JP7263602B1 - Welding robot system and judgment method - Google Patents

Abstract

A welding robot system and a determination method capable of determining whether the position of a sensor attached to the welding robot is correct or not. A welding robot system includes a welding robot that welds steel materials while moving the steel materials in a predetermined direction. The welding robot system includes a sensor attached to the welding robot, the predetermined direction side sensor attached to the welding robot on the predetermined direction side, and a sensor attached to the welding robot, the sensor attached to the welding robot on the side opposite to the predetermined direction side. an opposite side sensor attached to the opposite side; and a determination unit that determines whether each of the predetermined direction side sensor and the opposite side sensor is attached to the predetermined direction side or the opposite side. [Selection drawing] Fig. 2

Description

The present invention relates to a welding robot system and determination method.

Automatic welding using a welding robot is performed to join steel materials. During automatic welding, a self-propelled welding robot is arranged along the welded portion and continuously welds the groove formed in the welded portion in advance. 2. Description of the Related Art Position control by image processing is used in a welding robot controller to appropriately position a torch of a welding robot with respect to a groove.

Also, regarding arc welding, there is known a technique for observing the molten state of a welded portion (see, for example, Patent Document 1). According to this technique, the welding observation device is a welding observation device for observing a molten portion in arc welding, and includes first imaging means for imaging an image of a molten pool formed in the molten portion; and a first detection unit that detects bubbles generated in the molten pool from an image of the molten pool captured by the means.

Japanese Patent Application Laid-Open No. 2021-167010

Rail self-propelled welding robots have been introduced to construction sites in order to improve welding quality and solve labor shortages at construction sites. When using a self-propelled rail welding robot to measure the shape of the base material to be welded by image processing using a camera, the following points are of concern.
(1) If there is only one camera for the welding robot that captures the tip of the welding wire and the shape of the groove, there is a risk that there will be areas that cannot be captured due to interference with jigs and auxiliary equipment.
(2) When images are captured with a single camera due to optical reasons such as sunshine conditions, the accuracy of image processing and the execution of the processing itself may not be completed.

In order to address the above concerns, a case will be described in which two cameras are installed at symmetrical positions with respect to the welding torch. When a welding robot is introduced to a construction site, workers must carry the robot to the welding location, assemble it, and install it. In this process, if the operator sets the robot to the wrong mounting pedestal for the two registered cameras, it becomes impossible to properly use the two cameras properly.
For example, in Patent Document 1, in a welding robot, sensors such as cameras are installed at the front and rear of the torch in the direction of travel, image processing is performed on images obtained from both sides, and the welding situation is monitored. . However, Japanese Patent Laid-Open No. 2002-200002 does not mention preventing misidentification of images that may occur due to incorrect installation of a sensor such as a camera.

SUMMARY OF THE INVENTION An object of the present invention is to provide a welding robot system and a determination method capable of determining whether the position of a sensor attached to a welding robot is correct.

(1) A welding robot system according to an aspect of the present invention is a welding robot system that includes a welding robot that welds steel materials while moving the steel materials in a predetermined direction, the welding robot system comprising: a sensor attached to the welding robot, a predetermined direction side sensor attached to a predetermined direction side of the welding robot; a sensor attached to the welding robot, an opposite side sensor attached to a side opposite to the predetermined direction side of the welding robot; a determination unit that determines on which of the predetermined direction side and the opposite side each of the predetermined direction side sensor and the opposite side sensor is attached.

According to the present invention, a welding robot system includes a welding robot that welds steel materials while moving the steel materials in a predetermined direction. The welding robot system is a sensor attached to the welding robot, and includes a predetermined direction side sensor attached to the welding robot on the predetermined direction side and an opposite side sensor attached to the welding robot on the side opposite to the predetermined direction side. Prepare. The welding robot system includes a determination unit that determines whether each of the predetermined direction side sensor and the opposite side sensor is attached to the predetermined direction side or the opposite side. With this configuration, the welding robot system includes a determination unit that determines whether the predetermined direction side sensor and the opposite side sensor are mounted on the predetermined direction side or the opposite side, respectively. It is possible to judge whether the position is correct or not.

(2) A welding robot system according to an aspect of the present invention is the welding robot system according to (1) above, wherein the sensor includes a camera, and the welding robot system includes the predetermined direction side sensor and the opposite side sensor. and a control unit that performs control to image a subject installed between the predetermined direction side sensor and the opposite side sensor, and the determination unit controls the predetermined direction side sensor and the opposite side sensor. It is determined on which of the predetermined direction side and the opposite side the predetermined direction side sensor and the opposite side sensor are attached, using the image output by capturing the subject.

In welding robot systems, sensors include cameras. The welding robot system further includes a control unit that controls the predetermined direction sensor and the opposite side sensor to image an object placed between the predetermined direction sensor and the opposite side sensor. With this configuration, the determining section uses the images output by the predetermined direction sensor and the opposite side sensor to pick up and output the subject, and the predetermined direction side sensor and the opposite side sensor determine the image of the subject in the predetermined direction side and the opposite side. Since it can be determined in which direction the camera is attached, it is possible to determine whether the camera is attached in a correct or incorrect position.

(3) A welding robot system according to an aspect of the present invention is the welding robot system according to (2) above, wherein the subject is in the imaging range of each of the predetermined direction side sensor and the opposite side sensor. Located within a predetermined range.

In the welding robot system, the subject is positioned within a predetermined range of the imaging ranges of the predetermined direction side sensor and the opposite side sensor. With this configuration, the determination unit uses the images output by the predetermined direction sensor and the opposite side sensor to pick up and output a subject located within the predetermined range of the respective imaging ranges, and uses the predetermined direction sensor Since it is possible to determine whether the sensor on the predetermined direction or the opposite side is attached, it is possible to determine whether the mounting position of the camera is correct or not.

(4) A welding robot system according to an aspect of the present invention is the welding robot system according to (2) or (3) above, wherein the subject has a rectangular shape.

In the welding robot system, the shape of the object can be rectangular. With this configuration, the determination unit uses the images output by the predetermined direction sensor and the opposite side sensor to pick up and output a rectangular subject, and the predetermined direction side sensor and the opposite side sensor Since it is possible to determine on which side the camera is attached, it is possible to determine whether the camera is attached in a correct or incorrect position.

(5) A welding robot system according to an aspect of the present invention is the welding robot system according to any one of (2) to (4) above, wherein the subject has a rectangular shape, and The angle formed by the long side of the object and the long side of the imaging ranges of the predetermined direction side sensor and the opposite side sensor is unchanged.

In the welding robot system, the object has a rectangular shape, and the angle formed by the long side of the object and the long sides of the imaging ranges of the predetermined direction side sensor and the opposite side sensor can be made constant. It is sufficient if the angle formed by the long side of the subject and the long side of the imaging range does not change at the timing when the sensor on the predetermined direction side and the sensor on the opposite side pick up images. With this configuration, the determination unit uses the images output by the predetermined direction sensor and the opposite side sensor to capture and output a rectangular subject, and the predetermined direction side sensor and the opposite side sensor determine the predetermined direction. Since it can be determined whether the camera is installed on the side or the opposite side, it is possible to determine whether the camera is installed in a correct or incorrect position.

(6) A welding robot system according to an aspect of the present invention is the welding robot system according to any one of (2) to (5) above, wherein the determining unit includes the Using the coordinates of at least two vertices of the subject, it is determined whether the predetermined direction side sensor and the opposite side sensor are attached to the predetermined direction side or the opposite side.

In the welding robot system, the determination unit can use the coordinates of at least two vertices of the subject included in the image. With this configuration, the determination unit uses the coordinates of at least two vertices of the subject included in the image, and determines whether the predetermined direction side sensor and the opposite side sensor are attached to either the predetermined direction side or the opposite side. Therefore, it is possible to determine whether the mounting position of the camera is correct or not.

(7) A welding robot system according to an aspect of the present invention is the welding robot system according to any one of (2) to (6) above, wherein the subject is the predetermined direction sensor and the A calibration plate used for calibration for matching the coordinate system of the opposite side sensor and the coordinate system of the welding robot, and used for the calibration of the predetermined direction side sensor and the opposite side sensor.

In the welding robot system, the object is calibration for associating the coordinate system of the predetermined direction side sensor and the opposite side sensor with the coordinate system of the welding robot, and is used for the calibration of the predetermined direction side sensor and the opposite side sensor. can be a calibration plate. With this configuration, the determination unit uses images output by the predetermined direction sensor and the opposite side sensor to capture images of the calibration plate, and the predetermined direction sensor and the opposite side sensor determine the predetermined direction side and the opposite side sensor. Since it is possible to determine which side the camera is attached to, it is possible to determine whether the camera is attached in a correct or incorrect position.

(8) A welding robot system according to an aspect of the present invention is the welding robot system according to (7) above, wherein the calibration plate is also used for measuring the cross-sectional shape of the groove.

In the welding robot system, the calibration plate is also used to measure the cross-sectional shape of the groove. With this configuration, the determining unit uses an image output by the predetermined direction sensor and the opposite side sensor to capture and output the calibration plate, which is also used for measuring the cross-sectional shape of the groove, to determine the predetermined direction side. Since it is possible to determine whether the sensor and the opposite side sensor are attached to the predetermined direction side or the opposite side, it is possible to determine whether the mounting position of the camera is correct.

(9) A welding robot system according to an aspect of the present invention is the welding robot system according to (7) or (8) above, wherein the calibration plate is an inclination of the robot coordinate system with respect to the world coordinate system. It is also used to find

In welding robot systems, the calibration plate is also used to determine the tilt of the robot's coordinate system with respect to the world coordinate system. With this configuration, the determination unit outputs an image obtained by imaging the calibration plate, which is also used for determining the inclination of the coordinate system of the robot with respect to the world coordinate system, by the sensor on the predetermined direction side and the sensor on the opposite side. can be used to determine whether the predetermined direction side sensor and the opposite side sensor are attached to the predetermined direction side or the opposite side, so it is possible to determine whether the mounting position of the camera is correct.

(10) A welding robot system according to an aspect of the present invention is the welding robot system according to any one of (7) to (9) above, wherein the image includes the predetermined direction sensor and the The opposite side sensor is an image captured and output from the subject for the calibration.

In the welding robot system, the image can be an image output by imaging a subject for calibration by the sensor on the predetermined direction and the sensor on the opposite side. With this configuration, the determination unit uses an image output by the predetermined direction sensor and the opposite side sensor to pick up an image of the subject for calibration, and determines whether the predetermined direction sensor and the opposite side sensor Since it is possible to determine whether the camera is installed on the direction side or the opposite side, it is possible to determine whether the camera is installed in the correct or incorrect position.

(11) A welding robot system according to an aspect of the present invention is the welding robot system according to any one of (7) to (10) above, wherein the image includes the predetermined direction sensor and the Each of the predetermined direction side sensor and the opposite side sensor picks up and outputs an image of the object for distortion correction of the image picked up by each of the opposite side sensor.

In the welding robot system, an image is an image output from an object captured by each of the predetermined direction sensor and the opposite side sensor for distortion correction of the image captured by each of the predetermined direction sensor and the opposite side sensor. can do. With this configuration, the determination unit uses the image captured by the subject and output for distortion correction of the images captured by the predetermined direction sensor and the opposite side sensor, respectively. Since it can be determined whether the opposite side sensor is attached to the predetermined direction side or the opposite side, it is possible to determine whether the mounting position of the camera is correct.

(12) A welding robot system according to an aspect of the present invention is the welding robot system according to any one of (1) to (11) above, wherein the predetermined direction side sensor and the opposite side sensor an input unit for allowing a user to input information corresponding to a position where the is attached, a position corresponding to the information input by the input unit, and the predetermined direction side sensor determined by the determination unit and the opposite side and a notification unit that notifies the user when the position where the sensor is attached is different.

In the welding robot system, the welding robot system includes an input unit that allows a user to input information corresponding to the positions where the predetermined direction side sensor and the opposite side sensor are attached. An example of information corresponding to location is an IP address. The welding robot system notifies the user when the position corresponding to the information input by the input unit is different from the position where the sensor on the predetermined direction side and the sensor on the opposite side determined by the determination unit are attached. A notification part is provided. With this configuration, the welding robot system causes the welding robot to weld the steel material while moving the steel material in the predetermined direction based on the information corresponding to the positions where the predetermined direction sensor and the opposite side sensor are attached. be able to. The welding robot system can notify the user if the mounting position of the camera is incorrect.

(13) A determination method according to an aspect of the present invention is a determination method including a welding robot that welds a steel material while moving the steel material in a predetermined direction, wherein the welding robot is attached to the predetermined direction side of the welding robot and the welding robot is attached to the predetermined direction side of the welding robot. determining whether each of a side sensor and an opposite side sensor attached to the side opposite to the predetermined direction side of the welding robot is attached to the predetermined direction side or the opposite side. .

According to this invention, the determination method is executed by a welding robot system that includes a welding robot that welds steel materials while moving the steel materials in a predetermined direction. The determination method is based on whether the predetermined direction side sensor attached to the predetermined direction side of the welding robot and the opposite side sensor attached to the side opposite to the predetermined direction side of the welding robot are on the predetermined direction side or the opposite side. It has a step of determining whether it is attached. With this configuration, the welding robot system can determine whether the predetermined direction side sensor and the opposite side sensor are mounted on the predetermined direction side or the opposite side, respectively, so that the correctness of the mounting position of the camera can be determined. I can judge.

According to the embodiment of the present invention, it is possible to determine whether the position of the sensor attached to the welding robot is correct.

BRIEF DESCRIPTION OF THE DRAWINGS It is a figure which shows an example of the welding robot system which concerns on embodiment of this invention. BRIEF DESCRIPTION OF THE DRAWINGS It is a figure which shows an example of the welding robot system which concerns on this embodiment. It is a figure which shows an example of operation|movement of the welding robot system which concerns on this embodiment. It is a figure which shows an example of operation|movement of the welding robot system which concerns on this embodiment. It is a figure which shows an example of operation|movement of the welding robot system which concerns on this embodiment. It is a figure which shows an example of operation|movement of the welding robot system which concerns on this embodiment. It is a figure which shows an example of operation|movement of the welding robot system which concerns on this embodiment. 4 is a flow chart showing an example of the operation of the welding robot system according to the embodiment; 4 is a flow chart showing an example of the operation of the welding robot system according to the embodiment; 4 is a flow chart showing an example of the operation of the welding robot system according to the embodiment; 4 is a flow chart showing an example of the operation of the welding robot system according to the embodiment;

Next, the welding robot system and determination method of this embodiment will be described with reference to the drawings. The embodiments described below are merely examples, and embodiments to which the present invention is applied are not limited to the following embodiments.
In addition, in all the drawings for explaining the embodiments, the same reference numerals are used for the parts having the same functions, and repeated explanations are omitted.
In addition, "based on XX" in the present application means "based on at least XX", and includes cases based on other elements in addition to XX. Moreover, "based on XX" is not limited to the case of using XX directly, but also includes the case of being based on what has been calculated or processed with respect to XX. "XX" is an arbitrary element (for example, arbitrary information).

(embodiment)
(welding robot system)
FIG. 1 is a diagram showing an example of a welding robot system according to an embodiment of the invention.
A welding robot system 1 according to the present embodiment uses a welding robot 10 to automatically weld an object 2 to be welded. An example of the object to be welded 2 is steel.
A welding robot system 1 includes a welding robot 10 and a control device 9 .
The object to be welded 2 is formed with a groove-like groove 3 on a pair of edges to be welded. A travel rail 11 is installed along the groove 3 on the object 2 to be welded, and the welding robot 10 can move along the travel rail 11 .
In the welding robot 10, the direction intersecting with the surface of the object 2 to be welded is the Z-axis, the extending direction of the groove 3 and the running rail 11 is the Y-axis, and the direction across the groove 3 (perpendicular to the Z-axis and the Y-axis, respectively). direction) is the X-axis.
A welding robot 10 has a saddle 12 that moves along a travel rail 11. The saddle 12 supports a rectangular box-shaped case 13. As shown in FIG.
A moving mechanism (not shown) is installed inside the case 13, and the case 13 moves in a direction (Z-axis direction) toward and away from the running rail 11 and in a direction (X-axis direction) across the groove 3. It is possible.

A bracket 14 is installed on the side facing the groove 3 of the case 13 , a holder 15 is supported at the tip of the bracket 14 , and a welding torch 16 is held by the holder 15 . A welding wire 161 is supported at the tip of the welding torch 16 .
The holder 15 is rotatable on the bracket 14 and can be fixed at an arbitrary angular position around the rotation axis S, and the aiming angle At of the welding torch 16 can be adjusted by the angle of the holder 15 .
A controller 9 is connected to the welding robot 10 .

The welding robot 10 is equipped with an illumination device 21, a camera 22-1, and a camera 22-2. The cameras 22-1 and 22-2 are removable from the welding robot 10. FIG. An arbitrary camera out of the cameras 22-1 and 22-2 is referred to as a camera 22. FIG.
An example of the illumination device 21 is a line laser irradiation device, which irradiates the measurement site 31 of the groove 3 with a laser beam that spreads in the transverse direction (X-axis direction) of the groove 3 . By configuring in this way, the measurement site 31 can be continuously illuminated linearly in the transverse direction of the groove 3, so that the cross-sectional shape 32 can be highlighted brighter than the surroundings.
A camera 22-1 and a camera 22-2 are installed on both sides of the welding torch 16 as a pair. Send to the control device 9 .

An example of the pair of cameras 22 includes a solid-state imaging device such as a CCD (Charge Coupled Device), and is mounted on the side surface of the case 13 via a support panel 221 and a support arm 222 . It is supported by rails 223 .
Each camera 22 can be oriented with respect to the support panel 221 and can be moved along the support rail 223 in the X-axis direction. The field of view at the time of measurement, that is, the imaging area 220 on the welding object 2 including the measurement site 31 can be freely adjusted.

The welding robot system 1 has a panel 23 supported by the welding robot 10 .
The shape of the panel 23 is a rectangle such as a rectangle, and a two-dimensional gauge 230 is drawn on the surface of the panel 23 by a plurality of lines 232 and 233 arranged orthogonally.
Panel 23 may be a calibration plate. The calibration plate is used to perform calibration for associating the coordinate systems of the cameras 22-1 and 22-2 with the coordinate system of the welding robot . The coordinate system of welding robot 10 is a coordinate system for representing the position of welding robot 10 .
The calibration plate is used for calibration of each of camera 22-1 and camera 22-2. The calibration plate is also used for measuring the cross-sectional shape of the groove 3 . The calibration plate is also used to determine the tilt of the robot coordinate system with respect to the world coordinate system.
Information on the shape of the gauge 230, specifically information on the base end position, number, length, and tip position of the plurality of lines 232 and 233 arranged orthogonally on the panel 23 is stored in the control device 9 in advance. .
The panel 23 is supported by the bracket 14 via the arm 231, and is arranged so that at least the lower half thereof is inserted into the groove 3, and the surface of the panel 23 intersects the continuous direction of the groove 3.
The arm 231 is rotatably connected to the bracket 14 , and the panel 23 can be retracted out of the field of view of the camera 22 from the state of entering the groove 3 . Arm 231 and panel 23 may be removable from bracket 14 in order to retract panel 23 out of the field of view of camera 22 .
In the welding robot system 1 as described above, prior to the automatic welding operation on the object 2 to be welded, it is determined whether the camera position is correct or not, and the groove 3 is sensed.

FIG. 2 is a diagram showing an example of a welding robot system according to this embodiment. As shown in FIG. 2, the welding robot system 1 includes a control device 9, a travel rail 11, a saddle 12, a welding torch 16, an illumination device 21, a camera 22-1, and a camera 22-2. .
The control device 9 includes a welding operation control section 91, a saddle movement control section 92, an input section 93, a processing section 94, a storage section 95, a camera control section 96, a determination section 97, and a notification section 98. Prepare.
The control device 9 is configured by combining an existing computer system with a dedicated driver, and executes a program stored in the storage unit 95 to determine whether the position of the camera is correct, measure the groove shape, and perform the operation of the running rail 11 . It controls the operation of each part of the welding robot 10, such as traveling of the saddle 12 and the case 13 along the path, adjusting the attitude of the welding torch 16, adjusting the voltage and current supplied to the welding torch 16, and adjusting the feed speed of the welding wire.
The control device 9 measures the overall shape of the groove 3 by measuring the cross-sectional shape 32 at a plurality of measurement sites 31 for the groove 3 of the welding target 2, and measures the obtained groove shape. Based on this, the welding robot 10 is controlled.

The welding operation control section 91 controls the welding torch 16 . For example, the welding operation control unit 91 adjusts the attitude of the welding torch 16, adjusts the voltage and current supplied to the welding torch 16, and adjusts the feed speed of the welding wire.
A saddle movement control section 92 controls the saddle 12 . For example, the saddle movement control unit 92 controls traveling of the saddle 12 along the travel rail 11 .
The input unit 93 inputs information. As an example, the input unit 93 may have operation units such as a keyboard and a mouse. In this case, the input unit 93 inputs information according to the operation performed by the user on the operation unit. As another example, the input unit 93 may input information from an external device. The external device may be, for example, a portable storage medium.
Information corresponding to the positions at which the cameras 22-1 and 22-2 are attached is input to the input unit 93 by the user. An example of the information corresponding to the positions where the cameras 22-1 and 22-2 are attached is the IP addresses of the cameras 22-1 and 22-2, etc. This is the identification information used when doing so.
A case where the IP addresses of the cameras 22-1 and 22-2 are applied as an example of the information corresponding to the positions where the cameras 22-1 and 22-2 are attached will be described below.

For example, the cameras 22-1 and 22-2 are attached to the welding robot 10 on the predetermined direction side and the side opposite to the predetermined direction side. An example of the predetermined direction is the left side (negative side of the Y-axis), and an example of the opposite side is the right side (positive side of the Y-axis). As an example, the case where the predetermined direction side is the left side, the opposite side is the right side, and the camera 22-1 is mounted on the left side and the camera 22-2 is mounted on the right side will be described below.
The display section (not shown) displays a field for inputting the IP address corresponding to the camera 22-1 on the left side and a field for inputting the IP address corresponding to the camera 22-2 on the right side. The user inputs the IP address corresponding to the camera 22-1 on the left side and the IP address corresponding to the camera 22-2 on the right side to the input unit 93. FIG.

The processing unit 94 acquires from the input unit 93 the IP address corresponding to the left camera 22-1 and the IP address corresponding to the right camera 22-2. The processing unit 94 causes the storage unit 95 to store the acquired IP address corresponding to the left camera 22-1 and the acquired IP address corresponding to the right camera 22-2.
A camera control unit 96 controls the cameras 22-1 and 22-2. The camera control unit 96 is connected to the cameras 22-1 and 22-2 and acquires identification information from the cameras 22-1 and 22-2. An example of identification information is an identification number unique to the camera 22, such as a MAC address (Media Access Control address). The case where the MAC address is applied as an example of identification information for each of the cameras 22-1 and 22-2 will be described below.
The camera control unit 96 associates the MAC address obtained from the camera 22-1 with the IP address of the camera 22-1, and causes the storage unit 95 to store them. The camera control unit 96 associates the MAC address obtained from the camera 22-2 with the IP address of the camera 22-2 and stores it in the storage unit 95. FIG.

A welding robot 10 is installed on an object 2 to be welded. The illumination device 21 linearly illuminates the measurement site 31 of the bevel 3 in the transverse direction. The camera control unit 96 adjusts the imaging areas of the cameras 22-1 and 22-2 toward the bevel 3. As shown in FIG. The camera 22-1 and the camera 22-2 image the groove 3. As shown in FIG.
The processing unit 94 acquires image data from each of the cameras 22-1 and 22-2, and processes the acquired image data. The processing unit 94 prepares a calibration function for making the image data from the cameras 22-1 and 22-2 correspond to the world coordinate system based on the image obtained by processing the image data.
The processing unit 94 corrects distortion of the lens of the camera 22 . The camera control unit 96 controls the camera 22-1 and the camera 22-2 to image an object. An example of the subject is the panel 23 placed between the cameras 22-1 and 22-2 in the Y-axis direction. The camera control unit 96 controls each of the camera 22-1 and the camera 22-2 to arrange the gauge 230 drawn on the panel 23 in the imaging area and to image the gauge 230. FIG.
The orientations of the cameras 22-1 and 22-2 are adjusted with respect to the reference point of the gauge 230 (for example, one of the intersection points of the plurality of orthogonally arranged lines 232 and 233), and the camera 22 -1 and the optical axis of camera 22-2 are directed toward the reference point and fixed.

The positions of the cameras 22-1 and 22-2 supported by the welding robot 10 are usually at positions away from the groove 3, and from the front of the panel 23 (the Y-axis direction, which is the continuous direction of the groove 3) As can be seen, each of camera 22-1 and camera 22-2 is positioned with a displacement Dx in the X-axis direction and a displacement Dz in the Z-axis direction. Furthermore, there are respective tilts of the camera 22-1 and the camera 22-2, which are defined as respective tilt angles R of the cameras 22-1 and 22-2 about the optical axis.
Each of camera 22 - 1 and camera 22 - 2 images gauge 230 drawn on panel 23 . The processing unit 94 acquires image data from each of the cameras 22-1 and 22-2, and processes the acquired image data.
Based on the image of gauge 230 obtained by processing the image data, processing unit 94 sets the world coordinate system for the images captured by cameras 22-1 and 22-2. For example, the processing unit 94 sets the world coordinate system by determining the coordinates in the world coordinate system based on the coordinates on the image determined from the captured image of the gauge 230 . The processing unit 94 converts the image coordinate system to the camera coordinate system based on characteristics (internal parameters) unique to the cameras 22-1 and 22-2, such as image distortion and focal length. The processing unit 94 transforms from the camera coordinate system to the world coordinate system based on the external parameters.
In the captured image, the camera 22-1 and the camera 22-2 are at positions deviated by the displacement Dx in the X-axis direction, the displacement Dz in the Z-axis direction, and the tilt angle R, so the gauge drawn on the panel 23 The shape of 230 (for example, the lengths and angles formed by a plurality of lines 232 and 233 arranged orthogonally) appears deformed with respect to the original shape.

The processing unit 94 refers to the gauge 230 stored in the storage unit 95 (for example, the lengths and angles formed by the plurality of lines 232 and 233 arranged orthogonally), and processes the image data to obtain gauges. By performing a comparison operation with the gauge 230 appearing in the image of 230, the displacement Dx, the displacement Dz and the tilt angle R of each of the cameras 22-1 and 22-2 are calculated.
The processing unit 94 performs arithmetic processing such as homography transformation on the calculation results of the displacement Dx, the displacement Dz, and the tilt angle R of the camera 22-1 and the camera 22-2, respectively. 1 and camera 22-2, information for calibrating the cross-sectional shape of the groove 3 as viewed from the front, that is, from the continuous direction of the groove 3 is acquired.
The processing unit 94 causes the storage unit 95 to store the obtained external parameters of the cameras 22-1 and 22-2 in association with the IP addresses of the cameras 22-1 and 22-2. By configuring in this manner, a camera coordinate system corresponding to the world coordinate system can be set on the image of the subject captured by each of the cameras 22-1 and 22-2. The internal parameters of the cameras 22-1 and 22-2 are stored in the storage unit 95 in association with their respective MAC addresses.

The camera control unit 96 controls each of the cameras 22-1 and 22-2 to capture an image of a subject. An example of the subject is the panel 23 placed between the cameras 22-1 and 22-2 in the Y-axis direction. The cameras 22-1 and 22-2 capture images of subjects.
FIG. 3 is a diagram showing an example of the operation of the welding robot system according to this embodiment. In FIG. 3, the left diagram is an example of an image showing how the subject (panel 23) is imaged by the camera 22-1, and the right diagram is an example of an image showing how the subject is imaged by the camera 22-2. be.
Here, the IP address of camera 22-1 is 192.168. ＊＊＊. **1 and the MAC address is LL:LL:LL:LL:LL:LL. The IP address of camera 22-2 is 192.168. ＊＊＊. **2 and the MAC address is RR:RR:RR:RR:RR:RR.
The determination unit 97 acquires image data from each of the cameras 22-1 and 22-2, and processes the acquired image data. Determination unit 97 determines whether each of camera 22-1 and camera 22-2 is attached to the left or right side of welding robot 10 based on the image obtained by processing the image data. .

FIG. 4 is a diagram showing an example of the operation of the welding robot system according to this embodiment. In FIG. 4, the left diagram is an example of an image before distortion correction of the subject (panel 23) captured by the camera 22-1 (hereinafter referred to as "left subject image"), and the right diagram is an example captured by the camera 22-2. 1 is an example of an image of a subject (panel 23) before distortion correction (hereinafter referred to as a "right subject image").
As shown in FIG. 4, the subject (panel 23) has a rectangular shape.
According to FIG. 4, from an example of the image of the subject (panel 23) imaged by the camera 22-1, the subject is located in a predetermined range in the imaging range of the camera 22-1, and the subject imaged by the camera 22-2 From the example of the image (panel 23), it can be seen that the subject is located in a predetermined range within the imaging range of the camera 22-2.
The determination unit 97 determines the coordinates in the image coordinate system of at least two vertices of the subject (panel 23) included in the left subject image and the image coordinate system of at least two vertices of the subject (panel 23) included in the right subject image. Get the coordinates at . For example, the determination unit 97 acquires the coordinates in the image coordinate system of the facing vertices of the subject (panel 23) included in the left subject image, and obtains the image of the facing vertices of the subject (panel 23) included in the right subject image. Get coordinates in a coordinate system.

FIG. 5 is a diagram showing an example of the operation of the welding robot system according to this embodiment. In FIG. 5, the left diagram is an example of the left subject image after distortion correction, and the right diagram is an example of the right subject image after distortion correction. As indicated by the dashed lines, the angles (θL, θR) formed by the long sides of the subject and the long sides of the imaging ranges of the cameras 22-1 and 22-2 are constant at least at the timing of imaging.
The determination unit 97 acquires the coordinates of the opposing vertices of the two-dimensional gauge in the camera coordinate system from the subject (panel 23) included in each of the left subject image and the right subject image. For example, the determination unit 97 converts the image coordinate system to the camera coordinate system based on characteristics (internal parameters) unique to the cameras 22-1 and 22-2, such as image distortion and focal length.
The determination unit 97 acquires the coordinates of the origin (VL1) in the camera coordinate system of the two-dimensional gauge from the subject (panel 23) and the coordinates of the vertex (VL2) opposite the origin (VL1) from the subject (panel 23) in the left subject image. . The determination unit 97 acquires the coordinates of the origin (VR1) and the coordinates of the vertex (VR2) opposite the origin (VR1) in the camera coordinate system of the two-dimensional gauge from the subject (panel 23) in the right subject image.
The determination unit 97 converts the coordinates in the camera coordinate system of the facing vertices of the two-dimensional gauge obtained from the left subject image and the right subject image into coordinates in the world coordinate system. For example, in the left subject image, the determination unit 97 converts the coordinates of the origin (VL1) in the camera coordinate system to the coordinates (XiL(0), YiL(0)) in the world coordinate system based on the external parameters. , the coordinates of the vertex (VL2) facing the origin in the camera coordinate system are transformed into coordinates (XiL(max), YiLR(max)) in the world coordinate system.
The determination unit 97 converts the coordinates of the origin (VR1) in the camera coordinate system into the coordinates (XiR(0), YiR(0)) in the world coordinate system based on the external parameters in the right subject image, and converts the camera The coordinates of the vertex (VR2) opposite the origin in the coordinate system are transformed into the coordinates (XiR(max), YiR(max)) in the world coordinate system.

The determination unit 97 converts the coordinates of the origin (VR1) in the camera coordinate system into the coordinates in the world coordinate system and the coordinates of the vertex (VL2) opposite the origin in the camera coordinate system in the left subject image. Based on the results of conversion into coordinates in the world coordinate system, it is determined whether or not each of the camera 22-1 attached to the left and the camera 22-2 attached to the right is correct.
Specifically, the determination unit 97 determines that the X coordinate (XiL(max)) of the vertex (VL2) in the world coordinate system is higher than the X coordinate (XiL(0)) of the origin (VL1) in the world coordinate system. A large value, and the X coordinate (XiR(max)) of the vertex (VR2) in the world coordinate system is smaller than the X coordinate (XiR(0)) of the origin (VR1) in the world coordinate system If so, it is determined that the cameras 22-1 and 22-2 are installed correctly.
The determining unit 97 determines that the X coordinate (XiL(max)) of the vertex (VL2) in the world coordinate system is equal to or less than the X coordinate (XiL(0)) of the origin (VL1) in the world coordinate system, or When the X coordinate (XiR (max)) of the vertex (VR2) in the world coordinate system is equal to or greater than the X coordinate (XiR (0)) of the origin (VR1) in the world coordinate system, the camera 22- 1 and the camera 22-2 are not installed correctly.

The determining unit 97 determines that the X coordinate (XiL(max)) of the vertex (VL2) in the world coordinate system is equal to or less than the X coordinate (XiL(0)) of the origin (VL1) in the world coordinate system, and When the X coordinate (XiR (max)) of the vertex (VR2) in the world coordinate system is equal to or greater than the X coordinate (XiR (0)) of the origin (VR1) in the world coordinate system, the camera 22- 1 and the camera 22-2 are not installed correctly. Returning to FIG. 2, the description is continued.
When determining that the cameras 22-1 and 22-2 are not properly installed, the determination unit 97 notifies the notification unit 98 of this.
When notified by the determination unit 97, the notification unit 98 notifies the user that the cameras 22-1 and 22-2 are not installed at the correct positions. With this configuration, the positions corresponding to the IP addresses of the cameras 22-1 and 22-2 input to the input unit 93 and the positions of the cameras 22-1 and 22-2 determined by the determination unit 97 2 are installed in different positions.
Based on the image of gauge 230 obtained by processing the image data, processing unit 94 sets the camera coordinate system for the images captured by cameras 22-1 and 22-2.

By rotating the arm 231, the panel 23 is retracted out of the fields of view of the cameras 22-1 and 22-2. The processing unit 94 calibrates the origin of the camera coordinate system. For example, the welding wire is put out from the tip of the welding torch 16 of the welding robot 10 .
In FIG. 1, an arbitrary position of the cross-sectional shape 32 (for example, a bending point of the groove 3 used as a preset calibration point) is selected as a torch target position, and the welding robot 10 is moved in the X-axis direction and the Z-axis direction. to bring the tip of the welding wire 161 extending from the welding torch 16 into contact with the torch target position. As a result, the origin of the world coordinate system and the origin of the robot coordinate system are associated with each other.

The camera control unit 96 controls each of the cameras 22-1 and 22-2 to image the welding wire including the tip of the welding wire. Each of camera 22-1 and camera 22-2 images the welding wire including the tip of the welding wire. The processing unit 94 acquires image data from each of the cameras 22-1 and 22-2, and processes the acquired image data.
The welding wire is kept from coming out from the tip of the welding torch 16 of the welding robot 10.例文帳に追加The camera control unit 96 controls each of the cameras 22-1 and 22-2 to image the tip of the welding torch 16. FIG. Cameras 22 - 1 and 22 - 2 each capture an image of the tip of welding torch 16 . The processing unit 94 acquires image data from each of the cameras 22-1 and 22-2, and processes the acquired image data.

The processing unit 94 obtains an image of the wire including the wire tip based on the image of the wire including the wire tip obtained by processing the image data and the image of the tip of the welding torch 16 . The processing unit 94 acquires the coordinates of the welding wire tip (torch aim position) in the robot coordinate system based on the acquired image of the wire including the wire tip.
The processing unit 94 sets the acquired coordinates of the wire tip in the robot coordinate system as the origin of the world coordinate system. Since the welding wire tip (torch aim position) is detected as the current position in the robot coordinate system, the origin position in the world coordinate system can be transformed into the robot coordinate system.

The saddle movement control section 92 moves the welding robot 10 to the vicinity of the measurement site 31 of the groove 3 . The processing unit 94 causes the illumination device 21 to linearly illuminate the measurement site 31 in the transverse direction. The processing unit 94 determines a sensing point from the measurement site 31 of the groove 3 . The camera control unit 96 controls each of the camera 22-1 and the camera 22-2 to image sensing points included in the measurement site 31 of the groove 3. FIG.
Each of the camera 22-1 and the camera 22-2 captures an image of a sensing point included in the measurement site 31 of the groove 3. The processing unit 94 acquires image data from each of the cameras 22-1 and 22-2, and processes the acquired image data.
Using preparation data prepared in advance, the processing unit 94 uses the image of the sensing point included in the measurement site 31 of the groove 3 obtained by processing the image data to determine the characteristics of the welding target 2 sandwiching the sensing point. based on whether the left camera 22-1 can calculate the area, whether the right camera 22-2 can calculate the area, and whether both the left camera 22-1 and the right camera 22-2 can calculate the area. Determine if calculation is possible. Note that the process of step S3-1, which will be described later, is executed in an area determined by the processing unit 94 to be capable of area calculation by both the left camera 22-1 and the right camera 22-2.

FIG. 6 is a diagram showing an example of the operation of the welding robot system according to this embodiment. FIG. 6 shows the sensing point (1) to the sensing point (5) at the intermediate point of the construction jig in the object 2 to be welded.
The processing unit 94 acquires the position information of the erection jig, and based on the acquired position information of the erection jig, the left camera 22-1 at each of the sensing points (1) to (5). It is determined whether the area can be calculated, whether the area can be calculated with the right camera 22-2, or whether the area can be calculated with both the left camera 22-1 and the right camera 22-2. Here, the processing unit 94 may acquire the position information of the erection jig by sensing means, or may acquire the position information of the erection jig by prompting the user to input.
Since the sensing point (1) can be imaged by the right camera 22-2, the processing unit 94 determines that the area can be calculated by the right camera 22-2. Since sensing point (2) to sensing point (4) can be captured by both the left camera 22-1 and the right camera 22-2, the processing unit 94 captures the left camera 22-1 and the right camera 22- 2, it is determined that area calculation is possible. Since the sensing point (5) can be imaged by the left camera 22-1, the processing unit 94 determines that the area can be calculated by the left camera 22-1.
FIG. 7 is a diagram showing an example of the operation of the welding robot system according to this embodiment. In FIG. 7, the left figure is an example of an image of the sensing point (5) captured by the camera 22-1 on the left side. Since the sensing point (5) can be imaged by the left camera 22-1, it can be seen that the area can be calculated by the left camera 22-1.
The upper right figure is an example of an image of the sensing point (1) captured by the camera 22-2 on the right side. Since the sensing point (1) can be imaged by the right camera 22-2, it can be seen that the area can be calculated by the right camera 22-2. The lower right figure is an image obtained by horizontally reversing the upper right figure. Returning to FIG. 2, the description is continued.

The camera control unit 96 controls one or both of the left camera 22-1 and the right camera 22-2 determined to be capable of calculating the area to capture an image of the sensing point. The processing unit 94 acquires image data from each of the cameras 22-1 and 22-2, and processes the acquired image data. The processing unit 94 detects the cross-sectional shape of the groove 3 obtained by processing the acquired image data.
For example, the processing unit 94 performs inversion processing on one of the images of the measurement site 31 of the groove 3 obtained by processing the image data acquired from each of the cameras 22-1 and 22-2. The processing unit 94 calculates the length, angle, and Edge detection processing is performed by calculating plate thickness and the like.
The processing unit 94 derives the shape of the groove 3 and the reference point in the robot coordinate system based on the edge detection result of the cross-sectional shape of the groove 3 . If there is no error between the derived information specifying the shape of the groove 3 and the value of the reference point, the processing unit 94 determines the information specifying the shape of the groove 3 and the value of the reference point. The processing unit 94 causes the storage unit 95 to store the determined shape of the groove 3 and the reference point in the robot coordinate system.
While changing the sensing point included in the measurement site 31 of the groove 3 , this is repeated multiple times over the entire length or a partial section of the groove 3 . With this configuration, it is possible to obtain (sensing) the cross-sectional shape 32 along the continuous direction of the groove 3 .
The welding operation control unit 91, the saddle movement control unit 92, the processing unit 94, the camera control unit 96, and the determination unit 97 are computer programs stored in the storage unit 95 by a hardware processor such as a CPU (Central Processing Unit). software).
Some or all of these functional units are hardware (circuits) such as LSI (Large Scale Integration), ASIC (Application Specific Integrated Circuit), FPGA (Field-Programmable Gate Array), and GPU (Graphics Processing Unit). (including circuit), or by cooperation between software and hardware.

(Operation of welding robot system)
8 to 11 are flowcharts showing an example of the operation of the welding robot system according to this embodiment. Here, a case where a calibration plate is used as an example of the panel 23 will be described.
(Step S1-1)
In the control device 9, the user inputs IP addresses corresponding to the positions at which the cameras 22-1 and 22-2 are attached to the input unit 93. FIG. The processing unit 94 acquires from the input unit 93 the IP address corresponding to the left camera 22-1 and the IP address corresponding to the right camera 22-2. The processing unit 94 causes the storage unit 95 to store the acquired IP address corresponding to the left camera 22-1 and the acquired IP address corresponding to the right camera 22-2.
(Step S2-1)
In the control device 9, a camera control section 96 controls each of the cameras 22-1 and 22-2. The camera control unit 96 connects to each of the cameras 22-1 and 22-2 and acquires MAC addresses from each of the cameras 22-1 and 22-2.
The camera control unit 96 associates the MAC address obtained from the camera 22-1 with the IP address of the camera 22-1, and causes the storage unit 95 to store them. The camera control unit 96 associates the MAC address obtained from the camera 22-2 with the IP address of the camera 22-2 and stores it in the storage unit 95. FIG.

(Step S3-1)
In the control device 9, the camera control unit 96 causes each of the camera 22-1 and the camera 22-2 to place the gauge 230 drawn on the calibration plate (panel 23) in the imaging area and to image the gauge 230. control.
The orientations of the cameras 22-1 and 22-2 are adjusted with respect to the reference point of the gauge 230, and the optical axes of the cameras 22-1 and 22-2 are fixed toward the reference point. .
Each of camera 22-1 and camera 22-2 images gauge 230 drawn on the calibration plate (panel 23).
(Step S4-1)
In the control device 9, the processing section 94 acquires image data from each of the cameras 22-1 and 22-2, and processes the acquired image data. The processing unit 94 calculates characteristics (intrinsic parameters) unique to the cameras 22-1 and 22-2, such as image distortion and focal length, by processing the image data.
The processing unit 94 acquires image data from each of the cameras 22-1 and 22-2, and processes the acquired image data. The processing unit 94 applies distortion to the image of the gauge 230 obtained by processing the image data based on characteristics (internal parameters) unique to the cameras 22-1 and 22-2 such as image distortion and focal length. Make corrections.
Based on the image of gauge 230 obtained by processing the image data, processing unit 94 sets the world coordinate system for the images captured by cameras 22-1 and 22-2.
The processing unit 94 refers to the gauge 230 stored in the storage unit 95, and performs a comparison operation with the gauge 230 appearing in the image of the gauge 230 obtained by processing the image data. and the camera 22-2, the displacement Dx, the displacement Dz and the tilt angle R are calculated.
The processing unit 94 performs arithmetic processing such as homography transformation on the obtained displacement Dx, displacement Dz, and tilt angle R of the cameras 22-1 and 22-2. -2, information for calibrating the cross-sectional shape of the groove 3 as viewed from the front, that is, from the continuous direction of the groove is acquired. A homography transformation represents a "transformation between two images (of the same thing)". That is, the homography transform creates an undistorted image from the distorted image using the intrinsic parameters. Calculating the internal parameters may also be expressed as using homography transformation. The content of homography transformation is matrix calculation, and if a virtual screen is assumed in the world coordinate system, homography transformation may be performed in step S6-1, which will be described later.

(Step S5-1)
In the control device 9, the processing unit 94 associates the internal parameters of the cameras 22-1 and 22-2 with the MAC address of the camera 22-1 and the MAC address of the camera 22-2, and stores them in the storage unit 95. Let
(Step S6-1)
In the control device 9, the camera control section 96 controls each of the cameras 22-1 and 22-2 to capture an image of the calibration plate (panel 23). Each of camera 22-1 and camera 22-2 images the calibration plate (panel 23).
(Step S7-1)
In the control device 9, the determination section 97 acquires image data from each of the cameras 22-1 and 22-2, and processes the acquired image data. Determination unit 97 determines whether each of camera 22-1 and camera 22-2 is attached to the left or right side of welding robot 10 based on the image obtained by processing the image data. .
When determining that the cameras 22-1 and 22-2 are not properly attached, the determination unit 97 notifies the notification unit 98 of this. When notified by the determination unit 97, the notification unit 98 notifies the user that the cameras 22-1 and 22-2 are not properly attached. Here, the case where the determination unit 97 determines that each of the cameras 22-1 and 22-2 is properly attached will be described.

(Step S8-1)
In the control device 9, the processing unit 94 sets the world coordinate system in the images captured by the cameras 22-1 and 22-2 based on the image of the gauge 230 obtained by processing the image data. . The description continues with reference to FIG.
(Step S1-2)
By rotating the arm 231, the calibration plate (panel 23) is retracted out of the fields of view of the cameras 22-1 and 22-2.
In the control device 9, the processing section 94 calibrates the origin of the camera coordinate system. For example, the welding wire is put out from the tip of the welding torch 16 of the welding robot 10 . An arbitrary position of the cross-sectional shape 32 (for example, a bending point of the groove 3 used as a preset calibration point) is selected as a torch target position, and the welding robot 10 is moved in the X-axis direction and the Z-axis direction, The tip of the welding wire 161 extending from the welding torch 16 is brought into contact with the torch target position.
The camera control unit 96 controls each of the cameras 22-1 and 22-2 to image the welding wire including the tip of the welding wire. Each of camera 22-1 and camera 22-2 images the welding wire including the tip of the welding wire. The processing unit 94 acquires image data from each of the cameras 22-1 and 22-2, and processes the acquired image data.

(Step S2-2)
The welding wire is kept from coming out from the tip of the welding torch 16 of the welding robot 10.例文帳に追加
In the control device 9, the camera control section 96 controls the cameras 22-1 and 22-2 to image the tip of the welding torch 16 respectively. Cameras 22 - 1 and 22 - 2 each capture an image of the tip of welding torch 16 . The processing unit 94 acquires image data from each of the cameras 22-1 and 22-2, and processes the acquired image data.
(Step S3-2)
In the control device 9 , the processing section 94 acquires an image of the wire including the wire tip based on the image of the wire including the wire tip obtained by processing the image data and the image of the tip of the welding torch 16 . The processing unit 94 acquires the coordinates of the welding wire tip (torch aim position) in the robot coordinate system based on the acquired image of the wire including the wire tip.
(Step S4-2)
In the control device 9, the processing unit 94 sets the acquired coordinates of the wire tip in the robot coordinate system as the origin of the world coordinate system. The description continues with reference to FIG.

(Step S1-3)
The saddle movement control section 92 moves the welding robot 10 to the measurement site 31 of the groove 3 .
In the control device 9, the processing section 94 causes the illumination device 21 to linearly illuminate the measurement site 31 in the transverse direction. The processing unit 94 determines sensing points.
(Step S2-3)
In the control device 9, the processing unit 94 can calculate the area with the left camera 22-1 or with the right camera 22-2 based on the characteristics of the object to be welded sandwiching the determined sensing point. Alternatively, it is determined whether area calculation is possible with both the left camera 22-1 and the right camera 22-2.
(Step S3-3)
In the control device 9, the camera control unit 96 controls one or both of the left camera 22-1 and the right camera 22-2, which have been determined to be capable of area calculation, to image the sensing point. .
The camera control unit 96 accesses the IP address stored in the storage unit 95 to control the camera 22-1 and the camera 22-2 to image the measurement site 31 of the bevel 3 respectively. Each of the camera 22-1 and the camera 22-2 takes an image of the measurement site 31 of the bevel 3. As shown in FIG.

(Step S4-3)
In the control device 9, the processing section 94 acquires image data from each of the cameras 22-1 and 22-2, and processes the acquired image data. The processing unit 94 performs inversion processing on one of the images of the measurement site 31 of the groove 3 obtained by processing the image data obtained from each of the cameras 22-1 and 22-2.
(Step S5-3)
In the control device 9, the processing unit 94 performs the reversal process on the measurement site 31 of the groove 3 and the image of the measurement site 31 on the groove 3 without the reversal process. Edge detection processing is performed by calculating the length, angle, plate thickness, and the like. The description continues with reference to FIG.

(Step S1-4)
In the control device 9, the processing unit 94 determines whether or not only the right sensing point is within the use area (the area can be calculated).
(Step S2-4)
In the control device 9, when the processing unit 94 determines that only the right sensing point is within the use area (the area can be calculated), the processing unit 94 uses the right sensing point to determine the shape of the bevel 3 and the robot coordinates. A reference point in the system is derived, and information specifying the derived shape of the groove 3 and the value of the reference point are output.
(Step S3-4)
In the control device 9, when the processing unit 94 determines that only the right sensing point is not within the use area (the area can be calculated), the processing unit 94 determines that only the left sensing point is within the use area based on the result of the edge detection processing. It is determined whether or not it is inside (the area can be calculated).

(Step S4-4)
In the control device 9, when the processing unit 94 determines that only the left sensing point is within the use area (the area can be calculated), the processing unit 94 uses the left sensing point to determine the shape of the bevel 3 and the robot coordinates. A reference point in the system is derived, and information specifying the derived shape of the groove 3 and the value of the reference point are output.
(Step S5-4)
In the control device 9, when the processing unit 94 determines that only the right sensing point is not within the use area (the area can be calculated), it determines whether or not to perform the averaging process of the set parameters.
(Step S6-4)
In the control device 9, the processing unit 94 derives the shape of the groove 3 and the reference point in the robot coordinate system using the right sensing point when determining to perform the averaging of the setting parameters, are used to derive the shape of the groove 3 and the reference point in the robot coordinate system.
The processing unit 94 averages the shape of the groove 3 derived using the right sensing point and the shape of the groove 3 derived using the left sensing point. The processing unit 94 averages the reference point in the robot coordinate system derived using the right sensing point and the reference point in the robot coordinate system derived using the left sensing point.
The processing unit 94 uses the result of averaging the shape of the groove 3 derived using the right sensing point and the shape of the groove 3 derived using the left sensing point, and the right sensing point. and the result of averaging the reference points in the robot coordinate system derived using the left sensing point.

(Step S7-4)
In the control device 9, the processing unit 94 is set to check the setting parameters each time when it is determined that the setting parameters are not averaged.
(Step S8-4)
In the control device 9, the processing section 94 determines whether or not there is an error in the value output in any one of steps S2-4, S4-4 and S6-4.
(Step S9-4)
In the control device 9, if the processing unit 94 determines that there is an error in the output value in any of steps S2-4, S4-4, and S6-4, or checks the setting parameters each time in step S7-4, If so, a processing screen is displayed on the display unit (not shown).
On the processing screen, the user can see the shape of the groove 3 derived using the sensing points on the right side and the reference point in the robot coordinate system, and the shape of the groove 3 derived using the sensing points on the left side and the robot coordinate system. You can choose either the reference point in In the processing screen, the user can modify the data.
(Step S10-4)
In the control device 9, the processing section 94 determines the shape of the groove 3 and the reference point in the robot coordinate system when it is determined in step S8-4 that there is no error value. The processing unit 94 causes the storage unit 95 to store the determined shape of the groove 3 and the reference point in the robot coordinate system.
In step S3-1 of FIG. 8, the case where each of the camera 22-1 and the camera 22-2 captures an image of the gauge 230 drawn on the calibration plate (panel 23) has been described, but it is limited to this example. do not have. For example, an off-line image of the calibration plate (panel 23) may be acquired in advance.
In FIG. 8, steps S3-1 to S5-1 may be omitted after calculating and storing the internal parameters.

In the above-described embodiment, the case where the camera 22-1 and the camera 22-2 are attached to the welding robot 10 has been described, but the present invention is not limited to this example. For example, sensors capable of obtaining luminance information may be attached with each of camera 22-1 and camera 22-2, or instead of camera 22-1 and camera 22-2.
In the above-described embodiment, steps S1-2 to S4-2 in FIG. 9 and steps S1-3 to S5-3 in FIG. 10 may be executed sequentially or in parallel. , may be run separately.
In the above-described embodiment, the case where the two-dimensional gauge 230 is drawn on the surface of the panel 23 with a plurality of orthogonally arranged lines 232 and 233 has been described, but the present invention is not limited to this example.
For example, two arrows arranged orthogonally may be drawn on the surface of the panel 23, and the images captured by the cameras 22-1 and 22-2 may be drawn by the cameras 22-1 and 22-2, respectively. A figure whose orientation and inclination can be detected may be drawn, or an arrangement pattern of a plurality of points having different shapes may be drawn. The gauge 230 is not limited to being drawn on the panel 23 by printing or the like, and may be one that emits light.

In the above-described embodiment, the determination unit 97 determines the coordinates of the origin (VL1) in the camera coordinate system of the two-dimensional gauge from the subject (panel 23) and the vertex (VL2) opposite the origin (VL1) in the left subject image. In the right subject image, the coordinates of the origin (VR1) in the camera coordinate system of the two-dimensional gauge from the subject (panel 23) and the coordinates of the vertex (VR2) opposite the origin (VR1) are obtained. Although the case has been described, it is not limited to this example.
For example, in the left subject image, the determination unit 97 acquires the coordinates of the subject (panel 23) other than the origin (VL1) in the camera coordinate system of the two-dimensional gauge and the coordinates of the opposing apex other than the origin (VL1). , in the right subject image, coordinates other than the origin (VR1) in the camera coordinate system of the two-dimensional gauge from the subject (panel 23) and the coordinates of the vertex (VR2) facing other than the origin (VR1) may be obtained. .
In the above-described embodiment, the panel 23 on which the gauge 230 is displayed is retractable by the movable arm 231, but the present invention is not limited to this example. For example, the panel 23 may be detachable from the welding robot 10 .
In the above-described embodiment, a case where a line laser lighting device is used as the lighting device 21 has been described, but the present invention is not limited to this example.
For example, the illumination device 21 is not limited to a laser beam, and may be another light source, as long as it can illuminate the groove 3 continuously linearly in its transverse direction, or at multiple points aligned linearly, and the cross-sectional shape 32 is obtained. It suffices if the images can be imported collectively.

The welding robot system 1 according to this embodiment includes the welding robot 10 that welds steel materials while moving the steel materials in a predetermined direction. The welding robot system 1 includes a sensor attached to the welding robot 10, a predetermined direction side sensor attached to a predetermined direction side of the welding robot 10, and a sensor attached to the welding robot 10, a sensor attached to the welding robot 10 in a predetermined direction. An opposite side sensor attached to the side opposite to the side, and a determination unit 97 for determining whether the predetermined direction side sensor and the opposite side sensor are attached to the predetermined direction side or the opposite side.
With this configuration, the welding robot system 1 includes the determination unit 97 that determines whether the predetermined direction side sensor and the opposite side sensor are attached to the predetermined direction side or the opposite side. It is possible to judge whether the mounting position of the

In the welding robot system 1, the sensor includes a camera 22, and the welding robot system 1 detects an object installed between the predetermined direction side sensor and the opposite side sensor with the predetermined direction side sensor and the opposite side sensor. A control unit as a camera control unit 96 that controls imaging is further provided. The determining unit 97 determines whether the predetermined direction sensor and the opposite side sensor are mounted on the predetermined direction side or the opposite side by using the images output by the predetermined direction side sensor and the opposite side sensor. judge.
With this configuration, the determination unit 97 uses the images output by the predetermined direction sensor and the opposite side sensor to pick up the subject and determine whether the predetermined direction side sensor and the opposite side sensor are in the predetermined direction. and the opposite side, it is possible to determine whether the mounting position of the camera 22 is correct or not.

In the welding robot system 1, the subject is positioned within a predetermined range of the imaging ranges of the predetermined direction side sensor and the opposite side sensor.
With this configuration, the determination unit 97 uses the images output by the predetermined direction sensor and the opposite side sensor to pick up and output a subject located within a predetermined range of the respective imaging ranges, and determine the predetermined direction side sensor. Since it is possible to determine whether each of the sensor and the opposite side sensor is attached to the predetermined direction side or the opposite side, it is possible to determine whether the mounting position of the camera 22 is correct.

In the welding robot system 1, the subject has a rectangular shape. With this configuration, the determination unit 97 uses an image output by the predetermined direction sensor and the opposite side sensor to pick up and output a rectangular subject, and determines whether the predetermined direction side sensor and the opposite side sensor Since it can be determined whether the camera 22 is installed on the direction side or the opposite side, it is possible to determine whether the installation position of the camera 22 is correct or incorrect.
In the welding robot system 1, the object has a rectangular shape, and the angle formed by the long side of the object and the long sides of the imaging ranges of the predetermined direction side sensor and the opposite side sensor is constant.
With this configuration, the determining unit 97 uses an image output by the predetermined direction sensor and the opposite side sensor to pick up and output a rectangular subject, and determines whether the predetermined direction side sensor and the opposite side sensor Since it can be determined whether the camera 22 is installed on the direction side or the opposite side, it is possible to determine whether the installation position of the camera 22 is correct or incorrect.

In the welding robot system 1, the determination unit 97 uses the coordinates of at least two vertices of the subject included in the image to determine whether the predetermined direction side sensor and the opposite side sensor are attached to the predetermined direction side or the opposite side. determine whether the
With this configuration, the determination unit 97 uses the coordinates of at least two vertices of the subject included in the image to determine whether the predetermined direction side sensor and the opposite side sensor are attached to the predetermined direction side or the opposite side. Therefore, it is possible to determine whether the mounting position of the camera 22 is correct or not.

In the welding robot system 1, the object is calibration for associating the coordinate system of the predetermined direction side sensor and the opposite side sensor with the coordinate system of the welding robot, and the calibration of the predetermined direction side sensor and the opposite side sensor. This is a calibration plate used for calibration.
With this configuration, the determination unit 97 uses the images output by the predetermined direction sensor and the opposite side sensor to capture images of the calibration plate, and determines whether the predetermined direction sensor and the opposite side sensor are in the predetermined direction. Since it is possible to determine whether the camera 22 is installed on the side or the opposite side, it is possible to determine whether the installation position of the camera 22 is correct or incorrect.

In the welding robot system, the calibration plate is also used to measure the cross-sectional shape of the groove.
With this configuration, the determination unit 97 uses the image output by the predetermined direction side sensor and the opposite side sensor to capture and output the calibration plate, which is also used for measuring the cross-sectional shape of the groove, to determine the predetermined direction. Since it is possible to determine whether each of the side sensor and the opposite side sensor is attached to the predetermined direction side or the opposite side, it is possible to determine whether the mounting position of the camera 22 is correct.

In a welding robot system, the calibration plate is also used to determine the tilt of the robot's coordinate system with respect to the world coordinate system.
With this configuration, the determination unit 97 captures and outputs an image of the calibration plate that is also used by the predetermined direction side sensor and the opposite side sensor to determine the inclination of the robot coordinate system with respect to the world coordinate system. can be used to determine whether the predetermined direction side sensor and the opposite side sensor are mounted on the predetermined direction side or the opposite side, respectively.

In the welding robot system, the image is an image output by imaging a subject for calibration by a sensor on the predetermined direction side and a sensor on the opposite side. With this configuration, the determination unit 97 uses the images output by the predetermined direction sensor and the opposite side sensor to pick up the subject for calibration, and obtain the respective images of the predetermined direction side sensor and the opposite side sensor. Since it is possible to determine whether the camera is mounted on the predetermined direction side or the opposite side, it is possible to determine whether the mounting position of the camera is correct.

In the welding robot system 1, an image is output by capturing an object by each of the predetermined direction sensor and the opposite side sensor in order to correct the distortion of the image captured by each of the predetermined direction sensor and the opposite side sensor. This is an image with
With this configuration, the determination unit 97 allows the predetermined direction sensor and the opposite side sensor to image the subject in order to correct the distortion of the images captured by the predetermined direction sensor and the opposite side sensor. It is possible to determine whether the predetermined direction side sensor and the opposite side sensor are mounted on the predetermined direction side or the opposite side, respectively, using the image output by the camera.

In the welding robot system 1, an input unit 93 for allowing the user to input information corresponding to positions where the predetermined direction side sensor and the opposite side sensor are attached, a position corresponding to the information input by the input unit 93, and determination and a notification unit 98 for notifying a user when the predetermined direction side sensor and the opposite side sensor determined by the unit 97 are installed at different positions.
With this configuration, the welding robot system 1 causes the welding robot 10 to move the steel material in a predetermined direction based on the information corresponding to the positions where the predetermined direction sensor and the opposite side sensor are attached. can be welded. The welding robot system 1 can notify the user when the mounting position of the camera 22 is incorrect.

Although the embodiments have been described above, these embodiments are presented as examples and are not intended to limit the scope of the invention. These embodiments can be implemented in various other forms, and various omissions, replacements, changes, and combinations can be made without departing from the scope of the invention. These embodiments are included in the scope and gist of the invention, and at the same time, are included in the scope of the invention described in the claims and equivalents thereof.
Note that the control device 9 described above may be realized by a computer. In that case, a program for realizing the function of each functional block is recorded in a computer-readable recording medium. The program recorded on this recording medium may be loaded into the computer system and executed by the CPU. The "computer system" here includes hardware such as an OS (Operating System) and peripheral devices.
A "computer-readable recording medium" refers to a portable medium such as a flexible disk, a magneto-optical disk, a ROM, and a CD-ROM. A "computer-readable recording medium" includes a storage device such as a hard disk built into a computer system.

Furthermore, the "computer-readable recording medium" may include those that dynamically retain the program for a short period of time. For a short period of time, a program is dynamically stored in a communication line for transmitting a program via a network such as the Internet or a communication line such as a telephone line.
In addition, the "computer-readable recording medium" may also include a medium that retains the program for a certain period of time, such as a volatile memory inside a computer system that serves as a server or client. Further, the program may be for realizing part of the functions described above. Moreover, the above program may be one capable of realizing the functions described above in combination with a program already recorded in a computer system. Moreover, the program may be implemented using a programmable logic device. A programmable logic device is, for example, an FPGA.

The control device 9 described above has a computer therein. Each process of the control device 9 described above is stored in a computer-readable recording medium in the form of a program, and the above process is performed by reading and executing this program by a computer.
Here, the computer-readable recording medium includes a magnetic disk, a magneto-optical disk, a CD-ROM, a DVD-ROM, a semiconductor memory, and the like. Alternatively, the computer program may be distributed to a computer via a communication line, and the computer receiving the distribution may execute the program.
Further, the program may be for realizing part of the functions described above.
Further, it may be a so-called difference file (difference program) that can realize the above-described functions in combination with a program already recorded in the computer system.

1 Welding Robot System 10 Welding Robot 11 Traveling Rail 12 Saddle 13 Case 14 Bracket 15 Holder 16 Welding Torch 161 Welding Wire 2 Welding Object 21 Lighting Device 22, 22-1, 22-2 Camera 220 Imaging Area 221 Support Panel 222 Support Arm 223 support rail 23 panel 230 gauge 231 arm 232, 233 line 3 groove 31 measurement site 32 cross-sectional shape 9 control device 91 welding operation control section 92 saddle movement control section 93 input section 94 processing section 95 storage section 96 camera control section 97 determination Part 98 Notification part

Claims (13)

A welding robot system comprising a welding robot that welds steel materials while moving the steel materials in a predetermined direction,
a sensor attached to the welding robot, the predetermined direction side sensor attached to the predetermined direction side of the welding robot;
a sensor attached to the welding robot, the opposite side sensor attached to the side of the welding robot opposite to the predetermined direction;
a determination unit that determines on which of the predetermined direction side and the opposite side each of the predetermined direction side sensor and the opposite side sensor is attached;
with
The welding robot system , wherein the sensor is a sensor or a camera capable of acquiring luminance information . a control unit that controls the predetermined direction side sensor and the opposite side sensor to image an object placed between the predetermined direction side sensor and the opposite side sensor,
the sensor includes a camera;
The determination unit uses the images output by the predetermined direction sensor and the opposite side sensor to pick up and output the subject, and the predetermined direction side sensor and the opposite side sensor determine the predetermined direction side and the opposite side sensor. The welding robot system of claim 1 that determines where it is attached. 3. The welding robot system according to claim 2, wherein the subject is located within a predetermined range of the imaging range of each of the predetermined direction side sensor and the opposite side sensor. 3. The welding robot system according to claim 2 , wherein said object has a rectangular shape. The angle formed by the long side of the subject and the long side of the imaging range of each of the predetermined direction side sensor and the opposite side sensor is constant.
The welding robot system according to claim 4. The determination unit uses the coordinates of at least two vertices of the subject included in the image, and the predetermined direction side sensor and the opposite side sensor are attached to either the predetermined direction side or the opposite side. The welding robot system according to claim 2 , which determines whether The subject is calibration for associating the coordinate system of the predetermined direction side sensor and the opposite side sensor with the coordinate system of the welding robot, and is used for calibration of the predetermined direction side sensor and the opposite side sensor. Welding robot system according to claim 2 , which is a calibration plate used. The welding robot system according to claim 7, wherein the calibration plate is also used for measuring the cross-sectional shape of the groove. 8. The welding robot system of claim 7 , wherein the calibration plate is also used to determine the tilt of the welding robot's coordinate system with respect to the world coordinate system. 8. The welding robot system according to claim 7 , wherein said image is an image output by capturing images of said subject for said calibration by said predetermined direction side sensor and said opposite side sensor. The image is an image output from the subject captured by each of the predetermined direction sensor and the opposite side sensor in order to correct distortion of the image captured by each of the predetermined direction side sensor and the opposite side sensor. The welding robot system according to claim 2 , wherein: an input unit for allowing a user to input positional information corresponding to positions where the predetermined direction side sensor and the opposite side sensor are attached;
When the position corresponding to the positional information input by the input unit is different from the position where the predetermined direction sensor and the opposite side sensor are installed, which is determined by the determination unit, the user a notification unit that notifies,
The welding robot system according to any one of claims 1 to 11, comprising: A determination method executed by a welding robot system including a welding robot that welds a steel material while moving the steel material in a predetermined direction, comprising:
A predetermined direction side sensor mounted on the predetermined direction side of the welding robot and an opposite side sensor mounted on the side opposite to the predetermined direction side of the welding robot are respectively connected to either the predetermined direction side or the opposite side. determining whether it is attached to
The determination method , wherein the predetermined direction side sensor and the opposite side sensor are sensors or cameras capable of acquiring luminance information .

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