JP7693603B2 - Method for controlling an automatic conveyor - Google Patents

Description

This disclosure relates to a method for controlling an automatic conveyor, and in particular to a method for controlling an automatic conveyor in a vehicle production line.

There is a technology to control the travel of an automated transport vehicle. The automated transport vehicle travels, for example, along a magnetic tape installed on the floor surface, under the travel control of a control device. The automated transport vehicle, for example, tows or mounts a dolly loaded with luggage, and transports it to a specified destination.

Such automatic conveying machines are also used in vehicle production lines. In vehicle production lines, the travel of multiple automatic conveying machines equipped with carts is controlled collectively, making it possible to carry out multiple consecutive processes. Specifically, an object to be conveyed is placed on the cart mounted on each automatic conveying machine, and when a worker finishes one process of work on the object, the automatic conveying machine is moved to another worker, who then moves on to the next process.

Patent Document 1 discloses the following technology for a method of controlling an automatic conveying machine. An image capturing unit arranged to correspond to the operating area of the automatic conveying machine captures an image of a dolly moving along with the automatic conveying machine, and the state of the dolly is acquired based on the captured image. The state of the dolly that has been acquired is then judged, and the travel of the automatic conveying machine is controlled based on the result of this judgment.

JP 2019-139549 A

However, the method for controlling an automatic conveying machine described in Patent Document 1 performs shape recognition only at the starting point and waypoints of the automatic conveying machine, and is therefore unable to grasp the relative positions of multiple automatic conveying machines. Here, in a vehicle production line, multiple automatic conveying machines travel along a route, so it is necessary to grasp the relative positions of each automatic conveying machine. Therefore, this type of control method for an automatic conveying machine is unsuitable as a control method for an automatic conveying machine in a vehicle production line.

The present disclosure therefore aims to provide a method for controlling an automatic conveying machine that reduces the costs required in advance and controls the travel of multiple automatic conveying machines that are arranged in succession on a continuous process path.

The method of controlling an automatic conveying machine according to the present disclosure is a method of controlling a plurality of automatic conveying machines, each of which is mounted with a cart, that are successively arranged on a continuous process path, and that uses an aerial camera to capture a part or all of the continuous process path on which the plurality of automatic conveying machines are arranged, recognizes the shape of the frame of the cart mounted on the automatic conveying machine, identifies a reference point for the cart from the recognized shape of the frame, detects the position of the reference point on a map, and controls the travel of the plurality of automatic conveying machines based on the detected position of the reference point.

Here, the reference point of the cart may be the center point of the cart, and the position of the center point on the map may be detected, and the travel of the multiple automated conveyors may be controlled based on the detected position of the center point.

The cart may also have a frame portion that is colored along its outer edge, the frame portion may be photographed by the aerial camera, the shape of the frame portion may be recognized based on the photographed image, a virtual shape of the frame portion may be created from the recognized shape of the frame portion, and the reference point may be calculated based on the virtual shape of the frame portion that has been created.

In addition, a virtual area that includes the carts may be created based on the reference point, and when multiple virtual areas overlap while the multiple automated conveying vehicles are traveling, the multiple automated conveying vehicles may be stopped from traveling.

The aerial camera may be composed of multiple cameras, and the shooting ranges of the multiple cameras may overlap each other in part in a direction along the continuous process path.

The present disclosure provides a method for controlling an automatic conveying machine that reduces the costs required in advance and controls the travel of multiple automatic conveying machines that are arranged in succession on a continuous process path.

FIG. 1 is a diagram conceptually illustrating a configuration of a control system according to a first embodiment. FIG. 1 is a diagram conceptually illustrating a configuration of a control system according to a first embodiment. FIG. 2 is a diagram illustrating an example of control by the control system according to the first embodiment. FIG. 2 is a diagram illustrating an example of control by the control system according to the first embodiment. 4 is a flowchart showing an example of control by the control system according to the first embodiment; FIG. 2 is a diagram illustrating an example of control by the control system according to the first embodiment. FIG. 2 is a diagram illustrating an example of control by the control system according to the first embodiment. 4 is a flowchart showing an example of control by the control system according to the first embodiment; FIG. 11 is a diagram illustrating an example of control by a control system according to a second embodiment. 4 is a flowchart showing an example of control by the control system according to the first embodiment; 4 is a flowchart showing an example of control by the control system according to the first embodiment;

Although not publicly disclosed, a related technology filed by the applicant of the present application is a technology in which a marker capable of detecting the position is placed on a cart, a transported object, or an automatic transport machine, and the travel of the automatic transport machine is controlled by detecting the position using the marker. However, in order to control the travel of multiple automatic transport machines, it is necessary to place a marker on each cart, transported object, and automatic transport machine, which requires labor to place the markers and costs for the parts of the markers themselves. This led the inventor to conceive of the technology disclosed herein.

First embodiment
Hereinafter, the first embodiment will be described with reference to the drawings. FIGS. 1 and 2 are explanatory diagrams conceptually illustrating the configuration of an automatic conveying machine control system 1 according to the first embodiment. FIG. 1 illustrates a plan view of a part of a vehicle production line, and illustrates the configuration of the automatic conveying machine control system 1 as a block diagram. FIG. 2 illustrates a side view of a part of a vehicle production line, and illustrates the configuration of the automatic conveying machine control system 1 as a block diagram. As shown in FIGS. 1 and 2, the automatic conveying machine control system 1 (hereinafter referred to as the control system 1) includes an aerial camera 11, a control device 12, a travel control panel 13, and a wireless transceiver 14. The vehicle production line includes a continuous process path 21, a plurality of automatic conveying machines 22, and a plurality of carts 23. In this embodiment, the continuous process path 21 is actually designed as a loop path including a straight portion and a curved portion in a plan view, as shown in FIG. 3. 1 and 2 show a part of a vehicle production line, and the photographing range of an aerial camera 11 and the arrangement of a plurality of automatic carriers 22 and the like are explained by replacing them with a linear arrangement.

First, the configuration of the vehicle production line will be described. The continuous process path 21 is a path designed to carry out continuous work processes in the vehicle production line. The continuous process path 21 constitutes the travel path of the automatic conveyor 22. The continuous process path 21 is, for example, a magnetic tape installed on the floor surface. The continuous process path 21 is designed appropriately depending on the work content in the continuous work process, the size of the work area, and other circumstances. As shown in Figure 3, the continuous process path 21 is designed, for example, as a circular path including straight and curved sections in a plan view.

The automatic conveying machine 22 has a built-in wireless transceiver and receives commands from the travel control panel 13 via the wireless transceiver 14. The automatic conveying machine 22 performs operations such as traveling, stopping, and pausing on the continuous process path 21 based on the received commands. Each automatic conveying machine 22 is assigned, for example, an identification number that is different from other units, and is configured to be able to individually receive commands from the travel control panel 13. As shown in FIG. 3, for example, six automatic conveying machines 22 are arranged on the continuous process path 21. In FIG. 3, the six automatic conveying machines 22 are shown as 22a to 22f. Note that FIG. 1 shows three automatic conveying machines 22a, 22b, and 22c, and FIG. 2 shows two automatic conveying machines 22a and 22b.

The dolly 23 is configured to be able to carry an object to be transported. The dolly 23 is mounted on each automatic conveying machine 22. Here, the dolly 23 is connected to each automatic conveying machine 22. The dolly 23 carries an object to be transported (not shown) and moves on the continuous process path 21 as the automatic conveying machine 22 travels. The dolly 23 has a frame portion 231 provided along the outer edge and colored so as to be recognizable by the aerial camera 11 and the control device 12. The dolly 23 is formed, for example, in a rectangular shape in a plan view. In FIG. 3, the dollies 23 mounted on each automatic conveying machine 22 are shown as 23a to 23f. FIG. 1 shows dollies 23a, 23b, and 23c mounted on the automatic conveying machines 22a, 22b, and 22c, and FIG. 2 shows dollies 23a and 23b mounted on the automatic conveying machines 22a and 22b. Additionally, the frame portions 231 corresponding to the carts 23a, 23b, and 23c are shown as 231a, 231b, and 231c, respectively. In FIG. 3, the illustration of the frame portions 231 is omitted.

Next, the components of the control system 1 will be described with reference to Figs. 1 to 4. Fig. 3 is a plan view of a vehicle production line, showing an example of control by the control system 1. Fig. 4 is a plan view of one automatic conveyor 22 and a cart 23, showing an example of control by the control system 1.

The aerial camera 11 photographs part or all of the continuous process path 21. The aerial camera 11 photographs the continuous process path 21 and the multiple automatic conveyors 22 or multiple carts 23 arranged on the continuous process path 21 from above. The aerial camera 11 is installed, for example, on a ceiling or a pillar. The aerial camera 11 outputs the photographed image to the control device 12.

The aerial camera 11 is, for example, composed of a plurality of cameras. The plurality of cameras are arranged so that their respective shooting ranges overlap in a direction along the continuous process path 21. As a specific example, as shown in FIG. 3, the aerial camera 11 is composed of a first camera 111, a second camera 112, a third camera 113, and a fourth camera 114. The shooting ranges of the first camera 111, the second camera 112, the third camera 113, and the fourth camera 114 are indicated by the dashed lines in FIG. 3 as the first shooting range 111a, the second shooting range 112a, the third shooting range 113a, and the fourth shooting range 114a, respectively, with the respective symbols. As shown by the dashed lines in FIG. 3, the shooting ranges 111a to 114a overlap in a portion with each other in a direction along the continuous process path 21. As shown in FIG. 3, the cameras 111 to 114 are arranged so that, for example, each is adjacent to two different cameras. The shooting ranges 111a to 114a overlap each other partially in the direction along the continuous process path 21 at least at each position of the straight and curved portions of the continuous process path 21.

The control device 12 includes a map construction unit 121, an operation setting unit 122, a frame recognition unit 123, a reference point detection unit 124, a virtual area creation unit 125, a storage unit 126, and an operation control unit 127. The control device 12 is configured to be able to acquire and output various information related to the travel control of multiple automatic conveyors 22.

The map construction unit 121 constructs a map of the continuous process. The map is a virtual map created in a plan view that shows the area in the vehicle production line where the continuous process is performed. The map shows the entire area where the automatic conveyor 22 runs and the worker works. The map includes a part or all of the continuous process path 21. In the present embodiment 1, the map construction unit 121 creates a map that includes the entire continuous process path 21. The area shown on the map is set as a section in the continuous process path 21 that controls the running of the multiple automatic conveyors 22. The map construction unit 121 acquires images taken by the aerial camera 11 and constructs a map based on the acquired images. When the aerial camera 11 is composed of multiple cameras, the map construction unit 121 acquires and combines multiple images taken by the multiple cameras to construct a map.

The operation setting unit 122 sets the line operation settings for safe distances and abnormal distances. For example, the operation setting unit 122 sets the travel and temporary stop distances of multiple automatic conveyors 22 based on the travel distance required for one process in the vehicle production line and the size of the carts 23.

The frame recognition unit 123 recognizes the shape of the frame 231 of the trolley 23. For example, the frame recognition unit 123 performs image processing to extract the frame 231 of each trolley 23 from an image captured by the aerial camera 11. The frame recognition unit 123 creates a two-dimensional virtual shape of the frame 231 on the control device based on the image of the extracted frame 231. For example, the frame recognition unit 123 creates a virtual rectangle that corresponds to the shape of the frame 231 of the trolley 23.

The reference point detection unit 124 identifies the reference point 232 of the trolley 23 based on the frame shape of the trolley 23 recognized by the frame recognition unit 123. The reference point detection unit 124 also detects the position of the reference point 232 on the map. The reference point detection unit 124, for example, reads the shape of the virtual frame 231 created by the frame recognition unit 123 and calculates one point of the shape to identify the reference point 232 of the trolley 23. As shown in Figures 1 and 2, the reference point detection unit 124 detects, for example, the center point of the virtual rectangle created by the frame recognition unit 123 as the reference point 232. That is, in this embodiment, the reference point 232 of the trolley 23 is the center point of the trolley 23. The reference points 232 corresponding to the trolleys 23a to 23f are shown as 232a to 232f, respectively. In Figures 1 and 2, the reference points 232 corresponding to the carts 23a, 23b, and 23c are shown as 232a, 232b, and 232c, respectively.

The virtual area creation unit 125 creates a virtual area 233 that includes the cart 23. The virtual area 233 is, for example, a virtual area that is set to ensure safety around the automatic conveyor 22 on which the cart 23 is mounted. The size of the virtual area 233 is appropriately determined in consideration of the safety of workers who enter the continuous process path 21, and in accordance with circumstances such as the distance to be secured between the multiple carts 23. The virtual area creation unit 125 creates a virtual area 233 of a predetermined size that is larger than the frame shape of the frame portion 231 created by the frame portion recognition unit 123, for example, based on the reference point 232 of the cart 23 detected by the reference point detection unit 124. The virtual area creation unit 125 creates a virtual area 233 of a predetermined size that is larger than the frame portion 231 in both the short side direction and the long side direction, centered on the reference point 232. In FIG. 3, the virtual areas 233 corresponding to the carts 23a to 23f are shown as 233a to 233f, respectively.

The memory unit 126 stores various information used to control the multiple automatic conveyors 22. For example, the memory unit 126 stores information on the line operation settings made by the operation setting unit 122.

The operation control unit 127 controls the operation of multiple automated conveyors 22 that exist within the map constructed by the map construction unit 121. The operation control unit 127 links the cart 23 that detected the reference point 232 or created the virtual area 233 with the automated conveyor 22 that carries the cart 23, and stores this in the memory unit 126. The operation control unit 127 controls the running and stopping of each automated conveyor 22 based on various information such as line operation settings stored in the memory unit 126.

The operation control unit 127 also manages the distance between each of the trolleys 23 based on information on the reference point 232 of each of the trolleys 23. The operation control unit 127 ensures the work process range by managing the distance between each of the trolleys 23. As a specific example, as shown by the arrow in FIG. 1, the operation control unit 127 controls the operation of each of the automatic conveyors 22 via the travel control panel 13 so that the distance between the reference point 232 of one trolley 23 and the reference point 232 of another adjacent trolley 23 is always a constant distance on the continuous process path 21. Furthermore, when one virtual area 233 created by the virtual area creation unit 125 overlaps with another virtual area 233, the operation control unit 127 controls the operation of all of the automatic conveyors 22 via the travel control panel 13 to stop.

The travel control panel 13 outputs a command to each automated conveyor 22 to drive or stop based on the control by the operation control unit 127. The travel control panel 13 transmits a command to drive or stop to the wireless transceiver 14. The travel control panel 13 outputs an individual command corresponding to the individual identification number assigned to each automated conveyor 22.

The wireless transceiver 14 transmits and receives wireless signals to and from the automated conveyors 22. The wireless transceiver 14 transmits commands received from the travel control panel 13 to each automated conveyor 22. The wireless transceiver 14 may be configured to be built into the travel control panel 13.

Next, a specific method for controlling multiple automatic conveyors 22 by the control system 1 will be described with reference to Figures 3 to 8. First, a flow from the stage of constructing a map of a continuous process to the stage before the operation of the automatic conveyors 22 will be described with reference to Figures 3 to 5. Figure 5 is a flowchart showing an example of control by the control system 1.

First, the control device 12 uses the map construction unit 121 to construct a map of the continuous process based on the images acquired by the aerial camera 11 (step S301). As an example, as shown in Figures 3, 6, and 7, four images are acquired by cameras 111 to 114 (not shown), and the largest area formed by combining the four images is constructed as a map. Next, the control device 12 executes line operation settings for the constructed map (step S302).

Next, the control device 12 recognizes the shapes of the frames 231a to 231f of each of the trolleys 23a to 23f from the images acquired by the cameras 111 to 114 using the frame recognition unit 123 (step S303). The control device 12 also creates two-dimensional virtual shapes of the frames 231a to 231f. Next, the control device 12 reads the shapes of the created frames 231a to 231f using the reference point detection unit 124, and detects the reference points 232a to 232f of each of the trolleys 23a to 23f (step S304).

Next, the control device 12 uses the virtual area creation unit 125 to create virtual areas 233a to 233f that include each of the carts 23a to 23f (step S305). Next, the control device 12 links the carts 23a to 23f with the information of the automatic conveyors 22a to 22f that correspond to the carts 23a to 23f (step S306), and ends the process as a preliminary step to operating the automatic conveyor 22.

Next, the flow of operation control of multiple automatic conveyors 22 by the control system 1 will be described with reference to Figures 6 to 8. Figures 6 and 7 are plan views of a vehicle production line, showing an example of control by the control system 1. Figure 8 is a flowchart showing an example of control by the control system 1.

First, the control device 12 determines whether an operation enable command has been output by the operation control unit 127 (step S311). If an operation enable command has not been output (NO in step S311), the control device 12 waits for the output of the operation enable command. If an operation enable command has been output (YES in step S311), the process proceeds to the next step. Next, the travel control panel 13 performs a process of transmitting an operation command from the control device 12 via the wireless transceiver 14, and operates the automatic conveyor 22 (step S312). Here, the multiple automatic conveyors 22 perform operations such as moving forward or pausing, as indicated by the arrows in FIG. 6, based on the operation settings stored in the memory unit 126.

Next, the control device 12 determines whether multiple virtual areas 233 overlap (step S313). As shown in FIG. 7, if it is determined that multiple virtual areas 233 overlap (YES in step S313), the travel control panel 13 transmits a stop instruction from the control device 12 via the wireless transceiver 14 (step S314), stops the multiple automated conveyors 22 (step S315), and ends the process. If the control device 12 determines that multiple virtual areas 233 do not overlap (NO in step S313), it returns to step S311 and continues to determine whether to output an operation enable command.

As described above, the control system 1 recognizes the shape of the frame 231 of each cart 23, and creates a virtual frame shape based on the recognized shape of the frame 231. The control system 1 also detects the reference point 232 of each cart 23 from the created virtual frame shape. The control system 1 then controls the travel of the corresponding multiple automatic conveyors 22 based on the relationship between the detected reference points 232 of each cart 23. Therefore, the control system 1 can control the travel of multiple automatic conveyors 22 that are arranged in succession on a vehicle production line without incurring the cost of placing markers on the carts 23 or the conveyed object in advance. Such a control system 1 reduces the cost required in advance and can control the travel of multiple automatic conveyors 22 that are arranged in succession on a continuous process path.

In addition, the control system 1 detects the center point of each cart 23 as the reference point 232 of each cart 23, and therefore the control device 12 can constantly monitor the reference point 232 of each cart 23 and control the travel of the automated conveyor 22 so that the multiple carts 23 maintain a safe distance. In other words, the control system 1 can appropriately manage the distance between each cart 23 in a continuous work process.

The control system 1 also photographs the frame 231 that is colored along the outer edge of the cart 23, and recognizes the shape of the frame 231 based on the photographed image. This allows the control system 1 to recognize the shape of the frame 231 without being obstructed by an object to be transported, even when the object is placed on the cart 23.

The control system 1 also creates a virtual area 233 that includes each of the trolleys 23 based on the detected reference points 232. If the multiple virtual areas 233 overlap while the multiple automated conveyors 22 are traveling, the control system 1 stops the traveling of the multiple automated conveyors 22. This allows the control system 1 to prevent the multiple trolleys 23 from approaching each other too closely, and to operate the automated conveyors 22 while ensuring the safety of the workers. The created virtual area 233 can also be used for other control purposes, such as automatically stopping the traveling of the corresponding automated conveyor 22 when the virtual area 233 enters a previously set area.

In addition, the control system 1 configures the aerial camera 11 with multiple cameras 111 to 114. The multiple cameras 111 to 114 also have their shooting ranges 111a to 114a partially overlapping in the direction along the continuous process path 21. This allows the aerial camera 11 to supplement the shooting of a trolley 23 in a position where it is difficult to capture it with one camera due to an obstruction or the like, with another camera. In other words, the aerial camera 11 can continuously capture the multiple trolleys 23 moving along the continuous process path 21 while avoiding the influence of obstructions or the like. Therefore, the control system 1 can improve the accuracy of detecting the position of the trolley 23.

Embodiment 2
Hereinafter, the control system 1A of the automatic conveyor according to the second embodiment will be described with reference to the drawings. The same components as those of the control system 1 according to the first embodiment are denoted by the same reference numerals, and detailed description thereof will be omitted. FIG. 9 is a plan view of a part of a vehicle production line, showing an example of control by the control system 1A of the automatic conveyor. The control system 1A of the automatic conveyor (hereinafter referred to as the control system 1A) includes an aerial camera 11, a control device 12, a travel control panel 13, and a wireless transceiver 14. The vehicle production line also includes a continuous process path 21 further including a starting point 21a, a plurality of automatic conveyors 22, and a plurality of carts 23. That is, the control system 1A differs from the control system 1 in that the starting point 21a is provided on the continuous process path 21, and that the control method by the control device 12 differs according to the setting of the starting point 21a.

The starting point 21a is a point on the continuous process path 21 where the control device 12 starts to control the automatic conveyor 22 to perform a continuous work process. As shown in FIG. 9, the starting point 21a is provided at any position on the continuous process path 21 where it is desired to start controlling the travel of the multiple automatic conveyors 22. The starting point 21a is, for example, a mark that can be detected by the control device 12. The starting point 21a is provided within the shooting range of the aerial camera 11. The starting point 21a is provided, for example, at a position included in the shooting range of the first camera 111, which is one of the multiple cameras that make up the aerial camera 11.

A specific method for controlling multiple automatic conveyors 22 by the control system 1A will be described using Figures 9 to 11. First, the process before the automatic conveyor 22 passes the starting point 21a will be described using Figures 9 and 10. Figure 10 is a flowchart showing an example of control by the control system 1A, and shows the process before the automatic conveyor 22 passes the starting point 21a.

First, the control device 12 uses the map construction unit 121 to construct a map of the continuous process based on the images acquired by the aerial camera 11 (step S321). As an example, as shown in FIG. 9, two images are acquired by the first camera 111 and the second camera 112 (not shown), and the largest area constructed by combining the two images is constructed as a map. Next, the control device 12 executes line operation settings in the constructed map (step S322), and ends the process as a preliminary step before the automatic conveyor 22 passes the starting point 21a.

Next, the processing after the automatic conveyor 22 enters the starting point 21a will be described with reference to Figures 9 and 11. Figure 11 is a flowchart showing an example of control by the control system 1A, and shows the processing after the automatic conveyor 22 passes the starting point 21a.

First, the control device 12 determines whether the cart 23 mounted on the automatic conveyor 22 has passed the starting point 21a (step S331). If the control device 12 determines that the cart 23 has not passed the starting point 21a (NO in step S331), it waits for the cart 23 to pass the starting point 21a. If the control device 12 determines that the cart 23 has passed the starting point 21a (YES in step S331), it proceeds to the next step.

Next, the control device 12 recognizes the shape of the frame 231 of the cart 23 that has passed the starting point 21a from the image acquired by the first camera 111 using the frame recognition unit 123 (step S332). The control device 12 also creates a two-dimensional virtual shape of the frame 231. Next, the control device 12 reads the shape of the created frame 231 using the reference point detection unit 124, and detects the reference point 232 of the cart 23 (step S333).

Next, the control device 12 creates a virtual area 233 that includes the cart 23 by using the virtual area creation unit 125 (step S334). Next, the control device 12 links the cart 23 with information on the automatic conveyor 22 corresponding to the cart 23 (step S335). Note that the series of processes shown in steps S332 to S335 are executed for the cart 23 each time the cart 23 passes the starting point 21a. For example, as shown in FIG. 9, after the series of processes shown in steps S332 to S335 are executed for the cart 23b, if the cart 23a newly passes the starting point 21a, the series of processes shown in steps S332 to S335 are executed for the cart 23a. Then, the carts 23a and 23b become targets for the execution of the following processes by the control device 12.

Next, the control device 12 performs operations such as moving forward or pausing as indicated by the arrows in FIG. 9 on one or more automated conveyors 22 based on operation commands from the operation control unit 127 and the operation settings stored in the memory unit 126 (step S336). Here, the operation of each of the multiple automated conveyors 22 is controlled by the operation control unit 127 so that the distance between the reference point 232 of one cart 23 and the reference point 232 of another adjacent cart 23 is always a safe distance on the continuous process path 21.

Next, the control device 12 determines whether multiple virtual areas 233 overlap (step S337). If it is determined that multiple virtual areas 233 overlap (YES in step S337), the travel control panel 13 performs processing to transmit a stop instruction from the control device 12 via the wireless transceiver 14, stops the multiple automated conveyors (step S338), and ends the processing. If the control device 12 determines that multiple virtual areas 233 do not overlap (NO in step S337), the process returns to step S336 and continues operating the automated conveyor 22.

As described above, the control system 1A recognizes the shape of the frame 231 of each cart 23 that has passed the starting point 21a, and creates a virtual frame shape based on the recognized shape of the frame 231. The control system 1A also detects the reference point 232 of each cart 23 from the created virtual frame shape. The control system 1 then controls the travel of the corresponding multiple automatic conveyors 22 based on the relationship between the detected reference points 232 of each cart 23. Therefore, the control system 1A can control the travel of multiple continuous automatic conveyors 22 in a vehicle production line without incurring the cost of placing markers on the carts 23 or the conveyed object in advance. Such a control system 1A reduces the cost required in advance and can control the travel of multiple automatic conveyors 22 that are arranged in succession on a continuous process path.

That is, the control system 1A controls the travel of multiple automatic conveyors 22 arranged in succession in a portion of the continuous process path 21, and achieves the same effect as the control system 1 described in embodiment 1. The control system 1A can be applied to any section of a vehicle production line where it is desired to control the travel of multiple automatic conveyors 22 arranged in succession to perform continuous work processes.

Note that the present invention is not limited to the above embodiment, and can be modified as appropriate without departing from the spirit of the present invention. For example, in the above embodiment, the map construction unit 121 constructs the largest area photographed by the aerial camera 11 as a map, but a part of the photographed area may be constructed as a map. The map is constructed as an area requiring control of the automatic conveyor 22 in the continuous work process, and the range can be set as appropriate. In other words, the map constructed by the map construction unit 121 is set as appropriate depending on the design of the continuous process path, the photographing range of the aerial camera 11, and the section in which control of the automatic conveyor 22 is desired. As an example, in the first embodiment, the entire continuous process path 21 is the subject of map construction, but only a part of the continuous process path 21 may be the subject of map construction.

Although an example has been described in which the aerial camera 11 is configured with multiple cameras 111 to 114, this is not limiting. The number of cameras that configure the aerial camera 11 and the shooting range can be set appropriately as long as they can capture multiple trolleys 23 in the section where control of the automatic transporter 22 is desired. However, in order to avoid the influence of obstructions and the like and to continuously capture the trolleys 23, it is preferable that the aerial camera 11 is configured with multiple cameras with partially overlapping shooting ranges.

In addition, while an example of a method for recognizing the shape of the cart 23 is described above in which the shape of the colored frame 231 is recognized, this is not limiting. The method for recognizing the shape of the cart 23 can be changed as appropriate as long as the shape of the cart 23 can be recognized with the transported object placed on it and the reference point 232 can be detected based on the recognized shape of the cart 23. However, according to the above-mentioned method, the shape of the cart 23 can be recognized with a simple configuration, and the cost required in advance can be reduced.

Although an example has been described in which the center point of the trolley 23 is used as the reference point 232, this is not limiting. The reference point 232 may be any point on the recognized shape of the trolley 23 as long as it can identify the positional relationship between the multiple trolleys 23 by the control device 12 and function as a reference for creating the virtual area 233. For example, one corner of the trolley 23 may be used as the reference point.

In the above-described embodiment, the control system 1 or the control system 1A is applied to a vehicle production line, but the present invention is not limited to this. The control systems 1 and 1A can also be used when producing products other than vehicles. In other words, the control systems 1 and 1A can be applied in any environment that requires control of the travel of multiple continuous automatic conveyors 22 carrying carts 23.

Each component in the above-described embodiments may be configured with hardware or software, or both, and may be configured with one piece of hardware or software, or may be configured with multiple pieces of hardware or software. The functions (processing) of each device may be realized by a computer having a CPU (Central Processing Unit), memory, etc. For example, a program for performing a method in the embodiment (e.g., a control method) may be stored in a storage device, and each function may be realized by executing the program stored in the storage device with a CPU.

These programs can be stored and supplied to a computer using various types of non-transitory computer readable media. Non-transitory computer readable media include various types of tangible storage media. Examples of non-transitory computer readable media include magnetic recording media (e.g., flexible disks, magnetic tapes, hard disk drives), magneto-optical recording media (e.g., magneto-optical disks), CD-ROMs (Read Only Memory), CD-Rs, CD-R/Ws, and semiconductor memories (e.g., mask ROMs, PROMs (Programmable ROMs), EPROMs (Erasable PROMs), flash ROMs, and RAMs (random access memories)). The programs may also be supplied to a computer by various types of transitory computer readable media. Examples of transitory computer readable media include electrical signals, optical signals, and electromagnetic waves. The transitory computer readable media can supply the programs to a computer via wired communication paths such as electric wires and optical fibers, or wireless communication paths.

1, 1A Control system 11 Aerial camera 12 Control device 13 Travel control panel 14 Wireless transceiver 21 Continuous process path 21a Start point 22 Automatic transporter 23 Cart 111 First camera 111a First shooting range 112 Second camera 112a Second shooting range 113 Third camera 113a Third shooting range 114 Fourth camera 114a Fourth shooting range 121 Map construction unit 122 Operation setting unit 123 Frame recognition unit 124 Reference point detection unit 125 Virtual area creation unit 126 Memory unit 127 Operation control unit 231 Frame 232 Reference point 233 Virtual area

Claims (5)

A method for controlling a plurality of automatic conveyors each having a carriage mounted thereon, the method comprising the steps of:
An aerial camera is used to photograph a part or all of a continuous process path on which the plurality of automatic conveyors are arranged;
Recognizing a shape of a frame portion of the carriage mounted on the automatic conveying machine;
Identifying a reference point of the cart from the recognized shape of the frame portion;
Detecting the location of the reference point on a map;
controlling travel of the plurality of automated conveyors based on the detected positions of the reference points;
A method for controlling an automatic conveyor. The reference point of the carriage is a center point of the carriage,
locating the center point on the map;
controlling travel of the plurality of automated conveyors based on the detected positions of the center points;
A method for controlling an automatic conveyor according to claim 1. The cart has the frame portion colored along an outer edge,
The frame portion is photographed by the aerial camera,
Recognizing the shape of the frame portion based on the captured image;
creating a virtual shape of the frame portion from the recognized shape of the frame portion;
Calculating the reference point based on the created virtual shape of the frame portion;
3. A method for controlling an automatic conveying machine according to claim 1 or 2. creating a virtual area that includes the cart based on the reference point;
when a plurality of the virtual areas overlap while the plurality of the automatic conveying machines are traveling, the traveling of the plurality of the automatic conveying machines is stopped.
A method for controlling an automatic conveying machine according to any one of claims 1 to 3. The aerial camera is composed of a plurality of cameras,
The photographing ranges of the plurality of cameras partially overlap each other in a direction along the continuous process path.
A method for controlling an automatic conveying machine according to any one of claims 1 to 4.

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