5, and the roller tube 1 rotates in conjunction with the rotation of the intermediate plate 6. In this way, the motor 3 is disposed within the roller tube 1 via the inner frame 8, and generates a driving force to rotate the roller tube 1. The motor 3 may be any suitable type of motor, but in the example shown in Figure 2, it is a radial gap inner rotor type motor, with its rotor equipped with multiple permanent magnets and its stator equipped with multiple coils. The rotating magnetic field generated by passing current through each of the multiple coils interacts with the magnetic fields of the multiple permanent magnets, causing the rotor to rotate and the output shaft to rotate.

[0021] A connecting member 9 that closes one end of the inner frame 8 is fixedly attached to this one end, so that the inner frame 8 is fixed to the first support shaft 2a via the connecting member 9.

[0022] A communication control processor 4 is disposed between the motor 3 and the connecting member 9. The communication control processor 4 is a circuit for communicating with an external device, inputting and outputting data to and from the switching device CD, and controlling and driving the motor 3. More specifically, as shown in FIG. 3, the communication control processor 4 is connected to the hub MS and the switching device CD via a cable CB, and includes a control unit 40, a first processing unit 461, and a communication unit 50. In this embodiment, the external device is a conveyor management device (host device) SV that centrally manages the C-M-embedded rollers MR. The conveyor management device SV is, for example, configured by a computer with communications capabilities, and transmits control signals containing control information for the motors 3 of the C-M-embedded rollers MR. A conveyor device CS is typically equipped with a relatively large number of C-M-embedded rollers MR. Therefore, centralized management by the conveyor management device SV allows for efficient management of these C-M-embedded rollers MR. The hub MS is connected to the conveyor management device SV via a communication network NW such as a LAN (Local Area Network) or a WAN (Wide Area Network).

[0023] The communication unit 50 communicates with external devices. In this embodiment, the C-M built-in roller MR is communicatively connected to the conveyor management device SV via the cable CB, the hub MS, and the communication network NW by the communication unit 50, and communicates with the conveyor management device SV. The communication unit 50 is an interface that selectively performs either two-way communication or data input / output. The communication unit 50 performs one-to-one two-way communication with the conveyor management device SV and data input / output with the switching device CD. Such a communication unit 50 is, for example, an interface that complies with the IO-Link standard. In this case, the hub MS is configured with a so-called IO-Link master.

[0024] The control unit 40 controls the motor 3 in accordance with the control content contained in the control signal received by the communication unit 50. The control unit 40 controls the motor 3 in accordance with the control content, for example, to start, increase speed, maintain a constant speed, decelerate, stop, rotate forward CW, rotate reverse CCW, etc. For this reason, the control signal contains, as the control content, a set speed (target speed) [min －１ ] (Set rotation speed (target rotation speed) [rpm]) (Set speed 0 [min －１ ]) and the set rotation direction (target rotation direction).

[0025] The first processing unit 461 outputs the control content contained in the control signal received by the communication unit 50 to the switching device CD.

[0026] A specific circuit of the communication control processing unit 4 will be described later.

[0027] The switching device CD switches the control source (control source) depending on the communication status of the communication unit 50. When communication is normal and communication signals can be sent and received via the communication unit 50, the control source is switched to the conveyor management device SV so that the control unit 40 controls the motor 3 according to the control content contained in the control signal from the conveyor management device SV. When a communication abnormality occurs, such as a communication abnormality (communication failure) in the communication network NW, in which communication signals cannot be sent or received via the communication unit 50, the control source is switched to the switching device CD so that the control unit 40 controls the motor 3 according to the control content stored in the switching device CD. As shown in FIG. 3, the switching device CD includes a second processing unit 61 and a memory unit 62, and is configured, for example, with a one-chip computer or the like. The memory unit 62 stores data such as control content. When control content is input from the C-M built-in roller MR, the second processing unit 61 stores the control content in the memory unit 62.

[0028] In this embodiment, the first processing unit 461 in the communication control processing unit 4 further determines whether or not a communication abnormality occurs, and if a communication abnormality is determined, outputs the communication abnormality to the switching device CD. Furthermore, if a communication abnormality is input from the C-M built-in roller MR, the switching device CD causes the control unit 40 to control the motor in accordance with the control content stored in the storage unit 62.

[0029] A specific circuit of the communication control processing unit 4 will now be described. As shown in FIG. 4, the communication control processing unit 4 includes, for example, a capacitor 51, an IO-Link Trans'IC (hereinafter abbreviated as "Trans'IC") 52, a Comm'MCU 53, Level Shifters (hereinafter abbreviated as "Shifters") 54, 55, an inverter 41, a current sensor 42, a Hall sensor 43, a voltage sensor 44, a temperature sensor 45, a Motor Control MCU (hereinafter abbreviated as "MC-MCU") 46, and a connector CN having five first to fifth pins (pins, terminals) PN1 to PN5, and is connected to a cable CB by the connector CN.

[0030] The first pin PN1 is a power terminal connected to the power supply line LN1, and the third pin PN3 is a ground terminal connected to the ground line LN2. Power for driving the motor 3 is supplied to the first and third pins PN1 and PN3. The first and third pins PN1 and PN3 are connected to two power lines in the cable CB. In this embodiment, DC power of 24 V and 3 A is supplied. A smoothing capacitor 51 is connected between the power supply line LN1 and the ground line LN2. The power supply line LN1 and the ground line LN2 are connected to the MC-MCU 46 and the inverter 41, respectively, and DC power is supplied to each of them. The Trans'IC 52 is connected to the fifth pin PN5 and the ground line LN2, and DC power of, for example, 24 V is supplied from the fifth pin PN5. The Comm'MCU 53 is supplied with DC power of, for example, 5 V from the Trans'IC 52 .

[0031] The MC-MCU 46 is configured with an IC chip, for example, part number NM18101Y, and is connected to the Trans'IC 52, Comm'MCU 53, Shifters 54 and 55, inverter 41, current sensor 42, Hall sensor 43, voltage sensor 44, and temperature sensor 45. The current sensor 42 measures the current of the power supplied to the motor 3 and outputs the measured current value to the MC-MCU 46. The Hall sensor 43 measures the magnetic force (magnetic flux density) to measure the rotor position of the motor 3 and outputs the measured magnetic force to the MC-MCU 46. The Hall sensors 43 include, for example, three Hall sensors 43-1 to 43-3 (not shown) arranged at 120-degree intervals around the outer periphery of the rotor of the motor 3. The MC-MCU 46 determines the rotor position every 60 degrees based on the magnetic forces H1 to H3 of the output measurement results. The voltage sensor 44 measures the voltage of the power supplied to the motor 3 and outputs the measured voltage value to the MC-MCU 46. The temperature sensor 45 measures the temperature of the motor 3 (the temperature of the ambient environment of the motor 3) and outputs the measured temperature value to the MC-MCU 46. The MC-MCU 46 controls the motor 3 by controlling the inverter 41 based on the current value measured by the current sensor 42, the voltage value measured by the voltage sensor 44, and the rotor position determined based on the measurement results of the Hall sensor 43, so as to achieve the control contents (set speed (target speed) and set rotation direction (target rotation direction)) from the Comm'MCU 53 or the control contents (set speed (target speed) and set rotation direction (target rotation direction)) from the Shifter 54m, 55. The inverter 41 converts the supplied DC power into three-phase AC power of U-phase, V-phase, and W-phase according to the control of the MC-MCU 46, and outputs the converted three-phase AC power to the motor 3. This causes the motor 3 to operate in accordance with the control content. If the temperature measured by the temperature sensor 45 exceeds a preset threshold value (temperature determination threshold value), the MC-MCU 46 controls the motor 3 via the inverter 41 to stop the motor 3. This makes it possible to prevent the C-M built-in roller MR from overheating.

[0032] The fourth pin PN4 is a signal terminal connected to the Trans'IC 52 and the MC-MCU 46. The MC-MCU 46 determines whether or not a communication abnormality exists. When communication is normal, a communication signal is input / output to / from the fourth pin PN4, and the communication signal is input / output to / from the Trans'IC 52. The MC-MCU 46 then outputs control information to the switching device CD. When a communication abnormality occurs, the MC-MCU 46 outputs a signal indicating the communication abnormality (abnormality notification signal) to the fourth pin PN4, and the abnormality notification signal is output to the switching device CD. When communication is restored (when normal communication is determined after a communication abnormality has been determined), the MC-MCU 46 outputs a signal indicating the communication restoration (recovery notification signal) to the fourth pin PN4, and the recovery notification signal is output to the switching device CD. Although the MC-MCU 46 may directly determine whether or not there is a communication abnormality, in this embodiment using the IO-Link, the IO-Link master hub MS primarily detects whether or not there is a communication abnormality in the communication network NW and notifies the Trans'IC 52 of the result, which then notifies the MC-MCU 46 via the Comm'MCU 53, and the MC-MCU 46 determines whether or not there is a communication abnormality based on this notification. The IO-Link master hub MS transmits a communication signal, and if there is no reception response, it retries, and if the retry fails twice, it determines that there is a communication abnormality. On the other hand, the IO-Link master hub MS transmits a communication signal after a predetermined time has elapsed, and if a reception response is received and communication is successful, it determines that communication has been restored and notifies the Trans'IC 52 of the result, which then notifies the MC-MCU 46 via the Comm'MCU 53, and the MC-MCU 46 determines that communication has been restored based on this notification.

[0033] The MC-MCU 46 outputs enable signals to the Trans'IC 52 and the Comm'MCU 53, respectively, to enable or disable the Trans'IC 52 and the Comm'MCU 53, respectively.

[0034] The Trans'IC 52 is configured by an IC chip with product number MAX22515, for example, and is connected to the fourth pin PN4 and the Comm'MCU 53. The Trans'IC 52 transmits and receives communication signals in accordance with the IO-Link standard, and the communication contents (for example, control contents, communication abnormalities, normal communication, etc.) contained in the communication signals are output to the MC-MCU 46 via the Comm'MCU 53.

[0035] The Comm'MCU 53 is configured by an IC chip, for example, model number M251FC2AE, and is connected to both the Trans'IC 52 and the MC-MCU 46. Because the protocol of the UART (Universal Asynchronous Receiver / Transmitter) frame input / output by the Trans'IC 52 differs from the protocol of the UART frame input / output by the MC-MCU 46, the Comm'MCU 53 converts the UART frame protocol between the Trans'IC 52 and the MC-MCU 46, and enables data input / output between the Trans'IC 52 and the MC-MCU 46.

[0036] The second pin PN2 is a signal terminal connected to the input of the Shifter 54, and the output of the Shifter 54 is connected to the MC-MCU 46. A signal indicating the set rotation direction (set rotation direction signal) is input from the switching device CD to the second pin PN2. The set rotation direction signal is a voltage value corresponding to the set rotation direction. In this embodiment, for example, as shown in FIG. 5A , when the set rotation direction is forward CW, the set rotation direction signal is a voltage of 6.5 V or more. When a voltage of 6.5 V or more (6.5 to 24 V) is input, the Shifter 54 outputs a high-level (Hi-level) voltage indicating that the set rotation direction is forward CW, and this high-level voltage is input to the MC-MCU 46. As a result, the MC-MCU 46 recognizes that the set rotation direction of the control content is forward CW. On the other hand, when the set rotation direction is reverse CCW, the set rotation direction signal is a voltage of 4.5 V or less, and when a voltage of 4.5 V or less (0 to 4.5 V) is input, Shifter 54 outputs a low-level voltage indicating that the set rotation direction is reverse CCW, and this low-level voltage is input to MC-MCU 46. As a result, MC-MCU 46 recognizes that the set rotation direction of the control content is reverse CCW.

[0037] The second pin PN2 is also connected to the Trans'IC 52 in accordance with the IO-Link standard.

[0038] The fifth pin PN5 is a signal terminal connected to the input of the Shifter 55, and the output of the Shifter 55 is connected to the MC-MCU 46. The fifth pin PN5 selectively receives either a signal representing the control source (control source signal) or a signal representing the set speed (set speed signal) from the switching device CD. The control source signal is a voltage having a value corresponding to the control source being the conveyor management device SV (i.e., the control source in normal communication). In this embodiment, for example, as shown in FIG. 5B , the voltage is 18 V or higher (18 to 24 V), and the Shifter 55 does not output when a voltage of 18 V or higher is input. The switching device CD outputs a voltage of 18 V or higher (18 to 24 V) to the fifth pin PN5 by default during operation. The set speed signal is a voltage having a value corresponding to the set speed. In this embodiment, for example, as shown in FIG. 5B, a voltage value corresponding to the set speed is predefined in a voltage range of 2 to 10 [V], and when a voltage of the voltage value corresponding to the set speed is input, the shifter 55 changes the speed from 0 to the maximum speed [m / min]. －１ ], a voltage value corresponding to the rotation speed is predefined, and the Shifter 55 outputs a voltage value corresponding to the rotation speed of the set speed. Furthermore, 10 to 13 [V] is predefined as the set speed being the maximum speed, and when a voltage of 10 to 13 [V] is input, the Shifter 55 outputs a voltage value corresponding to the maximum speed. This voltage value corresponding to the rotation speed of the set speed is input to the MC-MCU 46. This allows the MC-MCU 46 to recognize the set speed of the control content. Note that the fact that the control source is the switching device CD is not explicitly indicated to the communication control processing unit 4, but is implicitly indicated to the communication control processing unit 4 by the input of a voltage value corresponding to the set speed in the voltage range of 2 to 13 [V] to the fifth pin PN5.

[0039] The fifth pin PN2 is also connected to the Trans'IC 52, and when communication is normal, DC power is supplied at a voltage of 18 V or more, preferably 24 V.

[0040] The fourth, second and fifth pins PN4, PN2 and PN5 are connected to three signal lines in the cable CB.

[0041] In the communication control processing unit 4 of such a circuit, the Trans'IC 52, the Comm'MCU 53, and the Shifters 54 and 55 correspond to an example of the communication unit 50. The inverter 41, the current sensor 42, the Hall sensor, the voltage sensor 44, the temperature sensor 45, and the MC-MCU 46 correspond to an example of the control unit 40. The MC-MCU 46 corresponds to an example of a first processing unit 461, and the first processing unit 461 is functionally configured in the MC-MCU 46 by executing a program.

[0042] A heat sink (not shown) may be provided to dissipate heat generated by the communication control processing unit 4, and the communication control processing unit 4, the heat sink, and the connecting member 9 may be arranged in this order in a connected manner. As a result, the heat generated by the communication control processing unit 4 is thermally conducted from the communication control processing unit 4 to the heat sink, the connecting member 9, the first support shaft 2a, and the first conveyor frame CFa in this order, and is dissipated by the first conveyor frame CFa.

[0043] Next, the operation of this embodiment will be described. Fig. 6 is a flowchart showing the operation of the communication control processing unit. Fig. 7 is a first sequence diagram showing the operations of the hub (IO-Link master) MS / conveyor management device SV, the communication control processing unit 4, and the switching device CD. Fig. 8 is a second sequence diagram showing the operations of the hub (IO-Link master) MS / conveyor management device SV, the communication control processing unit 4, and the switching device CD.

[0044] In a conveyor system configured as described above, when operation begins, the switching device CD outputs a voltage of 18 V or higher (18 to 24 V) to the fifth pin PN5 by default. In Figures 6 to 8, the communication control processor 4 determines whether communication is normal by referencing the voltage value of the fifth pin PN5 (S1, C1). If the result of this determination is normal (Yes), the communication control processor 4 transmits a communication signal (control inquiry communication signal) to inquire about control details from the conveyor management device SV (S2, C1). On the other hand, if the result of the above determination is abnormal (No), the communication control processor 4 then executes process S7 (C21).

[0045] The control inquiry communication signal is transmitted to the conveyor management device SV via the IO-Link master MS and the communication network NW, and the conveyor management device SV receives the control inquiry communication signal (C3).The conveyor management device SV transmits a communication signal (control reply communication signal) containing control content corresponding to the C-M-incorporated roller MR that sent the control inquiry communication signal to the communication control processing unit 4 of the C-M-incorporated roller MR that sent the control inquiry communication signal (C4).

[0046] The control reply communication signal is transmitted to the communication control processing unit 4 via the communication network NW and the IO-Link master MS, and the communication control processing unit 4 receives the control reply communication signal (S3, C5).

[0047] Upon receiving the control reply signal, the communication control processor 4 controls the motor 3 according to the control information contained in the control reply signal (S4, C6), outputs (notifies) the control information contained in the control reply signal to the switching device CD (S5, C7), and determines whether communication is normal by referencing the voltage value of the fifth pin PN5 (S6, C8). If communication is normal (Yes), the communication control processor 4 returns to step S2 (C2) (C9). This repeats steps S2 through S6. If communication is normal, the communication control processor 4 controls the motor 3 through communication with the conveyor management device SV via the IO-Link master MS and the communication network NW. On the other hand, if communication is abnormal (No), the communication control processor 4 then executes step S7 (C21). If a communication abnormality is received from the hub MS of the IO-Link master during control of the motor 3, the communication control processing unit 4 determines that the communication is not normal (communication abnormality).

[0048] On the other hand, the control content contained in the received control reply communication signal output to the switching device CD in the process S5 (C7) is input to the switching device CD, and the switching device CD accepts the input of the control content (C10), and the second processing unit 61 stores this input control content in the memory unit 62 (C11).

[0049] In the process S7 (C21), the communication control processing unit 4 outputs the abnormality notification signal indicating a communication abnormality to the switching device CD.

[0050] The abnormality notification signal is input to the switching device CD, which receives the input of the abnormality notification signal (C22) and outputs the control content stored in the memory unit 62 by the second processing unit 61 to the communication control processing unit 4 (C23). More specifically, in this embodiment, the switching device CD outputs a voltage of a voltage value corresponding to the set rotation direction of the control content stored in the memory unit 62 to the second pin PN2, and outputs a voltage of a voltage value corresponding to the set speed of the control content stored in the memory unit 62 to the fifth pin PN5.

[0051] The output of the control content is input to the communication control processing unit 4, and the communication control processing unit 4 controls the motor 3 based on the input control content (S8, C24). More specifically, in this embodiment, if the voltage value corresponding to the set rotation direction input to the second pin PN2 is 4.5 V or less, the Shifter 54 outputs a low-level voltage indicating that the set rotation direction is reverse CCW, and the MC-MCU 46 controls the motor 3 via the inverter 41 to rotate in reverse CCW. If the voltage value corresponding to the set rotation direction input to the second pin PN2 is 6.5 V or more, the Shifter 54 outputs a high-level voltage indicating that the set rotation direction is forward CW, and the MC-MCU 46 controls the motor 3 via the inverter 41 to rotate in forward CW. The shifter 55 outputs a voltage having a rotation speed corresponding to the voltage having a voltage value corresponding to the set speed input to the fifth pin PN2, and the MC-MCU 46 controls the motor 3 via the inverter 41 so that the rotation speed becomes the set speed. As a result, even in the event of a communication abnormality, the motor 3 is controlled and the operation of the conveyor device CS is maintained.

[0052] Next, the communication control processing unit 4 determines whether communication has been restored (S8, C25). If the result of this determination is that communication has been restored (Yes), the communication control processing unit 4 outputs the restoration notification signal indicating that communication has been restored to the switching device CD (S10, C26), and returns the process to process S1 (C1). If communication restoration (normal communication) is received from the hub MS of the IO-Link master during control of the motor 3, the communication control processing unit 4 determines that communication has been restored. On the other hand, if the result of the determination is that communication has not been restored (communication abnormality) (No), the communication control processing unit 4 returns the process to process S8 (C24). This allows control of the motor 3 to continue using the output from the switching device CD.

[0053] Meanwhile, the recovery notification signal is input to the switching device CD, which accepts the input of the recovery notification signal (C28), and outputs a voltage of 18 V or more to the fifth pin PN5 by the second processing unit 61 (C28).

[0054] By operating in this manner, the conveyor system of the embodiment including the CM built-in roller MR and the switching device CD can operate the conveyor device CS in a predetermined control mode even if a communication abnormality occurs.

[0055] The conveyor system in the embodiment may be used in a belt conveyor (first modified embodiment). That is, the conveyor system in this first modified embodiment includes a motorized conveyor roller MR, a switching device CD, and a conveyor device of a belt conveyor, and the multiple rollers in the conveyor device include one or more motorized conveyor rollers MR. The motorized conveyor roller MR and the switching device CD in the conveyor system of this first modified embodiment are similar to the motorized conveyor roller MR and the switching device CD in the conveyor system of the above-mentioned embodiment, so their description will be omitted and the conveyor device of the belt conveyor will be described here.

[0056] 9 is a plan view of a conveyor device in a first modified embodiment. The conveyor device CSa in this first modified embodiment is, for example, a belt conveyor device including a plurality of rollers MR, FR arranged side by side in one direction and a conveyor belt BTa stretched over the plurality of rollers MR, FR, and moving objects along the conveyor belt BTa as a moving path, as shown in FIG. More specifically, the conveyor device CSa includes a pair of first and second conveyor frames CFa, CFb, one or more motorized conveyor rollers MR, one or more driven rollers FR, and the conveyor belt BTa. The first and second conveyor frames CFa, CFb, motorized conveyor rollers MR, and driven rollers FR are similar to the first and second conveyor frames CFa, CFb, motorized conveyor rollers MR, and driven rollers FR in the above-described embodiment, respectively, and therefore will not be described again.

[0057] That is, while the conveyor device CS in the above-described embodiment is provided with a C-M-incorporated roller MR every third roller, and the C-M-incorporated roller MR and the adjacent driven roller FR are connected by a ring-shaped (annular) belt BT wound around one end thereof, the conveyor device CSa in this first modified embodiment has a plurality of rollers MR, FR arranged side by side in one direction, with the rollers arranged at both ends being C-M-incorporated rollers MR, and a wide conveyor belt BTa stretched across these. Note that one or more of the plurality of driven rollers FR arranged side by side between the C-M-incorporated rollers MR at both ends may be replaced with a C-M-incorporated roller MR.

[0058] According to the first modified embodiment, a conveyor system can be provided that further includes the conveyor device of the belt conveyor device. The conveyor system further includes the conveyor device of the belt conveyor device, and can operate the conveyor device in a predetermined control mode even when a communication abnormality occurs.

[0059] Although the switching device CD is provided separately from the C-M roller MR in the above-described embodiment and the first modified example, they may be integrated. That is, the C-M roller MR may incorporate the switching device CD (second modified example). Such a C-M roller MR has the functions of the switching device CD and includes, for example, a communication unit 50, a roller tube 1, a pair of support shafts 2a and 2b arranged opposite each other and rotatably supporting the roller tube 1, a motor 3 arranged inside the roller tube 1 and generating a driving force to rotate the roller tube 1, a control unit 71 arranged inside the roller tube 1 and controlling the motor 3 in accordance with the control content contained in the control signal received by the communication unit 50, and a memory unit 72 arranged inside the roller tube 1 and storing the control content contained in the control signal received by the communication unit 50. The control unit 71 also determines whether a communication abnormality exists and, if a communication abnormality is detected, controls the motor 3 in accordance with the control content stored in the memory unit 72. The control unit 71 and the storage unit 72 are provided in the communication control processing unit 4, instead of the control unit 40 and the first processing unit 461, as shown by the broken lines in FIG.

[0060] In this second modified embodiment, the CM-incorporated roller MR incorporates the switching device CD, so that the conveyor system can be simplified.

[0061] Alternatively, the switching device CD may be integrated with the hub (IO-Link master) MS (third variant).

[0062] This specification discloses various aspects of the technology as described above, but the main technologies among them are summarized below.

[0063] According to one aspect, the conveyor system includes a motorized conveyor roller and a switching device. The motorized conveyor roller includes a communication unit, a roller tube, a pair of support shafts facing each other and rotatably supporting the roller tube, a motor disposed inside the roller tube and generating a driving force to rotate the roller tube, a control unit disposed inside the roller tube and controlling the motor in accordance with control content contained in a control signal received by the communication unit, and a first processing unit disposed inside the roller tube and outputting the control content contained in the control signal received by the communication unit to the switching device. The switching device includes a memory unit and a second processing unit that, when the control content is input from the motorized conveyor roller, stores the control content in the memory unit. The first processing unit further determines whether a communication abnormality exists, and if it determines that a communication abnormality exists, outputs the communication abnormality to the switching device, and the second processing unit further causes the control unit to control the motor in accordance with the stored control content when the communication abnormality is input from the conveyor motor-integrated roller. Preferably, in the above conveyor system, the communication unit is an interface that selectively performs either bidirectional communication or data input / output. Preferably, in the above conveyor system, the communication unit is an interface that complies with the IO-Link standard.

[0064] In such a conveyor system, the motorized roller for a conveyor has a built-in control unit that controls the motor, and the control unit controls the motor according to control content contained in a control signal received by a communication unit and outputs the control content to a switching device, which stores the input control content. When the motorized roller for a conveyor determines a communication abnormality, it outputs the communication abnormality to the switching device, and when the switching device receives the communication abnormality input, it causes the control unit to control the motor according to the stored control content. Because the control source is thus switched from a control signal for normal communication to a switching device for communication abnormality, the conveyor system can operate the conveyor in a predetermined control mode even when a communication abnormality occurs.

[0065] In another aspect, in the conveyor system described above, the motorized conveyor roller incorporates the switching device. That is, the motorized conveyor roller includes a communication unit, a roller tube, a pair of support shafts arranged opposite each other and rotatably supporting the roller tube, a motor arranged inside the roller tube and generating a driving force to rotate the roller tube, a control unit arranged inside the roller tube and controlling the motor in accordance with control contents contained in a control signal received by the communication unit, and a memory unit arranged inside the roller tube and storing the control contents contained in the control signal received by the communication unit, wherein the control unit further determines whether or not a communication abnormality exists, and if the control unit determines that the communication abnormality exists, controls the motor in accordance with the stored control signal.

[0066] In such a conveyor system, the motorized roller for the conveyor has a built-in switching device, so the conveyor system can be simplified.

[0067] In another aspect, the conveyor system described above further comprises a roller conveyor device that includes a plurality of rollers arranged side by side in one direction and that moves an object along a movement path over the plurality of rollers, and the plurality of rollers include one or more of the motorized rollers for the conveyor.

[0068] This provides a conveyor system further comprising a roller conveyor device.

[0069] In another aspect, the conveyor system described above further comprises a belt conveyor device that includes a plurality of rollers arranged in parallel in one direction and a conveyor belt stretched over the plurality of rollers, and that moves objects along a path on the conveyor belt, and the plurality of rollers include one or more of the motor-integrated rollers for the conveyor.

[0070] This provides a conveyor system further including the belt conveyor device.

[0071] In order to express the present invention, the present invention has been properly and sufficiently described above through the embodiments with reference to the drawings, but it should be recognized that those skilled in the art can easily change and / or improve the above-mentioned embodiments. Therefore, unless the changes or improvements made by those skilled in the art are at a level that causes departure from the scope of the claims described in the claims, such changes or improvements are interpreted as being included in the scope of the claims.

[0072] According to the present invention, it is possible to provide a conveyor system including a motorized roller for use in a conveyor device and a switching device for switching control sources.

Claims

1. A conveyor system comprising a motor-integrated roller for conveyors and a switching device, wherein the motor-integrated roller for conveyors comprises: a communication unit; a roller tube; a pair of support shafts arranged opposite each other and rotatably supporting the roller tube; a motor arranged inside the roller tube and generating a driving force to rotate the roller tube; a control unit arranged inside the roller tube and controlling the motor in accordance with control contents contained in a control signal received by the communication unit; and a first processing unit arranged inside the roller tube and outputting the control contents contained in the control signal received by the communication unit to the switching device, wherein the switching device comprises: a storage unit; and a second processing unit which, when the control contents are input from the motor-integrated roller for conveyors, stores the control contents in the storage unit, wherein the first processing unit further determines whether or not a communication abnormality exists, and when it determines that a communication abnormality exists, outputs the communication abnormality to the switching device, The second processing unit further causes the control unit to control the motor in accordance with the stored control content when the communication abnormality is input from the roller incorporating a conveyor motor.

2. The conveyor system according to claim 1, wherein the conveyor motor-integrated roller incorporates the switching device.

3. A conveyor system as claimed in claim 1 or 2, further comprising a roller conveyor device having a plurality of rollers arranged in parallel along one direction, for moving an object along a moving path over the plurality of rollers, the plurality of rollers including one or more rollers with a built-in motor for the conveyor.

4. A conveyor system as claimed in claim 1 or 2, further comprising a belt conveyor device comprising a plurality of rollers arranged in parallel in one direction and a conveyor belt stretched across said plurality of rollers, and for moving objects along a moving path on said conveyor belt, said plurality of rollers including one or more rollers with built-in motors for said conveyor.

Images