JP7615430B2 - Transport system inspection device (Doctor Logistics) - Google Patents

Description

The present invention relates to a conveying system inspection device that automatically inspects conveying paths, such as belt conveyors or roller conveyors, and associated equipment.

Generally, when an item transport system at a distribution center in the retail industry breaks down and transport stops, it takes time to restore the system, which can result in missed delivery times to stores and other locations, resulting in significant losses. For this reason, regular maintenance is carried out at distribution centers, and depending on the nature of the breakdown, the transport route must be stopped to carry out repairs. These inspections and repairs need to be carried out quickly, but depending on the scale and nature of the breakdown, it can take time, resulting in extended downtime for the transport route or making it difficult to predict how long the repairs will take. In such cases, it can cause great inconvenience to users of the transport system, so it is important to detect signs of an impending breakdown in advance to prevent such situations from occurring.

In typical logistics centers such as mass retailers, items are transported in cardboard boxes, or when opening cardboard boxes to remove individually packaged products for transport, they are transported in plastic returnable boxes (foldable containers commonly known as "oricon"). Many of these items are standard products with flat bottoms, and large quantities must be transported at once. Since equipment costs must also be kept low, roller conveyors, which have rollers spaced appropriately on a frame to match the size of the items, are often used as the transport system.

When the transport system is a roller conveyor, problems such as malfunctions of the rollers and other rotating parts, and cracks and wear of the drive belt often occur. In addition, the "scanners" and "photocells" that are sensors attached to the conveyor frame to control the transported goods may become misaligned due to vibrations or other factors, making them unable to recognize the goods properly. Furthermore, the control equipment may malfunction due to the installation environment of the equipment (temperature, humidity, dust, etc.) or constant exposure to various noises from other surrounding equipment. Regular inspection and maintenance is essential to check for these symptoms.

Periodic inspections of all of these lengthy transport systems and detecting signs of potential failures in advance require a great deal of time and effort. Currently, experienced engineers patrol the transport systems and inspect areas where failures may occur by visual inspection and hammering inspections, relying on their years of intuition and experience. However, it is very difficult for engineers with little experience to detect signs of failure. Furthermore, inspections are even more difficult in places that are difficult for inspectors to access, such as when the transport routes are complicated or when the parts of the transport system that need to be inspected are tunnel-like within the walls of a building or are installed at high places.

In addition, in passenger baggage transport and sorting systems at airports, passengers entrust their baggage to be transported at a counter before boarding, and the baggage is given a baggage identifier ID using a barcode or similar at the counter. The baggage is then placed on a conveyor belt and automatically transported to a work area (make) for loading onto the designated aircraft. The baggage is then loaded onto the aircraft and airlifted to the destination, where it is quickly delivered to the customer at the baggage claim area at the airport upon arrival.

On departing flights, these baggage items are sorted and transported by a transport system according to flight number, destination, etc. The baggage is read by a baggage identifier ID reader (e.g., a barcode reader) installed on the transport aircraft, and is transported to the boarding aircraft within a designated time. On arriving flights, after being transported by the aircraft, the baggage is quickly transported to the conveyor system at the baggage claim area of the arrival airport.

In these passenger baggage transport systems, wide conveyor belts have traditionally been used to transport baggage of various sizes, but transport paths using wide, long rubber or other belts not only require a large amount of power from the driving motor, but also require a lot of effort for maintenance (inspection and repair).

Furthermore, in recent years, airport baggage handling at airports has been strengthened with greater emphasis on "reducing damage to luggage" and "countermeasures for irregularly shaped or fragile items." Traceability is also becoming important to prevent passengers' individual baggage from going missing. Therefore, instead of individually transporting various pieces of baggage of the same passenger on a wide belt, a system is being introduced in which the baggage is placed on uniformly shaped trays and transported all at once. This transport method involves transporting the items by placing narrow conveyor belts in contact with only the sides of the bottom of the tray (a system known as the "DCT system"). This two-row system of narrow belts has begun to spread in European airports, and similar systems are being introduced in airports in Japan as well.

Taking the airport baggage handling system mentioned above as an example, if the baggage handling system were to break down and stop for some reason, it could have a huge impact on aircraft takeoffs and landings, which could ultimately cause confusion and major disruptions to airport management. Normally, when a breakdown occurs in airport management, the economic losses caused by the impact are enormous.

Methods and devices for diagnosing abnormalities that could lead to breakdowns in an item transport system in advance have been proposed in the prior art documents listed below.

Patent Document 1 discloses a technical idea in which an ultrasonic detection device is provided at a predetermined location on the transport path, ultrasonic detection is used to detect ultrasonic waves from the transport device each time the transport device passes the predetermined location, and a characteristic value of the detected ultrasonic waves is calculated. If the characteristic value, which is calculated sequentially each time the transport device passes the predetermined location, exceeds a predetermined threshold value more than a predetermined number of times in succession, the transport device is determined to be abnormal.

However, this technology only detects abnormalities at specific points on the transport path, and does not capture signs of abnormalities or failures on the entire transport path.

JP 2009-115606 A

In view of these problems with the conventional technology, the present invention aims to provide a conveying system inspection device that can detect signs of impending failure in an item conveying path in advance.

More specifically, the objective is to provide a transport system inspection device that records various status information of the transport path under normal conditions and is able to detect signs of abnormalities by comparing this status information with information obtained during inspection.

Furthermore, it is also an objective of the present invention to provide a transport system inspection device that can perform inspections while the transport system is actually operating, transmit inspection result information in real time, and enable immediate inspection and repair of areas where a malfunction may occur.

In order to solve the above problems, the failure prediction transport system inspection device according to the first aspect of the present invention is configured to include a sensor attached to a transport body that can be transported on a transport path for transporting items, which acquires information related to one or more of sound, vibration, image, light, ultrasonic wave, pressure, and environment, an information recording device attached to the transport body and records the sensor information collected from the sensor, and an information analysis and processing unit that drives the sensor and the information recording device to transport the transport body on the transport path while causing the information recording device to record the sensor information on or near the transport path over time.

As a failure prediction transport system inspection device according to the second aspect of the present invention, in the first aspect, the information analysis/processing unit can also be provided with a function for determining signs of a failure occurring in the transport path based on the sensor information collected from the sensor.

As a failure prediction transport system inspection device according to the third aspect of the present invention, in the second aspect, the transport body is transported on the transport path during actual work related to transporting goods, and the information analysis/processing unit can compare the sensor information collected from the sensor with second sensor information previously recorded in the information recording device, determine signs of a failure occurring on the transport path, and record information related to the determined signs of a failure occurring on the information recording device.

As a failure prediction transport system inspection device according to the fourth aspect of the present invention, in the second or third aspect, the failure prediction transport system inspection device further includes a communication unit that transmits and receives information to and from the outside, and the control unit can also control the communication unit to transmit information related to the determined failure occurrence symptoms to the outside.

As a failure prediction transport system inspection device according to the fifth aspect of the present invention, in the first aspect, the failure prediction transport system inspection device further includes a communication unit that transmits and receives information to and from the outside, and the control unit transmits the sensor information collected from the sensor to an external analysis/processing device via the communication unit, and the control unit can also control the communication unit to receive failure occurrence symptom information from the external analysis/processing device.

As a failure prediction transport system inspection device according to the sixth aspect of the present invention, in the first aspect, a position detection device is further provided that detects the position of the transport body on the transport path or in the vicinity of the transport path, and the information analysis/processing unit can be configured to associate the sensor information with the position information detected by the position detection device and record it chronologically in the information recording device.

As a failure prediction transport system inspection device according to the seventh aspect of the present invention, in the sixth aspect, a gyrocompass and an accelerometer can be used as the position detection device.

As a failure prediction transport system inspection device according to the eighth aspect of the present invention, in the sixth aspect, an RF-ID reader can be used as the position detection device.

As a failure prediction transport system inspection device according to the ninth aspect of the present invention, in the sixth aspect, an image analysis device can be used as the position detection device.

As a failure prediction transport system inspection device according to the tenth aspect of the present invention, in the fourth aspect, the communication unit receives control information from the outside for controlling the information analysis and processing unit, and the information analysis and processing unit can also cause the sensor to acquire the sensor information based on the control information received by the communication unit.

As a failure prediction transport system inspection device according to an eleventh aspect of the present invention, in the tenth aspect, the control information can also include sensor information acquisition criteria information relating to the information acquisition criteria for acquiring the sensor information.

As a failure prediction transport system inspection device according to the twelfth aspect of the present invention, in the eleventh aspect, the sensor information acquisition standard information includes information that specifies a threshold level set for each type of sensor at each predetermined position on the transport path, and the control unit can also record the sensor information in the information recording device and transmit the sensor information to the outside when the sensor information exceeds the threshold level.

In order to solve the above problem, the conveying system according to the thirteenth aspect of the present invention is configured to include a conveying path for conveying an article, a sensor attached to a conveying body that can be conveyed on the conveying path for acquiring information related to one or more of sound, vibration, image, light, ultrasonic wave, pressure, and environment, an information recording device for recording the sensor information collected from the sensor, an information analysis and processing unit that drives the sensor and the information recording device to convey the conveying body on the conveying path while recording the sensor information on or near the conveying path in the information recording device over time, and a function for determining signs of a malfunction of the conveying path based on the sensor information.

As a conveying system according to the 14th aspect of the present invention, in the 13th aspect, the conveying body is conveyed on the conveying path while actual work related to article conveying is in progress, and the control unit can compare the sensor information collected from the sensor with second sensor information previously recorded in the information recording device, determine signs of a malfunction occurring on the conveying path, and record information related to the determined signs of a malfunction occurring on the information recording device.

As a conveying system according to the fifteenth aspect of the present invention, in the thirteenth or fourteenth aspect, the conveying system further includes a communication unit that transmits and receives information to and from the outside, and the control unit can control the communication unit to transmit information related to the determined failure occurrence symptom to the outside.

As a transport system according to the 16th aspect of the present invention, in the 13th aspect, the transport system further includes a communication unit that transmits and receives information to and from the outside, and the information analysis/processing unit transmits the sensor information collected from the sensor to an external analysis device via the communication unit, and the information analysis/processing unit can also control the communication unit to receive failure occurrence symptom information from the external analysis device.

As a conveying system according to the seventeenth aspect of the present invention, in the thirteenth aspect, a position detection mechanism is further provided for detecting the position of the conveying body on the conveying path or in the vicinity of the conveying path, and the information analysis/processing unit can be configured to associate the sensor information with the position information detected by the position detection mechanism and record it chronologically in the information recording device.

As a conveying system according to the 18th aspect of the present invention, in the 17th aspect, the position detection device can be configured to include an RF-ID tag provided at a predetermined point on the conveying path or near the conveying path, and an RF-ID reader provided on the conveying body.

As a conveying system according to the 19th aspect of the present invention, in the 17th aspect, the position detection device can be configured to include an optical marker provided at a predetermined point on the conveying path or near the conveying path, and an image analysis device provided on the conveying body and having a function of reading the optical marker.

As a conveying system according to the 20th aspect of the present invention, in the 17th aspect, the position detection device can be configured to include a conveying path configuration diagram recorded in the information recording device and a means for detecting a position on the conveying path by at least one of a specific sound, vibration, and impact associated with a specific point included in the conveying path configuration diagram.

As a transport system according to the twenty-first aspect of the present invention, in the fifteenth aspect, the communication unit receives control information from the outside for controlling the information analysis/processing unit, and the information analysis/processing unit can cause the sensor to acquire the sensor information based on the control information received by the communication unit.

As a transport system according to the twenty-second aspect of the present invention, in the twenty-first aspect, the control information can also include sensor information acquisition criteria information relating to information acquisition criteria for acquiring the sensor information.

As a conveying system according to the 23rd aspect of the present invention, in the 22nd aspect, a threshold level set for each type of sensor is defined for each predetermined position on the conveying path, the sensor information acquisition reference information includes information defining the threshold level, and the information analysis/processing unit can record the sensor information in the information recording device and transmit the sensor information to the outside when the sensor information exceeds the threshold level.

As a conveying system according to the 24th aspect of the present invention, in any of the 13th to 23rd aspects, the conveying body can be configured to include at least a first body that functions as an information collecting device for the purpose of acquiring the sensor information by the sensor, and a second body that functions as an information analysis and processing unit that judges the signs of a fault occurring in the conveying path based on the sensor information acquired by the first body, as separate bodies.

As a conveying system according to the 25th aspect of the present invention, in any of the 13th to 23rd aspects, the conveying body can be configured by connecting at least a first body that functions as an information collecting device for acquiring the sensor information by the sensor, a second body that functions as an information analysis and processing unit that judges a sign of a malfunction in the conveying path based on the sensor information acquired by the first body and acquires malfunction symptom information, and a third body that has a repair unit that cleans or maintains the sensor provided on the conveying path based on the sensor information acquired by the first body and/or the malfunction symptom information obtained by the second body.

As a conveying system according to the 26th aspect of the present invention, in the 25th aspect, the sensor includes a photoelectric switch having at least a light-emitting part and a light-receiving part, and the repair part can also have a function of cleaning dirt from the light-emitting part and/or the light-receiving part of the photoelectric switch by injecting compressed air.

As a conveying system according to the 27th aspect of the present invention, in any one of the 24th to 26th aspects, the information analysis and processing unit can also be equipped with a personal computer and analysis software.

The above-mentioned conveying system inspection device is conveyed on the actual conveying path, and the test measurement information of each sensor device during conveying is recorded. The test measurement information is compared with the information of the above-mentioned sensor device during normal operation, and the correlation with the test measurement information of the various sensor devices is investigated to correctly capture signs of failure occurrence, and is recorded as failure occurrence sign information, for example, in the above-mentioned information recording device. The failure occurrence sign information may be kept as it is in the conveying system inspection device according to one embodiment of the present invention, and read from the above-mentioned information recording device and judged after conveying on the conveying path is completed. (Offline) The above-mentioned failure occurrence sign information may also be transmitted to the outside by a wireless communication device, and the failure occurrence sign location may be immediately inspected. (Online)

The test measurement information from each of the sensor devices can be transmitted to the outside, and compared with the information from the sensor devices during normal operation, or correlations with the test measurement information from various sensor devices can be investigated to detect signs of a malfunction, all of which can be performed by an external information analysis and processing unit. Furthermore, the wireless communication device can receive control information from the outside, and the control information can be used to control the information acquisition method and information acquisition criteria of each of the devices.

By recording data from each device when the transport system is operating normally, and using these as reference values, and performing comparison and correlation processing with measurement data from normal inspections, it is possible to detect signs of a malfunction.

Similarly, based on the test information obtained as described above, a threshold level can be set for each position on the transport path, and if the test measurement information exceeds the above level, the corresponding test measurement information can be recorded and transmitted externally, allowing information to be transmitted in real time.

According to the present invention, by transporting a transport system inspection device according to one aspect of the present invention along an actual transport route, it is possible to grasp the status of the transport system (operating time, transported load, abnormality history, etc. from the control device of the equipment itself) and collect and analyze various data to detect signs of abnormality in advance, allowing the transport system to be operated efficiently and preventing economic losses.

In addition, because the transport status of transported items (goods/luggage) can be grasped, there is no need to use parts with excessive precision standards in order to prevent breakdowns in the transport system, making it possible to select the optimal transport system and reduce costs.

The inspection device of the present invention can be used to automatically inspect transport routes in locations where inspectors cannot easily access them, such as when the transport route is complicated, tunnel-shaped, or located at a high altitude.

In addition, since signs of a malfunction can be detected while the transport system is actually operating and information can be transmitted in real time, the affected area can be inspected in detail immediately and repaired if necessary, preventing losses due to the transport system being stopped.

1 is a schematic diagram showing an example of a transport system to which an embodiment of the present invention is applied; FIG. 11 is a schematic diagram showing another example of a transport system to which an embodiment of the present invention is applied. 1 is a block diagram of a transport system inspection apparatus according to an embodiment of the present invention. 1 is a block diagram of a voice analysis device according to an embodiment of the present invention. 1 is a schematic diagram showing the appearance of a transport system inspection device according to an embodiment of the present invention; FIG. 13 is a schematic view showing the appearance of a transport system inspection device according to another embodiment of the present invention. 13 is an explanatory diagram of a signal analysis and processing method of a transport system inspection device according to another embodiment of the present invention. FIG.

Below, the form for carrying out the present invention will be explained with reference to the drawings. Note that, below, the scope necessary for the explanation to achieve the object of the present invention will be shown in a schematic manner, and the scope necessary for the explanation of the relevant parts of the present invention will be mainly explained, and the parts where explanation is omitted will be based on publicly known technology.

An embodiment of the present invention will be described below by taking as an example a case in which the embodiment is applied to a baggage conveying system that can simplify the conveying path by conveying baggage of different shapes as described above on trays of approximately uniform shape. Regardless of the shape of the items being conveyed, the items are conveyed on trays of approximately uniform shape, so baggage conveying systems can be said to be very suitable as a subject for applying an embodiment of the present invention.

Figure 1 is a schematic diagram of a baggage conveying system according to one embodiment of the present invention, which conveys baggage 1 of different shapes on trays 2 of substantially uniform shape. The system is configured with a relatively narrow belt 4 driven by a drive source 3 that may include a motor on both sides of a substantially straight conveying path (curved conveying paths and branching conveying paths will not be described), a belt guide 5 arranged under the belt 4 to support the weight of the baggage being conveyed, a guide rail 6 to prevent the tray 2 from shifting left and right, a control unit 7 that optimally controls the number of rotations of the drive source 3 that drives the conveying path based on speed information of the entire conveying unit, and controls the drive source 3 of the conveying path to stop driving when there is no tray 2 or baggage 1 on the tray 2 on the conveying path, and a conveying path position information unit 8 to identify the position using identification information such as RFID or barcode.

The conveying system inspection device according to one embodiment of the present invention is configured to load various measuring devices (described below) into a housing 2-0 (described below) that is shaped so that it can be transported along the conveying path. The device observes the condition of the conveying path while transporting the actual conveying path, quickly detects and responds to signs of malfunction, and prevents breakdowns from occurring.

Figure 2 is a schematic perspective view of a conveying system inspection device according to one embodiment of the present invention applied to a conveying system using a roller conveyor 9. The same measuring devices as in Figure 1 are loaded onto a housing (or conveying body; the same applies below) 6-0 (not shown) that can be conveyed by the conveying system, forming a conveying system inspection device. A conveying path position information unit 10, which has the same function as the conveying path position information unit 8 in Figure 1, is provided on the guide rail 6. Note that when applying the above-mentioned conveying system inspection device to a wide belt conveyor conveying path, an inspection device of approximately the same shape can also be used.

Figure 3 is a block diagram showing the functional configuration of a conveying system inspection device Y according to one embodiment of the present invention. As shown in the figure, the conveying system inspection device Y according to one embodiment of the present invention is equipped with one or more of an acoustic analysis device 3-1, a vibration analysis device 3-2, an image analysis device 3-3, an optical measurement device 3-4, an ultrasonic analysis device 3-5, a pressure analysis device 3-6, and an environmental analysis device 3-7 as sensor devices for conveying system inspection, in a housing 5-0 (not shown) that can be transported on a conveying path. Each of the above sensor devices is connected to an information analysis/processing device 3-13 via an I/F device 3-8, and the information analysis/processing device 3-13 is also connected to a vibration device 3-10 and a position detection device 3-11 via the I/F device 3-8, and also to a wireless communication device 3-14 and an information recording device 3-12 via the I/F device 3-8.

The conveying system inspection device Y according to one embodiment of the present invention may analyze the stored data to detect signs of fault occurrence (offline) after being conveyed by an actual conveying system, or may wirelessly transmit data to the outside during conveying and detect signs of fault occurrence (online) in an external analysis device 3-30 (external view not shown). The external analysis/processing device 3-30 may be configured to include a wireless communication device 3-15 and a personal computer device, or a signal analysis device 3-16 with more advanced signal analysis capabilities and an information recording device 3-17.

Figure 4 is a block diagram showing the functional configuration of an acoustic analysis device according to one embodiment of the present invention, which is equipped with one or more microphones (hereinafter abbreviated as "microphones") M0, M1 to Mn in a housing 2-0 (not shown) to capture the direction of a sound source, detect external sounds, and housing vibration sounds. The microphones M0, M1 to Mn may be of the required frequency band, or may be a wideband microphone whose output is controlled to the required frequency band by a frequency filter FIL. Furthermore, it is preferable to have a volume control circuit AGC in case of a large volume such as a collision sound. This acoustic analysis device can capture or block only sounds of a specific frequency, and can detect the direction of sound generation by collecting and analyzing sound sources using multiple microphones.

In addition, since it is expected that the location where the transport path is installed will be subject to a large amount of ambient noise, a microphone M0 for detecting ambient sound may be provided, and the detected ambient noise may be subtracted from the information from microphones M1 to Mn, or the ambient noise floor may be detected by microphone M0 and set as a threshold level, and only information exceeding that level may be handled, or a noise canceling function may be provided.

The vibration analysis device 3-2 is composed of a vibration sensor and detects one or more of the following information: shock from the conveying path transmitted to the housing 5-0, amplitude, direction, displacement, frequency, and acceleration of the vibration. For example, looseness in a conveyor belt appears as intermittent vibration, and shaft displacement or wear of a drive motor appears as a specific vibration frequency, making it possible to detect signs of an impending breakdown.

The image analyzer 3-3 is made up of an image/video camera and is installed in the necessary locations of the housing 5-0. In addition to detecting foreign objects on the transport path, it can also detect distortions and scratches on the structures by comparing them with images of the structures on the transport path under normal conditions. It can also detect the current position on the transport path by attaching image ID tags such as barcodes to the guide rails and structures on the transport path and detecting the images.

The optical measurement device 3-4 is made up of a laser emitter and a laser receiver, and can accurately measure the distance from the housing 5-0, in which the inspection device according to one embodiment of the present invention is mounted, to an object, such as a guide rail. Furthermore, by scanning and receiving the emitted laser light, it is possible to observe the surface roughness and surface rust condition of the object.

The ultrasonic analyzer 3-5 is configured with an ultrasonic transmitter and an ultrasonic receiver, and can detect the generation of ultrasonic waves when metal breakage occurs in mechanical components along the transport path. In addition, the ultrasonic transmitter and receiver can be provided at specific positions in the housing 5-0, allowing flaws to be detected in the metal components that make up the transport path.

The pressure detection device 3-6 is a pressure sensor installed on the bottom or side of the housing 5-0, and is preferably a small sensor that can produce an electrical output, such as a semiconductor piezoresistance type. The pressure detection device 3-6 detects the pressure applied to the housing 5-0 as it moves along the transport path, and can detect abnormalities such as the housing 5-0 being pressed to one side more than the design value or hitting an unexpected protrusion on the transport path.

The environmental measuring device 3-7 is equipped with environmental measuring devices for temperature, humidity, air pressure, wind, dust, etc., and measures the conveying system environment. For example, when transporting items such as frozen foods, temperature control of the conveying path environment is important, and capturing temperature changes in advance makes it possible to prevent food accidents. In addition, observing heat generated by the driving equipment of the conveying path and heat generated by friction in the conveyor belt is also important for preventing accidents before they occur.

The vibration device 3-10 is composed of an electric vibrator and/or a tapping mechanism. A tapping mechanism is a device that drives a small hammer using an electric solenoid or motor drive to give a light impact to an object. This type of vibration device applies vibration or impact to necessary locations on the transport path, and the resulting reaction sounds are collected, analyzed, and diagnosed by the acoustic analysis device 3-1. The vibration analysis device also collects, analyzes, and diagnoses resonance frequencies. Usually, when a screw loosens or the structure becomes distorted or twisted, a reaction sound with a different frequency than normal is emitted, or a peculiar impact sound is emitted, making it possible to detect signs of an impending breakdown.

The position detection device 3-11 is equipped with a gyrocompass and an accelerometer, and is further equipped with a wireless device (hereinafter referred to as a "wireless device") such as RFID or Bluetooth (registered trademark) using an IC tag, and the accelerometer and gyrocompass are used to estimate the current self-position of the conveying system inspection device according to one embodiment of the present invention. This self-position estimation is performed by calculating the travel distance and direction using the accelerometer and gyrocompass with the start position of the conveying path as a reference, and estimating the current location. If there is a risk of error superposition, an IC tag, for example, can be installed at a reference point installed at a known key point, and the IC tag can be read with an RFID reader to correct the error. Error correction using a reference point may be performed by installing a visual marker such as a barcode or AR marker instead of an IC tag, and visually recognizing the marker with the above-mentioned image analysis device to perform error correction. The use of these IC tags, RFID readers, visual markers such as barcodes and AR markers, and image analysis devices is not limited to the above-mentioned error correction, and they can also be used as position detection devices. Also, characteristic points such as branching points in the conveying path can be detected by an image analyzer to perform position correction and/or position detection. Furthermore, position correction and/or position detection can be performed by detecting light from a photoelectric sensor that detects the passage of the conveyed object.

The I/F device 3-9 is an interface device for connecting information from each of the sensor devices 3-1 to 3-8 and the control lines of each sensor to the information analysis and processing unit. It also has a terminal 3-20 (not shown) for connecting to an external device.

The information recording device (also called the "memory device") 3-11 can store (memory) information from each of the sensor devices 3-1 to 3-8 under the control of the control device 3-12, and can also store information from each sensor device when the transport path is in a normal state as reference data. In addition, it also functions as a temporary memory and buffer memory similar to the memory device of a personal computer.

Furthermore, if a transport path configuration diagram is recorded in the information recording device, the position information from the position detection device can be compared with the transport path configuration diagram to more clearly determine where on the transport path the transport path testing device according to one embodiment of the present invention is located. The arrival of the transport path system inspection device according to one embodiment of the present invention at the transport path switching position can be detected by characteristic points of the transport path that can be seen from the transport path configuration diagram, such as specific vibrations and shocks that occur at the transport path switching position, and this can be used to correct errors in the position detection device.

The information analysis and processing unit 3-13 is made up of a CPU similar to that of a personal computer, and performs calculations on data from each sensor device, compares it with normal data, judges signs of failure based on the correlation of information from multiple sensors, stores data from each sensor including judged data in an information recording device, transmits data to the outside via a wireless communication device described below, and performs control using control information from the outside. In addition, as described below, it is also possible to estimate the position in the transport path configuration diagram by detecting a specific vibration frequency, and detect loose or peeling side panels using images and vibration frequencies.

As described above, in the transport system inspection device of the present invention, one method of determining signs of a failure based on information from each sensor under normal conditions is to compare information under normal conditions with information under failure. However, failures occur rarely, and it is difficult to obtain information when a failure occurs. For this reason, another method is to assume a certain failure, artificially create a failure state, and use the data from that time to predict the failure.

On the other hand, actual failures often occur in unexpected conditions, and the failure state may not be able to be described logically. In such cases, there is a method of determining the signs of failure by using learning means including an artificial neural network (ANN) using artificial intelligence (AI) in the information analysis and processing unit.

The AI method (here) can be implemented as application software used in the information analysis and processing device 3-13, and includes machine learning of information from each sensor using processing means such as the Naive Bayes method, the support vector machine method, the anomaly detection method, the neural network method, and the feature space method (K-means method, etc.), and can compare the data from each sensor under normal conditions, determine signs of failure based on correlations between data from multiple sensors, store data from each sensor including the determination information in the information recording device 3-12, transmit information to the outside via the wireless communication device 3-15 described below, and control the information analysis and processing device 3-13 using control information from the outside. The above information analysis and processing can accurately detect peculiar data information from each sensor, and can not only determine signs of failure, but also estimate the position in the transport path configuration diagram and detect the faulty part and fault condition.

Taking the feature space approach as an example of information analysis and processing using the above AI techniques, a correlation matrix is constructed using normalized measurement data from sensors, and a unit space is generated for the normal operating state of the transport equipment (hereafter abbreviated as normal state) using Yak-9 multivariate analysis. This unit space data is compared with data collected by the sensor to determine the degree of anomaly. The above relationship is shown in the block diagram of Figure 7.

The wireless communication device 3-14 is equipped with a transmitter/receiver for the wireless communication methods Wi-Fi, Bluetooth (registered trademark), ZigBee (registered trademark), or specific low-power radio, and under the control of the signal analysis device 3-12, transmits the failure symptom judgment results and information from each sensor device to the outside, and receives signals from the outside. The wireless communication method to be used is selected based on the required data transfer rate. In addition, the antenna used by the wireless communication device is selected based on the required communication range. In addition, it is also possible to transmit data from each sensor device directly to the outside and have it analyzed by an external analysis device with advanced analysis functions, which is called cloud processing.

A rechargeable battery is used as the power source. The battery capacity can be determined based on how many different types of sensor devices are installed.

Figure 5(a) is a schematic top view of a housing 5-0 having substantially the same configuration (shape, weight) as the tray 2 shown in Figure 1, and Figure 5(b) is a schematic bottom view of the housing 5-0. Figures 5(a) and (b) show a rectangular box-shaped housing 5-0 as an example, with a sensor bay SB1 on the side of the box-shaped housing 5-0 that houses the sensor units of various sensor devices, and sensor bays SB2 located in front and behind the housing 5-0. The sensor bays SB1 and SB2 should preferably house the following sensor devices (not shown): an acoustic analysis device 3-1, a vibration excitation device 3-10, a vibration analysis device 3-2, an image analysis device 3-3, an optical measurement device 3-4, and a pressure detection device 3-6.

As shown in FIG. 5(b), a sensor bay SB4 is provided on the bottom surface of the housing 5-0, and it is desirable to house sensor devices such as an acoustic analysis device 3-1, a vibration analysis device 3-2, an ultrasonic analysis device 3-5, and a position detection device 3-11. In addition, it is desirable to house a wireless communication device 3-14 in the upper part SB5 of the housing 2-0.

As another application example of the present invention, a protruding sensor bay SB3, shown by a dotted line in FIG. 5(a) at a position corresponding to the item storage section of the housing 5-0, may be provided so that the surroundings of the housing 5-0 can be overlooked. The sensor bay SB3 may house sensor devices (not shown): an acoustic analysis device 3-1, an image analysis device 3-3, an optical measurement device 3-4, and a wireless communication device 3-14.

Figures 6(a) and 6(b) are schematic diagrams of an inspection device according to another embodiment of the present invention when applied to a conveying path formed by a roller conveyor or wide belt conveyor as shown in Figure 2. The conveying system inspection device according to another embodiment of the present invention is housed in a housing 6-0 that has approximately the same shape as a typical transported object transported on the conveying path. The various measuring devices housed in housing 6-0 and the sensor bays SB1 to SB5 that house their sensor units are approximately the same as housing 5-0 shown in Figure 5, so detailed description will be omitted.

The present invention makes it possible to inspect the entire system of a large-scale transport system, such as an airport baggage handling system or a large logistics center, while the system is in operation. By quickly finding and dealing with areas where failures are likely to occur, it is possible to prevent accidents that could cause major disruption to the airport system.

In the explanation of Figure 1, an embodiment of the present invention is applied to a conveying device that conveys items placed on special trays, but it can also be applied to roller conveyor conveying systems and conveyor belt conveying systems that use wide belts.

When the conveying system is started before the goods are conveyed, a conveying system inspection device according to one embodiment of the present invention can be conveyed to inspect the conveying system, and then the actual goods can be conveyed. Alternatively, a conveying system inspection device Y according to one embodiment of the present invention can be conveyed at the same time while the actual goods are being conveyed, and a system inspection can be performed during actual conveyance, allowing both online and offline inspection of the goods conveying system.

The conveying system inspection device Y according to one embodiment of the present invention can be equipped with sensor devices 3-1 to 3-7 as described above, but can also handle simple inspections such as acoustic inspections, as well as more complex inspections that use a variety of sensors. In other words, it can be flexibly operated, such as performing simple inspections together with the items being conveyed under normal circumstances, and performing more complex periodic inspections at certain intervals, which helps to further improve the reliability of the conveying system.

Furthermore, in a system that transports items in trays, the device for the first tray at the front, like Doctor Yellow on the Shinkansen, may be configured as an information gathering device equipped with sensors for images, sound, light, ultrasound, etc., for the purpose of gathering information, the device for the second tray may be configured as an information analysis and processing unit that analyzes the information collected by the first device using a personal computer and dedicated analysis software, and the device for the third tray may be configured as a device with a repair function that uses the information obtained by the device in front to clean dirt from the light-emitting and light-receiving parts of photoelectric switches appropriately installed on the transport line by spraying compressed air, and other repair functions other than inspection functions may be provided.

Furthermore, in a system that transports trays carrying items, only a tray incorporating a transport system inspection device according to one embodiment of the present invention may be transported for transport system inspection, or an actual item may be loaded onto the tray incorporating the inspection device and inspected at the same time. In other words, while the item transport system is actually operating, the transport system inspection device according to one embodiment of the present invention can be transported on the same transport route as the item, and the operation of the transport system can be diagnosed, making this a groundbreaking technology that can automatically perform the same function as Doctor Yellow on the Shinkansen.

When the present conveying system inspection device is used for inspections at a logistics center built by the applicant, the control system of the center can be known in advance, and detailed information such as the positional relationship of the photoelectric switches can be accurately known before the inspection. Therefore, the exact positional relationship of the device can be determined using information obtained from these systems. However, at centers built by parties other than the applicant, it is difficult to obtain detailed information about the control system in advance, making it difficult to determine the status of the conveying line in advance. However, in the case of this device, the device itself has sensors such as image, sound, and light, and also has optical measuring devices such as lasers and autonomous positioning technology such as gyros, so the exact positional relationship of the device can be determined by utilizing information obtained from these devices. For this reason, it can be used in various conveying forms, such as roller conveyors, belt conveyors, and tray-type conveying systems such as DCT, and can be used in many logistics centers and airport facilities regardless of location.

As described above, the present invention can be widely used not only in airport baggage handling systems, but also in logistics center handling systems, warehouse management systems, production lines, and other locations that use handling systems, and is expected to make a significant contribution to future logistics management systems.

Although the above explanation focuses on applications to conveyor transport devices, the technology can also be widely applied to different industrial fields, such as inspecting the status of transport paths for automated guided vehicles (AGVs) in port facilities and inspecting the transport paths of automated guided vehicles in large markets such as Toyosu Market in Tokyo. In open space applications, a GPS device can be used as the position detection device in addition to the above-mentioned position detection device.

1...baggage, 2...tray, 3...driving source, 4...conveyor belt, 5...belt guide, 6...guide rail, 7...control unit, 8...transport path position information unit, 9...roller conveyor, 10...transport path position information unit, 21...transported object, 2-0...housing, 3-0...housing, 3-1...acoustic analysis device, 3-2...vibration analysis device, 3-3...image analysis device, 3-4...image analysis device, 3-5...ultrasonic analysis device, 3-6...pressure detection device, 3-7...environment analysis device, 3-8...interface device, 3-9...connection of external device, 3-10...vibration device, 3-11...position detection device, 3-12...information recording device, 3-13...information analysis/processing unit, 3-14...wireless communication device, 3-15...wireless communication device, 3-16...signal analysis device, 3-17...information recording device, 3-20...power supply device, M0 to Mn...microphone, AGC...automatic control circuit, FIL...frequency filter, C1, C2...control line, SB1 to SB5...sensor bay, Y...transport system inspection device

Claims (27)

a sensor attached to a conveyor that can be conveyed along a conveyance path for conveying an article, the sensor acquiring information related to sound ;
an information recording device that is attached to the carrier and records sensor information collected by the sensor;
and an information analysis and processing unit which drives the sensor and the information recording device to transport the transport body along the transport path while continuously recording the sensor information about the transport path or the vicinity of the transport path in the information recording device , applies vibration or impact to necessary locations on the transport path, collects, analyzes and diagnoses the resulting reaction sounds, and recognizes the emission of reaction sounds of a frequency different from normal times or the emission of a peculiar impact sound as a sign of an impending failure . The failure prediction transport system inspection device according to claim 1, characterized in that the information analysis and processing unit determines signs of a failure occurring in the transport path based on the sensor information collected from the sensor. The transport body is transported on the transport path in which actual work related to transporting items is in progress,
The failure prediction transport system inspection device according to claim 2, characterized in that the information analysis/processing unit compares the sensor information collected from the sensor with second sensor information previously recorded in the information recording device, determines signs of a failure occurring in the transport path, and records information related to the determined signs of a failure occurring in the information recording device. The failure prediction transportation system inspection device further includes a communication unit for transmitting and receiving information to and from an external device,
4. The failure prediction transportation system inspection device according to claim 2, further comprising a control unit that controls the communication unit so as to transmit information related to the determined failure occurrence symptom to an outside. The failure prediction transportation system inspection device further includes a communication unit for transmitting and receiving information to and from an external device,
The information analysis and processing unit transmits the sensor information collected from the sensor to an external analysis device via the communication unit,
2. The failure prediction transportation system inspection device according to claim 1, wherein the information analysis/processing unit controls the communication unit so as to receive failure occurrence symptom information from the external analysis device. a position detection device that detects a position of the transport body on the transport path or in the vicinity of the transport path;
2. The failure prediction transportation system inspection device according to claim 1, wherein the information analysis/processing unit associates the sensor information with position information detected by the position detection device and records it chronologically in the information recording device. The failure prediction transport system inspection device according to claim 6, characterized in that a gyrocompass and an accelerometer are used as the position detection device. The failure prediction transport system inspection device according to claim 6, characterized in that an RF-ID reader is used as the position detection device. The failure prediction transport system inspection device according to claim 6, characterized in that an image analysis device is used as the position detection device. The communication unit receives control information from an external device for controlling the information analysis and processing unit,
5. The failure prediction transport system inspection device according to claim 4, wherein the information analysis and processing unit causes the sensor to obtain the sensor information based on the control information received by the communication unit. The failure prediction transport system inspection device according to claim 10, characterized in that the control information includes sensor information acquisition criteria information relating to the information acquisition criteria for acquiring the sensor information. the sensor information acquisition standard information includes information that specifies a threshold level set for each type of the sensor at each predetermined position on the transport path,
12. The failure prediction transportation system inspection device according to claim 11, wherein the information analysis/processing unit records the sensor information in the information recording device and transmits the sensor information to the outside when the sensor information exceeds the threshold level. A conveying path for conveying an article;
a sensor attached to a carrier that can be transported on the transport path and that acquires information related to sound ;
an information recording device that records sensor information collected from the sensor;
an information analysis and processing unit which drives the sensor and the information recording device to transport the transport body along the transport path while continuously recording the sensor information about the transport path or the vicinity of the transport path in the information recording device , applies vibration or impact to necessary locations on the transport path, collects, analyzes and diagnoses the reaction sounds, and judges the indication of the occurrence of a failure of the transport path based on the sensor information when a reaction sound having a frequency different from that in normal times or a peculiar impact sound is generated ;
A transport system comprising: The transport body is transported on the transport path in which actual work related to transporting items is in progress,
The conveying system according to claim 13, characterized in that the information analysis/processing unit compares the sensor information collected from the sensor with second sensor information previously recorded in the information recording device, determines signs of a malfunction in the conveying path, and records information relating to the determined signs of a malfunction in the information recording device. The transport system further includes a communication unit that transmits and receives information to and from an external device,
15. The transport system according to claim 13, wherein the information analysis/processing unit controls the communication unit so as to transmit information relating to the determined failure occurrence symptom to an outside source. The transport system further includes a communication unit that transmits and receives information to and from an external device,
The information analysis and processing unit transmits the sensor information collected from the sensor to an external analysis device via the communication unit,
The transportation system according to claim 13 , wherein the information analysis/processing unit controls the communication unit so as to receive failure occurrence symptom information from the external analysis device. a position detection device that detects a position of the transport body on the transport path or in the vicinity of the transport path;
14. The transport system according to claim 13, wherein the information analysis and processing unit causes the sensor information to be associated with position information detected by the position detection device and to be recorded chronologically in the information recording device. The position detection device is
18. The conveying system according to claim 17, further comprising: an RF-ID tag provided at a predetermined point along the conveying path or near the conveying path; and an RF-ID reader provided on the conveying body. The position detection device is
an optical marker provided at a predetermined point on the conveying path or near the conveying path;
The conveying system according to claim 17 , further comprising: an image analyzing device provided on the conveying body and having a function of reading the optical marker. The position detection device is
A transport path configuration diagram recorded in the information recording device;
The conveying system according to claim 17, further comprising: a means for detecting a position on the conveying path by at least one of a specific sound, a vibration, and an impact associated with a predetermined point included in the conveying path configuration diagram. The communication unit receives control information from an external device for controlling the information analysis and processing unit,
16. The transport system according to claim 15, wherein the information analysis and processing section causes the sensor to obtain the sensor information based on the control information received by the communication section. The transport system according to claim 21, characterized in that the control information includes sensor information acquisition criteria information relating to information acquisition criteria for acquiring the sensor information. A threshold level is set for each type of the sensor at each predetermined position of the transport path,
The sensor information acquisition standard information includes information that defines the threshold level,
23. The transportation system according to claim 22, wherein the information analysis and processing unit records the sensor information in the information recording device and transmits the sensor information to the outside when the sensor information exceeds the threshold level. The carrier includes at least
A first entity that functions as an information collecting device for acquiring the sensor information by the sensor;
The conveying system according to any one of claims 13 to 23, wherein a second body functions as an information analysis and processing unit that determines a sign of a failure occurring in the conveying path based on the sensor information acquired by the first body, and the second body is configured as a separate body. The transport system of claim 24, wherein the information analysis and processing unit includes a personal computer and analysis software. The conveying system according to claim 24 or 25, wherein the information analysis and processing unit compares information from each sensor when the conveying path is not normal with information from each sensor when the conveying path is operating normally. The conveying system according to any one of claims 24 to 26, wherein the information analysis/processing unit is equipped with application software that utilizes artificial intelligence (AI).

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