JPH03234491A - Automatic loading device using robot - Google Patents

Abstract

PURPOSE:To increase the speed of loading and unloading work by providing an image processing means for detecting the difference in level of a load from the image signal of a band reflected light inputted from a camera and outputting a difference-in-level signal of the load, and a robot means for loading and unloading the load onto a pallet according to the difference-in-level signal of the load inputted from the image processing means. CONSTITUTION:A light source 9 radiating a band light onto a load 3 and a camera 10 for detecting the reflected light are disposed in positions angled to each other. Hence, when the load 3 has a difference in level, the difference in level of the load 3 is detected by the displacement of the band light detected by the camera 10, and the difference in level of the load is confirmed, whereby the loading and unloading of the load 3 can be certainly conducted by a robot means 4.

Description

DETAILED DESCRIPTION OF THE INVENTION Field of Industrial Application The present invention relates to an automatic transfer device using a robot for loading and unloading palletized boxes and loads of similar shapes onto and from pallets using a transfer robot. It is related to.

Conventional technology As a transfer device using a conventional robot, Utility Model 61-1
A transfer device disclosed in Japanese Patent No. 10640 is known. This conventional transfer equipment! In this system, an image sensor detects a unique mark written on the top surface of a load loaded on a pallet, and this sends detection signals such as the type, direction, and position of the load to the control system. The controller then calculates the data input for the load among the data set for each type of load and the input described above, to send the movement signal most suitable for the load to the transfer robot. is giving to Also, pallets and loads are placed on the table lifter! The height of the top of the load is adjusted by the table lifter to the level detected by the level detection device.

Problems to be Solved by the Invention However, with conventional robot-based transfer devices, as the load on the pallet is depalletized by the transfer robot, the height of the load gradually decreases, and the image sensor - A table lifter and a level detection device were required because of the loss of focus. In particular, the table lifter is large in size because it supports the entire 7R weight of the load and pallet and moves it up and down, which poses a problem in terms of cost and inspection and maintenance.

In order to solve the above problems, cameras having a zoom function have been adopted. However, because the camera itself has a large depth of field, even if there is a part where there is no load in the arrangement of loads on the top tier (hereinafter referred to as missing), it will still detect the loads on the lower tier. There was a problem in that it was not possible to determine if there was a gap.

The present invention solves the above problems, and aims to provide an automatic transfer device using a robot that can reduce the cost and burden of inspection and maintenance, and can detect the arrangement of loads even if there are gaps. That is.

Means for Solving the Problems In order to solve the above-mentioned problems, the automatic transfer device using a robot of the present invention includes a light source that irradiates a band-shaped light from above or diagonally above the cargo onto the bottom of the cargo loaded on a pallet; A camera detects the reflected light of the load from the light source from diagonally above or above in a direction orthogonal to the band-shaped light, and a step difference signal of the load is detected by detecting the step of the load from an image signal of the band-shaped reflected light inputted from the camera. and a robot means for loading and unloading loads onto the pallet in accordance with a load level difference signal inputted from the image processing means.

Effect With the above configuration, the light source that emits a band-shaped light under the load and the camera that detects the light reflected from the load are installed at diagonal positions, so that when there is a step in the load, the band-shaped light that is detected by the camera is By shifting the position of the light, a level difference in the load is detected, and by confirming the level difference in the load, the robot means can reliably load and unload the load.

Example An embodiment of the present invention will be described below based on the drawings.

FIG. 1 is a block diagram of an automatic transfer device using a robot according to the present invention.

1 is a conveyor, and by this conveyor 1, a load 3 loaded on a pallet 2 is conveyed at a constant speed in the α direction indicated by an arrow. The transfer robot 4 uses a vacuum hand 4A to depalletize the load 3 that has been conveyed to the first position 1 (depalletizing position 1) by the conveyor 1, and this robot 4 is controlled by the robot controller 5. Further, the first position is detected by a first optical sensor 6 provided along the conveyor 1.

At a second position upstream from the first position, a second optical sensor 7 is provided along the conveyor 1 to detect that the load 3 has been conveyed to the second position 1. Second place! A laser light source 9 is provided above the center of the conveyor 1 to irradiate the load 3 with a band-shaped light 8 in a direction perpendicular to the conveyance direction of the load 3. 9 receives the band-shaped reflected light of the load 3;
A CD type camera 10 is provided. The image signal of this first camera 10 is input to the first image processing device 11,
The width of the load 3 and the height of the load 3 at the second position are detected.

The principle of detecting the width and height of the load 3 by the first image processing device 11 will be explained based on FIGS. 2 and 3.

Now, as shown in FIG. 1, a case will be described in which the load 3 on the front right side of the load 3 on the pallet 2 is missing. In FIGS. 2 and 3, ρ1 is the width of the load 3 on the right side, g2 is the width of the load 3 on the left side, hl is the height of the load 3 on the right side, and h2 is the height of the load 3 on the left side.

As shown in FIG. 2(b), the first camera 10 sees the band-shaped light 8 from an oblique direction, so if there is a missing part, the band-shaped light 8 will have a high pitch as shown in FIG. There will be a step corresponding to the height. Therefore, the height h from the top of pallet 2
t, h2 are detected by band-shaped light 8, and @Ω1. of load 3 is detected by @(length) of light 8. ρ2 is detected. This second position data is detected every time an X coordinate signal from the conveyor controller 18 (described later) is input, and along with the X coordinate, image data (Xn, (11, R2, h1h2
) and output to the overall controller 14, which will be described later.

Additionally, a second CC is placed above the center of the pallet 2 transported to the first position so as to overlook the arrangement of the loads 3 on the pallet 2.
A D-type camera 12 is provided, and the image of this second camera 12! The signal is input to the second image processing device 13. Furthermore, the second camera 12 is equipped with a zoom <m configuration), and a second image processing device! The lens is focused in accordance with the position signal No. 13.

The second image processing device 13 calculates the zoom position of the second camera 12 in accordance with a zoom signal consisting of data on the height of the topmost load 3 on the pallet 2 inputted from a general controller 14 to be described later. When the position signal is output to the second camera 12 and the image signal is input from the second camera 12, the unique mark 1 provided on the top surface of the load 3 is displayed as shown in FIG.
5 all at once, and corrects the distortion in the horizontal direction of the image due to the use of zoom using the distortion learned in advance at the height direction position, and for each load 3, the image is detected in the X-Y plane with the center of the robot 4 as the origin. The central coordinates (x, y) of the load 3 and the longitudinal inclination θ of the load 3 from the
, θ) to the overall controller 14.

Further, as shown in FIG. 1, a pulse encoder 17 is connected to a motor 16 that drives the conveyor 1. The pulse signal from the pulse encoder 17 and the pallet detection signals from the first and second optical sensors 6.7 are input to the conveyor controller 18, and the above signals and the overall controller 14
Conveyor controller 18 in response to a movement command signal from
drives the motor 16 and laser light source 9 of the conveyor 1, and outputs necessary signals to the general controller 14 and the first image processing device 11.

The conveyor controller 18 will be explained in detail based on the block diagram of FIG.

As shown in FIG. 5, the conveyor controller 18 includes a motor control unit 19, a motor drive unit 20 that drives the motor 16 using a drive signal from the motor control unit 19, a counter 21 that counts pulse signals from the pulse encoder 17, and image processing data. It is composed of a section 22.

The motor control unit 19 is a control unit that stops the conveyor 1 when the pallet 2 arrives at the first position, and restarts the conveyor 1 in response to a movement command signal from the general controller 14.
When the detection signal of the first optical sensor 6 is OFF or the movement command signal from the general controller 14 is ON, a drive signal is output to the motor drive section 20, and when the detection signal of the first optical sensor 6 is turned ON. , outputs a pallet arrival signal to the first position to the general controller 14.

The image processing data section 22 is a control section that executes image processing using the first camera 10 when the pallet 2 arrives at the second position, and when the detection signal of the second optical sensor 7 is turned on. When the detection signal of the second optical sensor 7 does not change from off to on, the counter 21 is reset, and while the detection signal of the second optical sensor 7 is on, the counter 21 is reset. Every time the count value increases by n counts, an X coordinate signal corresponding to the count value, xl,
x2.

x3... to the first image processing device 11, and a signal during image processing to the general controller 14.

The overall controller 14 will be explained based on the block diagram of FIG.

The general controller 14 obtains accurate image data for each stage of the load 3 on the pallet 2 based on the image data input from the first and second image processing devices ff11.13, and sequentially sends the image data to the robot controller 5 for each stage. It outputs necessary signals to the conveyor controller 18 and the second image processing device 13, and the image data storage section 23,
It is composed of a planar image forming section 24, an image data forming section 25, and a control section 26.

The image data storage unit 23 stores the image data (Xn,
j2t, A2. ht, h2) are stored in order, and when the signal during image processing is turned off, the image data (hl, h2'
), the detected height of the load 3 is searched and output to the control unit 26.

In the case of the shape of the load 3 shown in Fig. 1, the height of the load 3 is H
, 2H are searched.

When the flat image forming section 24 receives the image forming signal from the control section 26, the planar image forming section 24 displays the object 3 searched in the image data storage section 23.
Image data (X,
A1. fi2. hl, h2) to form plane data (plan view) as shown in Fig. 7, and when the formation is completed,
A formation completion signal is output to the control section 26, and a reset signal for used image data is output to the image data storage section 23.

Upon receiving the image forming signal and the height signal of the load 3 from the control unit 26, the image data forming unit 25 inputs planar data from the planar image forming unit 24 in accordance with the height signal of the load 3, and
The input image data (x, y
, θ), only the image data included in this planar data is picked up and output to the control unit 26 as image data in units of rows.

Therefore, among the image gA signals detected by the second camera 12, data other than the items 3 arranged in the uppermost row are erased.

The control section 26 will be explained according to the flowchart in FIG.

When the control unit 26 first receives a pallet arrival signal from the conveyor controller 18 (step 5-1), it outputs an image forming signal to the planar image forming unit 24 (step 5-1).
2) Next, when a formation end signal is input from the flat image forming unit 24 (step 5-3), the items 3 are arranged in descending order of height from the height H, 2H data input from the image data storage unit 23. (Step 5-4), a zoom signal is formed from the high height data (2H) of the load 3, that is, from the height data of the topmost layer, and is output to the second image processing device 13 (Step 5-4). 5), then output an image forming signal to the image data forming section 25 (step S6), and when inputting image data in units of columns from the image data forming section 25 (step 5-7), the image data in units of columns and the final A motion command signal consisting of the height of the upper load 3 is formed and output to the robot controller 5 (step 5-8).The robot controller 5 controls the robot 4 based on the input image data, and from above the pallet 2. The load 3 on the top stage is depalletized, and upon completion, a stage unit completion signal is output. Control unit 26
When inputting this stage unit completion signal (step 5-9)
, check if there is data on the height of the next load 3 (step S-10), and if there is data on this height, step S-10)
5, and steps S-5 to S-9 are executed, for example, at the height H of the load. If it is confirmed in step 5-10 that there is no height data for the next load, it is assumed that all stages have been transferred and a movement command signal is output to the conveyor controller 18 (step S-11).

With the configuration of the automatic transfer device using the robot described above, when the load 3 transported by the conveyor 1 reaches the second position, a band-shaped light is irradiated onto the load 3 from the laser light source 9, and at the same time, the load 3 passes through. In other words, image data (xn, Ω1.ρ2h1.h2) is formed and accumulated from the image signal detected by the first camera 10 for each x-coordinate signal. When the load 3 reaches the first position, the load 3 is stopped;
The accumulated image data (Xn, A1.t22
+ hth2), plane data is formed for each height, and within this plane data is image data (x, y, θ) based on an image signal from the second camera 12 that is zoom-controlled to the height of this plane data. is confirmed, and only the confirmed data (x, y, θ) is output to the robot controller 5, and the robot 4 depallets the load 3 arranged at the top of the load height. Similarly, the loads 3 in the next stage are depalletized in order, and when the transfer of all stages is completed, the empty pallet 2 is conveyed by the conveyor 1.

In this way, the height of the load 3 passing through the second position is detected by the laser light source 9, the first camera 10, and the first image processing device 11, thereby confirming the condition of missing teeth. This makes it possible to delete the data corresponding to the position of the missing tooth from the image data detected by the camera 12 with a large depth of field, and therefore, when the robot 4 moves the vacuum hand 4A to the missing part, it is unnecessary. It is possible to eliminate repetitive movements and speed up the depalletizing work. In addition, the conventional table lifter is no longer necessary, reducing costs and the burden of inspection and maintenance.

In this embodiment, the laser light source 9 is installed directly above the second digit 1! Then, move the first camera 10 diagonally upward! However, the first camera 10 is placed directly above the second position! However, the same effect can be obtained even if the laser light source 9 is installed obliquely upward. Furthermore, in this embodiment, the loads 3 are moved by the conveyor 1 to form planar data for each height of the loads 3, but it is determined that the loads 3 are loaded in three rows as shown in FIG. 3, a laser light source 9 is installed above the load 3, the irradiation angle of the beam light from this laser light source 9 is switched, the beam light is irradiated sequentially to each row of loads 3, and the reflected light from each load 3 is captured by the camera 1.
By detecting at 0, for example, an image signal shown in FIG. 10 can be obtained, and a step difference in the load 3 can be detected without moving the load 3 by the conveyor 1. In addition, in this embodiment, the load 3 is depalletized from the pallet 2, but the robot 4 collects data (x, y, θ).
It is also possible to stack another load 3 on top of the load 3 obtained.

Effects of the Invention As described above, according to the present invention, if there is a step difference in the load on the pallet, the band-shaped light detected by the camera detects the difference in level or the position of the load on the pallet. The condition of the level difference can be checked, and therefore the robot means can reliably load and unload the load while paying attention to the level difference, and the speed of loading and unloading work can be increased. In addition, the conventional table lifter is no longer necessary, reducing costs and the burden of inspection and maintenance.

[Brief explanation of drawings]

The drawings show an embodiment of an automatic transfer device using a robot according to the present invention, in which Fig. 1 is a configuration diagram, and Fig. 2 fa) and (b) show the arrangement of a laser light source and a first camera. figure,
Figure 3 is a screen diagram of the light recognized by the first camera, Figure 4 is a coordinate diagram of the load recognized by the second camera and second image processing device, and Figure 5 is a block diagram of the conveyor controller. ,
Figure 6 is a block diagram of the overall controller, Figure 7 (a)
and fb) are plan views for each load height, Figure 8 is a flowchart of the control unit of the general controller, and Figure 9 is a diagram of the laser light source and the first camera when the laser light source is installed above each row of loads. 10 is a screen diagram of light recognized by the first camera in FIG. 9. 1... Conveyor, 2... Pallet, 3... Load, 4
...Robot, 5...Robot controller, 6.
...First optical sensor, 7... Second optical sensor, 8...
- Light, 9... Laser light source, 10... First camera, 11... First image processing device, 12... Second camera, 13... Second image processing device, 14... General controller, 15... Unique mark, 16... Motor, 17... Pulse encoder, 18... Conveyor controller.

Claims (1)

[Claims] 1. A light source that irradiates a strip of light onto a load loaded on a pallet from above or diagonally above the load, and detects light reflected from the load by the light source from diagonally above or above in a direction perpendicular to the strip of light. a camera; an image processing means for detecting a step difference in the load from an image signal of the band-shaped reflected light inputted from the camera and outputting a step difference signal for the load; A robot-based automatic transfer device equipped with robot means for loading and unloading loads onto pallets.