JP5891399B2 - Work detection system setting method and work detection system using the same - Google Patents

Description

  The present invention relates to a work detection system setting method and a work detection system using the method.

  2. Description of the Related Art Conventionally, a manufacturing apparatus has been proposed that includes a fiber sensor for detecting the position of a workpiece (see, for example, Patent Document 1). The fiber sensor includes a light emitting unit and a light receiving unit that receives light emitted from the light emitting unit, and the light emitted from the light emitting unit passes through a wafer notch provided on the detection target wafer and is received by the light receiving unit. As a result, the position of the wafer notch is detected.

JP 11-340306 A

  In order to detect the presence or absence of a workpiece using the fiber sensor disclosed in Patent Document 1, it is necessary to arrange a light emitting unit and a light receiving unit across a place where the workpiece is placed. Since it was necessary to install multiple fiber sensors, it took time to install.

  The present invention has been made in view of the above problems, and an object of the present invention is to provide a method for setting a work detection system that can easily set a detection region and a detection order, and a work detection system using the same. There is.

  The setting method of the present invention is a setting method for a work detection system including a distance image sensor, a detection device, a notification device, and a setting device. The distance image sensor outputs a distance image of the work area. The detection device targets a work subject appearing in the distance image or a work handled by the work subject, and outputs a notification command when an abnormality in the work content is detected based on the distance image. When the notification command is input, the notification device performs a notification operation. The setting device sets a plurality of detection areas in which the detection device detects the presence or absence of a detection target and the detection order thereof in the distance image. In this setting method, the work area is set in a state where a setting sheet formed with a size corresponding to the detection area to be set and attached with an identification code including detection order information is arranged in the work area. Take a picture with a two-dimensional camera. The setting device detects the position and range of the setting sheet disposed in the work area and the identification code attached to the setting sheet by analyzing the image of the two-dimensional camera. The setting device sets a detection area based on the detected position and range of the setting sheet, and sets a detection order based on an identification code attached to the setting sheet. It is characterized by.

  In this setting method, the identification code includes type information of a workpiece detected in the corresponding detection area, and the setting device is based on the identification code attached to the setting sheet. It is also preferable to set the type of workpiece detected in the corresponding detection area.

  The work detection system of the present invention uses any one of the setting methods described above, and includes the distance image sensor, the detection device, the notification device, and the setting device.

  According to the present invention, when a setting sheet is photographed with a two-dimensional camera while the setting sheet is placed in a desired detection area, the setting device sets the detection area and the detection order by analyzing the image of the two-dimensional camera. Is done. Therefore, it is possible to realize a work detection system setting method in which the detection area and the detection order can be easily set and a work detection system using the method.

It is explanatory drawing of the setting method of embodiment, (a) (c) is a top view, (b) (d) is a sectional side view. It is a figure explaining another detection method same as the above, (a) (c) is a top view, (b) (d) is a sectional side view. It is explanatory drawing of another detection method same as the above, (a) is a front view, (b) is a side view, (c) is a top view of (b). It is explanatory drawing of the reflection member used for the detection method same as the above. It is a figure explaining the detection method same as the above, (a) is a top view of the state which put the workpiece | work, (b) is a side view. It is a block diagram of the work detection system using the object detection method same as the above. The work area where the same as the above is applied is shown, (a) is a front view, (b) is a side view. (A)-(e) is explanatory drawing of the operation content of a detection target. (A)-(i) is a figure which shows an example of the captured image for every work process. It is a flowchart explaining operation | movement same as the above.

  Hereinafter, an embodiment of a work detection system using a setting method according to the present invention will be described with reference to the drawings. The work detection system according to the present embodiment determines whether or not a work (detection target) is placed at a predetermined position in a packing work in which an operator packs a plurality of works (for example, finished products and instruction manuals) in a box. Used to detect. The application example of the work detection system is not limited to this embodiment, and can be applied to various uses.

  FIG. 7 shows a work table 50 to which the work detection system of this embodiment is applied. FIG. 7A is a front view of the work table 50, and FIG. 7B is a side view of the work table 50. In the following description, unless otherwise specified, the vertical and horizontal directions are defined in the direction shown in FIG. 7A, and the left side in FIG. 7B is described as the front side and the right side as the rear side.

  The work table 50 includes a frame 51 configured by combining metal pipes and three-stage shelf plates 52, 53, and 54 respectively supported by the frame 51. The lower and middle shelf plates 52 and 53 are shelf plates having a substantially square shape in plan view and have substantially the same outer dimensions. The personal computer PC1 is placed on the lower shelf 52. The middle shelf 53 is provided at a height position where the worker can easily work (for example, a height position near the waist of the worker), and a packing operation to be inspected is performed on the shelf 53. The upper shelf board 54 is formed in a rectangular shape in plan view, and the width dimension in the left-right direction is the same as that of the shelf board 53, but the depth dimension is smaller than the shelf board 53. It is provided near the back side and is used as a parts shelf on which works W1 and W2 to be put in a box are placed. Above the frame 51, a support portion 55 configured by combining metal pipes is provided at a position higher than the height of the worker, and the distance image sensor 1, the sound output device 4, and the irradiation device 5 are provided on the support portion 55. Is attached.

  FIG. 6 is a block diagram of the work detection system. This work detection system includes a distance image sensor 1, a detection device 2, an input device 3, a sound output device 4, an irradiation device 5, and a monitor 6 as main components. The detection device 2, the input device 3, and the monitor 6 are realized by, for example, a notebook personal computer PC1.

  The distance image sensor 1 is attached to the support portion 55 and photographs the middle shelf 53 and the upper shelf 54 as work areas from above. The measurement method of the distance image sensor 1 is a known measurement method such as a method of projecting a laser pattern or a TOF (Time Of Flight) method. The distance image sensor 1 detects the distance to the object existing in the imaging region using these known measurement methods, creates a distance image in which the pixel value of each pixel is the distance to the detection target, and the image of the distance image Data is output to the detection device 2. The distance image sensor 1 also has a function of capturing a two-dimensional image within the imaging range, and outputs the two-dimensional image data to the detection device 2 in addition to the distance image image data. That is, in the present embodiment, the distance image sensor 1 also serves as a two-dimensional camera that captures a two-dimensional image of the work area. However, the distance image sensor 1 may include a two-dimensional camera separately from the distance image sensor 1.

  The input device 3 is composed of input devices such as a keyboard and a mouse provided in the personal computer PC1.

  The sound output device 4 includes a speaker (not shown) that outputs sound in a space including a work area, and is attached to the support unit 55 with the speaker facing downward, such as a notification sound that notifies the occurrence of an abnormality. The sound is output downward.

  The irradiation device 5 is composed of a liquid crystal projector, for example, and is attached to the support unit 55, and the upper shelf plate 54 and the middle shelf plate 53 are used as a light projection range. The irradiation device 5 has a function of limiting light irradiated to a part of the projection range, and can irradiate light to desired positions of the shelf board 53 and the shelf board 54.

  Here, the sound output device 4 and the irradiation device 5 constitute a notification device that performs a notification operation with sound and light in accordance with a notification command from the detection device 2, and the sound output device 4 and the irradiation device are used as the notification device. Only one of 5 may be provided.

  The monitor 6 is composed of, for example, a liquid crystal display included in the personal computer PC1. The display content is controlled by the detection device 2, and a setting screen for setting a detection region and a detection order is displayed, and a detection result and the like are displayed.

  The detection device 2 detects the presence or absence of a detection object based on the distance image, with a workpiece or a part of the worker's body (for example, a hand) appearing in the distance image input from the distance image sensor 1 as a detection target. Thus, it is determined whether there is an abnormality in the work content. When the detection device 2 determines that the work content is abnormal, the detection device 2 outputs a notification command to the notification device (the sound output device 4 and the irradiation device 5) to notify the occurrence of the abnormality. Here, the detection apparatus 2 includes a personal computer PC1 and includes a setting unit 7 and an abnormality determination unit 8 which are realized by the calculation function of the personal computer PC1. The setting unit 7 (setting device) detects the presence / absence of a detection target in each detection area according to a detection area for detecting the presence / absence of a detection target (for example, a workpiece or a worker's hand) in a distance image, or a work procedure. The order is set, and the setting method will be described later. The abnormality determination unit 8 detects the presence / absence of the detection target based on the distance image input from the distance image sensor 1. And the abnormality determination part 8 does not detect the detection target object which should be detected in any detection area, or another detection target object is detected, or in an order different from the detection order in any detection area. When a detection target is detected, it is determined as abnormal and a notification command is output to the notification device.

  Next, the detection operation of the detection target object by the work detection system of this embodiment is demonstrated based on FIGS.

  FIGS. 8A to 8E are explanatory views showing each work process of the packing work. In the distance image P1 photographed by the distance image sensor 1, four pieces placed on a shelf board 54 serving as a parts shelf are shown. The boxes B1 to B4 and the box B10 placed on the shelf board 53 are shown. Different types of works W1 to W4 are placed in the four boxes B1 to B4, respectively, and the operator takes out the works W1, W2, W3, and W4 one by one in the order of the boxes B1, B2, B3, and B4. B10 is boxed. FIG. 8A shows a state before the packing operation, and the box B10 is empty. FIG. 8B shows a state where the worker has taken out one workpiece W1 from the leftmost box B1 and put it in the box B10. FIG. 8C shows a state where the worker has taken out one workpiece W2 from the second box B2 from the left end and put it in the box B10. FIG. 8D shows a state where the worker has taken out one workpiece W3 from the third box B3 from the left end and put it in the box B10. FIG. 8E shows a state where the worker has taken out one workpiece W4 from the rightmost box B4 and put it in the box B10. The state shown in FIG. 8E is a state in which one cycle of packing work has been completed, and four types of workpieces W1 to W4 are put in the box B10 one by one.

  When performing the inspection of the packing work using the work detection system of the present embodiment, the setting operator first detects a detection area and a detection order in which a detection target should be detected in each step of the packing work by a setting method described later. Is set in the detection device 2, and thereafter, the presence or absence of an abnormality is detected according to the set content. FIGS. 9A to 9I are explanatory diagrams for explaining processing for determining the presence or absence of abnormality in the above-described packing operation, and boxes B1 to B4 that contain workpieces in the distance image P1 and the workpieces are boxed. Box B10 is set as the detection area. In addition, a detection area where the operator places his hand H1 at the start of work is set as the start area A1.

  FIG. 10 is a flowchart for explaining the determination process performed by the abnormality determination unit 8. The detection device 2 is photographed from the distance image sensor 1 at a predetermined time interval (a time interval at which an operator's movement can be detected continuously). A distance image is input (step ST1). When the distance image is input from the distance image sensor 1, the abnormality determination unit 8 determines whether or not the abnormality determination process is being performed (step ST2).

  If the abnormality determination process is stopped (No in step ST2), the abnormality determination unit 8 determines whether or not an operator is detected in the start area A1 (step ST3). As shown in FIG. 9A, the worker places his hand H1 in the start area A1 every time one cycle of packing work is started, and the abnormality determination unit 8 detects the worker in the start area A1. Therefore, it is determined that the work is started, and the abnormality determination process is started (step ST4). If it is determined in step ST3 that there is no detection target in the start area A1, the abnormality determination unit 8 returns to step ST1 and waits for input of a distance image.

  On the other hand, if the abnormality determination process is being performed (Yes in step ST2), the abnormality determination unit 8 determines whether or not a detection target is detected in any detection region (step ST5). If it is determined in step ST5 that no detection object is detected in any detection region, the abnormality determination unit 8 returns to the process in step ST1 and waits for input of a distance image. In addition, when a detection target is detected in any detection region in the determination of step ST5, the abnormality determination unit 8 detects that the order of the detection regions in which the detection target is detected is set in advance by the setting unit 7. It is determined whether or not the order is different (step ST6). When the worker performs the packing operation described with reference to FIG. 8, as shown in FIGS. 9B to 9I, the operator's hand H1 is box B1 → box B10 → box B2 → box B10 → box B3 → It will be detected in the order of box B10 → box B4 → box B10. Also, since the work B1, the work W2, the work W3, and the work W4 are sequentially packed in the box B10, the work W1, the work W2, the work W3, and the work W4 are detected in that order in the detection area including the box B10. Will be. Here, the order of the detection areas in which the operator's hand H1 is detected from the distance image periodically input is different from the detection order set according to the work process, or the work W1 in the detection area including the box B10. When the order in which .about.W4 is detected is different from the detection order set according to the work process (Yes in step ST6), the abnormality determination unit 8 determines that the work different from the predetermined work content has been performed. At this time, the abnormality determination unit 8 outputs a notification command to the sound output device 4 and the irradiation device 5 and causes the storage unit 9 to store the detection history of the detection target determined to be abnormal. When the notification command is input, the sound output device 4 outputs a predetermined notification sound and notifies the occurrence of abnormality by sound. When the notification command is input, the irradiating device 5 irradiates, for example, light on a detection region determined to have a different detection order, and notifies the occurrence of an abnormality with light (step ST7).

  In step ST6, the order of the detection areas in which the hand H1 of the worker is detected is the same as the predetermined detection order, and the order in which the workpieces W1 to W4 are detected in the detection area including the box B10 is the predetermined detection order. (No in step ST6), the abnormality determination unit 8 determines whether or not the packing operation has been completed for one cycle (step ST8). Here, if the packing work for one cycle is not completed (No in step ST8), the abnormality determination unit 8 returns to step ST1 and waits for input of a distance image to prepare for detection of the next process. On the other hand, if the packing work for one cycle has been completed (Yes in step ST8), the abnormality determination unit 8 determines that the packing work for one cycle has been normally performed, and ends the abnormality determination process.

  In the packing operation described with reference to FIG. 8, every time one workpiece is taken from the boxes B1, B2, B3, and B4, the workpiece is put in the box B10. It may be placed in a tray (not shown) and finally transferred from the tray to box B10. The detection order in this case is box B1 → box B2 → box B3 → box B4 → box B10, and the abnormality determination unit 8 detects the detection target in an order different from the above detection order in any detection region. Then, it is determined that an abnormality has occurred.

  Here, in this work detection system, a setting method for setting a plurality of detection areas for detecting the presence / absence of a detection target and its detection order will be described with reference to FIGS.

  As shown in FIG. 1B, when the presence / absence of the workpieces W11, W12, W13, and W14 is detected in each of the rectangular detection areas A11, A12, A13, and A14 set on the shelf 53 as a work area. The detection areas A1 to A4 and their detection order need to be set in the detection device 2. As shown in FIG. 1B, the detection areas A11, A12, A13 are set side by side on the lower side of the shelf 53 in the figure, and the detection area A14 is set on the upper left of the shelf 53 in the figure. ing.

  In the setting method of the present embodiment, setting sheets S11 to S14 having shapes and sizes corresponding to the detection areas A11 to A14 to be set are used to set the detection areas A11 to A14 (FIG. 1A). reference). The setting sheets S11 to S14 have a rectangular shape, and the vertical and horizontal lengths of the corresponding detection areas A11 to A14 are set to be substantially the same. In addition, an identification code including information on detection order information is displayed at a main point (for example, the upper left corner) of the setting sheets S11 to S14 by a method such as printing. Here, “01” is displayed as an identification code on the setting sheet S11, “02” is displayed on the setting sheet S12, “03” is displayed on the setting sheet S13, and “04” is displayed on the setting sheet S14. ing. Here, the identification codes given to the setting sheets S11 to S14 are not limited to numbers such as “01”, “02”..., And may be letters such as alphabets, or a combination of letters and numbers. A barcode or a two-dimensional code may be used. Alternatively, the setting sheets S11 to S14 may have different colors, and the identification code may be configured with the colors of the setting sheets S11 to S14. For the setting sheets S11 to S14, it is also preferable to use an antistatic sheet that is easily available at the manufacturing site. The colors of the setting sheets S11 to S14 are preferably colors that increase the contrast with the surface of the work area (the upper surface of the shelf board 53). The sheets S11 to S14 are preferably white.

  First, as shown in FIG. 1A, the setting operator uses setting sheets S11, S12, S13, and S14 formed in the same shape and size as the detection areas A11, A12, A13, and A14 to be set. It arrange | positions in the position to set on the shelf board 53. FIG. Thereafter, when the setting operator inputs a setting command to the detection device 2 using the input device 3, the setting unit 7 of the detection device 2 activates the distance image sensor 1 based on the setting command, and the shelf board which is a work area 53 two-dimensional images are taken. Then, the setting unit 7 performs image processing (edge detection, labeling processing, etc.) on the two-dimensional image captured by the distance image sensor 1, thereby setting the position, shape, and size of the setting sheets S <b> 11 to S <b> 14 and the setting sheet. The identification code displayed in S11 to S14 is extracted. In the example of FIG. 1A, numbers “01”, “02”, “03”, and “04” are assigned as identification codes to the setting sheets S11, S12, S13, and S14, respectively. The ascending order of the numbers given to the sheets S11 to S14 is set as the detection order of each detection area. Therefore, the setting unit 7 sets the areas where the setting sheets S11, S12, S13, and S14 are placed as detection areas A11, A12, A13, and A14. The setting unit 7 sets the detection order of the detection areas A11 to A14 in ascending order of the identification codes attached to the setting sheets S11, S12, S13, and S14. In the example of FIG. The detection order is set in the order of A12 → A13 → A14. The identification codes “01”, “02”, “03”, and “04” also include information indicating the type of work that is a detection target. Thus, the setting unit 7 sets the detection targets in the detection areas A11, A12, A13, and A14 as workpieces W11, W12, W13, and W14, respectively.

  When the setting unit 7 sets the detection area and its detection order as described above, the setting unit 7 displays the setting content on the monitor 6. When the setting operator confirms the setting content displayed on the monitor 6 and inputs the setting completion using the input device 3, the setting unit 7 sets the detection area and its detection order based on the setting completion input. The contents are stored in the storage unit 9 and the setting process is terminated. Thereafter, when the detection device 2 starts the inspection process, the inspection process of the work content is executed according to the detection area and the detection order stored in the storage unit 9.

  Here, when the detection areas A11, A12, A13, and A14 in which the workpieces W11, W12, W13, and W14 are detected are changed as shown in FIG. It is necessary to set a later detection area and its detection order. In the example of FIG. 1D, the detection areas A11 to A13 are set on the upper side in the figure on the shelf 53, and the detection area A14 is set on the lower left side in the figure on the shelf 53.

  When it is desired to change the detection area as shown in FIG. 1D, the setting operator sets sheets S11, S12, and S13 corresponding to the detection areas A11, A12, A13, and A14, respectively, as shown in FIG. , S14 are arranged at positions to be set on the shelf board 53. When the setting operator inputs a setting command to the detection device 2 using the input device 3, the setting unit 7 of the detection device 2 activates the distance image sensor 1 based on the setting command, and the shelf board which is a work area 53 two-dimensional images are taken. At this time, the setting unit 7 detects the position, shape, and size of the setting sheets S11 to S14 by performing image processing on the two-dimensional image captured by the distance image sensor 1, and sets the setting sheets S11 to S14. The identification code displayed in is extracted. Then, the setting unit 7 sets the areas where the setting sheets S11, S12, S13, and S14 are placed as detection areas A11, A12, A13, and A14. The setting unit 7 sets the detection order of the detection areas A11 to A14 in ascending order of the identification codes attached to the setting sheets S11, S12, S13, and S14. In addition, since the identification code includes information on the workpiece to be detected, the setting unit 7 determines whether or not the workpieces W11, W12, W13, and W14 exist in the changed detection areas A11, A12, A13, and A14, respectively. Set the detection target to detect.

  The setting unit 7 displays the setting content on the monitor 6 when the changed detection area and the detection order are set as described above. When the setting operator confirms the setting contents displayed on the monitor 6 and inputs setting completion using the input device 3, the setting unit 7 detects the changed detection area and its detection based on the setting completion input. The setting contents of the order are stored in the storage unit 9, and the setting process is terminated. Thereafter, when the detection device 2 starts the inspection process, the inspection process for the work content is executed according to the changed detection area and the detection order stored in the storage unit 9.

  In the above setting example, the positions of the detection areas A11 to A14 are different between before and after the change, but the detection order of the detection areas A11 to A14 can be changed.

  As shown in FIG. 2A, the setting sheets S11, S12, S13, and S14 are arranged on the shelf board 53 as the work area, and the corresponding detection areas A11, A12, A13, and A14 are positioned by the setting method described above. It is assumed that the range is set as shown in FIG. Here, “A01”, “B02”, “C03”, and “D04” are displayed as identification codes on the setting sheets S11, S12, S13, and S14, respectively. The identification code consists of a combination of a single alphabet and a two-digit number. The one-character alphabet is type information indicating the type of work. The 2-digit number is information indicating the detection order of the corresponding detection area. If this identification code is used, the work detected in each detection area and the detection order of each detection area can be set separately. The setting unit 7 sets the detection targets in the corresponding detection areas A11, A12, A13, and A14 based on the alphabets of the identification codes attached to the setting sheets S11, S12, S13, and S14, respectively. In the example of FIG. 2, the detection target of the detection area A11 is set to the work W11, the detection target of the detection area A12 is set to the work W12, the detection target of the detection area A13 is set to the work W13, and the detection target of the detection area A14 is set to the work W14. Is done. In addition, if component information such as height, area, and shape is registered in advance in the storage unit 9 for a plurality of types of workpieces, the setting unit 7 sets the workpieces W11 to W14 that are detection targets of the detection regions A11 to A14. The component information can be read from the storage unit 9. This eliminates the need for the operator to input the workpiece component information and the processing for detecting and registering the component information of the workpieces W11 to W14 placed in the detection areas A11 to A14 from the two-dimensional image and the distance image. . Further, the setting unit 7 sets the detection order of the corresponding detection areas A11, A12, A13, and A14 based on the numbers of the identification codes attached to the setting sheets S11, S12, S13, and S14, respectively, from A11 to A12 to A13. → Set as A14.

  Here, a case where the detection order of the detection areas A11, A12, A13, and A14 is changed from A13 to A12 to A11 to A14 will be described below.

  In this case, the ranges of the detection areas A11 to A14 and the workpieces to be detected are not changed, and only the detection order of the detection areas A11 and A13 is switched. That is, the identification code of the setting sheet S11 corresponding to the detection area A11 is changed to “A03”, and the identification code of the setting sheet S13 corresponding to the detection area A13 is changed to “C01”.

  When setting the detection area after the change, the setting operator first sets the setting sheet S11 with the identification code “A03” and the setting sheet S12 with the identification code “B02” as shown in FIG. Then, the setting sheet S13 whose identification code is “C01” and the setting sheet S14 whose identification code is “D04” are arranged at desired positions on the shelf board 53. When the setting operator inputs a setting command to the detection device 2 using the input device 3, the setting unit 7 of the detection device 2 activates the distance image sensor 1 based on the setting command, and the shelf board which is a work area 53 two-dimensional images are taken. At this time, the setting unit 7 detects the positions, shapes, and sizes of the setting sheets S11 to S14 by performing image processing (edge detection, labeling processing, etc.) on the two-dimensional image captured by the distance image sensor 1. . The setting unit 7 extracts the identification code displayed on the setting sheets S11 to S14 by performing image processing (pattern matching or the like) on the two-dimensional image. Then, the setting unit 7 detects the areas where the setting sheets S11, S12, S13, and S14 are placed based on the alphabets of the identification codes, as detection areas A11, Set as A12, A13, and A14 (see FIG. 2D). The setting unit 7 sets the detection order of the detection areas A11 to A14 in the order of A13 → A12 → A11 → A14 based on the number of the identification code.

  The setting unit 7 displays the setting content on the monitor 6 when the changed detection area and the detection order are set as described above. When the setting operator confirms the setting contents displayed on the monitor 6 and inputs setting completion using the input device 3, the setting unit 7 detects the changed detection area and its detection based on the setting completion input. The setting contents of the order are stored in the storage unit 9, and the setting process is terminated. After that, when the inspection apparatus starts the inspection process, the inspection apparatus 2 executes the inspection process of the work content according to the changed detection area and the detection order stored in the storage unit 9.

  As described above, in the setting method of the present embodiment, since the detection areas and the detection order are set using the setting sheets S11 to S14 respectively corresponding to the detection areas A11 to A14, it is easy to change the detection order. It can correspond to. In addition, when the workpiece detected in each detection area is changed, if the detection area is set using the setting sheet in which the type information included in the identification code is changed, the detection is detected in each detection area. The type of workpiece can be easily changed.

  Moreover, if the detection method of this embodiment is used, the operation | work which changes the range (shape and magnitude | size) of each detection area | region A11-A14 can also be performed easily.

  As shown in FIG. 3 (a), setting sheets S11, S12, S13, and S14 are arranged on a shelf 53 as a work area, and the corresponding detection areas A11, A12, A13, and A14 are positioned by the setting method described above. And the range is set as shown in FIG. Here, “01”, “02”, “03”, and “04” are displayed as identification codes on the setting sheets S11, S12, S13, and S14, respectively. The identification code consists of two numbers, and this identification code indicates the detection order and includes information on the workpieces W11, W12, W13, and W14 that are detection targets. Thus, the setting unit 7 detects the detection order of the corresponding detection areas A11, A12, A13, and A14 and the detection areas based on the identification codes assigned to the setting sheets S11, S12, S13, and S14. The detection target in is set respectively.

  Here, the case where the ranges (shape and size) of the detection areas A11, A12, A13, and A14 are changed will be described below. In this case, the detection order of the detection areas A11 to A14 and the detection target workpiece are not changed, and only the ranges of the detection areas A11, A12, A13, and A14 are changed.

  The setting operator prepares setting sheets S21, S22, S23, and S24 having shapes and sizes respectively corresponding to the detection areas A11, A12, A13, and A14 after the change (see FIG. 3D). Since there is no change in the detection order of the detection areas A11 to A14 and the workpieces to be detected, the setting sheets S21, S22, S23, and S24 have identification codes “01”, “02”, “03”, and “04”, respectively. Numbers are attached. Then, as shown in FIG. 3C, the setting operator arranges setting sheets S21, S22, S23, and S24 at positions corresponding to the changed detection areas A11, A12, A13, and A14, respectively.

  Thereafter, when the setting operator inputs a setting command to the detection device 2 using the input device 3, the setting unit 7 of the detection device 2 activates the distance image sensor 1 based on the setting command, and the shelf board which is a work area 53 two-dimensional images are taken. At this time, the setting unit 7 detects the position, shape, and size of the setting sheets S21 to S24 by performing image processing (edge detection, labeling processing, etc.) on the two-dimensional image captured by the distance image sensor 1. . The setting unit 7 extracts the identification code displayed on the setting sheets S21 to S24 by performing image processing (pattern matching or the like) on the two-dimensional image. Then, based on the extracted identification code, the setting unit 7 determines the areas where the setting sheets S21, S22, S23, and S24 are placed, as detection areas A11, W11, W13, and W14 corresponding to the workpieces W11, W12, W13, and W14, respectively. Set as A12, A13, A14. The setting unit 7 sets the detection order of the detection areas A11 to A14 in the order of A11 → A12 → A13 → A14 based on the extracted identification code.

  As described above, in the setting method of the present embodiment, the detection areas and the detection order thereof are reset using the setting sheets S21 to S24 having shapes and sizes respectively corresponding to the detection areas A11 to A14 after the change. Therefore, it is possible to easily cope with a change in the range (shape and size) of the detection area.

  As described above, the setting method of the present embodiment includes the distance image sensor 1, the detection device 2, the notification device (the sound output device 4 and the irradiation device 5), and the setting device (setting unit 7). It is a setting method of a work detection system. The distance image sensor 1 outputs a distance image of the work area. The detection device 2 targets a work subject appearing in the distance image or a work handled by the work subject, and outputs a notification command when an abnormality in the work content is detected based on the distance image. The notification device performs a notification operation when a notification command is input. The setting device sets a plurality of detection areas in which the detection device 2 detects the presence / absence of the detection target and the detection order thereof in the distance image. In this setting method, the work area is set in the two-dimensional camera in a state where the setting sheet formed with the same size as the detection area to be set and attached with the identification code including the detection order information is arranged in the work area. The distance image sensor 1 is also used for photographing. The setting device detects the position of the setting sheet arranged in the work area and the identification code attached to the setting sheet by analyzing the image of the two-dimensional camera. The setting device sets a detection area based on the detected position and range of the setting sheet, and sets a detection order based on an identification code attached to the setting sheet. To do.

  Accordingly, when the setting sheet is photographed with the two-dimensional camera in a state where the setting sheet is placed in the desired detection area, the setting device analyzes the image of the two-dimensional camera, thereby setting the detection area and its detection order. Therefore, the setting operator can set the detection area and the detection order simply by placing a setting sheet having a shape and size matching the range of the detection area at a desired position and photographing the state with a two-dimensional camera. Therefore, it is possible to easily set the detection area and the detection order.

  In this setting method, the identification code includes the type information of the workpiece detected in the corresponding detection area, and the setting device detects in the corresponding detection area based on the identification code attached to the setting sheet. It is also preferable to set the type of workpiece to be processed.

  As a result, even when the type of workpiece detected in each detection area is changed, the setting sheet with the identification code with the changed type information can be used to easily handle the type change of the workpiece. can do. In addition, if component information such as height, area, and shape is registered in advance in the storage unit 9 for a plurality of types of workpieces, the setting device stores the component information of the workpieces to be detected in each detection area from the storage unit 9. Can be read. Therefore, there is no need for an operator to input workpiece part information or a process for detecting and registering workpiece part information placed in each detection area from a two-dimensional image or a distance image.

  In addition, the work detection system of the present embodiment uses any of the setting methods described above, the distance image sensor 1, the detection device 2, the notification device (the sound output device 4 and the irradiation device 5), and the setting device (setting). Unit 7) and a two-dimensional camera (shared with the distance image sensor 1).

  Thereby, the operation | work detection system which can set a detection area and a detection order easily is realizable.

  In the setting method of the present embodiment, the workpiece detection area and the detection order are set. However, workpiece height information detected in the detection area can also be set.

  First, as shown in FIG. 4A, the setting worker arranges setting sheets S11, S12, S13, and S14 on the shelf board 53 that is a work area, and the corresponding detection areas A11 and A12 by the setting method described above. , A13, A14 and the detection order thereof. Next, as shown in FIG. 4B, the setting operator puts the workpieces W11, W12, W13, and W14 detected in each detection area on the setting sheets S11, S12, S13, and S14, and then inputs them. A registration command for registering workpiece height information is input using the apparatus 3. At this time, the setting unit 7 of the detection device 2 activates the distance image sensor 1 based on the registration command, and captures a distance image of the shelf board 53 that is a work area. And the setting part 7 is based on the distance image imaged by the distance image sensor 1, and the height dimension of the workpiece | work W11, W12, W13, W14 arrange | positioned in each of detection area | region A11, A12, A13, A14, and The area value is detected and registered in the storage unit 9.

  Here, a method of detecting the height dimension and area value of the workpiece W11 from the distance image will be described taking the workpiece W11 as an example. 5A is a plan view of a state in which the work W11 is placed on the shelf board 53, and FIG. 5B is a side view of a state in which the work W11 is placed on the shelf board 53. In the setting unit 7, an upper limit value h2 and a lower limit value h3 of the height dimension and an upper limit value and a lower limit value of the area are set in advance for each of the workpieces W11 to W14. The setting unit 7 obtains the number of pixels whose height dimension is between the upper limit value h2 and the lower limit value h3 as the work area. The setting unit 7 extracts a group of pixels whose height dimension falls between the upper limit value h2 and the lower limit value h3, and determines the pixel group whose area falls between the upper limit value and the lower limit value as the work W11. Then, the setting unit 7 obtains the height dimension h1 of the workpiece W11 by obtaining the average value of the height dimensions that fall between the upper limit value h2 and the lower limit value h3 for this pixel group, and the pixels included in the pixel group Find the area from the number. The setting unit 7 performs the same process on the other workpieces W12 to W14 to obtain the height dimension and area, and stores the height dimension and area value of the workpieces W11 to W14 in the storage unit 9. Thereby, it is not necessary to register the accurate height information of the workpiece in the detection device 2 in advance, and the height information of each workpiece W11 to W14 is actually placed in a state where the workpieces W11 to W14 are placed in the detection area. Since it can be acquired, the setting effort is simplified.

1. Distance image sensor (two-dimensional camera)
2 Detection device 4 Sound output device (notification device)
5 Irradiation device (notification device)
7 Setting part (setting device)
53 Shelf A11-A14 Detection area S11-S14 Setting sheet W11-W14 Workpiece

Claims (3)

A distance image sensor that outputs a distance image of a work area, and a work subject appearing in the distance image or a work handled by the work subject is detected, and a notification command is output when an abnormality in work content is detected based on the distance image A detection device that performs a notification operation when the notification command is input, and a setting device that sets a plurality of detection areas and a detection order in which the detection device detects presence or absence of a detection target in the distance image. A method for setting a work detection system comprising:
Each of the work areas is photographed with a two-dimensional camera in a state where a setting sheet formed with a size corresponding to the detection area to be set and attached with an identification code including detection order information is arranged in the work area.
The setting device detects the position and range of the setting sheet arranged in the work area and the identification code attached to the setting sheet by analyzing the image of the two-dimensional camera;
A work detection system that sets a detection area based on the detected position and range of the setting sheet and sets a detection order based on an identification code attached to the setting sheet. Setting method. The identification code includes type information of a workpiece detected in the corresponding detection area,
2. The work detection system setting method according to claim 1, wherein the setting device sets a type of a work detected in a corresponding detection area based on an identification code attached to the setting sheet. .   A work detection system using the setting method according to claim 1, wherein the distance image sensor, the detection device, the notification device, the setting device, and the two-dimensional camera A work detection system comprising:

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