Patent ID: 12258220

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

1. First Preferred Embodiment

(1) Configuration of Transport System

A configuration of a transport system100according to a first preferred embodiment will be described with reference toFIGS.1and2.FIG.1is a diagram illustrating the configuration of the transport system100.FIG.2is a diagram illustrating a control configuration of the transport system100.

The transport system100is a system for transporting an article W. The transport system100includes a plurality of vehicles1, transport devices3aand3b, a dispenser5, a load detector7, and a reader9. The transport system100includes, as a control configuration, a body controller10(an example of a first controller), a transport controller20, a vehicle controller30(an example of a second controller), a host controller40(an example of a third controller), and a restart command generator50.

The vehicle1is a vehicle that travels on a pair of traveling rails1awith thrust generated by a linear motor. The vehicle1transports the article W in the transport system100in a manner that the vehicle1travels along the pair of traveling rails1ain a state where the article W is placed on a placement portion1bprovided on the upper surface of the vehicle1. Each of the plurality of vehicles1has a different piece of identification information. The identification information of the vehicle1is, for example, machine information of the vehicle1. The identification information of the vehicle1is indicated by, for example, a barcode attached to the vehicle1.

The transport devices3aand3bare devices capable of transporting an article W, such as a conveyor provided along the pair of traveling rails1a, for example. The transport device3atransports the article W transferred from the vehicle1to a predetermined place (unloading). The transport device3btransfers the article W transported from a predetermined place to the vehicle1(loading). The arrangement and number of the transport devices3aand3bin the transport system100can be freely changed depending on the scale of the transport system100and the like.

The dispenser5is a dispensing station to which the article W of which transport is to be stopped is dispensed. The dispenser5is provided at a predetermined position near the traveling rail1a.

“Dispensing of the article W” means that the vehicle1that supports the article W is stopped in the dispenser5, and the article W is moved from the placement portion1bof the vehicle1into the dispenser5. The article W is dispensed into the dispenser5when the vehicle1determined to have a problem by a consistency process stops the transport of the article W.

The dispenser5may be provided separately from the transport devices3aand3b, or a portion of a station used for unloading and/or loading during a normal operation may be used as the dispenser5as necessary.

The load detector7is provided near a first position P1of the pair of traveling rails1a(an example of a traveling route of the vehicle), and detects whether or not the article W is placed on the placement portion1bof the vehicle1at the first position P1. The load detector7is, for example, a camera, a photoelectric sensor including a light emitter that generates a laser beam and a light receiver that receives the laser beam, or the like.

When the load detector7is a camera, and for example, when the presence of an image of the article W on the vehicle1at the first position P1is recognized by image processing, it can be determined that the article W is placed on the placement portion1bof the vehicle1.

When the load detector7is a photoelectric sensor, and the light emitter and the light receiver of the photoelectric sensor are disposed with the pair of traveling rails1ainterposed therebetween, and for example, when a laser beam generated from the light emitter of the photoelectric sensor is blocked by the article W and is not received by the light receiver of the photoelectric sensor, it can be determined that the article W is placed on the placement portion1bof the vehicle1.

On the other hand, when the light emitter and the light receiver of the photoelectric sensor are disposed on the same side with respect to the pair of traveling rails1a, and when the laser beam generated from the light emitter of the photoelectric sensor is reflected by the article W and received by the light receiver of the photoelectric sensor, it can be determined that the article W is placed on the placement portion1bof the vehicle1.

The reader9is provided at a second position P2of the pair of traveling rails1a, and reads the identification information of the vehicle1at the second position P2. The reader9is, for example, a barcode reader, and can determine which of the plurality of vehicles1is present at the second position P2, by reading a barcode indicating the identification information of the vehicle1(for example, the machine information of the vehicle1).

As illustrated inFIG.1, the second position P2at which the reader9is provided is located at the same position as the first position P1at which the load detector7is provided. Thus, it is possible to simultaneously determine whether or not the vehicle1has placed the article W on the placement portion1band the identification information of the vehicle1. The first position P1and the second position P2may not be the same position, and the second position P2may be located near the first position P1. The second position P2may be located away from the first position P1.

(2) Control Configuration of Transport System

The body controller10is a computer system including a CPU, a storage device (RAM, ROM, and the like), and various interfaces, and controls the plurality of vehicles1.

The body controller10calculates a signal for traveling control of each vehicle1and a signal for control of the placement portion1bwhen the article W is transferred between each vehicle1and the transport devices3aand3b, based on an operation command (described later) related to an operation desired to be performed by the vehicle1for transporting the article W. Then, the body controller10outputs the signals to the vehicle1to be controlled.

The body controller10determines an operation status of each vehicle1in the transport system100. Specifically, the body controller10determines the operation status of the vehicle1based on the details of the command when various controls are commanded to each vehicle1, stores information (check information) indicating the determined operation status in the storage device of the computer system forming the body controller10, and transmits the stored information to the vehicle controller30.

In another preferred embodiment, for example, when a sensor is provided in the vehicle1, the body controller10may determine the operation status of the vehicle1based on information from the sensor of the vehicle1.

Further, the body controller10manages information (arrangement order information) regarding an arrangement order of the plurality of vehicles1on the traveling rail1a. The arrangement order information includes the arrangement order of the plurality of vehicles1on the traveling rail1aand information on a state of each vehicle1. The information on the state of each vehicle1indicates, for example, any one of a state in which the vehicle1is guided to the traveling rail1aand operated (line-input state), a state in which the vehicle1is inoperable (down-line input state), and a state in which the vehicle1is detached even from the traveling rail1a(down-line-out state).

In the present preferred embodiment, when the restart of the transport system100is commanded, the body controller10performs an operation of checking the arrangement order of the plurality of vehicles1on the traveling rail1aand the state of each vehicle1and generating the arrangement order information (machine check operation), and an operation of detecting whether or not the article W is placed on each vehicle1.

After performing the above operation, the body controller10transmits the arrangement order information generated in the machine check operation to the vehicle controller30. In addition, when performing the consistency process which will be described later, the body controller10transmits a detection result (load information) of whether or not the article W is placed on the vehicle1, to the vehicle controller30.

The transport controller20is a computer system including a storage device (RAM, ROM, and the like) and various interfaces, and controls the transport devices3aand3bbased on a command from the vehicle controller30.

The vehicle controller30is a computer system including a storage device (RAM, ROM, and the like) and various interfaces, and controls to manage the body controller10. Specifically, the vehicle controller30is configured or programmed to generate an operation command based on a transport command (described later) received from the host controller40, and transmit the operation command to the body controller10.

The operation command is a command for an instruction of each operation to be performed by the vehicle1in the transport of the article W. Specifically, the operation command is, for example, a command to cause the vehicle1to travel, a command to causing the vehicle1to perform a loading operation, a command to cause the vehicle1to perform an unloading operation, or the like.

The command to perform the loading operation is, for example, a command to move the vehicle1to the target transport device3band transfer the article W from the target transport device3bto the vehicle1.

The command to perform the unloading operation is, for example, a command to move the vehicle1to the target transport device3aand transfer the article W from the vehicle1to the target transport device3a.

The vehicle controller30receives the check information, the arrangement order information, and the load information transmitted from the body controller10, and stores the check information, the arrangement order information, and the load information in the storage device of the computer system of the vehicle controller30.

When receiving the check information, the vehicle controller30determines a progress status of the transport of the article W by the vehicle1based on the check information, and generates information (progress information) indicating the determined progress status. The progress information is, for example, information for reporting that the loading operation by the vehicle1has been completed and information for reporting that the transport of the article W by the vehicle1has been completed. The generated progress information is transmitted to the host controller40.

The number of pieces of progress information transmitted by the vehicle controller30is less than the number of pieces of check information received by the vehicle controller30. That is, the progress information is not transmitted one by one during the operation of the transport system100, but is transmitted when the transport status of the article is performed in the transport system100to some extent.

When the restart of the transport system100is commanded, the vehicle controller30performs the following process of checking consistency between the information of the body controller10and the information of the vehicle controller30.

The vehicle controller30performs a process (called a machine check process) to check the consistency between (1) the arrangement order information transmitted from the body controller10after the machine check operation is performed and (2) the arrangement order information managed by the vehicle controller30. When the arrangement order information is not consistent, the vehicle controller30updates the arrangement order information managed by the vehicle controller30so as to be consistent with the arrangement order information from the body controller10.

In another preferred embodiment, when it is determined that the pieces of arrangement order information do not have consistency as a result of the machine check process, the vehicle controller30may report an occurrence of a problem indicating that the arrangement order information is not consistent, without updating the arrangement order information managed by the vehicle controller30.

The vehicle controller30performs the consistency process based on (1) the above load information, (2) the check information stored by the body controller10at a timing at which the restart is commanded, and (3) the check information stored by the vehicle controller30at the timing at which the restart is commanded. That is, the check information stored by the vehicle controller30at the timing at which the restart is commanded is the check information received from the body controller10and stored in the vehicle controller30when the transport system100is normal.

The consistency process is a process of determining whether there is a contradiction (inconsistency) between the state of each vehicle1, which is determined by the body controller10when the restart is commanded, and the state of each vehicle1, which is determined by the vehicle controller30, that is, the state of each vehicle1when the transport system100is normal.

When it is determined that there is no consistency between the state of each vehicle1, which is determined by the body controller10, and the state of each vehicle1, which is determined by the vehicle controller30, as a result of the above consistency process, the vehicle controller30determines that a problem has occurred in the vehicle1having no consistency.

The host controller40is a computer system including a storage device (RAM, ROM, and the like) and various interfaces, to manage the transport of the article W in the transport system100. Specifically, the host controller40is configured or programmed to generate a transport command to transport the article W between the target transport devices3aand3bin the transport system100, and transmits the transport command to the vehicle controller30.

The host controller40stores the progress information received from the vehicle controller30. Further, when a command of canceling the progress information stored in the host controller40is transmitted from the vehicle controller30, as a result of the consistency process, the host controller40cancels the progress information and, as necessary, transmits, to the vehicle controller30, a command of performing a rejection process (which will be described later) for the vehicle1in which the problem has occurred.

In this case, in the transport system100, both a cancellation process and a rejection process which will be described later are performed.

The restart command generator50is, for example, an input interface (for example, a button, a keyboard, a mouse, a touch panel, or the like) that outputs a command to restart the transport system100. In the present preferred embodiment, the restart of the transport system100is commanded to the host controller40by an operator operating the restart command generator50after the transport system100is stopped due to a problem.

The host controller40that has received this command transmits a command to restart the transport system100to the vehicle controller30. Then, a restart process of the transport system100is started.

In another preferred embodiment, the restart command generator50may be provided in the host controller40as the configuration. In this case, the host controller40determines that a problem has occurred in the transport system100, and performs the restart process when the transport system100needs to be restarted. That is, in this case, the host controller40can detect the occurrence of the problem in the transport system100and autonomously perform the restart process even though there is no notification from the operator.

(3) Operation of Transport System

(3-1) Transport Operation of Article

An operation of the transport system100having the above configuration will be described below. First, a transport operation of the article W in the transport system100will be described with reference toFIG.3.FIG.3is a flowchart illustrating the transport operation of the article W in the transport system100.

The transport of the article W in the transport system100is started when the transport controller20transmits, to the vehicle controller30, a notification that the article W to be transported has reached the vicinity of the traveling rail1aby the transport device3bas a transport source of the article W.

In Step S1, the vehicle controller30that has received the notification transmits a transport command request to the host controller40. The transport command request includes information regarding the arrangement position of the transport device3bas the transport source of the article W.

In Step S2, the host controller40that has received the transport command request generates a transport command based on the received transport command request, and transmits the transport command to the vehicle controller30that has transmitted the transport command request.

The transport command includes information regarding the arrangement position of the transport device3bas the transport source of the article W and information regarding the arrangement position of the transport device3aas a transport destination of the article W.

In Step S3, the vehicle controller30that has received the transport command generates an operation command for performing an operation (a loading operation) of transferring the article W from the transport device3bto the vehicle1in the transport source of the article W, based on the received transport command. Then, the vehicle controller30transmits the operation command to the body controller10.

The operation command generated in Step S3 includes a command to move a specific vehicle1to the arrangement position of the transport device3bthat is the transport source of the article W, and a command to transfer the article from the transport device3bto the vehicle1at this position.

The body controller10that has received the operation command for performing the loading operation controls the vehicle1based on the operation command. Specifically, the body controller10performs traveling control of moving the specific vehicle1to the arrangement position of the transport device3bas the transport source of the article W. Then, the body controller10performs control of transferring the article W from the transport device3bas the transport source to the placement portion1bof the vehicle1.

In Steps S4 to S7, in the middle of performing the loading operation, the body controller10determines the operation status of each vehicle1, and generates and stores check information indicating the determined operation status. The body controller10transmits the generated check information to the vehicle controller30. The vehicle controller30stores the received check information.

Specifically, in Step S4, the body controller10that has commanded a loading movement operation to the vehicle1determines “loading movement start” as the operation status, generates and stores check information indicating “loading movement start”, and transmits the check information to the vehicle controller30.

In addition, for example, when the sensor or the like is provided in the vehicle1, the body controller10may determine “loading movement start” as the operation status, when the movement of the vehicle1is detected by the sensor of the vehicle1after a command of the loading movement operation.

The vehicle1arrives at the transport device3bbeing the transport source. In Step S5, the body controller10that has commanded transfer of the article W from the transport device3bto the vehicle1determines “loading start” as the operation status, generates and stores check information indicating “loading start”, and transmits the check information to the vehicle controller30.

In addition, for example, when the sensor or the like is provided in the vehicle1, the body controller10may determine “loading start” as the operation status at a timing at which the sensor detects the movement of the article W from the transport device3bto the vehicle1after the sensor of the vehicle1detects the stop of the vehicle1.

Then, in Step S6, during a period after transfer of the article W from the transport device3bto the vehicle1is commanded (after “loading start” is determined) until loading of the article W onto the vehicle1is completed, the body controller10determines “loading” as the operation status, generates and stores check information indicating “loading”, and transmits the check information to the vehicle controller30.

Furthermore, in Step S7, the body controller10that has determined that the transfer of the article W to the vehicle1has been completed determines “loading completion” as the operation status, generates and stores check information indicating “loading completion”, and transmits the check information to the vehicle controller30.

In Step S8, the vehicle controller30that has received the check information indicating the loading completion generates progress information indicating that the loading operation has been completed, and transmits the progress information to the host controller40. The host controller40stores the received progress information.

When transmitting the progress information to the host controller40, the vehicle controller30may transmit the check information itself indicating the loading completion, which has been received from the body controller10, to the host controller40as the progress information without generating new progress information indicating that the loading operation has been completed.

In Step S9, the vehicle controller30that has received the check information indicating the loading completion generates an operation command for performing an operation (an unloading operation) of transferring the article W from the vehicle1to the transport device3ain the transport destination of the article W, based on the transport command received in Step S2. Then, the vehicle controller30transmits the operation command to the body controller10.

The operation command generated in Step S9 includes a command to move the vehicle1that has completed the loading operation to the arrangement position of the transport device3athat is the transport destination of the article W, and a command to transfer the article W from the vehicle1to the transport device3aat this position.

The body controller10that has received the operation command for performing the unloading operation controls the vehicle1based on this operation command. Specifically, the body controller10performs traveling control of moving the vehicle1that has completed the loading operation to the arrangement position of the transport device3aas the transport destination of the article W. Then, the body controller10performs control of transferring the article W from the vehicle1to the transport device3athat is the transport destination.

In Steps S10to S13, in the middle of performing the unloading operation, the body controller10determines the operation status of each vehicle1, and generates and stores check information indicating the determined operation status. The body controller10transmits the generated check information to the vehicle controller30. The vehicle controller30stores the received check information.

Specifically, in Step S10, the body controller10that has commanded an unloading movement operation to the vehicle1determines “unloading movement start” as the operation status, generates and stores check information indicating “unloading movement start”, and transmits the check information to the vehicle controller30.

In addition, for example, when the sensor or the like is provided in the vehicle1, the body controller10may determine “unloading movement start” as the operation status, when the movement of the vehicle1is detected by the sensor of the vehicle1after a command of the unloading movement operation.

The vehicle1arrives at the transport device3abeing the transport destination. In Step S11, the body controller10that has commanded transfer of the article W from the vehicle1to the transport device3adetermines “unloading start” as the operation status, generates and stores check information indicating “unloading start”, and transmits the check information to the vehicle controller30.

In addition, for example, when the sensor or the like is provided in the vehicle1, the body controller10may determine “unloading start” as the operation status at a timing at which the sensor detects the movement of the article W from the vehicle1to the transport device3aafter the sensor of the vehicle1detects the stop of the vehicle1.

Then, in Step S12, during a period after transfer of the article W from the vehicle1to the transport device3ais commanded (after “unloading start” is determined) until unloading of the article W from the vehicle1is completed, the body controller10determines “unloading” as the operation status, generates and stores check information indicating “unloading”, and transmits the check information to the vehicle controller30.

Furthermore, in Step S13, the body controller10that has determined that the transfer of the article W from the vehicle1to the transport device3abeing the transport destination has been completed determines “unloading completion” as the operation status, generates and stores check information indicating “unloading completion”, and transmits the check information to the vehicle controller30.

In Step S14, the vehicle controller30that has received the check information indicating the unloading completion generates progress information indicating that the transport of the article W has been completed, and transmits the progress information to the host controller40. The host controller40stores the received progress information.

When transmitting the progress information to the host controller40, the vehicle controller30may transmit the check information itself indicating the unloading completion, which has been received from the body controller10, to the host controller40as the progress information without generating new progress information indicating that the unloading operation has been completed.

As described above, in the transport system100, while the vehicle1is performing the operation related to the transport of the article W, the body controller10determines the operation status of the vehicle1, and generates and stores the check information. The generated check information is transmitted to the vehicle controller30and stored in the vehicle controller30. In this manner, it is possible to share the operation status of the vehicle1between the body controller10and the vehicle controller30.

The progress information regarding the progress of the transport of the article W is stored based on the check information received by the vehicle controller30. The progress information is transmitted to the host controller40and stored in the host controller40. In this manner, it is possible to share the progress status of the transport of the article W in the transport system100between the vehicle controller30and the host controller40.

(3-2) Restart Operation of Transport System

An operation when the transport system100is restarted will be described with reference toFIG.4.FIG.4is a flowchart illustrating a restart operation of the normal transport system100. The restart operation illustrated inFIG.4is an operation when the transport system100is restarted by the operator operating the restart command generator50after the transport system100is stopped due to a problem.

The problem that causes the stop of the transport system100occurs, for example, when power supply to each component or element of the transport system100is cut off due to power failure, when the vehicle1and the transport devices3aand3bfail to transfer the article W, when it is detected that an intrusion door (not illustrated) provided in the transport system100is open, when a fire notification is made, when an earthquake is detected, or the like.

The body controller10and/or the vehicle controller30store initial arrangement order information in the transport system100, in advance. For example, the initial arrangement order information may be information input in advance by the operator, may include default information as a reference, or may be blank information in which nothing is described.

When the restart command generator50is operated and an instruction of restart is issued, the host controller40transmits the restart command to the vehicle controller30in Step S101.

The vehicle controller30that has received the restart command starts an operation for restarting the transport system100. First, in Step S102, the vehicle controller30commands the body controller10to perform the machine check operation.

The body controller10commanded to perform the machine check operation first performs traveling control of causing the vehicle1to make one round of the traveling rail1ain order to cause the vehicle1to pass through the load detector7and the reader9.

During a period in which the vehicle1makes one round of the traveling rail1a, the reader9provided at the second position P2reads an identification number of each vehicle1that has passed through the second position P2. The body controller10generates arrangement order information by arranging the identification numbers of the vehicles1in order of the reader9reading the identification numbers.

During a period in which all the vehicles1make one round of the traveling rail1a, the load detector7provided at the first position P1detects whether the article W is placed on each vehicle1that has passed through the first position P1. The body controller10generates the load information in association with a detection result of whether the article W is placed on the vehicle1and the identification number of the vehicle1, which has been read by the reader9.

As described above, the load detector7and the reader9are close to each other. Thus, the detection result of whether or not the article W is placed on the vehicle1and the identification number of the vehicle1are acquired substantially simultaneously. Thus, the body controller10generates the load information in association with the detection result of the article W and the identification number of the vehicle1, which have been acquired simultaneously or with a slight time shift.

As described above, the machine check operation is performed based on the pieces of information acquired by the load detector7and the reader9provided near the traveling rail1a. Thus, it is not necessary to provide a sensor or the like that acquires information for performing the machine check operation for each vehicle1, and thus, it is possible to reduce the cost of the transport system100.

After generating the arrangement order information and the load information, the body controller10transmits the arrangement order information to the vehicle controller30in Step S103.

The vehicle controller30that has received the arrangement order information performs the machine check process of checking consistency between the arrangement order information received from the body controller10and the arrangement order information managed by the vehicle controller30. When it is determined that the two pieces of arrangement order information do not have consistency, the vehicle controller30updates the arrangement order information managed by the vehicle controller30so as to have consistency with the arrangement order information received from the body controller10.

After performing the machine check process, the vehicle controller30transmits the updated arrangement order information to the body controller10as a result of the machine check process, in Step S104.

When there is no consistency between the updated arrangement order information received from the vehicle controller30and the arrangement order information managed by the body controller10, the body controller10stops the restart operation. The above process is performed, for example, when only the vehicle controller30is extended in function.

When it is determined that the updated arrangement order information received from the vehicle controller30and the arrangement order information managed by the body controller10do not have consistency, the vehicle controller30does not have to update the arrangement order information managed by the vehicle controller30so as to have consistency with the arrangement order information received from the vehicle controller30. In this case, the vehicle controller30may stop the restart operation when it is determined that there is no consistency.

Examples of a case where there is no consistency between the updated arrangement order information received from the vehicle controller30and the arrangement order information managed by the body controller10include (1) a case where the vehicle1determined to be operable in the arrangement order information managed by the body controller10is determined to be inoperable in the arrangement order information of the vehicle controller30, (2) a case where information regarding the vehicle1determined to be operable in the arrangement order information managed by the body controller10is not included in the arrangement order information of the vehicle controller30, and the like.

After performing the machine check process, the vehicle controller30performs the consistency process. When performing the consistency process, the vehicle controller30transmits a check information request to the body controller10in Step S105. The check information request is a command to request transmission of the check information and the load information stored in the body controller10to the vehicle controller30.

In Step S106, the body controller10that has received the check information request transmits the stored check information and load information to the vehicle controller30at a timing at which the check information request has been received.

After receiving the check information from the body controller10, the vehicle controller30performs the consistency process for all the vehicles1determined to be operable in the arrangement order information based on (1) the check information received from the body controller10and stored in the vehicle controller30when the transport system100is normal, (2) the check information received from the body controller10when the transport system100stops due to a problem and the restart command is issued, and (3) the load information described above (i.e., whether or not the article W is placed on the vehicle1).

If it is determined by the consistency process that there is consistency between the state of the vehicle1, which is determined by the body controller10, and the state of the vehicle1, which is determined by the vehicle controller30, the vehicle controller30transmits a start command to the body controller10in Step S107.

The start command is a command to make the transport system100be operable by making the vehicle1(and the transport devices3aand3b) and the like be operable.

The body controller10that has received the start command makes the transport system100be operable by making the vehicle1and the like be operable. When the transport system100becomes operable, the body controller10transmits, to the vehicle controller30, a message (start report) indicating that the transport system100becomes operable in Step S108.

Then, in Step S109, the vehicle controller30further transmits, to the host controller40, a message indicating that the transport system100becomes operable, and thus the restart of the transport system100is completed.

If it is determined by the consistency process that the state of the vehicle1, which is determined by the body controller10, and the state of the vehicle1, which is determined by the vehicle controller30, does not largely have contradiction but have no consistency, the vehicle controller30determines that a problem has occurred in the vehicle1in which there is inconsistency between the states determined by the two controllers.

When there is the vehicle1in which the problem has occurred, in the transport system100, a process (cancellation process) of canceling the check information regarding the vehicle1in which the problem has occurred and/or a process (rejection process) of dispensing the article W placed on the placement portion1bfor transport by the vehicle1to the dispenser5is performed.

When there is the vehicle1in which the problem has occurred, whether the cancellation process is performed, the rejection process is performed, or both of the two processes are performed is determined in accordance with the type of the inconsistency occurring between the states of the vehicle1, which have been determined by the two controllers.

For example, when some pieces of check information are stored in the body controller10but no check information is stored in the vehicle controller30, it is determined that inconsistency that pieces of the check information stored in the body controller10and the vehicle controller30do not coincide with each other has occurred. Thus, the cancellation process of canceling the check information of the body controller10is performed.

In addition, for example, when the article W is not placed on the vehicle1in which the problem has occurred, but the check information indicating the loading completion or the check information (unloading start, unloading) regarding the unloading operation is stored in the body controller10and the vehicle controller30, it is determined that the inconsistency has occurred due to the article W being removed from the vehicle1for some reasons. Thus, the cancellation processing of canceling the stored check information is performed.

For example, when the article W is placed on the vehicle1in which the problem has occurred, but the check information is stored in neither the body controller10nor the vehicle controller30, it is determined that the inconsistency has occurred due to the article W being unintentionally disposed on the vehicle1. Thus, the rejection process of dispensing the article W placed on the vehicle1in which the problem has occurred is performed.

For example, when the article W is placed on the vehicle1in which the problem has occurred and some pieces of check information are stored in the body controller10, but the check information is not stored in the vehicle controller30, it is determined that inconsistency that pieces of the check information stored in the body controller10and the vehicle controller30do not coincide with each other has occurred. Thus, the cancellation process of canceling the check information of the body controller10and the rejection process of dispensing the article W placed on the vehicle1in which the problem has occurred are performed.

(3-3) Cancellation Process

Specific operations of the transport system100in the cancellation process and rejection process will be described below. First, the specific operation of the cancellation process in the transport system100will be described below with reference toFIG.5.FIG.5is a flowchart illustrating the restart operation when the cancellation process is performed. In the flowchart of the restart operation illustrated inFIG.5, the cancellation process is realized by processes (Steps S201to S203) included in an area surrounded by the broken line.

The processes of Steps S201to S203are performed when the check information and the load information are transmitted from the body controller10to the vehicle controller30in Step S106, and then the vehicle controller30performs the consistency process and determines to perform the cancellation process.

When it is determined to perform the cancellation process as a result of the consistency process, in Step S201, the vehicle controller30transmits, to the body controller10, a command (a cancellation operation command) to cancel the check information which is the check information of the vehicle1determined to have a problem by the consistency process and is determined to be canceled among pieces of the check information stored in the body controller10.

The body controller10that has received the cancellation operation command cancels the check information commanded to perform cancellation in the received cancel operation command from the body controller10.

Then, in Step S202, the body controller10cancels the check information to be canceled and transmits a message indicating that a cancellation operation has been completed (cancellation operation completion report) to the vehicle controller30.

When receiving the cancellation operation completion report, the vehicle controller30cancels the check information to be canceled if there is the check information to be canceled among the pieces of check information stored in the vehicle controller30. Then, in Step S203, the vehicle controller30cancels the check information to be canceled and transmits a message indicating that the cancellation process has ended (cancellation report) to the host controller40.

The host controller40that has received the cancellation report cancels the progress information corresponding to the check information canceled by the cancellation process, as necessary.

In another preferred embodiment, the vehicle controller30that has received the cancellation operation completion report does not have to cancel the check information to be canceled and transmit the message indicating that the cancellation process has ended (cancellation report) to the host controller40.

After the cancellation process (Steps S201to S203) is performed, Steps S107to S109described above are performed to start the transport system100.

(3-4) Rejection Process

Next, a specific operation of the rejection process in the transport system100will be described with reference toFIG.6.FIG.6is a flowchart illustrating the restart operation when the rejection process is performed. In the flowchart of the restart operation illustrated inFIG.6, the rejection process is realized by processes (Steps S301to S303) included in an area surrounded by the one-dot chain line.

The processes of Steps S301to S303are performed when the check information and the load information are transmitted from the body controller10to the vehicle controller30in Step S106, and then the vehicle controller30performs the consistency process and determines to perform the rejection process.

When it is determined to perform the rejection process as a result of the consistency process, the vehicle controller30transmits a request of a command to perform the rejection process (rejection command request) to the host controller40in Step S301. The rejection command request includes information (for example, the identification information) regarding the vehicle1on which the article W to be dispensed to the dispenser5is placed.

In Step S302, the host controller40that has received the rejection command request generates a command (a rejection command) to perform the rejection process on the vehicle1on which the article W to be dispensed to the dispenser5is placed, and transmits the command to the vehicle controller30.

In Step S303, the vehicle controller30that has received the rejection command generates a rejection operation command to command an operation of moving the vehicle1on which the article W to be dispensed to the dispenser5is placed up to the arrangement position of the dispenser5and transferring the article W from the vehicle1to the dispenser5at this position, based on the received rejection command. Then, the vehicle controller30transmits the rejection operation command to the body controller10.

The body controller10that has received the rejection operation command performs the rejection process by performing traveling control of moving the vehicle1(that is, the vehicle1in which the problem has occurred) on which the article W to be dispensed to the dispenser5is placed up to the dispenser5in order to stop the transport, and performing control of transferring the article W of which the transport is to be stopped from the vehicle1to the dispenser5at this position.

After the rejection process (Steps S301to S303) is performed, Steps S107to S109described above are performed to start the transport system100.

The article W dispensed to the dispenser5by the rejection process is transported again. Specifically, for example, information on the article W dispensed to the dispenser5and a command to transport the article W are input to the vehicle controller30and/or the host controller40by the operator or the like. Then, the host controller40transmits a transport command of the article W to the vehicle controller30, so that the dispensed article W is transported.

When both the rejection process and the cancellation process are performed, the cancellation process in Steps S201to S203is performed after the consistency process, and thus the check information and the progress information of the vehicle1determined to have a problem by the consistency process are canceled.

Then, the cancellation report of the check information and the progress information canceled by the cancellation process is issued, and the rejection process in Steps S301to S303is further performed. Thus, a rejection command to command dispensing of the article W placed on the vehicle1of which the check information and the progress information have been canceled by the cancellation process is issued from the host controller40to the vehicle controller30. Then, the rejection process of dispensing the article W from the vehicle1of which the check information and the progress information have been canceled by the cancellation process, to the dispenser5is performed.

(4) Conclusion

The transport system has the configuration and the function as follows.

A transport system (for example, the transport system100) includes a vehicle (for example, the vehicle1), a dispenser (for example, the dispenser5), a first controller (for example, the body controller10), a second controller (for example, the vehicle controller30), and a restart command generator (for example, the restart command generator50).

The vehicle transports an article (for example, the article W). An article of which transport is to be stopped is dispensed to the dispenser. The first controller controls the vehicle based on an operation command related to the transport of the article, and generates and stores check information indicating an operation status of the vehicle.

The second controller transmits the operation command to the first controller, and receives and stores the check information from the first controller.

The restart command generator commands a restart of the transport system.

When the transport system is stopped due to a problem and then the restart command generator commands a restart of the transport system, the first controller transmits the check information to the second controller.

The second controller performs a consistency process based on the check information received from the first controller and stored in the second controller when the transport system is normal, and the check information received from the first controller when the restart of the transport system is commanded after the transport system is stopped due to the problem. If there is a vehicle determined to have the problem by the consistency process, the second controller commands the first controller to cancel the check information regarding the vehicle and/or to dispense the article supported by the vehicle for the transport to the dispenser.

In the transport system, when the transport system is stopped due to an occurrence of the problem and then a command to restart the transport system is issued, the first controller that controls the vehicle transmits the check information stored and saved when the transport system is restarted, to the second controller.

The second controller performs the consistency process based on the check information which is received from the first controller when the transport system is normal, and stored and saved when the transport system is restarted, and the above check information received from the first controller when the restart of the transport system is commanded after the transport system is stopped due to the problem.

When, as a result of the consistency process, an inconsistency occurs between a state of the vehicle, which is determined by the first controller at time of restarting, and a state of the vehicle, which is determined by the second controller at the time of restarting and when the transport system is normal, it is determined that the problem has occurred in this vehicle.

If there is the vehicle in which the problem has occurred, the second controller commands the first controller to cancel the check information related to the vehicle in which the problem has occurred and/or to dispense the article supported for the transport by the vehicle in which the problem has occurred, to the dispenser.

As described above, consistency between the states of the vehicle, which are determined by the first controller and the second controller is automatically checked. When an inconsistency has occurred between the states of the vehicle, which are determined by the two controllers, the first controller automatically performs a process of deleting the check information of the vehicle in which the inconsistency has occurred, and/or control of dispensing the article supported for the transport by the vehicle in which the inconsistency has occurred.

Thus, when an inconsistency has occurred between information determined by the first controller due to the problem in the transport system and information when the transport system is normal, which is determined by the second controller, it is possible to prevent an occurrence of a situation in which the transport system is abnormally stopped due to the inconsistency.

The transport system further includes a load detector (for example, the load detector7) that is provided at a first position (for example, the first position P1) of a traveling route (for example, the traveling rail1a) of the vehicle and detects whether or not the vehicle at the first position supports the article.

In this case, when the restart command generator commands the restart of the transport system, the first controller performs traveling control of causing the vehicle to pass through the first position, and transmits a detection result of whether or not the vehicle that has passed through the first position supports the article, to the second controller. In addition, the second controller performs the consistency process based on the check information received from the first controller and stored in the second controller when the transport system is normal, the check information received from the first controller when the restart of the transport system is commanded after the transport system is stopped due to a problem, and the detection result.

Thus, it is possible to determine consistency more accurately between the pieces of the information of the vehicle, which are determined by the two controllers including the information on whether or not the article for transport is actually supported by the vehicle.

The transport system further includes a third controller (for example, the host controller40). The third controller transmits a transport command for generating the operation command to the second controller.

In this case, the second controller transmits progress information regarding a progress status of the transport of the article by the vehicle to the third controller. In addition, if there is a vehicle determined to have a problem by the consistency process, the second controller commands the third controller to cancel the progress information of the vehicle.

Thus, it is possible to eliminate inconsistency in a higher controller (that is, the third controller) that manages the transport of the article in the entire transport system.

The third controller receives a command to cancel the progress information from the second controller, and then commands the second controller to dispense the article supported for the transport by the vehicle of which the progress information is canceled, to the dispenser.

Thus, it is possible to eliminate the inconsistency in the higher controller that manages the transport of the article in the entire transport system.

In the transport system, a plurality of vehicles are present. In addition, each of the plurality of vehicles has a different piece of identification information. In this case, the transport system further includes a reader. The reader is provided at a second position of the traveling route of the vehicle, and reads identification information of the vehicle at the second position.

In addition, when the restart command generator commands the restart of the transport system, the first controller performs traveling control of causing a plurality of vehicles to pass through the second position, generates and stores arrangement order information indicating an arrangement order of the plurality of vehicles in the traveling route, and transmits the arrangement order information to the second controller.

Thus, in the transport system including the plurality of vehicles, it is possible to perform the consistency process in consideration of the arrangement order of the plurality of vehicles.

2. Other Preferred Embodiments

Some preferred embodiments of the present invention have been described above, but the present invention is not limited to the above preferred embodiments, and various modifications can be made without departing from the gist of the present invention. In particular, a plurality of preferred embodiments and alternative preferred embodiments described in the present specification can be freely combined as necessary.

(A) The execution order of each step and the process details of each step described in the flowcharts illustrated inFIGS.3to6can be changed without departing from the gist of the invention.

(B) The restart command may be automatically transmitted to the vehicle controller30when the host controller40satisfies a predetermined condition, without operating the restart command generator50. For example, the host controller40can also issue the restart command to the vehicle controller30after a predetermined time elapses after a problem occurs in the transport system100and the transport system100stops.

(C) In the first preferred embodiment described above, each vehicle1does not include the own control unit, and the external body controller10controls each vehicle1. However, the present invention is not limited thereto, and the technique described above can also be applied to a transport system in which each vehicle1includes a control unit or controller.

(D) In the first preferred embodiment described above, the vehicle1is a vehicle that travels on the pair of traveling rails1awith the thrust generated by the linear motor. However, the present invention is not limited thereto, and the technique described above can also be applied to a transport system having another vehicle such as a stacker crane.

(E) In the first preferred embodiment described above, when both the cancellation process and the rejection process are performed, the rejection process is individually performed after the cancellation process is performed. However, the present invention is not limited thereto, and the cancellation process and the rejection process may be performed simultaneously.

(F) The arrangement position of the dispenser5is not limited to the vicinity of the traveling rail1a. For example, the dispenser5may be provided at a position away from the traveling rail1a. In this case, a rejection line extending from the pair of traveling rails1ato the dispenser5is provided. Preferred embodiments of the present invention can be widely applied to a transport system including a vehicle that transports an article and a controller that controls the vehicle.

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.