JP7046226B2 - Automatic welding system, manufacturing method of elevator car room parts, and automatic welding method - Google Patents

Description

The present invention relates to an automatic welding system for welding a workpiece to be welded, a method for manufacturing an elevator car chamber part, and an automatic welding method.

As a conventional automatic welding system, NC (Numerical Control) data generated by a CAM (Computer-Aided Manufacturing) system is obtained from CAD (Computer-Aided Design) data including information such as the shape and mounting position of an object to be welded. , A system that corrects by the measurement result regarding the installation position of the object to be welded by a sensor such as a camera is known (see, for example, Patent Document 1 and Patent Document 2).

Japanese Unexamined Patent Publication No. 2002-336994 Japanese Unexamined Patent Publication No. 7-23310

In such an automatic welding system, it is necessary to prepare CAD data in which welding position information of each work is described. However, when the dimensions and welding position change depending on the specifications required by the customer, such as the panel shape member of an elevator, it is necessary to prepare CAD data for each specification. Therefore, when applying the conventional automatic welding system, there is a problem that it takes time and effort.

In addition, when applying the method of sensing the welding position with a sensor such as a camera and welding to a product such as a large structure with many welding points and a huge amount of data, sensing is performed for a long time. There is a problem that it is necessary and productivity does not improve.

The present invention has been made to solve the above-mentioned problems, and even when the work size and the welding position change depending on the required specifications of the customer, CAD data corresponding to each required specification is prepared. It is an object of the present invention to obtain an automatic welding system, a method for manufacturing elevator cage parts, and an automatic welding method capable of improving the workability for welding of various workpieces to be welded without need.

In the automatic welding system according to the present invention, the data storage unit and the welding of the work to be welded are stored in association with the drawing number of the work to be welded and the dimensional data necessary for calculating the welding position of the work to be welded. A calculation unit that calculates the position, a camera that can shoot the welding position of the work to be welded, an actual installation position of the work to be welded obtained from the shooting results by the camera , and the work to be welded obtained from the welding position calculated by the calculation unit . Equipped with an image processing device that compares the regular installation position and calculates the amount of installation error, which is the difference between the regular installation position and the actual installation position, and a welding machine that welds the welding position calculated by the calculation unit . , The standard drawing corresponding to the drawing number includes a calculation formula for deriving the drawing variable related to the welding position from the dimensional data, and the calculation unit is a drawing variable and dimensional data corresponding to the drawing number output from the data storage unit. The welding position of the work to be welded is calculated based on the above, and the welding position after correction is calculated by recalculating the welding position based on the installation error amount calculated by the image processing device, and based on the welding position after correction. The welding machine is made to perform welding of the work to be welded.
Further, the method for manufacturing an elevator car room part according to the present invention is a method for manufacturing an elevator car room part using the automatic welding system according to the present invention, and the work to be welded is a floor plate which is an elevator car room part. It is either the ceiling, the door of the car, or the wall of the car room.
Further, in the automatic welding method according to the present invention, the welding position of the work to be welded is calculated using a calculation formula for deriving drawing variables related to the welding position based on the drawing number and dimensional data output from the data storage unit. Comparison between the actual installation position of the work to be welded obtained from the shooting result by a camera capable of photographing the welding position of the work to be welded and the regular installation position of the work to be welded obtained from the calculated welding position. Then, the corrected welding position is calculated by recalculating the welding position based on the process of calculating the installation error amount, which is the difference between the regular installation position and the actual installation position, and the calculated installation error amount. It includes a process and a welding process in which a welding machine executes welding of the work to be welded based on the welded position after correction.

According to the automatic welding system according to the present invention, even when the work size and the welding position change depending on the required specifications of the customer, it is not necessary to prepare the CAD data corresponding to each required specification, and the work to be welded can be subjected to various works. It is possible to obtain an automatic welding system, a method for manufacturing elevator cage parts, and an automatic welding method that can improve the workability of welding.

It is a perspective view of the elevator car room manufactured by the welding method according to Embodiment 1 of this invention. It is explanatory drawing of the component of the elevator car chamber manufactured by the welding method by Embodiment 1 of this invention. It is a figure which shows the whole structure of the automatic welding system which concerns on Embodiment 1 of this invention. It is a schematic diagram which showed another structure for expanding the reach range of the welding robot in Embodiment 1 of this invention. It is a schematic diagram which shows the exchange of information between each component in the automatic welding system by Embodiment 1 of this invention. It is a flowchart which shows the flow of the series of welding processing by the automatic welding system which concerns on Embodiment 1 of this invention. It is a figure which shows the relationship of the calculation formula associated with the drawing number by Embodiment 1 of this invention. It is a schematic diagram which showed the specific example of the work to be welded by Embodiment 1 of this invention. It is explanatory drawing which showed the specific example of the calculation formula about the dimension, the installation position, and the welding position of the reinforcing member according to Embodiment 1 of this invention. It is explanatory drawing which showed the specific example of the calculation formula about the dimension, the installation position, and the welding position of the reinforcing member according to Embodiment 1 of this invention. It is a top view of the work to be welded according to Embodiment 1 of this invention. It is a front view of the work to be welded according to Embodiment 1 of this invention. It is explanatory drawing which excerpted a part of the welding instruction by Embodiment 1 of this invention. It is a schematic diagram of the image taken by the camera by Embodiment 1 of this invention. It is explanatory drawing of the welding position correction method by Embodiment 1 of this invention. It is a schematic diagram of the butt welding according to Embodiment 2 of this invention. It is explanatory drawing of the welding condition by Embodiment 3 of this invention. It is explanatory drawing of the detailed welding condition by Embodiment 3 of this invention. It is a perspective view of the clamp jig according to Embodiment 4 of this invention. It is explanatory drawing which showed the correspondence of the welding position and the clamp position by Embodiment 4 of this invention.

Hereinafter, a preferred embodiment of the automatic welding system, the method for manufacturing elevator car chamber parts, and the automatic welding method according to the present invention will be described with reference to the drawings.

Embodiment 1.
FIG. 1 is a perspective view of an elevator car chamber 400 manufactured by the manufacturing method according to the first embodiment of the present invention. Further, FIG. 2 is an explanatory diagram of components of an elevator car chamber manufactured by the welding method according to the first embodiment of the present invention. As shown in FIGS. 1 and 2, the car room 400 is composed of a combination of a ceiling 401, a car door 402, a car room wall 403, and a floor plate 404.

FIG. 3 is a diagram showing the overall configuration of the automatic welding system according to the first embodiment of the present invention. The automatic welding system according to the first embodiment includes a server 10 as a data storage unit, a computer 20 as a calculation unit, an image processing device 30, and a welding machine 100. Then, the automatic welding system according to the first embodiment welds the work to be welded 200 mounted on the welding stage 300.

Software for calculating the welding position of the work 200 to be welded is installed in the computer 20 connected to the server 10. The computer 20 causes the welding machine 100 to perform welding of the work to be welded 200 based on the calculated welding position.

The welding machine 100 includes a welding robot 110 as a robot and a robot control device 140 as a control device. A welding torch 120 and a camera 31 are attached to the tip of the manipulator 111 corresponding to the arm of the welding robot 110. As the manipulator 111, a manipulator having 6 drive shafts is used. As another configuration example, a 7-axis manipulator or a 3-axis to 5-axis manipulator can also be used.

The welding robot 110 is installed on the movable stage 130. The position control and motion control of the welding robot 110, the welding torch 120, the movable stage 130, and the camera 31 are performed by the robot control device 140. The robot control device 140 is connected to the computer 20 and the image processing device 30.

The camera 31 is connected to the image processing device 30. The camera 31 can photograph the work 200 to be welded, and the photographed image is output to the image processing device 30 as a shooting result. The image processing device 30 can acquire information on the point cloud and contour from the image, and can detect the two-dimensional position or the three-dimensional position of the work to be welded 200 and the posture of the work to be welded 200 appearing in the image. As such a method of position detection and posture detection, any method can be used.

The welding robot 110 is installed so as to be arranged so that the work to be welded 200 can be welded by the welding torch 120 and the welding position of the work to be welded 200 can be photographed by the camera 31. ..

Here, it is assumed that the work 200 to be welded is a component constituting an elevator. In this case, the work to be welded 200 is a large structure having a maximum side of several meters, and the entire work to be welded 200 cannot be welded within the reach range of the normal welding robot 110.

Therefore, in FIG. 3, the welding robot 110 is installed on a movable stage 130 that can move the entire welding robot 110 in a direction perpendicular to the paper surface. With such a configuration, the reach range of the welding robot 110 can be expanded, and the entire work to be welded 200 can be welded by the welding torch 120.

Further, FIG. 4 is a schematic view showing another configuration for expanding the reach range of the welding robot 110 in the first embodiment of the present invention. As shown in FIG. 4, by suspending the welding robot 110 on a structure 131 that can move in the same manner as an overhead crane that can move in two horizontal directions, a larger work to be welded 200 can be welded.

Next, a series of flow of automatic welding by the automatic welding system according to the first embodiment will be described with reference to FIGS. 5 and 6. FIG. 5 is a schematic diagram showing the exchange of information between each component in the automatic welding system according to the first embodiment of the present invention. FIG. 5 shows each component of a server 10, a computer 20 equipped with welding position calculation software, an image processing device 30 connected to a camera 31, and a welding machine 100. These components are connected by a wired cable, a wireless radio wave, or the like. As a result, a local network has been constructed in the automatic welding system according to the first embodiment.

FIG. 6 is a flowchart showing a flow of a series of welding processes by the automatic welding system according to the first embodiment of the present invention. Hereinafter, the welding operation procedure in the first embodiment will be described according to the exchange of information between the components shown in FIG. 5 and the flowchart shown in FIG.

First, in step S601, the order number for specifying the work to be welded 200 is read by the barcode reader. Then, the read order number is transmitted to the server 10.

The server 10 stores the order number, the drawing number of the work to be welded 200 corresponding to the order number, and the dimensional data necessary for calculating the welding position of the work to be welded 200 in association with each other. In the following description, it is assumed that the vertical dimension and the horizontal dimension of the work to be welded 200 are stored in the server 10 as the dimensional data necessary for calculating the welding position.

After the order number is transmitted from the barcode reader to the server 10, in step S602, the server 10 extracts the drawing number and the vertical dimension and the horizontal dimension as the dimension data according to the input result of the order number. Further, in step S603, the server 10 transmits the extracted drawing number, the vertical dimension, and the horizontal dimension to the computer 20.

A calculation formula for calculating the welding position from the data of the vertical dimension and the horizontal dimension is installed in the computer 20 as the welding position calculation software according to each drawing number. That is, in the welding position calculation software, the parameters required for the calculation of the welding position are the vertical dimension and the horizontal dimension of the work to be welded 200. Therefore, in step S604, the computer 20 can calculate the welding position of the work to be welded 200 by substituting the vertical dimension and the horizontal dimension received from the server 10 into the calculation formula corresponding to the drawing number.

Next, in step S605, the computer 20 transmits a movement command including the calculated welding position information to the robot control device 140, and the robot control device 140 operates the manipulator 111 and uses the camera 31 to determine the welding position. Take a picture. Next, in step S606, the image processing device 30 acquires the image data taken by the camera 31. Further, the image processing device 30 calculates the amount of installation error, which is the difference between the regular installation position of the work to be welded 200 and the actual installation position.

Here, the image processing apparatus 30 can calculate the position where the work to be welded 200 should be originally installed as the regular installation position based on the welding position calculated by the computer 20. Further, the image processing device 30 can calculate the position where the work to be welded 200 is actually installed as the actual installation position by performing image processing on the image data acquired from the camera 31. Then, the image processing device 30 transmits to the computer 20 the amount of installation error calculated as the difference between the regular installation position and the actual installation position.

Next, in step S607, the computer 20 compares the installation error amount with the predetermined permissible error amount. Then, the computer 20 determines whether or not the installation error amount is within the allowable error amount, and if it is within the allowable error amount, proceeds to the next step S608.

On the other hand, when the installation error amount exceeds the permissible error amount, the computer 20 notifies the error and prompts the operator to move the work to be welded 200 to the correct position.

When the process proceeds to step S608, the computer 20 calculates the corrected welding position by recalculating the welding position based on the installation error amount calculated by the image processing device 30. That is, the computer 20 recalculates the weld position offset in consideration of the installation error amount as the corrected welding position.

Finally, in step S609, the computer 20 transmits the recalculated corrected welding position to the robot control device 140, and starts automatic welding by the welding robot 110.

Next, the details of each step shown in FIG. 6 will be described with reference to FIGS. 7 to 16. First, details of steps S601 to S603 will be described. FIG. 7 is a diagram showing the relationship between the calculation formulas associated with the drawing numbers according to the first embodiment of the present invention. The drawings Nos. A to C shown in FIG. 7 are standard drawings of the work 200 to be welded. The standard drawing data is stored in the storage device of the computer 20. As shown in FIG. 7, the work 200 to be welded is given a plurality of drawing numbers depending on the type.

Then, in each drawing, each calculation formula regarding the reinforcement length, the number of reinforcements, the pitch between reinforcements, and the welding position regarding the reinforcement member is given. As shown in FIG. 7, each calculation formula associated with the drawing number is stored in the computer 20 as welding position calculation software.

The parameters of these formulas are defined by the vertical and horizontal dimensions of the workpiece 200 to be welded. Therefore, the computer 20 can calculate the welding position if the drawing number, the vertical dimension, and the horizontal dimension regarding the work to be welded 200 are known. Therefore, it is not necessary to input the information regarding the welding position of the reinforcing member to the computer 20. Alternatively, it is not necessary to create CAD data that reflects the dimensional data and the welding position for each changing customer's required specifications.

As described above, the drawing number, the vertical dimension, and the horizontal dimension corresponding to the work to be welded 200 are stored in the server 10 in association with the order number. Therefore, for example, by reading the bar code or the like used for tracking the production line to acquire the order number and collating the read order number with the server 10, the computer 20 has a drawing corresponding to the work 200 to be welded. You can get numbers, vertical dimensions, and horizontal dimensions.

Of course, as a method of acquiring the order number, a known method other than reading the barcode may be used, or a tracking code other than the barcode may be used.

Next, the details of step S604 of FIG. 6 will be described. FIG. 8 is a schematic view showing a specific example of the work to be welded 200 according to the first embodiment of the present invention. Here, a method of calculating the welding position will be described in the case where the reinforcing member 202 is welded to the design panel 201, using the work to be welded 200 shown in FIG. 8 as an example. The design panel 201 and the reinforcing member 202 correspond to the work 200 to be welded.

As described with reference to FIG. 7, the calculation formula is instructed in the drawing with the dimension relating to the welding position of the reinforcing member 202 as a variable. This calculation formula is stored as welding position calculation software. 9 and 10 are explanatory views showing specific examples of calculation formulas relating to the dimensions, installation position, and welding position of the reinforcing member 202 according to the first embodiment of the present invention. Examples of the calculation formula stored as the welding position calculation software include those shown in FIGS. 9 and 10.

In the calculation formula exemplified in FIG. 9, the length of the reinforcing member and the number of welds are the drawing variables Z, and are described by the vertical dimension A of the design panel 201. Further, as shown in FIG. 10, the number N of the reinforcing members 202 and the pitch length Q between the reinforcing members 202 are also drawing variables, and are described by the horizontal dimension B of the design panel 201.

FIG. 11 is a plan view of the work to be welded 200 according to the first embodiment of the present invention. Further, FIG. 12 is a front view of the work to be welded 200 according to the first embodiment of the present invention. FIG. 13 is an explanatory diagram excerpting a part of the welding instruction according to the first embodiment of the present invention. This becomes a welding symbol called fillet welding. The boundary between the reinforcing plate and the decorative plate at the tip of the arrow in the drawing is welded. The specific meanings of the numbers in the welding symbols shown in FIG. 13 are that the front leg length is 3 mm, the welding length is 50 mm, the number of welds is Z3, and the pitch is 200 mm. As an example here, the drawing variable in FIG. 9 and the number of welds are linked.

The computer 20 can derive the length of the reinforcing member 202, the number of welds, the number N of the reinforcing members 202, and the pitch length Q between the reinforcing members 202 from the calculation formulas shown in FIGS. 9 and 10. As a result, the computer 20 can determine the drawing dimensions shown in FIGS. 11 and 12 and determine the welding position.

Next, the details of steps S605 to S607 of FIG. 6 will be described. Here, the case where the design panel 201 and the reinforcing member 202 (a) in FIG. 11 are used as the work to be welded 200 will be described as an example.

As shown in FIG. 11, the lower left corner of the design panel 201 is set as the origin O, the horizontal direction is set as the x-axis, and the vertical direction is set as the y-axis. Next, the lower left G and the upper left H of the reinforcing member 202 (a) are photographed by the camera 31. Here, with respect to the origin O, the regular xy coordinates of the lower left G are G (a, b), and the regular xy coordinates of the upper left H are H (a, b + Z1).

FIG. 14 is a schematic view of a photographed image of the camera 31 according to the first embodiment of the present invention. Specifically, FIG. 14 (a) shows an image in which the lower left portion G is imaged, and FIG. 14 (b) shows an image in which the upper left portion H is imaged. The image processing device 30 acquires an image taken by the camera 31 as shown in FIG. The image processing apparatus 30 obtains contours by executing edge extraction processing on the design panel 201 and the reinforcing member 202 (a) based on the acquired image. After that, the image processing device 30 obtains the coordinates of the lower left G and the upper left H of the reinforcing member 202 (a).

The image processing apparatus 30 acquires the position coordinates G (a, b) and H (a, b + Z1) calculated from the calculation formula by the computer 20 as regular installation positions. Further, the image processing device 30 performs the above-mentioned image processing on the image acquired by the camera 31, and as shown in FIG. 14, the position coordinates G (a + δa, b + δb), H (a + δa', b + Z1 + δb' ) Is calculated as the actual installation position.

Therefore, the image processing apparatus 30 has the position coordinates G (a, b) and H (a, b + Z1) which are the regular installation positions and the position coordinates G (a + δa, b + δb) and H (a + δa') which are the actual installation positions. , B + Z1 + δb'), δa, δb, δa', δb'can be specified as the installation error amount. If the amount of these installation errors exceeds the allowable error amount, the error is terminated.

Similarly, the image processing device 30 reinforces each of the lower left and upper left portions of the reinforcing members 202 (b), 202 (c), 202 (d), and 202 (e) based on the images taken by the camera 31. The amount of installation error of the member 202 is calculated, and it is determined whether or not the amount of installation error exceeds the allowable error amount. When determining an error, the operator can quickly take necessary measures by notifying which reinforcing member the installation position exceeds the permissible error amount. Further, the error determination and the notification processing associated with the occurrence of an error can be performed on the computer 20 side that has received the installation error amount.

Finally, step S608 and step S609 of FIG. 6 will be described in detail. FIG. 15 is an explanatory diagram of a welding position correction method according to the first embodiment of the present invention. For example, as shown in FIG. 15, when the reinforcing member 202 is installed at the actual installation position shown by the solid line, deviating from the regular installation position shown by the two-dot chain line, based on the amount of installation error. A method of calculating the welded position after correction will be described.

First, the image processing apparatus 30 transmits the installation error amounts δa, δb, δa', δb'calculated in step S606 to the computer 20. The computer 20 calculates the corrected welding position by recalculating the trajectory of the welding torch 120 from the received installation error amount according to the following formula.

The welding start point and the welding end point are linear. Therefore, the computer 20 can create a welding line in consideration of the amount of installation error by linearly complementing the positions of these two points. Therefore, the computer 20 can supplement the welding position even when the position during welding is the blind spot of the camera 31. The computer 20 can similarly determine the weld lines of the other reinforcing members 202. Therefore, by transmitting these data to the robot control device 140, the computer 20 can cause the robot control device 140 to perform welding of the work to be welded 200 by the welding robot 110.

As described above, according to the first embodiment, prior to the actual welding, the welding position is photographed by using a camera, and the installation error amount of the work to be welded is calculated by the image processing device using the photographed result. Therefore, the position and locus data of the welding torch obtained by the offline teaching based on the drawing number and the dimensional data can be corrected. As a result, it is possible to deal with the installation error of each work and the variation of the work itself, and it is possible to improve the welding accuracy.

In addition, it has a configuration in which the welding position of the reinforcing member can be automatically calculated by a calculation formula. Therefore, it is not necessary to mark the welding position in advance, and it is not necessary for the operator to manually input the welding position. Therefore, it is possible to reduce welding mistakes, and by eliminating the need for an operator, there is an advantage that workability can be improved and labor costs can be reduced.

Therefore, the automatic welding system according to the first embodiment can be easily applied even when the work size and the welding position change depending on the specifications required by the customer, such as the panel shape member of an elevator. ..

Embodiment 2.
In the first embodiment, a method has been described in which two points, a welding start point and a welding end point, are photographed by using a camera 31 and the welding position is corrected by using the two photographed points. However, the number of points used for correction is not limited to two points, and may be increased to three or more points. Therefore, in the second embodiment, a case where the welding position correction process is performed based on the recognition results of three or more points will be described.

FIG. 16 is a schematic view of butt welding according to the second embodiment of the present invention. For example, when the welded member 210 (a) and the welded member 210 (b) are butt-welded using the laser 122 as shown in FIG. 16, the welding position is corrected based on the recognition results of three or more points. The effect of performing

Consider a case where the laser 122 emitted from the optical head 121 irradiates the boundary portion 211 between the welding member 210 (a) and the welding member 210 (b) to perform welding. In this case, if the focal diameter of the laser 122 is small and the focal point of the laser 122 deviates from the boundary portion 211, the welding strength is significantly reduced, and if the deviating width is large, welding cannot be performed. Therefore, it is necessary to accurately follow the focal position of the laser 122 to the boundary portion 211. In such a case, the accuracy of the welding position can be improved by increasing the number of recognition points used for correction to three or more points.

Embodiment 3.
In the above-mentioned first and second embodiments, the case where the actual installation position of the work 200 to be welded is obtained by using the camera 31 has been described. However, in addition to the camera 31, a laser sensor, an ultrasonic sensor, a contact-type distance sensor, or the like may be used to determine the actual installation position of the work to be welded 200. Further, the camera 31 or the above-mentioned sensor only needs to be able to acquire information on the actual installation position of the work 200 to be welded, and does not necessarily have to be mounted on the welding robot 110.

Further, in the above-described first and second embodiments, the case where the arc welding work and the laser welding work are applied has been described. However, it is also possible to apply other working robots.

For example, instead of the welding torch 120, a welding electrode may be attached to the robot and applied to an application for spot welding. Alternatively, a grinder may be attached to the robot instead of the weld torch 120 and used for deburring or for removing weld beads.

Further, the work to be applied is not limited to the parts to be welded of the elevator, and any work can be applied as long as the work whose welding position is determined by the calculation formula from the outer diameter shape of the work. .. In particular, by applying the system configuration according to the present invention to a high-mix low-volume product, a great effect can be realized.

Further, in the first to third embodiments, a case where a calculation formula is used to calculate the welding position of the work to be welded from the drawing number and the dimensional data has been described. However, instead of the calculation formula, it is also possible to adopt a configuration in which the welding position of the work to be welded is calculated by using a function with drawing numbers and dimensional data as parameters or a table with drawing numbers and dimensional data as parameters. Is.

Further, the welding conditions can be automatically selected by transmitting the data of the material and the plate thickness of the work to be welded from the server 10 to the computer 20 in addition to the drawing number and the dimensional data.

FIG. 17 is an explanatory diagram of welding conditions according to the third embodiment of the present invention. Further, FIG. 18 is an explanatory diagram of detailed welding conditions according to the third embodiment of the present invention. Specifically, as shown in FIGS. 17 and 18, welding conditions corresponding to the materials and plate thickness prepared in advance are automatically selected and welding is performed. This makes it possible to apply even if the material type and plate thickness are changed according to the customer's specifications.

Embodiment 4.
FIG. 19 is a perspective view of the clamp jig according to the fourth embodiment of the present invention. The clamp jig 301 of the work to be welded is composed of a stage 302, a beam 303, and a clamp portion 304. By preparing a clamp position calculation formula with drawing numbers and dimensional data as parameters in the computer 20, the clamp position can be automatically adjusted according to the dimensions and installation position of the work to be welded.

This makes it possible to automate the clamp position adjusting process before welding. The clamp portion 304 of the clamp jig 301 is composed of, for example, an air cylinder, and is clamped by pressing a work to be welded. The beam 303 and the clamp portion 304 are composed of, for example, a ball screw and a linear guide so as to be movable in the x-axis direction and the y-axis direction.

FIG. 20 is an explanatory diagram showing the correspondence between the welding position and the clamp position according to the fourth embodiment of the present invention. As shown in FIG. 20, the gap between the design panel 201 and the reinforcing member 202 is minimized by automatically moving the position of the clamp portion 304 so as to always clamp the portion closest to the welding position calculated by the computer 20. It can be limited and the welding quality can be improved.

10 servers, 20 computers, 30 image processing equipment, 31 cameras, 100 welding machines, 110 welding robots, 111 manipulators, 120 welding torch, 130 movable stages, 140 robot control devices, 200 workpieces to be welded, 201 design panels, 202 reinforcement members. , 301 Clamp jig, 302 stage, 303 beam, 304 clamp part, 305 torch, 400 car room, 401 ceiling, 402 car door, 403 car room wall, 404 floor board.

Claims (12)

A data storage unit that stores the drawing number of the work to be welded and the dimensional data necessary for calculating the welding position of the work to be welded in association with each other.
A calculation unit that calculates the welding position of the work to be welded.
A camera capable of photographing the welding position of the work to be welded,
The actual installation position of the work to be welded obtained from the shooting result by the camera is compared with the regular installation position of the work to be welded obtained from the welding position calculated by the calculation unit, and the regular installation is performed. It is equipped with an image processing device that calculates the amount of installation error, which is the difference between the position and the actual installation position, and a welding machine that welds the welding position calculated by the calculation unit.
The standard drawing corresponding to the drawing number includes a formula for deriving drawing variables for the weld position from the dimensional data.
The calculation unit
The welding position of the work to be welded is calculated based on the drawing variables corresponding to the drawing numbers and the dimensional data output from the data storage unit.
The corrected welding position is calculated by recalculating the welding position based on the installation error amount calculated by the image processing device.
An automatic welding system that causes the welding machine to perform welding of the work to be welded based on the corrected welding position. The work to be welded is formed by welding a first member and a plurality of second members.
The drawing variables include any one of the length of the second member, the number of the second members, the number of welds of the second member, and the pitch length between the second members.
The automatic welding system according to claim 1. The installation error amount is calculated from the coordinates of the first member and the coordinates of the second member.
The automatic welding system according to claim 2. The first member is a panel member.
The second member is a reinforcing member.
The automatic welding system according to claim 2 or 3. The image processing device calculates the installation error amount of each of the reinforcing members, and determines whether or not the installation error amount exceeds the permissible error amount.
The automatic welding system according to claim 4. The data storage unit stores material data of the work to be welded, and the calculation unit determines the welding conditions of the work to be welded based on the material data . Any one of claims 1 to 5. The automatic welding system described in. The welding machine
Welding of the work to be welded is performed by controlling the position of the robot based on the robot having at least three drive shafts and the modified welding position received from the calculation unit and the welding torch mounted on the tip portion. The automatic welding system according to any one of claims 1 to 6, further comprising a control device for executing the above. The welder further comprises a movable stage on which the robot is installed and capable of moving the entire robot.
The automatic according to claim 7 , wherein the control device controls the positions of the robot and the movable stage based on the corrected welding position received from the calculation unit to execute welding of the work to be welded. Welding system. The camera is mounted on the robot and
The calculation unit outputs a movement command for moving the robot to a position where the welding position can be photographed, and outputs a movement command to the control device.
The control device controls the position of the robot based on the movement command, and causes the camera to photograph the welding position.
The automatic welding system according to claim 7 or 8 , wherein the image processing device calculates the amount of installation error by using the shooting result of the welding position by the camera mounted on the robot. The camera captures two points, a welding start point and a welding end point, included in the welding position.
The automatic welding system according to any one of claims 1 to 9 , wherein the image processing device calculates the installation error amount based on the imaging result regarding the welding start point and the imaging result regarding the welding end point. A method for manufacturing an elevator car chamber part using the automatic welding system according to any one of claims 1 to 10 .
The work to be welded is either a floor plate, a ceiling, a car door, or a car room wall, which are elevator car room parts.
How to manufacture elevator car room parts. A process of calculating the welding position of the work to be welded using a calculation formula for deriving drawing variables related to the welding position based on the drawing number and dimensional data output from the data storage unit.
The actual installation position of the welding target work obtained from the shooting result by a camera capable of photographing the welding position of the welding target work, and the regular installation position of the welding target work obtained from the calculated welding position. The process of comparing and calculating the amount of installation error, which is the difference between the regular installation position and the actual installation position,
A process of calculating the corrected welding position by recalculating the welding position based on the calculated installation error amount, and
An automatic welding method comprising a welding step of causing a welding machine to perform welding of the work to be welded based on the corrected welding position.

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