JP5647050B2 - Temporary stop analysis device and temporary stop analysis program for welding robot - Google Patents

Description

  The present invention relates to a welding robot temporary stop analysis device and a temporary stop analysis program for analyzing a cause of a temporary stop of a welding robot and a correction method thereof.

  In the automatic operation system of a welding robot, if a temporary stop of a line (hereinafter referred to as “chocolate stop”) due to a slight trouble occurs, automation is hindered and productivity is lowered. Therefore, it is necessary to improve such a chocolate stop, but in order to improve the chocolate stop, it is necessary to collect and analyze information to find out the cause. In addition, when collecting and analyzing information, what kind of information is to be analyzed is important. However, since the chocolate stop occurs due to various factors such as wear and variation of the equipment, experience and knowledge are required to determine the cause.

  For example, in Patent Document 1, in a system configured by a machine controller, a computer, and a local area network, a sensor is connected to the computer, and the stop time and the variation in the number of productions for each failure item are displayed. A chocolate stop diagnosis device that can analyze the causal relationship has been proposed. According to the device proposed in Patent Document 1, the failure content (whether it is a sudden failure or a chocolate stop) can be determined from the time transition graph of the worst 7 stop item, and the stop item can be determined from the number of stops and the stop time. The contents can be analyzed, and furthermore, the productivity drop due to the chocolate stop can be confirmed from the transition graph of the production number.

  Further, in Patent Document 2, in order to improve the choke stop caused by defective arc start, the welding wire is brought close to and brought into contact with the work piece, and then reversed to separate the welding wire from the work piece to be initial. There has been proposed an arc start control method in which an arc is generated and the welding wire is again fed in a direction to approach the workpiece to be transferred to a steady arc. The improvement of the chocolate stop here includes both meanings of eliminating the chocolate stop and reducing the number of times of the chocolate stop.

JP-A-2-145247 JP 2002-205169 A

  The chocolate stop diagnosis device proposed in Patent Document 1 is effective in managing the occurrence of a chocolate stop because it determines whether a sudden failure or a chocolate stop has occurred or analyzes the effect of productivity due to a temporary stop. is there. However, since the chocolate stop diagnosis device proposed in Patent Document 1 does not collect and analyze information related to the occurrence position of the chocolate stop, it cannot contribute to the improvement of the chocolate stop that greatly affects the productivity.

  In addition, the arc start control method proposed in Patent Document 2 has a problem that the choke stop at the arc start may not be improved depending on the welding conditions. For example, when an insulator such as temporary attachment is disposed on the workpiece (member to be welded), it is not possible to conduct electricity and an arc (initial arc) does not occur. Therefore, it is necessary to change the position of the arc start. Furthermore, the arc start control method proposed in Patent Document 2 has a problem that it is not possible to improve the chocolate stop in a situation other than the arc start time.

  The present invention has been made in view of such problems, and can contribute to the improvement of the chocolate stop in various situations, and even if there is no experience and knowledge, measures for the chocolate stop can be taken. It is an object of the present invention to provide a temporary stop analysis device and a temporary stop analysis program for a welding robot that can easily specify a place to perform.

In order to solve the above-described problems, a welding robot temporary stop analysis apparatus according to the present invention is a welding robot temporary stop analysis apparatus that analyzes a cause of a temporary stop of the welding robot and a correction method thereof. From the robot controller, the robot position information indicating the position of the welding robot, the robot operation information indicating the content of the operation of the welding robot, the welding condition information indicating the welding conditions by the welding robot, and the welding robot temporarily stopped Operation error information indicating the content of the operation error at the time of acquisition, acquisition means for acquiring , each condition of the robot position information, the robot operation information and the welding condition information associated with the operation error information, and ginseng and how to correct the estimated cause and pause pause corresponding to the condition, but the tables described previously in Doing, analysis means for each information acquired by the acquisition means analyzing the cause and fix the method of suspension of the welding robot that matches the condition, an output means for outputting the analysis result of said analyzing means has analysis And a configuration comprising:

  The welding robot temporary stop analysis apparatus having such a configuration inputs four pieces of data, that is, the position of the welding robot, the operation status of the welding robot, the welding conditions, and the content of the operation error at the time of the temporary stop. The corresponding cause of pause and the correction method of pause can be output as analysis results.

  In the welding robot temporary stop analysis apparatus according to the present invention, the robot position information includes a teaching program number indicating the type of a welding teaching program executed by the welding robot, and a welding teaching program executed by the welding robot. Sensing information indicating whether or not the welding robot is sensing whether the robot operation information includes a step number indicating the number of steps and a pass number indicating the number of passes of the welding teaching program executed by the welding robot Welding information indicating whether the welding robot is welding, reproduction information indicating whether the welding robot is reproducing the welding teaching program, and whether the welding robot is temporarily stopped And the welding condition information indicates whether or not weaving is performed by the welding robot. And groove type information indicating the type of groove of the workpiece to be welded, sensing type information indicating the type of sensing by the welding robot, and preset when the arc does not occur at the welding start position. Arc retry function information indicating whether or not to use the arc retry function, which is a function that repeats the arc generation operation, and the position of the weld line is automatically detected during welding to follow the displacement of the weld line. Arc sensor presence / absence information indicating whether or not the arc sensor is used, and the operation error information is a welding section in which the welding robot performs a welding operation, and a sensing section in which the welding robot performs a sensing operation. In the air cut section that is a section other than the welding section and the sensing section, the welding robot is temporarily stopped. It is preferable to adopt a configuration including a predetermined error message for each contents of operation errors in.

  The welding robot temporary stop analysis device having such a configuration acquires the program number, step number, and pass number of the welding teaching program executed by the welding robot as information indicating the position of the welding robot, and operates the welding robot. Information indicating whether the welding robot is sensing or not as information indicating the content of the welding robot, and information indicating whether or not weaving by the welding robot is acquired as information indicating the welding condition of the welding robot, and the welding robot is temporarily stopped An error message is acquired as information indicating the content of the error. Therefore, the welding robot pause analysis device can acquire the detailed situation when the welding robot is paused, and analyzes the estimated cause of the pause and the correction method of the pause according to the detailed situation. As a result, it can be output.

In order to solve the above-described problem, a welding robot temporary stop analysis program according to the present invention is configured to analyze a cause of a temporary stop of a welding robot, from a robot controller of the welding robot, to a position of the welding robot. The robot position information indicating the robot operation information indicating the operation content of the welding robot, the welding condition information indicating the welding conditions by the welding robot, and the content of the operation error when the welding robot is temporarily stopped Operation error information, acquisition means for acquiring , each condition of the robot position information, the robot operation information and the welding condition information associated with the operation error information, and an estimated cause of the pause corresponding to these conditions and a method of correcting pause, but by referring to the table described previously, the acquisition unit Analysis means acquired the information to analyze the pause causes and how to correct the welding robot that matches the condition, and a configuration in which the analysis means is caused to function as an output means for outputting an analysis result of the analysis.

  The welding robot temporary stop analysis program having the above-described configuration inputs four pieces of data including the position of the welding robot, the operation status of the welding robot, the welding conditions, and the content of the operation error at the time of temporary stop. The corresponding cause of pause and the correction method of pause can be output as analysis results.

  In the welding robot temporary stop analysis program according to the present invention, the robot position information includes a teaching program number indicating a type of a teaching program for welding executed by the welding robot, and a teaching program for welding executed by the welding robot. Sensing information indicating whether or not the welding robot is sensing whether the robot operation information includes a step number indicating the number of steps and a pass number indicating the number of passes of the welding teaching program executed by the welding robot Welding information indicating whether the welding robot is welding, reproduction information indicating whether the welding robot is reproducing the welding teaching program, and whether the welding robot is temporarily stopped And the welding condition information indicates whether or not weaving is performed by the welding robot. If the arc does not occur at the welding start position, the groove type information indicating the type of groove of the workpiece to be welded, the sensing type information indicating the type of sensing by the welding robot, Arc retry function information indicating whether or not to use the arc retry function, which is a function for repeating the arc generation operation for a set number of times, and the position of the welding line automatically during welding in order to follow the displacement of the welding line. Arc sensor presence / absence information indicating whether or not an arc sensor is used for detecting the operation, and the operation error information is a welding section in which the welding robot performs a welding operation, and a section in which the welding robot performs a sensing operation. In the air cut section, which is a section other than the sensing section, the welding section, and the sensing section, the welding robot is temporarily It is preferable to adopt a configuration including a predetermined error message for each contents of operation errors when sealed.

  The welding robot temporary stop analysis program configured as described above acquires the position of the welding robot from the program number, step number, and pass number of the welding teaching program executed by the welding robot as information indicating the position of the welding robot. Information indicating whether the welding robot is sensing or not as information indicating the operation content of the welding robot, and acquiring information such as the presence or absence of weaving by the welding robot as information indicating the welding conditions of the welding robot. Then, an error message is acquired as information indicating the content of the error when the welding robot is temporarily stopped. Therefore, the welding robot pause analysis program can acquire the detailed situation when the welding robot pauses, and analyzes the estimated cause of pause and the correction method of the pause according to the detailed situation. As a result, it can be output.

  According to the welding robot temporary stop analysis device and the welding robot temporary stop analysis program according to the present invention, it is possible to contribute to the improvement of the chocolate stop under various circumstances, and even when there is no experience and knowledge. It is possible to easily identify the place where measures for chocolate stop are taken.

It is the schematic which shows the whole structure of the temporary stop analysis apparatus which concerns on embodiment of this invention, and the apparatus structure of the periphery. It is a block diagram which shows the whole structure of the temporary stop analysis apparatus which concerns on embodiment of this invention. It is an error message generation | occurrence | production ratio pie chart produced | generated by the analysis means of the temporary stop analysis apparatus which concerns on embodiment of this invention. It is a flowchart which shows the operation | movement of the whole suspension analysis apparatus which concerns on embodiment of this invention. It is a flowchart which shows operation | movement of the analysis means with which the temporary stop analysis apparatus which concerns on embodiment of this invention is provided. It is a flowchart which shows the analysis process in the welding area of the analysis means with which the temporary stop analysis apparatus which concerns on embodiment of this invention is provided. It is a flowchart which shows the analysis process in the sensing area of the analysis means with which the temporary stop analysis apparatus which concerns on embodiment of this invention is provided. It is a flowchart which shows the analysis process in the air cut area of the analysis means with which the temporary stop analysis apparatus which concerns on embodiment of this invention is provided.

[Pause analysis device]
Hereinafter, a pause analysis device according to an embodiment will be described with reference to the drawings. As shown in FIG. 1, the temporary stop analysis device 3 uses a variety of data inputted from the robot controller (RC) 2 of the welding robot 1 to cause the temporary stop (temporary stop) of the welding robot 1 and a correction method thereof. Is analyzed. More specifically, the temporary stop analysis device 3 is intended to receive various data related to welding performed by the welding robot 1 in the past and perform analysis processing for improving the chocolate stop in the future. . For example, past welding data for three months is input to the temporary stop analysis device 3. More specifically, the choke stop refers to a failure that can be easily recovered by an operator (operator) among failures in which equipment suddenly stops during automatic operation.

  Here, before describing the specific configuration of the pause analysis device 3, the configuration around the pause analysis device 3 shown in FIG. 1 will be briefly described. First, as shown in FIG. 1, the welding robot 1 welds a workpiece (a member to be welded) W with a welding torch installed at the tip. Here, as shown in FIG. 1, the welding robot 1 is composed of a pair. As shown in FIG. 1, the robot controller (RC) 2 controls the operation of the welding robot 1 and outputs various data input from the welding robot 1 to the temporary stop analysis device 3. Here, as shown in FIG. 1, the robot controller 2 is configured as a pair corresponding to the welding robot 1, and is connected to the temporary stop analysis device 3. Further, as shown in FIG. 1, the display device 4 displays the analysis result input from the suspension analysis device 3, and includes, for example, a personal computer monitor. In addition to these configurations, a pair of welding power sources is provided, but the illustration is omitted.

[Specific configuration of pause analysis device]
As shown in FIG. 2, the temporary stop analysis device 3 includes an acquisition unit 31, an analysis unit 32, a table storage unit 33, and an output unit 34. Hereinafter, the structure with which the temporary stop analysis apparatus 3 is provided is demonstrated in detail.

  The acquisition unit 31 acquires various information from the robot controller 2 of the welding robot 1. Here, as shown in FIG. 2, the acquisition unit 31 acquires robot position information, robot operation information, welding condition information, and operation error information from the robot controller 2.

  The robot position information is information indicating the position of the welding robot 1. The robot position information includes, for example, a teaching program number (program number subdivided in the main program) indicating the type of the teaching program for welding that the welding robot 1 has executed in the past, and the welding robot 1 that has executed in the past. This includes a step number indicating the number of steps of the welding teaching program and a pass number indicating the number of passes of the welding teaching program (the number of welding passes) executed by the welding robot 1 in the past. That is, since the welding robot 1 operates (welding and sensing) in accordance with a predetermined welding teaching program, the welding robot 1 acquires the type, step number, and pass number of the welding teaching program. It is possible to grasp the exact position.

  The robot operation information is information indicating the content of the operation of the welding robot 1. The robot operation information includes, for example, sensing information indicating whether or not the welding robot 1 is sensing, welding information indicating whether or not the welding robot 1 is welding, and whether or not the welding robot 1 is reproducing a welding teaching program. Reproduction information indicating that, and pause information indicating whether or not the welding robot 1 is paused.

  More specifically, the above-described sensing information includes a sensing ON signal indicating that the welding robot 1 has started sensing, and a sensing OFF signal indicating that the welding robot 1 has finished sensing. This is a binary flag signal. More specifically, the welding information is a binary value composed of a welding ON signal indicating that the welding robot 1 has started welding and a welding OFF signal indicating that the welding robot 1 has ended welding. This is a flag signal. More specifically, the reproduction information includes a reproduction ON signal indicating that the welding robot 1 has started executing the welding teaching program, and a reproduction indicating that the welding robot 1 has finished executing the welding teaching program. This is a binary flag signal composed of an OFF signal. More specifically, the temporary stop information includes a temporary stop ON signal indicating that the welding robot 1 has been temporarily stopped (choco stop), and that the welding robot 1 has resumed operation from the temporary stop (choco stop) state. Is a binary flag signal composed of a temporary stop OFF signal indicating. These flag signals are generated by the robot controller 2 corresponding to the operation of the welding robot 1, and are output to the acquisition unit 31 together with time information indicating the time when the flag signal is generated.

  The welding condition information is information indicating conditions for welding the workpiece W by the welding robot 1. The welding condition information includes, for example, weaving information indicating the presence or absence of weaving by the welding robot 1, groove type information indicating the type of groove of the workpiece W to be welded, and sensing type indicating the type of sensing by the welding robot 1. Information, arc retry function information indicating whether or not to use an arc retry function which is a function to automatically retry when the welding robot 1 is temporarily stopped, and an arc sensor indicating whether or not an arc sensor is used to detect whether or not an arc has occurred Information.

  Here, the above-described weaving information is more specifically composed of presence / absence of weaving and a weaving amplitude value. More specifically, the above-described groove type information is composed of groove types such as downward and horizontal. More specifically, the arc retry function information includes an arc retry function ON signal indicating that the welding robot 1 has started using the arc retry function, and that the welding robot 1 has finished using the arc retry function. It is a binary flag signal composed of an arc retry function OFF signal shown. More specifically, the arc sensor information includes an arc sensor ON signal indicating that the welding robot 1 has started using the arc sensor, and an arc sensor OFF indicating that the welding robot 1 has ended the use of the arc sensor. Signal, and a binary flag signal. These flag signals are generated by the robot controller 2 corresponding to the operation of the welding robot 1, and are output to the acquisition unit 31 together with time information indicating the time when the flag signal is generated.

  The operation error information is information indicating the content of the operation error when the welding robot 1 is temporarily stopped (chocolate stopped). The operation error information includes, for example, a welding section where the welding robot 1 performs a welding operation, a sensing section where the welding robot 1 performs a sensing operation, an air cut section which is a section other than the welding section and the sensing section, An error message as shown in the following Table 1 is included for each operation error when the welding robot 1 is temporarily stopped.

  Here, “error type” in Table 1 means a type that briefly represents the content of the error message. Further, the arc abnormality means a state in which the arc is interrupted during welding. Further, over-wire feeding means a state in which contact is not detected even when a predetermined amount of inching is performed when sensing is performed by feeding a wire. Touch-on means a state in which contact detection is not performed even if the welding robot 1 is operated for a predetermined distance when sensing is performed. Further, the touch-off means a state where the welding robot 1 is not in contact with the workpiece W even if it is operated for a predetermined distance when the welding robot 1 is operated so that the wire changes from the contact state to the non-contact state. Further, the detection before sensing means a state in which no sensing voltage is applied when the sensing operation is started because the workpiece W is already in contact before the sensing operation is started. The scanning abnormality means a state where the arc scanning amount is equal to or greater than a predetermined value. These error messages are generated by the robot controller 2 in response to the operation of the welding robot 1 and are output to the acquisition unit 31 together with time information indicating the time at which the error message was generated.

  As described above, the temporary stop analysis apparatus 3 acquires the program number, step number, and pass number of the welding teaching program executed by the welding robot 1 as information indicating the position of the welding robot 1, and performs the operation of the welding robot 1. Information indicating whether or not the welding robot 1 is sensing is acquired as information indicating the contents, information such as the presence or absence of weaving by the welding robot is acquired as information indicating the welding conditions of the welding robot 1, and the welding robot 1 By acquiring an error message as information indicating the content of the error at the time of the temporary stop, it is possible to acquire a detailed situation when the welding robot 1 is temporarily stopped, and a temporary stop according to the detailed situation. The estimated cause and the method of correcting the pause can be output as the analysis result.

  As shown in FIG. 2, the robot position information, the robot operation information, the welding condition information, and the operation error information are input to the acquisition unit 31 together with the respective time information, as shown in FIG. 2. And the acquisition means 31 outputs such information to the analysis means 32, as shown in FIG.

  The analysis means 32 analyzes the cause of the temporary stop (choco stop) of the welding robot 1 and the correction method. The analysis means 32 includes the following table 2 in which the robot position information, robot operation information, welding condition information and operation error information, the estimated cause of the temporary stop and the correction method of the temporary stop corresponding thereto are described in advance. The analysis process is performed by referring to the table as shown in FIG. The table shown in Table 2 below is stored in advance by the table storage means 33 as shown in FIG. The estimated cause and the correction contents in the table shown in Table 2 are obtained experimentally and empirically.

  That is, the analysis unit 32 applies the robot position information, robot operation information, welding condition information, and operation error information generated at the same time among the generated information to the table shown in Table 2, thereby Extract possible causes and corrections. For example, as shown in the second row of Table 2, the analysis means 32 has a section at a certain time as a “welding section”, an error type at a certain time as “arc abnormal”, and a temporary stop position at a certain time as “ If it is “immediately after the start of welding” and the robot operation / welding condition at a certain time is “not using the arc retry function”, select “there is an insulator at the welding start position” and “wire feeding failure” as the probable cause. Then, “Review of teaching position”, “Use of arc retry function” and “Confirmation of wire feedability” are selected as correction contents of the chocolate stop (symbol (a)).

  Here, in Table 2, the section is “welding section” means that the welding ON signal is input as robot operation information from the acquisition unit 31 to the analysis unit 32, and the section is “sensing section”. "" Means that a sensing ON signal is input as robot operation information from the acquisition means 31 to the analysis means 32, and that the section is an "air cut section" is analyzed from the acquisition means 31. It means that a welding OFF signal and a sensing OFF signal are input to the means 32 as robot operation information.

  In Table 2, if the error type is “arc abnormality”, the acquisition means 31 sends an error message (see Table 1) “Arc abnormality has occurred” to the analysis means 32 as operation error information. It means that it was entered.

  In Table 2, the temporary stop position is “immediately after the start of welding”. The teaching program number and step number input as robot position information from the acquisition unit 31 to the analysis unit 32 are determined in advance. It means that it is smaller than the lower limit value, and that the temporary stop position is a “welding intermediate point”, the teaching program number and step number input as robot position information from the acquisition means 31 to the analysis means 32 are Each means a value near the middle, and that the temporary stop position is “in crater processing” means that the teaching program number and step number input as robot position information from the acquisition means 31 to the analysis means 32 Is smaller than a predetermined upper limit value.

  Further, in Table 2, the temporary stop position is “immediately after nozzle cleaning” is executed immediately after nozzle cleaning is performed by the teaching program number input as robot position information from the acquisition unit 31 to the analysis unit 32. This is a number indicating the teaching program. Since nozzle cleaning is set in advance to be performed between the teaching program, whether the temporary stop position is “immediately after nozzle cleaning” by inputting the teaching program number as the robot position information. It is possible to grasp whether “not immediately after nozzle cleaning”.

  Moreover, in Table 2, the pause position “occurs at a plurality of positions” means that a choke stop of the same error type has occurred at a plurality of positions. This means that a plurality of pieces of robot position information indicating different positions generated at different times are input. That is, for example, error 1 occurs at position A at 10:00, error 1 occurs at position B at 12:00, and error 1 occurs at position C at 14:00. On the other hand, in Table 2, the temporary stop position “occurs at a specific position” means that a chocolate stop of the same error type occurs at the same position, and for the same type of error message This means that a plurality of pieces of robot position information indicating the same position generated at different times are input. That is, for example, error 2 occurs at position D at 11:00, error 2 occurs at position D at 13:00, and error 2 occurs at position D at 15:00.

  In addition, “revise teaching position” in Table 2 means that the teaching program for welding is corrected, and “confirmation of wire feedability” means that the wire is instructed to the feeding speed commanded. This means that the direction and the number of arc retries are corrected, and that the revision and the number of arc retries are corrected. This means that the weaving amplitude value is corrected. “Reviewing the nozzle cleaning method” means correcting the nozzle cleaning method.

  Further, as shown in Table 3 below, the analysis unit 32 counts the number of error messages for each robot position information, thereby generating a ranking by chocolate stop occurrence position that ranks the number of chocolate stops by the occurrence position. The result is output to the output means 34 as one of the analysis results. In Table 3 below, PRG means a teaching program number, STEP means a step number, and PASS means a pass number.

  Further, as shown in FIG. 3, the analysis unit 32 classifies the error messages for each type to generate an error message occurrence rate pie chart indicating the error message occurrence rate, and outputs it as one of the analysis results. 34.

  Further, as shown in Table 4 below, the analysis means 32 extracts from the analysis results using Table 3 those with the most frequent occurrences of chocolate stops (here, the top three), and each correction target A chocolate stop priority correction list in which the number of positions and the number of correction target errors are calculated is generated and output to the output means 34 as one of the analysis results.

  Here, in Table 4, the number of pauses is, for example, in the welding data input to the pause analysis device 3 from the robot controller 2 in the case of the “arc abnormality” column in the second row of the table. This means the total number of “arc abnormalities”. The number of positions to be corrected is the same as the example of the “arc abnormality” column in the second row of the table. In the welding data input to the temporary stop analysis device 3, the section is “welding section”. The position of the welding robot 1 where the temporary stop position is “immediately after the start of welding” and the robot operation / welding condition is “not using the arc retry function” (specified by PRG, STEP, PASS in Table 3). The number of welding robots 1). The number of correction target errors indicates the number of chocolate stops at the position of the welding robot 1.

  The temporary stop analysis apparatus 3 according to the embodiment can easily grasp the estimated cause of the chocolate stop and the correction method by generating the chocolate stop priority correction list as shown in Table 4, and the chocolate stop is It is possible to easily grasp where it occurs frequently.

  Further, as shown in Table 5 below, the analysis unit 32 calculates an effect when the chocolate stop is corrected according to Table 4, generates a chocolate stop correction effect list, and outputs the output unit 34 as one of the analysis results. Output to.

  Here, the operating rate before correction of the chocolate stop in Table 5 can be calculated by the following formula (1), and the arc occurrence rate before correction of the chocolate stop in Table 5 is calculated by the following formula (2). be able to.

Operation rate before correction = ((time from start of regeneration of welding robot 1 to end of regeneration) − (time from pause to restart of welding robot 1)) / (time from start of regeneration of welding robot to end of regeneration) ) × 100 (1)

Arc generation rate before correction = ((Time from start of welding of welding robot 1 to end of welding) / (Time from start of regeneration of welding robot to end of reproduction) × 100 (2)

  Moreover, the operation rate after correction of the chocolate stop in Table 5 can be calculated by the following formula (3), and the arc occurrence rate after correction of the chocolate stop in Table 5 is calculated by the following formula (4). Can do.

Operation rate after correction = ((Time from the start of regeneration of the welding robot 1 to the end of regeneration) − (Time from the temporary stop to restart of the welding robot 1 × Choco stop reduction rate)) / (From the start of the regeneration of the welding robot) Time until the end of playback) x 100 (3)

Arc generation rate after correction = ((Time from start of welding of welding robot 1 to end of welding) / (Time from start of regeneration of welding robot to end of regeneration × Choco stop reduction rate) × 100 (4)

  In Equation (3) and Equation (4), the chocolate stop reduction rate can be calculated by the following Equation (5).

Chocolate stop reduction rate = number of errors to be corrected x number of occurrences x 100 (5)

  As shown in FIG. 2, the robot position information, the robot operation information, the welding condition information, and the operation error information are input to the analysis unit 32 together with the time information from the acquisition unit 31. The table shown in Table 2 is input from the storage unit 33. And the analysis means 32 produces | generates the ranking according to chocolate stop generation | occurrence | production position, an error message generation | occurrence | production ratio pie chart, a chocolate stop priority correction list | wrist, and a chocolate stop correction effect list | wrist by the above-mentioned method, This is output means 34.

  The table storage means 33 stores in advance the table shown in Table 2 used in the analysis means 32. Specifically, the table storage unit 33 is implemented by a memory, a hard disk, or the like that can store data. And the table memory | storage means 33 is comprised so that the table shown in above-mentioned Table 2 may be recorded, and these may be output to the analysis means 32 as needed. As shown in FIG. 2, the table storage unit 33 is provided inside the pause analysis device 3, but may be provided outside the pause analysis device 3.

  The output unit 34 outputs the analysis result analyzed by the analysis unit 32. As shown in FIG. 2, the output means 34 is a ranking according to chocolate stop occurrence position, an error message occurrence ratio pie chart, a chocolate stop priority correction list, and a chocolate stop correction effect list inputted from the analysis means 32. Are output to the display device 4.

  The temporary stop analysis apparatus 3 having the above configuration inputs these four data: the position of the welding robot 1, the operation status of the welding robot 1, the welding conditions, and the content of the operation error at the time of the temporary stop. The estimated cause of suspension and the correction method of suspension can be output as analysis results. And according to the temporary stop analysis apparatus 3, while being able to contribute to the improvement of the chocolate stop in various situations, even if there is no experience and knowledge, the location where the countermeasure for the chocolate stop is easily identified. be able to.

[Operation of pause analysis device]
Hereinafter, the operation of the temporary stop analysis apparatus 3 according to the embodiment will be described with reference to Tables 1 and 2 and FIGS.

  First, as shown in FIG. 4, the acquisition means 31 acquires each information from the robot controller 2, that is, robot position information, robot operation information, welding condition information, and operation error information (step S1). Next, the analysis means 32 analyzes the cause of the temporary stop of the welding robot 1 and the correction method with reference to the table shown in Table 2 previously stored in the table storage means 33 (step S2). Details of the analysis process in step S2 will be described later. Next, the output means 34 analyzes the display device 4 with the analysis result analyzed by the analysis means 32, that is, ranking by chocolate stop occurrence position, error message occurrence rate pie chart, chocolate stop priority correction list, chocolate stop A list of correction effects is output.

(Details of step S2)
Hereinafter, details of the analysis processing by the analysis unit 32 of the suspension analysis apparatus 3 according to the embodiment will be described. The analysis process by the analysis means 32 described below is performed by applying the generated robot position information, robot operation information, welding condition information, and operation error information to the table shown in Table 2 and estimating the cause and correction. This corresponds to a process of selecting contents.

  First, as shown in FIG. 5, when the analysis means 32 starts the analysis process (step S2), the section in Table 2 is selected with reference to the generated robot motion information (step S21). If the robot operation information includes the welding ON signal, the “welding section” in Table 2 is selected and the process proceeds to step S22. If the robot operation information includes the sensing ON signal, the above-described operation is performed. When the “sensing section” in Table 2 is selected and the process proceeds to step S24, neither the welding ON signal nor the sensing ON signal is included in the robot operation information, that is, the welding OFF signal and the sensing OFF signal are included in the robot operation information. Is included, the “air cut section” in Table 2 is selected, and the process proceeds to step S26.

(Details of step S22)
Hereinafter, the process when the “welding section” is selected in step S21 shown in FIG. 5 and the process proceeds to step S22 will be described with reference to FIG. First, as shown in FIG. 6, the robot position information and the operation error information generated at the same time as the robot operation information referred in step S21 are referred to. And it is determined whether it is “immediately after the start of welding” (step S221). If the teaching program number and step number in the robot position information indicate immediately after the start of welding, and the error message (see Table 1) that “Arc abnormality has occurred” is included in the operation error information, It is determined that the error type and the temporary stop position in Table 2 are “arc abnormal and immediately after start of welding” (Yes in step S221), and the process proceeds to step S222.

  Next, as shown in FIG. 6, with reference to the welding condition information generated at the same time as the robot position information and the operation error information referred in step S221, the robot operation / welding conditions in Table 2 described above are “arc retry”. It is determined whether or not “function not used” (step S222). If the arc retry function OFF signal is included in the welding condition information, it is determined that the robot operation / welding condition in Table 2 is “not using the arc retry function” (Yes in step S222), and step S223. Go to and select the presumed cause and the correction contents described in the row of the symbol (a) in Table 2. On the other hand, if the arc retry function ON signal is included in the welding condition information, it is determined that the robot operation / welding condition in Table 2 is not “not using the arc retry function” (No in step S222), and step S224. Go to and select the presumed cause and the correction contents described in the row of the symbol (b) in Table 2.

  Here, as shown in FIG. 6, in step S221, the teaching program number in the robot position information and the step number do not indicate immediately after the start of welding, or an error message “Arc abnormality has occurred” in the operation error information ( If the error type and the temporary stop position in Table 2 are not “arc abnormal and immediately after start of welding” (No in step S221), the process proceeds to step S225.

  Next, as shown in FIG. 6, with reference to the robot position information and the operation error information generated at the same time as the robot operation information referred in step S21, the error type and the pause position in Table 2 described above are “arc”. It is determined whether or not it is “abnormal and welding intermediate point” (step S225). When the teaching program number and step number in the robot position information indicate the welding intermediate point, and the error message (see Table 1) that “Arc abnormality has occurred” is included in the operation error information, It is determined that the error type and the temporary stop position in Table 2 are “arc abnormalities and welding intermediate point” (Yes in Step S225), and the process proceeds to Step S226 and is described in the row of the symbol (c) in Table 2 Select the probable cause and correction details.

  Here, as shown in FIG. 6, in step S225, the teaching program number or step number in the robot position information does not indicate a welding intermediate point, or an error message “Arc abnormality has occurred” in the operation error information ( If the error type and the temporary stop position in Table 2 are not “arc abnormal and welding intermediate point” (No in step S225), the process proceeds to step S227.

  Next, as shown in FIG. 6, with reference to the robot position information and the operation error information generated at the same time as the robot operation information referred in step S21, the error type and the pause position in Table 2 described above are “arc”. It is determined whether or not "abnormal and crater treatment is in progress" (step S227). If the teaching program number and step number in the robot position information indicate that crater processing is in progress, and the error message (see Table 1) that "Arc abnormality has occurred" is included in the operation error information, It is determined that the error type and the temporary stop position in Table 2 are “arc abnormal and crater is being processed” (Yes in Step S227), and the process proceeds to Step S228 and is described in the row of the symbol (d) in Table 2 Select the probable cause and correction details.

  Here, as shown in FIG. 6, in step S227, the teaching program number or step number in the robot position information does not indicate that crater treatment is in progress, or an error message “Arc abnormality has occurred” in the operation error information ( If the error type and the temporary stop position in Table 2 are not “arc abnormal and crater is being processed” (No in step S227), the process proceeds to step S229.

  Next, as shown in FIG. 6, with reference to the operation error information generated at the same time as the robot operation information referred in step S21, it is determined whether or not the error type in Table 2 is “nozzle contact”. Determination is made (step S229). If the operation error information includes an error message (see Table 1) “Nozzle has contacted the workpiece”, it is determined that the error type in Table 2 is “Nozzle contact” (step S229). Yes), the process proceeds to step S230.

  Next, as shown in FIG. 6, referring to the robot position information generated at the same time as the operation error information referred in step S229, the temporary stop positions in Table 2 are “occurred at a plurality of positions”. Is determined (step S230). If “nozzle contact” occurs at a plurality of positions, it is determined that the temporary stop position in Table 2 is “occurrence at a plurality of positions” (Yes in step S230), and the process proceeds to step S231. The presumed cause and the correction content described in the row of the symbol (e) in Table 2 are selected.

  Here, as shown in FIG. 6, when “nozzle contact” occurs in a concentrated manner at a specific position in step S <b> 230, the pause positions in Table 2 described above are not “occurred at a plurality of positions”. (No in step S230), the process proceeds to step S232.

  Next, as shown in FIG. 6, the welding condition information generated at the same time as the robot position information referred in step S230 is referred to, and the robot operation / welding condition in Table 2 is “use arc sensor”. It is determined whether or not (step S232). When the arc sensor ON signal is included in the welding condition information, it is determined that the robot operation / welding condition in Table 2 is “use arc sensor” (Yes in step S232), and the process proceeds to step S233. The presumed cause and the correction content described in the row of the symbol (f) in Table 2 are selected. On the other hand, when the arc sensor OFF signal is included in the welding condition information, it is determined that the robot operation / welding condition in Table 2 is not “use of arc sensor” (No in step S232), and the process proceeds to step S234. The presumed cause and the correction contents described in the row of the symbol (g) in Table 2 are selected.

  Here, as shown in FIG. 6, in step S229, when the error message (see Table 1) “Nozzle has contacted the workpiece” is not included in the operation error information, the error type in Table 2 described above Is not “nozzle contact” (No in step S229), the process proceeds to step S235.

  Next, as shown in FIG. 6, with reference to the motion error information generated at the same time as the robot motion information referred in step S21, it is determined whether or not the error type in Table 2 is “Straight Abnormal”. Determination is made (step S235). If the error message (see Table 1) that “the arc scanning amount has been exceeded” is included in the operation error information, it is determined that the error type in the above-described Table 2 is “copying abnormality” (step S235). Yes), the process proceeds to step S236, and the presumed cause and the correction contents described in the row of the symbol (h) in Table 2 are selected. On the other hand, if the error message (see Table 1) that “the arc scanning amount has been exceeded” is not included in the operation error information (No in step S235), the process ends.

(Details of step S24)
Hereinafter, the processing when the “sensing section” is selected in step S21 shown in FIG. 5 and the process proceeds to step S24 will be described with reference to FIG. First, as shown in FIG. 7, with reference to the motion error information generated at the same time as the robot motion information referred in step S21, it is determined whether or not the error type in Table 2 is “pre-sensing detection”. Determination is made (step S241). If the operation error information includes an error message (see Table 1) that “the sensing voltage is not applied” (see Table 1), it is determined that the error type in Table 2 is “detection before sensing” (step S241). Yes), the process proceeds to step S242.

  Next, as shown in FIG. 7, the robot position information generated at the same time as the operation error information referred in step S241 is referred to, and the temporary stop position in Table 2 is “occurred at a specific position”. Is determined (step S242). If the “pre-sensing detection” is concentrated at the same position, it is determined that the temporary stop position in Table 2 is “occurred at a specific position” (Yes in step S242), and step S243. Go to and select the presumed cause and the correction contents described in the row of the symbol (i) in Table 2. On the other hand, if “pre-sensing detection” occurs at a plurality of positions, it is determined that the pause position in Table 2 is not “occurred at a specific position” (No in step S242), and the process proceeds to step S244. The presumed cause and the correction contents described in the row of the symbol (j) in Table 2 are selected.

  Here, as shown in FIG. 7, when the error message “No sensing voltage is applied” (see Table 1) is not included in the operation error information in step S241, the error type in Table 2 described above is displayed. It determines with it not being "detection before sensing" (it is No at step S241), and progresses to step S245.

  Next, as shown in FIG. 7, the operation error information generated at the same time as the robot operation information referred in step S21 is referred to, and whether or not the error type in Table 2 is “wire feeding over”. Is determined (step S245). If the operation error information includes an error message (see Table 1) that says "Wire feed amount exceeded", it is determined that the error type in Table 2 is "Wire feed over". (Yes in step S245), the process proceeds to step S246, and the estimated cause and the correction contents described in the row of the symbol (k) in Table 2 are selected.

  Here, as shown in FIG. 7, in step S245, if the error message (see Table 1) indicating that the wire feed amount has been exceeded is not included in the operation error information, the error in Table 2 described above It is determined that the type is not “wire feeding over” (No in step S245), and the process proceeds to step S247.

  Next, as shown in FIG. 7, it is determined whether or not the error type in Table 2 is “touch-on” by referring to the operation error information generated at the same time as the robot operation information referred in step S21. (Step S247). If the error message (see Table 1) indicating that the sensing detection operation distance has been exceeded is included in the operation error information, it is determined that the error type in Table 2 is “touch on” (step S247). Yes), the process proceeds to step S248, and the estimated cause and the correction content described in the row of the symbol (l) in Table 2 are selected.

  Here, as shown in FIG. 7, in step S247, if the error message (see Table 1) indicating that the sensing detection operation distance has been exceeded is not included in the operation error information, the error in Table 2 described above It is determined that the type is not “touch-on” (No in step S247), and the process proceeds to step S249.

  Next, as shown in FIG. 7, it is determined whether or not the error type in Table 2 is “touch-off” by referring to the operation error information generated at the same time as the robot operation information referred in step S21. (Step S249). Then, if the error message (see Table 1) that “does not move away from the wall even if it operates for a predetermined distance” is included in the operation error information, it is determined that the error type in Table 2 is “touch-off”. (Yes in step S249), the process proceeds to step S250, and the estimated cause and the correction content described in the row of the symbol (m) in Table 2 are selected.

  Here, as shown in FIG. 7, in step S249, when the operation error information does not include an error message (see Table 1) that says “the object does not move away from the wall even if it operates for a predetermined distance”, the above table is displayed. 2 determines that the error type is not “touch-off” (No in step S249), and proceeds to step S251.

  Next, as shown in FIG. 7, the motion error information generated at the same time as the robot motion information referred in step S21 is referred to, and the error type in Table 2 is “simultaneous contact between nozzle and wire”. It is determined whether or not (step S251). If the error message (see Table 1) that “the nozzle and the wire are in contact at the same time” is included in the operation error information, the error type in Table 2 is “simultaneous contact between the nozzle and the wire”. Determination is made (Yes in step S251), and the process proceeds to step S252.

  Next, as shown in FIG. 7, referring to the robot position information generated at the same time as the operation error information referred in step S <b> 251, the temporary stop position in Table 2 is “not immediately after nozzle cleaning”. Whether or not (step S252). If the teaching program number and the step number in the robot position information indicate that it is not immediately after nozzle cleaning, it is determined that the temporary stop position in Table 2 is “not immediately after nozzle cleaning” (in step S252). Yes), the process proceeds to step S253, and the presumed cause and the correction content described in the row of the symbol (n) in Table 2 are selected. On the other hand, when the teaching program number and the step number in the robot position information indicate that the nozzle is immediately after nozzle cleaning, it is determined that the temporary stop position in Table 2 is not “not immediately after nozzle cleaning” (in step S252). No), proceeding to step S254, the presumed cause and the correction content described in the row of the symbol (o) in Table 2 are selected.

  Here, as shown in FIG. 7, when the error message “Nozzle and wire touched simultaneously” (see Table 1) is not included in the operation error information in step S251, the error in Table 2 described above It is determined that the type is not “simultaneous contact between nozzle and wire” (No in step S251), and the process proceeds to step S255.

  Next, as shown in FIG. 7, the operation error information generated at the same time as the robot operation information referred in step S21 is referred to, and whether or not the error type in Table 2 is “nozzle contact” is determined. Determination is made (step S255). If the operation error information includes an error message (see Table 1) “Nozzle has contacted the workpiece”, it is determined that the error type in Table 2 is “Nozzle contact” (step S255). Yes), the process proceeds to step S256.

  Next, as shown in FIG. 7, the robot position information generated at the same time as the operation error information referred in step S <b> 255 is referred to, and the temporary stop position in Table 2 is “occurred at a specific position”. It is determined whether or not (step S256). When the “nozzle contact” is concentrated at the same position, it is determined that the temporary stop position in Table 2 is “occurred at a specific position” (Yes in step S256), and the process proceeds to step S257. Go ahead and select the probable cause and the correction content described in the row of the symbol (p) in Table 2. On the other hand, if “nozzle contact” has occurred at a plurality of positions, it is determined that the pause position in Table 2 is not “occurred at a specific position” (No in step S256), and the process proceeds to step S258. The presumed cause and the correction content described in the row of the symbol (q) in Table 2 are selected.

  Here, as shown in FIG. 7, in step S255, when the error message (see Table 1) “Nozzle has contacted the workpiece” is not included in the operation error information, the error type in Table 2 described above Is not “nozzle contact” (No in step S255), and the process ends.

(Details of step S26)
Hereinafter, the processing when the “air cut section” is selected in step S21 shown in FIG. 5 and the process proceeds to step S26 will be described with reference to FIG. First, as shown in FIG. 8, it is determined whether or not the error type in Table 2 is “nozzle contact” by referring to the operation error information generated at the same time as the robot operation information referred to in step S21. (Step S261). If the operation error information includes an error message (see Table 1) “Nozzle has contacted the workpiece”, it is determined that the error type in Table 2 is “Nozzle contact” (step S261). Yes), the process proceeds to step S262.

  Next, as shown in FIG. 8, the robot position information generated at the same time as the operation error information referred in step S261 is referred to, and the temporary stop position in Table 2 is “occurrence at a specific position”. It is determined whether or not (step S262). If the “nozzle contact” is concentrated at the same position, it is determined that the temporary stop position in Table 2 is “occurred at a specific position” (Yes in step S262), and the process proceeds to step S263. Go ahead and select the probable cause and the correction content described in the row of the symbol (r) in Table 2. On the other hand, if “nozzle contact” has occurred at a plurality of positions, it is determined that the temporary stop position in Table 2 is not “occurred at a specific position” (No in step S262), and the process proceeds to step S264. The presumed cause and the correction content described in the row of the symbol (s) in Table 2 are selected.

  Here, as shown in FIG. 8, if the error message (see Table 1) “Nozzle has contacted the workpiece” is not included in the operation error information in step S261, the error type in Table 2 described above Is not “nozzle contact” (No in step S261), and the process ends.

[Pause analysis program]
Here, the temporary stop analysis device 3 can be realized by operating a general computer with a program that causes each of the above-described means and units to function. This program can be distributed via a communication line, or can be written on a recording medium such as a CD-ROM for distribution.

  As described above, the temporary stop analysis device and the temporary stop analysis program according to the present invention have been specifically described with reference to the embodiments and examples for carrying out the invention, but the gist of the present invention is not limited to these descriptions. Should be construed broadly based on the claims. Needless to say, various changes and modifications based on these descriptions are also included in the spirit of the present invention.

1 Welding robot 2 Robot controller (RC)
3 Temporary stop analysis device 4 Display device 31 Acquisition means 32 Analysis means 33 Table storage means 34 Output means W Workpiece (member to be welded)

Claims (4)

A welding robot temporary stop analysis device for analyzing the cause of a temporary stop of the welding robot and a correction method thereof,
From the robot controller of the welding robot, robot position information indicating the position of the welding robot, robot operation information indicating the content of the operation of the welding robot, welding condition information indicating a condition of welding by the welding robot, and the welding An acquisition means for acquiring operation error information indicating the content of the operation error when the robot is temporarily stopped;
Each condition of the robot position information, the robot operation information, and the welding condition information associated with the operation error information, a presumed cause of a pause corresponding to these conditions , and a method for correcting the pause are described in advance. By referring to the table, the analysis means for analyzing the cause of the temporary stop of the welding robot and the correction method thereof each information acquired by the acquisition means matches the condition ,
Output means for outputting an analysis result analyzed by the analysis means;
A temporary stop analysis device for a welding robot, comprising: The robot position information is
A teaching program number indicating the type of welding teaching program executed by the welding robot;
A step number indicating the number of steps of the teaching program for welding executed by the welding robot;
A pass number indicating the number of passes of the welding teaching program executed by the welding robot,
The robot operation information is
Sensing information indicating whether the welding robot is sensing,
Welding information indicating whether or not the welding robot is welding;
Reproduction information indicating whether or not the welding robot is reproducing the welding teaching program;
Pause information indicating whether or not the welding robot is paused, and
The welding condition information is
Weaving information indicating the presence or absence of weaving by the welding robot;
Groove type information indicating the type of groove of the workpiece to be welded;
Sensing type information indicating the type of sensing by the welding robot;
Arc retry function information indicating whether or not to use an arc retry function, which is a function of repeating the arc generation operation for a preset number of times when no arc has occurred at the welding start position;
Arc sensor presence / absence information indicating whether or not to use an arc sensor that automatically detects the position of the weld line during welding in order to follow the displacement of the weld line,
The operation error information includes a welding section where the welding robot performs a welding operation, a sensing section where the welding robot performs a sensing operation, an air cut section which is a section other than the welding section and the sensing section. 2. The welding robot temporary stop analysis device according to claim 1, further comprising an error message predetermined for each operation error when the welding robot is temporarily stopped. To analyze the cause of the suspension of the welding robot,
From the robot controller of the welding robot, robot position information indicating the position of the welding robot, robot operation information indicating the content of the operation of the welding robot, welding condition information indicating a condition of welding by the welding robot, and the welding Acquisition means for acquiring operation error information indicating the content of an operation error when the robot is temporarily stopped;
Each condition of the robot position information, the robot operation information, and the welding condition information associated with the operation error information, a presumed cause of a pause corresponding to these conditions , and a method for correcting the pause are described in advance. Analysis means for analyzing the cause of the temporary stop of the welding robot in which each piece of information acquired by the acquisition unit matches the condition and a correction method thereof by referring to the table that has been performed,
Output means for outputting an analysis result analyzed by the analysis means;
A temporary stop analysis program for a welding robot, characterized in that The robot position information is
A teaching program number indicating the type of welding teaching program executed by the welding robot;
A step number indicating the number of steps of the teaching program for welding executed by the welding robot;
A pass number indicating the number of passes of the welding teaching program executed by the welding robot,
The robot operation information is
Sensing information indicating whether the welding robot is sensing,
Welding information indicating whether or not the welding robot is welding;
Reproduction information indicating whether or not the welding robot is reproducing the welding teaching program;
Pause information indicating whether or not the welding robot is paused, and
The welding condition information is
Weaving information indicating the presence or absence of weaving by the welding robot;
Groove type information indicating the type of groove of the workpiece to be welded;
Sensing type information indicating the type of sensing by the welding robot;
Arc retry function information indicating whether or not to use an arc retry function, which is a function of repeating the arc generation operation for a preset number of times when no arc has occurred at the welding start position;
Arc sensor presence / absence information indicating whether or not to use an arc sensor that automatically detects the position of the weld line during welding in order to follow the displacement of the weld line,
The operation error information includes a welding section where the welding robot performs a welding operation, a sensing section where the welding robot performs a sensing operation, an air cut section which is a section other than the welding section and the sensing section. 4. The welding robot pause analysis program according to claim 3, further comprising an error message predetermined for each operation error when the welding robot pauses.

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