JP2015229224A - Industrial robot - Google Patents

Abstract

PROBLEM TO BE SOLVED: To solve a problem in that, in a conventional monitoring system that detects a malfunction, an imaging apparatus is required other than an industrial robot, making the system complex and the cost high, and there may be a case where an imaging apparatus cannot be attached depending on the environment where an industrial robot is used, which may not be able to acquire and check an image relating to a malfunction.SOLUTION: An industrial robot comprises: a control part that controls the industrial robot; and a monitoring part that monitors the state of an industrial robot. When a monitoring part detects a predetermined detection trigger set in advance, a teaching device stores a display that has been shown on the teaching part of the teaching device, as image data by means of a capture function and transmits the display to the control device. By using image data on the display of the teaching device, the reproducibility of occurrence of an abnormal state is improved. Thus, accuracy in the diagnosis of a malfunction of the industrial robot can be improved.

Description

  The present invention relates to an industrial robot having a monitoring function such as abnormality detection.

  In an automated production system, operation status is generally monitored. By constantly monitoring the operating state, if any abnormality occurs in the production system, the information can be promptly communicated to the monitor. Note that the amount and accuracy of the information at that time are very important in the subsequent diagnosis of the cause of the failure.

  Information to be notified when an abnormality occurs includes, in addition to the abnormality occurrence information itself, information output from the production system used for monitoring the operating state, that is, FA equipment including industrial robots, etc. Information useful for the diagnosis of The information output from the FA device includes, for example, a motor current of a motor that operates the FA device.

  As other information, there is image data obtained by photographing a video of the production system itself by a photographing device such as a camera, and there is a monitoring method using this image data (for example, see Patent Document 1).

  FIG. 8 is a diagram showing a configuration of alarm data which is information to be notified when an abnormality occurs in the conventional monitoring method. The alarm data 101 is information that is notified when an abnormality occurs. The contact instruction 102 is information for instructing how to process the alarm notification 104 and the image data 106. The sensor 103 is a sensor for detecting an abnormality in the production system. The alarm notification 104 is an alarm notification transmitted from the sensor 103. The imaging unit 105 is a photographing device such as a camera. Image data 106 is image data transmitted from the imaging unit 105. The monitoring system creates alarm data 101 and sends it to the outside when an abnormality occurs.

JP 2004-096694 A

  The conventional monitoring system requires an imaging device in addition to an industrial robot. Therefore, there is a problem that the system becomes complicated and the cost increases. Moreover, depending on the use environment of an industrial robot, an imaging device may not be attached. In this case, there is a problem that an image relating to an abnormality of the industrial robot cannot be acquired and confirmed.

  In the present invention, the image data displayed on the display screen of the teaching device can be obtained and confirmed when an abnormality occurs in the industrial robot without using a separate imaging device such as a camera. The purpose is to provide an industrial robot that improves the accuracy of information.

  In order to solve the above problems, an industrial robot of the present invention is an industrial robot having a manipulator, a control device that controls the manipulator, and a teaching device that communicates with the control device. A control unit that controls a robot; and a monitoring unit that monitors a state of the industrial robot. When the monitoring unit detects a predetermined detection trigger set in advance, the teaching device The screen displayed on the teaching unit of the teaching device when the image is detected is stored as image data and sent to the control device.

  In addition to the above, the teaching robot stores image data by the capture function in the industrial robot of the present invention.

  In addition to the above, in the industrial robot of the present invention, the detection trigger is a determination result of whether or not the detection value has reached the threshold value, and not only when the detection value reaches 100% of the threshold value, The image data is also stored when the ratio reaches a preset value of less than 100%.

  In the industrial robot of the present invention, in addition to the above, the detection trigger may include at least one of an operation load amount of the control unit, a motor current value of a motor for operating the manipulator, or a temperature of a predetermined portion of the manipulator. Including.

  In addition to the above, in the industrial robot of the present invention, the stored image data includes line number information of an operation program when the industrial robot is performing a program operation.

  In addition to the above, in the industrial robot of the present invention, the control device stores the image data received from the teaching device in a storage unit connected to the industrial robot, or can communicate with the industrial robot. Is transmitted to the external device connected to the PC and stored in the external device.

  As described above, according to the present invention, the reproducibility of the abnormality occurrence state can be improved by using the image data of the screen of the teaching apparatus, for example, the accuracy of the failure diagnosis of the industrial robot can be improved.

The figure which shows schematic structure of the industrial robot in Embodiment 1 of this invention. The figure for demonstrating the process from abnormality detection to image data preservation | save in Embodiment 1 of this invention (A) The monitoring target data in the first embodiment of the present invention, for example, a diagram when abnormality is detected when the motor current value exceeds a certain reference (b) The monitoring target data in the first embodiment of the present invention For example, when the motor current value is within a certain range and an abnormality is detected (A) The monitoring target data in the first embodiment of the present invention, for example, a diagram when abnormality is detected when the CPU load exceeds a certain standard (b) The monitoring target data in the first embodiment of the present invention For example, when the CPU load amount is within a certain range, an abnormality is detected. (A) The figure which shows the screen of a teaching device when it is detected that it is abnormal in the case of FIG. 3 (a) in Embodiment 1 of this invention (b) FIG. 3 (b) in Embodiment 1 of this invention ) Is a diagram showing a screen of the teaching device when it is detected as abnormal in the case of (A) FIG. 4 (b) shows the screen of the teaching device when it is detected as abnormal in the case of FIG. 4 (a) in Embodiment 1 of the present invention. FIG. 4 (b) in Embodiment 1 of the present invention. ) Is a diagram showing a screen of the teaching device when it is detected as abnormal in the case of The figure which shows schematic structure at the time of the image | photographed image data in Embodiment 1 of this invention being preserve | saved The figure which shows the information notified when abnormality occurs in the conventional monitoring method

(Embodiment 1)
Embodiment 1 of the present invention will be described with reference to FIGS. FIG. 1 is a diagram showing a schematic configuration of an industrial robot. FIG. 2 is a diagram for explaining a process from abnormality detection to image data storage. FIG. 3 is a diagram for explaining abnormality detection performed in accordance with the trigger setting conditions. FIG. 3A is a diagram in a case where abnormality is detected when, for example, the motor current value which is monitoring target data exceeds a certain reference. FIG. 3B is a diagram in a case where warning detection is performed before an abnormality is detected due to, for example, the motor current value being monitoring target data being within a certain range. FIG. 4 is a diagram for explaining abnormality detection performed in accordance with the trigger setting conditions. FIG. 4A is a diagram in a case where an abnormality is detected when, for example, the CPU operation load amount that is monitoring target data exceeds a certain reference. FIG. 4B is a diagram in the case where warning detection is performed before abnormality is detected when, for example, the CPU operation load amount that is the monitoring target data is within a certain range. FIG. 5 is a diagram illustrating a state in which an abnormality or a warning state is detected during the automatic operation of the robot 1 and appears on the screen of the teaching device. FIG. 5A is a diagram showing a screen when an abnormality is detected in the case of FIG. FIG. 5B is a diagram illustrating a screen of the teaching device when it is detected that the warning state is present before the abnormality is detected in the case of FIG. FIG. 6 is a diagram illustrating a state in which an abnormality or a warning state is detected during manual operation of the robot 1 and appears on the screen of the teaching device. FIG. 6A is a diagram showing a screen of the teaching device when it is detected that there is an abnormality in the case of FIG. FIG. 6B is a diagram illustrating a screen of the teaching device when it is detected that the warning state is detected in the case of FIG. FIG. 7 is a diagram illustrating a schematic configuration when captured image data is stored in the storage unit 6 and / or the external device 7 connected to the robot control apparatus 2.

  In FIG. 1, the robot 1 is controlled by a robot control device 2 and a teaching device 3 connected to the robot control device 2. The robot 1 is also called a manipulator.

  The robot control device 2 includes a monitoring unit 4 that monitors the state of the robot 1 and a control unit 5 that controls the robot 1. The robot control device 2 is connected to a storage unit 6 that stores image data and an external device 7 that can communicate with the robot control device 2 and stores image data. The storage unit 6 is, for example, an external storage medium such as an SD card that is detachably attached to the robot control device 2. The external device 7 is, for example, a personal computer (hereinafter also referred to as a PC) provided in a management room or the like in a remote place away from the industrial robot. The robot control device 2 has a storage unit (not shown) having a smaller storage capacity than the storage unit (not shown) included in the storage unit 6 and the external device 7, and is stored more than the storage unit 6 and the external device 7. Although the number is small, the robot controller 2 can also store a predetermined amount of image data.

  The teaching device 3 includes a teaching unit 8 having a function of projecting the operation state of the robot 1 as image data. Further, the worker can operate the robot 1 using the teaching device 3.

In FIG. 2, the robot control apparatus 2 has a trigger condition setting unit 9 for setting a trigger condition. Various trigger conditions are set in the trigger condition setting unit 9 as shown in FIG. The trigger condition set by the trigger condition setting unit 9 is a condition when the monitoring unit 4 monitors the state of the robot 1.
For example, the motor current flowing in a motor (not shown) constituting the robot 1, the temperature of a motor (not shown) constituting the robot 1, the amount of communication data between the robot control device 2 and the teaching device 3, and the control unit 5 are constituted. This is a condition for monitoring the CPU operating load of the CPU (Central Processing Unit).
More specifically, for example, an electrical system abnormality threshold, a temperature system abnormality threshold, a system system abnormality threshold, and the like. The monitoring unit 4 monitors the state of the robot 1 in accordance with the trigger conditions, and detects the abnormality when the trigger condition is satisfied, for example, when the reference value A of the trigger for the electrical system abnormality is exceeded.

  When an abnormality is detected, the monitoring unit 4 instructs the teaching device 3 to capture the screen displayed on the teaching unit 8. The capture is a function for directly saving the image data of the screen displayed on the teaching unit 8 of the teaching device 3 without using an external device such as a camera. Receiving this instruction, the teaching apparatus 3 captures the screen displayed on the teaching unit 8 and transmits the image data to the control unit 5. The control unit 5 stores the image data in the storage unit 6 and / or the external device 7. When the operator views the stored image data, and the image data is stored in the PC that is the external device 7, the image data is confirmed by operating the PC. When the data is stored in an SD card or the like as the storage unit 6, the image data is confirmed by connecting the SD card or the like to the PC and operating the PC.

  When the trigger condition setting unit 9 sets two reference values (threshold values) for one monitoring item, the monitoring target of the electric system such as a motor current is a trigger condition related to an electric system abnormality. While within a range from a certain reference value A to a reference value B, it is detected that the warning state has occurred before becoming abnormal. Even when this warning state is detected, the monitoring unit 4 instructs the teaching device 3 to capture the screen displayed on the teaching unit 8. Thereby, the image data can be stored while the detection target of the electric system is in the range from the reference value A to the reference value B. The trigger condition setting unit 9 sets the storage interval of the image data while the detection target of the electric system is in the range from the reference value A to the reference value B. When the electrical monitoring target exceeds a reference value A that is larger than the reference value B, it is detected that there is an abnormality, and the monitoring unit 4 instructs the teaching unit 3 about the teaching unit 8. Instructs to capture the screen displayed on the screen.

  A plurality of trigger conditions can be set. For example, it is possible to set a plurality of types of triggers such as an electrical system abnormality trigger, a temperature system abnormality trigger, and a system system abnormality trigger. The monitoring unit 4 can monitor all of them simultaneously, and instructs the teaching device 3 to save the image data every time one of the trigger conditions is satisfied. In response to the instruction, the teaching device 3 stores image data in the storage unit 6 and / or the external device 7 as a set with information on the satisfied trigger condition.

  In FIG. 3, FIG. 3A is an example when only one threshold value that is the first threshold value 10 is set as the trigger condition. FIG. 3B shows an example in which two threshold values of the first threshold value 10 and the second threshold value 13 are set as trigger conditions.

  In FIG. 3A, the first threshold 10 is, for example, a reference value A for electrical system abnormality in the trigger condition setting unit 9 shown in FIG. The first motor current value 11 of the motor constituting the robot 1 indicates a time change of the motor current value indicating the behavior exceeding the first threshold value 10. The monitoring unit 4 detects that there is an abnormality when the first motor current value 11 exceeds the first threshold value 10 at a certain time, and the monitoring unit 4 instructs the teaching unit 8 to Gives only one instruction to capture the screen being projected.

  In FIG. 3B, the second threshold 13 is, for example, a reference value B for electrical system abnormality in the trigger condition setting unit 9. The second motor current value 12 indicates a time change of the motor current value when the behavior that can take between the first threshold value 10 and the second threshold value 13 is shown. When the second motor current value 12 is a value greater than or equal to the second threshold 13 and less than the first threshold 10 from a certain time to a certain time, the monitoring unit 4 abnormally The monitoring unit 4 detects that the warning state has been reached before, and continues to give an instruction to the teaching device 3 to capture the screen displayed on the teaching unit 8 at a certain interval. Thereafter, when the second motor current value 12 becomes less than the second threshold value 13, the monitoring unit 4 determines that it is not in a warning state, and the monitoring unit 4 is displayed on the teaching unit 8 with respect to the teaching device 3. Stop the instruction to capture the current screen. Thereafter, when the second motor current value 12 again becomes a value greater than or equal to the second threshold value 13 and less than the first threshold value 10, the monitoring unit 4 detects the warning state, and the monitoring unit 4 Continues to give instructions to the teaching device 3 to capture the screen displayed on the teaching unit 8 at certain intervals. Thereafter, when the second motor current value 12 becomes equal to or greater than the first threshold value 10, the monitoring unit 4 detects that there is an abnormality, and the monitoring unit 4 displays the teaching device 3 on the teaching unit 8. The instruction to capture the displayed screen is given only once.

  In FIG. 4, FIG. 4A is an example when only one threshold that is the third threshold 14 is set as the trigger condition. FIG. 4B shows an example in which two threshold values, ie, a third threshold value 14 and a fourth threshold value 17 are set as trigger conditions.

  In FIG. 4A, the third threshold 14 is a reference value E that is a trigger for a system system abnormality in the trigger condition setting unit 9 shown in FIG. 2, for example. The first CPU operation load amount 15 of the CPU constituting the control unit 5 of the robot control device 2 indicates a time change of the CPU operation load amount that exhibits a behavior exceeding the third threshold value 14. The monitoring unit 4 detects that there is an abnormality when the first CPU operation load 15 exceeds the third threshold value 14 at a certain time, and the monitoring unit 4 instructs the teaching device 3 to use the teaching unit 8. An instruction to capture the screen displayed on the screen is issued only once.

  In FIG. 4B, the fourth threshold value 17 is a reference value F that is a trigger for a system system abnormality in the trigger condition setting unit 9, for example. The second CPU operation load amount 16 indicates a change over time of the CPU operation load amount when showing a behavior that can take between the third threshold value 14 and the fourth threshold value 17. When the second CPU operation load amount 16 is a value greater than or equal to the fourth threshold value 17 and less than the third threshold value 14 from a certain time to a certain time, the monitoring unit 4 is The monitoring unit 4 detects that the warning state has been reached before becoming, and continues to issue an instruction to capture the screen displayed on the teaching unit 8 to the teaching device 3 at a certain interval. Thereafter, when the second CPU operation load amount 16 becomes less than the fourth threshold value 17, the monitoring unit 4 determines that it is not in a warning state, and the monitoring unit 4 displays the teaching device 3 on the teaching unit 8. Stop the instruction to capture the current screen. Thereafter, when the second CPU operation load amount 16 again becomes a value that is greater than or equal to the fourth threshold value 17 and less than the third threshold value 14, the monitoring unit 4 detects a warning state, and the monitoring unit 4 continues to instruct the teaching apparatus 3 to capture the screen displayed on the teaching unit 8 at a certain interval. Thereafter, when the second CPU operation load amount 16 becomes equal to or greater than the third threshold value 14, the monitoring unit 4 detects that there is an abnormality, and the monitoring unit 4 causes the teaching unit 3 to Gives only one instruction to capture the screen being projected.

  FIG. 5 is displayed on the teaching unit 8 of the teaching device 3 when it is detected that the robot 1 is in an automatic operation state based on the operation program, or when it is detected as being abnormal or a warning state. The first screen 18 or the second screen 20 is shown.

  FIG. 5A shows a first screen 18 displayed on the teaching unit 8 of the teaching device 3 when it is detected as abnormal in the case of FIG. The first screen 18 displays operation execution instructions and line numbers (composing operation programs) indicating the automatic operation state of the robot 1 in order of execution, and also displays monitoring information (for example, motor current value). ing. Further, a first message 19 indicating that an abnormality has been detected is displayed in front of them. The first message 19 is displayed when an instruction is received from the monitoring unit 4, and immediately after that, the teaching apparatus 3 captures the first screen 18 at the moment when an abnormality is detected to create image data, Transmit to the robot controller 2. The robot control device 2 stores the image data received from the teaching device 3 in the storage unit 6 and / or the external device 7. By saving the image data including the line numbers constituting the operation program, it is possible to confirm what kind of operation the industrial robot was performing.

  Here, the reason why the image data is stored in the storage unit 6 or the external device 7 connected to the robot control device 2 will be described. The image data has a large capacity. Therefore, the storage capacity of the robot control device 2 and the storage capacity of the teaching device 3 can be saved by storing the data in the storage unit 6 and the external device 7 instead of the robot control device 2 and the teaching device 3. It is possible to prevent the processing capacity of the apparatus 3 from being lowered. In addition, when an abnormality occurs in an industrial robot, it is often analyzed not in the field but in a remote management room or the like. Therefore, it is very useful to send image data to an external device 7 such as a PC in a remote place.

  FIG. 5B shows a second screen 20 displayed on the teaching unit 8 of the teaching device 3 when it is detected that the state is a warning state in the case of FIG. 3B. Similar to the first screen 18 in FIG. 5A, the second screen 20 displays an operation execution command and line numbers indicating the automatic operation state of the robot 1 in the order of execution, and monitoring information ( For example, motor current value) is displayed. However, since this is a warning state before an abnormality occurs, the first message 19 indicating that an abnormality has been detected is not displayed.

  Each time the teaching unit 8 of the teaching device 3 receives an instruction from the monitoring unit 4, the teaching unit 8 captures the second screen 20 at that moment, creates image data, and transmits the image data to the robot control device 2. By saving the image data including the line numbers constituting the operation program, it is possible to confirm what kind of operation the industrial robot was performing when it was in a warning state. In addition, since a plurality of image data is stored in the warning state, the progress in the warning state can be known.

  FIG. 6 shows the teaching device 3 when the robot 1 is in a manual operation state based on the operation of the teaching device 3 by an operator, when it is detected as abnormal or when it is detected as a warning state. The third screen 21 or the fourth screen 23 displayed on the teaching unit 8 is shown.

  FIG. 6A shows a third screen 21 displayed on the teaching unit 8 of the teaching device 3 when it is detected that there is an abnormality in the case of FIG. 4A. The third screen 21 displays a state in which execution of a new process is instructed in a state in which a plurality of setting changes of the robot control device 2 are simultaneously processed in the manual operation state of the robot 1, for example. Further, a second message 22 indicating that an abnormality has been detected is displayed in front of them. The second message 22 is displayed when an instruction is received from the monitoring unit 4, and immediately after that, the teaching device 3 captures the third screen 21 at the moment when an abnormality is detected to create image data, Transmit to the robot controller 2. The robot control device 2 stores the image data received from the teaching device 3 in the storage unit 6 and / or the external device 7.

  In this way, by capturing and saving the screen at the time of occurrence of an abnormality, it is possible to know what kind of processing has been performed and an abnormality in the CPU operation load amount has occurred.

  FIG. 6B shows a fourth screen 23 displayed on the teaching unit 8 of the teaching device 3 when it is detected that the state is a warning state in the case of FIG. 4B. Similar to the third screen 21 in FIG. 6A, the fourth screen 23 includes a new operation state in which a plurality of setting changes of the robot control device 2 are simultaneously processed in the manual operation state of the robot 1. The state instructing the execution of various processes is displayed. However, since this is a warning state before an abnormality occurs, the second message 22 indicating that an abnormality has been detected is not displayed.

  Each time the teaching unit 8 of the teaching device 3 receives an instruction from the monitoring unit 4, the teaching unit 8 captures the fourth screen 23 at that moment, creates image data, and transmits the image data to the robot control device 2.

  In this way, by capturing and saving the screen at the time of occurrence of the warning state, it is possible to know what kind of processing has been performed and the warning state of the CPU operation load amount has occurred.

  In FIG. 7, the captured image data is sent from the robot control device 2 to a plurality of storage units 6 and / or a plurality of external devices according to information about where to store the captured image data in the storage destination setting unit 24 of the robot control device 2. It is stored in the device 7. For example, the plurality of storage units 6 that are external storage media such as SD cards may be different external storage media, and the plurality of external devices 7 such as PCs may be different external devices. Each of the plurality of external devices 7 has a storage unit. In addition, the plurality of external devices 7 may be connected to the robot control device 2 via a communication network, and the robot control device 2 and the plurality of external devices 7 may exist in remote locations.

  As described above, the industrial robot according to the present embodiment includes the robot 1, the robot control device 2 that controls the robot 1, and the teaching device 3 connected to the robot control device 2. Includes a monitoring unit 4 that monitors the state of the robot 1 and a control unit 5 that controls the robot 1. When the monitoring unit 4 detects a predetermined detection trigger that is set in advance, the control unit 5 The screen displayed on the teaching unit 8 of the teaching device 3 when an abnormality is detected by the trigger is stored as image data in the storage unit 6 and / or the external device 7 connected to the robot control device 2. Thereby, the reproducibility of the abnormality occurrence state can be improved, for example, the accuracy of failure diagnosis can be improved.

  The present invention can store image data on the screen of a teaching device when an abnormality occurs in a production system using an industrial robot, and can use the image data for high precision at a production site or a remote place. It can be used for fault diagnosis and the like, and is industrially useful as an industrial robot having an abnormality detection function.

DESCRIPTION OF SYMBOLS 1 Robot 2 Robot control apparatus 3 Teaching apparatus 4 Monitoring part 5 Control part 6 Storage part 7 External device 8 Teaching part 9 Trigger condition setting part 10 1st threshold value 11 1st motor current value 12 2nd motor current value 13 1st 2 threshold value 14 3rd threshold value 15 1st CPU operation load amount 16 2nd CPU operation load amount 17 4th threshold value 18 1st screen 19 1st message 20 2nd screen 21 3rd screen 22 Second message 23 Fourth screen 24 Save destination setting section

Claims (6)

An industrial robot having a manipulator, a control device that controls the manipulator, and a teaching device that communicates with the control device,
A control unit for controlling the industrial robot;
A monitoring unit for monitoring the state of the industrial robot;
When the monitoring unit detects a predetermined detection trigger set in advance, the teaching device stores the screen displayed on the teaching unit of the teaching device when the detection trigger is detected as image data. Industrial robots sent to the controller. The industrial robot according to claim 1, wherein the teaching device stores image data by a capture function. The detection trigger is a determination result of whether or not the detection value has reached the threshold value, and not only when the detection value reaches 100% of the threshold value, but also when a value of a ratio smaller than 100% set in advance is reached The industrial robot according to claim 1 or 2, wherein image data is stored. The industry according to any one of claims 1 to 3, wherein the detection trigger includes at least one of an operation load amount of the control unit, a motor current value of a motor for operating the manipulator, or a temperature at a predetermined location of the manipulator. Robot. The industrial robot according to any one of claims 1 to 4, wherein the stored image data includes line number information of an operation program when the industrial robot is performing a program operation. The control device stores the image data received from the teaching device in a storage unit connected to the industrial robot, or transmits the image data to an external device communicatively connected to the industrial robot and stores it in the external device. The industrial robot according to any one of claims 1 to 5.

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