JP2002297226A - Simulation device for automatic conveyance system and its method and its simulation program - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide the simulation device of an automatic conveyance system for facilitating countermeasures to the constitution of a complicate conveying facility, and for simulating the operation of a conveying facility and an object to be conveyed in a real time. SOLUTION: This simulation device 1 for simulating the operation of an automatic conveyance system for automatically conveying an object to be conveyed under the control of control controllers (conveyer control panels) CC and so on is provided with a simulating means (model executing part) 18 for simulating the operation of a conveying based on an output signal from the control controller CC, and for simulating the conveyance of the object to be conveyed according to the simulating operation, and for outputting a simulation signal from the conveying facility, an input and output managing means (input and output data managing part) 17 for managing the input and output signal, a communication managing means (communicating managing part) 12 for managing communication, and a display means (display) 6 for displaying the simulating operation. The simulating means 18 performs one cycle processing synchronously with one cycle processing in the control controller CC.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a simulation apparatus for an automatic transport system that simulates the operation of an automatic transport system for automatically transporting articles, a simulation method for the automatic transport system, and a simulation program for the automatic transport system.

[0002]

2. Description of the Related Art Automatic transfer systems for automatically transferring goods have been introduced in various fields such as production factories, distribution centers, and distribution centers. The automatic transport system includes various conveyors for transporting the transported articles, various sensors for detecting the position of the transported articles, and a controller for controlling the various conveyors based on information from the various sensors and the like. ing. The role of the automatic transport system is to move the transported article from an arbitrary location to a target location at a set timing and arrival order so as to satisfy the required lead time and throughput. Also, from the viewpoint of the safety of the automatic transport system, when an erroneous operation, abnormality detection, or emergency stop occurs or when they are released, each device is appropriately stopped /
It also needs to be activated. In order to construct an automatic transfer system that satisfies these conditions, system design and various conveyors and various sensors are important, but the reliability and quality of the control program of the control controller are also important.

[0005] In order to improve the reliability and quality of the control program, a debug test of the control program is performed before operating the automatic transport system. In general, this debug test involves a pre-shipment test that is performed without connecting the controller and the controller for the conveyors and sensors of the automatic transfer system, and the control and the controller for the conveyors and sensors that are actually provided in the automatic transfer system. It is performed in two stages of on-site testing performed in a coupled state. The pre-shipment test is performed by connecting a panel switch with a control panel with a built-in control program, manually generating a signal pattern from various sensors that changes as the conveyed object moves, etc., or according to a time chart prepared in advance. It generates signals mechanically.

As an example of a pre-shipment test, see JP-A-7-3
Japanese Patent No. 25803 discloses a virtual CIM (Computer Integrated M
anufacturing) system. In this virtual CIM system, the entire factory is virtually operated by connecting a real equipment emulator that emulates each real equipment in the factory to a factory distribution control controller instead of the real equipment. In this virtual CIM system, the real device emulator has a faster response time than the response time of each real device to be emulated,
The entire factory is virtually operated so that the CIM system actually constructed operates faster than the real time.

[0005] In the case of a simple automatic transport system, since a signal pattern to be generated is also simple, a sufficient test can be performed by a pre-shipment test. But,
In the case of a complex automatic transport system where confluence, branching, and intricate confluence, such as a conveyor, the signal pattern becomes complicated due to the effects of waiting time due to control and the arrival pitch of the conveyed products. A sufficient test that satisfies a complicated signal pattern cannot be performed. Therefore, the debugging test of the automatic transport system has mainly been the on-site test.

[0006]

However, in the case of a field test, since the transport equipment such as a conveyor and even the transported object may be large in some cases, the operation test condition not only in a normal state but also in an abnormal state or an emergency state is required. It is difficult to produce all of them in terms of transport equipment, time, people, cost, and the like. For this reason, in practice, only the normal operation is checked by a field test, and the automatic transfer system is put into operation without checking the operation at the time of abnormality or emergency. Therefore, there are many cases where a problem occurs after the operation is started. When a problem occurs, the operation of the automatic transport system is temporarily stopped, and the operation is resumed after the problem is solved. Therefore, the user of the automatic transport system suffers damage due to the stoppage of the operation, and requests the manufacturer of the automatic transport system to resume the operation at an early stage. However, the manufacturer of the automatic transfer system is likely to be away from the site when a problem occurs, so it takes time to understand the situation of the problem, analyze the problem, and take measures.

In the automatic transport system, the layout of each conveyor and the layout of each sensor are set according to a request from the user. Further, in the automatic transport system, the layout of each conveyor and the layout of each sensor may be changed even during development so that the transported object can be smoothly and automatically transported. Therefore, it is necessary to confirm by an on-site test in order to confirm whether or not the conveyed object can move smoothly in accordance with such setting or change of the layout. However, it is difficult to carry out the on-site test by moving the conveyor or the like every time the layout is changed, in terms of the transport equipment, time, people, cost, and the like. Therefore,
There is a need for a simulation device that can respond to the complicated configuration of each conveyor and can check the operation of the automatic transport system according to the control program without depending on the transported objects and transport equipment that make up the actual automatic transport system. Becomes

In the above-described virtual CIM system, by constructing an actual device emulator corresponding to each actual device, it is possible to virtually operate the entire factory having a complicated configuration. However, the operation of the entire factory can be performed in real time. It cannot be operated virtually. Therefore, in this virtual CIM system, it is necessary to confirm while adjusting the conveyor merging point, the accurate mounting position of sensors and stoppers at the branch point, the conveyor speed control, and the timer in the program, which are important in the automatic transport system. Can not. for that reason,
It is not possible to check whether or not the conveyed objects flow without colliding with each other or whether or not the stopper lifts the conveyed objects.

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a simulation apparatus for an automatic transport system, a method for simulating an automatic transport system, and a method for simulating the operation of the transport equipment and a transported object in real time, which can cope with the configuration of a complicated transport facility. An object of the present invention is to provide a simulation program for an automatic transport system.

[0010]

A simulation apparatus for an automatic transfer system according to the present invention which has solved the above-mentioned problems, comprises:
A control device for controlling a transfer facility by a controller, and a simulation device for simulating an operation of an automatic transfer system for automatically transferring a conveyed object by the transfer facility, wherein the transfer facility is controlled based on an output signal from the control controller. Simulation means for simulating the operation of the above, simulating the conveyance of the conveyed object by this simulation operation, and outputting a simulation signal from the conveyance equipment, and an output signal from the control controller and / or a simulation from the simulation means. Input / output management means for managing signals, communication management means for managing signal communication between the control controller and the simulation means, and display means for displaying a simulation operation of the transport equipment and / or the conveyed object. Wherein the simulation means synchronizes with one cycle of processing by the control controller and performs one cycle of processing. And performing processing cycle.

According to the simulation apparatus of the automatic transport system, the simulating means adjusts the processing time of one cycle to the processing time of one cycle in the control controller. As a result, with this simulation device, the operation of the transport equipment can be simulated in real time when the control controller is controlling in the actual automatic transport system. it can.

Further, in the simulation apparatus for the automatic transport system, the controller for control may include:
An output signal is output every cycle, and the input / output management unit notifies the simulation unit of a reception time point of the output signal from the control controller, and the simulation unit notifies the reception time point of the input / output management unit. The processing of the next cycle is started from the point in time.

According to the simulation apparatus of the automatic transport system, the simulation means executes the next cycle of processing as a trigger at the time of receiving the output signal from the control controller. That is, in the simulation means, the start point of one cycle of processing is set as the reception point of the output signal from the control controller, and after the completion of one cycle of processing, reception is waited until the output signal is received.

Further, in the simulation device for the automatic transport system, the control device includes timer management means for measuring one cycle time in the control controller, and the simulation means includes a timer for the control controller measured by the timer management means. One cycle of processing is performed in one cycle.

According to the simulation apparatus of the automatic transport system, the simulation means synchronizes with the processing of one cycle by the control controller based on the time of one cycle by the control controller measured by the timer management means. One cycle of processing is performed. That is, the simulation means does not perform the processing of the next cycle until the time of one cycle measured by the timer management means has elapsed.

Further, in the simulation apparatus for the automatic transport system, an input means for inputting a command to the simulation means, and an external signal for generating an external signal to the simulation means in response to the command from the input means Generating means.

According to the automatic transport system simulation apparatus, the operator can input any command from the input means assuming various operating conditions in the automatic transport system,
In response to the input, a command can be given from the external signal generation means to the simulation means. Therefore, in this simulation device, an abnormal time or an emergency can be randomly generated, and the operation at that time can be simulated.

Further, in the simulation apparatus for the automatic transport system, a simulation time of one cycle in the simulation means can be set to an arbitrary time, and the simulation means performs simulation for the simulation time in one cycle. Features.

According to the simulation apparatus of the automatic transport system, the simulation means can simulate at an arbitrary simulation time in one cycle, so that the real time when the control controller is controlling in the actual automatic transport system is used. The operation of the transport equipment can be simulated earlier or later, and the operation of the transported object can be simulated earlier or later than real time.

Further, the simulation apparatus for the automatic transport system includes a model creating means for creating a model of the transport equipment, and a model storing means for storing the created model, wherein the simulating means comprises the model storing means. The operation of the transport equipment is simulated by the model stored in the storage device.

According to this automatic transport system simulation apparatus, a model of the transport equipment can be created by the model creating means and the model created by the model storage means can be stored, so that a simulation model of the automatic transport system can be easily constructed. be able to.

According to a method of simulating an automatic transport system according to the present invention, which solves the above-described problems, a transport controller is controlled by a control controller, and the operation of an automatic transport system that automatically transports a transported object by the transport facility is simulated. A simulation method, which simulates the operation of the transport facility based on an output signal from the control controller, simulates the transport of the article by the simulated operation, and outputs a simulated signal from the transport facility. A process, an input / output management process for managing an output signal from the control controller and / or a simulation signal from the simulation process, and a communication management for managing signal communication between the control controller and the simulation process. Process and
A display step of displaying a simulation operation of the transport equipment and / or the transported object. In the simulation step, one cycle is performed in synchronization with one cycle of processing by the control controller.
Cycle processing is performed.

According to the simulation method of the automatic transport system, in the simulating step, the processing time of one cycle is adjusted to the processing time of one cycle in the control controller. As a result, in this simulation method, the operation of the transport equipment can be simulated in real time when the control controller is controlling in the actual automatic transport system, so that the operation of the transported object can be simulated in real time. it can.

Further, in the method for simulating the automatic transport system, the controller for controlling may include:
An output signal is output for each cycle, and in the input / output management step, a reception time point of the output signal from the control controller is notified to the simulation step. The processing of the next cycle is started from the point in time.

According to the simulation method of the automatic transport system, in the simulation step, the next cycle of processing is executed as a trigger when an output signal from the control controller is received. That is, in the simulation process, the start time of one cycle of processing is set as the reception time of the output signal from the control controller, and after the completion of one cycle of processing, reception is waited until the output signal is received.

Further, in the method for simulating the automatic transfer system, a timer management step for measuring one cycle time in the control controller is included, and in the simulation step, the timer for the control controller measured in the timer management step is used. One cycle of processing is performed in one cycle.

According to the method of simulating the automatic transport system, the simulation process is performed in synchronization with the one-cycle processing of the control controller in the simulation process based on the time of one cycle in the control controller measured in the timer management process. One cycle of processing is performed.

Further, in the simulation method of the automatic transport system, an input step for inputting a command to the simulation step, and an external signal for generating an external signal for the simulation step in response to a command from the input step. Generating step.

According to the simulation method of the automatic transfer system, the operator can input an arbitrary command in the input step assuming various operation conditions in the automatic transfer system, and start the external signal generation step in accordance with the input. Commands can be given to the simulation process. Therefore, in this simulation method, an abnormal time or an emergency can be generated at random, and the operation at that time can be simulated.

Further, in the simulation method of the automatic transfer system, a simulation time of one cycle in the simulation step can be set to an arbitrary time, and in the simulation step, simulation is performed for the simulation time in one cycle. Features.

According to the simulation method of the automatic transfer system, in the simulation step, simulation can be performed for an arbitrary simulation time in one cycle. The operation of the transport equipment can be simulated earlier or later than the time, and the operation of the transported object can be simulated earlier or later than the real time.

Further, the method for simulating the automatic transfer system includes a model creation step for creating a model of the transfer facility, and a model storage step for storing the created model. The operation of the transport equipment is simulated by the model stored in the step (1).

According to the simulation method of the automatic transfer system, a model of the transfer equipment can be created in the model creation step, and the model created in the model storage step can be stored, so that a simulation model of the automatic transfer system can be easily constructed. be able to.

A simulation program for an automatic transport system according to the present invention that solves the above-mentioned problems controls a transport facility by a control controller and simulates the operation of an automatic transport system that automatically transports articles by the transport facility. A simulation program for simulating the operation of the transport equipment based on an output signal from the control controller. A simulation process of outputting a signal,
An input / output management step of managing an output signal from the control controller and / or a simulation signal from the simulation step, a communication management step of managing signal communication between the control controller and the simulation step, And a display step of displaying a simulation operation of the transport equipment and / or the transported object. In the simulation step, one cycle of processing is performed in synchronization with one cycle of processing by the control controller. It is characterized by realizing. further,
In addition to the simulation program of the automatic transport system, the control controller outputs an output signal every cycle, and in the input / output management step, the reception point of the output signal from the control controller is used in the simulation step. In the simulation process, the process of the next cycle is started from the time when the reception time is notified from the input / output management process. Further, in addition to the simulation program of the automatic transport system, a timer management step of measuring one cycle time in the control controller is realized, and in the simulation step,
The present invention is characterized in that one cycle of processing is performed in one cycle of time in the control controller measured in the timer management step. Further, in addition to the simulation program of the automatic transport system, an input step for inputting a command to the simulation step, and an external signal generation for generating an external signal for the simulation step in response to a command from the input step And the steps are realized. Further, in addition to the simulation program of the automatic transfer system, a simulation time of one cycle in the simulation step can be set to an arbitrary time, and the simulation step realizes simulation in the one cycle corresponding to the simulation time. It is characterized by making it. Furthermore, in addition to the simulation program of the automatic transfer system, a model creation step of creating a model of the transfer facility and a model storage step of storing the created model are realized.
In the simulation step, the operation of the transport equipment is simulated using the model stored in the model storage step.

According to the simulation program of the automatic transport system, the simulation program is loaded or installed in a computer, and the simulation program is executed, thereby realizing the simulation method for performing the above-described simulation.

[0036]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a block diagram showing a configuration of an automatic transport system simulation apparatus and an automatic transport system simulation method according to an embodiment of the present invention;

The automatic transport system simulation apparatus according to the present invention communicates signals with a control controller of the automatic transport system to simulate the operation of the transport equipment of the automatic transport system in real time. For this purpose, the simulation device according to the present invention provides a waiting time during the processing time of one cycle in the simulation device, thereby reducing the processing time of one cycle in the simulation device to the processing time of one cycle in the control controller. Synchronize with the controller for control. In particular, the simulation device according to the present invention synchronizes with the control controller with high accuracy by starting one cycle of processing by the simulating means with the time point of receiving the output signal from the control controller as a trigger.

In the present embodiment, the simulation apparatus for an automatic transport system according to the present invention is applied to a simulation apparatus for simulating an automatic transport system having an accumulation type conveyor in a shipping system using digital picking. The automatic transport system according to the present embodiment is disposed over a plurality of floors of a building in which the automatic transport system is configured, and includes a conveyor control panel (control controller) and transport equipment such as various conveyors and various sensors on each floor. In addition to the above, transport equipment such as a conveyor control panel and an elevator type conveyor is provided between each floor. For such an automatic transport system, the simulation apparatus according to the present embodiment is configured for each floor, communicates signals with a conveyor control panel on each floor, and simulates the operation of the transport equipment on each floor. . In the present embodiment, a simulation program stored in a storage medium (CD-ROM or the like) or a simulation program distributed on a net (Internet or the like) is used as a personal computer (hereinafter referred to as a personal computer).
The simulation program is loaded or installed in a computer, and the simulation program is executed by a personal computer to configure a simulation apparatus for performing a simulation, thereby realizing a simulation method.

First, the configuration of the automatic transport system S will be described with reference to FIGS. FIG. 1 is a configuration diagram of the automatic transport system S. 2A and 2B are perspective views of the conveyor CV of the automatic transport system S, wherein FIG. 2A is a conveyor CV at a picking point PP, and FIG. 2B is a conveyor CV at a merging point JP.

The automatic transfer system S is an automatic transfer system used in a shipping system based on digital picking, and includes pallets PT,.
Is automatically transferred from the top floor where the automatic transfer system S is provided to a sorting machine (not shown) on the first floor. During the automatic conveyance, goods are put into the pallets PT,... By digital picking, and the pallets PT,. After the sorting, the goods put on the pallets PT,... Are shipped from the truck yard (not shown) by truck. In the present embodiment, the conveyor CV corresponds to one of the transport facilities described in the claims, and the pallet PT corresponds to the transported articles described in the claims.

In the automatic transfer system S, transfer equipment such as various conveyors CV,... And a conveyor control panel CC for controlling the transfer equipment are provided on each floor.
An elevator-type conveyor and an inter-floor control panel EC for controlling the conveyor are provided between each floor. Conveyor C
V has a conveyor drive motor CVa, and the drive of the conveyor drive motor CVa is controlled by a conveyor control board CC. Further, the conveyor CV has an emergency stop button SB, and the emergency stop button SB enables the worker OP to stop the conveyor CV. The conveyor control panel CC is a PLC (Programmable Lo
gic Controller), a motor drive unit, a sensor input unit, and the like, and a control program is stored in the PLC. The conveyor control panel CC operates periodically with a certain fixed time as one cycle based on a PLC timer. In addition, the automatic transport system S manages shipping of the entire shipping system and controls the conveyor control panel C.
A high-order personal computer PC for controlling C,... Is provided. In this embodiment, the conveyor driving motor C
Va, the emergency stop button SB, the floor control panel EC, and the upper-level personal computer PC are one of the transfer equipments described in the claims.
The conveyor control panel CC corresponds to a control controller described in the claims.

In order to perform digital picking,
Conveyor CV has optical sensor SR and barcode reader B
R, stopper ST and conveyor CV
A product shelf RK is arranged beside the. The light sensor SR has a light emitting unit and a light receiving unit disposed on both sides of the conveyor CV, and detects the passage of the pallet PT based on whether or not the laser light emitted from the light emitting unit can be received by the light receiving unit. The barcode reader BR is provided on one side of the conveyor CV, and reads information on the barcode BC from the barcode BC attached to each pallet PT. The stopper ST is provided movably up and down below the conveyor CV, and stops the pallet PT. The product shelf RK has a plurality of levels of shelves, and stores different types of products that are divided into predetermined widths for each level of shelves. Further, the product shelf RK includes a display unit DP for each product. The display unit DP includes an indicator light L
T, a product number display unit (not shown), a completion button (not shown), and the like. In the present embodiment, each of the optical sensor SR, the barcode reader BR, the stopper ST, and the indicator lamp LT corresponds to one of the transport facilities described in the claims.

The conveyor control board CC receives signals from the picking transfer completion button PB, the optical sensor SR, the limit switch LS, the emergency stop button SB, and the like, and performs a conveyor drive motor CVa in accordance with a control program based on the received information. , Stopper ST, barcode reader BR
And a control signal to the picking transfer completion button PB and the like. The signal from the picking transfer completion button PB is a completion signal when the button is pressed. Optical sensor S
The signal from R is On while the pallet PT is passing.
This signal is an Off signal when the pallet PT is not passing. The signal of the emergency stop button SB is an On signal when pressed, and an Off signal when not pressed.
Signal. The control signal to the conveyor drive motor CVa is an On signal when driving the conveyor CV, and an Off signal when stopping the conveyor CV. The control signal to the stopper ST includes a pallet PT
Is an On signal when the pallet PT is stopped, and an Off signal when the pallet PT is not stopped. As a control signal to the bar code reader BR, when the passage of the pallet PT is detected by the optical sensor SR, the pallet P passing therethrough is detected.
This is a read signal for reading the T barcode BC.
Incidentally, after reading the barcode BC, the barcode reader BR transmits the read information to the host computer P.
Send to C. The control signal to the picking transfer completion button PB is an On signal when the lamp is turned on, and an Off signal when the lamp is turned off.

The conveyor control panel CC transmits and receives signals to and from the host computer PC according to the control program. The signal received from the host computer PC is, for example, a stop instruction signal when it is necessary to perform picking on the pallet PT, and a start instruction signal when the picking is completed.・ ・
The operation mode setting signal is used when the operation mode is set, and the merge mode setting signal is used when setting the pallet PT merging order at the merging point JP. The signal to be transmitted to the host computer PC is, for example, a pallet arrival notification signal when the passage of the pallet PT is detected by the optical sensor SR. Also, conveyor control panel CC
Transmits and receives signals to and from the floor control panel EC according to the control program. The signal received from the floor control panel EC is, for example, a payout request signal for loading a pallet PT lowered by an elevator type conveyor (not shown). The signal transmitted from the floor control panel EC is, for example, a reception enable signal when the pallet PT can be received in response to the payout request signal. Further, the conveyor control panel CC transmits and receives signals to and from a sorter (not shown) according to a control program.

The operation of the automatic transport system S configured as described above will be described based on control from the conveyor control panel CC. Conveyor control panel CC has optical sensor S
The presence / absence of the pallet PT on the conveyor CV is determined based on the detection of R, and the pallet PT existing within the drive range of the conveyor CV is moved by driving the conveyor drive motor CVa. Further, at the merging point JP and the picking point PP, the following pallets PT,. For this purpose, the conveyor control panel CC
Stops the leading pallet PT by raising the stopper ST while driving the conveyor drive motor CVa. Further, when cutting out the leading pallet PT from the pallets PT,... That are closely packed forward, the conveyor control panel CC lowers the stopper ST once and raises it again to cut out the leading pallet PT.

In order to perform digital picking,
When the conveyor control panel CC determines that the pallet PT is passing through the picking point PP by detecting the optical sensor SR, the conveyor control panel CC transmits a read signal to a barcode reader BR near the upstream side of the optical sensor SR, and transmits the read signal to the host computer PC.
A pallet arrival notification signal is transmitted to C. Then, the barcode reader BR reads the barcode BC of the passing pallet PT, and transmits the read information to the host computer PC. Subsequently, based on the received information of the barcode BC, the higher-level personal computer PC determines whether there is a necessary product on the product shelf RK of the picking location PP. If there is a necessary product, higher-level personal computer PC
Transmits a stop instruction signal to the conveyor control panel CC. Then, the conveyor control panel CC sends an On signal to the stopper ST to raise the stopper ST and stop the pallet PT. Also, the upper-level personal computer PC transmits an On signal and the number to be picked to the display lamp LT of the required product, and turns on the display lamp LT. When the indicator LT lights up,
The operator OP takes out the required number of the products and puts them in the pallet PT. When the operation is completed, the operator OP presses a completion button (not shown) of the display unit DP to turn off the display lamp LT. Subsequently, the signal that the completion button is pressed is transmitted to the host computer P.
C, and upon receiving all the completions of the area, the host computer PC sends a start instruction signal to the conveyor control board C.
Send to C. Then, the conveyor control panel CC turns on the picking transfer completion button PB, turns off the light by pressing the operator OP, transmits an Off signal to the stopper ST, lowers the stopper ST, and starts the pallet PT. An Off signal is transmitted to the indicating lamp LT to turn off the indicating lamp LT. On the other hand, if there is no required product,
Transmits a start instruction signal to the conveyor control panel CC. Then, the conveyor control panel CC continues the movement of the pallet PT.

In front of the merging point JP, the conveyor control panel CC detects the pallet P
If T determines that it is passing just before the merging point PP, it transmits a read signal to the barcode reader BR near the upstream side of the optical sensor SR and transmits a pallet arrival notification signal to the host computer PC. Then, the barcode reader BR reads the barcode BC of the passing pallet PT, and transmits the read information to the host computer PC. Subsequently, the upper-level personal computer PC sets the transfer order, line balance, etc. of the pallets PT,. And transmits a merge mode setting signal, a start instruction signal, or a stop instruction signal to the conveyor control panel CC. Then, on the basis of the transmitted signal, the conveyor control panel CC transmits a signal to the stopper ST or the like, stops one of the pallets PT by the stopper ST, and sets the pallet PT,
Adjust the order of.

Next, the configuration of the simulation apparatus 1 will be described with reference to FIGS. FIG. 3 is a configuration diagram of the simulation device 1. The simulation apparatus 1 is an apparatus that simulates the operation of the transport equipment other than the conveyor control panel CC and the operation of the upper-level personal computer PC (broken line portion in FIG. 1) among the components of the automatic transport system S. And send and receive signals. The signals to be transmitted and received are all signals transmitted and received by the conveyor control panel CC, for example, the signals in the description of the automatic transport system S described above.

The simulation apparatus 1 has a personal computer 2 in which a simulation program is incorporated, and the simulation program is executed to configure each section in the computer main body 3 of the personal computer 2. The simulation device 1 can create a model of the transport equipment constituting the automatic transport system S in response to an input from the operator, and when the operator executes the model, displays the transport status of the pallets PT,. . For this purpose, the input to the simulation device 1 is performed by the keyboard 4 and the mouse 5, and the output from the simulation device 1 is displayed on the display 6. In the present embodiment, the keyboard 4 and the mouse 5 correspond to the input means described in the claims, and the display 6 corresponds to the display means described in the claims.

The components of the simulation apparatus 1 configured in the computer main body 3 include an input / output unit 10, a communication board 11, a communication management unit 12, a memory 13, a model creation unit 14, a model storage unit 15, and an input / output data direct access unit 16 , An input / output data management unit 17, a model execution unit 18, and an input / output data tracking unit 19. In the present embodiment, the communication management unit 12 corresponds to a communication management unit described in the claims, the model creation unit 14 corresponds to a model creation unit described in the claims, and the model storage unit 15 Corresponds to the model storage means described in the claims, the input / output data direct access unit 16 corresponds to the external signal generation means,
The input / output data management unit 17 corresponds to an input / output management unit described in the claims, and the model execution unit 18 corresponds to a simulation unit described in the claims.

The input / output unit 10 will be described. The input / output unit 10 manages input / output of information between the simulation device 1 and the outside. The input / output unit 10 sends key input information from the keyboard 4 or selection information or movement information from the mouse 5 to the model creation unit 14, the input / output data direct access unit 16, or the model execution unit 18. Also, the input / output unit 1
0 sends display information from the model creation unit 14, the input / output data direct access unit 16 or the model execution unit 18 to the display 6.

The communication board 11 will be described. The communication board 11 is a communication medium for transmitting and receiving signals between the simulation device 1 and the conveyor control panel CC,
DI (Digital Input) / DO (Digital Input)
Output) board, AI (AnalogInput) / AO (Analog Out)
put) board, Ethernet (registered trademark), a memory sharing board, or the like. Which communication medium is to be selected depends on the simulation device 1 according to the purpose of debugging.
And the response time to be guaranteed between the conveyor control board CC.

The communication manager 12 will be described. The communication management unit 12 stores the data in the simulation device 1 managed by the input / output data management unit 17 and the communication board 11.
Manages the correspondence with the data of the conveyor control panel CC received as a medium, converts the format into data that can be interpreted by the other party, and controls the communication board 11. In addition, the communication management unit 12 controls the simulation device 1
In the memory 13 or write or rewrite data from the conveyor control panel CC to the memory 13.

The memory 13 will be described. Memory 13
Is a memory for storing data handled between the simulation apparatus 1 and the conveyor control board CC, and a part of a RAM (Random Access Memory) of the computer main body 3 is allocated.

The model creating section 14 will be described. The model creation unit 14 creates a model of a transport facility of the automatic transport system S operated by the simulation device 1 according to an input from an operator. Therefore, the model creation unit 1
4, the various conveyors C included in the automatic transport system S
.. And modules corresponding to transport equipment such as a higher-level personal computer PC. Further, the model creation unit 1
In No. 4, a pallet PT module is prepared. For example, the conveyor module is a block unit of the conveyor CV driven by the same conveyor drive motor CVa in the automatic transport system S, and also manages devices such as the optical sensor SR and the stopper ST provided on the conveyor CV. I have. The model to be created is created for each floor where the transport equipment of the automatic transport system S is provided.

Here, an example of the conveyor module will be described with reference to FIG. FIG. 4 is an example of a configuration of a conveyor module in the model creating unit 14. FIG. 4 shows a standard conveyor CV and a conveyor CV having a stopper ST.
Conveyor CV equipped with a transformer and a translator (direction changing unit)
4 shows the configuration of three examples of a conveyor module corresponding to (transer). The standard conveyor module 14a includes:
The transport equipment includes a conveyor, an optical sensor, and a bar code reader. Conveyor module with stopper 14b
Has a conveyor, an optical sensor, a stopper, and a barcode reader as transport equipment. Transa module 1
4c has a conveyor, an optical sensor, a transer, a barcode reader, and a limit switch as transport equipment.

Further, parameters are prepared for each conveyor equipment of the conveyor module, and are set by an operator when a model is created. Conveyor parameters are conveyor length, conveyor acceleration, conveyor deceleration, conveyor speed, and drive conditions. The parameter of the optical sensor is the sensor position. The parameter of the limit switch is the position of the transer (up state, down state). The barcode reader parameter is the reader position. The parameters of the stopper are up time, down time, and driving conditions. The parameters of the transer are the conversion time and the driving conditions. Further, external communication variable names are set in the respective transport facilities of the conveyor module as names on the simulation device 1 for data for communicating with the conveyor control panel CC. The external communication variable name of the conveyor is a motor drive variable. The external communication variable name of the optical sensor is a sensor output variable. The external communication variable name of the barcode reader is a barcode variable. The external communication variable name of the stopper is a stopper driving variable. The external communication variable name of the transer is a transer driving variable. The external communication variable name of the limit switch is a sensor output variable.

By the way, at the time of model creation, a conveyor module is selected and arranged in the model creation window 20 by the operator, and is connected to the adjacently arranged conveyor module (see FIG. 7). Further, the operator sets parameters of each transport facility of the arranged conveyor module.

The higher-order personal computer module has, as parameters, a bar code read value of each pallet, a parameter of a work time distribution function required for picking, and the like.
The pallet module has, as parameters, the type and size of the pallet, a display method on the display 6, barcode information, and the like. And when creating the model,
The parameters are set for these modules by the operator.

The parameters relating to the time of the created model (for example, conveyor speed) are set in units of a simulation time described later.

The model storage unit 15 will be described. The model storage unit 15 is a memory that stores the model of the transport equipment of the automatic transport system S created by the model creation unit 14, and is assigned a part of an auxiliary storage device such as a hard disk of the computer main body 3.

The input / output data direct access unit 16 will be described. During execution of the simulation, the input / output data direct access unit 16
By the operation of the operator at 0 (see FIG. 9), various data can be input / output at an arbitrary timing. Various data handled by the input / output data direct access unit 16 is input / output to / from the model execution unit 18 via the input / output data management unit 17. As the various data, for example, the data of the On signal of the emergency stop button, the data of the On signal of the limit switch, the data of the On signal of the fire alarm, the input data of the pallet from an arbitrary position, and the higher-level personal computer output The data includes an operation mode setting signal data, a merge mode setting signal data, and a payout request signal data of a floor control panel.

For this purpose, the input / output data direct access section 16 prepares a direct access window 31 in the simulation window 30 and enables input / output of various data according to an input operation to the direct access window 31. The input / output data direct access unit 16
In this example, various data handled in the direct access window 31 can be added, changed, deleted, etc., by an operation by the operator.

The input / output data management unit 17 will be described. The input / output data management unit 17 manages data output from the model execution unit 18 to the conveyor control panel CC and data output from the conveyor control panel CC to the model execution unit 18. Further, the input / output data management unit 17 manages data input / output to / from the input / output data direct access unit 16. Further, the input / output data management unit 17 can output the data to the input / output data tracking unit 19 at the timing when the model execution unit 18 inputs and outputs the data. Data managed by the input / output data management unit 17 is stored in the memory 13 and is accessible from the communication management unit 12 and the model execution unit 18.

The input / output data management unit 17 has a function of monitoring a change in a value for each data unit. Therefore, in response to the value change notification registration request in data units from the model execution unit 18, the input / output data management unit 17 executes the model execution when the registered data unit values change during simulation execution. A value change notification message is issued to the unit 18.

The model execution unit 18 will be described. The model execution unit 18 reads a model of the transport equipment of the automatic transport system S stored in the model storage unit 15 and executes the model to simulate the operation of the transport equipment of the automatic transport system S. When the model is executed, there are two time units, real time and simulation time.
The real time is a time indicating the lapse of the real time from an arbitrary time after the start of one simulation. The simulation time is a time representing the elapsed time in the model from the start of the simulation. In this embodiment, the simulation time corresponds to the simulation time described in the claims.

The model execution unit 18 operates periodically in units of one cycle when the model is executed. The contents of the processing in this one cycle are described in the input / output data management unit 17.
Data (data to the conveyor control panel CC)
Data from the input / output data management unit 17 (conveyor control panel C
C and data from the input / output data direct access unit 16), and execution of processing in the model. In addition,
In the model execution unit 18, data input and data output are performed at once, and there is only one data input opportunity and one data output opportunity in one cycle.

In the execution of the in-model processing, the command state of each transport facility in the model is changed according to the input data. This command state is, for example, a drive command / stop command for the conveyor drive motor when the input data is an On signal / Off signal for the conveyor drive motor, and the input data is an On signal / O signal for the stopper.
In the case of the ff signal, it is a command for raising / lowering the stopper, and when the input data is a read signal for the bar code reader, it is a read command of the bar code reader. The input data is an On signal to the picking transfer completion button. In the case of the / Off signal, it is a lighting command / light-off command of the picking transfer completion button.

Subsequently, in the execution of the in-model processing, the changed command state is not changed during the scan time of the simulation time (during the execution of the in-model processing in one cycle), and the moving position of the pallet and the light are not changed. The state change of all the transport equipment including the output data of the transport equipment such as sensors and limit switches is obtained. Further, the data regarding display such as the moving position of the pallet is converted into display data in the change of the state of the transport equipment, and the display data is output to the display 6 via the input / output unit 10. The output data of the transport equipment such as the optical sensor and the limit switch is output collectively when outputting data to the input / output data management unit 17 (data to the conveyor control panel CC).

The model execution unit 18 synchronizes with the conveyor control panel CC in order to simulate the transport equipment of the automatic transport system S in real time. For this purpose, the model execution unit 18 adjusts the time of one cycle to the time of one cycle of the conveyor control panel CC. Incidentally, the conveyor control panel CC also operates periodically in units of one cycle as described above. Also in the conveyor control panel CC, data input and data output are performed at once, and there is only one opportunity to input data and one opportunity to output data in one cycle.

Referring to FIG. 5, a description will be given of a synchronization method in model execution unit 18. FIG. FIGS. 5A and 5B are explanatory diagrams of a synchronization method in the simulation apparatus 1. FIG. 5A is a configuration diagram of one cycle processing in the case of the communication synchronization method, and FIG. It is a block diagram of a process, (c) is a block diagram of the process of one cycle in the case of an asynchronous system. In addition, as shown in FIG.
The processing of one cycle in step 8 starts with output of data to the input / output data management unit 17, data input from the input / output data management unit 17, and execution of in-model processing for the simulation time scan time. Is

The real-time scan time in FIG. 5 is the time of one cycle in the conveyor control panel CC. The simulation time scan time in FIG. 5 is the time of the in-model processing executed by the model execution unit 18 in one cycle. In the simulation device 1, the SYNC CYCLE of the information display section 32 of the simulation window 30 is displayed.
The simulation time scan time (si
m) and the real-time scan time (real) can be set (see FIG. 9). If the real time scan time and the simulation time scan time are set to the same time,
The model execution unit 18 operates the transport equipment for the same time as the actual time in one cycle, and simulates the operation of the automatic transport system S in the actual time. When the simulation time scan time is set to a longer time than the real time scan time, the model execution unit 18 operates the transfer equipment for a longer time than the actual time in one cycle, and makes the operation of the automatic transfer system S earlier than the actual time. Simulate in time (specifically, the pallet is transported faster than it actually is). If the simulation time scan time is set shorter than the real time scan time,
The model execution unit 18 operates the transfer equipment for a shorter time than the actual time in one cycle, and simulates the operation of the automatic transfer system S for a longer time than the actual time (specifically, the pallet operates at a lower speed than the actual time). Transported).

The communication synchronization method will be described. The communication synchronization method is a method in which the output timing of data from the conveyor control panel CC is used as the start timing of one cycle of processing of the model execution unit 18. Therefore, the model execution unit 1
8 issues a value change notification registration request to the input / output data management unit 17 for data (hereinafter, referred to as synchronization data) that is always rewritten in one cycle of processing in the conveyor control panel CC, and outputs the synchronization data. Registered in the input / output data management unit 17. And one of the conveyor control panels CC
For each cycle, the synchronization data whose value has been rewritten from the conveyor control panel CC is input via the communication management unit 12,
The value of the synchronization data stored in the memory 13 is rewritten. The input / output data management unit 17 issues a value change notification message to the model execution unit 18 at the same time as the synchronization data is rewritten. Then, in the model execution unit 18 which has been in a waiting state after the completion of the in-model processing, the input / output data management unit 1
7 starts outputting data.

That is, as shown in FIG. 5A, when the execution of the intra-model processing for the simulation time scan time is completed, the model execution unit 18 waits for rewriting of the synchronization data (that is, the value Wait for change notification message). The conveyor control panel CC outputs the synchronization data every cycle (ie, every real time scan time). Therefore, the time of one cycle of the model execution unit 18 is the output time of data to the input / output data management unit 17, the input time of data from the input / output data management unit 17, the processing time in the model for the simulation time scan time, and It consists of a waiting time for rewriting the synchronization data, which exactly matches the real time scan time (one cycle time of the conveyor control panel CC).

The time synchronization method will be described. The time synchronization method uses a timer in the simulation device 1
This is a method in which one cycle time of the model execution unit 18 is adjusted to one cycle time (real time scan time) of the conveyor control panel CC. For this purpose, the simulation apparatus 1 includes a timer management unit (not shown) that manages time based on the clock frequency of the computer main body 3. Then, the timer management unit starts measuring time from the time when the model execution unit 18 starts outputting data to the input / output data management unit 17 (the time when the measurement time described later becomes the real-time scan time). When the measurement time reaches the real-time scan time, the model execution unit 18 is notified. Then
The model execution unit 18 that has been in a waiting state after the completion of the in-model processing starts outputting data to the input / output data management unit 17 when receiving this notification. In the present embodiment, the timer management unit corresponds to a timer management unit described in the claims.

That is, as shown in FIG. 5B, when the execution of the in-model processing for the simulation time scan time is completed, the model execution unit 18 waits for the elapse of the real time scan time (that is, the model execution unit 18). Wait for notification from timer management unit). Therefore, the time of one cycle of the model execution unit 18 is the output time of data to the input / output data management unit 17, the input time of data from the input / output data management unit 17, the processing time in the model for the simulation time scan time, and It consists of a synchronous waiting time, which coincides with the real time scan time (one cycle time of the conveyor control board CC).

The asynchronous system will be described. The asynchronous method is a method of performing one cycle of processing in the model execution unit 18 regardless of the time of one cycle of the conveyor control panel CC. This asynchronous system is used for simply checking the operation of the created model when the conveyor control panel CC and the simulation device 1 are not connected at the time of model creation or the like. In this case, since the input data from the conveyor control panel CC is not input, it is input from the input / output data direct access unit 16 by the operator. The model execution unit 18 outputs data to the input / output data management unit 17 without providing a waiting time,
The input of the data from 7 and the execution of the in-model processing for the simulation time scan time are continuously performed.

That is, as shown in FIG. 5C, the time of one cycle of the model execution unit 18 is determined by the output time of data to the input / output data management unit 17 and the data output time from the input / output data management unit 17. It consists of the processing time in the model for the input time and the scan time for the simulation time, and varies.

Further, the model execution unit 18 has a display function in a case where a process that must be executed in one cycle cannot be executed within one cycle of the conveyor control panel CC. This is because various types of arithmetic processing are executed in the in-model processing by the model execution unit 18, and the load due to this arithmetic is mainly affected by the scale of the model and the number of pallets. For example, if the calculation load is increased by increasing the number of pallets, the processing in the model for the simulation time scan time is performed until the next communication synchronization value change notification message is received or during the real time scan time of the time synchronization method. May not be executed at all. In order to allow the operator to recognize such a case, the model execution unit 18 uses the information display unit 32 of the simulation window 30.
In the DEAL column 32b, the waiting time (NOW) during one cycle in the current cycle, the maximum time required to execute the processing of one cycle (MAX), and the processing time of one cycle in one cycle of the conveyor control panel CC The number of times (CNT) that could not be executed is displayed (see FIG. 9).

In the case where the computer 3 has insufficient arithmetic processing capability, the simulation time scan time with respect to the real time scan time is set to a short time (the pallet is transported at a lower speed than the actual time), and the load of the arithmetic processing is reduced. Can be reduced. In this case, it is necessary to change the timer value in the control program of the conveyor control panel CC in accordance with this setting.

The input / output data tracking section 19 will be described. The input / output data tracking unit 19 can set the input / output data when the input / output data management unit 17 outputs the input / output data to the input / output data tracking unit 19 at the timing of inputting / outputting data to / from the model execution unit 18. For a short time, and a part of an auxiliary storage device such as a hard disk of the computer main unit 3 is allocated. The input / output data tracking unit 19 can also output the stored input / output data to a file, the display 6, or the like as needed. These data are used when verifying data when a failure occurs and when reproducing the failure with the simulation device 1.

The simulation apparatus 1 having the above-described configuration has the following functions in the simulation apparatus 1 and the conveyor control panel CC in order to further secure the reliability of communication with the conveyor control panel CC. Have. In the simulation apparatus 1, the response time of data between the selected communication board 11 and the conveyor control panel CC changes. Therefore, two programs are added to the control program of the conveyor control panel CC and data relating thereto are added so that the operator can recognize the response time. The simulation device 1 also has a function of displaying the transmission time and the like on the information display section 32 of the simulation window 30 (see FIG. 9). Therefore, the two programs added to the control program and the processing in the simulation device 1 will be described.

The first additional program to the control program will be described. First, count-up data is prepared. In this program, the count-up data is incremented by one for each process of the conveyor control panel CC in one cycle, and the count-up data is output.

The processing of the count-up data in the simulation device 1 will be described. The simulation apparatus 1 subtracts the previously input and stored count-up data from the count-up data input in the current cycle, and determines whether or not the subtracted value has exceeded 1. In the simulation apparatus 1, if the subtraction value does not exceed 1, the conveyor control panel C
It is determined that the output from C is fetched stably, and if the subtraction value exceeds 1, it is determined that the output from the conveyor control panel CC is not fetched every cycle. Further, in the simulation device 1, the Check column 32c of the information display unit 32 of the simulation window 30 is displayed.
When the subtraction value exceeds 1 in this cycle, the subtraction value (OverNow), the maximum value of the subtraction value exceeding 1 in the past (OverMax), and the number of times the subtraction value exceeds 1 (Count) are displayed. (See FIG. 9).

That is, despite the fact that the conveyor control panel CC outputs count-up data counted up by one every cycle, the subtraction value of the previous and current count-up data exceeds 1 in the simulation apparatus 1. This means that the data from the conveyor control panel CC cannot be taken in every cycle by the simulation apparatus 1. This may be due to variations in the communication time of the selected communication board 11,
It is conceivable that the execution of the in-model processing for the simulation time scan time could not be executed within the real time scan time, or that in the time synchronization method, the deviation of the timer accuracy between the conveyor control panel CC and the simulation device 1 is accumulated. .

Incidentally, this count-up data is
Since the conveyor control panel CC counts up and outputs one by one for each cycle, it is also used as synchronization data of the communication synchronization system.

Next, a second additional program to the control program will be described with reference to FIG. FIG.
It is explanatory drawing of the response time confirmation method in the simulation apparatus 1, (a) is a block diagram of a process in one cycle in the conveyor control panel CC, (b) is between the simulation apparatus 1 and the conveyor control panel CC. FIG. 4 is an explanatory diagram of response time in FIG. Note that, in the description here, the simulation device 1 performs synchronization by the communication synchronization method, and releases the waiting state when synchronization data from the conveyor control panel CC arrives.

In the conveyor control panel CC, one cycle of processing is performed as follows. As shown in FIG. 6A, the processing in the conveyor control panel CC is periodically performed with a real-time scan time as one cycle, and collectively outputs data to outside, collectively inputs data from outside, and The control program is executed in the order of execution based on the input data, and there is a waiting state until the real time scan time elapses. Therefore, since the input and output of data with the outside are performed collectively in one cycle,
Conveyor control panel C data even slightly after batch input
Upon arriving at C, this data is entered in the next cycle. Therefore, the data that arrives late is not reflected in the execution of the control program in the cycle at the time of arrival, but is reflected in the execution of the control program in the next cycle.

First, handshake data is prepared. In the additional program on the conveyor control panel CC, when handshake data recognized as 1 in the previous cycle was recognized as 0 in the current cycle, 0 was output, and 0 was recognized in the previous cycle. When the handshake data is recognized as 1, the output is 1. By the way, in the conveyor control panel CC, even if one handshake data arrives during the execution of the control program, the batch input has been completed. Therefore, the handshake data is not recognized as 1 in this cycle. Therefore, one handshake data is collectively input in the next cycle and is recognized by the control program in the next cycle.

The simulation apparatus 1 outputs 1 when the handshake data recognized as 1 in the previous cycle is recognized as 0 in the current cycle, and outputs the handshake data recognized as 0 in the previous cycle. When the data is recognized as 1, 0 is output. By the way, in the simulation device 1, even if one handshake data arrives during the execution of the in-model processing, the batch input has been completed, and therefore, in this cycle, the handshake data is not recognized as one. Therefore, one handshake data is input collectively in the next cycle and is recognized during execution of the in-model processing in the next cycle.

In the simulation apparatus 1, the number of cycles until the handshake data is recognized as 0 to 1 or 1 to 0 is defined as the response time, and the response time of the information display unit 32 of the simulation window 30 is set as the response time.
The current response time (NOW) and the past maximum response time (MAX) are displayed in the nse column 32d (see FIG. 9).

The input / output of handshake data and the response time between the simulation apparatus 1 and the conveyor control panel CC will be described with reference to FIG. The device-side input values and the control-board-side input values in this figure indicate the values of handshake data recognized by batch input of data in one cycle of processing. Therefore, when the handshake data arrives after the data is input, the value of the arriving handshake data is not reflected on the device-side input value and the control panel-side input value. In the example of this figure, since the handshake data arriving in each cycle has arrived after the batch input of data, the value of the arriving handshake data is recognized in the next cycle. Therefore, in the example of this figure, the response time is the maximum response time when normal data is input and output between the simulation device 1 and the conveyor control panel CC.

In a certain cycle, the simulation apparatus 1
Recognizes 0 as handshake data (S
1). The simulation device 1 has a conveyor control panel CC
, One handshake data arrives (S2). At the time of arrival, data input has been completed. Therefore, in the next cycle, the simulation device 1 inputs and stores the arrived one handshake data.
Subsequently, the simulation device 1 recognizes 1 as handshake data (S3). In the next cycle, the simulation device 1 outputs 0 as the handshake data (S4) and waits for the arrival of the handshake data.

The handshake data of 0 arrives at the conveyor control panel CC from the simulation device 1 (S
5). Since the data input has been completed at the time of arrival, the conveyor control panel CC recognizes 1 as the previously stored handshake data (S6). In the next cycle, the conveyor control panel CC inputs and stores the arriving 0 handshake data. Subsequently, the conveyor control panel CC recognizes 0 as handshake data (S
7) Output 0 as handshake data (S)
8).

Handshake data of 0 arrives at the simulation device 1 from the conveyor control panel CC (S
9). At the time of arrival, data input has been completed. Therefore, in the next cycle, the simulation device 1 inputs the arriving handshake data of 0,
Remember. Subsequently, the simulation device 1 recognizes 0 as handshake data (S10). By the way, in the simulation device 1, until the previous cycle,
The handshake data is recognized as 1.

Therefore, the simulation device 1 requires four cycles from the recognition of the handshake data as 1 to the recognition of the handshake data as 0, so the response time is set to 4.

The operation of the simulation apparatus 1 by the operation of the operator will now be described with reference to FIGS. In the description of the operation, the description will be made separately on the creation of the model and the execution (simulation) of the model. FIG.
Is an automatic transport system S by the simulation device 1
3 is an example of a model creation window 20 of the transfer equipment.
FIG. 8 is an example of a parameter setting window of each conveyor module by the simulation device 1. FIG.
Is an automatic transport system S by the simulation device 1
Is an example of a simulation window 30 of the operation of FIG.

The creation of a model will be described. When creating a model of the transport equipment of the automatic transport system S, the operator executes a simulation program on the personal computer 2. Then, the simulation device 1 is configured in the personal computer 2 and a main menu window (not shown) is displayed on the display 6. Therefore, the operator selects model creation from the main menu window. Then, a model creation window 20 shown in FIG. 7 is displayed on the display 6. This model creation window 2
0 mainly has a module selection window 21 and a module arrangement area 22. In the module selection window 21, modules such as a conveyor module as shown in FIG. 4 are prepared.

The operator selects the module selection window 21
The necessary conveyor module is selected from the list, and is arranged in the module arrangement area 22 in consideration of the line configuration of the conveyor in the automatic transport system S. Further, the conveyor module is connected to the conveyor module arranged before, and a conveyor line in the automatic transport system S is configured. Specifically, as shown in FIG. 7, the operator operates an arbitrary conveyor module 21a.
Is dragged and dropped from the module selection window 21 to the module arrangement area 22. Then, the arranged conveyor module 22d is connected to the previously arranged conveyor module 22c. Then, the conveyor modules 22a to 22c which are sequentially arranged and further connected
With the use of 22g, a model of the conveyor line of the automatic transport system S is created.

Further, the operator sets parameters of the conveyor equipment of each conveyor module as shown in FIG. 4 for the arranged conveyor modules 22a to 22g.
Specifically, the operator double-clicks the conveyor modules 22a to 22g arranged in the module arrangement area 22. Then, a parameter setting window 23 is displayed in the module placement area 22 as shown in FIG. The operator sets the parameter setting window 23
The user inputs a conveyor label, a conveyor number, a conveyor length, and the like. Then, in the simulation device 1, as shown in FIG.
The schematic diagrams 22a1 to 22g1 of the conveyors corresponding to the conveyor modules 22a to 22g are displayed along g.

The parameter setting window 23
A call button 23 of a parameter setting window for setting parameters relating to the speed of the conveyor and parameters of other transport equipment such as an optical sensor and a stopper.
a, 23b and 23c are provided. Then, the operator clicks the speed button 23a. Then, a speed parameter setting window 24 is displayed. Then, the operator inputs the conveyor speed, the conveyor acceleration, the conveyor deceleration, and the like in the speed parameter setting window 24. Further, the operator calls each parameter setting window by the stopper button 23b and the optical sensor button 23c, and inputs parameters to each parameter setting window (not shown). Then, in the simulation apparatus 1, as shown in FIG. 8, a schematic diagram 22i of an optical sensor, a schematic diagram 22j of a barcode reader, a schematic diagram 22k of a stopper, and the like are displayed beside the schematic diagram 22h of the conveyor.

Further, the operator calls up modules (not shown) of other transport equipment such as a host computer or a floor control panel, and sets parameters in these modules. The operator calls the pallet module,
The pallet type, size, display method on the display 6, bar code information, and the like are set. The setting for the pallet module may be performed before the model is executed.

As described above, the operator forms the conveyor line formed on each floor of the automatic transport system S in the module disposition area 22 and further sets the parameters of each transport facility, whereby the automatic transport system S for each floor is set. Create a model of the transfer equipment. After the model is created, the operator calls a main menu window (not shown) on the display 6. Then, the operator selects model storage from the main menu window. Then, the simulation device 1 stores the created model. In the storage of this model, a model for each floor in the automatic transport system S is stored.

Next, the execution of the model will be described. Before starting the simulation, the operator makes the following preparations. The operator connects the personal computer 2 and the conveyor control panel CC via Ethernet. Further, the following settings are made in order to insert a pallet as a conveyed object during the simulation. The operator calls a main menu window (not shown) on the display 6. Then, the operator selects a load (pallet) loading condition from the main menu window. Then, a load condition window (not shown) is displayed on the display 6. Therefore, the operator inputs the loading position for each pallet type, loading start time,
Set the feeding interval, feeding quantity, etc. By making this setting, the pallet is loaded based on the loading conditions during the simulation. Further, the operator selects an arbitrary loading condition of the conveyed product (pallet) from the main menu window. Then, an arbitrary loading condition window (not shown) is displayed on the display 6. Therefore, the operator displays the conveyed article arbitrary input condition window as follows:
Each key of the keyboard 4 is assigned to each combination of the input position and the pallet type. By making this setting, the pallet can be loaded at any time and at any interval from any loading position by a key operation on the keyboard 4 by the operator during the simulation. The key operation is input via the input / output data direct access unit 16.

After the above preparation, the operator operates the display 6
A main menu window (not shown) is called.
Then, the operator selects model execution from the main menu window. Then, the simulation apparatus 1 displays a simulation window 30 on the display 6 as shown in FIG. Then, the operator calls a model of a floor on which simulation is desired from the File menu 30a. Then, the simulation apparatus 1 displays a schematic diagram 33 of the called conveyor line on the called floor, a schematic diagram 34 of the product shelf, and the like in the simulation window 30 and also displays a number of lines along the side of the schematic diagram 33 of the conveyor line. Schematic diagram of optical sensor 35,
,..., And stopper schematic diagrams 37,. In addition, in the schematic diagram 33 of the conveyor line, it is cut in view of the screen size, but in the actual automatic transport system S, the conveyor end 3 is cut.
3a is connected to the conveyor end 33b. In the schematic diagram 33 of the conveyor line, an elevator type conveyor from the upper floor is connected to the conveyor end 33c.

In the simulation apparatus 1, a direct access window 31 and an information display section 32 are displayed in the simulation window 30. The operator can input and output various data set in the direct access window 31 at an arbitrary timing during the simulation. Before performing the simulation, the operator sets the SYNC CYCLE column 32a of the information display unit 32.
, A simulation time scan time (sim) and a real time scan time (real) are set. In the example of FIG. 9, since the simulation time scan time and the real time scan time are both set to 40 mS, the simulation is performed in real time of the automatic transport system S. Further, the operator can confirm the calculation load on the simulation device 1 by the DEAL column 32b of the information display unit 32 during the simulation. In the example of FIG. 9, CNT in the DEAL column 32b is 1 and MAX is 41.
Since it is mS, it can be understood that the processing in the model could not be executed within the real time scan time, requiring only 41 mS once. Also, during the simulation, the operator
Check column 32c and Responses of information display unit 32
It is possible to confirm whether or not the communication state between the conveyor control panel CC and the simulation device 1 is good by the e column 32d.

After setting the SYNC CYCLE column 32a of the information display section 32, the operator executes the model from the Run menu 30b of the simulation window 30, and starts the simulation. Then, the simulation device 1 simulates the operation of the host computer,
It outputs data such as a start instruction signal and an operation mode setting signal to the conveyor control panel CC. Next, the conveyor control panel CC
Then, an On signal or the like to the conveyor drive motor is output to the simulation device 1. Then, the simulation device 1 simulates the operation of each conveyor or the like according to the parameters set by the operator, and further inputs the pallets according to the input conditions set by the operator. Then, in the simulation window 30, the schematic diagrams 38,... Of many pallets move on the schematic diagram 33 of the conveyor line. Incidentally, when the simulation time scan time and the real time scan time are set to the same time (40 mS), in the simulation apparatus 1, the speed at which the pallet schematic diagrams 38,. Move at the same speed as.

At the picking point 33d, the following simulation is performed. Simulation device 1
Then, a schematic diagram 38 of a certain pallet is a schematic diagram 3 of an optical sensor.
After passing through 5, the operation of the optical sensor is simulated, and the On signal data of the optical sensor is output to the conveyor control panel CC. Then, the conveyor control panel CC outputs a read signal to the barcode reader near the downstream side of the optical sensor and a pallet arrival notification signal to the host computer, to the simulation device 1. When data of these signals is input, the simulation device 1
Then, the operation of the high-order personal computer is simulated, and the presence or absence of the necessary product on the product shelf at the picking location 33d is determined based on the barcode information. If there is a necessary product, the simulation apparatus 1 outputs a stop instruction signal and data of information on the required product to the conveyor control panel CC. Then, the conveyor control panel CC outputs the data of the On signal to the stopper to the simulation device 1. Then, the simulation device 1 simulates the operation of the stopper and stops the movement of the pallet.
Further, the simulation device 1 simulates the operation of the host computer and outputs the data of the start instruction signal to the conveyor control panel CC after the lapse of the work time required for picking set as a parameter. Then, the conveyor control panel CC outputs an Off signal to the stopper to the simulation device 1. Then, the simulation device 1 simulates the operation of the stopper, lowers the stopper, and resumes the movement of the pallet. As a result, on the schematic diagram 33 of the conveyor line on the simulation screen 30, the schematic diagram 38 of the pallet stops for a predetermined time. On the other hand, when there is no necessary product, the simulation device 1 simulates the operation of the host personal computer and outputs the data of the start instruction signal to the conveyor control panel CC.
Then, the conveyor control panel CC is a schematic diagram of a pallet 38.
Continue to move.

At the junction 33e, the following simulation is performed. The simulation device 1 simulates the operation of the host personal computer,
A merging mode is set based on the bar code information of the pallet before this, and data of a merging mode setting signal and a start instruction signal / stop instruction signal are output to the conveyor control panel CC. In the conveyor control panel CC, based on the merging mode and the start instruction / stop instruction, the confluence point 33 is sent to the simulation device 1.
It outputs an On signal / Off signal to the two stoppers before e. The simulation device 1 simulates the operation of the two stoppers, raises one of the stoppers to stop the movement of the pallet, and lowers the other stopper to move the pallet. As a result, the confluence point 3 in the schematic diagram 33 of the conveyor line on the simulation screen 30
In 3e, the schematic diagram 38 of one pallet stops, and the schematic diagram of the other pallet moves to the junction 33e.

Further, in the simulation apparatus 1, the operator can insert a pallet at an arbitrary time and at an arbitrary interval from an arbitrary insertion position by a key operation set in an arbitrary load condition window for a conveyed object, so that various conditions can be satisfied. 38,... Can be confirmed. Further, in the simulation device 1, when the operator inputs the data of the On signal of the emergency stop button from the direct access window 31,
Automatic transport system S in various situations such as abnormal or emergency situations
Operation can be confirmed.

Further, before starting the simulation, the operator can select the tracking by a main menu window (not shown) and start the tracking. In this case, the simulation device 1 stores data input and output by the model execution unit 18 together with time data, and enables output of this data to a file or the like.

According to the simulation apparatus 1, when it is desired to confirm the operation of the control program of the conveyor control panel CC, a model of the transfer equipment of the automatic transfer system S can be easily constructed, and the control by the simulation using the model can be performed. The program can be verified.
Further, according to the simulation apparatus 1, the conveyor C is used according to the model of the transfer equipment of the automatic transfer system S without actually constructing the transfer equipment of the automatic transfer system S.
V,... Line configuration, optical sensor SR, stopper ST
Can be confirmed on the display 6.
Further, according to the simulation apparatus 1, the movement state of the pallets PT,... Under various conditions, the state of digital picking, and the state at the merging point JP are displayed by simulation using a model of the transfer equipment of the automatic transfer system S. 6, various inconveniences can be resolved before the transport equipment is actually constructed. As a result, troubles are reduced in an on-site test after constructing the transfer equipment of the actual automatic transfer system S.

Further, according to the simulation apparatus 1, the converging modules prepared for the various conveyors are arranged in the module arrangement area 22 of the model creation window 20, and the parameters of the arranged conveyer modules are set. It is possible to easily configure a complicated conveyor line layout including points and branch points. Therefore, if the simulation apparatus 1 is used, a layout change in response to a user request, a layout change at the time of debugging, and a parameter change can be easily performed.

Further, according to the simulation apparatus 1, the operation of the automatic transport system S can be simulated in real time by synchronizing one cycle of the conveyor control panel CC with one cycle of the model execution unit 18. it can. In particular, in the simulation device 1, by using the count-up data rewritten every cycle from the conveyor control panel CC, synchronization can be achieved with high accuracy by a simple method. Therefore, in the simulation device 1, since the exact position and speed of the pallets at the merging point according to the operation of the automatic transport system S in real time, the exact interval between the pallets, and the like can be confirmed, the pallets can be checked. It is possible to check whether or not a collision occurs on the conveyor.

Further, in this simulation apparatus 1,
Since the input / output data can be stored together with the time data, a defect or the like can be easily reproduced. Further, in the simulation device 1, the communication state with the conveyor control panel CC can be confirmed based on the count-up data and the handshake data. Moreover,
In the simulation device 1, by providing the input / output data direct access unit 16, various data can be input / output at an arbitrary timing, and debugging can be performed efficiently.

Further, the control programs for the conveyor control panel CC and the like have been conventionally developed by skilled programmers who are well-versed in the actual transport equipment of the automatic transport system S and the problems in field tests. However, by using the simulation apparatus 1, the transfer equipment of the automatic transfer system S can be easily modeled and debugged by this model, so that development by a programmer with a poor knowledge of the work site becomes possible, and training of the programmer is also possible. Can be done quickly.

Although the embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments, but can be implemented in various forms. For example, the simulation device according to the present embodiment is applied to an automatic transport system in a shipping system using digital picking,
The present invention is not limited to this automatic transport system, but can be applied to other automatic transport systems. Further, although the simulation apparatus according to the present embodiment is configured by incorporating a simulation program into a personal computer, the simulation apparatus may be configured as a dedicated machine. Also,
In the automatic transport system according to the present embodiment, the transported object is transported by the conveyor, but may be transport equipment other than the conveyor.

[0118]

According to the first aspect of the present invention, the simulation apparatus for an automatic transport system performs one cycle of processing by the simulation means in synchronization with one cycle of processing by the control controller. The operation of the transported object can be simulated in real time.

According to a second aspect of the present invention, there is provided a simulation apparatus for an automatic transport system, wherein the timing at which one cycle of processing is started by the simulating means is set to the time when an output signal from the control controller is received. And can be synchronized with high accuracy.

A simulation apparatus for an automatic transport system according to a third aspect of the present invention comprises a control controller
By measuring the time of the cycle, it is possible to synchronize with the control controller.

The automatic transport system simulation apparatus according to the fourth aspect of the present invention can arbitrarily give a command from the outside by the external signal generating means. Can be

In the simulation apparatus for an automatic transport system according to the fifth aspect of the present invention, the simulation means can simulate an arbitrary simulation time in one cycle. It can be simulated earlier or later than the real time when you are.

The automatic transport system simulation apparatus according to claim 6 of the present invention can easily construct a simulation model of the automatic transport system by creating a model of the transport equipment.

In the simulation method of the automatic transport system according to claim 7 of the present invention, the process in one cycle is performed in synchronization with the one-cycle process in the control controller in the simulation process. Can be simulated in real time.

[0125] In the simulation method for an automatic transport system according to claim 8 of the present invention, the timing at which one cycle of processing is started in the simulating step is set to the time when the output signal from the control controller is received. Synchronization can be performed with high accuracy.

According to a ninth aspect of the present invention, there is provided a method for simulating an automatic transport system, comprising the steps of:
By measuring the time of the cycle, it is possible to synchronize with the control controller.

In the method for simulating an automatic transport system according to the tenth aspect of the present invention, since an external signal can be arbitrarily given in the external signal generating step, an abnormal or emergency operation in the automatic transport system can be simulated. Can be

In the simulation method for an automatic transport system according to claim 11 of the present invention, the simulation can be performed for an arbitrary simulation time in one cycle in the simulation process. It can be simulated earlier or later than the real time when you are.

In the simulation method of the automatic transport system according to the twelfth aspect of the present invention, a simulation model of the automatic transport system can be easily constructed by creating a model of the transport equipment.

A simulation program for an automatic transport system according to a thirteenth aspect of the present invention can realize the above-described simulation method when executed by a computer.

[Brief description of the drawings]

FIG. 1 is a configuration diagram of an automatic transport system according to an embodiment.

FIG. 2 is a perspective view of a conveyor of the automatic transport system of FIG. 1, where (a) is a conveyor at a picking position;
(B) is a conveyor at the junction.

FIG. 3 is a configuration diagram of a simulation device according to the present embodiment.

FIG. 4 is an example of a configuration of a conveyor module in a model creation unit in FIG. 3;

5A and 5B are explanatory diagrams of a synchronization method in the simulation device according to the present embodiment, where FIG. 5A is a configuration diagram of one cycle of processing in the case of a communication synchronization method, and FIG. FIG. 13 is a configuration diagram of one cycle of processing in the case (c).
FIG. 5 is a configuration diagram of one cycle of processing in the case of an asynchronous system.

FIG. 6 is an explanatory diagram of a response time confirmation method in the simulation device according to the present embodiment, and (a) is a configuration diagram of a process in one cycle in a conveyor control panel;
(B) is an explanatory diagram of a response time between the simulation device and the conveyor control panel.

FIG. 7 is an example of a model creation window of a transfer facility of the automatic transfer system by the simulation apparatus according to the present embodiment.

FIG. 8 is an example of a parameter setting window of each conveyor module by the simulation device according to the present embodiment.

FIG. 9 is an example of a simulation window of the operation of the automatic transport system by the simulation device according to the present embodiment.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Simulation apparatus 2 ... Personal computer 3 ... Computer body 4 ... Keyboard (input means) 5 ... Mouse (input means) 6 ... Display (output means) 10 ... ON Output unit 11 Communication board 12 Communication management unit (communication management unit) 13 Memory 14 Model creation unit (model creation unit) 15 Model storage unit (model storage unit) 16 ... Input / output data direct access unit (external signal generation means) 17 ... Input / output data management unit (input / output management means) 18 ... Model execution unit (simulation means) 19 ... Input / output data tracking unit S・ ・ ・ Automatic transfer system BR ・ ・ ・ Bar code reader (transport equipment) CC ・ ・ ・ Conveyor control panel (control controller) CV ・ ・ ・ Conveyor (transport equipment) CVa ・・ Conveyor drive motor (transportation equipment) EC: Inter-floor control panel (transportation equipment) LT: Indicator light (transportation equipment) PC: Host computer (transportation equipment) PT: Pallet (transportation object) LS: Limit switch (transport equipment) SB: Emergency stop button (transport equipment) SR: Optical sensor (transport equipment) ST: Stopper (transport equipment)

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 3F022 EE02 FF01 LL31 MM08 MM22 MM36 NN38 PP04 QQ01 QQ12 5H223 AA05 CC01 CC08 DD03 DD07 DD09 EE30 FF05

Claims (13)

[Claims] 1. A simulation device for controlling a transfer facility by a control controller and simulating an operation of an automatic transfer system for automatically transferring a conveyed object by the transfer facility, comprising: an output signal from the control controller; Simulating the operation of the transport facility based on the simulated operation, simulating the transport of the article by the simulated operation and outputting a simulated signal from the transport facility, and an output signal from the control controller and / or Input / output management means for managing a simulation signal from a simulation means, communication management means for managing signal communication between the control controller and the simulation means, and simulation operation of the transport equipment and / or the conveyed object. And a display means for displaying the following. The simulation means is a one-cycle process in the control controller. And performing one cycle of processing in synchronization with the automatic transport system. 2. The control controller outputs an output signal every cycle, the input / output management unit notifies the simulation unit of a reception time point of an output signal from the control controller, and the simulation unit The simulation apparatus for an automatic transport system according to claim 1, wherein the processing of the next cycle is started from a point in time at which a reception point is notified from the input / output management unit. 3. A timer management means for measuring one cycle time in the control controller, wherein the simulation means performs one cycle of one cycle time in the control controller measured by the timer management means. The simulation device for an automatic transport system according to claim 1, wherein the simulation is performed. 4. An input means for inputting a command to the simulation means, and an external signal generating means for generating an external signal to the simulation means in response to a command from the input means. The simulation device for an automatic transport system according to claim 1, wherein: 5. The simulation time of one cycle in the simulation means can be set to an arbitrary time, and the simulation means performs simulation for the simulation time in one cycle. 5. The simulation device for an automatic transport system according to claim 4. 6. A model creating means for creating a model of the transport equipment, and a model storage means for storing the created model, wherein the simulating means includes a model for the transport equipment based on the model stored in the model storage means. The simulation device of the automatic transport system according to claim 1, wherein the simulation device simulates an operation. 7. A simulation method for simulating an operation of an automatic transport system for controlling transport equipment by a control controller and automatically transporting a transported object by the transport equipment, wherein an output signal from the control controller is A simulation step of simulating the operation of the transport equipment based on the simulation operation, simulating the transport of the conveyed object by this simulated operation and outputting a simulation signal from the transport equipment, and an output signal from the control controller and / or An input / output management step of managing a simulation signal from a simulation step; a communication management step of managing signal communication between the control controller and the simulation step; a simulation operation of the transport equipment and / or the transported object. And a display step of displaying a. Performing one cycle of processing in synchronization with the process. 8. The control controller outputs an output signal every cycle, and in the input / output management step, notifies the simulation step of a reception point of an output signal from the control controller; 8. The simulation method for an automatic transport system according to claim 7, wherein a process of a next cycle is started from a point in time when a reception point is notified from the input / output management step. 9. A timer management step of measuring one cycle time in the control controller, wherein the simulating step includes processing of one cycle with one cycle time in the control controller measured in the timer management step. 9. The method for simulating an automatic transport system according to claim 7, wherein the simulation is performed. 10. An input step for inputting a command to the simulation step, and an external signal generation step for generating an external signal for the simulation step in response to a command from the input step. The method for simulating an automatic transport system according to any one of claims 7 to 9, wherein 11. The simulation time of one cycle in the simulation step can be set to an arbitrary time, and in the simulation step, simulation is performed for the simulation time in one cycle. The method for simulating an automatic transport system according to any one of claims 10 to 13. 12. A model creating step of creating a model of the transport facility, and a model storing step of storing the created model. In the simulating step, the model of the transport facility is stored based on the model stored in the model storing step. The method of simulating an automatic transport system according to any one of claims 7 to 11, wherein the operation is simulated. 13. A simulation program for simulating an operation of an automatic transport system that controls transport equipment by a control controller and automatically transports a transported object by the transport equipment. Any one of claims 12
A simulation program for an automatic transport system, which realizes the simulation method described in the section.