Conveyance Unit Control for False Stop Correction
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Solution Overview
Problem
Conventional conveyance devices experience frequent stops due to erroneous load presence sensor detections, leading to congestion and overall system shutdowns.
Innovation Solution
A conveyance device with a host control device that monitors movement situations and executes correction operations when objects are stuck, and a distributed control system with individual control devices that exchange information to guide objects to their estimated paths, reducing erroneous deliveries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If distributed control with individual zone controllers is used, then system autonomy and local decision-making are improved, but system-wide coordination and error detection capability deteriorate
Solution Approach 1:
The control system is segmented into independent zone controllers that each manage their own conveyance units, enabling local autonomy while the host controller provides overarching coordination through centralized monitoring of all zone statuses
Solution Approach 2:
The host controller acts as an intermediary between individual zone controllers, receiving status information from all zones and issuing coordinated correction commands to maintain system-wide reliability without interfering with local autonomous operations
2Measurement precision
If load presence sensors are used for drive condition detection, then object detection capability is improved, but false detection and erroneous stop frequency worsen
Solution Approach 1:
The host controller continuously monitors the operational status of all zones and provides feedback to identify when a zone is improperly stopped due to false sensor readings, enabling correction of erroneous stop decisions through centralized oversight
Solution Approach 2:
The system performs preliminary monitoring of zone statuses and sensor readings to detect potential false detection conditions before they cause erroneous stops, allowing preventive correction commands to be issued
3Adaptability or versatility
If zone stops are permitted based on local drive conditions, then local control flexibility is improved, but system-wide congestion and stop propagation worsen
Solution Approach 1:
The host controller monitors the downstream status of each zone and provides feedback to determine whether a zone should maintain its stop or resume operation, preventing unnecessary stop propagation that would reduce overall system throughput
Solution Approach 2:
The control system dynamically adjusts zone operation statuses based on real-time monitoring of downstream conditions, allowing flexible local control decisions to be overridden when system-wide productivity would be compromised
Data Source
AI summary
A conveyance device capable of reducing the frequency of stopping. A plurality of conveyance units are connected to form a conveyance path. The conveyance unit includes a drive device that drives the conveyance unit, and an individual control device that controls the conveyance unit. The individual control device drives the conveyance unit when a specific drive condition is satisfied. The conveyance device includes a host control device that performs communication with the individual control device. The host control device includes a movement situation monitoring unit that monitors a movement situation of an actual object on the conveyance path, and when the conveyance unit on which a specific object is placed is stopped even in a situation where the specific object is movable on the basis of a state around the specific object, a correction operation to drive the conveyance unit is executed regardless of the drive condition.