JP6385091B2 - Industrial robot system monitoring device, monitoring method, and monitoring program - Google Patents

Description

  The present invention relates to a monitoring device for monitoring the status of an industrial robot system that requires human work.

  In recent years, industrial robots have been put into practical use in various fields. Among industrial robots, welding robots are particularly in high demand. For example, spot welding robots that perform spot welding of thin sheet metal are used in car body welding lines of automobiles. Such a robot control system for an automobile production line can fully automate the operation from the start to the end by omitting the maintenance work of the operating operator. For example, Patent Document 1 discloses a robot control system connected via a network so as not to interfere with robot operation.

  On the other hand, arc welding robots are used for welding large welded structures such as construction machines, steel frames, and marine engine frames. Such an arc welding robot of a large structure requires several hours from the start of operation to the end of product construction to perform a thick plate welding operation, and requires maintenance work by the operator during that time. The operator performs work posture changing work such as work reversal and nozzle cleaning work during welding work, for example.

JP 2004-306200 A

  By the way, in order to improve the work efficiency of the arc welding robot system as described above, it is necessary to grasp the work time and work contents of the robot and the work time and work contents of the operator. In view of this, it is conceivable to take a video of the main body of the robot and the work situation and analyze the captured video.

  However, this method has a problem that analysis takes enormous time, and the monitoring target is only the robot body and work time, and the operator's work content cannot be accurately grasped. This problem is common to not only arc welding robots but also industrial robots that require human work during robot operation.

  Therefore, the present invention has been made to solve such problems, and it is possible to improve the work efficiency by grasping the respective work time and work contents of industrial robots and people who need work by people. The purpose is to connect.

  In order to solve the above problems, an industrial robot system monitoring apparatus according to an aspect of the present invention performs at least one operation corresponding to the application (hereinafter referred to as an application-compatible operation) and is performed by one or more people. An industrial robot that requires maintenance work, an operation input unit for inputting a start operation or stop operation of the robot by a human, and the robot according to the start operation or stop operation input by the operation input unit A monitoring device that monitors an operation status of an industrial robot system, comprising: a control unit that starts or stops and controls the operation of the robot so that the robot performs the application-compatible operation according to a preset operation program; And based on the operation of the robot in accordance with the operation program, A first work acquisition unit that acquires data including a work time of one or more first works performed by the robot, and the application corresponding to at least the start or stop of the robot according to the start operation or the stop operation A second work acquisition unit that acquires data including a work time of one or more second work performed by a person among the work and the maintenance work, and each work data acquired by the first and second work acquisition units is stored. A storage unit; and a data output unit that outputs each work data stored in the storage unit.

  According to the above configuration, in an industrial robot system that requires human work, the time required for human (operator) work together with the time required for robot work based on each work time output by the data output unit. Therefore, it becomes easy to grasp the operation rate of the robot and useless work by humans. Thereby, it can lead to the improvement of the working efficiency of the whole system.

  The industrial robot may be an arc welding robot, and the first work data may include an arc time in an arc welding operation of the robot.

  With the above configuration, when the present system is applied to an arc welding robot, it is possible to calculate an arc time rate and improve work efficiency. For example, the present system may be applied to an arc welding robot for a large-sized welded structure such as a frame block of a marine diesel engine.

  The first work data may include a sensing time of a sensing operation of the arc welding robot, and the second work data may include a work time and a correction amount of the sensing misalignment confirmation and correction work performed by a person. Good.

  In general, an arc welding robot that welds a large welded structure requires a sensing operation such as touch sensing before welding. Checking and correcting the misalignment of touching sensing is an operation to visually check whether the actual target position detected by touch sensing has been misaligned due to the bending of the wire, etc., and to correct the misalignment of the tip position of the welding torch. is there. The positional deviation has a great influence on the welding quality. For this reason, in order to ensure a certain welding quality, position confirmation and correction work by a person are effective means. The sensing operation includes not only touch sensing but also sensing operation using other known sensor technologies such as laser sensing and camera image sensing.

  With the above configuration, it is possible to accurately grasp the time required for the positional deviation confirmation and correction work by the field operator accompanying the sensing operation of the arc welding robot. This facilitates the grasp and reduction of useless work by the field operator.

  In addition, by acquiring the target position deviation correction amount, the correction tendency of the target position can be grasped and used as correction data for automatic correction. This eliminates the need for operator work.

  The second work data may include a work time of a nozzle cleaning work of a welding torch performed by a person. With the above-described configuration, the time required for the nozzle cleaning work of the welding torch by the field operator can be accurately grasped, so that it is easy to grasp and reduce wasteful work by the field operator. When the robot automatically performs the nozzle cleaning work, the nozzle cleaning work time by the robot may be acquired.

  The second work data may include a work time of a work reversing work performed by a person. With the above configuration, the time required for the work reversing work by the field operator can be accurately grasped, so that it is easy to grasp and reduce wasteful work by the field operator.

  You may further provide the work notification part which notifies outside that it is necessary to start the said 2nd operation | work and the time to the time which the said 2nd work should start.

  With the above configuration, the operator who is doing another work is ready to operate the robot for sensing misalignment confirmation and correction work of the arc welding robot, work reversing work, and nozzle cleaning work, reducing lead time Can be connected. For example, the time up to the time at which work should be started may be digitally displayed and counted down. Moreover, you may display simply the time required for starting (for example, work is needed after 10 minutes).

  An error information acquisition unit that acquires information about error contents that occurred during the first operation of the robot, and an error notification unit that notifies the error contents acquired by the error information acquisition unit to the outside Good.

  With the above-described configuration, the operator can make appropriate preparations according to the content of the error that occurred during the robot operation and shift to the recovery operation. Here, the first work of the robot may include an automatic nozzle cleaning work or an air cut operation in addition to arc welding and touch sensing.

  In the error state of the arc welding robot, the second work data includes a work start waiting time until a person starts recovery work and error recovery performed by a person after notifying the error content to the outside by the error notification unit. The work time of the work may be included.

  With the above configuration, even when an error occurs during the work of the arc welding robot, it is possible to accurately grasp the time required for the error recovery work by the field operator. It leads to reduction. In addition, it can be used to formulate standard work manuals for error recovery work.

  The information on the error content includes information on the error content and the location where the error occurred, and the error information acquisition unit may generate an error occurrence frequency map indicating the error content for each error location. With the above configuration, it is possible to investigate the cause of error occurrence and to take appropriate measures.

  The error information acquisition unit may create the error occurrence frequency map at regular intervals. With the above-described configuration, it is possible to grasp a change in the error frequency with time, so that it is possible to optimize the number of hardware maintenance in the robot system. The error occurrence frequency map may be created or updated every month or year, for example.

  The information on the error content may include information on the error content and the number of times of nozzle cleaning performed until the error occurs, and the error information acquisition unit may generate data on the number of times of nozzle cleaning for each error. With the above configuration, the number of nozzle cleanings can be optimized.

  The information regarding the error content may include information regarding the error content and the torch attitude when the error occurs, and the error information acquisition unit may generate data regarding the torch attitude for each error. With the above configuration, the torch posture can be changed or the torch posture can be optimized.

The monitoring method for an industrial robot system according to another aspect of the present invention is for industrial use that performs one or more work corresponding to the application (hereinafter referred to as application-compatible work) and requires maintenance work by one or more people. A robot, an operation input unit for inputting a start operation or a stop operation of the robot by a person, and the robot starts or stops according to the start operation or the stop operation input by the operation input unit, and is set in advance And a control unit that controls the operation of the robot so that the robot performs the application-compatible operation according to the operation program, wherein the first operation acquisition unit monitors the operation status of the industrial robot system. By the above-mentioned operations corresponding to the use and maintenance work based on the operation of the robot according to the operation program The step of acquiring data including the work time of one or more first operations performed by the robot, and the second operation acquisition unit based on at least the start or stop of the robot according to the start operation or the stop operation. A step of acquiring data including a work time of one or more second operations performed by a person out of the use-response operation and the maintenance operation, and each operation data acquired by the first and second operation acquisition units is stored in the storage unit. A step of outputting each work data stored in the storage unit by a data output unit;
including.

  An industrial robot system monitoring program according to another aspect of the present invention is an industrial program that performs one or more tasks corresponding to the application (hereinafter referred to as application-compatible operations) and requires maintenance work by one or more people. A robot, an operation input unit for inputting a start operation or a stop operation of the robot by a person, and the robot starts or stops according to the start operation or the stop operation input by the operation input unit, and is set in advance A monitoring program for causing a computer to execute a monitoring method for monitoring an operation status of an industrial robot system comprising: a control unit that controls the operation of the robot so that the robot performs the application-compatible operation in accordance with the operated operation program. Then, the first work acquisition unit performs the application pair based on the operation of the robot according to the operation program. Of the work and the maintenance work, the step of obtaining data including the work time of one or more first work performed by the robot, and the second work obtaining unit, at least according to the start operation or the stop operation A step of acquiring data including a work time of one or more second operations performed by a person out of the application-compatible operation and the maintenance operation based on activation or stop of the robot, and acquisition by the first and second operation acquisition units The computer is caused to execute a step of storing each work data in the storage unit and a step of outputting each work data stored in the storage unit by the data output unit.

  The monitoring program may be executed by a robot control device of an industrial robot system. In other words, by adding the monitoring program to the basic operation program that realizes robot control, operation input, etc., it is possible to add the monitoring function of the robot system in the robot control device, so the cost and maintenance of additional equipment are unnecessary. Besides, customization is also easy.

  ADVANTAGE OF THE INVENTION According to this invention, the data which lead to work efficiency improvement can be acquired by grasping | ascertaining each work time and work content by the industrial robot and person who require work by a person.

FIG. 1 is a configuration diagram of a system in which a monitoring device for an industrial robot system according to an embodiment of the present invention is mounted. FIG. 2 is a block diagram showing a specific configuration of the control device (monitoring device) of FIG. FIG. 3 is a perspective view showing an appearance of the control device of FIG. FIG. 4 is a flowchart showing the flow of the robot operation and monitoring process of the control device of FIG. FIG. 5 is a flowchart showing the flow of processing when an error occurs in FIG. FIG. 6 is a table showing an example of acquired data stored in the control device (monitoring device) of FIG. FIG. 7 is a graph illustrating an example of an analysis result of acquired data collected by the control device (monitoring device) of FIG.

  Hereinafter, embodiments according to the present invention will be described with reference to the drawings.

[Constitution]
FIG. 1 is a configuration diagram of a system in which an industrial robot system monitoring apparatus according to the present embodiment is mounted. As shown in FIG. 1, an industrial robot system (hereinafter simply referred to as a robot system) 100 includes a robot 1, a control device 2, a welding power source 3, a robot moving device 4, an alarm device 5, and a display device. 6, a system control device 7, and a data collection device 8. In the present embodiment, the monitoring device 2a of the robot system 100 is mounted on the control device 2.

The robot 1 is not particularly limited as long as it is an industrial robot that requires human work. In the present embodiment, an arc welding robot is exemplified as such a typical industrial robot. The robot 1 is an arc welding robot that welds the workpiece W with a welding torch 11 installed at the tip. The workpiece W is, for example, a large welded structure. Here, for example, it is a component block of a frame of a marine diesel engine having a height of 5 m and a plate thickness of 50 mm. The welding operation is alternately performed on both the back side and the front side of the workpiece W. In the present embodiment, the pair of robots 1 performs one or more first operations corresponding to arc welding (hereinafter also referred to as application-compatible operations). As in this embodiment, the robot 1 used for a large-sized welded structure requires a sensing operation such as touch sensing before welding. Here, the application corresponding work includes a touch sensing operation and an arc welding operation before welding. Although the sensing operation is touch sensing in the present embodiment, the robot 1 may perform sensing operation using other known sensor technologies such as laser sensing and camera image sensing.

Since the robot 1 performs multi-layer welding of thick plates, it requires one or more second operations by the field operator from the start to the end of operation. Here, the second work includes an auxiliary work such as a block reversing work in addition to a work for confirming and correcting a shift of the target position at the time of touching sensing, a maintenance work such as a nozzle cleaning work during welding.

  The work for correcting the deviation of the target position at the time of touching sensing is to confirm whether the actual target position detected by the touch sensing is not shifted due to the bending of the wire or the like, and to detect the deviation of the tip position of the welding torch 11. It is work to correct. Since the positional deviation has a great influence on the welding quality, in order to ensure a certain welding quality, the position confirmation and correction work by a person is an effective means. Specifically, with respect to the weld line to be welded, a typical teaching position is corrected with a teach pendant, and other teaching points are changed based on the correction amount.

  In addition, the arc welding robot may be temporarily stopped due to an error due to various factors such as poor energization due to welding slag and poor welding wire feedability. For this reason, the maintenance work includes an error recovery work by a field operator.

  The control device 2 controls the robot 1 and monitors the robot system 100. In the present embodiment, the control device 2 is composed of two robot controllers. The control device 2 records monitoring data including the measured work time as log data. The data collection device 8 acquires data from the control device 2. The control device 2 is configured by a controller such as a microcontroller, a PLC (programmable logic controller), and a processor, for example. In addition, the control device 2 may be configured by not only a single controller that performs centralized control but also a plurality of controllers that perform distributed control in cooperation with each other.

  The welding power source 3 supplies power to the welding torch of the robot 1. In the present embodiment, the welding power source 3 is controlled by the control device 2 and is configured to supply electric power to the welding torch 11 and the workpiece W of the robot 1. The robot 1 includes the tip of the welding torch 11 and the workpiece. The workpiece W is welded by an arc generated between it and W.

  The robot moving device 4 includes a mechanism for moving the robot 1. In the present embodiment, the robot moving device 4 is motor-controlled by the control device 2 and moves the position of the robot 1 in the vertical and horizontal directions.

  The alarm device 5 notifies the surrounding field operators that the robot 1 is in an error state. In the present embodiment, the alarm device 5 is controlled by a signal from the control device 2 and notifies an error by a Patlite (registered trademark) light and a melody horn alarm. The error of the robot 1 may be notified by other means.

  The display device 6 displays the state of the robot 1 to surrounding field operators. While the alarm device 5 notifies an error state, the display device 6 displays not only an error state but also a normal state. In the present embodiment, the display device 6 is controlled by the system control device 7 based on a signal from the control device 2, displays character information with an electric light indicator, and notifies the site operator of the state of the robot 1. For example, by displaying error details such as “Error occurrence”, “Arc out”, “Touch sensing failure”, “Touch sensing position adjustment”, “Nozzle cleaning”, “Work reversal”, etc. Encourage operation or work. Further, as the display device 6, the state of the robot 1 may be displayed by another display device such as an LED or an LCD. Also, the time until the time when the work should be started may be digitally displayed and counted down.

  The system control device 7 is linked to the control device 2 and performs relay control of various devices such as the alarm device 5 and the display device 6 other than the robot 1 control in the robot system 100. The system control device 7 and the control device 2 may be configured as a single control device.

  The data collection device 8 collects data including the work time measured by the control device 2 from the control device 2, and displays or analyzes the collected data. In the present embodiment, the data collection device 8 is configured by a personal computer that is communicably connected to the robot control device 2. The data collection device 8 may be installed at the arc welding site, or may be installed at a management office away from the site. As long as the data collection device 8 has a communication function with the control device 2, the data collection device 8 may be composed of other communication terminals.

  FIG. 2 is a block diagram showing a specific configuration of the robot control device 2 of FIG. As shown in FIG. 2, the robot control device 2 includes an operation input unit 21, a control unit 22 that controls the robot 1, a first work acquisition unit 23 that acquires data including the work time of the robot 1, and a field operator A second work acquisition unit 24 that acquires data including the work time, an error information acquisition unit 25, a storage unit 26, and a data output unit 27.

  The operation input unit 21 is provided in order to input various operations that are necessary for starting operation or operation of the robot 1 by a person (site operator). In the present embodiment, the operation input unit 21 includes, for example, a touch panel, a display panel on which input operation buttons and a simple display device are attached. The field operator operates the display panel to perform various operations necessary for starting and operating the entire robot system.

  The control unit 22 starts or stops the robot 1 in accordance with the start operation or stop operation input by the operation input unit 21, and performs the work corresponding to the application according to the preset operation program. Control the behavior. The operation program is stored in an appropriate storage unit (for example, a dedicated storage unit or storage unit 26 not shown), and the control unit 22 reads out the operation program and executes a predetermined operation. In the present embodiment, the control unit 22 controls the operation of the robot 1 so that the robot 1 performs the arc welding operation and the touch sensing operation according to the operation program.

The first task acquisition unit 23 obtains the first operation data including the operation time of the first working of one or more of performing the previous SL robot based on the operation of the robot in accordance with the operation program. The work time is measured by, for example, a clock built in the above-described controller. In the present embodiment, the first work time includes the arc time in the arc welding operation of the robot 1 and the sensing time of the touch sensing operation before welding.

The second work acquisition unit 24 acquires second work data including a work time of one or more second works performed by a person based on at least the start or stop of the robot according to the start operation or the stop operation. To do. The work time is measured by, for example, a clock built in the above-described controller. In the present embodiment, the second work time is the waiting time for the operator until the on-site operator starts the error recovery work in the error state of the robot 1 and the work time of the touch sensing misalignment correction work, the nozzle cleaning work, and the robot 1 Including time, recovery work time and work reversal work time.

  The error information acquisition unit 25 acquires information regarding the content of an error that has occurred in the robot 1 from the control device 2. The error information acquisition unit 25 acquires information about the acquired error content (hereinafter also simply referred to as error information), that is, data to be notified to an external field operator through the alarm device 5 or the display device 6 of FIG.

  The storage unit 26 stores data including each work time acquired by the first work acquisition unit 23 and the second work acquisition unit 24. In the present embodiment, the storage unit 26 is a memory mounted inside the control device 2 and stores various data including error information.

  The data output unit 27 outputs various data stored in the storage unit 26. In the present embodiment, the data output unit 27 requests various data including each work time and error information stored in the storage unit 26 from the external data collection device 8 via the input / output interface provided in the control device 2. According to the output. These functional units 21 to 27 are functional blocks realized by the above-described controller operating according to predetermined software (program). In the present embodiment, the monitoring device 2a of the robot system 100 is realized by the first work acquisition unit 23, the second work acquisition unit 24, the error information acquisition unit 25, and the storage unit 26. That is, the monitoring function of the robot system 100 is added to the control device 2 by adding the monitoring program describing the functional blocks 23 to 27 to the basic operation program for realizing control of the robot 1 and operation input. This eliminates the expense and maintenance of additional equipment and is easy to customize.

  FIG. 3 is a perspective view showing the external appearance of the control device 2. As shown in FIG. 3, the control device 2 is housed in a dedicated frame 31 with casters, and includes an operation unit including an operation input unit 21 at the top of the main body. The display panel of the operation input unit 21 includes a control power switch, a control power lamp, a display meter for control power on time, a robot start / stop switch, a cycle start switch, an error lamp, an error release switch, an emergency stop switch, and the like. Is provided. An input / output interface connector 32 is provided on the side surface of the main body of the control device 2 to perform data communication with the data collection device 8.

[Operation]
Next, the monitoring method of the robot system 100 will be described using the operation method of the robot 1 and the flowchart of FIG. Monitoring processing such as measurement of work time is executed in parallel with normal operation of the robot 1 in the control device 2. The left side of FIG. 4 shows the operation flow of the robot 1, and the right side shows the monitoring flow.

  First, the site operator starts operating the robot 1. The site operator turns on the control power switch and the start switch of the operation input unit 21 of the control device 2. As a result, the robot system is activated and the robot 1 is switched to a repeatable (automatic) operable state.

  Next, the site operator inputs a work type with a teach pendant (not shown) and turns on the cycle start switch. Thereby, the robot 1 starts a repeat (automatic) operation. The control unit 22 controls the operation of the robot 1 so that the robot 1 performs an application corresponding operation according to a preset operation program. In the present embodiment, the robot 1 performs touch sensing before arc welding (step S1). The first work acquisition unit 23 starts measuring the cycle time when the repeat operation of the robot 1 is started (step S′1). Here, the cycle time is the time from the start to the end of the operation program (cumulative time / by block).

  On the other hand, the first work acquisition unit 23 measures the touch sensing time (step S′2). The touch sensing time is measured based on the touch sensing start and end signals output from the control device 2. When the touch sensing is finished, the robot 1 temporarily stops the operation according to the operation program. The control device 2 notifies the on-site operator that the touch sensing is completed through the display device 6 and waits for the on-site operator to correct the target position deviation (step S2). The site operator corrects the target position deviation of the robot 1 temporarily stopped by the operation program, and restarts the robot 1 after the work is completed. On the other hand, the second work acquisition unit 24 measures the time of the target position deviation correction work by the field operator (step S'3). Here, the time for the correction work is measured based on a touch sensing end (notification) signal output from the control device 2 and a start (restart) signal by the field operator. The control device 2 also measures a target misalignment correction amount.

  The robot 1 completes the misalignment correction work and starts the arc welding operation after the system is restarted (step S3). On the other hand, the first work acquisition unit 23 measures the arc time (step S′4). The arc time is measured based on a WCR (Weld Current Relay) signal output from the welding power source 3 to the control device 2.

  When arc welding of a certain number of welding lines is completed, the robot 1 temporarily stops the operation according to the operation program. The control device 2 notifies the site operator that the predetermined number of welding lines for arc welding has been completed through the display device 6, and waits for the nozzle cleaning operation of the welding torch by the site operator (step S4). The field operator cleans the nozzle of the welding torch of the robot 1 temporarily stopped by the operation program, and restarts the robot 1 after the work is completed. On the other hand, the second work acquisition unit 24 measures the work time of the nozzle cleaning work by the field operator (step S'5). The cleaning operation time is measured based on a stop signal and a start (restart) signal output from the control device 2 to the robot 1.

  Furthermore, in this embodiment, when the nozzle cleaning of the welding torch of the robot 1 is completed, it is determined whether or not the construction of all the welding lines on one surface of the workpiece has been completed (step S5). If the construction is incomplete, sensing of the incomplete weld line is performed (return to step 1). On the other hand, when the construction is completed, the control device 2 notifies the site operator through the display device 6 and waits for the work reversal work of the site operator (step S6). The site operator performs work reversal work after the robot 1 is temporarily stopped by the operation program, and restarts the robot 1 after the work is completed. On the other hand, the second work measuring unit 24 measures the work time of the work reversing work by the field operator (step S'6). The work reversing time is measured based on a stop signal and a start (restart) signal output from the control device 2 to the robot 1.

  And the said step is repeated until construction of all the welding lines of the workpiece | work W is complete | finished (S7). The cycle time measurement by the first work acquisition unit 23 ends with the end of the construction of all the weld lines of the workpiece W as a trigger (S'7).

  In the flowchart of FIG. 4, the sensing operation by the robot 1 and each operation by the field operator may be omitted as appropriate.

  FIG. 5 is a flowchart showing the flow of monitoring processing when an error occurs during operation of the robot. Here, the left side of FIG. 5 shows the operation flow of the robot 1, and the right side shows the monitoring flow. As shown in FIG. 5, when an error occurs during the operation of the robot 1 of FIG. 4 (touch sensing, arc welding, automatic nozzle cleaning, or air cut), the control device 2 includes an alarm device 5 and a display device. The error is notified to the field operator through 6 (step S21). Here, the control device 2 detects information on the error content based on the error detection signal. The error information acquisition unit 25 acquires information on the error content from the control device 2 and stores it in the storage unit 26.

  The control device 2 waits for the site operator to arrive and press the error release button (step 22). When the field operator arrives, he presses the error release button. The control device 2 cancels the system error. The second work measurement unit 24 measures the time from the occurrence of the error until the error is released as an operator waiting time based on the error detection signal and the error release signal (step S′22).

  Further, the control device 2 waits until the operator arriving at the work site performs the restoration work, presses the cycle start button after restoration, and restarts the system (step S23). The second work acquisition unit 24 measures the time from the error cancellation by the operator to the restart of the cycle start as an error recovery work time based on the error release signal and the cycle start activation signal (step S'23). Thereafter, the robot 1 resumes touch sensing, arc welding work, automatic nozzle cleaning, or air cut operation. The first work acquisition unit 23 and the second work acquisition unit 24 store measurement data including each measured work time in the storage unit 26 as log data.

  FIG. 6 is a table showing an example of measurement data stored in the storage unit 26 of the control device 2 of FIG. As shown in FIG. 6, the cycle time, arc time rate, error occurrence time, and error information are stored as measurement data related to the robot operation. Here, the cycle time is the time (cumulative time) from the start to the end of the construction program. The arc time rate is arc time / cycle time (%). The error occurrence time is the time (cumulative time) during which the error continues from the occurrence of the error. The error information is information relating to errors such as error occurrence date / time, error content, error occurrence location, and the like. The error occurrence location is information relating to the position of the robot, the traveling speed, the lift position, and the attitude of the welding torch when the error occurs. Although the arc time rate is calculated inside the control device 2, it may be calculated by the external data collection device 8 or another device as long as it has a calculation function.

  On the other hand, as shown in FIG. 6, the error recovery waiting time, the error recovery time, the operator operation waiting time, the target misalignment correction time, and the target misalignment correction amount are measured as measurement data related to the operator action. Here, the error recovery waiting time is the time from the occurrence of an error until the arrival of the operator. The error recovery time is the time from error reset to cycle start restart. The operator operation waiting time is the time required from a temporary stop (operator call) to a cycle start restart due to work reversal or the like.

  The target position deviation correction time is the time for manually correcting the target position deviation. The aim position deviation correction amount is a value obtained by correcting the aim position deviation, and is represented by three-dimensional coordinates (X, Y, Z). Thereby, since the correction tendency of the sensing target position can be grasped, the correction amount of the target position deviation can be used as correction data for automatic correction, and operator work can be eliminated.

  As described above, the control device 2 recognizes the signals and program variables acquired and output by the control unit 22 and records the signal ON period, the ON count, the error content, and the like in the storage unit 26 as log data. The data output unit 27 outputs various data including each work time and error information stored in the storage unit 26 in response to a request from the external data collection device 8 via an input / output interface provided in the control device 2.

  This makes it possible to accurately grasp the time required for the operator's work as well as the robot operation time (arc time rate, etc.) based on each work time output by the data output unit 27. Leads to the understanding and reduction. As a result, the work efficiency of the entire system is improved.

  Furthermore, according to the present embodiment, since a log such as a cycle time can be collected and recorded only by a minimum required operator operation, an operation intervention for acquiring a log by the field operator is not required.

  Further, since not only the operation of the robot 1 and equipment but also the on-site operator work time is logged, not only equipment malfunction but also wasteful work by the operator can be grasped and improved.

  In addition, since error information including device error contents and the position and orientation of the robot is automatically recorded inside the control device 2, it can be used as maintenance data. For example, the error information acquisition unit 25 may extract data relating to the error occurrence location and the error content shown in FIG. 6 and generate an error occurrence frequency map indicating the error content for each error occurrence. As a result, the cause of the error can be investigated and appropriate countermeasures can be taken. In addition, by creating such an error occurrence frequency map every certain period (for example, one month or one year), it is possible to recognize a change in the error frequency over time, which leads to optimization of the number of times of hardware maintenance. be able to.

  Moreover, the error information acquisition part 25 can clarify an improvement item by performing a statistical process also about other acquired data. For example, by counting the number of times of nozzle cleaning performed until an error occurs, the number of times of nozzle cleaning can be optimized.

  Also, data related to the torch posture at the time of the error occurrence shown in FIG. 6 can be extracted and used to change the torch posture or optimize the torch posture.

  Further, by extracting and using data related to the error recovery waiting time and the error recovery time shown in FIG. 6, it can be used to formulate a standard work manual for error recovery work.

  FIG. 7 is a graph showing an example of the analysis result of the monitoring data collected by the control device 2. As shown in FIG. 7, the upper graph (a) shows the construction time for each block when seven blocks (blk1 to blk7) form one engine frame. The construction time for each block is composed of operator work time and robot work time. In the arc welding robot of the present embodiment, since the arc time rate is an important index, the arc time is shown in the graph. The robot work time in the graph includes sensing time, air cut time, etc., excluding arc time. The operator work time includes time required for work reversal, error cancellation, manual aim position correction work, and manual cleaning work.

  The lower graph (b) shows the time ratio for each block. Here, the ratio of the construction time for every block about five blocks (blk1-blk5) is shown. Here, the construction time ratio indicates a ratio when the robot work time and the operator work time are compared.

  Thus, by graphing the log data with software, each work time can be grasped more easily and clearly. The work efficiency of the entire system can be easily improved.

  The workpiece W of the robot system according to the present embodiment is a marine engine frame, but is not limited thereto, and may be a metal structure such as a construction machine or a building as long as it is a welded structure. .

  The robot 1 according to the present embodiment is an arc welding robot. However, the present invention is not limited to this, and any other industry may be used as long as it requires maintenance work by an operator from the start to the end of operation. It may be an industrial robot.

  In the present embodiment, the nozzle cleaning operation is performed by the site operator. However, the robot may automatically perform the nozzle cleaning operation, and the nozzle cleaning operation time by the robot may be included in the measurement data.

  From the foregoing description, many modifications and other embodiments of the present invention are obvious to one skilled in the art. Accordingly, the foregoing description should be construed as illustrative only and is provided for the purpose of teaching those skilled in the art the best mode of carrying out the invention. The details of the structure and / or function may be substantially changed without departing from the spirit of the invention.

  The present invention can be used for an arc welding robot for welding a large-sized welded structure.

DESCRIPTION OF SYMBOLS 1 Robot 2 Robot control apparatus 3 Welding power supply 4 Robot moving apparatus 5 Alarm apparatus 6 Display apparatus 7 System control apparatus 8 Data collection apparatus 11 Torch main body 12 Wire supply apparatus 21 Operation input part 22 Control part 23 1st work acquisition part 24 2nd Work acquisition unit 25 Error information acquisition unit 26 Storage unit 27 Data output unit 31 Dedicated frame 32 of control device Input / output interface connector 100 Industrial robot system W Workpiece

Claims (14)

An industrial robot that performs one or more first operations corresponding to the application of the industrial robot and requires a second operation including a maintenance operation and an auxiliary operation by one or more people, and a starting operation of the robot by a person Alternatively, an operation input unit for inputting a stop operation, and the robot is started or stopped according to a start operation or a stop operation input by the operation input unit, and the robot is operated according to a preset operation program. A monitoring device for monitoring the work status of an industrial robot system, comprising: a control unit that controls the operation of the robot so as to perform the work of 1;
A first work acquisition unit that acquires first work data including a work time of one or more of the first works performed by the robot based on an action of the robot according to the action program;
A second work acquisition unit that acquires second work data including a work time of one or more of the second work performed by a person based on at least the start or stop of the robot according to the start operation or the stop operation; ,
A storage unit for storing the first work data and the second work data acquired by the first and second work acquisition units;
A data output unit for outputting the first work data and the second work data stored in the storage unit;
An industrial robot system monitoring device comprising: The industrial robot is an arc welding robot,
The industrial robot system monitoring device according to claim 1, wherein the first work data includes an arc time in an arc welding operation of the robot. The first work data includes a sensing time of a sensing operation of the arc welding robot,
The industrial robot system monitoring apparatus according to claim 2, wherein the second work data includes a work time and a correction amount of the sensing misalignment confirmation and correction work performed by a person.   The industrial robot system monitoring device according to claim 2, wherein the second work data includes a work time of a nozzle cleaning work of a welding torch performed by a person.   The industrial robot system monitoring device according to claim 2, wherein the second work data includes a work time of a work reversing work performed by a person.   The work notification unit according to any one of claims 3 to 5, further comprising a work notification unit that notifies the outside that the start of the second work is necessary and the time until the time at which the second work should be started. Industrial robot system monitoring device. An error information acquisition unit for acquiring information on error contents generated during the first operation of the robot;
The industrial robot system monitoring apparatus according to any one of claims 1 to 3, further comprising an error notification unit configured to notify an error content acquired by the error information acquisition unit to the outside. The second work data includes the work start waiting time until the person starts recovery work and the error recovery work performed by the person after the error notification unit notifies the outside of the error in the error state of the robot . The monitoring apparatus for an industrial robot system according to claim 7, comprising a work time. The information on the error content includes information on the error content and the location where the error occurred,
The industrial robot system monitoring apparatus according to claim 7, wherein the error information acquisition unit generates an error occurrence frequency map indicating an error content for each error occurrence place.   The industrial robot system monitoring apparatus according to claim 9, wherein the error information acquisition unit creates the error occurrence frequency map at regular intervals. The information on the error content includes information on the error content and the number of nozzle cleanings performed until the error occurred,
The industrial robot system monitoring apparatus according to claim 7, wherein the error information acquisition unit generates data related to the number of times of nozzle cleaning for each error. The information on the error content includes information on the error content and the torch attitude when the error occurs,
The industrial robot system monitoring apparatus according to claim 7, wherein the error information acquisition unit generates data relating to a torch posture for each error. An industrial robot that performs one or more first operations corresponding to the application of the industrial robot and requires a second operation including a maintenance operation and an auxiliary operation by one or more people, and a starting operation of the robot by a person Alternatively, an operation input unit for inputting a stop operation, and the robot is started or stopped according to a start operation or a stop operation input by the operation input unit, and the robot is operated according to a preset operation program. A monitoring method for monitoring a work status of an industrial robot system comprising: a control unit that controls the operation of the robot so as to perform the work of 1;
Acquiring, by a first work acquisition unit, first work data including a work time of one or more of the first works performed by the robot based on the action of the robot according to the action program;
The second work acquisition unit acquires second work data including a work time of one or more second works performed by a person based on at least the start or stop of the robot according to the start operation or the stop operation. And steps to
Storing the first work data and the second work data acquired by the first and second work acquisition units in a storage unit;
Outputting the first work data and the second work data stored in the storage unit by a data output unit;
A method for monitoring an industrial robot system, including: An industrial robot that performs one or more first operations corresponding to the application of the industrial robot and requires a second operation including a maintenance operation and an auxiliary operation by one or more people, and a starting operation of the robot by a person Alternatively, an operation input unit for inputting a stop operation, and the robot is started or stopped according to a start operation or a stop operation input by the operation input unit, and the robot is operated according to a preset operation program . A monitoring program for causing a computer to execute a monitoring method for monitoring an operation status of an industrial robot system comprising: a control unit that controls the operation of the robot so as to perform the operation of 1 .
Acquiring, by a first work acquisition unit, first work data including a work time of one or more of the first works performed by the robot based on the action of the robot according to the action program;
The second work acquisition unit acquires second work data including a work time of one or more second works performed by a person based on at least the start or stop of the robot according to the start operation or the stop operation. And steps to
Storing the first work data and the second work data acquired by the first and second work acquisition units in a storage unit;
Outputting the first work data and the second work data stored in the storage unit by a data output unit;
Industrial robot system monitoring program that causes computers to execute.

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