Overhead Conveyance Vehicle Obstacle Detection
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Solution Overview
Problem
Conventional overhead conveyance vehicles in semiconductor manufacturing facilities face issues with obstacle detection due to the limitations of optical obstacle sensors, including short device life, inability to detect small obstacles, and the need for precise optical axis alignment, which complicates handling and maintenance.
Innovation Solution
An overhead conveyance vehicle equipped with an imaging device that captures images to determine obstacles, eliminating the need for a driving mechanism to adjust radiation angles and allowing for detection of small obstacles without requiring precise alignment, using predetermined indicators and standardized shapes to set monitoring ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If an optical obstacle sensor with a mechanical driving mechanism is used to adjust radiation angles, then the detection range can be widened, but the device mechanism wears due to friction leading to short device life
Solution Approach 1:
The patent replaces the mechanical driving mechanism with an imaging device (camera) that captures images to detect obstacles. The imaging device has no moving parts and does not require mechanical adjustment of radiation angles, eliminating friction and wear while maintaining wide detection coverage through image processing.
Solution Approach 2:
The patent uses an imaging device to create a visual copy (image) of the obstacle detection area. Instead of using light beams that require mechanical angle adjustment, the camera captures a complete visual copy of the space, allowing obstacle detection without any mechanical motion.
2Device complexity
If an optical obstacle sensor with fixed projection pitch is used, then the device structure is simplified, but small obstacles fitting into the middle of the projection pitch cannot be detected
Solution Approach 1:
The imaging device captures a complete visual image of the entire detection area, creating a detailed copy of the space. This allows detection of small obstacles anywhere within the field of view without being constrained by fixed projection pitches, as the image provides continuous spatial information rather than discrete angular measurements.
3Area of stationary object
If light is emitted downward from the ceiling-mounted obstacle sensor, then the detection range is extended, but precise optical axis alignment is required which complicates handling and maintenance
Solution Approach 1:
The patent replaces the optical alignment system with an imaging device that does not require precise optical axis alignment. The camera can be positioned and oriented more freely, and the system uses image processing to determine obstacle presence without requiring the optical axis to be precisely aligned with the load port, significantly simplifying installation and maintenance.
4Device complexity
If a single light source is used in the optical obstacle sensor, then the device structure is simplified, but the detection range cannot be covered at once requiring repeated detection at different angles
Solution Approach 1:
The imaging device captures a complete visual copy of the entire detection area in a single image, allowing all obstacles within the field of view to be detected simultaneously. This eliminates the need for repeated detections at different angles, significantly improving detection speed while keeping the device structure simple.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a long-lasting obstacle detection mechanism that can detect all objects within its range, reducing maintenance efforts and eliminating the need for operators to manually adjust the system, thereby improving handling and operational efficiency.
Implementation Method 1
The obstacle sensor emits light in a predetermined detection range so as to check the presence or absence of an obstacle in the detection range based on the amount of reflected light etc.
Data Source
AI summary
In an overhead conveyance vehicle that travels along a rail serving as a conveyance track mounted on a ceiling and conveys a target magazine along the rail, when an elevating unit holding the magazine is hoisted or lowered between a conveyance position and a transfer position, a controller for controlling the operation of the overhead conveyance vehicle determines, based on an image captured by a camera, the presence or absence of an obstacle in an imaging range captured by the camera.