Patent ID: 12227110

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, preferred embodiments of aspects of the present invention will be described in detail with reference to the drawings. In the description of the drawings, the same elements will be denoted by the same reference symbols, without redundant description.

As illustrated inFIG.1, a rail-guided vehicle system1is a system to transport an article10between placement sections9,9(seeFIG.2) using a travel vehicle6capable of moving along a traveling rail (rail)4. The article10includes a FOUP (Front Opening Unified Pod) to accommodate a plurality of semiconductor wafers, a container to store glass substrates, a container such as a reticle pod, and general parts. The rail-guided vehicle system1is provided with a plurality of travel vehicles6, the traveling rail4and a plurality of placement sections9.

The travel vehicle6travels on the traveling rail4to transport an article10. The travel vehicle6is configured to be capable of transferring an article10. The travel vehicle6is an overhead hoist transport. The number of the travel vehicles6included in the rail-guided vehicle system1is not specifically limited and is more than one. The travel vehicle6includes a body unit7, a travel unit50, and a control unit35. The body unit7has a body frame22, a lateral moving unit24, a θ drive26, an elevating drive unit28, an elevating platform30, and a cover33.

The body frame22is connected with the travel unit50to support the lateral moving unit24, the θ drive26, the elevating drive unit28, the elevating platform30, and the cover33. The lateral moving unit24laterally slides the θ drive26, the elevating drive unit28, and the elevating platform30all together in a direction orthogonal to a traveling direction of the traveling rail4. The θ drive26rotates at least any of the elevating drive unit28and the elevating platform30within a predetermined angle range in a horizontal plane. The elevating drive unit28elevates and lowers the elevating platform30by reeling and unreeling a suspender such as a rope and a belt. A chuck is attached to the elevating platform30to grip or release an article10freely. A pair of the covers33are provided, for example, at front and rear of a traveling direction of the travel vehicle6. Claws or the like (not illustrated) that come out from the cover33prevent an article10from dropping during transport.

The travel unit50causes the travel vehicle6to travel along the traveling rail4. The travel unit50includes travel rollers51, side rollers52, regenerative brakes (brakes)53, a resistor54, feed cores57and LDMs (Linear DC Motor)59.

The travel rollers51roll on lower surface portions40B of the traveling rail4. The travel rollers51are arranged at both left-right ends of front and rear of the travel unit50. The side rollers52are provided to be able to come in contact with side surface portions40C of the traveling rail4. The regenerative brake53is a device to brake the travel vehicle6by converting kinetic energy into electric energy, and, for example, includes the control unit35that controls LDM59and a driver (not illustrated). The resistor54converts electric energy that has been generated by the regenerative brakes53into heat energy and releases it into atmosphere.

The feed cores57are arranged at front and rear of the travel unit50with the LDM59interposed in a left/right direction. Each feed core57supplies a feed unit40E arranged at the traveling rail4with power in a non-contact manner and sends/receives various signals from/to the feed unit40E in a non-contact manner. The feed core57sends/receives signals to/from the control unit35. The LDMs59are provided at front and rear of the travel unit50. Magnetic force to accelerate or brake the travel vehicle6is generated between an electromagnet provided at the LDM59and a magnetic plate40F arranged on top surface of the traveling rail4.

The traveling rail4is a predetermined travel path on which the travel vehicle6travels. The traveling rail4includes a cylindrical rail body unit40, the feed unit40E and the magnetic plate40F. The rail body unit40includes a pair of lower surface portions40B,40B, a pair of side surface portions40C,40C, and a top portion40D. The rail body unit40accommodates (includes) the travel unit50of the travel vehicle6. The lower surface portion40B extends in a traveling direction of the travel vehicle6to define a bottom surface of the rail body unit40. The lower surface portion40B is a plate-shaped member on which the travel roller51of the travel vehicle6rolls and travels. The side surface portion40C extends in a traveling direction of the travel vehicle6to define a side surface of the rail body unit40. The side surface portion40C is a plate shaped member on which the side roller52of the travel vehicle6rolls. The top surface portion40D extends in a traveling direction of the travel vehicle6to define a top surface of the rail body unit40.

The feed unit40E supplies power to the feed core57of the travel vehicle6and sends/receives signals to/from the feed core57. The feed unit40E is fixed to each of the pair of side surface portions40C,40C and extends in a traveling direction. The feed unit40E supplies power to the feed core57in a non-contact manner. The magnetic plate40F generates magnetic force in the LCM59of the travel vehicle6to travel or stop. The magnetic plate40F is fixed to the top surface portion40D and extends in a traveling direction.

As illustrated inFIG.2, the traveling rail4includes an in-building transport unit T1arranged at each floor of buildings (a first building B1and a second building B2) and a transport unit between buildings T2connecting between the first building B1and the second building B2. In the in-building transport unit T1, the traveling rail4is laid, for example, near a ceiling in a space above a head of a worker. The traveling rail4is suspended and supported, for example, from the ceiling of the building by masts40A,40A (SeeFIG.1).

The transport unit between buildings T2includes a descending rail T21, an ascending rail22, and a connection rail T23. The descending rail T21connects between floors having a difference in height in a vertical direction. Also, the descending rail T21is laid for the travel vehicle6to move downward. The ascending rail T22connects between floors having a difference in height in a vertical direction. Also, the ascending rail T22is laid for the travel vehicle6to move upward. The descending rail T21and the ascending rail T22connect between the bottommost position where the connection rail T23is placed and the topmost position which is the top floor of the first building B1. The connection rail T23connects locations having no difference in height in a vertical direction. Also, the connection rail T23is laid for the travel vehicle6to move horizontally.

As illustrated inFIG.3, the descending rail T21is arranged in a helical manner. As illustrated inFIG.1andFIG.3, the descending rail T21includes a traveling rail4which defines a first section71where electric energy, which is generated when a regenerative brake53included in the travel vehicle6works, is converted into heat energy in a resistor54. The descending rail T21also includes a traveling rail4which defines a second section72where the heat energy converted in the first section71is released from the resistor54.

A descending gradient of the traveling rail4in the first section71is larger than a descending gradient of the traveling rail4in the second section72. In the present preferred embodiment, the traveling rail4in the second section72extends in a horizontal direction. Further, the descending rail T21includes traveling rails4which define straight sections73arranged so as to be parallel or substantially parallel to each other in a plan view seen from above in a vertical direction. The descending rail T21also includes a traveling rail4which defines a curved section74provided at end portions of the traveling rails4defining the straight sections73.

The ascending rail T22is arranged in a helical manner and includes a traveling rail4which defines a third section75which is an ascending gradient, and a traveling rail4which defines a fourth section76extending in a horizontal direction. In addition, the ascending rail T22includes the traveling rails4which define straight sections73arranged so as to be parallel or substantially parallel to each other in a plan view seen from above in a vertical direction. The ascending rail T22also includes a traveling rail4which defines the curved section74provided at end portions of the traveling rails4defining the straight sections73. The ascending rail T22is arranged so as to overlap with the descending rail T21in a plan view seen from above in a vertical direction.

The descending rail T21and the ascending rail T22are supported by a frame81. The frame81includes a lateral frame81A and a longitudinal frame81B. The descending rail T21and the ascending rail T22are supported, for example, by the frames81via a support member40G (seeFIG.1). The frame81is provided in an area surrounded by the descending rail T21and the ascending rail T22arranged in a helical manner. A plurality of steps (stepstools)85for a worker to do maintenance work for the travel vehicle6or the traveling rail4are arranged in the frame81at a predetermined space in a vertical direction. That is, the steps85are arranged in an area surrounded by the descending rail T21and the ascending rail T22arranged in a helical manner. A ladder83is provided between the ground and the bottommost step85and between the steps85,85adjacent to each other for a worker to move up and down.

As illustrated inFIG.2, the placement sections9are arranged along the traveling rail4and provided at positions that enable an article10to be delivered from/to the travel vehicle6. A buffer and a delivery port are included in each placement section9. The buffer is a placement part on which an article10is temporarily placed. The buffer is a placement part where an article10is temporarily placed when the article10being transported by the travel vehicle6cannot be transferred to a targeted delivery port, for example, for the reason that the targeted delivery port is occupied by another article10. The delivery port is a placement part for delivering an article10from/to a semiconductor processing device (not illustrated), for example, a washing device, a deposition system, a lithography system, an etching device, a heat treatment device, or a flattening device. The processing device is not specifically limited and may include various devices.

The control unit35illustrated inFIG.1is an electronic control unit including CPU (Central Processing Unit), ROM (Read Only Memory), RAM (Random Access Memory), or the like. The control unit35is configured or programmed to control various operations in the travel vehicle6. Specifically, the control unit35controls the travel unit50, the lateral moving unit24, θ drive26, the elevating drive unit28, and the elevating platform30. The control unit35may be configured as, for example, software in which program stored in ROM is loaded on RAM and is executed with CPU. The control unit35may be configured as hardware such as an electric circuit. The control unit35communicates with a controller90using the feed unit40E (or feeder wire) of the traveling rail4.

When the travel vehicle6travels in the first section71(seeFIG.2andFIG.3) which is a descending gradient, the control unit35in the present preferred embodiment controls a driver or the like to activate brakes of the regenerative brakes53, causing the travel vehicle6to travel at a predetermined safe speed. When the travel vehicle6travels in the second section72(seeFIG.2andFIG.3) having no gradient, the control unit35controls a driver or the like to release brakes of the regenerative brakes53and controls the LDM59to cause the travel vehicle6to travel at a predetermined speed. When the travel vehicle6travels in the third section75and the fourth section76(seeFIG.2andFIG.3), the control unit35controls a driver or the like to release brakes of the regenerative brakes53and controls the LDM59to cause the travel vehicle6to travel at a predetermined speed.

The controller90is an electronic control unit including CPU, ROM, RAM, or the like. The controller90can be configured as, for example, software in which program stored in ROM is loaded on RAM and is executed with CPU. The controller90may be configured as hardware such as an electric circuit. The controller90transmits to the travel vehicle6a transport instruction to transport an article10.

Actions and effects in the rail-guided vehicle system1of the present preferred embodiment will be described. As illustrated inFIG.3, in the rail-guided vehicle system1of the present preferred embodiment, the descending rail T21is arranged in a helical manner, so that a gradient of the descending rail T21can be adjusted to be appropriate for the travel vehicle6to travel thereon and the descending rail T21can be formed into a compact flat space. The descending rail T21in the rail-guided vehicle system1of the present preferred embodiment includes not only a traveling rail4in the first section71where heat energy converted from the kinetic energy is generated when the regenerative brakes53works, but also a traveling rail4in the second section72where the heat energy generated in the first section71is released. As a result, the heat energy or the electric energy that has been generated in the first section71can be released or consumed in the second section72, respectively, thus preventing defects of the regenerative brakes53caused by invalidation of regeneration or damage due to an excessive heat generation in the resistor54. As a result, the regenerative brakes53of the traveling vehicle6can work properly in the descending rail T21connecting between floors having a difference in height.

In the rail-guided vehicle system1of the present preferred embodiment, since the traveling rail4in the second section72extends in a horizontal direction, the second section72can be formed with a simplified configuration. The second section72is a section where heat energy that has been generated when a travel vehicle traveled in the first section71is released. Further, in such a horizontal section, the travel vehicle6can place an article10on the placement section9from various directions and also can branch or join easily.

In the rail-guided vehicle system1of the present preferred embodiment, since a descending gradient of the traveling rail4in the first section71is larger than a descending gradient of the traveling rail4in the second section72, the second section72can be formed with a simplified configuration. The second section72is a section where heat energy that has been generated when a travel vehicle traveled in the first section71is released.

In the rail-guided vehicle system1of the present preferred embodiment, the descending rail T21includes the traveling rails4which define straight sections73arranged so as to be parallel or substantially parallel to each other in a plan view seen from above in a vertical direction and the traveling rail4which defines the curved section74provided at ends of the traveling rails4defining the straight sections73. In the rail-guided vehicle system1of the present preferred embodiment, the ascending rail T22is arranged so as to overlap with the descending rail T21in a plan view from above in a vertical direction. In the rail-guided vehicle system1with such a configuration, the ascending rail and the descending rail can be installed integrally in a narrow and long space between buildings.

In the rail-guided vehicle system1of the present preferred embodiment, the step85for a worker to do maintenance work is provided in an area surrounded the descending rail T21and the ascending rail T22arranged in a helical manner. As a result, a space can be used effectively and the maintenance work in the descending rail T21and the ascending rail T22can be performed easily.

One preferred embodiment has been described above, the present invention is not limited to the above-described preferred embodiment. Various changes can be made without departing from the scope of the present invention.

Modification 1

For example, in the rail-guided vehicle system1according to a modification 1, as illustrated inFIG.4, in addition to the configuration of the rail-guided vehicle system1according to the above-described preferred embodiment, branching portion91and joining portion92are provided between the bottommost position and the topmost position. When the descending rail T21or the ascending rail T22is regarded as a main line rail, the branching portion91is a portion that branches from the main line rail into a branch line rail which is a rail installed at each floor. When the descending rail T21or the ascending rail T22is regarded as a main line rail, the joining portion92is a portion that joins into the main line rail from the branch line rail. When the first building B1includes a plurality of floors, the branching portion91and the joining portion92are provided corresponding to each floor. The branching portion91and the joining portion92are provided at the traveling rail4extending in a horizontal direction.

In the rail-guided vehicle system1according to the modification 1, a downward movement to each of the plurality of floors and an upward movement to each of the plurality of floors can be performed easily. As a result, an article10can be transported by the traveling vehicle6to a processing device installed at each floor in the first building B1.

Modification 2

In the rail-guided vehicle system1according to the above-described preferred embodiment and the modification 1, as illustrated inFIG.3andFIG.4, it was described as an example that the descending rail T21and the ascending rail T22have the traveling rails4which define straight sections73arranged so as to be parallel or substantially parallel to each other in a plan view seen from above in a vertical direction and the traveling rail4which defines the curved section74provided at end portions of the traveling rails4defining the straight sections73. However, the present invention is not limited thereto.

The descending rail T21of the rail-guided vehicle system1according to a modification 2 includes, for example, as illustrated inFIG.5, a traveling rail4extending radially from a helical center C of the descending rail T21arranged in a helical manner. Curved line rails78are provided at the descending rail T21of the modification 2, so that the traveling rail4extends radially from the helical center C. As with the rail-guided vehicle system1according to the above-described preferred embodiment and the modification 1, the descending rail T21of the rail-guided vehicle system1according to the modification 2 has a traveling rail4which defines the first section71where electric energy, which is generated when the regenerative brakes53included in the travel vehicle6works, is converted into heat energy in the resistor54, and a traveling rail4which defines the second section72where the heat energy, which has been converted in the first section71, is released from the resistor54.

In the rail-guided vehicle system1according to the modification 2, the curved section74is provided at folded portion of the traveling rail4extending radially. The curved section74is defined by the traveling rail4extending in a horizontal direction. As with the modification 1, the branching portion91and the joining portion92are provided at the curved section74.

In the rail-guided vehicle system1according to the modification 2, a downward movement to the plurality of floors and an upward movement to the plurality of floors can be performed easily. As a result, an article10can be transported by the traveling vehicle6to a processing device installed at each floor in the first building B1. In addition, with this configuration, the vertical spacing between the descending rails T21can be increased by easily adjusting length of the traveling rail4.

Modification 3

In the rail-guided vehicle system1according to a modification 3, as illustrated inFIG.6, in addition to the descending rail T21according to the modification 2, the ascending rail T22is provided. The ascending rail T22is arranged so as to overlap with the descending rail T21in a plan view seen from above in a vertical direction. Also in the rail-guided vehicle system1according to the modification 3, the same effect as that of the rail-guided vehicle system1according to the modification 2 can be obtained.

Another Modification

It was described as an example that electric energy generated when the regenerative brakes53work is converted into heat energy in the resistor54included in the travel vehicle6used for the rail-guided vehicle system1according to the above-described preferred embodiment and the modifications. However, the travel vehicle6may be provided with a battery54A instead of the resistor54. The travel vehicle6including the battery54A can cause electric energy generated when the regenerative brakes53work to be stored in the battery54A.

In the rail-guided vehicle system1including a travel vehicle6with such a configuration, electric energy generated when the regenerative brakes53work, is stored into the battery54A in the first section71of the descending rail T21, and the electric energy that has been stored in the first section71, is consumed from the battery54A in the second section72. In the present preferred embodiment, the electric energy is used to generate magnetic force in the LDM59. The magnetic force is for causing the travel vehicle6to travel between the LDM59and the magnetic plate F arranged on top surface of the traveling rail4. With such a configuration, defects of the regenerative brakes53caused by invalidation of regeneration or decrease in longevity of the battery54A due to overcharge into the battery54A can be prevented. As a result, the regenerative brakes53of the travel vehicle6can work properly in the descending rail T21connecting between floors having a difference in height.

In the above modification, it was described that the battery54A is provided at each travel vehicle6. For example, a battery may be installed at least at one position along the descending rail T21, and electric energy that has been generated at each travel vehicle6may be transferred through the traveling rail4or a conductive member arranged along an extending direction of the traveling rail4. With such a configuration, the travel vehicle6uses electric energy stored in a battery provided along the descending rail21when traveling in the second section72, so that the same effect as that of the above modification can be obtained.

In the above-described preferred embodiment and the modifications, it was described as an example that the regenerative brakes53of power conversion system are used for the brakes of the travel vehicle6. For example, brakes for heat conversion system may be used. In this case, heat generated in the first section71is released in the second section72by the brakes for heat conversion system, so that the same effect as that of the above-described preferred embodiment and the modifications can be obtained.

The number of floors of the first building B1and the direction when the traveling rail4extends radially illustrated in the above-described preferred embodiment and the modifications are not limited thereto and can be set properly.

While preferred embodiments of the present invention have been described above, it is to be understood that variations and modifications will be apparent to those skilled in the art without departing from the scope and spirit of the present invention. The scope of the present invention, therefore, is to be determined solely by the following claims.