WO2020137184A1

WO2020137184A1 - Automatic welding system, method for manufacturing elevator cage parts, and automatic welding method

Info

Publication number: WO2020137184A1
Application number: PCT/JP2019/043673
Authority: WO
Inventors: 岸本　直樹; 武司阿部
Original assignee: 三菱電機株式会社
Priority date: 2018-12-27
Filing date: 2019-11-07
Publication date: 2020-07-02
Also published as: CN113195142A; CN113195142B; JP7046226B2; JPWO2020137184A1

Abstract

This automatic welding system comprises: a data storage unit in which an order number, a drawing number, and dimension data about a workpiece to be welded are stored in association with each other; a calculation unit which calculates the welding position of the workpiece to be welded on the basis of the drawing number and the dimension data corresponding to the result of entering the order number; an image processing device that calculates an error amount between the actual installation position of the workpiece to be welded, obtained from the result of photographing by means of a camera and the regular installation position of the workpiece to be welded, obtained from the welding position calculated by the calculation unit; and a welding machine. The calculation unit recalculates the welding position on the basis of the error amount to calculate the corrected welding position, and causes the welding machine to perform welding on the workpiece to be welded on the basis of the corrected welding position.

Description

Automatic welding system, manufacturing method for elevator cab parts, and automatic welding method

The present invention relates to an automatic welding system for welding workpieces to be welded, a method for manufacturing elevator cab parts, and an automatic welding method.

As a conventional automatic welding system, NC (Numerical Control) data generated by a CAM (Computer-Aided Manufacture) system from CAD (Computer-Aided Design) data including information such as the shape and attachment position of an object to be welded is used. 2. Description of the Related Art A system is known in which correction is performed based on a measurement result regarding the installation position of an object to be welded by a sensor such as a camera (see, for example, Patent Documents 1 and 2).

JP, 2002-336994, A Japanese Unexamined Patent Publication No. 7-230310

In such an automatic welding system, it is necessary to prepare CAD data that describes the welding position information of each work. However, for example, when the dimensions and the welding position change depending on the customer's required specifications such as a panel-shaped member of an elevator, it is necessary to prepare CAD data for each specification. Therefore, when applying the conventional automatic welding system, there is a problem that it takes time.

In addition, when applying the method of welding by sensing the welding position with a sensor such as a camera to a product with a large number of welding points and a large amount of data, sensing is performed for a long time. Therefore, there is a problem that productivity is not improved.

The present invention has been made to solve the above problems, and prepares CAD data corresponding to each required specification even when the work size and the welding position change depending on the required specification of the customer. An object of the present invention is to obtain an automatic welding system, a method for manufacturing elevator cab components, and an automatic welding method capable of improving workability for welding various workpieces to be welded without necessity.

In the automatic welding system according to the present invention, an order number, a drawing number of a work to be welded corresponding to the order number, and dimension data necessary for calculating a welding position of the work to be welded are stored in association with each other. Server, computer that calculates the welding position of the workpiece to be welded based on the drawing number and dimension data output from the server according to the input result of the order number, a camera that can capture the welding position of the workpiece to be welded, and an image taken by the camera Compare the actual installation position of the workpiece to be welded obtained from the result with the regular installation position of the workpiece to be welded obtained from the welding position calculated by the computer, and find the difference between the regular installation position and the actual installation position. An image processing device that calculates a certain installation error amount and a welder that welds the welding position calculated by the computer are provided, and the computer recalculates the welding position based on the installation error amount calculated by the image processing device. The corrected welding position is calculated by and the welding machine is caused to perform the welding of the workpiece to be welded based on the corrected welding position.
Further, the method for manufacturing an elevator cab room part according to the present invention is a method for manufacturing an elevator cab room part using the automatic welding system according to the present invention, wherein the workpiece to be welded is a floor plate that is an elevator cab part, It is either the ceiling, the door of the car or the wall of the cab.
Furthermore, the automatic welding method according to the present invention uses a step of calculating the welding position of the workpiece to be welded based on the drawing number and the dimension data output from the data storage unit, and a camera capable of photographing the welding position of the workpiece to be welded. The actual installation position of the workpiece to be welded obtained from the shooting result is compared with the regular installation position of the workpiece to be welded obtained from the calculated welding position, and it is the difference between the regular installation position and the actual installation position. The process of calculating the installation error amount, the process of calculating the corrected welding position by recalculating the welding position based on the calculated installation error amount, and the welding target for the welding machine based on the corrected welding position And a welding process for executing the welding of the work.

According to the automatic welding system according to the present invention, even when the work size and the welding position change depending on the customer's required specifications, it is possible to perform various welding on workpieces without needing to prepare CAD data corresponding to each required specification. It is possible to obtain an automatic welding system, a manufacturing method of elevator cab room parts, and an automatic welding method capable of improving workability of welding.

FIG. 3 is a perspective view of an elevator cab manufactured by the welding method according to the first embodiment of the present invention. FIG. 3 is an explanatory diagram of components of an elevator cab manufactured by the welding method according to the first embodiment of the present invention. It is a figure which shows the whole automatic welding system structure which concerns on Embodiment 1 of this invention. FIG. 6 is a schematic diagram showing another configuration for expanding the reach range of the welding robot in the first embodiment of the present invention. FIG. 3 is a schematic diagram showing exchange of information between each component in the automatic welding system according to the first embodiment of the present invention. 5 is a flowchart showing a flow of a series of welding processes by the automatic welding system according to the first embodiment of the present invention. It is a figure which shows the relationship of the calculation formula linked|related with the drawing number by Embodiment 1 of this invention. It is the schematic which showed the specific example of the workpiece|work to be welded by Embodiment 1 of this invention. It is explanatory drawing which showed the specific example of the calculation formula regarding the dimension, installation position, and welding position of the reinforcement member by Embodiment 1 of this invention. It is explanatory drawing which showed the specific example of the calculation formula regarding the dimension, installation position, and welding position of the reinforcement member by Embodiment 1 of this invention. FIG. 3 is a plan view of a workpiece to be welded according to the first embodiment of the present invention. FIG. 3 is a front view of the workpiece to be welded according to the first embodiment of the present invention. It is explanatory drawing which extracted a part of welding instruction|indication by Embodiment 1 of this invention. FIG. 3 is a schematic diagram of a captured image of the camera according to the first embodiment of the present invention. It is explanatory drawing of the welding position correction method by Embodiment 1 of this invention. It is a schematic diagram of the butt welding by Embodiment 2 of this invention. It is explanatory drawing of the welding conditions by Embodiment 3 of this invention. It is explanatory drawing of the detailed welding conditions by Embodiment 3 of this invention. It is a perspective view of the clamp jig by Embodiment 4 of this invention. It is explanatory drawing which showed the correspondence of the welding position and clamp position by Embodiment 4 of this invention.

Hereinafter, preferred embodiments of the automatic welding system, the method for manufacturing an elevator cab room component, and the automatic welding method according to the present invention will be described with reference to the drawings.

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

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

The computer 20 connected to the server 10 is installed with software for calculating the welding position of the workpiece 200 to be welded. The computer 20 causes the welder 100 to weld the workpiece 200 to be welded based on the calculated welding position.

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

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

The camera 31 is connected to the image processing device 30. The camera 31 can photograph the workpiece 200 to be welded, and the photographed image is output to the image processing device 30 as a photographing result. The image processing device 30 can acquire the information of the point cloud and the contour from the image, and can detect the two-dimensional position or the three-dimensional position of the welding target work 200 and the posture of the welding target work 200 shown in the image. Arbitrary methods can be used for the position detection and the attitude detection.

The welding robot 110 is installed such that the welding torch 120 can weld the welding target work 200 and the camera 31 can take an image of the welding position of the welding target work 200. ..

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

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

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

Next, a series of flows of automatic welding by the automatic welding system according to the first embodiment will be described with reference to FIGS. 5 and 6. FIG. 5 is a schematic diagram showing exchange of information between each component in the automatic welding system according to the first embodiment of the present invention. In FIG. 5, each component of the server 10, the computer 20 in which the welding position calculation software is installed, the image processing device 30 connected to the camera 31, and the welding machine 100 is shown. These constituent elements are connected by a wired cable or radio waves. As a result, a local network is constructed in the automatic welding system according to the first embodiment.

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

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

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

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

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

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

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

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

On the other hand, when the installation error amount exceeds the allowable error amount, the computer 20 notifies the error and prompts the operator to move the welding target work 200 to the correct position.

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

Finally, in step S609, the computer 20 transmits the recalculated and corrected welding position to the robot controller 140, and causes the welding robot 110 to start automatic welding.

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

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

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

As described above, the drawing number, the vertical dimension, and the horizontal dimension corresponding to the workpiece 200 to be welded are stored in the server 10 in association with the order number. Therefore, for example, by reading the bar code or the like used for tracking the manufacturing line, the order number is acquired, and the read order number is collated by the server 10, so that the computer 20 displays the drawing corresponding to the workpiece 200 to be welded. The number, the vertical dimension, and the horizontal dimension can be obtained.

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

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

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

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

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

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

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

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

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

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

Therefore, the image processing device 30 has position coordinates G(a, b) and H(a, b+Z1) that are regular installation positions and position coordinates G(a+δa, b+δb) and H(a+δa′) that are actual installation positions. , B+Z1+δb′), it is possible to specify δa, δb, δa′, δb′ as installation error amounts. If these installation error amounts exceed the allowable error amount, the processing ends with an error.

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

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

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

　The welding start point and welding end point are linear. Therefore, the computer 20 can create a welding line in consideration of the installation error amount by linearly complementing the positions of these two points. Therefore, the computer 20 can complement the welding position even when the position in the middle of welding is the blind spot of the camera 31. The computer 20 can similarly obtain the welding line of the other reinforcing member 202. Therefore, the computer 20 can cause the robot controller 140 to perform welding of the workpiece 200 to be welded by the welding robot 110 by transmitting these data to the robot controller 140.

As described above, according to the first embodiment, prior to actual welding, the welding position is photographed by using the camera, and the image processing apparatus is used to calculate the installation error amount of the welding target workpiece using the photographed result. Thus, the position and locus data of the welding torch obtained by off-line teaching based on the drawing number and dimension data can be corrected. As a result, it is possible to deal with the installation error of each work and the variation of the work itself, and it is possible to improve the welding accuracy.

Also, the welding position of the reinforcing member can be automatically calculated by a calculation formula. Therefore, it is not necessary to mark the welding position in advance, and the operator does not need to manually input the welding position. Therefore, it is possible to reduce welding mistakes and eliminate the need for an operator, which improves workability and reduces labor costs.

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

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

FIG. 16 is a schematic diagram of butt welding according to the second embodiment of the present invention. For example, when butt welding the welding member 210(a) and the welding member 210(b) using the laser 122 as shown in FIG. 16, the welding position correction process is performed based on the recognition result of three or more points. The effect of doing is demonstrated.

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

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

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

For example, instead of the welding torch 120, a welding electrode may be attached to the robot and may be applied to spot welding. In addition, a grinder may be attached to the robot instead of the welding torch 120 and used for deburring or for removing the welding bead.

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

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

In addition to the drawing number and dimensional data, the welding condition can be automatically selected by transmitting the material and plate thickness data of the workpiece to be welded from the server 10 to the computer 20.

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

Fourth Embodiment
FIG. 19 is a perspective view of a clamp jig according to the fourth embodiment of the present invention. The clamp jig 301 for the workpiece to be welded includes a stage 302, a beam 303, and a clamp portion 304. By preparing a clamp position calculation formula having the drawing number and the dimension data as parameters in the computer 20, the clamp position can be automatically adjusted according to the dimension and installation position of the workpiece to be welded.

With this, the clamp position adjustment process before welding can be automated. The clamp portion 304 of the clamp jig 301 is composed of, for example, an air cylinder, and is clamped by pressing a workpiece to be welded. The beam 303 and the clamp portion 304 are composed of, for example, a ball screw and a linear guide so as to be movable in the x-axis direction and the y-axis direction.

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

10 server, 20 computer, 30 image processing device, 31 camera, 100 welding machine, 110 welding robot, 111 manipulator, 120 welding torch, 130 movable stage, 140 robot control device, 200 welding target work, 201 design panel, 202 reinforcement member , 301 clamp jig, 302 stage, 303 beam, 304 clamp part, 305 torch, 400 cab room, 401 ceiling, 402 basket door, 403 cab room wall, 404 floor board.

Claims

A data storage unit in which an order number, a drawing number of a workpiece to be welded corresponding to the order number, and dimension data necessary for calculating a welding position of the workpiece to be welded are stored in association with each other,
A calculator that calculates a welding position of the workpiece to be welded based on the drawing number and the dimension data output from the data storage unit according to the input result of the order number.
A camera capable of photographing the welding position of the workpiece to be welded,
The actual installation position of the workpiece to be welded obtained from the image taken by the camera is compared with the regular installation position of the workpiece to be welded obtained from the welding position calculated by the calculator, and the regular installation is performed. An image processing device that calculates an installation error amount that is a difference between a position and the actual installation position, and a welding machine that welds the welding position calculated by the calculation unit,
The calculator calculates a corrected welding position by recalculating the welding position based on the installation error amount calculated by the image processing device, and the welder based on the corrected welding position. An automatic welding system that causes the above-mentioned workpiece to be welded.
The automatic welding system according to claim 1, wherein the data storage unit stores material data of the workpiece to be welded, and the calculation unit determines welding conditions of the workpiece to be welded based on the material data.
The welder is
Welding of the workpiece to be welded is performed by controlling the position of the robot based on the robot having the welding torch attached to the tip thereof and having at least three drive axes, and the corrected welding position received from the calculator. The automatic welding system according to claim 1 or 2, further comprising:
The welding machine further includes a movable stage on which the robot is installed and which can move the entire robot,
The automatic control according to claim 3, wherein the control device performs welding of the workpiece to be welded by performing position control of the robot and the movable stage based on the corrected welding position received from the calculation unit. Welding system.
The camera is mounted on the robot,
The calculation unit outputs a movement command for moving the robot to a position where the welding position can be imaged, to the control device,
The control device controls the position of the robot based on the movement command, causes the camera to photograph the welding position,
The automatic welding system according to claim 3, wherein the image processing device calculates the installation error amount by using a photographing result of the welding position by the camera mounted on the robot.
The camera photographs two points of a welding start point and a welding end point included in the welding position,
The automatic welding system according to any one of claims 1 to 5, wherein the image processing device calculates the installation error amount based on a shooting result regarding the welding start point and a shooting result regarding the welding end point.
A method of manufacturing an elevator cab part, which uses the automatic welding system according to any one of claims 1 to 6,
The work to be welded is either a floor plate that is an elevator car room part, a ceiling, a car door or a car room wall,
Manufacturing method of elevator cab parts.
A step of calculating the welding position of the workpiece to be welded based on the drawing number and the dimension data output from the data storage unit,
The actual installation position of the welding target work obtained from the photographing result by the camera capable of photographing the welding position of the welding target work, and the regular installation position of the welding target work obtained from the calculated welding position Comparing, calculating the installation error amount that is the difference between the regular installation position and the actual installation position,
Calculating a corrected welding position by recalculating the welding position based on the calculated installation error amount;
A welding step of causing a welding machine to perform welding of the workpiece to be welded based on the corrected welding position.