JP2021062442A - Repair welding device and repair welding method - Google Patents

Abstract

To further efficiently perform repair welding by re-aligning output orders of multiple defect parts acquired from visual inspection to a work to be welded that is produced by normal welding so as to be matched with an operation direction of a welding robot.SOLUTION: A repair welding device includes: an acquisition unit for acquiring a visual inspection result including information on multiple defect parts of a weld bead of a work to be welded that is produced by normal welding by a welding robot; and a robot control unit for instructing the welding robot to execute repair welding in a target section on the basis of the multiple defect parts for which output orders of the multiple defect parts are re-aligned to orders matched with an operation direction of the welding robot on the basis of the visual inspection result.SELECTED DRAWING: Figure 8

Description

The present disclosure relates to a repair welding apparatus and a repair welding method.

In Patent Document 1, slit light is projected onto the weld bead, shape lines sequentially formed on the weld bead are imaged by scanning the slit light, and the weld bead is based on the imaging data of the sequentially formed shape lines. A shape inspection device that acquires the three-dimensional shape of the above as point cloud data is disclosed. This shape inspection device corresponds to the cutting line by setting an arbitrary cutting line different from the shape line formed by scanning the slit light on the welding bead displayed based on the point cloud data according to the input. The cross-sectional shape of the weld bead at the cutting line is calculated from the point cloud data. Further, the shape inspection device compares the various feature amounts calculated according to the calculated cross-sectional shape with the permissible range of the various feature amounts registered in advance, and determines the quality of the feature amount.

Japanese Unexamined Patent Publication No. 2012-37487

The present disclosure is a repair welding apparatus that rearranges the output order of a plurality of defective parts obtained by visual inspection of the workpiece produced by the main welding so as to match the operation direction of the welding robot and performs repair welding more efficiently. And repair welding methods are provided.

The present disclosure includes an acquisition unit that acquires appearance inspection results including information on a plurality of defective parts of a welding bead of a work to be welded produced by main welding by a welding robot, and the plurality of defects based on the appearance inspection results. Repair welding including a robot control unit that instructs the welding robot to execute repair welding of a target section based on the plurality of defective parts in which the output order of the parts is rearranged in an order that matches the operation direction of the welding robot. Provide the device.

Further, the present disclosure is a repair welding method executed by a repair welding apparatus, and acquires visual inspection results including information on a plurality of defective parts of a welding bead of a work to be welded produced by main welding by a welding robot. Based on the process and the visual inspection result, the output order of the plurality of defective parts is rearranged in an order that matches the operation direction of the welding robot, and the repair welding of the target section based on the plurality of defective parts is executed. Provided is a repair welding method having a step of instructing a welding robot.

According to the present disclosure, the output order of a plurality of defective parts obtained by visual inspection of the workpiece to be welded produced by the main welding can be rearranged so as to match the operating direction of the welding robot, and repair welding can be performed more efficiently.

Schematic diagram showing a system configuration example of a welding system The figure which shows the internal structure example of the inspection control apparatus, the robot control apparatus and the higher-order apparatus which concerns on Embodiment 1. A sequence diagram showing an example of operating procedures for main welding and repair welding by the welding system according to the first embodiment. A sequence diagram showing a modified example of the operation procedure of main welding and repair welding by the welding system according to the first embodiment. The figure which shows typically the 1st operation outline example about the rearrangement for ordering the output order of a plurality of detection points to match the operation direction of a welding robot. The figure which shows typically the rearranging example of the plurality of detection points shown in FIG. The figure which shows typically the 2nd operation outline example about the rearrangement for ordering the output order of a plurality of detection points to match the operation direction of a welding robot. The figure which shows typically the rearranging example of the plurality of detection points shown in FIG. The figure which shows typically the 3rd operation outline example about the rearrangement for ordering the output order of a plurality of detection points to match the operation direction of a welding robot. The figure which shows typically the rearranging example of the plurality of detection points shown in FIG. Flowchart showing an example of operating procedure for creating a repair welding program The figure which shows the internal structure example of the inspection control apparatus, the robot control apparatus and the higher-order apparatus which concerns on Embodiment 2. A sequence diagram showing an example of operating procedures for main welding and repair welding by the welding system according to the second embodiment. A sequence diagram showing a modified example of the operation procedure of main welding and repair welding by the welding system according to the second embodiment. The figure which shows the internal structure example of the inspection control apparatus, the robot control apparatus and the higher-level apparatus which concerns on Embodiment 3. A sequence diagram showing an example of operating procedures for main welding and repair welding by the welding system according to the third embodiment. A sequence diagram showing an example of operating procedures for main welding and repair welding by the welding system according to the third embodiment.

(Background to this disclosure)
In the prior art including Patent Document 1, based on the appearance inspection result of the work produced by the main welding (hereinafter referred to as "work to be welded"), repair or the like is performed at a place where a welding defect (that is, a defect) occurs. The technique of automatically performing repair welding for correction by a welding robot or the like has not yet been disclosed. In order for the repair welding to be performed automatically by the welding robot, it is necessary to prepare in advance a program for repair welding that specifies the location where the repair welding is to be performed, as in the case of the main welding. Created to produce the work to be welded in order to prevent interference between the tip of the welding robot and the work to be welded or the jig for fixing the work to be welded during the actual repair welding of the defective part of the weld. It is considered preferable to create a repair welding program by partially changing the main welding program. In other words, by skillfully utilizing the operation locus of the welding robot during the main welding, the operation of the welding robot during repair welding can be stabilized.

In the visual inspection of the workpiece to be welded, information (for example, coordinates) regarding the position of the defective portion of welding (hereinafter, simply referred to as “defective portion”) is detected by an inspection device such as a camera or a sensor that projects laser light. It is output as defective part information. Here, the direction of detecting the presence or absence of a defective portion in the workpiece to be welded at the time of visual inspection may not match the direction of the main welding performed by the welding robot at the time of the main welding. For example, when a plurality of defective parts are detected by the visual inspection, the order in which the defective part information is output does not match the direction in which the welding robot repairs and welds. If there is such a discrepancy, the welding robot repairs and welds in the order in which the defective part information is output. Therefore, for example, it is necessary to go back and forth between the defective parts to perform repairs and the like, and the work of the welding robot during repair welding. There is a problem that efficiency deteriorates.

Therefore, in the following embodiment, the output order of a plurality of defective parts obtained by the visual inspection of the work to be welded produced by the main welding is rearranged so as to match the operation direction of the welding robot, and is automatically and efficiently. An example of a repair welding device and a repair welding method for repair welding will be described.

Hereinafter, embodiments in which the repair welding apparatus and the repair welding method according to the present disclosure are specifically disclosed will be described in detail with reference to the drawings as appropriate. However, more detailed explanation than necessary may be omitted. For example, detailed explanations of already well-known matters and duplicate explanations for substantially the same configuration may be omitted. This is to avoid unnecessary redundancy of the following description and to facilitate the understanding of those skilled in the art. It should be noted that the accompanying drawings and the following description are provided for those skilled in the art to fully understand the present disclosure, and are not intended to limit the subject matter described in the claims.

(Embodiment 1)
The repair welding apparatus according to the first embodiment acquires visual inspection results including information on a plurality of defective parts of the welding beads of the work to be welded produced by main welding by a welding robot, and based on the visual inspection results, obtains visual inspection results. Welding robot executes repair welding of the target section based on multiple defective parts by rearranging the output order of multiple defective parts in the order that matches the operating direction of the welding robot (for example, the operating direction during main welding or repair welding). Instruct. Hereinafter, the work to be main-welded is the "original work", the work produced (manufactured) by the main welding is the "work to be welded", and the defective portion of welding detected in the "work to be welded" is repair-welded. The work is defined as "repaired welded work". In addition, the process of producing the work to be welded by joining the original work and other original works by a welding robot is called "main welding", and the process of repairing defective parts of the work to be welded by the welding robot is performed. Defined as "repair welding". The "work to be welded" or "work to be repaired" is not limited to the work produced by one main welding, but may be a composite work produced by two or more main weldings.

(Welding system configuration)
FIG. 1 is a schematic view showing a system configuration example of the welding system 100. The welding system 100 includes a host device 1 connected to each of the external storage ST, the input interface UI1 and the monitor MN1, a robot control device 2, an inspection control device 3, a main welding robot MC1a, and a repair welding robot MC1b. It is a configuration that includes. The welding robot MC1a and the repair welding robot MC1b may be configured as separate robots, or may be configured as the same welding robot MC1. In order to make the following description easier to understand, it will be described that the main welding and repair welding steps are executed by the welding robot MC1. Although FIG. 1 shows only one pair of one robot control device 2, the main welding robot MC1a, and the repair welding robot MC1b, a plurality of these pairs may be provided. Further, the welding system 100 may be configured to further include an inspection device 4.

The host device 1 as an example of the repair welding device collectively controls the execution of the main welding (for example, the start and completion of the main welding) executed by the welding robot MC1 via the robot control device 2. For example, the host device 1 reads out welding-related information input or set in advance by a user (for example, a welding operator or a system administrator; the same applies hereinafter) from the external storage ST, and uses the welding-related information to obtain welding-related information. An execution command for the main welding including the contents is generated and sent to the corresponding robot control device 2. When the main welding by the welding robot MC1 is completed, the host device 1 receives a main welding completion report from the robot control device 2 to the effect that the main welding of the original work by the welding robot MC1 is completed, and the corresponding original work book. The status is updated to the effect that welding is completed and recorded in the external storage ST. The above-mentioned execution command for the main welding is not limited to being generated by the host device 1, and for example, an operation panel (for example, PLC: Programmable Logical Controller) of equipment in a factory or the like where the main welding is performed, or a robot control device. It may be generated by the operation panel of 2a, 2b, ... (For example, TP: Welding Pendant). The teach pendant (TP) is a device for operating the main welding robots MC1a, MC1b, ... Connected to the robot control devices 2a, 2b, ....

Further, the host device 1 controls the execution of the visual inspection (for example, the start and completion of the visual inspection) executed by the inspection device 4 via the inspection control device 3 in an integrated manner. For example, when the host device 1 receives the main welding completion report of the original work from the robot control device 2, it generates an execution command for visual inspection of the work to be welded produced by the welding robot MC1 and sends it to the inspection control device 3. When the appearance inspection by the inspection device 4 is completed, the higher-level device 1 receives an appearance inspection report from the inspection control device 3 to the effect that the appearance inspection of the work to be welded by the inspection device 4 is completed, and receives the appearance inspection report of the corresponding work to be welded. The status is updated to the effect that the visual inspection is completed and recorded in the external storage ST.

Further, the host device 1 controls the execution of repair welding (for example, start and completion of repair welding) executed by the welding robot MC1 via the robot control device 2 in an integrated manner. For example, when the host device 1 receives the appearance inspection report of the work to be welded from the inspection control device 3, it generates an execution command for repair welding of the work to be welded (that is, the work to be welded produced by the welding robot MC1). It is sent to the robot control device 2. When the repair welding of the work to be welded by the welding robot MC1 is completed, the host device 1 receives a repair welding completion report from the robot control device 2 to the effect that the repair welding of the work to be welded by the welding robot MC1 is completed, and responds. The status is updated to the effect that the repair welding of the work to be welded is completed and recorded in the external storage ST.

Here, the welding-related information is information indicating the content of the main welding executed by the welding robot MC1, and is created in advance for each main welding process and registered in the external storage ST. Weld-related information includes, for example, the number of original workpieces used for main welding, workpiece information including the ID, name and welding location of the original workpiece used for main welding, and the scheduled execution date when main welding is executed. It includes the number of workpieces to be welded and various welding conditions at the time of main welding. The welding-related information does not have to be limited to the data of the above-mentioned items. The robot control device 2 causes the welding robot MC1 to execute the main welding using a plurality of original workpieces specified by the execution command based on the execution command sent from the higher-level device 1. The welding-related information described above is not limited to being managed by the host device 1 with reference to the external storage ST, and may be managed by, for example, the robot control device 2. In this case, since the robot control device 2 can grasp the completion of the main welding, the actual execution date may be managed instead of the scheduled execution date on which the welding process is scheduled to be executed in the welding-related information. In the present specification, the type of the main welding is not limited, but in order to make the explanation easy to understand, the steps of joining each of the plurality of original workpieces will be described as an example.

The host device 1 is connected so that data can be input / output from each of the monitor MN1, the input interface UI1 and the external storage ST, and further, data can be communicated with the robot control device 2. It is connected so that it becomes. The host device 1 may be a terminal device PP1 that integrally includes a monitor MN1 and an input interface UI1, and may further include an external storage ST integrally. In this case, the terminal device PP1 is a PC (Personal Computer) used by the user prior to the execution of the main welding. The terminal device PP1 is not limited to the PC described above, and may be a computer device having a communication function such as a smartphone or a tablet terminal.

The monitor MN1 may be configured by using a display device such as an LCD (Liquid Crystal Display) or an organic EL (Electroluminescence). The monitor MN1 may display, for example, a screen output from the host device 1 indicating that the main welding of the original work has been completed or that the repair welding of the work to be welded has been completed. Further, a speaker (not shown) may be connected to the host device 1 instead of the monitor MN1 or together with the monitor MN1, and the host device 1 may notify that the main welding of the original work has been completed, or the work to be welded. A voice indicating that the repair welding has been completed may be output via the speaker.

The input interface UI 1 is a user interface that detects a user's input operation and outputs it to the host device 1, and may be configured by using, for example, a mouse, a keyboard, a touch panel, or the like. The input interface UI 1 accepts, for example, an input operation when the user creates welding-related information, or receives an input operation when sending a main welding execution command to the robot control device 2.

The external storage ST is configured by using, for example, a hard disk drive (Hard Disk Drive) or a solid state drive (Solid State Drive). The external storage ST stores, for example, data of welding-related information created for each main welding, work information of the work to be welded produced by the main welding or the work information of the work to be repaired produced by the repair welding (see above).

The robot control device 2 as an example of the repair welding device is connected to the higher-level device 1 so as to be able to communicate data, and is also connected to the welding robot MC1 so as to be able to communicate data. When the robot control device 2 receives the execution command of the main welding sent from the higher-level device 1, the robot control device 2 controls the welding robot MC1 using the corresponding original work based on the execution command to execute the main welding. When the robot control device 2 detects the completion of the main welding of the original work, it generates a main welding completion report indicating that the main welding of the original work is completed and notifies the higher-level device 1. As a result, the host device 1 can properly detect the completion of the main welding of the original work based on the robot control device 2. The method of detecting the completion of the main welding by the robot control device 2 may be, for example, a method of determining based on a signal indicating the completion of the main welding from a sensor (not shown) provided in the wire feeding device 300, or a known method. The method may be used, and the content of the method for detecting the completion of the main welding is not limited.

Further, when the robot control device 2 receives the repair welding execution command sent from the host device 1, the robot control device 2 follows the repair welding program created by the inspection control device 3 and uses the corresponding workpiece to be welded based on the execution command. Welding robot MC1 is controlled to execute repair welding. When the robot control device 2 detects the completion of the repair welding of the work to be welded, it generates a repair welding completion report to the effect that the repair welding of the work to be welded is completed and notifies the higher-level device 1. As a result, the host device 1 can appropriately detect the completion of repair welding of the workpiece to be welded based on the robot control device 2. The method of detecting the completion of repair welding by the robot control device 2 may be, for example, a method of determining based on a signal indicating the completion of repair welding from a sensor (not shown) provided in the wire feeding device 300, or a known method. The method may be used, and the content of the method for detecting the completion of repair welding does not have to be limited.

The welding robot MC1 as an example of the welding robot is connected to the robot control device 2 so as to be able to communicate data. The welding robot MC1 executes main welding or repair welding commanded by the host device 1 under the control of the corresponding robot control device 2. As described above, the welding robot MC1 may be composed of the main welding robot MC1a provided for the main welding and the repair welding robot MC1b provided for the repair welding.

The inspection control device 3 as an example of the repair welding device is connected so that data can be communicated with each of the host device 1, the robot control device 2, and the inspection device 4. When the inspection control device 3 receives the execution command of the appearance inspection sent from the higher-level device 1, the inspection control device 3 inspects the appearance of the welded portion of the work to be welded produced by the welding robot MC1 (for example, the work to be welded formed by the main welding). (Inspection of whether or not the weld bead of (1) conforms to the predetermined shape of the master bead) is performed by the inspection device 4. For example, the inspection control device 3 controls the inspection device 4 to detect the shape of the weld bead formed at the welded portion based on the welded portion information of the work to be welded included in the execution command of the visual inspection, and main welding. The shapes of the predetermined welding master bead (not shown) and the actually detected welding bead are compared for each. The inspection control device 3 generates a visual inspection report based on the above-mentioned comparison, and sends the visual inspection report to the higher-level device 1.

Further, when the inspection control device 3 determines that the appearance inspection of the work to be welded has failed, the inspection control device 3 obtains the appearance inspection result including the position information of the detection point indicating the place where the welding defect obtained from the inspection device 4 is detected. Use it to create a repair welding program to repair defective parts of welding. In the present specification, there are a plurality of detection points included in the visual inspection result. The inspection control device 3 associates this repair welding program with the appearance inspection result and sends it to the robot control device 2.

The inspection device 4 is connected so that data can be communicated with the inspection control device 3. Although not shown in FIG. 1, when the inspection device 4 is attached to the welding robot MC1 (see FIG. 2), the inspection device 4 responds to the drive of the manipulator 200 based on the control of the robot control device 2. Therefore, the mounting table on which the work Wk is mounted can be operated in a three-dimensional scan. The inspection device 4 responds to the drive of the manipulator 200 based on the control of the robot control device 2 in response to an execution command for visual inspection sent from the inspection control device 3 in order to inspect the presence or absence of welding defects in the work Wk. Based on this, the welding location information included in the execution command and the shape data of the welding bead at the welding location are acquired and sent to the inspection control device 3. The inspection control device 3 determines the presence or absence of welding defects at the welded portion based on the shape data obtained from the inspection device 4 and the shape data of the master bead described above (visual inspection). The inspection control device 3 creates defect location information (for example, a detection point indicating a location where a welding defect is detected, a welding defect type) among the welded portions as a visual inspection report.

FIG. 2 is a diagram showing an example of internal configurations of the inspection control device 3, the robot control device 2, and the host device 1 according to the first embodiment. In order to make the explanation easier to understand, the monitor MN1 and the input interface UI1 are not shown in FIG.

Under the control of the robot control device 2, the welding robot MC1 executes various processes such as main welding and repair welding commanded by the host device 1, for example. The welding robot MC1 performs, for example, arc welding in the main welding or repair welding process. However, the welding robot MC1 may perform welding other than arc welding (for example, laser welding, gas welding) and the like. In this case, although not shown, the laser head may be connected to the laser oscillator via an optical fiber instead of the welding torch 400. The welding robot MC1 has a configuration including at least a manipulator 200, a wire feeding device 300, a welding wire 301, and a welding torch 400.

The manipulator 200 includes articulated arms, and each arm is moved based on a control signal from the robot control unit 25 (see below) of the robot control device 2. Thereby, the manipulator 200 can change the positional relationship between the work Wk and the welding torch 400 (for example, the angle of the welding torch 400 with respect to the work Wk) by driving the arm.

The wire feeding device 300 controls the feeding speed of the welding wire 301 based on a control signal (see below) from the robot control device 2. The wire feeding device 300 may include a sensor (not shown) capable of detecting the remaining amount of the welding wire 301. The robot control device 2 can detect that the main welding or repair welding process has been completed based on the output of this sensor.

The welding wire 301 is held by the welding torch 400. When electric power is supplied to the welding torch 400 from the power supply device 500, an arc is generated between the tip of the welding wire 301 and the work Wk, and arc welding is performed. The configuration for supplying the shield gas to the welding torch 400 and the like are omitted from the illustration and description for convenience of explanation.

The host device 1 uses welding-related information input or set in advance by the user to perform repair welding such as repairing defective parts of main welding using each of a plurality of original workpieces or welding of the workpiece to be welded. Execution commands for various processes are generated and sent to the robot control device 2. The host device 1 has a configuration including at least a communication unit 10, a processor 11, and a memory 12.

The communication unit 10 is connected so that data can be communicated with each of the robot control device 2 and the external storage ST. The communication unit 10 sends an execution command of various processes of main welding or repair welding generated by the processor 11 to the robot control device 2. The communication unit 10 receives the main welding completion report, the visual inspection report, or the repair welding completion report sent from the robot control device 2 and outputs the repair welding completion report to the processor 11. The execution command of the main welding or the repair welding may include, for example, a control signal for controlling each of the manipulator 200, the wire feeding device 300, and the power supply device 500 included in the welding robot MC1.

The processor 11 is configured by using, for example, a CPU (Central Processing Unit) or an FPGA (Field Programmable Gate Array), and performs various processes and controls in cooperation with the memory 12. Specifically, the processor 11 functionally realizes the cell control unit 13 by referring to the program held in the memory 12 and executing the program.

The memory 12 includes, for example, a RAM (Random Access Memory) as a work memory used when executing the processing of the processor 11, and a ROM (Read Only Memory) for storing a program defining the processing of the processor 11. Data generated or acquired by the processor 11 is temporarily stored in the RAM. A program that defines the processing of the processor 11 is written in the ROM. Further, the memory 12 stores the welding-related information data read from the external storage ST and the work information (see below) of the work to be welded or the work to be repaired to be repaired sent from the robot control device 2, respectively.

Based on the welding-related information stored in the external storage ST, the cell control unit 13 performs the main welding or the work to be welded using a plurality of original works specified (in other words, set) in the welding-related information. Generate an execution command to perform repair welding. Further, the cell control unit 13 performs an appearance inspection on driving the welding robot MC1 at the time of appearance inspection of the work Wk (for example, the work to be welded) after the main welding based on the welding-related information stored in the external storage ST. Program, and an execution command for the visual inspection program including this visual inspection program are created. The appearance inspection program may be created in advance and stored in the external storage ST. In this case, the cell control unit 13 simply reads the appearance inspection program from the external storage ST and acquires it. The cell control unit 13 may generate different execution commands for each of the various processes of main welding or repair welding executed by the welding robot MC1. The execution command of the main welding or the repair welding generated by the cell control unit 13, or the execution command of the appearance inspection program including the appearance inspection program is sent to the corresponding robot control device 2 via the communication unit 10.

The robot control device 2 is a welding robot MC1 (specifically, a manipulator 200, a wire feeding device 300, a power supply device 500) based on an execution command of main welding or repair welding sent from the host device 1. Control the process. The robot control device 2 has a configuration including at least a communication unit 20, a processor 21, and a memory 22.

The communication unit 20 is connected so that data can be communicated with the host device 1, the inspection control device 3, and the welding robot MC1. Although the illustration is simplified in FIG. 2, the robot control unit 25 and the manipulator 200, the robot control unit 25 and the wire feeding device 300, and the power supply control unit 26 and the power supply device 500 During that time, data is transmitted and received via the communication unit 20, respectively. The communication unit 20 receives an execution command for main welding or repair welding sent from the host device 1. The communication unit 20 sends the work information of the work to be welded produced by the main welding or the work to be repaired produced by the correction by the repair welding to the host device 1.

Here, the work information includes not only the ID of the work to be welded or the work to be repaired, but also the ID, name, welding location, welding conditions at the time of execution of the main welding, and repair of a plurality of original works used for the main welding. At least the welding conditions at the time of performing the welding are included. Further, the work information may include information (for example, coordinates) indicating the positions of the plurality of detection points indicating the defective portion of the work to be welded. The welding conditions or repair welding conditions include, for example, the material and thickness of the original work, the material and wire diameter of the welding wire 301, the shield gas type, the flow rate of the shield gas, the set average value of the welding current, and the set average value of the welding voltage. The feeding speed and feeding amount of the welding wire 301, the number of weldings, the welding time, and the like. In addition to these, information indicating the type of main welding or repair welding (for example, TIG welding, MAG welding, pulse welding), the moving speed of the manipulator 200, and the moving time may be included.

The processor 21 is configured by using, for example, a CPU or an FPGA, and cooperates with the memory 22 to perform various processes and controls. Specifically, the processor 21 refers to the program stored in the memory 22 and executes the program to function the welding program creation unit 23, the calculation unit 24, the robot control unit 25, and the power supply control unit 26. Realize.

The memory 22 has, for example, a RAM as a work memory used when executing the processing of the processor 21, and a ROM for storing a program defining the processing of the processor 21. Data generated or acquired by the processor 21 is temporarily stored in the RAM. A program that defines the processing of the processor 21 is written in the ROM. Further, the memory 22 stores the data of the execution command of the main welding or the repair welding sent from the higher-level device 1 and the data of the work information of the work to be welded produced by the main welding or the work to be repaired produced by the repair welding. Remember each one. Further, the memory 22 stores the main welding program executed by the welding robot MC1. The main welding program is a program that defines a specific procedure (process) of the main welding for joining a plurality of original workpieces using the welding conditions in the main welding.

The main welding program creation unit 23 is based on the main welding execution command sent from the host device 1 via the communication unit 20, and the work information (for example, ID, name, etc.) of each of the plurality of original works included in the execution command. And the welded part of the original work) is used to generate the main weld program of the main weld executed by the welding robot MC1. This welding program includes a welding current, a welding voltage, an offset amount, a welding speed, and a welding torch 400 for controlling a power supply device 500, a manipulator 200, a wire feeding device 300, a welding torch 400, etc. during the execution of the main welding. Various parameters such as the posture of the device may be included. The generated main welding program may be stored in the processor 21 or may be stored in the RAM in the memory 22.

The calculation unit 24 performs various calculations. For example, the calculation unit 24 is a welding robot MC1 (specifically, a manipulator 200, a wire feeding device 300, and a wire feeding device 300) controlled by a robot control unit 25 based on the welding program generated by the welding program creation unit 23. The parameters for controlling each of the power supply devices 500) are calculated.

The robot control unit 25 drives the welding robot MC1 (specifically, each of the manipulator 200, the wire feeding device 300, and the power supply device 500) based on the welding program generated by the welding program creation unit 23. To generate a control signal for. The robot control unit 25 sends this generated control signal to the welding robot MC1. Further, the robot control unit 25 is a welding robot during the visual inspection so as to cover the operating range of the welding robot MC1 defined in this welding program based on the visual inspection program sent from the host device 1. The manipulator 200 of MC1 is driven. As a result, the inspection device 4 (see FIG. 2) attached to the welding robot MC1 can be moved along with the operation of the welding robot MC1 to perform an appearance inspection of welding defects on the welding beads of the work Wk.

The power supply control unit 26 drives the power supply device 500 based on the main welding program generated by the main welding program creation unit 23 and the calculation result of the calculation unit 24.

The inspection control device 3 controls the processing of the appearance inspection of the work to be welded or the work to be repaired to be repaired produced by the main welding by the welding robot MC1 based on the execution command of the appearance inspection sent from the higher-level device 1. In the visual inspection, for example, whether or not the shape of the weld bead formed on the work to be welded or the work to be repaired meets the predetermined welding standard or the strength standard of the welded part, and the quality standard of the work to be welded or the work to be repaired. It is an inspection of. For simplification of the following description, the inspection control device 3 has a work Wk (for example, a work to be welded or a work to be welded) based on 3D (Dimension) point cloud data indicating the shape of the weld bead acquired by the inspection device 4. A visual inspection is performed to see if the weld bead formed on the repair weld work) meets a predetermined welding standard (for example, the same or similar to the shape of a predetermined master bead according to the work Wk). Hereinafter, the welded points determined to be significantly different from the shape of the master bead (that is, neither match nor similar to the shape of the master bead) in the 3D point cloud data indicating the shape of the weld bead are defined as "detection points". To do. In other words, the information indicating the position of the detection point (for example, 3D position coordinates) is detected by the inspection control device 3. The inspection control device 3 has a configuration including at least a communication unit 30, a processor 31, a memory 32, and an inspection result storage unit 33.

The communication unit 30 is connected so that data can be communicated with the host device 1, the robot control device 2, and the inspection device 4. Although the illustration is simplified in FIG. 2, data is transmitted and received between the shape detection control unit 35 and the inspection device 4 via the communication unit 30, respectively. The communication unit 30 receives the visual inspection execution command sent from the host device 1. The communication unit 30 sends the appearance inspection result of the appearance inspection using the inspection device 4 (for example, the presence or absence of a welding defect in the work to be welded or the work to be repaired) to the higher-level device 1.

The processor 31 is configured by using, for example, a CPU or an FPGA, and performs various processes and controls in cooperation with the memory 32. Specifically, the processor 31 refers to the program held in the memory 32 and executes the program to execute the determination threshold storage unit 34, the shape detection control unit 35, the data processing unit 36, and the inspection result determination unit 37. And the repair welding program creation unit 38 is functionally realized.

The memory 32 has, for example, a RAM as a work memory used when executing the processing of the processor 31, and a ROM for storing a program defining the processing of the processor 31. Data generated or acquired by the processor 31 is temporarily stored in the RAM. A program that defines the processing of the processor 31 is written in the ROM. Further, the memory 32 contains data of an execution command for visual inspection of the work to be welded sent from the host device 1, data of work information of the work to be welded produced by main welding or work information of the work to be repaired produced by repair welding. Are memorized respectively. Further, the memory 32 stores the data of the repair welding program created by the repair welding program creation unit 38. The repair welding program rearranges the output order of the plurality of detection points included in the welding conditions and the appearance inspection result in the repair welding so as to match the operation direction during the main welding or the repair welding of the welding robot MC1. A program that defines specific procedures (processes) for repair welding that repairs, etc., each of multiple defective parts of welding in the workpiece to be welded, using the position information of the target section (see below) based on points. Is. This program is created by the repair welding program creation unit 38, and is sent from the inspection control device 3 to the robot control device 2.

The inspection result storage unit 33 is configured by using, for example, a hard disk or a solid state drive. The inspection result storage unit 33 stores data showing the appearance inspection result of the welded portion in the work Wk (for example, the work to be welded or the work to be repaired) as an example of the data generated or acquired by the processor 31. The data showing the visual inspection result is generated by, for example, the inspection result determination unit 37.

The determination threshold storage unit 34 is composed of, for example, a cache memory provided in the processor 31, and the threshold value used in the determination process by the inspection result determination unit 37 according to the welding location (for example, each set according to the welding location). Threshold) is memorized. Each threshold value is, for example, an allowable range (threshold value) for misalignment of the welded portion, a threshold value for the height of the weld bead, and a threshold value for the width of the weld bead. The determination threshold storage unit 34 has a permissible range (for example, a minimum permissible value and a maximum permissible value regarding the height of the welding bead) that satisfy the minimum welding quality required by a customer or the like as each threshold value at the time of visual inspection after repair welding. Etc.) may be memorized. Further, the determination threshold value storage unit 34 may store the upper limit value of the number of appearance inspections for each welded portion. As a result, the inspection control device 3 determines that it is difficult or impossible to correct the defective part by the automatic repair welding by the welding robot MC1 when the upper limit of the predetermined number of times is exceeded when the defective part is corrected by the repair welding. , It is possible to suppress a decrease in the operating rate of the welding system 100.

In the shape detection control unit 35, the robot control device 2 performs an appearance inspection in the appearance inspection based on an execution command of the appearance inspection of the welded portion of the work Wk (for example, the work to be welded) sent from the host device 1 or the robot control device 2. While the welding robot MC1 to which the inspection device 4 is attached is operated based on the test device 4, the shape data of the weld bead (for example, 3D point group data) at the welding point sent from the inspection device 4 is acquired. When the shape detection control unit 35 is located at a position where the inspection device 4 can image the welded portion (in other words, can detect the three-dimensional shape of the welded portion) in response to the drive of the manipulator 200 by the robot control device 2 described above, For example, a laser beam is irradiated from the inspection device 4 to acquire shape data of the weld bead at the welded portion. When the shape detection control unit 35 receives the shape data of the weld bead acquired by the inspection device 4, the shape detection control unit 35 passes the shape data to the data processing unit 36.

The data processing unit 36 converts the shape data of the weld bead at the welded portion from the shape detection control unit 35 into image data showing the three-dimensional shape of the welded portion. The shape data is, for example, point cloud data of a shape line composed of a reflection locus of a laser beam applied to the surface of a weld bead. The data processing unit 36 executes statistical processing on the input shape data and generates image data regarding the three-dimensional shape of the weld bead at the welded portion. The data processing unit 36 may perform edge enhancement correction that emphasizes the peripheral portion of the weld bead in order to emphasize the position and shape of the weld bead. The data processing unit 36 counts the number of appearance inspections for each welded part or defective part, and if the number of appearance inspections exceeds the number of times stored in advance in the memory 32, the welding inspection result is not good, automatic repair welding is performed. It may be determined that it is difficult or impossible to correct the defective part by the above. In this case, the inspection result determination unit 37 generates an alert screen including the position of the defective portion and the defect factor, and sends the generated alert screen to the host device 1 via the communication unit 30. The alert screen sent to the host device 1 is displayed on the monitor MN1.

The inspection result determination unit 37 uses the threshold value stored in the determination threshold value storage unit 34, and the welded portion sets a predetermined welding standard based on the shape data of the weld bead at the welded portion acquired by the shape detection control unit 35. Whether or not the condition is satisfied (for example, whether or not the weld bead formed by main welding or repair welding matches or resembles the shape of the corresponding master bead) is determined. The inspection result determination unit 37 measures the position of the welding defect detection point (see above) (for example, the start position and end position of the defective portion (see FIGS. 4, 6 and 8), etc.) and analyzes the content of the defect. And estimate the cause of failure. In the above-mentioned determination, the inspection result determination unit 37 calculates an inspection score for each welding location on the welding line formed on the welding bead based on the shape data of the welding bead. The inspection result determination unit 37 as an example of the acquisition unit generates and acquires each of the measured position of the defective part, the inspection score, and the estimated defect factor as the appearance inspection result (appearance inspection report) for the welded part. The generated visual inspection result is stored in the memory 32 and sent to the host device 1 via the communication unit 30. The inspection result determination unit 37 determines whether repair welding by the welding robot MC1 is possible based on the above-mentioned inspection score (in other words, repair welding by the welding robot MC1 is preferable, or manual repair welding is performed. Is it okay?), And the judgment result may be included in the visual inspection result (visual inspection report) and output.

The repair welding program creation unit 38 uses the inspection result determination unit 37 to check the appearance of the work Wk (for example, the work to be welded or the work to be repaired) and the work information of the work to be welded or the work to be repaired (for example, the work to be welded or the work to be repaired). Repair of work Wk (for example, work to be welded or work to be repaired) to be executed by the welding robot MC1 using information such as coordinates indicating the positions of multiple detection points of welding defects generated in the repair welding work. Create a welding program. The details of the procedure for creating the repair welding program will be described later with reference to FIGS. 4, 5, 6, 7, 7, 8, 9 and 10. The repair welding program includes welding current, welding voltage, offset amount, welding speed, welding torch 400, etc. for controlling the power supply device 500, the manipulator 200, the wire feeder 300, the welding torch 400, etc. during the execution of repair welding. Various parameters such as the posture of the device may be included. The generated repair welding program may be stored in the processor 31 or in the RAM in the memory 32.

The inspection device 4 is, for example, a three-dimensional shape sensor, which is attached to the tip of the welding robot MC1 and can acquire a plurality of point group data capable of identifying the shape of the welded portion on the work Wk (for example, the work to be welded). Yes, based on this point group data, shape data of the welded portion (in other words, image data of the weld bead) is generated and sent to the inspection control device 3. When the inspection device 4 is not attached to the tip of the welding robot MC1 and is arranged separately from the welding robot MC1, the inspection device 4 is based on the position information of the welding portion sent from the inspection control device 3. A laser light source (not shown) configured to scan the welded portion on the work Wk (for example, the work to be welded or the workpiece to be repaired) and an imaging region including the periphery of the welded portion are arranged so as to be able to image the welded portion. It may be configured by a camera (not shown) that captures the reflection locus (that is, the shape line of the welded portion) of the reflected laser light among the laser light radiated to the weld. In this case, the inspection device 4 sends the shape data of the welded portion (in other words, the image data of the weld bead) based on the laser beam imaged by the camera to the inspection control device 3. The camera described above includes at least a lens (not shown) and an image sensor (not shown). The image sensor is a solid-state image sensor such as a CCD (Charge Coupled Device) or a CMOS (Complementary Metal Oxide Semi-conductor), and converts an optical image imaged on an imaging surface into an electric signal.

(Operation of welding system)
Next, the operation procedure of the main welding and the repair welding by the welding system 100 according to the first embodiment will be described with reference to FIG. 3A. FIG. 3A is a sequence diagram showing an example of operating procedures for main welding and repair welding by the welding system 100 according to the first embodiment. FIG. 3B is a sequence diagram showing a modified example of the operation procedure of the main welding and the repair welding by the welding system 100 according to the first embodiment. In the description of FIGS. 3A and 3B, the host device 1 and the robot control are used for each process of main welding using a plurality of original workpieces and repair welding performed based on the failure of the visual inspection of the workpiece to be welded. The operation procedure performed between the device 2 and the inspection control device 3 will be described as an example.

In FIG. 3A or FIG. 3B, the host device 1 acquires the work information (for example, ID, name, and welded portion of the original work) of the original work to be welded, respectively (St1), and obtains the work information of the original work. Generate a command to execute the main welding including. The host device 1 sends a command for executing the main welding including the work information of the original work to the robot control device 2 (St2). The robot control device 2 may execute the processes of step St1 and step St2, respectively, without going through the host device 1. In this case, the memory 22 of the robot control device 2 stores the same data as the data stored in the external storage ST, or the robot control device 2 is connected so that data can be acquired from the external storage ST. Is preferable.

When the robot control device 2 receives the execution command of the main welding sent from the higher-level device 1, the robot control device 2 uses the work information of each of the plurality of original workpieces included in the execution command to execute the main welding by the welding robot MC1. The main welding program is created, and the welding robot MC1 is made to execute the main welding according to the main welding program (St3). When the robot control device 2 determines the completion of the main welding of the plurality of original workpieces by the welding robot MC1 by various known methods, the robot control device 2 notifies the completion of the main welding of the plurality of original workpieces to the effect that the main welding of the plurality of original workpieces has been completed. Generate and send to higher-level device 1 (St4). Upon receiving this welding completion notification, the host device 1 generates an execution command for visual inspection of the workpiece to be welded and sends it to the inspection control device 3 (St5). As shown in FIG. 3B, when the host device 1 receives the main welding completion notification, it generates an execution command for an appearance inspection program including an appearance inspection program for the workpiece to be welded and sends it to the robot control device 2. Good (St4.5). In this case, as shown in FIG. 3B, the robot control device 2 generates an execution command for the appearance inspection of the workpiece to be welded and sends it to the inspection control device 3 (St5), and at the same time, the higher-level device 1 is accompanied by the start of the appearance inspection. The inspection device 4 attached to the welding robot MC1 is operated by executing the visual inspection program received from.

The inspection control device 3 performs the work to be welded based on the execution command of the visual inspection sent in step St5 while the inspection device 4 is moving so as to be able to scan the welded portion of the work to be welded by the robot control device 2. The target visual inspection is performed by the inspection device 4 (St6). As a result of the visual inspection in step St6, the inspection control device 3 determines that repair welding is necessary based on the inspection score and the like because the workpiece to be welded has a plurality of defective parts of welding (St7), and the main welding is performed. The program is acquired from the robot control device 2 (St8), and a repair welding program is created by modifying a part of this welding program (St8). In addition, a part to be modified is a content indicating, for example, a place (range) where repair welding is performed. Further, although detailed illustration is omitted in FIG. 3A, the inspection control device 3 requests the data of the present welding program from the robot control device 2 in step St8, and is sent from the robot control device 2 in response to this request. The data of the main welding program may be acquired, or the data of the main welding program sent from the robot control device 2 after step St3 may be acquired in advance. As a result, the inspection control device 3 can efficiently create the data of the repair welding program by partially modifying the acquired data of the main welding program. The inspection control device 3 generates an appearance inspection report including the determination result in step St7 and the repair welding program and sends it to the robot control device 2 (St9). Further, the inspection control device 3 sends the similarly generated visual inspection report to the higher-level device 1 (St10).

Upon receiving the visual inspection report in step St10, the host device 1 generates a repair welding execution command for the work to be welded and sends it to the robot control device 2 (St11). When the robot control device 2 receives the repair welding execution command sent from the host device 1, the robot control device 2 receives the repair welding execution command for the work to be welded specified by the execution command based on the repair welding program (received in step St9). The welding robot MC1 is made to perform repair welding according to the repair welding program (St12). When the robot control device 2 determines the completion of the repair welding of the work to be welded by the welding robot MC1 by various known methods, the work information of the work to be repaired produced by the repair welding (for example, the ID of the work to be repaired) , Work information including the IDs of the plurality of original works used for the main work (for example, the ID and name of the original work, the welding location of the original work), and the welding conditions at the time of each execution of the main work and the repair weld). It is sent to the host device 1 (St13).

When the host device 1 receives the work information including the ID of the welded work to be repaired sent from the robot control device 2, it sets a management ID suitable for the user company corresponding to the ID of the welded work to be repaired, and also sets the management ID suitable for the user company. The data indicating that the welding of the work to be repaired corresponding to the management ID has been completed is saved in the external storage ST (St14).

Next, in creating the repair welding program, the output order of the plurality of detection points is set to the main welding of the welding robot MC1 by using the plurality of detection points (that is, the positions indicating the defective welding points) output from the inspection device 4. An example of an outline of the operation of rearranging the parts so as to match the operation direction at the time of time or repair welding will be described in detail with reference to FIGS. 4, 5, 6, 7, 8, 9, and 10. As a premise of the following explanation, the direction of detecting the presence or absence of defective parts in the workpiece to be welded at the time of visual inspection does not match the direction of main welding and repair welding performed by the welding robot MC1 at the time of main welding and repair welding, and is opposite. The direction (see FIGS. 4, 6, and 8).

(Example of the first operation outline)
FIG. 4 is a diagram schematically showing a first operation outline example relating to rearrangement for matching the output order of a plurality of detection points with the operation direction of the welding robot MC1. FIG. 5 is a diagram schematically showing an example of rearranging a plurality of detection points shown in FIG. FIG. 10 is a flowchart showing an example of an operation procedure for creating a repair welding program. In the first embodiment, the flowchart shown in FIG. 8 is executed by the processor 31 (specifically, the repair welding program creation unit 38) built in the inspection control device 3. In the first operation outline example, there are a plurality of detection points indicating the positions of defective parts on the welding line (the operation locus of the welding robot MC1 during the main welding. The same applies hereinafter). It is assumed that the bead chipping (that is, the welding bead is partially lost due to the main welding) occurs.

In FIG. 10, the repair welding program creation unit 38 acquires the appearance inspection result generated by the inspection result determination unit 37 (St8-1). The visual inspection result includes at least information indicating the positions of a plurality of detection points, a type of welding defect, and point cloud data indicating the shape of the weld bead included in the visual inspection result. Referring to FIG. 4, a plurality of detection points (specifically, detection points P1, P2, P3, P4) are detected by visual inspection on the operation locus of the welding robot MC1 on the welding line WLN1. It is detected in the order of P3 and P4. The detection point P1 has attributes as an end detection point, the detection point P2 has attributes as a start detection point, the detection point P3 has attributes as an end detection point, and the detection point P4 has attributes as a start detection point and is output as an appearance inspection result.

The repair welding program creation unit 38 is the operation section of the welding robot MC1 specified in the main welding program sent from the robot control device 2 (specifically, a continuous combination of the main welded sections ZN1, ZN2, ZN3). Based on, the welding line WLN1 including the detection point is divided into sections (St8-2). Referring to FIG. 4, the repair welding program creation unit 38 includes the welding line WLN1 including each of the detection points P3, P2, P1 and P4 based on the point cloud data indicating the shape of the welding bead included in the visual inspection result. Is divided into sections ZN1, ZN2, and ZN3. The detection point P3 is included in the linear section ZN1 (division section number "1"), the detection points P2 and P1 are included in the arcuate section ZN2 (division section number "2"), and the detection point P4 is linear. Is included in the section ZN3 (division section number "3") of.

The end point D1 is one end point (for example, a start point) of the section ZN1. The end point D2 is the other end point (for example, the end point) of the section ZN1 and further, one end point (for example, the start point) of the section ZN2. The end point D3 is the other end point (for example, the end point) of the section ZN2, and further is one end point (for example, the start point) of the section ZN3. The end point D4 is the other end point (for example, the end point) of the section Z3. The start point indicates the start position in the operating direction of the welding robot MC1 during main welding and repair welding, and the end point indicates the end position of the welding robot MC1 in the operating direction during main welding and repair welding.

The repair welding program creation unit 38 uses the information indicating the positions of the detection points P3, P2, P1, and P4 to determine the position of the detection points included in each of the sections ZN1 to ZN3 from the start point of the corresponding section. A parameter (for example, a distance or a ratio) indicating whether or not it exists is calculated and recorded in the memory 32 (St8-3). Referring to FIG. 4, the repair weld program creating unit 38, for example the distance S ₃ or the ratio (section in proportion) from the detection point P3 is the starting point in the interval ZN1 division section number "1" (i.e. end point D1) S Calculate ₃ / L _1. Note that L ₁ indicates the length of the section ZN 1. Similarly, in the repair welding program creation unit 38, the distances or ratios (in-section ratios) of the detection points P2 and P1 in the section ZN2 of the division section number “2” along the arc from the start point (that is, the end point D2) are respectively. ), Further, the distance or ratio (intra-section ratio) of each of the detection points P4 in the section ZN3 of the division section number “3” from the start point (that is, the end point D3) is calculated.

The repair welding program creation unit 38 uses the calculation result of step St8-3 to create a table TBL1 showing the relationship between the division section number corresponding to the detection point and the distance within the section (the ratio within the section is also possible. The same shall apply hereinafter). Is temporarily stored in the memory 32 (see FIG. 5). The repair welding program creation unit 38 refers to the table TBL1 and generates a table TBL2 in which the detection points are sorted (sorted) in the order of the division section number and the distance within the section (St8-4). In other words, it is first sorted by the division section number, and when a plurality of detection points are included in the section having the same division section number, it is sorted by the distance within the section. As a result, the repair welding program creation unit 38 sets the output order of each of the plurality of detection points P1, P2, P3, and P4 obtained in the visual inspection as the operation direction of the welding robot MC1 during the main welding and the repair welding. It can be rearranged in the matching order (specifically, the order of detection points P3, P2, P1, P4).

The repair welding program creation unit 38 sets the order of the detection points P3, P2, P1, P4 sorted in step St8-4 (an example of the alignment result) and the attributes of each detection point (start detection point or end detection point). Based on this, the repair welding section is determined and set (St8-5). With reference to FIG. 4, the repair welding program creation unit 38 considers that the detection direction of the visual inspection and the operation direction of the welding robot MC1 at the time of main welding or repair welding are opposite to each other, and the attributes of the respective detection points. From the detection point P3, which can be said to be the end point of visual inspection (in other words, the start point at the time of repair welding), to the detection point P2, which can be said to be the start point of visual inspection (in other words, the end point at the time of repair welding). Is set as the first repair welding section. Further, the repair welding program creation unit 38 starts from the detection point P1 which can be said to be the end point of the visual inspection (in other words, the start point at the time of repair welding) to the end point of the visual inspection (in other words, the end point at the time of repair welding). Up to the detection point P4, which can be said to be, is set as the second repair welding section.

The repair welding program creation unit 38 creates a repair welding program that defines the repair welding section determined in step St8-5 and various parameters (for example, welding conditions) used in repair welding (St8-6).

(Example of second operation outline)
FIG. 6 is a diagram schematically showing a second operation outline example relating to rearrangement for matching the output order of a plurality of detection points with the operation direction of the welding robot MC1. FIG. 7 is a diagram schematically showing an example of rearranging the plurality of detection points shown in FIG. In the second operation outline example, there are a plurality of detection points indicating the positions of defective parts at positions other than the welding line. For example, the bead is chipped as a welding defect (that is, the weld bead is partially missing due to the main welding). What you did) occurs. In the second operation outline example, the description of the content that overlaps with the description of FIGS. 4 and 5 will be simplified or omitted, and different contents will be described.

In FIG. 10, the repair welding program creation unit 38 acquires the appearance inspection result generated by the inspection result determination unit 37 (St8-1). Referring to FIG. 6, a plurality of detection points (specifically, detection points P7, P6, P5, P8) are detected by visual inspection at positions distant from the operation locus of the welding robot MC1 on the welding line WLN1. , P6, P7, P8 are detected in this order. The detection point P5 has an attribute as an end detection point, the detection point P6 has an attribute as a start detection point, the detection point P7 has an attribute as an end detection point, and the detection point P8 has an attribute as a start detection point and is output as an appearance inspection result.

The repair welding program creation unit 38 is the operation section of the welding robot MC1 specified in the main welding program sent from the robot control device 2 (specifically, a continuous combination of the main welded sections ZN1, ZN2, ZN3). Based on the above, the welding line WLN1 including the corresponding points P7h, P6h, P5h, and P8h on the welding line WLN1 closest to the detection point is divided into sections (St8-2). Referring to FIG. 6, the repair welding program creation unit 38 includes the welding line WLN1 including each of the corresponding points P7h, P6h, P5h, and P8h based on the point cloud data indicating the shape of the welding bead included in the visual inspection result. Is divided into sections ZN1, ZN2, and ZN3. The corresponding point P7h is included in the linear section ZN1 (division section number "1"), the corresponding points P6h and P5h are included in the arc-shaped section ZN2 (division section number "2"), and the corresponding point P8h is linear. Is included in the section ZN3 (division section number "3") of.

The repair welding program creation unit 38 uses the information indicating the positions of the corresponding points P7h, P6h, P5h, and P8h to determine the position of the corresponding points included in each of the sections ZN1 to ZN3 from the start point of the corresponding section. A parameter (for example, a distance or a ratio) indicating whether or not it exists is calculated and recorded in the memory 32 (St8-3). With reference to FIG. 6, the repair welding program creation unit 38 calculates, for example, the distance or ratio (ratio within the section) from the starting point (that is, the end point D1) of the corresponding point P7h in the section ZN1 of the division section number “1”. .. Similarly, in the repair welding program creation unit 38, the distances or ratios (in-section ratios) of the corresponding points P6h and P5h in the section ZN2 of the division section number “2” along the arc from the start point (that is, the end point D2). ), Further, the distance or ratio (intra-section ratio) of each of the corresponding points P8h in the section ZN3 of the division section number “3” from the start point (that is, the end point D3) is calculated.

The repair welding program creation unit 38 uses the calculation result of step St8-3 to create a table TBL3 showing the relationship between the division section number corresponding to the corresponding point and the distance within the section (the ratio within the section is also possible. The same shall apply hereinafter). Is temporarily stored in the memory 32 (see FIG. 7). The repair welding program creation unit 38 refers to the table TBL3 and generates a table TBL4 in which the detection points are sorted (sorted) in the order of the division section number and the distance within the section (St8-4). In other words, it is first sorted by the division section number, and when a plurality of corresponding points are included in the section having the same division section number, it is sorted by the distance within the section. As a result, the repair welding program creation unit 38 sets the output order of each of the plurality of detection points P5, P6, P7, and P8 obtained in the visual inspection as the operation direction of the welding robot MC1 during the main welding and the repair welding. It can be rearranged in the order of matching (specifically, the order of corresponding points P7h, P6h, P5h, P8h).

The repair welding program creation unit 38 sets the order of the corresponding points P7h, P6h, P5h, and P8h sorted in step St8-4 (an example of the alignment result) and the attributes of each detection point (start detection point or end detection point). Based on this, the repair welding section is determined and set (St8-5). With reference to FIG. 6, the repair welding program creation unit 38 considers that the detection direction of the visual inspection and the operation direction of the welding robot MC1 at the time of main welding or repair welding are opposite to each other, and the attributes of the respective detection points. To the corresponding point P7h, which can be said to be the end point of visual inspection (in other words, the start point at the time of repair welding), to the corresponding point P6h, which can be said to be the start point of visual inspection (in other words, the end point at the time of repair welding). Is set as the first repair welding section, and further, from the corresponding point P5h, which can be said to be the end point of the visual inspection (in other words, the start point at the time of repair welding), the end point of the visual inspection (in other words, the end point at the time of repair welding). ) Is set as the second repair welding section up to the corresponding point P8h.

The repair welding program creation unit 38 creates a repair welding program that defines the repair welding section determined in step St8-5 and various parameters (for example, welding conditions) used in repair welding (St8-6).

(Example of 3rd operation outline)
FIG. 8 is a diagram schematically showing a third operation outline example relating to rearrangement for matching the output order of a plurality of detection points with the operation direction of the welding robot MC1. FIG. 9 is a diagram schematically showing an example of rearranging the plurality of detection points shown in FIG. In the third operation outline example, there are a plurality of detection points indicating the positions of defective parts, which are divided into a position not on the welding line and a position on the welding line. It is assumed that the welding bead is partially lost due to this). In the third operation outline example, the description of the content overlapping with the description of FIGS. 4, 5, 6 and 7 will be simplified or omitted, and different contents will be described.

In FIG. 10, the repair welding program creation unit 38 acquires the appearance inspection result generated by the inspection result determination unit 37 (St8-1). Referring to FIG. 8, a plurality of detection points (specifically, detection points P11, P10, P9, P12) appear on the operation locus of the welding robot MC1 on the welding line WLN1 or at a position away from the operation locus. By inspection, detection points P9, P10, P11, and P12 are detected in this order. The detection point P9 has attributes as an end detection point, the detection point P10 has attributes as a start detection point, the detection point P11 has attributes as an end detection point, and the detection point P12 has attributes as a start detection point and is output as an appearance inspection result.

The repair welding program creation unit 38 is the operation section of the welding robot MC1 specified in the main welding program sent from the robot control device 2 (specifically, a continuous combination of the main welded sections ZN1, ZN2, ZN3). Based on the above, the welding line WLN1 including the corresponding points P10h and P12h on the welding lines WLN1 closest to the detection points P11h and P9 or the detection points P10 and P12 is divided into sections (St8-2). With reference to FIG. 8, the repair welding program creation unit 38 has the detection point P11, the corresponding point P10h, the detection point P9, and the corresponding point P12h, respectively, based on the point cloud data indicating the shape of the welding bead included in the visual inspection result. The welding line WLN1 including the above is divided into sections ZN1, ZN2, and ZN3. The detection point P11 is included in the linear section ZN1 (division section number "1"), the corresponding point P10h and the detection point P9 are included in the arcuate section ZN2 (division section number "2"), and the corresponding point P12h is. It is included in the linear section ZN3 (division section number "3").

The repair welding program creation unit 38 uses information indicating the positions of the detection point P11, the corresponding point P10h, the detection point P9, and the corresponding point P12h, and uses the information indicating the positions of the detection point P11, the corresponding point P10h, and the corresponding point P12h, and the detection point or the corresponding section corresponding to each of the sections ZN1 to ZN3 A parameter (for example, a distance or a ratio) indicating what position is present from the start point of the above is calculated and recorded in the memory 32 (St8-3). With reference to FIG. 8, the repair welding program creation unit 38 calculates, for example, the distance or ratio (ratio within the section) from the start point (that is, the end point D1) of the detection point P11 in the section ZN1 of the division section number “1”. .. Similarly, in the repair welding program creation unit 38, the distances or ratios (sections) of the corresponding points P10h and the detection points P9 in the section ZN2 of the division section number “2” along the arc from the start point (that is, the end point D2). The distance or ratio (intra-section ratio) of each of the corresponding points P12h in the section ZN3 of the division section number “3” from the start point (that is, the end point D3) is calculated.

The repair welding program creation unit 38 uses the calculation result of step St8-3 to show the relationship between the division section number corresponding to the detection point or the corresponding point and the distance within the section (the ratio within the section is also possible. The same shall apply hereinafter). Is temporarily stored in the memory 32 (see FIG. 9). The repair welding program creation unit 38 refers to the table TBL5 and generates a table TBL6 in which the detection points are sorted (sorted) in the order of the division section number and the distance within the section (St8-4). In other words, it is first sorted by the division section number, and when a section having the same division section number includes a plurality of detection points or corresponding points, it is sorted by the distance within the section. As a result, the repair welding program creation unit 38 sets the output order of each of the plurality of detection points P9, P10, P11, and P12 obtained in the visual inspection as the operation direction of the welding robot MC1 during the main welding and the repair welding. It can be rearranged in the order of matching (specifically, the order of detection point P11, corresponding point P10h, detection point P9, corresponding point P12h).

The repair welding program creation unit 38 describes the order of the detection points P11, the corresponding points P10h, the detection points P9, and the corresponding points P12h sorted in step St8-4 (an example of the alignment result) and the attributes of each detection point (start detection point or The repair welding section is determined and set based on the end detection point) (St8-5). With reference to FIG. 8, the repair welding program creation unit 38 considers that the detection direction of the visual inspection and the operation direction of the welding robot MC1 at the time of main welding or repair welding are opposite to each other, and the attributes of the respective detection points. From the detection point P11, which can be said to be the end point of visual inspection (in other words, the start point at the time of repair welding), to the corresponding point P10h, which can be said to be the start point of visual inspection (in other words, the end point at the time of repair welding). Is set as the first repair welding section, and further, from the detection point P9, which can be said to be the end point of the visual inspection (in other words, the start point at the time of repair welding), the end point of the visual inspection (in other words, the end point at the time of repair welding). ) Is set as the second repair welding section up to the corresponding point P12h.

The repair welding program creation unit 38 creates a repair welding program that defines the repair welding section determined in step St8-5 and various parameters (for example, welding conditions) used in repair welding (St8-6).

As described above, in the welding system 100 according to the first embodiment, the repair welding apparatus (for example, the inspection result determination unit 37) has a plurality of defective parts (for example) of the weld beads of the work to be welded produced by the main welding by the welding robot MC1. The visual inspection result including the information of each position of the detection points P1 to P4) is acquired. The repair welding device (for example, the robot control unit 25) is an object based on a plurality of defective parts in which the output order of each of the plurality of defective parts is rearranged in the order matching the operation direction of the welding robot MC1 based on the visual inspection result. The welding robot MC1 is instructed to execute the repair welding of the section (for example, the first repair welding section and the second repair welding section).

As a result, the repair welding device automatically and efficiently rearranges the output order of the plurality of defective parts obtained by the visual inspection of the workpiece produced by the main welding so as to match the operation direction of the welding robot. Can be repair welded. Therefore, even if the detection direction of the presence or absence of welding defects in the visual inspection and the operating direction of the welding robot MC1 at the time of main welding or repair welding are opposite to each other, the repair welding apparatus can be used for a plurality of repair welding devices obtained by the visual inspection. Since repair welding can be performed in accordance with the operation direction of the welding robot MC1 in each output order of the detection points, deterioration of the work efficiency of the welding robot MC1 can be suppressed. Further, since the repair welding device can suppress interference with the work to be repaired or the jig for fixing the work to be welded during repair welding, the smooth drive of the welding robot MC1 can be efficiently performed. Can help. In addition, the repair welding device can easily create a repair welding program by only partially changing a part of the main welding program created by the robot control device 2 (for example, information on defective parts to be repaired). Welding programs can be created efficiently.

Further, the repair welding device executes repair welding of the target section (see above) of the repair welding set after rearranging a plurality of detection points according to the operation direction of the welding robot MC1 based on the visual inspection result. Create a repair welding program. The repair welding device causes the welding robot MC1 to repair weld the target section according to the created repair welding program. As a result, the repair welding apparatus automatically adjusts the output order of each of the plurality of detection points P1 to P4 obtained in the visual inspection to the operating direction of the welding robot MC1 at the time of repair welding, and automatically via the welding robot MC1. Efficient repair welding is possible.

Further, the repair welding device divides the operation locus into a plurality of sections ZN1, ZN2, ZN3 when each of the plurality of defective parts is located on the operation locus of the welding robot MC1 at the time of main welding, and a plurality of defective parts. For each of the above, the distance or ratio from the start point of each operation direction of the plurality of sections is calculated, and the output order of the plurality of defective parts is arranged so as to match the operation direction using the section and the distance or ratio. Set the target section instead. As a result, the repair welding apparatus can rearrange the output order of each of the plurality of detection points existing on the welding line obtained by the visual inspection so as to match the operation direction of the welding robot MC1, and the detection after the rearrangement. Since repair welding can be performed in the order of points, repair welding can be performed efficiently without limiting the detection direction of the inspection device 4.

Further, the repair welding device divides the operation locus into a plurality of sections ZN1, ZN2, ZN3 when all of the plurality of defective parts are not located on the operation locus of the welding robot MC1 at the time of main welding, and a plurality of defective parts. For each recent contact point (for example, corresponding points P7h, P6h, P5h, P8h) from each of the above to the operation locus, the distance or ratio from the start point of each operation direction of a plurality of sections is calculated, and the section and the distance or ratio are calculated. Use to rearrange the output order of multiple defective parts so that they match the operation direction, and set the target section. As a result, the repair welding apparatus can rearrange the output order of each of the plurality of detection points that do not exist on the welding line obtained by the visual inspection so as to match the operation direction of the welding robot MC1, and detect after the rearrangement. Since repair welding can be performed in the order of corresponding points corresponding to the points, repair welding can be performed efficiently without limiting the detection direction of the inspection device 4.

Further, the repair welding apparatus has a plurality of operation loci when a part of a plurality of defective parts is located on the operation locus of the welding robot MC1 at the time of main welding and the rest of the plurality of defective parts is not located on the operation locus. Sections ZN1, ZN2, and ZN3 are divided into sections ZN1, ZN2, and ZN3, and the distance or ratio from the start point of each operation direction of a plurality of sections is calculated for each recent contact point from a part of the defective parts or the remaining defective parts to the operation locus. , The target section is set by rearranging the output order of a plurality of defective parts so as to match the operation direction using the section and the distance or ratio. As a result, the repair welding apparatus can rearrange the output order of the detection points existing on the welding line and the detection points not existing on the welding line obtained by the visual inspection so as to match the operation direction of the welding robot MC1. Since repair welding can be performed according to the order of the corresponding points corresponding to the detected points after the rearrangement, the repair welding can be efficiently performed without limiting the detection direction of the inspection device 4.

(Embodiment 2)
In the first embodiment, the repair welding program is created by the inspection control device 3. In the second embodiment, an example in which the repair welding program is performed by the robot control device 2a will be described.

(Welding system configuration)
FIG. 11 is a diagram showing an example of internal configurations of the inspection control device 3, the robot control device 2a, and the host device 1 according to the second embodiment. In the description of FIG. 11, the same reference numerals are given to those having the same configuration as each part of FIG. 2, and the description is simplified or omitted, and different contents will be described. Further, the configuration of the welding system 100a according to the second embodiment is the same as that of the welding system 100 according to the first embodiment (see FIG. 1).

The robot control device 2a as an example of the repair welding device corresponds to the welding robot MC1 (specifically, based on the execution command of the main welding or the repair welding sent from the host device 1 or the execution command of the visual inspection program. Controls the processing of the manipulator 200, the wire feeding device 300, and the power supply device 500). The robot control device 2a has a configuration including at least a communication unit 20, a processor 21a, and a memory 22.

The processor 21a is configured by using, for example, a CPU or an FPGA, and cooperates with the memory 22 to perform various processes and controls. Specifically, the processor 21a refers to the program stored in the memory 22, and by executing the program, the main welding / repair welding program creation unit 23a, the calculation unit 24, the robot control unit 25, and the power supply control unit. 26 is functionally realized.

The main welding / repair welding program creation unit 23a is based on the main welding execution command sent from the host device 1 via the communication unit 20, and the work information (for example, ID) of each of the plurality of original works included in the execution command. , Name, and weld location of the original work) to generate the main weld program of the main weld performed by the welding robot MC1. In addition, the main welding / repair welding program creation unit 23a uses the inspection result determination unit 37 for the appearance inspection result of the work Wk (for example, the work to be welded or the work to be repaired) and the work information of the work to be welded or the work to be repaired (for example, the work to be repaired). A work Wk (for example, a work to be welded or a work to be repaired) to be executed by the welding robot MC1 using information such as coordinates indicating the position of a welding defect detection point of the work to be welded or the work to be repaired. Create a repair welding program. The details of the procedure for creating the repair welding program are the same as those described in the first embodiment with reference to FIGS. 4 to 10, and thus the description thereof will be omitted. The generated main welding program and repair welding program may be stored in the processor 21a or in the RAM in the memory 22.

(Operation of welding system)
Next, the operation procedure of the main welding and the repair welding by the welding system 100a according to the second embodiment will be described with reference to FIG. 12A. FIG. 12A is a sequence diagram showing an example of operating procedures for main welding and repair welding by the welding system 100a according to the second embodiment. FIG. 12B is a sequence diagram showing a modified example of the operation procedure of the main welding and the repair welding by the welding system 100a according to the second embodiment. In the description of FIGS. 12A and 12B, the host device 1 and the robot control are used for each process of the main welding using a plurality of original workpieces and the repair welding performed based on the failure of the visual inspection of the workpiece to be welded. The operation procedure performed between the device 2a and the inspection control device 3 will be described as an example. Further, in the description of FIG. 12A or FIG. 12B, the same step number is assigned to the process overlapping with the process of FIG. 3A or FIG. 3B to simplify or omit the description, and different contents will be described.

In FIG. 12A or FIG. 12B, the robot control device 2a may execute the processes of step St1 and step St2, respectively, without going through the host device 1. In this case, the memory 22 of the robot control device 2a stores the same data as the data stored in the external storage ST, or the robot control device 2a is connected so as to be able to acquire data from the external storage ST. Is preferable. As shown in FIG. 10B, similarly to FIG. 3B, when the host device 1 receives the main welding completion notification, the robot generates an execution command of the appearance inspection program including the appearance inspection program of the workpiece to be welded. It may be sent to the control device 2a (St4.5). In this case, as shown in FIG. 10B, the robot control device 2a generates an execution command for the appearance inspection of the workpiece to be welded and sends it to the inspection control device 3 (St5), and at the same time, the higher-level device 1 is accompanied by the start of the appearance inspection. The inspection device 4 attached to the welding robot MC1 is operated by executing the visual inspection program received from.

The inspection control device 3 performs a visual inspection in cooperation with the inspection device 4 while the inspection device 4 is being moved so as to be able to scan the work to be welded by the robot control device 2, and as a result of the visual inspection in step St6, the inspection control device 3 is subjected to the inspection. It is determined that repair welding is necessary based on the inspection score, etc. because there are multiple defective parts in the welded work (St7), and an appearance inspection report including the determination result in step St7 is generated and robot control is performed. It is sent to the device 2a (St21). When the robot control device 2a receives the visual inspection report sent in step St21, the robot control device 2a creates a repair welding program using the contents of the visual inspection report (that is, the visual inspection result) (St22). When the robot control device 2a receives the repair welding execution command sent from the host device 1, the robot control device 2a is based on the repair welding program (created in step St22) for the work to be welded specified by the execution command. The welding robot MC1 is made to perform repair welding according to the repair welding program (St12). Since the processing after step St12 is the same as that in FIG. 3A, the description thereof will be omitted.

As described above, in the welding system 100a according to the second embodiment, the robot control device 2a rearranges a plurality of detection points according to the operation direction of the welding robot MC1 based on the visual inspection result, and then the repair welding is set. Create a repair welding program to execute repair welding of the target section (see above). The repair welding device causes the welding robot MC1 to repair weld the target section according to the created repair welding program. As a result, the repair welding apparatus automatically adjusts the output order of each of the plurality of detection points P5 to P8 obtained in the visual inspection to the operating direction of the welding robot MC1 at the time of repair welding, and automatically via the welding robot MC1. Efficient repair welding is possible.

(Embodiment 3)
In the second embodiment, the repair welding program is created by the robot control device 2a. In the third embodiment, an example in which the repair welding program is performed by the host device 1a will be described.

(Welding system configuration)
FIG. 13 is a diagram showing an example of internal configurations of the inspection control device 3, the robot control device 2, and the host device 1a according to the third embodiment. In the description of FIG. 13, the same reference numerals are given to those having the same configuration as each part of FIG. 2, and the description is simplified or omitted, and different contents will be described. Further, the configuration of the welding system 100b according to the third embodiment is the same as that of the welding system 100 according to the first embodiment (see FIG. 1).

The host device 1a as an example of the repair welding device collectively controls the execution of repair welding (for example, the start and completion of repair welding) executed by the welding robot MC1 via the robot control device 2. For example, when the host device 1a receives the appearance inspection report from the inspection control device 3, it creates a repair welding program and generates a repair welding execution command for the work to be welded produced by the welding robot MC1 to generate a repair welding program. Is sent to the robot control device 2. The host device 1a has a configuration including at least a communication unit 10, a processor 11a, and a memory 12.

The processor 11a is configured by using, for example, a CPU or an FPGA, and cooperates with the memory 12 to perform various processes and controls. Specifically, the processor 11a functionally realizes the cell control unit 13 and the repair welding program creation unit 14 by referring to the program stored in the memory 12 and executing the program.

The repair welding program creation unit 14 determines the appearance inspection result of the work Wk (for example, the work to be welded or the work to be repaired) sent from the inspection control device 3 and the work information of the work to be welded or the work to be repaired (for example, the work to be welded). Alternatively, a repair welding program for the work Wk (for example, the work to be welded or the work to be repaired) to be executed by the welding robot MC1 using information such as coordinates indicating the position of a welding defect detection point of the work to be repaired. To create. The details of the procedure for creating the repair welding program are the same as those described in the first embodiment with reference to FIGS. 4 to 10, and thus the description thereof will be omitted. The generated repair welding program may be stored in the processor 11a or in the RAM in the memory 12.

(Operation of welding system)
Next, the operation procedure of the main welding and the repair welding by the welding system 100b according to the third embodiment will be described with reference to FIG. 14A. FIG. 14A is a sequence diagram showing an example of operating procedures for main welding and repair welding by the welding system 100b according to the third embodiment. FIG. 14B is a sequence diagram showing a modified example of the operation procedure of the main welding and the repair welding by the welding system 100b according to the third embodiment. In the description of FIGS. 14A and 14B, the host device 1a and the robot control are used for each process of the main welding using a plurality of original workpieces and the repair welding performed based on the failure of the visual inspection of the workpiece to be welded. The operation procedure performed between the device 2 and the inspection control device 3 will be described as an example. Further, in the description of FIG. 14A or FIG. 14B, the same step number is assigned to the process overlapping with the process of FIG. 3A or FIG. 3B to simplify or omit the description, and different contents will be described.

In FIG. 14A or FIG. 14B, the robot control device 2 may execute the processes of step St1 and step St2, respectively, without going through the host device 1a. In this case, the memory 22 of the robot control device 2 stores the same data as the data stored in the external storage ST, or the robot control device 2 is connected so that data can be acquired from the external storage ST. Is preferable. As shown in FIG. 12B, similarly to FIG. 3B, when the higher-level device 1a receives the main welding completion notification, the robot generates an execution command of the appearance inspection program including the appearance inspection program of the workpiece to be welded. It may be sent to the control device 2 (St4.5). In this case, as shown in FIG. 12B, the robot control device 2 generates an execution command for the visual inspection of the workpiece to be welded and sends it to the inspection control device 3 (St5), and at the same time, the higher-level device 1a is accompanied by the start of the visual inspection. The inspection device 4 attached to the welding robot MC1 is operated by executing the visual inspection program received from.

The inspection control device 3 performs a visual inspection in cooperation with the inspection device 4 while the inspection device 4 is being moved so as to be able to scan the work to be welded by the robot control device 2, and as a result of the visual inspection in step St6, the inspection control device 3 is subjected to the inspection. It is determined that repair welding is necessary based on the inspection score, etc. because there are multiple defective parts in the welded work (St7), and an appearance inspection report including the determination result in step St7 is generated and robot control is performed. Send to device 2 (St21). Further, the inspection control device 3 sends the similarly generated visual inspection report to the host device 1a (St10).

Upon receiving the visual inspection report sent in step St10, the host device 1a creates a repair welding program using the contents of the visual inspection report (that is, the visual inspection result) (St31). The host device 1a generates a repair welding execution command for the work to be welded and sends the repair welding program to the robot control device 2 (St32). When the robot control device 2 receives the repair welding execution command sent from the host device 1a, the robot control device 2 receives the repair welding execution command for the work to be welded specified by the execution command based on the repair welding program (received in step St32). The welding robot MC1 is made to perform repair welding according to the repair welding program (St12). Since the processing after step St12 is the same as that in FIG. 3A, the description thereof will be omitted.

As described above, in the welding system 100b according to the third embodiment, the host device 1a rearranges a plurality of detection points according to the operation direction of the welding robot MC1 based on the visual inspection result, and then sets the repair welding. Create a repair welding program to execute repair welding of the target section (see above). The repair welding device causes the welding robot MC1 to repair weld the target section according to the created repair welding program. As a result, the repair welding apparatus automatically adjusts the output order of each of the plurality of detection points P9 to P12 obtained in the visual inspection to the operating direction of the welding robot MC1 at the time of repair welding, and automatically via the welding robot MC1. Efficient repair welding is possible.

Although various embodiments have been described above with reference to the drawings, it goes without saying that the present disclosure is not limited to such examples. It is clear that a person skilled in the art can come up with various modifications, modifications, substitutions, additions, deletions, and equality within the scope of the claims. It is understood that it naturally belongs to the technical scope of the present disclosure. Further, each component in the various embodiments described above may be arbitrarily combined as long as the gist of the invention is not deviated.

The present disclosure is a repair welding apparatus that rearranges the output order of a plurality of defective parts obtained by visual inspection of the workpiece produced by the main welding so as to match the operation direction of the welding robot and performs repair welding more efficiently. And useful as a repair welding method.

1, 1a Upper device 2, 2a Robot control device 10, 20, 30 Communication unit 11, 11a, 21, 21a, 31 Processor 12, 22, 32 Memory 13 Cell control unit 14, 38 Repair welding program creation unit 23 Welding program Creation unit 24 Calculation unit 25 Robot control unit 26 Power supply control unit 33 Inspection result storage unit 34 Judgment threshold storage unit 35 Shape detection control unit 36 Data processing unit 37 Inspection result judgment unit 100, 100a, 100b Welding system 200 Manipulator 300 Wire feeding Device 301 Welding wire 400 Welding torch 500 Power supply device MC1 Welding robot MC1a Main welding robot MC1b Repair welding robot ST External storage

Claims (6)

An acquisition unit that acquires visual inspection results including information on multiple defective parts of the weld bead of the work to be welded produced by main welding by a welding robot.
Based on the visual inspection result, the welding robot is subjected to repair welding of the target section based on the plurality of defective parts by rearranging the output order of the plurality of defective parts in an order that matches the operation direction of the welding robot. It is equipped with a robot control unit that gives instructions.
Repair welding equipment. A repair welding program creation unit for creating a repair welding program for executing repair welding of the target section based on the visual inspection result is further provided.
The robot control unit causes the welding robot to repair weld the target section according to the repair welding program.
The repair welding apparatus according to claim 1. When each of the plurality of defective parts is located on the operation locus of the welding robot at the time of main welding, the repair welding program creating unit divides the operation locus into a plurality of sections and divides the operation locus into a plurality of sections. For each, the distance or ratio from the start point of each of the operation directions of the plurality of sections is calculated, and the output order of the plurality of defective parts is set as the operation direction by using the section and the distance or ratio. Sort to match and set the target section,
The repair welding apparatus according to claim 2. When all of the plurality of defective parts are not located on the operation loci of the welding robot at the time of main welding, the repair welding program creating unit divides the operation loci into a plurality of sections and divides the operation loci into a plurality of sections. The distance or ratio from the start point of each of the operation directions of the plurality of sections is calculated for each recent contact from each to the operation locus, and the plurality of defective points are calculated using the section and the distance or ratio. The target section is set by rearranging the output order of the above so as to match the operation direction.
The repair welding apparatus according to claim 2. When a part of the plurality of defective parts is located on the operation locus of the welding robot at the time of main welding and the rest of the plurality of defective parts is not located on the operation locus, the repair welding program creating unit is used. The operation locus is divided into a plurality of sections, and the distance from the start point of each of the operation directions of the plurality of sections for each recent contact from the partial defective portion or the remaining defective portion to the operation locus or In addition to calculating the ratio, the target section is set by rearranging the output order of the plurality of defective parts so as to match the operation direction using the section and the distance or ratio.
The repair welding apparatus according to claim 2. A repair welding method performed by a repair welding device.
The process of acquiring visual inspection results including information on multiple defective parts of the weld bead of the work to be welded produced by the main welding by the welding robot, and
Based on the visual inspection result, the welding robot is subjected to repair welding of the target section based on the plurality of defective parts by rearranging the output order of the plurality of defective parts in an order that matches the operation direction of the welding robot. Has a process to instruct,
Repair welding method.

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