Transportation system of a floated-carrier type

The present invention relates to a transportation system of a floated-carrier type, and more particularly, to a transportation system of a floated-carrier type which comprises a guide rail, composed of main and branch lines, in order that a carrier can be transferred from the main lines to the branch lines.

To increase office or factory automation, transpor­tation systems have recently been installed in some buildings. Such systems are used to transport slips, documents, cash, samples, or the like, between a plural­ity of locations in the buildings.

In order to avoid spoiling the environment of the offices or factories, transportation systems of this type are expected not to produce dust or high levels of noise. Thus, in one such conventional transportation system, described in U.S. Pat. Appl. No. 726,975/85, filed previously by the inventor hereof, a carrier is kept floating, in a non-contact manner, above a guide rail, by means of an electromagnetic attractive force acting between the carrier and the rail, when the carrier is propelled along the rail.

The carrier must be transported smoothly to various locations in a building, and, to attain this, the guide rail is composed of main lines, connecting principal locations in the building, and branch lines, which diverge from the main lines and connect various secondary locations therein.

It is necessary, therefore, to provide means for transferring the carrier, running along the main lines, to the branch lines, and vice versa. Prior art examples of a transfer means of apparatus are disclosed in the following publications:

U.S. Pat. No. 4,l09,584 describes a transportation system, which is provided with a rail-switching device at a diverging section, where branch lines diverge from main lines. When the switching device is operated mechanically, the main lines are disconnected from one another, and are connected to the branch lines, so that a carrier can be transferred from the main lines to the branch lines.

In a system described in Japanese Patent Disclosure No. 50-l50ll2, no rail-switching device is provided, and main and branch lines are connected directly at a diverging section. A guide plate is provided at the diverging section, whereby the rollers of a carrier are guided from the diverging section to the branch lines. As the rollers slide along the guide plate, the carrier is transferred from the main lines to the branch lines.

As has been described above, however, the apparatus for transferring the carrier, from the main lines to the branch lines, requires a mechanical switching device. Therefore, the transfer apparatus is increased in size, thereby reducing the available space in the office. Moreover, the switching device is operated mechanically, and, especially in the system described in Japanese Patent Disclosure No. 50-l50ll2, the rollers of the carrier are in contact with the guide plate while the carrier is being transferred. As a result, noise is produced by the transfer apparatus.

Thus, such a transfer apparatus is liable to spoil the environment of the office, in which case the main lines should not be provided with transfer apparatuses. In this therefore, the carrier cannot run smoothly along the guide rail, and can reach its destination only after a long period of time.

The object of the present invention is to provide a transportation system of a floated-carrier type, in which a small-sized apparatus is used to transfer a carrier from main lines to branch lines, and in which noise is prevented from being produced by the transfer apparatus.

A transportation system of a floated-carrier type, according to the present invention, comprises a guide rail formed of main lines and branch lines intersecting one another, a coupling section connecting the main and branch lines, and a carrier for carrying cargo, the carrier being capable of running along the guide rail. The carrier is kept floating, i.e., in a non-contact manner, from the guide rail, by means of an electro­magnetic attractive force. Transfer means is provided at the coupling section. At the coupling section, the carrier, having so far been running along the main lines, is stopped, and then transferred to the branch lines, all in a non-contact manner.

This invention can be more fully understood from the following detailed description when taken in con­junction with the accompanying drawings, in which:

• Fig. l is a perspective view of a transportation system of a floated-carrier type according to an embodi­ment of the present invention;
• Fig. 2 is a perspective view of the transportation system shown in Fig. l, with its guide rail cover and part of the transfer apparatus removed;
• Fig. 3 is a sectional view of a magnetic unit for causing a carrier to float from a guide rail;
• Fig. 4 is a plan view of the transportation system shown Fig. l, with its guide rail cover removed;
• Fig. 5 is a block diagram of a control device for controlling a transfer apparatus of the transportation system shown in Fig. l;
• Figs. 6 to 9 are plan views of the transportation system shown in Fig. l, with its guide rail cover re­moved, illustrating the way the carrier is transferred from the main lines to the branch lines;
• Fig. l0 is a plan view showing a modified example of the transportation system, with its guide rail cover removed, in which branch lines extend from both sides of the main lines;
• Fig. ll is a plan view showing another modified example of the transportation system, with its guide rail cover removed, in which the positions of stators of three linear induction motors are changed;
• Fig. l2 is a plan view showing still another modi­fied example of the transportation system, with its guide rail cover removed, in which a transfer apparatus is provided with air nozzles;
• Fig. l3 is a plan view showing a further modified example of the transportation system, with its guide rail cover removed, using a stator of a linear induction motor for bi-directioal transportation; and
• Figs. l4A, l4B, and l4C are flow charts showing the steps when the carrier is transferred from the main lines to the branch lines.

In a transportation system of a floated-carrier type, as shown in Figs. l and 2, guide rail l, including main lines 32 and branch lines 33, is arranged in an office. Carrier 2 is kept floating, in a non-contact manner, below rail l, by means of a magnetic attractive force acting between carrier 2 and rail l, as the carrier is propelled along the rail.

As is shown in Fig. 2, carrier 2 is provided with rectangular plate ll, facing the underside of guide rail l. Magnetic units l2-l, l2-2, l2-3, and l2-4 are arranged on the four corners of the upper surface of plate ll. They serve to cause carrier 2 to float below rail l. Carrier box l3 is supported by the lower sur­face of plate ll. Reaction plate l4 is located in the center of the upper surface of plate ll, so as to face stators 43-l, 43-2, and 43-3 of the four linear induc­tion motors of transfer apparatus 43, which will be described in detail later.

As is shown in Fig. 3, magnetic units l2-l to l2-4 are each provided with yokes 25 and 26, facing guide rail l. Conducting wires are wound around yokes 25 and 26, thus forming coils 27 and 28. Air gap P is defined between the top face of each yoke and the lower surface of rail l. Permanent magnet 24 is used to couple yokes 25 and 26 magnetically. Thus, magnet 24, yokes 25 and 26, gaps P, and rail l constitute a magnetic circuit. Each magnetic unit is further provided with a gap sensor 29 for detecting the amount of clearance of gap P.

Carrier 2 is suspended floating from guide rail, in a non contact manner, by means of a magnetic attractive force acting between magnetic units l2-l to l2-4 and guide rail l. In this embodiment, units l2-l to l2-4 are controlled by zero-power control device 30, so that the minimum necessary electric current is supplied to coils 27 and 28 when carrier 2 is made to float. In other words, four permanent magnets 24 always generate an attractive force equal to the total weight of carrier 2 itself and the load. At the same time, coils 27 and 28 are excited, so as to maintain the air gap clearance at which the attractive force between the magnetic units and rail l balances with the total weight of the carrier itself and the load. Coils 27 and 28 serve to subordinately cause carrier 2 to float. If the total weight of carrier 2 is changed by the load, the supply of current to coils 27 and 28 is controlled so that gap P is adjusted to a distance such that the attractive force from magnet 24 is equal to the total weight of carrier 2. In other words, by controlling the current supply to the coils, gap P is adjusted to a distance such that carrier 2 is caused to float by means of the magnetic energy of magnet 24 only, despite the existence of disturbances. (The zero-power control device is described in detail in U.S. Pat. Appl. No. 726,975/85, filed previously by the inventor hereof.)

Guide rail l, formed of ferromagnetic material, as shown Figs. 2 and 4, is composed of paired main lines 32 which extend parallel to each other, and paired parallel branch lines 33 which extend substantially at right angles to the main lines. The distance between lines 32 is equal to that between magnetic units l2-l and l2-2 (or l2-3 and l2-4). The distance between lines 33 is equal to that between magnetic units l2-3 and l2-l (or l2-4 and l2-2). the width of each main line 32 is equal to the distance between yokes 25 and 26. The width of each branch line 33 is equal to the width of each yoke.

As shown in Fig. 4, moreover, main and branch lines 32 and 33 are connected by coupling plate 34. Plate 34 is formed with a pair of main-line connecting portions 35 and a pair of branch-line connecting portions 36. Connecting portions 35, which are connected to main lines 32, are spaced at a distance equal to that between lines 32. Connecting portions 36, which are connected to branch lines 33, are spaced at a distance equal to that between lines 33. Portions 35 intersect portions 36 substantially at right angles, at crossings B. Corner pad portions 37 are formed individually at the junctions of crossings B and lines 33, and at the junctions of crossings B and connecting portions 36. Portions 37 have a low magnetic resistance. When carrier 2 is stopped under plate 34, therefore, it is attracted to plate 34 at portions 37. Thus, carrier 2 is positioned accurately, with respect to coupling plate 34, when the carrier is stopped. Projections 38 are formed individ­ually at crossings B, on the opposite side thereof to connecting portions 36, thereby lowering the magnetic resistance of crossings B. Thus, when carrier 2, at­tracted by crossings B, is located under plate 34, pro­jections 38 prevent the carrier from yawing by being attracted to the side of branch lines 33, which have a low magnetic resistance.

As is shown in Fig. l, main and branch lines 32 and 33 and coupling plate 34 are fitted with guide rail cover 3l for protection. Opening 39 is formed in the center of cover 3l. Support plate 4l for supporting stators 43-l, 43-2, and 43-3 is situated over opening 39.

As is shown in Figs. l and 4, stators 43-l to 43-3 of the three linear induction motors are fixed to the lower surface of support plate 4l. They constitute transfer apparatus 43 for transferring carrier 2 from main lines 32 to branch lines 33. Stator 43-2 is situated so as to apply a propelling force, along the main lines, to carrier 2. On the other hand, stators 43-l and 43-3 are arranged so as to apply a propelling force, along the branch lines, to carrier 2.

As is shown in Fig. 4, main-line connecting por­tions 35 and branch-line connecting portions 36 are fitted with reflector-type optical sensors 44-l, 44-2, and 44-3, respectively. Each of these sensors emits light to irradiate reaction plate l4 of carrier 2, and senses light reflected from plate l4. Thus, sensors 44-l to 44-3 detect the position of carrier 2 relative to coupling plate 34.

In control device 45 of transfer apparatus 43, as is shown in Fig. 5, stators 43-l, 43-2, and 43-3 are connected with solid-state relays 54-l, 54-2, and 54-3, respectively, for switching their corresponding stators. Stators 43-l to 43-3 and relays 54-l to 54-3 are con­nected to three-phase AC power source 52, by means of variable resistor 53. Detection signals from optical sensors 44-l to 44-3 are applied to the input of micro­computer 5l. Then, microcomputer 5l delivers commands to relays 54-l to 54-3.

In control device 45, microcomputer 5l determines the timing for the application of the propelling force to carrier 2 or the timing for the stopping of carrier 2, in accordance with the position of carrier 2, detect­ed by optical sensors 44-l to 44-3. In response to com­mands based on the judgment of microcomputer 5l, solid­state relays 54-l to 54-3 supply stators 43-l to 43-3, respectively, with current, in the predetermined direc­tion. If stator 43-2, for example, is supplied with current, an traveling field is generated in stator 43-2, so that the current is induced to reaction plate l4. Through an interaction between the traveling field and the induced current, plate l4 is subjected to thrust from stators 43-2, and a propelling force along the main lines is applied to carrier 2. By changing the phase of the current supplied to the stators, the respec­tive directions of the traveling field in the stators and the thrust on plate l4 can be varied, thus producing a braking force. If, on the other hand, stators 43-l and 43-3 are supplied with the current, a propelling force along the branch lines is applied to carrier 2. Thus, the stators to be energized are selected by micro­computer 5l, and carrier 2 is transferred in the desired direction.

Meanwhile, carrier 2, made to float by means of magnetic unit l2, is propelled along main or branch lines 32 or 33, by a transportation system (not shown) for main- or branch-line transportation, which includes induction motors (not shown). Thus, reaction plate l4 is subjected to an electromagnetic force from the stators of the induction motors of the transportation system, and carrier 2 is urged by a propelling force along main or branch lines 32 or 33.

While it is running along main lines 32, carrier 2 is transferred to branch lines 33 in accordance with the flow chart of Fig. l4. First, carrier 2 is stopped under coupling plate 34. Then, whether or not carrier 2 is stopped at a proper position, for propelling carrier 2 from coupling plate to branch lines, is determined. If not, the stop position of carrier 2 is adjusted. When carrier 2 is stopped at the predetermined stop position, it is transferred from coupling plate 34 to branch lines 33. Referring now to Fig. l4, the indi­vidual steps of the flow chart will be described in detail.

In step l0l, all the solid-state relays (SSRs) are turned off, in response to the commands from microcom­puter 5l, before carrier 2 reaches the location of coupling plate 34. In this state, none of stators 43-l to 43-3 are energized, and a timer is reset. The out­puts of all optical sensors 44-l to 44-3 are read.

When carrier 2 reaches the location of coupling plate 34, as is shown in Fig. 6, whether or not all the optical sensors are off is determined in step l02. If any of the sensors is found to be on, microcomputer 5l concludes that carrier 2 is at the location of plate 34.

In such a case, whether or not carrier 2 is expect­ed to be transferred from main lines 32 to branch lines 33 is determined in step l03. If there is a demand for such transfer, carrier 2 is controlled, in steps l04 to l08, so as to be stopped at the predetermined position in which it is transferred from the coupling plate to branch lines.

If there is no such demand, carrier 2 is made to pass coupling plate 34 and keep on running along main lines 32. In this case, therefore, the SSR which causes carrier 2 to keep on running along the main lines, is selected and turned on, in step l3l. Stators 43-2 is energized in the direction indicated by the arrows in Fig. 6. In step l32, the outputs of all the optical sensors are read. If all the sensors are found to be off, in step l33, microcomputer 5l concludes that carrier 2 has passed coupling plate 34.

In step l04, the SSR for stopping carrier 2 is selected, the timer is set, and the selected SSRs are turned on. Thus, stators 43-2 is energized to apply a thrust force to the running carrier. As a result, carrier 2 is running to the predetermined stop position.

Thereupon, in step l05, the outputs of optical sen­sors 44-l and 44-3 are read. In step l06, whether or not carrier 2 has reached the predetermined stop posi­tion is determined. In other words, whether or not sen­sors 44-l and 44-3 are both on is determined. If either of these sensor is off, the flow from step l2l through l05 to l06 is repeated endlessly. If the two sensors are found to be simultaneously on, it is concluded that carrier 2 has reached the predetermined stop position.

If the two sensors are both on, all the SSRs are turned off, in step l07. Thus, stators 43-2 ceases to be energized, so that carrier 2 is stopped. The timer is reset, and the stators are kept off for a predeter­mined period of time. This is because even if carrier 2 is somewhat deviated from the predetermined stop posi­tion, it is attracted thereto by the action of corner pad portions B, whose magnetic resistance is relatively low. In step l08, thereafter, the outputs of optical sensors 44-l and 44-3 are read. In step l09, whether or not carrier 2 is stopped at the predetermined position is determined. In other words, whether or not optical sensors 44-l and 44-3 are both on is determined. If the two sensors are simultaneously on, it is concluded that carrier 2 is stopped at the predetermined position, as is shown in Fig. 7.

If either of the two sensors is off, in step l09, it is concluded that carrier 2 is deviated from the pre­determined stop position. If the force of inertia of carrier 2 is great, as is shown in Fig. 8, for example, the carrier may sometimes be stopped after passing the predetermined position. In such a case, the flow is returned to step l04. Stator 43-2 is energized in the direction indicated by the arrows in Fig. 8, to adjust the stop position of carrier 2.

Finally, if carrier 2 is found to be stopped at the predetermined position, the SSRs for transferring it to the branch lines is selected, the timer is set, and the selected SSR is turned on, in step ll0. Thereupon, sta­tors 43-l and 43-3 are energized in the direction indi­cated by the arrows in Fig. 9, so that carrier 2 is transferred to the branch lines. In step lll, the out­puts of all the optical sensors are read. In step ll2, whether or not all the optical sensors are off is deter­mined. If all the sensors are found to be off, it is concluded that carrier 2 is running along the branch lines, after leaving coupling plate 34. Thus, carrier 2 is transferred from the main lines to the branch lines.

If YES is given in any of steps l2l, l34, and l4l, that is, if the timer is found to have counted for one minute or more, it is concluded that carrier 2 is at a standstill. In this case, therefore, carrier 2 is regarded as out of order, and in step l22, all the SSRs are turned off, and an alarm is given.

Whether carrier 2 approaches coupling plate 34 from the right-hand side of Figs. 6 to 9, or whether it travels along branch lines 33 when it comes to plate 34, the carrier is transferred to the branch or main lines by transfer apparatus 43.

In the embodiment described above, only a very small setting space is required by the transfer appara­tus for transferring carrier 2, from main lines 32 to branch lines 33. Therefore, a number of branch lines can be arranged so as to diverge from a single main line, so that a number of carriers 2 can run in their respective directions, with less possibility of stagna­tion. Thus, the travelling time of carrier 2 can be reduced. Since the transfer apparatus does not have any mechanical elements, moreover, neither noise nor dust can be produced when carrier 2 is transferred from the main lines to the branch lines.

In the embodiment described above, furthermore, the branch lines extend only in one direction from the main lines. Alternatively, however, branch lines 45 may be arranged so as to extend from both sides of main lines 32, as is shown in Fig. l0.

As is shown in Fig. ll, moreover, transfer appara­tus 43 may include stator 6l-2, located in the center of coupling plate 34, and stators 6l-l and 6l-3 on either side of stator 6l-2. Stator 6l-2 applies a propelling force along the branch lines, to carrier 2, while stators 6l-l and 6l-3 apply a propelling force along the main lines, to the carrier. In this arrangement, the range is wider in which transfer apparatus 43 or stators 6l-l and 6l-3 apply the propelling force along the main lines, to carrier 2.

The carrier transfer apparatus may alternatively be designed so as to transfer carrier 2 by utilizing air pressure. As is shown in Fig. l2, for example, air nozzles 62 may be arranged so that they can blow air against carrier 2, thereby transferring the carrier from coupling plate 34 to branch lines 46. In this case, no space is required for stators, so that rein­forcing member 63 can be provided instead.

As is shown in Fig. l3, furthermore, transfer apparatus 43 may include stator 70 of linear induction motor for bi-directional transport, which is situated in the center of coupling plate 34. In this case, carrier 2 is driven along both main and branch lines, by the single stator, so that the setting space for the trans­fer apparatus, in plate 34, is narrower.

According to the aforementioned embodiment, more-­over, the guide rail includes a pair of main lines and a pair of branch lines. Alternatively, however, the main or branch lines used may be one, or three, or more, in number. Also, the magnetic unit may be constructed so that the carrier is caused to float by means of the magnetic force of the coils only, without using the per­manent magnet.

In the embodiment described above, furthermore, the main lines are distinguished from the branch lines. This distinction, however, is made for convenience only. Thus, the transportation system of a floated-carrier type, according to the present invention, may be applied to a crossing carrier-transporting path, in which there is no distinction between main and branch lines.