JP2894449B2 - Automatic transfer device using camera - Google Patents

Description

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a camera which is used when a palletized box and a load having a similar shape are unloaded from a pallet by a transfer robot. The present invention relates to an automatic transfer device used.

2. Description of the Related Art As a conventional transfer device using a robot, there is a Japanese Utility Model Application
A transfer device disclosed in Japanese Patent Application Publication No. 0640 is known. In this conventional transfer device, a unique mark written on the upper surface of a load loaded on a pallet is detected by an image sensor, and a detection signal such as the type and direction of the load and the position is sent to a control device. Input, and in the control device, by calculating the data input of the load among the data set for each type of load and the aforementioned input,
The most suitable operation signal for the load is given to the transfer robot. The pallet and the load are placed on a table lifter, and the height of the top of the load is adjusted by the table lifter to a level detected by the level detection device.

Problems to be Solved by the Invention However, in a conventional transfer device using a robot, the load on the pallet is depalletized (unloaded) by the transfer robot.
As the height of the load gradually decreased, and the image sensor became out of focus, a table lifter and a level detector were required. Particularly, the table lifter has a problem that it is large in size to support the load and the entire load of the pallet and to move it up and down, so that the load is large in terms of cost and inspection and maintenance.

SUMMARY OF THE INVENTION An object of the present invention is to solve the above-mentioned problem, and an object of the present invention is to provide an automatic transfer apparatus using a camera that reduces the cost and the burden of inspection and maintenance.

Means for Solving the Problems To solve the above problems, the present invention provides a camera equipped with a zoom as a means for recognizing the arrangement of loads on the pallet by marks on the upper surface of the loads loaded on the pallet at a predetermined position, The pallet is arranged at a position overlooking the predetermined position so that the pallet can be seen. Obtain the height data of the load in the upper stage, drive the lens of the camera based on the height data of the load, focus the camera, recognize the arrangement of the load at once by the one-side image data of the camera, The robot is driven based on the recognized arrangement of the loads, and the load is transferred by the robot.

According to the above configuration, the camera is installed at a position above the predetermined position where the pallet is placed so that the pallet can be overlooked. The position coordinates are transmitted together. Each time the depalletization of a single-stage load is completed, the height data of the top-level load is obtained from the data of the array of loads stacked on the pallet and the data of the number of stowage stages. When the lens of the camera is driven based on the information, the focus of the camera is smoothly and accurately adjusted at one time, and the mark provided on the upper surface of the load is accurately recognized.

An embodiment of the present invention will be described below with reference to the drawings.

FIG. 1 is a layout diagram of an automatic transfer device using a camera according to the present invention, and FIG. 2 is a control configuration diagram thereof.

The transfer robot 1 uses the vacuum hand 1A to transfer the flat box-shaped load 4 on the pallet 3 transported and placed on the left loading tray 2 using a hand lift or the like to the left conveyor 5.
The load 4 placed on the right receiving tray 6 is also depalletized to the right conveyor 7. Cameras 8, 9 overlooking the pallet 3 are installed on the upper ceiling surface of the left and right receiving platforms 2, 6, respectively.
Is input to the image processing device 11 housed in the control panel 10. Further, a zoom (mechanism) is attached to the cameras 8 and 9, and the lenses of the cameras 8 and 9 are driven according to a position signal from the image processing device 11 to perform focusing of the lenses.

The control panel 10 is provided with an image processing apparatus 11, a controller 12 of the robot 1, and a controller 16 of the conveyors 5 and 7, which are controlled by a general controller 13. The general controller 13 has an input setting device 14 And 1 on the left and right
The monitor 15 which displays the arrangement | sequence of the load 4 of a step, etc. is connected, respectively. Further, illumination lamps 17 and 18 for cameras 8 and 9 are connected to a conveyor controller 16 connected to the robot controller 12.

In addition, safety fences 20 and 2 for protecting workers from the operation of the robot 1 are provided on the loading / unloading passage side of the pallets 3 of the loading trays 2 and 6.
The safety fences 20 and 21 are provided with a limit switch 22 that is turned off when the safety fence 20 or the safety fence 21 is opened. The limit switch 22 is connected to the robot controller 12.

Further, photodetectors 23 and 24 for detecting the load 4 are provided downstream of the conveyors 5 and 7, respectively, and outputs of the photodetectors 23 and 24 are also connected to the robot controller 12. The robot controller 12 detects that the conveyor is full by inputting the output signals of the photodetectors 23 and 24 continuously for a certain period of time.

Further, an emergency stop button 2 for emergency stop of the robot 1 and the conveyors 5, 7 is provided on the front of the door of the control panel 10.
5. An abnormality indicator lamp 26, 27 indicating completion of depalletizing for each of the left and right receiving trays 2, 6; an abnormality indicator lamp 28 indicating that an abnormality has occurred in the left conveyor 5, etc .; and an abnormality has occurred in the right conveyor 7, etc. An abnormality display lamp 29 is attached to the robot controller 12 to indicate the fact.

The arrangement of the loads 4 loaded on the pallet 3 (hereinafter, referred to as a pallet pattern) varies depending on the size of the load 4 or the like, for example, as shown in FIG. 3 and FIG. The number of loads 4 per stage changes to seven or eight.
A pattern code is defined for each of these pallet patterns, and the height h of the load 4 is determined by the pattern code.
In addition, as shown in FIGS. 4 (a) and 4 (d), the arrangement of the planes of the loads 4 is alternately inverted for each step, as shown in FIGS. (X, y) coordinates are determined. In addition, pallet 3
Is placed on the receiving tables 2 and 6 with the arrow B as the front, the arrangement of the planes is reversed, so that data in the arrangement direction (A or B) of the uppermost stage of the load 4 is required.

The functions of the image processing device 11, the overall controller 13, the robot controller 12, and the conveyor controller 16 will be described in order.

The image processing apparatus 11 collectively inputs (x, y, z) coordinates (z coordinates are coordinates in the height direction) of each of the top loads 4 of the pallet 3 from the general controller 13 and, based on the z coordinates, obtains a camera.
After calculating the zoom positions of 8, 9 and outputting the position signals to the cameras 8 and 9 and inputting the image signals from the cameras 8 and 9, the unique mark provided on the upper surface of the load 4 as shown in FIG. 30 are detected collectively, and the horizontal distortion of the image due to the use of the zoom is corrected by the distortion previously learned at the height direction position, and then the center coordinate (x, y) and the x coordinate are calculated for each load 4. And calculates the inclination θ of the load 4 in the longitudinal direction and collectively outputs the detected data (x, y, θ) to the general controller 13 in units of stages.

The overall controller 13 stores in advance the data of the pallet pattern for each pattern code of the pallet pattern, that is, the data of the center (x, y) coordinates of the load 4 and the height h of the load 4 in the alternate row. Enter the pattern code, the number of stacking stages of the load 4, the arrangement direction of the uppermost stage, and the code (left or right) of the left and right receiving trays 2, 6 from
The pallet pattern is searched and (x,
y, z) coordinates are calculated, and the pallet pattern is output to the left or right monitor 15. When a work start command signal is input from the setting device 14, the (x, y, z) coordinates are output to the image processing device 11 in a lump, and the detection data (x, y, θ) is output from the image processing device 11. When input, z-coordinate data is added, and transfer data composed of (x, y, z, θ) for each stage is output to the robot controller 12 in a lump. When a stage transfer completion signal is input from the robot controller 12, (x,
The above operation is repeated by calculating the (y, z) coordinates, and when the transfer of all the stages is completed, the completion indicator lamps 26 and 27 are turned on. Further, it controls the lighting and extinguishing of the illumination lamps 17 and 18.

The robot controller 12 sequentially drives the arm 1B and the hand 1A of the robot 1 for each load 4 based on the transfer data (x, y, z, θ) coordinates input in units of stages, and transfers the load 4 to the respective conveyors 5, 7,. Then, when the transfer in units of a stage is completed, the completion of the stage transfer is output to the overall controller 13. It also has an interlock for driving the robot 1 and the conveyors 5 and 7, and has an emergency stop button 25, limit switches for safety fences 20 and 21, a conveyor controller 16 or a conveyor 5,
The abnormality of 7 is monitored, and signals from the photodetectors 23 and 24 are input to perform control such as an interlock operation described later.

The conveyor controller 16 is the robot controller 12
Conveyor according to conveyor start or stop signal from
5 and 7 are driven, and the lighting lamps 17 and 18 are turned on or off according to the lighting or turning off signals of the lighting lamps 17 and 18.

The transfer operation according to the above configuration will be described with reference to the work flowchart of FIG.

Loading of Pallet (Step J-1) The worker loads the pallet 3 loaded with the load into the receiving trays 2 and 6 using a hand lift or the like and places it thereon.

Safety fence closed (Step J-2) The worker closes safety fences 20 and 21. Thereby, the interlock of the robot controller 12 is released.

Data input (step J-3) To the general controller 13, from the setting device 14, the pattern code, the number of stacking stages of the load 4, the arrangement direction of the uppermost stage, and the code (left or right) of the left and right loading tables 2 and 6. Enter the data.

Pattern Display (Step J-4) The overall controller 13 searches the input data for a pallet pattern shown in FIGS.
Display to

Confirmation of Input Pattern (Step J-5) The operator confirms the pallet pattern displayed on the monitor 15, and resets if an input error is found.

Data input for next operation (step J-6) When the pallet pattern is confirmed, data for the next operation is input.

Work start instruction (step J-7) A work start command signal is input from the setting device 14 to the overall controller 13.

Depalletizing Operation (Step J-8) The depalletizing operation will be described with reference to the flowchart of FIG.

First, when the work start command signal is input, the general controller 13 includes the (x, y) coordinates of the uppermost stage of the searched pallet pattern and the z coordinate in the height direction obtained from the number of stacking stages (x , y, z) coordinates are output to the image processing apparatus 11 in a lump. The (x, y, z) coordinate data is output for each of the receiving platforms 2, 6 (step K-1). Further, an illumination signal for turning on the illumination lamps 17 and 18 for the cameras 8 and 9 is output to the robot controller 12 (step K-2).

When this illumination signal is input, the robot controller 12 transfers the signal to the conveyor controller 16, and the conveyor controller 16 turns on the illumination lamps 17 and 18 (step K-).
3).

When the (x, y, z) coordinate data for each of the receiving tables 2 and 6 is input, the image processing device 11 first outputs a position signal for zooming to the cameras 8 and 9 based on the z coordinates, and focuses the cameras 8 and 9 on the focal points. Top load 4
(Step K-4). The cameras 8 and 9 output the uppermost plane image of the load 4 to the image processing device 11 as an image signal (step K-5). The image processing device 11
After correcting the image shift due to the distortion, the unique mark 30 for each load 4 is detected based on the contrast of the image, and the center (x, y) coordinate and the inclination θ of the load 4 in the longitudinal direction from the x coordinate are detected for each load 4. Is calculated, and the detection data is collectively set in units of one stage, for example, if the detection data is the detection data of the left receiving tray 2, the data (x _L1 , y
_L1 , θ _L1 ), (x _L2 , y _L2 , θ _L2 ) ...
(Step K-6).

When the supervisory controller 13 inputs the detection data of the uppermost stage of the load 4 on the left and right receiving trays 2 and 6 from the image processing device 11,
Transfer data (x _L1 , y _L1 , z _L , θ _L1 ), (x _L ) for adding the z-coordinate data to transfer the load 4 on the left receiving tray 2 to the conveyor 5
_{L2, y L2, z L,} θ L2) ..., and transfer data for transferring the right to load 4 on receiving platform 6 to the conveyor _{7 (x R1, y R1,} z R, θ R1),
(X _R2 , y _R2 , z _R , θ _R2 ) are collectively output to the robot controller 12 in units of one stage (step K-7).

When the above left and right transfer data is input, the robot controller 12 first turns on the emergency stop button 25,
It is confirmed that the limit switch 22 of 0, 21 is ON, and that the interlock condition of the abnormality of the conveyor controller 16 or the conveyor 5, 7 is not inputted, and a conveyor start signal is outputted to the conveyor controller 16 (step K-).
8). Next, the robot controller 12 calculates the data of the first load 4 at the uppermost stage of the left loading tray 2 and outputs the data to the robot 1. That is, as shown in FIG. 5, (x _L , Y _L ) coordinates corresponding to the origin of the loading table 2 are added, and the left drive coordinates [(x _L
+ X _L1 ), (Y _L + y _L1 ), z _L , θ _L1 ]. In FIG. 5, the x-coordinate is the coordinate facing the receiving tables 2 and 6, the Y-coordinate is the coordinate along the loading direction of the pallet 3, and the origin is the robot 1.
The center of the turning of the arm 1B is shown (step K-9).

The conveyor controller 16 activates the left and right conveyors 5 and 7 based on the conveyor activation signal (step K-10), and the robot 1 rotates the arm 1B based on the left driving coordinates, and θ
The inclination of the hand 1B is corrected by _L1 , and the first load 4 is lifted and transferred to the left conveyor 5. At the end of transfer, a completion signal is output to the robot controller 12 (step K-1).
1).

When the robot controller 12 inputs the completion signal from the robot 1, the right drive coordinates of the right receiving platform 6 first load 4 uppermost _{[(-x R + x R1),} (Y L + y R1), z R, θ R1 ] Is output. When the right first load 4 is transferred to the right conveyor 7 by the robot 1, the left second load 4, the right second load 4 and the left and right loads 4 are alternately transferred to the conveyor 5, 5. Transfer to 7 When the transfer of the uppermost load 4 is completed for each of the left and right load receiving tables 2 and 6, the robot controller 12 outputs a step transfer completion signal to the overall controller 13 (steps K-9 and K-11).

When the general controller 13 inputs the stage transfer completion signal,
It is confirmed whether transfer of all the stages is completed (step K-12). If transfer of all the stages is not completed, the (x, y) coordinates of the next stage and the z coordinate of the next stage in the height direction from the pallet pattern searched for. (X, y, z) coordinate data consisting of
In the (x, y) coordinates, the arrangement of the loads is reversed.

Hereinafter, the transfer of the load 4 is performed based on the detection data of the image processing device 11.

When the overall controller 13 confirms that all the stages have been transferred,
Conveyor controller via robot controller 12
A signal for turning off the lighting lamps 17 and 18 and a signal for stopping the conveyors 5 and 7 are output to 16 (step K-13).
8 turns off, and conveyors 5 and 7 stop (step K-1).
Four).

Completion of work (Step J-9) Further, the supervisory controller 13 inputs a stage transfer completion signal of the robot controller 12 to each of the left and right receiving trays 2 and 6, and the lowermost load 4 is also transferred. That is, when the completion of transfer of all stages is detected, the left completion display lamp 26 or the right completion display lamp 27 is turned on via the robot controller 12.

Pallet removal (Step J-10) When the operator confirms that the completion indicator lamp 26 or 27 is lit, the operator opens the safety fences 20 and 21 and removes the empty pallet 3 using a hand lifter or the like. Then, in step J-1, the pallet 3 loaded with the next load 4 is carried in.

 Hereinafter, the same operation is performed.

The operation when the robot controller 12 detects an abnormality will be described.

First, when the output signal of the photodetector 23 is continuously input for a certain period of time, it is determined that the left conveyor 5 is full, and the transfer of the load 4 to the left conveyor 5 is continued until the output signal of the light output device 23 disappears. The operation is suspended, and only the transfer to the right conveyor 7 is performed. Photo detector
When 24 output signals are continuously input for a certain period of time, only transfer to the left conveyor 5 is performed.

Further, when an abnormality of the left conveyor 5 or the right conveyor 7 is input via the conveyor controller 16, the transfer to the abnormal conveyor is interrupted until the abnormality is recovered, and an abnormality display of the abnormal side is performed. Lamp 28
Or turn on 29.

If the emergency stop button is turned on, the limit switch 22 is turned off (safety fences 20, 21 open), or if an error occurs in the robot 1, all transfer operations are stopped and both error display lamps are stopped.
Lights both 28 and 29 to warn workers. In this case, the worker is reset by inputting a work start instruction and resetting.

As described above, the cameras 8 and 9 are installed on the ceiling above the loading tables 2 and 6 on which the pallets 3 are placed.
8 and 9 can see the whole on pallet 3 and one at a time
The image processing device 11 can recognize the arrangement of the tiered loads,
Therefore, the detection data can be sent to the general controller 13 at one time, and the data transmission time can be shortened.
Further, by focusing the cameras 8 and 9 by zooming each time the depalletization of the one-stage load is completed, the unique mark 30 provided on the upper surface of the load 4 can be accurately recognized. The movement can be made accurate, and abnormalities such as poor lifting of the load 4 can be prevented.

In this embodiment, the pallet pattern (the arrangement of the loads 4) is used.
Is recognized by the center coordinates (x, y) and the inclination θ of each load 4, and the pallet pattern is the total number of the central tapes 19A of the loads 4 on each stage of the pallet 3 and the length of the central tape 19A of each load 4. It can also be recognized by its width and width.

In this case, the image processing device 11 detects the number of the central tapes 19A and the length and width of each central tape 19A from the image signals from the cameras 8 and 9 and outputs the detected central tape 19A to the general controller 13. The number of loads 4 is detected from the number of tapes 19A, and the length and width of each center tape 19A are pallet pattern data based on the pattern code input from the setting unit 14 (the total number of Each load 4
(X, y, z, θ) of the pallet pattern by the pattern code
Is output to the robot controller 12.

When the data of the pallet pattern does not match, the general controller 13 displays the alarm on the monitor 15 and gives an alarm.

Effect of the Invention As described above, according to the present invention, a camera is installed at a position overlooking a pallet above a predetermined position where the pallet is placed, and image data of one stage of load is obtained at a time by this camera. Thereby, it is possible to recognize the arrangement of the loads one stage at a time, and to transmit the recognized data at a time, thereby shortening the data transmission time. Further, every time the depalletization of one load is completed, the height data of the uppermost load is obtained from the data of the arrangement of the loads loaded on the pallet and the data of the number of loading stages. By driving the camera lens based on the data and focusing the camera, you can focus smoothly and accurately at one time, thus improving the overall accuracy and accurately recognizing the arrangement of the load, The movement of the robot can be made accurate. In addition, the need for a conventional table lifter is eliminated, and the burden on costs and inspection and repair can be reduced.

[Brief description of the drawings]

1 to 7 show one embodiment of the present invention.
Fig. 2 is a layout diagram of an automatic transfer device using a camera, Fig. 2 is a control configuration diagram of the automatic transfer device using a camera, and Figs.
(C) is a plan view, a front view, and a side view showing a pallet pattern, respectively, and FIGS. 4 (a) to (d) are a top plan view, a front view, a side view, and two steps from the top showing a pallet pattern, respectively. FIG. 5 is a plan view of the eye (next stage), FIG. 5 is a coordinate diagram for explaining the positioning of the arm and hand of the robot, and FIG.
FIG. 7 is a work flowchart, and FIG. 7 is a depalletizing work flowchart. 1 ... Robot, 2 ... Receiving table (predetermined left position), 3 ...
Pallet, 4 ... Load, 6 ... Receiving stand (predetermined right position), 8
…… Camera, 9 …… Camera, 11 …… Image processing device, 12…
... Robot controller, 13 ... Overall controller, 14
…… Setting device.

Continuation of the front page (56) References JP-A-63-110436 (JP, A) JP-A-62-226308 (JP, A) JP-A-2-239029 (JP, A) JP-A-60-146374 (JP) , A) JP-A-63-115274 (JP, A) JP-A-61-110640 (JP, U)

Claims (1)

(57) [Claims] A means for recognizing an arrangement of loads on a pallet by a mark on an upper surface of a load loaded on a pallet at a predetermined position, a camera with a zoom attached to a position above the predetermined position where the pallet can be seen. Every time the depalletizing of one load is completed, the height data of the uppermost load is obtained from the data of the arrangement of the loads loaded on the pallet and the data of the number of loading stages. Driving the lens of the camera based on the height data, focusing the camera, recognizing the array of loads at once based on the one-sided image data of the camera, and driving the robot based on the recognized array of loads An automatic transfer device using a camera, wherein the load is transferred by a robot.