JP2021108856A - Sewing device - Google Patents

Abstract

To improve productivity by eliminating the trouble of teaching a movement locus to a robot for each type of workpiece.SOLUTION: A sewing device 10 includes: a sewing machine 30; a camera 50 for imaging a workpiece W; a robot 40 for moving the workpiece W with respect to a sewing needle 35 on a sewing machine table 32; and a control part 60 (PC 60) for performing image processing of the camera 50, and operation control of the robot 40 and the sewing machine 30. The PC 60 sets a plurality of sewing position coordinates of the workpiece W in which the sewing needle 35 is penetrated based on the shape data of the workpiece W acquired by the image processing of the camera 50 and the sewing condition, operates the robot 40 so that the sewing position coordinates reach the position of the sewing needle 35 in the predetermined order, and performs sewing.SELECTED DRAWING: Figure 4

Description

The present invention includes a sewing machine that sews a work to be sewn at a predetermined position on a sewing machine table, a camera that photographs the work, and a robot that moves the work on the sewing machine table with respect to the sewing machine needle of the sewing machine. The present invention relates to a sewing device including the image processing of the camera, the robot, and a control unit for controlling the operation of the sewing machine.

Patent Document 1 describes a technique related to the above-mentioned sewing apparatus. As shown in FIG. 16, the sewing apparatus 100 described in Patent Document 1 includes a sewing machine 102, a robot 104 that moves two workpieces 100w stacked vertically on a jig 103 with respect to the sewing machine needle 102n, and a robot 104. It is equipped with a camera (not shown) that captures the sewn part. Further, the sewing device 100 includes an image processing unit that processes an image taken by the camera and a control unit that controls the robot 104. When sewing the work 100w, the first arm 104a and the second arm 104b of the robot 104 are operated based on the image information obtained by the camera, and the sewn portion of the work 100w is supplied to the position of the sewing machine needle 102n. In this state, the work 100w is sewn by operating the robot 104 in synchronization with the sewing machine 102 based on the program of the control unit.

Japanese Patent No. 6439004

In the sewing device described above, it is necessary to program (teaching) the movement locus of the robot 104 in advance. Therefore, when sewing a plurality of types of workpieces 100w having different shapes, the robot 104 needs to be taught each time. Therefore, the productivity in high-mix production is low.

The present invention has been made to solve the above problems, and the problem to be solved by the present invention is to eliminate the trouble of teaching the movement locus of the robot for each type of sewing material (work) and to produce the product. It is to improve the sex.

The above-mentioned problems are solved by each invention. In the first invention, a sewing machine for sewing a work to be sewn at a predetermined position on a sewing machine table, a camera for photographing the work, and the work are moved on the sewing machine table with respect to the sewing machine needle of the sewing machine. A sewing device including a robot and a control unit that performs image processing of the camera, the robot, and a control unit that controls the operation of the sewing machine. The control unit is the shape data of the work obtained by image processing of the camera. And, based on the sewing conditions, a plurality of sewing position coordinates of the work through which the sewing machine needle is passed are set, and the robot reaches the sewing machine needle positions in a predetermined order. Is operated to sew.

According to the present invention, the control unit sets a plurality of sewing position coordinates of the work through which the sewing machine needle of the sewing machine is passed based on the sewing conditions and the shape data of the work. Then, the control unit operates the robot so that the sewing position coordinates reach the positions of the sewing machine needles in a predetermined order to perform sewing. That is, since the robot is configured to move the work on the sewing machine table so that the predetermined sewing position coordinates of the work reach the position of the sewing machine needle by a signal from the control unit, the movement trajectory of the robot is programmed (teaching) in advance. ) No need to do. Therefore, even when sewing a wide variety of workpieces, the complexity of teaching the robot is eliminated.

According to the second invention, the sewing machine is configured to move the sewing machine needle up and down at a fixed position, and the robot is configured to move the work with respect to the sewing machine needle at a predetermined speed. Therefore, the sewing pitch and the like can be freely set according to the operating speed of the robot.

According to the third invention, the shape data of the work is configured to be registrable in the memory of the control unit, and when the shape data of the work taken by the camera is registered, the shape data of the registered work is used. The robot is operated based on the sewing conditions and the sewing position coordinates to perform sewing. That is, once the registration is performed, in the case of the same type of work, the sewing operation can be performed promptly from the next time.

According to the fourth invention, when the shape data of the work taken by the camera is not registered, the shape data of the work is registered, and the robot is based on the shape data of the work, the sewing conditions, and the sewing position coordinates. Is operated to sew. That is, when the shape data of the work is not registered, the sewing operation is performed after the registration.

According to the fifth invention, the robot moves the work on the sewing machine table in a state where the work is pressed against the table surface of the sewing machine table from above.

According to the sixth invention, a seam line is set inside by the size of the seam allowance with respect to the shape data of the work, and a plurality of seam position coordinates are set at a position overlapping the seam line.

According to the seventh invention, when the shape data of the work and the seam line meander more than the permissible value, the stitch position coordinates can be set within the meandering range of the meandering seam line. Has been done. Therefore, even if the shape data of the work and the seam line are meandering, the work can be sewn without meandering.

According to the eighth invention, the seam line is set based on the design surface of the work, and a plurality of seam position coordinates are set at the positions overlapping the seam line. Therefore, even if the outer shape (shape data) of the work changes due to the cutting error of the work, the work can be sewn without affecting the design surface of the work.

According to the ninth invention, a first robot that moves one work, a second robot that moves the other work superimposed on the one work in the same direction as the one work, and the one work. It is provided with a sewing machine that sews the other work in a state of being overlapped with each other, and the speed at which the first robot moves the one work and the speed at which the second robot moves the other work. And are configured to be configurable respectively. Therefore, for example, by making the feed rate (movement speed) of one work larger than the feed speed of the other work, it becomes possible to make one work into a wavy shape and sew it to the other work.

According to the present invention, since it is not necessary to program (teaching) the movement locus of the robot for each type of the object to be sewn (work), there is no complexity due to the teaching of the robot even when sewing a wide variety of workpieces.

It is a side view of the sewing apparatus which concerns on Embodiment 1 of this invention. It is a front view of the sewing apparatus. It is a top view of the sewing apparatus. It is a block diagram of the sewing apparatus. It is a perspective view which shows the state which the work is sewn in the sewing apparatus. It is a side view which shows the state which the work is sewn in the sewing apparatus. This is an example of an image showing the shape data of the work, the seam line, and the pressing position obtained by the image processing. It is an enlarged view (VIII arrow view enlarged view of FIG. 7) which shows the shape data of a work, a seam line, and a stitch position coordinate. It is a drawing which shows the sewing position coordinates when the shape data of a work and a seam line meandering beyond an allowable value. It is a flowchart which shows the registration procedure of a work. It is a flowchart which shows the sewing work of a work. It is an enlarged side view of the sewing apparatus which concerns on the modification. It is a top view which shows the sewing position coordinates of the work in the sewing apparatus which concerns on the modification. It is a side view which shows the work after sewing. It is an enlarged view which shows the shape data of the work in the sewing apparatus which concerns on the modification example, the seam line, and the stitch position coordinates. It is an overall perspective view which shows the conventional sewing apparatus.

[Embodiment 1]
Hereinafter, the sewing apparatus 10 according to the first embodiment of the present invention will be described with reference to FIGS. 1 to 15. The sewing device 10 according to the present embodiment is a device for sewing the edge edges of two vertically stacked sewn objects W (hereinafter referred to as work W) having the same shape. Here, the front-back, left-right, and top and bottom shown in the figure correspond to the front-back, left-right, and top and bottom of the sewing device 10 according to the present embodiment.

<Overview of sewing device 10>
As shown in FIGS. 1 to 3, the sewing apparatus 10 includes an apparatus pedestal 20 assembled in a rectangular parallelepiped shape by a frame 22, a sewing machine table 32 provided on the apparatus pedestal 20, and a sewing machine 30 on the sewing machine table 32. , A robot 40 installed on the left middle beam portion 24 of the device stand 20 is provided. Further, the sewing device 10 includes a camera 50 for photographing the work W (see FIGS. 4, 5 and the like) placed on the sewing machine table 32, and the camera 50 is as shown in FIGS. 1 to 3. , It is supported by a camera pedestal 53 erected at the front end of the device pedestal 20. Further, the sewing device 10 includes a PC 60 (see FIG. 4) as a control unit that performs image processing of the camera 50 and controls the operation of the robot 40 and the sewing machine 30.

<About sewing machine table 32 and sewing machine 30>
As shown in FIG. 3, the sewing machine table 32 is a rectangular table that is long in the front-rear direction, and is installed horizontally from the upper right end to the central portion of the device stand 20. The sewing machine 30 is installed at the rear left side of the sewing machine table 32. The sewing machine 30 has a configuration in which the sewing machine needle 35 is moved up and down at a fixed position C, and as shown in FIG. 4, the vertical movement speed of the sewing machine needle 35 can be adjusted based on a signal from the PC 60.

<About Robot 40>
As shown in FIG. 5 and the like, the robot 40 presses the work W from above on the sewing machine table 32, moves the work W while sliding it on the table surface 32f, and supplies the work W to the sewing machine needle 35 of the sewing machine 30. As shown in FIGS. 1 to 4, the robot 40 includes an articulated robot main body 43, a robot controller 44 (see FIG. 4) provided on the robot main body 43, and a hand of the robot main body 43. It is equipped with a robot hand 450 mounted on the mounting portion 43h. As shown in FIGS. 5 and 6, the robot hand 450 is composed of a horizontal frame 451 connected to the hand mounting portion 43h and a work holding portion 453 that presses the work W at the tip of the horizontal frame 451. ..

As shown in FIG. 6, the work holding portion 453 of the robot hand 450 has a connecting plate 455 connected horizontally to the tip of the horizontal frame 451 and a state in which the work holding portion 453 can move up and down by a certain dimension with respect to the connecting plate 455. It is provided with a holding plate 456 connected by. The presser plate 456 is configured to be able to move up and down in a state parallel to the connecting plate 455 by the action of a plurality of guide shafts (not shown) protruding downward from the lower surface of the connecting plate 455. A coil spring 457 urged in a direction away from the connecting plate 455 is mounted around each guide shaft. Further, a cushion rubber 458 that presses the work W is attached to the lower surface of the presser plate 456.

With the above configuration, as shown in FIG. 4, when the drive signal from the PC 60 is input to the robot controller 44 of the robot 40, the robot main body 43 operates and the work W on the sewing machine table 32 is the work W of the robot hand 450. It is pressed from above by the pressing portion 453. As a result, the work W on the sewing machine table 32 is pressed from above by the pressing plate 456 of the workpiece pressing portion 453 by the force caused by the spring force of the coil spring 457 and the elastic force of the cushion rubber 458. Then, in this state, the robot main body 43 operates in the direction of moving the work W, so that the work W moves with respect to the sewing machine needle 35 of the sewing machine 30 while sliding on the table surface 32f.

<About camera 50>
The camera 50 is a camera for photographing the work W on the sewing machine table 32 from directly above and grasping the shape of the work W. The position of the camera 50 is adjusted so that the optical axis of the camera 50 is perpendicular to the table surface 32f of the sewing machine table 32. As shown in FIGS. 1 to 3, the camera 50 is set in a horizontal position and a height position so that the work W placed on the sewing machine table 32 can be photographed in front of the sewing machine 30. As shown in FIG. 4, the image data of the camera 50 is transmitted to the PC 60 and image-processed in the PC 60. Here, the installation position of the camera 50, the installation position of the robot 40, and the installation position of the sewing machine 30 are held in a constant positional relationship.

<About PC60>
The PC 60 stores the shape data (shape and size), which is the two-dimensional shape of the work W on the sewing machine table 32, as point cloud data by performing image processing on the image data of the camera 50. FIG. 7 shows the shape data of the work W taken within the angle of view of the camera 50 on the monitor, and is represented by reference numeral D. Here, the X coordinate and the Y coordinate displayed on the monitor represent positions on the sewing machine table 32. The PC60 is provided with an input device such as a keyboard so that sewing conditions such as sewing conditions H, seam allowance m, sewing pitch p, reverse stitching portion y, and edge approximation processing k can be input from the keyboard or the like. It is configured.

When the seam allowance m of the sewing condition is input, the PC 60 sets the seam line L inward by the dimension of the seam allowance m with respect to the shape data D as shown in FIGS. 7 and 8. Further, when the sewing pitch p of the sewing condition is input, the PC 60 sets a plurality of sewing position coordinates Z in which the sewing machine needle 35 is passed on the sewing line L in accordance with the sewing pitch p within the sewing range H. Then, the PC 60 sets the reverse stitch portion y at the sewing end position in order to prevent fraying. The reverse stitch portion y is set at the portion of the seam allowance m between the shape data D and the seam line L. Here, since the two workpieces W are turned inside out after the sewing is completed, the reverse stitch portion y formed in the seam allowance m is not visible from the front.

When a part of the outer peripheral edge of the work W is frayed or the like, as shown in FIG. 9, a part of the shape data D obtained by the image processing of the PC 60 may meander. In this case, the seam line L also meanders according to the seam allowance m. In this case, when the meandering of the seam line L exceeds the permissible value, the edge approximation process k is performed by the PC 60, and the sewing position coordinates Za are set in a state close to a straight line within the range of the meandering of the seam line L. That is, in the meandering range of the seam line L, the sewing position coordinates are the positions shown in Za (see the black circle in FIG. 9). Further, as shown in FIG. 7, the PC 60 sets the pressing position Q of the work W pressed by the robot hand 450 according to the shape data D.

The PC 60 includes the shape data D of the work W and the sewing conditions set based on the shape data D, that is, the sewing range H, the seam allowance m, the sewing pitch p, the reverse stitch portion y, and the condition of the edge approximation process k. Register the presser position Q of the work W. The PC 60 operates the robot 40 so that the plurality of sewing position coordinates Z of the registered work W reach the positions of the sewing machine needles 35 of the sewing machine 30 in a predetermined order (in order in the feed direction), and further the sewing machine. Sewing is performed by driving 30. Here, when the sewing pitch p (see FIG. 8 and the like) is constant, the robot 40 moves the work W with respect to the sewing machine 30 at a constant speed.

<Regarding the procedure for registering work W>
Next, the procedure for registering the work W will be described based on the flowchart of FIG. First, the operator sets two workpieces W having the same shape, which are stacked one above the other, within a predetermined area on the sewing machine table 32, that is, within the angle of view of the camera 50 (step S101 in FIG. 10). The misalignment of the work W on the sewing machine table 32 in terms of arrangement is corrected in the image processing in the PC 60, so that there is no particular problem. In this state, the work W is photographed by the camera 50, and the image data of the work W is transmitted to the PC 60. Then, the image data of the camera 50 is image-processed by the PC 60 (step S102 in FIG. 10), and the shape data D of the work W is displayed on the monitor as shown in FIG. 7 (step S103 in FIG. 10).

At this time, for example, when the sewing range H is not within the angle of view of the camera 50 in the shape data D of the work W (step S104 NO in FIG. 10), the position of the work W on the sewing machine table 32 is adjusted. As a result, the processes of steps S101 to S103 are executed again. When the sewing range H of the shape data D of the work W is within the angle of view of the camera 50 (YES in step S104 in FIG. 10), the sewing conditions and the like are input from the keyboard or the like (step S105 in FIG. 10). That is, conditions such as a sewing range H, a seam allowance m, a sewing pitch p, a reverse stitch portion y, and an edge approximation process k are input from a keyboard or the like. As a result, as shown in FIG. 8 and the like, the PC 60 sets a plurality of sewing position coordinates Z through which the sewing machine needle 35 is passed on the seam line L and a pressing position Q of the work W pressed by the robot hand 450. Then, the shape data D of the work W, the sewing conditions, the sewing position coordinates Z, and the pressing position Q of the work W are registered in the memory of the PC60.

<About sewing work procedure>
Next, the sewing work procedure of the work W will be described based on the flowchart of FIG. First, the operator sets two workpieces W having the same shape, which are stacked one above the other, in a predetermined area on the sewing machine table 32 (step S201 in FIG. 11). Next, the work W is photographed by the camera 50, and the image data of the work W is transmitted to the PC 60. In the PC 60, the image data of the camera 50 is image-processed (step S202 in FIG. 11), and it is determined whether or not the shape data D of the work W is registered in advance (step S203 in FIG. 11). When the shape data D of the work W is registered (YES in step S203 in FIG. 11), the shape data D of the registered work W, the sewing conditions (sewing range H, seam allowance m, sewing pitch p, reverse stitching portion y, and edge). The approximation process k) and the pressing position Q of the work W are displayed on the monitor (step S205 in FIG. 11).

Next, the sewing operation is started based on the sewing conditions and the like described above (step S206 in FIG. 11). In the sewing operation, the PC 60 first drives the robot 40 so that the robot hand 450 presses the pressing position Q of the work W. Next, the PC 60 operates the robot 40 so that the plurality of sewing position coordinates Z of the registered work W reach the positions of the sewing machine needles 35 of the sewing machine 30 in order in the feed direction, and further, the sewing machine 30 is referred to as the robot 40. Sewing is performed by driving in synchronization. That is, the robot 40 supplies the work W to the sewing machine 30 at a constant speed so that the sewing pitch p becomes constant. Then, the sewing operation is completed with the work W sewn to the sewing end position (step S207 in FIG. 11). Further, when the shape data D of the work W is not registered (step S203 NO in FIG. 11), as described in the registration of the work in FIG. 10, after the work W is registered (step S100 in FIG. 11), the sewing conditions are sewn. The sewing operation is performed based on the above (FIGS. 11 steps S205 to S207).

<Correspondence between the term of the sewing apparatus 10 according to the first embodiment and the term according to the present invention>
The PC 60 according to the present embodiment corresponds to the control unit of the present invention.

<Advantages of the sewing device 10 according to this embodiment>
According to the sewing device 10 according to the present embodiment, the PC 60 (control unit) has a plurality of sewing position coordinates Z of the work W through which the sewing machine needle 35 of the sewing machine 30 is passed based on the sewing conditions and the shape data D of the work W. To set. Then, the PC 60 operates the robot 40 so that the sewing position coordinates Z reach the positions of the sewing machine needles 35 in a predetermined order to perform sewing. That is, since the robot 40 is configured to move the work W on the sewing machine table 32 so that the predetermined sewing position coordinate Z of the work W reaches the position of the sewing machine needle 35 by the signal from the PC 60, the movement locus of the robot 40. There is no need to program (teaching) in advance. Therefore, even when sewing a wide variety of work Ws, there is no complexity due to teaching of the robot 40. Further, once the shape data D of the work W is registered, in the case of the same type of work W, the sewing operation can be performed promptly from the next time.

<Change example>
Here, the present invention is not limited to the above-described embodiment, and changes can be made without departing from the gist of the present invention. For example, in the present embodiment, an example is shown in which two workpieces W having the same shape are slid on the sewing machine table 32 by one robot 40 and supplied to the sewing machine 30 to perform sewing. However, as shown in FIG. 12, it is also possible to have a structure in which the works W1 and W2 can be sucked and held by the robot hand 450, and the upper and lower works W1 and W2 are supplied to the sewing machine 30 from the same direction by the upper and lower robots 40, respectively. Is. As a result, for example, the feed rate of the work W1 in the upper robot 40 (first robot 40) is made faster than the feed rate of the work W2 in the lower robot 40 (second robot 40). 13. As shown in FIG. 14, the upper work W1 can be sewn to the lower work W2 in a wavy shape. Note that Au, Bu, Cu and the like of the work W1 shown in FIG. 13 represent the sewing position coordinates Z of the work W1, and Ad, Bd, Cd and the like of the work W2 represent the sewing position coordinates Z of the work W2.

Further, in the present embodiment, as shown in FIGS. 7, 8 and the like, an example in which the seam line L is set by the shape data D of the work W and the seam allowance m is shown. However, as shown in FIG. 15, the design surface shape may be determined from the center EC of the work W and the seam line L may be set. This makes it less susceptible to the cutting error of the work W. Further, the work W according to the present embodiment may be a seat cover or the like, or may be clothing or the like. Further, it may be a curtain, a rug, a mattress or the like.

Further, in the present embodiment, as shown in FIG. 1 and the like, an example in which the camera 50 is installed above the sewing machine table 32 is shown. However, for example, the camera 50 can be installed in a place where the shape of the work W can be recognized, such as a conveyor, a lift, or a work shelf that conveys the work W on the sewing machine table 32.

10 ... Sewing machine 30 ... Sewing machine 32 ... Sewing machine table 32f ... Table surface 35 ... Sewing machine needle 40 ... Robot 50 ... Camera 60 ... PC (control unit)
D ... Shape data L ... Seam line H ... Sewing range (sewing conditions)
m ... Seam allowance (sewing conditions)
p ... Sewing pitch (sewing conditions)
y ... Reverse stitching (sewing conditions)
k ... Edge approximation processing (sewing conditions)
Z ... Sewing position coordinates W ... Work (sewing)

Claims (9)

A sewing machine that sews a work to be sewn at a predetermined position on a sewing machine table, a camera that photographs the work, a robot that moves the work on the sewing machine table with respect to the sewing machine needle of the sewing machine, and the camera. A sewing device including a control unit that performs image processing, the robot, and an operation control of the sewing machine.
The control unit sets a plurality of sewing position coordinates of the work through which the sewing machine needle is passed based on the shape data of the work obtained by image processing of the camera and sewing conditions, and the sewing position coordinates. A sewing device that operates the robot to sew so that the sewing machine needles reach the positions of the sewing machine needles in a predetermined order. The sewing apparatus according to claim 1.
The sewing machine has a configuration in which the sewing machine needle is moved up and down at a fixed position.
The robot is a sewing device configured to move a work with respect to the sewing machine needle at a predetermined speed. The sewing apparatus according to claim 1 or 2.
The shape data of the work is configured to be registerable in the memory of the control unit.
When the shape data of the work taken by the camera is registered, the sewing device operates the robot based on the sewing conditions and the sewing position coordinates in the shape data of the registered work to perform sewing. The sewing apparatus according to claim 3.
When the shape data of the work taken by the camera is not registered, the shape data of the work is registered, and the robot is operated based on the shape data of the work, the sewing conditions, and the sewing position coordinates to perform sewing. Sewing equipment to perform. The sewing apparatus according to any one of claims 1 to 4.
The robot is a sewing device that moves the work on the sewing machine table while the work is pressed against the table surface of the sewing machine table from above. The sewing apparatus according to any one of claims 1 to 5.
A seam line is set inside by the size of the seam allowance with respect to the shape data of the work.
A sewing device in which a plurality of sewing position coordinates are set at positions overlapping the seam lines. The sewing apparatus according to claim 6.
When the shape data of the work and the seam line meander more than the permissible value, the sewing position coordinates are configured to be set within the meandering range of the meandering seam line. .. The sewing apparatus according to any one of claims 1 to 5.
The seam line is set based on the design surface of the work.
A sewing device in which a plurality of sewing position coordinates are set at positions overlapping the seam lines. The sewing apparatus according to any one of claims 1 to 8.
A first robot that moves one work, a second robot that moves the other work superimposed on the one work in the same direction as the one work, and the one work and the other work. Equipped with a sewing machine that sew in a stacked state,
A sewing device configured so that the speed at which the first robot moves the one work and the speed at which the second robot moves the other work can be set.

Images