1. Field of the Invention
The present invention relates to a system of transport vehicles and to charging transport vehicles, and more specifically relates to charging transport vehicles in a system where the transport vehicles travel using an electric storage device as a power source.
2. Description of the Related Art
A rechargeable secondary battery has been mounted on an overhead travelling vehicle, a rail-guided vehicle or an automated transport vehicle as an on-vehicle power source. Regarding this aspect, JPH05-207611A proposes that a battery of an overhead travelling vehicle is exchanged by a battery exchanger. For a transport vehicle system using a secondary battery, it is necessary not only to manage the residual capacity of an electric storage device, but also to minimize the drop in operation efficiency of transport vehicles by performing charging in a short time.
Preferred embodiments of the present invention provide a system that charges an electric storage device of a transport vehicle in a short time without an excessive facility.
A transport vehicle system according to a preferred embodiment of the present invention causes a plurality of transport vehicles to travel under control of a ground controller with electric storage devices in the transport vehicles as power sources along a predetermined travelling route, the system including chargers provided with rectifiers arranged to rectify alternate current into direct current, electric storage devices in the chargers charged by the rectifiers, and charging couplers arranged to charge the electric storage devices in the transport vehicles and disposed in a plurality of locations along the travelling route; the transport vehicles include communication units that report positions of the transport vehicles and residual capacities of the electric storage devices in the transport vehicles to the ground controller; and the ground controller includes a charging management unit that selects a transport vehicle in need of charging in accordance with the residual capacities of the electric storage devices in the transport vehicles and the positions of the transport vehicles, selects and specifies a charging coupler for the selected transport vehicle, and performs control so that the selected transport vehicle stops at the specified charging coupler and charges the electric storage device in the selected transport vehicle from the electric storage device in a charger via the specified charging coupler.
A charging method for transport vehicles according to another preferred embodiment of the present invention causes a plurality of transport vehicles travel under control of a ground controller, with electric storage devices in the transport vehicles as power sources, along a predetermined travelling route, the system further includes chargers provided with rectifiers arranged to rectify alternate current into direct current, electric storage devices in the chargers charged by the rectifiers, and charging couplers arranged to charge the electric storage devices in the transport vehicles, wherein the chargers are disposed in a plurality of locations along the travelling route, the method includes the steps of making the transport vehicles report positions of the transport vehicles and residual capacities of the electric storage devices in the transport vehicles to the ground controller via communication units in the transport vehicles; making the ground controller select a transport vehicle in need of charging in accordance with the residual capacities of the transport electric storage devices in the transport vehicles and the positions of the transport vehicles, and select and specify a charging coupler to the selected transport vehicle via a communication unit; and making the selected transport vehicle stop at the specified charging coupler and charge an electric storage device in the selected transport vehicle from an electric storage device in a charger via the specified charging coupler. In this specification, descriptions of the transport vehicle system may be directly applied to the charging method for the transport vehicles.
In various preferred embodiments of the present invention, the electric storage devices in the transport vehicles are not charged directly by the rectifiers, but via the electric storage devices in the chargers. Hence, the electric storage devices in the transport vehicles are quickly charged with large current from the electric storage devices in the chargers via the charging couplers. Since the downtime due to charging is approximately in inverse proportion to the charging current, the downtime of the transport vehicles due to charging is decreased by the electric storage devices in the chargers, and operation efficiency of the transport vehicles is improved. The wiring to the rectifiers and the power source to the rectifier preferably has a small capacity, and therefore, it is not necessary to dispose a power supply and wiring for large current in the ground space. Further, the chargers are disposed in a plurality of locations along the travelling route, so as to select and specify a charging coupler to charge in accordance with the position of the transport vehicle and the residual capacity of the electric storage device in the transport vehicle. This ensures all transport vehicles travel with sufficient residual capacities in the electric storage devices in the transport vehicles. The electric storage devices in the transport vehicles and the electric storage devices in the chargers may be secondary batteries, such as lithium ion batteries or electric double layer capacitors, for example.
It is preferable that the charging couplers are disposed at transfer points including load ports or buffers. By this configuration, transport vehicles may be charged while the transport vehicle is stopping at a stopping point, such as a load port, and therefore, the vehicle downtime due to charging is further decreased. Positions appropriate to dispose the charging coupler, other than the transfer points, are located before and after the transfer point, and a standby position where the transport vehicle stops and stands by.
It is preferable that a plurality of charging couplers are connected to one electric storage device in a charger in parallel along the travelling route, and that the charging management unit makes a plurality of overhead travelling vehicles stop simultaneously at the plurality of charging couplers connected in parallel and simultaneously charge. If a transport vehicle stops to be charged, the travelling route is blocked during this time. Therefore, if the plurality of transport vehicles are stopped in adjacent positions and are simultaneously charged, time when the travelling route is blocked due to charging may be decreased. The transport vehicles are charged via the electric storage device in the charger, therefore even if a plurality of transport vehicles are simultaneously charged, charging current does not become insufficient, and one electric storage device in the charger may be shared by a plurality of charging couplers.
It is particularly preferable that the transport vehicles are overhead travelling vehicles travelling along a travelling rail disposed in a ceiling space, and the rectifiers and the electric storage devices in the chargers are disposed in a ground space. Inefficiency arises when an alternate current wiring is laid along the ceiling space and the electric storage device in the charger, which is a heavy load, is provided therein. If the rectifier and the electric storage device in the charger are disposed in the ground space, on the other hand, wiring to an equipment, where goods are delivered, may be used as an alternate current source to the rectifier, and direct current wiring may be laid from the ground to the travelling rail so that a plurality of charging couplers may be wired along the travelling rail.
It is preferable that the ground controller determines the charging amount via the specified charging coupler in accordance with a frequency of transport request generation. Then, if many transportation requests are generated, the operation efficiency of the transport vehicles is increased by decreasing the charging amount that is charged each time, and if few transportation requests are generated, a drop in transport efficiency due to charging may be prevented by increasing the charging amount that is charged each time. It is preferable that the ground controller determines the charging amount via the specified charging coupler in accordance with a frequency of generation of instructions for travelling via the specified charging coupler. Then, if there are many travelling instructions provided via the charging coupler used for the charging, interrupting the traveling of other vehicles is prevented by decreasing the charging amount that is charged each time. The charging amount is preferably determined in accordance with both the generation frequency of transportation requests and the generation frequency of the travelling instruction provided via the charging coupler used for the charging.
The above and other elements, features, steps, characteristics and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments with reference to the attached drawings.
Preferred embodiments of the present invention will now be described.
As described above, the charging coupler 10 is disposed directly above the load port 26, but may also be disposed above a buffer (not illustrated), at positions before or after the buffer, and at standby positions, for example. Two to several charging coupler groups (a “charging coupler group” is a plurality of charging couplers 10 connected to one charger main unit 28) are provided for each intra-bay route 6, for example, and several charging coupler groups are disposed in the inter-bay route 4. As a result, an overhead travelling vehicle 8 may reach a nearby charging coupler 10 if it travels several tens of meters to 100 meters, for example.
An inverter 45 converts the output of the secondary battery 46 and the capacitor 47 into alternate current, and supplies the alternate current to a travelling motor of the travelling unit 41 and a motor of the transfer unit 42, and the secondary battery 46 and the capacitor 47 receive DC power from the coupler 10 in the charger via the coupler 48 in transport vehicle. When the overhead travelling vehicle 8 is accelerating and the liftable frame is ascending, power is supplied from both the capacitor 47 and the secondary battery 46, and when power consumption is low, such as during constant speed travelling, power is supplied only from the secondary battery 46. Energy regenerated by deceleration of the overhead travelling vehicle 8 and descending of the liftable frame is stored in the capacitor 47 and the secondary battery 46. The residual capacity of the capacitor 47 is made to return to a predetermined value in each cycle from the start of travelling of the overhead travelling vehicle 8 to the completion of transfer, so that the net power consumption in each cycle is supplied from the secondary battery 46. If the capacitor 47 is disposed, peak current discharged from the second battery 46 may be decreased, and discharge current from the secondary battery 46 may be equalized, hence a small capacity secondary battery 46 may be used, and battery life of the secondary battery 46 may be extended. The capacitor 47 need not be disposed, or only the capacitor 47 may be disposed without the secondary battery 46.
A travelling instruction generation unit 59 generates travelling instructions so that the overhead travelling vehicles execute transport instructions, allocation instructions, charging instructions or the like. The travelling instructions specify the target positions and the target velocities after a predetermined time interval, and the instructions are generated with the time interval, for example. A transport instruction file 60 stores transport instructions and execution results thereof, and a vehicle state file 61 stores the positions, velocities and states of vehicles and residual capacities of the secondary batteries and the capacitors.
The charging management unit of the ground controller determines the charging amount for the transport vehicle A, that is the percentage of the charge when a fully charged state is 100%. The amount is determined in accordance with both the generation frequency of transport requests from the manufacturing execution system to the ground controller and the generation frequency of travelling instructions via the charging coupler used for charging. However, it is not always necessary to use both the generation frequency of transport requests and the generation frequency of the travelling instructions. The charging amount may be determined in accordance with one of the generation frequencies. The charging amount is increased when the number of transport requests is higher and when the number of travelling instructions via the target charging coupler is higher. The charging amount is decreased when these numbers are lower. It may be determined to fully charge the transport vehicle when the generation frequency of transport requests is low, and a number of travelling instructions via the target charging coupler is low.
The generation frequency of transport requests preferably are determined with a moving average of the frequency of transport request generation per unit time, or with a predictive value of the frequency of transport request generation per unit time in the future based on the moving average, for example. If the generation of transport requests has some regularity, such as periodical changes, then a predictive value determined based on the regularity may be used. Further, the number of generated transport requests may be a moving average of transport instructions assigned by the ground controller per unit time, or a predictive value thereof. The generation frequency of transport requests indicates the level of the transport load of the entire transport system. The number of generation of transport requests is a base for the generation frequency of transport requests. The number of generation of transport requests is one generated in the entire transport system, ignoring loading positions and unloading positions, for example.
The generation frequency of travelling instructions via the charging coupler used for the charging indicates how the travelling route is blocked due to the charge and how many other transport vehicles are forced to wait. The travelling instruction is an instruction to a transport vehicle that involves travelling, and includes not only a transport instruction but also an allocation instruction, a charging instruction, and an instruction to go out of a travelling route. However, only transport instructions, out of these instructions, may be considered.
The charging management unit determines x=aα+bβ (a and b are positive constants), where α is a number of generation of transport instructions in the entire transport system, and β is a number of times of generation of a travelling instructions via the charging coupler used for charging. The charging management unit decreases the charging amount when the value x is large and increases the charging amount when the value x is small. For the number of generation α of transport requests in the entire transport system, a predictive value is important so as to quickly execute the transport requests generated in the future. For the number of generation β of transport requests via the charging coupler used for charging, the current value is more important than the predictive value so that the travelling of other vehicles is not interrupted.
If the transport vehicle A of which residual capacity is the lowest is charged to a predetermined capacity, the charging management unit of the ground controller instructs transport vehicles being charged via adjacent charging couplers to stop charging. The period that the travelling route is blocked may be decreased if the plurality of overhead travelling vehicles stop charging all at once. The charging is performed using power of the electric storage device 38, hence a plurality of overhead travelling vehicles may be charged simultaneously. Since the charging coupler is disposed in a position directly above the load port, an overhead travelling vehicle, which transfers a good with a load port where the charging coupler is disposed, is charged, unless the overhead travelling vehicle is fully charged. In this case as well, other overhead travelling vehicles are also stopped at adjacent charging couplers and are charged.
According to the present preferred embodiment, the following advantageous effects are obtained.
Charging with large current in a short time is possible, since the overhead travelling vehicle 8 is charged from the electric storage device 38. The downtime due to charging is approximately in inverse proportion to the charging current, hence charging with large current improves the operation efficiency of the overhead travelling vehicles 8.
Wiring is easy since the AC power supply 32 for the equipment is used as the power source to the electric storage device 38. By charging the overhead travelling vehicle 8 from the electric storage device 38 in a short time, and normally charging the electric storage device 38 from the AC power supply 32, the capacity of the ground wiring required for charging may be decreased.
A plurality of overhead travelling vehicles preferably are charged simultaneously, since a plurality of charging couplers 10 are connected to one electric storage device 38 in parallel. This decreases the time of blocking the travelling route due to charging.
The electric storage device 38 and the rectifier 36 are disposed in the ground space and need not be supported in the ceiling space.
By installing two to several charging coupler groups in each intra-bay route 6 and installing several charging coupler groups in the inter-bay route 4 as well, the overhead travelling vehicle is preferably charged at approximately 100 meters or less travelling distance, for example. Further, the charging management unit 58 monitors the positions of the overhead travelling vehicles and the residual capacity of the secondary battery or the like, hence no overhead travelling vehicles run out of battery power.
The charging coupler 10 is disposed directly above the load port 26, and therefore, the period to transfer goods may be used for charging.
These features as a whole decrease the period of the overhead travelling vehicles consumed by charging. The operation efficiency of the overhead travelling vehicles is increased.
The residual capacity level to be reached by charging is determined in accordance with the generation frequency of transport requests and the generation frequency of travelling instructions via the charging coupler. Therefore, if the generation frequency of transports request is high, the charge amount for each charge is decreased to improve the operation efficiency of the transport vehicles. If the number of travelling instructions via the charging coupler is high, the charging amount for each charge is decreased so that the travelling of other transport vehicles is not interrupted. If the generation frequency of transport requests is low and the number of travelling instructions via the charging coupler is small, the charging amount for each charge is increased so that the transport vehicles are charged enough for the next busy period while not interfering with the travelling of other transport vehicles.
While preferred embodiments of the present invention have been described above, it is to be understood that variations and modifications will be apparent to those skilled in the art without departing from the scope and spirit of the present invention. The scope of the present invention, therefore, is to be determined solely by the following claims.
Number | Date | Country | Kind |
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2011-193717 | Sep 2011 | JP | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/JP2012/068577 | 7/23/2012 | WO | 00 | 2/28/2014 |