WO2023002754A1 - 溶接関連情報の表示方法、表示装置、溶接システム、プログラム、および溶接関連情報の表示画面 - Google Patents
溶接関連情報の表示方法、表示装置、溶接システム、プログラム、および溶接関連情報の表示画面 Download PDFInfo
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/09—Arrangements or circuits for arc welding with pulsed current or voltage
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/095—Monitoring or automatic control of welding parameters
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/10—Other electric circuits therefor; Protective circuits; Remote controls
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
- B23K9/124—Circuits or methods for feeding welding wire
Definitions
- the present invention relates to a welding-related information display method, display device, welding system, program, and welding-related information display screen.
- GMAW gas metal arc welding
- welding behavior various welding phenomenon behaviors (hereinafter referred to as spatter and fume) occur during welding.
- Some welding behaviors such as spatter and fume, are harmful to welding quality.
- a method for measuring various kinds of information and displaying the information has been demanded.
- Patent Document 1 As a conventional display method, in Patent Document 1, it is proposed to confirm in chronological order how the chronological data of at least one of the welding current and the welding voltage are related to the teaching steps of the work program.
- An intended display method is disclosed. Specifically, the time-series data of both the welding current and the welding voltage obtained during arc welding are associated with the work program used for welding, and the teaching steps of the work program are displayed on the display screen in time-series with markers. Displaying in correspondence with data is disclosed.
- Patent Document 2 discloses a display method for the purpose of improving the quality of advanced automatic welding work by quickly grasping information on the welding state and sensitively responding to changes in the welding work environment. ing. Specifically, average current, average voltage, average arc short time, etc. are displayed as status data, and lamination, weaving, groove, welding current, welding voltage, Y-axis control, Z-axis control, etc. are displayed on one screen. An enabling method is disclosed.
- Patent Literature 1 shows only current and voltage as measurement items, and it can be said that the information for solving various problems related to welding is insufficient.
- Patent Document 2 lamination, weaving, groove, welding current, welding voltage, Y-axis control, Z-axis control, etc. are displayed on one screen.
- each measurement item is displayed in one graph, making it difficult to compare each measurement item.
- displaying these multiple measurement items by graph on one screen makes it easier for workers to quickly recognize information. hard.
- the purpose of the present invention is to enable workers to quickly recognize a plurality of pieces of welding-related information and to easily acquire useful information when solving more advanced welding-related problems.
- the present invention has the following configuration. That is, a method for displaying welding-related information, a display step of displaying at least two of the plurality of measurement items included in the welding-related information on the same graph in association with at least one of time series and position information; each of the at least two measurement items is displayed by changing at least one of color and line type on the graph; at least one of a display screen of the graph and a display screen of a moving image of welding associated with the measurement item displayed in the graph or a display screen of history information of errors detected in the measurement item; is switchable,
- the welding-related information includes at least one of welding setting information, welding status information, production status information, correction information, and welding phenomenon information.
- a display device for welding-related information display means for displaying at least two of the plurality of measurement items included in the welding-related information on the same graph in association with at least one of time series and position information; each of the at least two measurement items is displayed by changing at least one of color and line type on the graph; at least one of a display screen of the graph and a display screen of a moving image of welding associated with the measurement item displayed in the graph or a display screen of history information of errors detected in the measurement item; is switchable,
- the welding-related information includes at least one of welding setting information, welding status information, production status information, correction information, and welding phenomenon information.
- a welding device i.e. a welding device; a sensor; a measuring device that measures welding-related information using the values detected by the sensor;
- a welding system having a display device that displays the welding-related information, The display device display means for displaying at least two of the plurality of measurement items included in the welding-related information on the same graph in association with at least one of time series and position information; each of the at least two measurement items is displayed by changing at least one of color and line type on the graph; at least one of a display screen of the graph and a display screen of a moving image of welding associated with the measurement item displayed in the graph or a display screen of history information of errors detected in the measurement item; is switchable,
- the welding-related information includes at least one of welding setting information, welding status information, production status information, correction information, and welding phenomenon information.
- a method for displaying welding-related information a display step of displaying at least two of the plurality of measurement items included in the welding-related information on the same graph in association with at least one of time series and position information; each of the at least two measurement items is displayed by changing at least one of color and line type on the graph; a display screen of the graph, and at least one of a display screen of a moving image of welding associated with the measurement item displayed in the graph and a display screen of history information of errors detected in the measurement item.
- the welding-related information includes at least one of welding setting information, welding state information, production status information, correction information, and welding phenomenon information.
- the program to the computer executing a display step of displaying at least two of the plurality of measurement items included in the welding-related information on the same graph in association with at least one of time series and position information; each of the at least two measurement items is displayed by changing at least one of color and line type on the graph; at least one of a display screen of the graph and a display screen of a moving image of welding associated with the measurement item displayed in the graph or a display screen of history information of errors detected in the measurement item; is switchable,
- the welding-related information includes at least one of welding setting information, welding status information, production status information, correction information, and welding phenomenon information.
- the welding-related information includes at least one of welding setting information, welding status information, production status information, correction information, and welding phenomenon information.
- workers can quickly recognize a plurality of pieces of welding-related information, and can easily acquire useful information when solving more advanced welding-related problems.
- FIG. 1 is a schematic diagram showing a configuration example of a robot control device according to an embodiment of the present invention
- FIG. 1 is a schematic diagram showing an example of the mechanical configuration of a data processing device according to an embodiment of the present invention
- FIG. 2 is a screen diagram showing a configuration example of a display screen according to one embodiment of the present invention
- FIG. 2 is a screen diagram showing a configuration example of a display screen according to one embodiment of the present invention
- FIG. 2 is a screen diagram showing a configuration example of a display screen according to one embodiment of the present invention
- FIG. 2 is a screen diagram showing a configuration example of a display screen according to one embodiment of the present invention
- FIG. 2 is a screen diagram showing a configuration example of a display screen according to one embodiment of the present invention
- FIG. 1 is a schematic diagram showing a configuration example of a robot control device according to an embodiment of the present invention
- FIG. 1 is a schematic diagram showing an example of the mechanical configuration of a data processing device according to an embodiment
- FIG. 2 is a screen diagram showing a configuration example of a display screen according to one embodiment of the present invention
- FIG. 2 is a screen diagram showing a configuration example of a display screen according to one embodiment of the present invention
- FIG. 2 is a screen diagram showing a configuration example of a display screen according to one embodiment of the present invention
- FIG. 2 is a screen diagram showing a configuration example of a display screen according to one embodiment of the present invention
- FIG. 2 is a screen diagram showing a configuration example of a display screen according to one embodiment of the present invention
- FIG. 2 is a screen diagram showing a configuration example of a display screen according to one embodiment of the present invention
- 4 is a flow chart showing the flow of processing according to an embodiment of the present invention
- FIG. 1 is a screen diagram showing a configuration example of a display screen according to one embodiment of the present invention
- FIG. 2 is a screen diagram showing a configuration example of a display screen according to one embodiment of the present invention
- FIG. 2 is a screen diagram showing
- FIG. 4 is an explanatory diagram for explaining generation of each color component image according to one embodiment of the present invention.
- 4 is a flowchart showing element classification processing according to an embodiment of the present invention;
- FIG. 4 is an explanatory diagram for explaining a case where an image includes an obstacle;
- FIG. 4 is an explanatory diagram for explaining transition of an image according to one embodiment of the present invention;
- FIG. 4 is an explanatory diagram for explaining transition of an image according to one embodiment of the present invention;
- the method of measuring and displaying welding behavior according to the present invention is useful not only for welding but also for additive manufacturing technology utilizing GMAW, specifically metal additive manufacturing technology (WAAM: Wire and Arc Additive Manufacturing).
- WAAM Wire and Arc Additive Manufacturing
- the term additive manufacturing is sometimes used in a broad sense as a term for additive manufacturing or rapid prototyping, but in the present invention, the term additive manufacturing is used uniformly.
- welding is replaced with “welding”, “additive manufacturing”, “laminate manufacturing”, or the like.
- welding behavior when treated as welding, it is “welding behavior”, but when using the present invention as additive manufacturing, it is rephrased as “welding behavior”, and when treated as welding, it is “welding system”, but as additive manufacturing When utilizing the present invention, it can be rephrased as an “additional manufacturing system”.
- Welding and welding of additive manufacturing technology differ in some of the objects to be measured and managed depending on the operation and the like. Accordingly, the items included in the "welding-related information" described later and the "welding-related information" in the additive manufacturing technology may differ.
- FIG. 1 shows a configuration example of a welding system 1 according to this embodiment.
- the welding system 1 may be read as an additive manufacturing system
- the welding robot 10 may be read as an additive manufacturing robot.
- the welding robot 10 shown in FIG. 1 is composed of a 6-axis articulated robot, and a welding torch 11 for GMAW is attached to its tip.
- GMAW includes, for example, MIG (Metal Inert Gas) welding and MAG (Metal Active Gas) welding, and in this embodiment, MAG welding will be described as an example.
- the welding robot 10 is not limited to a six-axis articulated robot, and may be a small portable robot, for example.
- a welding wire 13 is supplied from a wire feeding device 12 to the welding torch 11 .
- Welding wire 13 is delivered from the tip of welding torch 11 toward a welding location.
- Power supply 30 supplies power to welding wire 13 .
- This electric power applies an arc voltage between the welding wire 13 and the workpiece W to generate an arc.
- the power supply device 30 includes a current sensor (not shown) that detects a welding current (hereinafter also referred to as a current) flowing from the welding wire 13 to the work W during welding, and an arc voltage between the welding wire 13 and the work W ( hereinafter also referred to as voltage) is provided.
- the power supply device 30 has a processing unit and a storage unit (not shown).
- the processing unit is configured by, for example, a CPU (Central Processing Unit).
- the storage unit is configured by, for example, a volatile or non-volatile memory such as a HDD (Hard Disk Drive), a ROM (Read Only Memory), a RAM (Random Access Memory), or the like.
- the processing unit controls the power applied to the welding wire 13 by executing the computer program for power supply control stored in the storage unit.
- the power supply device 30 is also connected to the wire feeding device 12 , and the processing section controls the feeding speed and feeding amount of the welding wire 13 .
- the composition and type of the welding wire 13 are selectively used according to the object to be welded.
- the welding behavior according to the present embodiment includes arc deflection, arc pressure, amount of oxide coating on the molten pool, droplet transfer mode, droplet detachment period, number of short circuits, welding such as pits. Occurrence of defects and the like can be mentioned.
- the visual sensor 40 is composed of, for example, a CCD (Charge Coupled Device) camera.
- the location of the visual sensor 40 is not particularly limited, and it may be directly attached to the welding robot 10, or may be fixed at a specific peripheral location as a monitoring camera. When the visual sensor 40 is directly attached to the welding robot 10 , the visual sensor 40 moves in accordance with the operation of the welding robot 10 so as to photograph the periphery of the tip of the welding torch 11 .
- the number of cameras constituting the visual sensor 40 may be plural.
- the direction in which the visual sensor 40 captures images is not particularly limited.
- the direction in which welding progresses is defined as the front, it may be arranged to capture the front side, or the side and rear sides may be captured. can be arranged as follows. Therefore, the imaging range of the visual sensor 40 may be appropriately determined according to the welding behavior of the object to be measured.
- a visual sensor 40 fixed at a specific location is used to capture a moving image as a welding image so that the imaging range includes at least the workpiece W, the welding wire 13, and the arc.
- Various shooting settings related to welding images may be defined in advance, or may be switched according to operating conditions of the welding system 1 .
- Shooting settings include, for example, the frame rate, the number of pixels of an image, the resolution, the shutter speed, and the like.
- the visual sensor 40 is shown as a representative example, but sensors for detecting other information may also be provided.
- the sensors may include laser sensors. The laser sensor detects the groove shape of the gap width before welding, captures the scanning position, weaving correction amount, etc. based on the data, and can output it as correction information described later. Details of an example of the sensors according to this embodiment will be described later, but the number, installation positions, detection principles, and the like may be changed in accordance with information intended for monitoring or the like.
- the parts that make up the welding system 1 are communicably connected by various wired/wireless communication methods.
- the communication method here is not limited to one, and connection may be made by combining a plurality of communication methods.
- FIG. 2 shows a configuration example of a robot control device 20 that controls the operation of the welding robot 10.
- the robot control device 20 includes a CPU 201 that controls the entire device, a memory 202 that stores data, an operation panel 203 that includes a plurality of switches, a teaching pendant 204 that is used for teaching work, a robot connection section 205, and a communication section 206. Configured.
- the memory 202 is configured by, for example, a volatile or non-volatile storage device such as ROM, RAM, and HDD.
- Memory 202 stores a control program 202A used to control welding robot 10 .
- CPU 201 controls various operations of welding robot 10 by executing control program 202A.
- the teaching pendant 204 is mainly used for inputting instructions to the robot control device 20 .
- the teaching pendant 204 is connected to the main body of the robot control device 20 via the communication section 206 .
- An operator can use the teach pendant 204 to enter a teach program.
- Robot controller 20 controls the welding operation of welding robot 10 according to a teaching program input from teaching pendant 204 .
- the teaching program can also be automatically created based on CAD (Computer-Aided Design) information or the like, for example, using a computer (not shown).
- the operation contents defined by the teaching program are not particularly limited, and may differ according to the specifications of the welding robot 10 and the welding method.
- the teaching pendant 204 includes an operation unit and a display unit (not shown) in addition to the operation panel 203, and can display a display screen, which will be described later, for example.
- a driving circuit of the welding robot 10 is connected to the robot connecting portion 205 .
- CPU 201 outputs a control signal based on control program 202A to a drive circuit (not shown) included in welding robot 10 via robot connector 205 .
- the communication unit 206 is a communication module for wired or wireless communication.
- a communication unit 206 is used for data communication with the power supply device 30 , the data processing device 50 , and the teaching pendant 204 .
- the communication method and standard used by the communication unit 206 are not particularly limited, and a plurality of methods may be combined.
- the current value of the welding current detected by a current sensor (not shown) and the voltage value of the arc voltage detected by a voltage sensor (not shown) are supplied from the power supply device 30 to the CPU 201 via the communication unit 206 .
- the robot control device 20 also controls the moving speed and target position of the welding torch 11 by controlling each axis of the welding robot 10 .
- the robot controller 20 also controls the weaving operation of the welding robot 10 according to the set cycle, amplitude, and welding speed.
- the weaving operation refers to alternately oscillating the welding torch 11 in a direction intersecting the advancing direction of welding.
- the robot controller 20 performs welding line tracing control together with the weaving operation.
- the welding line tracing control is an operation of controlling the left and right positions of the welding torch 11 with respect to the advancing direction so that a bead is formed along the welding line.
- the robot control device 20 also controls the feeding speed of the welding wire 13 by controlling the wire feeding device 12 via the power supply device 30 .
- FIG. 3 is a diagram for explaining an example of the functional configuration of the data processing device 50.
- the data processing device 50 includes, for example, a CPU, a ROM, a RAM, a hard disk device, an input/output interface, a communication interface, and a video output interface (not shown).
- the data processing device 50 includes a storage unit 51, an image processing unit 52, an image dividing unit 53, a calculation unit 54, a display control unit 55, a display unit 56, and a sensor control unit 57 by cooperation of the respective components described above. come true.
- a series of steps performed by the image processing unit 52 , the image dividing unit 53 , the calculating unit 54 , the display control unit 55 , and the display unit 56 may be performed by software installed on the data processing device 50 .
- the storage unit 51 records and manages image data captured by the visual sensor 40, and provides image data in response to requests from each processing unit.
- the image data referred to here may be still image data, or moving image data obtained by continuously capturing still image data at an arbitrary frame rate.
- the frame rate here indicates the number of still image data captured by the visual sensor 40 at predetermined time intervals such as one second. Preferably, it should be determined in the range of 1 to 10 FPS (Frames Per Second). It should be noted that, in the case of using information on welding behavior, that is, real-time measurement of welding phenomenon information and traceability of welding phenomenon information, it is preferable to record the information as a moving image.
- the image processing unit 52 uses the image data stored in the storage unit 51 to perform preprocessing for measurement according to the present embodiment.
- preprocessing include contrast correction, brightness correction, color correction, monochrome image conversion such as binarization, noise removal, edge enhancement, contraction/expansion, and image feature extraction.
- the image dividing unit 53 creates divided images divided into a plurality of images for each predetermined constituent element based on the processed image data to which various image processing is applied in the image processing unit 52 .
- the predetermined constituent elements include spatter, fume, and arc light as welding behavior, welding wire 13 and nozzle, base material, molten pool, obstacles, and other backgrounds, which are components of the welding system 1. is mentioned. Here, description will be made with a particular focus on spatter, fume, and arc light.
- the processing performed by the image processing unit 52 is not limited to preprocessing for generating divided images of the image dividing unit 53 .
- the image processing unit 52 may process the divided images as necessary.
- the calculation unit 54 calculates various index values for quantitatively measuring spatter, fume, and arc light as welding behavior based on divided images and processed image data.
- the calculation here is preferably performed in chronological order, for example.
- the time series includes, for example, the elapsed time, the order of teaching programs, the order of continuous still image data constituting a moving image, and the like.
- the display control unit 55 receives information obtained from sensors such as the visual sensor 40 , the laser sensor 41 , the current sensor 42 , or the voltage sensor 43 , information recorded in the robot control device 20 or the like, Using the calculated information and the like, the results of time-series data for a plurality of predetermined measurement items are configured as images. Then, the display control unit 55 causes the display unit 56 and a display unit (not shown) of the teaching pendant 204 to output. A specific example of the image generated here will be described later.
- the display unit 56 displays the screen generated by the display control unit 55. At this time, the display unit 56 synchronizes the values detected by the current sensor 42 and the voltage sensor 43 and various information acquired from the robot control device 20 in chronological order and displays them on the screen.
- the display unit 56 is configured by, for example, a liquid crystal display (not shown) provided in the data processing device 50 or a display provided in the teaching pendant 204 .
- the sensor control unit 57 controls the operations of the sensors provided in the welding system 1.
- a visual sensor 40, a laser sensor 41, a current sensor 42, a voltage sensor 43, etc. are illustrated as sensors.
- the sensor control unit 57 may be configured to control, for example, the visual sensor 40 and the laser sensor 41 among these sensors.
- the visual sensor 40 is of an installation type other than the welding robot 10, it is preferable to employ a camera having at least a PTZ function as the visual sensor 40.
- the sensor control unit 57 may control the pan, tilt, zoom, etc. of the camera in accordance with the operation of the welding robot 10 .
- the sensor control section 57 may acquire information about the operation of the welding robot 10 from the robot control device 20 and control the operation of the visual sensor 40 based on the information. Further, when the laser sensor 41 is provided, the sensor control section 57 may control the direction, intensity, timing, etc. of laser irradiation.
- welding-related information can be displayed on the display screen during or after welding.
- the welding-related information according to the present embodiment includes welding setting information such as initial setting values and threshold values, welding state information that varies according to the state of welding work performed based on the setting values, production state information, correction information, and welding At least welding phenomenon information, which is information related to behavior, is included.
- the welding setting information includes a welding current setting value, an arc voltage setting value, a feeding speed setting value, a shielding gas flow rate setting value, a shielding gas pressure setting value, and the like.
- the welding state information includes detected welding current, arc voltage, feed speed, welding speed, shield gas flow rate, and shield gas pressure.
- the production status information includes wire consumption amount/consumption rate, arc rate, feeding load, number of short circuits, and the like.
- the correction information includes a sensing correction amount, an arc sensor correction amount (hereinafter also referred to as a scanning amount), and the like.
- Welding phenomenon information includes spatter, fume, arc length, arc width, welding defect, molten pool width, molten pool height, molten pool or droplet temperature, and the like.
- the combinations of measurement items displayed on the graphs on each display screen to be described later are just examples, and are not limited to these.
- at least two measurement items displayed on one graph are at least two of the welding setting information, welding state information, production state information, correction information, and welding phenomenon information included in the welding-related information as described above. It is preferable to select and display from one. In particular, it is preferable to include combinations that are more correlated when a given welding behavior occurs. Examples include a combination of welding current and spatter, and a combination of arc voltage and fume.
- the welding robot 10 includes a tandem-type welding torch 11 , that is, two welding torches 11 .
- the welding torch that precedes the welding torch 11 in the traveling direction is also called a "leading pole", and the welding torch that follows the leading pole is also called a “following pole”.
- Leading/trailing is switched according to the direction of progress of welding, and the two welding torches 11 play that role as appropriate.
- FIG. 4A shows a configuration example of a display screen 400 according to this embodiment.
- a display screen 400 includes a graph area 401 , check boxes 402 for designating items to be displayed in the graph area 401 , and graph information 403 of the graph displayed in the graph area 401 .
- the "preceding set current” indicating the set value of the welding current as the welding setting information
- the "preceding set voltage” indicating the set value of the arc voltage
- the "preceding actual current” indicating the welding current as the welding state information
- Four items of "current" and "previous actual voltage” indicating the arc voltage are configured to be specifiable with check boxes 402.
- the item for the leading electrode is shown as an example.
- the check box 402 includes a “step” item that can be designated, and by designating this item, a step number 407 corresponding to the position information of the welding robot 10 is displayed in the graph area 401 .
- the graph information 403 may display, for example, information for identifying the welding robot 10, information on the executed teaching program, information on the welding path, information on the date and time the welding was executed, and the like.
- the date and time information is indicated by "XXXX” indicating the year, "YY” indicating the month, and "ZZ” indicating the day, followed by the time. Note that the display order and arrangement of each piece of information are not particularly limited.
- the vertical axis is divided into the scale related to current and the scale related to voltage, but it is not limited to this. may be displayed.
- the horizontal axis shows the time and the step number, other time-series items may be shown. From the viewpoint of facilitating the operator's understanding of observation and measurement results, it is preferable that at least one of the time and the step number is displayed, and it is more preferable that these two items are displayed together. .
- the display range of the upper and lower limits on the vertical axis and the time interval on the horizontal axis may be arbitrarily specified by the operator, or may be defined in advance according to the operating conditions of welding or the like.
- each graph is displayed in a different display format so as to be identifiable.
- the display format here is an example, and the line shape, color, and the like may be changed for display.
- the operator can quickly recognize the time-series data of a plurality of items. In particular, it is possible to collectively check whether the actual current and actual voltage are output as set values.
- the display of three or more items with a larger amount of information can be grasped more clearly and easily, it is possible to provide a screen with higher distinguishability when displaying three or more items.
- FIG. 4B shows a configuration example of a display screen 410 according to this embodiment.
- the basic configuration is similar to that of the display screen 400 shown in FIG. 4A, but here, the display screen targets the control amount related to the tracing control of the welding line, that is, the tracing amount.
- an arc sensor is generally used to detect the amount of scanning, the amount of scanning may be detected using another sensor such as a laser sensor.
- the display screen 410 includes a graph area 411 , check boxes 412 for designating items to be displayed in the graph area 411 , and graph information 413 of the graph displayed in the graph area 411 .
- FIG. 4B shows a configuration example of a display screen 410 according to this embodiment.
- the basic configuration is similar to that of the display screen 400 shown in FIG. 4A, but here, the display screen targets the control amount related to the tracing control of the welding line, that is, the tracing amount.
- an arc sensor is generally used to detect the amount of scanning
- the amount of scanning
- the graph information 413 includes, for example, information for identifying the welding robot 10, information on the executed teaching program, information on the welding path, welding execution information, and so on. Information such as the date and time of the event may be displayed.
- scales corresponding to the graphs of the amount of scanning of the leading electrode in the vertical and horizontal directions and the rotation of the scanning of the trailing electrode are displayed.
- a vertical axis 414 on the left side of the graph area 411 displays a scale in millimeters [mm] corresponding to the scanning amount in the vertical and horizontal directions.
- a scale of degrees [°] corresponding to the rotation angle is displayed on the vertical axis 415 on the left side of the graph area 411 .
- a horizontal axis 416 of the graph area 411 indicates time, and a graph in chronological order is shown.
- FIG. 4C shows a configuration example of the display screen 420 according to this embodiment.
- the display screen here is intended for the amount of correction of the welding position by touch sensing.
- laser sensing may be used instead of touch sensing.
- the display screen 420 includes a graph area 421 , check boxes 422 for specifying items to be displayed in the graph area 421 , and graph information 423 of the items displayed in the graph area 421 .
- check boxes 422 are configured to be able to specify three items for each axis in a predefined XYZ three-dimensional coordinate system.
- the check box 422 includes an item “step” that can be designated, and by designating this item, a step number 426 is displayed in the graph area 421 .
- the graph information 423 includes, for example, information for identifying the welding robot 10, information on the executed teaching program, information on the welding path, welding execution information, and so on. Information such as the date and time of the event may be displayed.
- scales corresponding to the correction amount are displayed in order to display the graph of the correction amount corresponding to each axis direction.
- a vertical axis 424 on the left side of the graph area 421 displays a scale of millimeters [mm] corresponding to the correction amount.
- a horizontal axis 425 of the graph area 421 indicates time, and a graph in chronological order is shown.
- FIG. 4D shows a configuration example of the display screen 430 according to this embodiment.
- the basic configuration is similar to that of the display screen 400 shown in FIG. 4A, but here, the display screen is intended for information relating to the feeding of the welding wire by the wire feeding device 12.
- the display screen 430 includes a graph area 431 , check boxes 432 for designating items to be displayed in the graph area 431 , and graph information 433 of the graph displayed in the graph area 431 .
- check boxes 432 for designating items to be displayed in the graph area 431
- graph information 433 of the graph displayed in the graph area 431 In the example of FIG.
- the command value of the welding wire feed speed of the leading electrode as the welding setting information (hereinafter, the command value may be referred to as the set value), the actual feed speed and the wire feed speed as the welding state information
- the three items of the feed load are configured to be specifiable with check boxes 432 .
- the check box 432 includes an item “step” that can be specified, and by specifying this, a step number 437 is displayed in the graph area 431 .
- the graph information 433 includes, for example, information for identifying the welding robot 10, information on the executed teaching program, information on the welding path, welding execution information, and so on. Information such as the date and time of the event may be displayed.
- scales corresponding to the welding wire feeding speed and feeding load are displayed in order to display the graph.
- a percentage [%] scale corresponding to the feeding load is displayed on the vertical axis 434 on the left side of the graph area 431.
- a vertical axis 435 on the left side of the graph area 431 displays a scale of MPM [m/m] corresponding to the feeding speed.
- a horizontal axis 436 of the graph area 431 indicates time, and a graph in chronological order is shown.
- the data processing device 50 performs various error checks based on the acquired information and displays them on the display screen. Display screens related to the error check will be described below.
- error check according to this embodiment, three error checks are performed: set value error, reference value error, and absolute value error. Note that the contents of the error checks shown here are examples, and a part of them may be executed, or other error checks may be carried out.
- the setting value error check if the difference between the setting value and the actual measurement value, that is, the feedback value exceeds the allowable range, that is, the threshold value, it is determined that there is a setting value error.
- Items to be checked for set value errors include current [A], voltage [V], welding speed [cm/min], wire feed speed [m/min], weaving width [mm], and the like.
- the average value is obtained for each of the reference value and the feedback value in a predetermined time unit, and if the difference between the average values exceeds the allowable range, that is, the threshold value, it is determined as a reference value error.
- the reference value here may be, for example, an actual measurement value when a good welding result is obtained.
- Reference value error check targets include current [A], voltage [V], wire feeding speed [m/min], weaving width [mm], and the like.
- the absolute value error check if the feedback value deviates from the allowable upper and lower limits for a predetermined period of time, it is determined as an absolute value error. Items to be checked for the absolute value error include the wire feed load [%], heat input [J/cm], and the like.
- FIG. 5A shows a configuration example of a display screen 500 based on the error check results according to the present embodiment, and here shows a screen capable of displaying the check results of set value errors and reference value errors for current.
- the display screen 500 includes a graph area 501 , check boxes 502 for designating items to be displayed in the graph area 501 , graph information 503 of the graph displayed in the graph area 501 , and transition buttons 507 .
- check boxes 502 for designating items to be displayed in the graph area 501 includes a graph area 501 , check boxes 502 for designating items to be displayed in the graph area 501 , graph information 503 of the graph displayed in the graph area 501 , and transition buttons 507 .
- FIG. 5A shows a configuration example of a display screen 500 based on the error check results according to the present embodiment, and here shows a screen capable of displaying the check results of set value errors and reference value errors for current.
- the display screen 500 includes a graph area 501 , check boxes 502 for design
- Check boxes 502 are configured to be able to specify four items: “Actual current after set value error” and “Actual current after reference value error” indicating a location determined to be a reference value error.
- the items for the trailing electrode are shown as an example.
- the check box 502 includes a “step” item that can be designated, and by designating this item, a step number 506 corresponding to the position information of the welding robot 10 is displayed in the graph area 501 .
- the graph information 403 may display, for example, information for identifying the welding robot 10, information on the executed teaching program, information on the welding path, information on the date and time the welding was executed, and the like.
- a transition button 507 is a button for transitioning to the display screen 510 shown in FIG. 5B.
- FIG. 5B shows a configuration example of a display screen 510 based on the error check result according to this embodiment, and is a display screen corresponding to the display screen 500 in FIG. 5B.
- a display screen 510 is roughly divided into two areas 511 and 512 .
- the area 511 includes a graph area 513 , check boxes 514 for designating items to be displayed in the graph area 513 , and graph information 515 of the graph displayed in the graph area 513 .
- Two items, "succeeding set current” indicating the set value of the welding current as welding setting information and “succeeding actual current” indicating the welding current as welding state information, are configured to be specifiable with check boxes 514.
- the items for the trailing electrode are shown as an example.
- respective graphs are displayed in graph area 513 in chronological order.
- Check box 514 also includes a “step” item that can be specified, and by specifying this item, the step number corresponding to the position information of welding robot 10 is displayed in graph area 513 .
- the area 512 includes a graph area 516 , check boxes 517 for specifying items to be displayed in the graph area 516 , and graph information 518 of the graph displayed in the graph area 516 .
- "Following setting current” that indicates the set value of the welding current as welding setting information
- "Following actual current” that indicates the welding current as welding state information
- "Set value error following Four items of "actual current” and "actual current after reference value error” indicating the location determined to be a reference value error are configured to be specifiable with check boxes 517.
- FIG. Here, the items for the trailing electrode are shown as an example. When one or more items are selected from check boxes 517, respective graphs are displayed in graph area 516 in chronological order.
- Check box 514 also includes a “step” item that can be designated, and by designating this item, the step number corresponding to the position information of welding robot 10 is displayed in graph area 516 .
- the range indicated by the dashed line 519 indicates the range of the actual current determined as the reference value error. That is, the average value is obtained for each of the reference value and the feedback value in a predetermined unit of time, and the difference between the average values becomes the allowable range, that is, the point where the threshold value is exceeded.
- FIG. 6A shows a configuration example of a list screen 600 showing history information 601 regarding errors.
- the screen may be changed to the list screen 600 by selecting the range.
- the history information is recorded in the storage unit 51 or the like as appropriate when it is determined that an error has occurred.
- the items included in the history information 601 are examples, and items other than those shown in FIG. 6A may be included.
- the graph display button 602 is pressed, the screen transitions to the screen of the transition source, for example, the display screen 500 .
- the close button 603 is pressed, the list screen 600 is closed.
- FIG. 6B shows a configuration example of a display screen 610 for playing back moving images held in association with history information when error determination is performed. For example, when a portion determined to be an error is displayed in a graph on the display screen 500, by selecting an arbitrary position, a transition is made to the display screen 610 in order to reproduce the moving image corresponding to that position. It's okay. Alternatively, by selecting an arbitrary error from the history information 601 included in the list screen 600 of FIG. good.
- a display area 611 is an area for reproducing moving images.
- the operation area 612 displays various operation icons for accepting operations when reproducing moving images.
- the operation icons include, but are not limited to, icons corresponding to operations such as playback, stop, fast-forward, and rewind for moving images.
- FIG. 6C shows a configuration example of a setting screen 620 for setting various error determinations according to the present embodiment.
- the setting item 621 includes items for setting various thresholds and setting values used for checking the above-described setting value error, reference value error, and absolute value error. Note that the items shown here are only examples, and may be increased or decreased according to the content of the error check.
- the setting button 622 is pressed, the setting is performed with the value input to the setting item 621 .
- the cancel button 623 is pressed, the settings are canceled and this screen is closed.
- the system according to this embodiment has a plurality of displayable parts such as the display section 56 on the data processing device 50 side and the display section of the teaching pendant 204 . Therefore, the screen configuration to be displayed may be changed according to the portion to be displayed.
- FIG. 7 shows another configuration example of the display screen.
- a display screen 700 includes display areas 701 , 702 , and 705 .
- a display area 701 displays an overview of the display of the display areas 702 and 705 and related information.
- a display area 702 displays various graphs in chronological order. Here, graphs of welding current and arc current as actual measurements are displayed. Note that the ampere [A] scale corresponding to the current is displayed on the left vertical axis 703 of the display area 702, and the volt [V] scale corresponding to the voltage is displayed on the left vertical axis 704. This scale changes according to the graph to be displayed.
- the display area 705 detailed information related to the graph displayed in the display area 702 is displayed.
- three pieces of information 706, 707, and 708 are displayed in the display area 705 as an example.
- the information 706 indicates current values and voltage values of the leading electrode and the trailing electrode at the current point in time, that is, at the point corresponding to the end of the graph displayed in the display area 702 .
- the information 707 indicates the fluctuation trend of the welding current at the present time with an arrow icon.
- Information 708 indicates the trend of arc voltage fluctuation at the present time. A trend of change may be indicated by an easily visible icon, for example an increase, decrease, maintenance or no change compared to the previous value in position or time.
- an upward arrow indicates an upward change in the graph
- a downward arrow indicates a downward change in the graph.
- the symbol used for the icon is not particularly limited to the figure.
- the amount of change may be identifiably indicated by the size, color, and tone of the arrow.
- the green arrow indicates a change of less than 1 mm
- the yellow arrow indicates a change of 1 mm or more and less than 2 mm
- the red arrow indicates a change of 2 mm or more. good too.
- the evaluation of the increase or decrease of the values in the graph may be determined from the sampling point at any observation time or position and at least two or more points in the vicinity.
- a linear model of, for example, a linear expression can be created from the sampling point and at least two or more points in the vicinity at an arbitrary observation time or position, and an increase or decrease can be determined based on the slope of the linear model.
- the term "nearby" as used herein may be defined in advance as within a predetermined number of points or within a predetermined time, with reference to a sampling point at an arbitrary observation time or position.
- the sampling interval may be 0.2 seconds
- the display screen may be updated, that is, the graph may be updated at intervals of 1 second.
- increase/decrease evaluation may be performed at intervals of 1 second as the graph is updated.
- the display screen according to the present embodiment compares the measured value with an arbitrary value, such as a reference value or a past value, and then easily checks for errors. Can present identifiable information.
- an arbitrary value such as a reference value or a past value
- Can present identifiable information When the actual measured value is the welding current, it is possible to extract the position judged to be an error by comparing it with the past value and the set value. If the measured value is spatter or fume, compare it with the reference data to identify the location where spatter or fume is generated more than the standard value. Workers can easily grasp and analyze specific defects such as spatter and fume. Therefore, on the display screen, it is more preferable to display the welding phenomenon information and at least one of the other information in association with each other. Among the other information, at least the welding state information and the welding phenomenon information are displayed in association with each other. It is even more preferable to
- each display screen shown in FIG. 5A, FIG. 5B, and FIG. 6B is configured to be transitionable, and by referring to these, when items including the set value and actual measurement value of the welding current and the spatter, Using the difference between the welding current set value and the measured value as a measure of the defect, it is possible to easily grasp how much spatter has increased.
- the gas supply shortage is determined from the difference between the set value and actual measurement value of gas flow rate, and the welding defects when the gas supply is insufficient. It is possible to grasp the presence or absence of occurrence or the amount of occurrence. In this way, the welding behavior and the factors that cause the welding behavior can be readily known.
- a method of measuring spatter, fume, and arc light and deriving the indices will be described below.
- the display method of each measured index on the display screen may be adjusted as appropriate according to the above configuration.
- FIG. 8 is a diagram for explaining a series of flows when measuring a plurality of welding behaviors from image data.
- FIG. 8 shows a series of processes for measuring spatter, fume, and arc light, which are examples of welding behavior. good too.
- a plurality of index values are calculated for one welding behavior, but it is not necessary to calculate all the index values. may be switched to calculate
- This embodiment is an example of processing video data after the end of welding for the purpose of traceability. you can go
- the processing unit of the data processing device 50 executes the program stored in the storage unit in parallel with the welding operation or when measuring the welding behavior using images captured during welding. may be realized by loading and executing each part shown in FIG. 3 to function.
- the data processing device 50 acquires moving image data to be processed.
- imaging conditions such as frame rate and shutter speed are set in the visual sensor 40, and the range of welding positions to be photographed is imaged by the visual sensor 40 as moving image data.
- the imaging condition may be set to an arbitrary value by the operator, or a predetermined fixed value may be used.
- the captured moving image data may be directly stored in the storage unit 51 of the data processing device 50 , or if the visual sensor 40 itself has a memory, it may be temporarily stored in the memory of the visual sensor 40 and then transferred to the storage unit 51 . Moving image data may be transferred. Note that the subsequent processing is performed on each of the plurality of still image data included in the moving image data.
- the data processing device 50 performs color component separation processing on the acquired moving image data.
- the moving image data according to the present embodiment is composed of, for example, a color image in which each pixel is composed of RGB signals representing red, green, and blue color components.
- the RGB signal is represented by 8 bits for each color component and a total of 24 bits per pixel.
- the signal value corresponding to each color component takes a value of 0-255.
- moving image data divided into RGB color components is created.
- one piece of moving image data is divided into moving image data of only the R color component, moving image data of only the G color component, and moving image data of only the B color component. More specifically, when moving image data of only the R color component is generated, color component separation processing is performed by converting the signal values of G and B of the moving image data to 0.
- FIG. 9 is a diagram for explaining the generation of moving image data of only RGB color components from moving image data.
- the still image data of only three color components generated from one piece of still image data included in the moving image data have different representations, and even if the same welding behavior occurs, Different characteristics can be captured.
- still image data of only the R color component, still image data of only the G color component, and still image data of only the B color component are referred to as "red component image”, “green component image”, and “blue component image”, respectively. will be described.
- Thermal energy light is an arc light or fume related phenomenon.
- the blue component image it is possible to extract light with light and dark shades in thermal energy light, and based on this light, it is possible to calculate the fume that diffuses to the surroundings, which was difficult to extract until now. do.
- the inventor of the present application has found, as a result of experiments and verifications, that the red component image can be clearly confirmed in high-temperature luminescence of metal, slag, and the like. That is, by using the red component image, it is possible to capture spatter, molten pool, or fume with high particle density based on the high-temperature emission contained therein.
- a fume with a high particle density on an image is also referred to as a "dense fume”
- a fume with a low particle density is also referred to as a "light fume”.
- the density here is relative, and the density value is not limited.
- the welding behavior is not limited to this, and the welding behavior may be measured by further using the green component image.
- a green component image may be used in identifying regions of constituent elements, which will be described later.
- RGB color space is described as an example in the present embodiment, it is not limited to this.
- other color spaces that can be converted corresponding to each parameter of R, G, and B may be used. More specifically, available color spaces include RGBA, YCbCr, YUV, and the like.
- the data processing device 50 uses the image processing unit 52 to apply background subtraction processing to the blue component image.
- background subtraction processing may be performed by removing noise using a known Rolling Ball algorithm.
- background subtraction processing may be performed by filtering processing using a predetermined filter. By the processing of this step, it is possible to remove a spike-like signal and obtain a pixel value that fluctuates smoothly. In this embodiment, this smoothly varying pixel value is treated as originating from a thin fume.
- the data processing device 50 uses the calculation unit 54 to calculate the total luminance value as the light fume index value in the blue component image subjected to the background subtraction processing in S803.
- the total value weighted based on each brightness value may be calculated as the index value.
- the data processing device 50 causes the image processing unit 52 to apply background subtraction processing to the red component image.
- the method of background removal processing is not particularly limited, but background subtraction may be performed by removing noise using a known Rolling Ball algorithm, for example, as in the processing of S803.
- background subtraction processing may be performed by filtering processing using a predetermined filter. By the processing of this step, it is possible to remove a spike-like signal and obtain a pixel value that fluctuates smoothly.
- the data processing device 50 calculates the total luminance value as the arc light index value in the red component image on which the background subtraction processing has been performed by the calculation unit 54 in S805.
- the total value weighted based on each brightness value may be calculated as the index value.
- the data processing unit 50 causes the image processing unit 52 to calculate the luminance value of the red component image after the background subtraction process generated in S805 from the luminance value of each pixel of the red component image generated in S802. to exclude. By this process, it is possible to exclude smoothly varying pixel values in the red component image.
- the data processing device 50 uses the image processing unit 52 to perform binarization processing on the red component image after the processing in S807 to generate a binarized image.
- the binarization method here is not particularly limited, and a known method may be used.
- the setting of the threshold value in the binarization process is not particularly limited, and for example, the median value of possible pixel values may be used as the threshold value.
- the data processing device 50 causes the image processing unit 52 to perform labeling processing for each region included in the image using the binarized image generated at S808.
- a binarized image includes a plurality of regions each composed of one or more pixels, and each region is extracted.
- each region composed of pixels having a pixel value of "1" is labeled as a region corresponding to any of the components caused by the welding behavior.
- the labeling method is not particularly limited, and a known technique may be used.
- the lower limit of the size of the area is not particularly limited, and for example, the minimum area may be an area consisting of one pixel. It should be noted that if a region consisting of pixels with a pixel value of "0" corresponds to a component caused by welding behavior, it may be labeled.
- the data processing device 50 causes the image dividing unit 53 to perform element classification processing on each region in the image labeled at S809. Details of this step will be described with reference to FIG. This process is performed each time based on the result of the labeling process performed using each of the plurality of red component images to be processed.
- the image dividing unit 53 focuses on an unprocessed area among one or more labeled areas included in the binarized image.
- the order of attention is not particularly limited, but for example, the areas may be sorted in descending order based on the size of the area, and attention may be paid in order from the largest size.
- the image dividing unit 53 determines whether or not the number of pixels forming the region of interest is equal to or less than the first threshold.
- the first threshold here is explained as 300 pixels.
- the first threshold may be defined according to the overall size of the red component image, or may be changed according to the welding situation. For example, if the visual sensor 40 is a fixed-position surveillance camera, the welding position changes, that is, the distance between the position of the visual sensor 40 and the welding position, or the imaging direction or imaging angle changes. Change. Therefore, the relationship between the distance, the direction, and the size of the object may be established in advance, and the first threshold may be changed based on this relationship.
- the magnification of the camera may be changed so that the size of the object to be photographed may be kept constant, that is, the first threshold may be kept constant. If the number of pixels in the region of interest is equal to or less than the first threshold, that is, if YES in S1002, the processing of the image dividing unit 53 proceeds to S1004. On the other hand, if the number of pixels in the region of interest is larger than the first threshold, that is, if NO in S1002, the process of the image dividing unit 53 proceeds to S1003.
- the image dividing unit 53 determines whether or not the region of interest is located in the center of the image and has the largest size among the labeled regions.
- the arc light is positioned in the center, and the area of the arc light is the largest area in the image.
- the region of interest is treated as noise.
- FIG. 7 shows an example in which an obstacle is reflected on the image. In such a case, an image is obtained in which the arc light is not positioned at the center of the image.
- the range of the center here may be set in advance, and may change according to the image size, welding behavior, and the like.
- the maximum size used in the determination in this step is a relative size between a plurality of regions in the image, and thus differs depending on the image. If the region of interest satisfies the above conditions, that is, if YES in S1003, the processing of the image dividing unit 53 proceeds to S1005. On the other hand, if the region of interest does not satisfy the above conditions, that is, if NO in S1003, the processing of the image dividing unit 53 proceeds to S1006.
- the image dividing unit 53 determines whether or not the size of the region of interest is equal to or larger than the second threshold.
- the second threshold is set as the ratio of the number of pixels in the region of interest to the number of pixels in the rectangular region, defining the smallest rectangular region that includes the region of interest. Therefore, the size of the rectangular region changes according to the size of each region of interest.
- the second threshold here is explained as 15%. In other words, determination in this step is based on whether or not the following conditions are satisfied.
- Second threshold ⁇ (size of region of interest)/(size of rectangular region including region of interest) If the size of the region of interest is greater than or equal to the second threshold, that is, if YES in S1004, the process of the image dividing unit 53 proceeds to S1007. On the other hand, if the size of the region of interest is smaller than the second threshold, that is, if NO in S1004, the processing of the image dividing unit 53 proceeds to S1008.
- the image dividing unit 53 classifies the region of interest as an arc light region. Then, the processing of the image dividing unit 53 proceeds to S1009.
- the image dividing unit 53 classifies the region of interest as a noise region. Then, the processing of the image dividing unit 53 proceeds to S1009.
- the image dividing unit 53 classifies the region of interest as a spatter region. Then, the processing of the image dividing unit 53 proceeds to S1009.
- the image dividing unit 53 classifies the region of interest as a dark fume region. Then, the processing of the image dividing unit 53 proceeds to S1009.
- the image dividing unit 53 determines whether or not there is an unprocessed area. If there is an unprocessed area, that is, if YES in S1009, the process of the image dividing unit 53 returns to S1001 and repeats the process. On the other hand, if there is no unprocessed area, that is, if NO in S1009, this processing flow ends and proceeds to S811 in FIG.
- the data processing device 50 generates a binarized image made up of areas classified as arc light by the element classification process described with reference to FIG.
- This binarized image may be generated by extracting the area classified as arc light from the binarized image labeled in S809.
- the binarized image at this time contains components corresponding to the flare.
- a flare is light that is generated by being reflected in a lens or a camera that constitutes the visual sensor 40 . Therefore, the data processing device 50 performs contraction/expansion processing on the generated binarized image by the image dividing unit 53 in order to remove the components of the flare.
- a well-known technique may be used for contraction/expansion processing. In order to properly remove flare components, multiple erosion and expansion processes may be performed, and the order of the processes is not particularly limited.
- the data processing device 50 uses the calculation unit 54 to calculate the index value of the arc light using the binarized image processed at S811.
- the calculator 54 counts the number of pixels in the arc light area included in the binarized image, and uses the counted value as the index value.
- the arc light index value based on the luminance value is calculated in the processing of S806, and the arc light index value based on the number of pixels is calculated in the processing of S812. These may be treated as separate index values, or one index value for the entire arc light may be derived from the above two index values. Further, the arc width, arc length, direction of arc deflection, etc. may be calculated as index values of the arc light based on the area, center of gravity, principal axis angle, etc. in the area of the arc light.
- the data processing unit 50 causes the image processing unit 52 to use the red component image processed in S807 to generate a red component image composed of the regions classified as spatter in the element classification processing of FIG. Generate.
- the data processing device 50 uses the calculation unit 54 to calculate the index value of the spatter using the red component image generated at S813.
- the calculation unit 54 removes, from the regions of each spatter included in the red component image, regions having an area equal to or greater than a predetermined threshold, that is, regions having the number of pixels equal to or greater than a predetermined threshold. This assumes that each spatter is smaller than a given size, and removes the area as background.
- the threshold here is not particularly limited, it is defined in advance.
- the calculation unit 54 identifies the remaining spatter region, and calculates the number of the pixels and the number of regions formed by the identified pixels as the index value of the spatter. At this time, when counting the number of pixels, only pixels whose R value is equal to or greater than a predetermined threshold may be counted.
- the correspondence relationship between the actually measured amount of generated spatter and the value calculated from the image according to the present embodiment is defined in advance by a relational expression, a table, or the like. may be used to derive the index value.
- a relational expression or a table may be used to convert the calculated value from the image into the amount of spatter indicating the weight per unit time.
- the data processing unit 50 subtracts the value of the spatter region generated in S813 from the image generated in S807 by the image processing unit 52, thereby generating an image from which the spatter is removed.
- the data processing device 50 causes the image processing unit 52 to perform gamma correction on the image generated at S815.
- gamma correction By converting the luminance value with gamma correction, a region with minute luminance values in the image is excluded.
- the threshold value for the area to be excluded is not particularly limited, and is defined in advance here.
- a known method may be used for gamma correction, and for example, the configuration of the gamma curve is not particularly limited.
- the data processing device 50 causes the image processing unit 52 to perform filtering on the image processed at S816. Edges in the image are detected by filtering, and portions with steep luminance value gradients are emphasized.
- a Laplacian filter can be used, but other filters may be used.
- the data processing device 50 causes the image processing unit 52 to segment the image to which the filtering process has been applied in S817 based on the luminance gradient.
- the region division processing here is performed using, for example, the Watershed algorithm. With the watershed algorithm, it is possible to finely divide and emphasize the magnitude of brightness, that is, the portion with a sharp gradient of light and shade. Note that the region dividing method to be used is not particularly limited, and other methods may be used.
- the data processing device 50 uses the calculation unit 54 to calculate a dark fume index value based on the image generated in S818.
- the image is divided into a plurality of areas. At this time, the greater the number of small divided regions, the greater the gradation.
- a region with many shades, that is, a divided region having a predetermined area or less is regarded as a dense fume generation location, and the total area value is assumed as an index value indicating the dense fume.
- a dense fume index value is derived using the following equation (1).
- the correspondence relationship between the actually measured amount of generated fumes and the calculated value from the image according to the present embodiment is defined in advance by a relational expression, a table, or the like. may be used to derive the index value.
- a relational expression or a table may be used to convert the measured value from the image into the Hume amount indicating the weight per unit time.
- index value of light fume is calculated in the processing of S804, and the index value of dark fume is calculated in the processing of S819.
- index value of light fume is calculated in the processing of S804, and the index value of dark fume is calculated in the processing of S819.
- the data processing device 50 displays them on a screen (not shown) by the display unit 56 .
- a plurality of welding behaviors such as spatters and fumes identified by the calculated index values are preferably displayed in chronological order.
- Voltage values and the like may also be synchronized in chronological order and displayed side by side, that is, displayed so that comparison objects can be easily visually recognized.
- FIG. 12 shows the transition of the image from the red component image to the generation of the image for each component, and corresponds to the image processing of S805 to S815 in the processing sequence of FIG.
- An image 1201 shows an example of a red component image, and shows an image after color component separation processing.
- An image 1202 shows an image after applying binarization processing to the image 1201 .
- Images 1203 and 1205 show images generated for each component by applying labeling processing and element decomposition processing to the image 1202 .
- An image 1203 is an image composed of regions classified as spatter, and corresponds to the image generated in S811.
- An image 1205 is an image composed of areas classified as arc light, and corresponds to the image generated in S815.
- An image 1204 is an image obtained by removing the area regarded as the background from the image 1203, and corresponds to the image generated in S814.
- An image 1206 shows a case where the obstacle is not reflected in the image 1205 .
- the image 1206 has an area classified as arc light in the center of the image.
- FIG. 13 shows the transition of the image from the red component image to the segmentation, and corresponds to the image processing of S815 to S818 in the processing sequence of FIG.
- An image 1301 shows an example of a red component image from which the spatter area is removed, and corresponds to the image generated in S815.
- An image 1302 is an image obtained by applying gamma correction and filtering processing to the image 1301, and corresponds to the image after the processing in S817.
- An image 1303 is an image obtained by applying area division to the image 1302, and corresponds to the image after the processing in S818.
- the operator can quickly recognize a plurality of pieces of welding-related information, and can easily acquire useful information when solving more advanced welding-related problems. In particular, it is possible to easily grasp the welding situation while comparing a plurality of items.
- the configuration may be such that the measurement time can be set. For example, in moving image data of a predetermined length of time, it may be possible to specify a time period to be measured. Then, in this time zone, pixels and brightness values of fume, spatter, and arc light may be counted, and each index value may be calculated. As a result, for example, it is possible to check the welding behavior while taking into consideration the welding conditions in a predetermined time period.
- the operation of the welding robot 10, the power supply device 30, and the visual sensor 40 may be controlled based on the measurement results and error check results.
- the imaging setting of the visual sensor 40 may be switched, and various welding parameters of the welding robot 10 and the power supply device 30 may be controlled.
- the welding robot 10 can be operated more appropriately according to the occurrence of welding behavior.
- a program or application for realizing the functions of one or more embodiments described above is supplied to a system or device using a network or a storage medium, and one or more programs in the computer of the system or device It is also possible to implement a process in which the processor reads and executes the program.
- circuits that realize one or more functions include, for example, ASICs (Application Specific Integrated Circuits) and FPGAs (Field Programmable Gate Arrays).
- this specification discloses the following matters. (1) having a display step of displaying at least two of the plurality of measurement items included in the welding-related information on the same graph in association with at least one of time series and position information; each of the at least two measurement items is displayed by changing at least one of color and line type on the graph; at least one of a display screen of the graph and a display screen of a moving image of welding associated with the measurement item displayed in the graph or a display screen of history information of errors detected in the measurement item; is switchable,
- the welding-related information includes at least one of welding setting information, welding status information, production status information, correction information, and welding phenomenon information.
- a method of displaying welding-related information characterized by: According to this configuration, the operator can quickly recognize a plurality of pieces of welding-related information, and can easily acquire useful information when solving more advanced welding-related problems.
- the display method according to (1) characterized by: According to this configuration, it is possible to easily grasp the fluctuation tendency of a plurality of measurement items on one screen.
- the figure is an arrow;
- the direction of the arrow indicates increase, decrease, or no change, and the color, tone, or size of the arrow indicates the amount of change.
- the display method according to (2) characterized by: According to this configuration, it is possible to visually and easily grasp the variation trends of a plurality of measurement items on one screen.
- the trend of variation in the measurement item is determined based on the values of at least two points in the vicinity of the sampling point at the time or position of interest, 4.
- the value of the measurement item and at least one of past data and reference data of the measurement item are displayed in association with each other;
- the at least two measurement items are selected and displayed from at least two of welding setting information, welding state information, production status information, correction information, and welding phenomenon information included in the welding-related information.
- the measurement items related to the welding setting information include at least one set value of welding current, arc voltage, feed speed, welding speed, shield gas flow rate, and shield gas pressure.
- the measurement items related to the welding state information include a detected value of at least one of welding current, arc voltage, feed speed, welding speed, shield gas flow rate, and shield gas pressure.
- the measurement items related to the production status information include at least one detection value of wire consumption, wire consumption rate, arc rate, feeding load, and number of short circuits.
- the measurement item related to the correction information includes at least one detection value of a sensing correction amount and an arc sensor correction amount.
- the measurement items related to the welding phenomenon information include at least one detection value of spatter, fume, arc length, arc width, welding defect, molten pool width, molten pool height, molten pool or droplet temperature.
- At least one of measurement items of spatter, fume, arc length, arc width, welding defect, molten pool width, molten pool height, molten pool or droplet temperature is displayed on the display screen. displayed in the The display method according to any one of (1) to (13), characterized by: According to this configuration, at least one of spatter, fume, arc length, arc width, welding defect, molten pool width, molten pool height, molten pool or droplet temperature is measured as the measurement item of the welding phenomenon information. It can be displayed on the display screen.
- display means for displaying at least two of the plurality of measurement items included in the welding-related information on the same graph in association with at least one of time series and position information; each of the at least two measurement items is displayed by changing at least one of color and line type on the graph; at least one of a display screen of the graph and a display screen of a moving image of welding associated with the measurement item displayed in the graph or a display screen of history information of errors detected in the measurement item; is switchable,
- the welding-related information includes at least one of welding setting information, welding status information, production status information, correction information, and welding phenomenon information.
- a display device for welding-related information characterized by: According to this configuration, the operator can quickly recognize a plurality of pieces of welding-related information, and can easily acquire useful information when solving more advanced welding-related problems.
- a welding device (16) a welding device; a sensor; a measuring device that measures welding-related information using the values detected by the sensor;
- a welding system having a display device that displays the welding-related information, The display device display means for displaying at least two of the plurality of measurement items included in the welding-related information on the same graph in association with at least one of time series and position information; each of the at least two measurement items is displayed by changing at least one of color and line type on the graph; at least one of a display screen of the graph and a display screen of a moving image of welding associated with the measurement item displayed in the graph or a display screen of history information of errors detected in the measurement item; is switchable,
- the welding-related information includes at least one of welding setting information, welding status information, production status information, correction information, and welding phenomenon information.
- a welding system characterized by: According to this configuration, the operator can quickly recognize a plurality of pieces of welding-related information, and can easily acquire useful information when solving more advanced welding-related problems.
- (17) having a display step of displaying at least two of the plurality of measurement items included in the welding-related information on the same graph in association with at least one of time series and position information; each of the at least two measurement items is displayed by changing at least one of color and line type on the graph; a display screen of the graph, and at least one of a display screen of a moving image of welding associated with the measurement item displayed in the graph and a display screen of history information of errors detected in the measurement item.
- the welding-related information includes at least one of welding setting information, welding state information, production status information, correction information, and welding phenomenon information,
- a method of displaying welding-related information characterized by: According to this configuration, the operator can quickly recognize a plurality of pieces of welding-related information, and can easily acquire useful information when solving more advanced welding-related problems.
- the welding-related information includes at least one of welding setting information, welding status information, production status information, correction information, and welding phenomenon information.
- a display screen for welding-related information each of the at least two measurement items is displayed by changing at least one of color and line type on the graph; at least one of a display screen of the graph and a display screen of a moving image of welding associated with the measurement item displayed in the graph or a display screen of history information of errors detected in the measurement item; is switchable,
- the welding-related information includes at least one of welding setting information, welding status information, production status information, correction information, and welding phenomenon information.
- a display screen for welding-related information characterized by: According to this configuration, the operator can quickly recognize a plurality of pieces of welding-related information, and can easily acquire useful information when solving more advanced welding-related problems.
- Welding System 10 Welding Robot 11 Welding Torch 12 Wire Feeding Device 13 Welding Wire 20 Robot Control Device 30 Power Supply Device 40 Vision Sensor 41 Laser Sensor 42 Current Sensor 43 Voltage Sensor 50 Data Processing Device 51 Storage Unit 52 Image Processing Unit 53 Image Division Unit 54 Calculation Unit 55 Display Control Unit 56 Display Unit 57 Sensor Control Unit 201 CPU (Central Processing Unit) 202 memory 202A control program 203 operation panel 204 teaching pendant 205 robot connection section 206 communication section
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Abstract
Description
溶接関連情報に含まれる複数の計測項目のうちの少なくとも2つの計測項目を、時系列および位置情報の少なくとも一方に対応付けて同一のグラフ上にて表示する表示工程を有し、
前記少なくとも2つの計測項目それぞれは、前記グラフ上において色彩および線種の少なくとも一方を変更して表示され、
前記グラフの表示画面と、前記グラフに表示された計測項目に関連付けられた溶接の動画像の表示画面または当該計測項目にて検出されたエラーの履歴情報の表示画面のうちの少なくとも一方の画面とが切替可能に構成され、
前記溶接関連情報は、溶接設定情報、溶接状態情報、生産状況情報、補正情報、溶接現象情報のうちの少なくとも一つを含む。
溶接関連情報に含まれる複数の計測項目のうちの少なくとも2つの計測項目を、時系列および位置情報の少なくとも一方に対応付けて同一のグラフ上にて表示する表示手段を有し、
前記少なくとも2つの計測項目それぞれは、前記グラフ上において色彩および線種の少なくとも一方を変更して表示され、
前記グラフの表示画面と、前記グラフに表示された計測項目に関連付けられた溶接の動画像の表示画面または当該計測項目にて検出されたエラーの履歴情報の表示画面のうちの少なくとも一方の画面とが切替可能に構成され、
前記溶接関連情報は、溶接設定情報、溶接状態情報、生産状況情報、補正情報、溶接現象情報のうちの少なくとも一つを含む。
溶接装置と、
センサと、
前記センサによって検出された値を用いて溶接関連情報を計測する計測装置と、
前記溶接関連情報を表示する表示装置と
を有する溶接システムであって、
前記表示装置は、
前記溶接関連情報に含まれる複数の計測項目のうちの少なくとも2つの計測項目を、時系列および位置情報の少なくとも一方に関連付けて同一のグラフ上にて表示する表示手段を有し、
前記少なくとも2つの計測項目それぞれは、前記グラフ上において色彩および線種の少なくとも一方を変更して表示され、
前記グラフの表示画面と、前記グラフに表示された計測項目に関連付けられた溶接の動画像の表示画面または当該計測項目にて検出されたエラーの履歴情報の表示画面のうちの少なくとも一方の画面とが切替可能に構成され、
前記溶接関連情報は、溶接設定情報、溶接状態情報、生産状況情報、補正情報、溶接現象情報のうちの少なくとも一つを含む。
溶着関連情報に含まれる複数の計測項目のうちの少なくとも2つの計測項目を、時系列および位置情報の少なくとも一方に関連付けて同一のグラフ上にて表示する表示工程を有し、
前記少なくとも2つの計測項目それぞれは、前記グラフ上において色彩および線種の少なくとも一方を変更して表示され、
前記グラフの表示画面と、前記グラフに表示された計測項目に関連付けられた溶着の動画像の表示画面または当該計測項目にて検出されたエラーの履歴情報の表示画面のうちの少なくとも一方の画面とが切替可能に構成され、
前記溶着関連情報は、溶着設定情報、溶着状態情報、生産状況情報、補正情報、溶着現象情報のうちの少なくとも一つを含む。
コンピュータに、
溶接関連情報に含まれる複数の計測項目のうちの少なくとも2つの計測項目を、時系列および位置情報の少なくとも一方に関連付けて同一のグラフ上にて表示する表示工程を実行させ、
前記少なくとも2つの計測項目それぞれは、前記グラフ上において色彩および線種の少なくとも一方を変更して表示され、
前記グラフの表示画面と、前記グラフに表示された計測項目に関連付けられた溶接の動画像の表示画面または当該計測項目にて検出されたエラーの履歴情報の表示画面のうちの少なくとも一方の画面とが切替可能に構成され、
前記溶接関連情報は、溶接設定情報、溶接状態情報、生産状況情報、補正情報、溶接現象情報のうちの少なくとも一つを含む。
前記少なくとも2つの計測項目それぞれは、前記グラフ上において色彩および線種の少なくとも一方を変更して表示され、
前記グラフの表示画面と、前記グラフに表示された計測項目に関連付けられた溶接の動画像の表示画面または当該計測項目にて検出されたエラーの履歴情報の表示画面のうちの少なくとも一方の画面とが切替可能に構成され、
前記溶接関連情報は、溶接設定情報、溶接状態情報、生産状況情報、補正情報、溶接現象情報のうちの少なくとも一つを含む。
以下、本願発明に係る一実施形態について図面を参照しつつ説明する。
図1は、本実施形態に係る溶接システム1の構成例を示す。図1に示す溶接システム1は、溶接ロボット10、ロボット制御装置20、電源装置30、視覚センサ40、およびデータ処理装置50を含んで構成される。なお、本願発明に係る手法を付加製造に適用して用いる場合は、例えば、溶接システム1を付加製造システム、溶接ロボット10を付加製造用ロボットと読み替えてもよい。
図2は、溶接ロボット10の動作を制御するロボット制御装置20の構成例を示す。ロボット制御装置20は、装置全体を制御するCPU201、データを記憶するメモリ202、複数のスイッチを含む操作パネル203、教示作業で使用する教示ペンダント204、ロボット接続部205、および通信部206を含んで構成される。メモリ202は、例えば、ROM、RAM、HDDなどの揮発性や不揮発性の記憶装置により構成される。メモリ202には、溶接ロボット10の制御に用いられる制御プログラム202Aが記憶される。CPU201は、制御プログラム202Aを実行することにより、溶接ロボット10による各種動作を制御する。
図3は、データ処理装置50の機能構成の例を説明するための図である。データ処理装置50は、例えば、不図示のCPU、ROM、RAM、ハードディスク装置、入出力インタフェース、通信インタフェース、映像出力インタフェース等により構成される。データ処理装置50は、上記の各構成部位が連携することにより、記憶部51、画像処理部52、画像分割部53、算出部54、表示制御部55、表示部56、およびセンサ制御部57を実現する。画像処理部52、画像分割部53、算出部54、表示制御部55、および表示部56で行われる一連の工程は、データ処理装置50に上にインストールされたソフトウェアによってなされてもよい。
続いて、本実施形態に係る各種情報の表示画面の構成例について説明する。本実施形態では、溶接中または溶接後において、溶接関連情報を表示画面上にて表示可能である。本実施形態に係る溶接関連情報は、初期設定値や閾値等の溶接設定情報、設定値に基づいて行われる溶接作業の状況に応じて変動する溶接状態情報、生産状況情報、補正情報、および溶接挙動に係る情報である溶接現象情報を少なくとも含む。より具体的に、溶接設定情報としては、溶接電流の設定値、アーク電圧の設定値、送給速度の設定値、シールドガス流量の設定値、シールドガス圧力の設定値等が挙げられる。溶接状態情報としては、検出した溶接電流、アーク電圧、送給速度、溶接速度、シールドガス流量、シールドガス圧力が挙げられる。生産状況情報としては、ワイヤ消費量・消費率、アーク率、送給負荷、短絡回数等が挙げられる。補正情報としては、センシング補正量、アークセンサ補正量(以降、倣い量とも称する)等が挙げられる。溶接現象情報としては、スパッタ、ヒューム、アーク長、アーク幅、溶接欠陥、溶融池幅、溶融池高さ、溶融池または溶滴の温度等が挙げられる。
本実施形態に係るデータ処理装置50は、取得した情報に基づいて、各種エラーチェックを行い、表示画面上に表示を行う。以下、エラーチェックに係る表示画面について説明する。
図6Aや図6Bに示したように、本実施形態に係る表示画面は、実測値と、任意の値、例えば、基準値や過去の値と比較した上で、エラーのチェックを行って容易に識別可能な情報を提示することができる。実測値が溶接電流である場合、過去の値や設定値と比較してエラーと判定される位置を抽出できる。実測値がスパッタやヒュームである場合は、参考データと比較して、標準値以上にスパッタやヒュームが発生している箇所を特定したり、さらに溶接電流等、他の項目と比較することによって、スパッタ、ヒューム等の具体的な不具合に対し、作業者は容易に把握、分析を行ったりすることができる。よって、表示画面においては、溶接現象情報とその他の情報のうち少なくとも一つの情報を対応付けて表示することがより好ましく、その他の情報のうち、少なくとも溶接状態情報と溶接現象情報を対応付けて表示することがさらにより好ましい。
図8は、画像データから複数の溶接挙動を計測する際の一連の流れを説明するための図である。図8では、溶接挙動の一例であるスパッタ、ヒューム、およびアーク光を計測する一連の処理を示しているが、これらすべてを計測する必要は無く、その一部を計測するような構成であってもよい。また、図8では、例えば、1の溶接挙動に対して、複数の指標値を算出しているが、必ずしもすべての指標値を算出する必要はなく、1の溶接挙動に対して1の指標値を算出するように切り替えてもよい。なお、本実施形態は、トレーサビリティを目的として、溶接終了後の動画像データを処理した例であるが、処理は溶接終了後に限らず、溶接動作と並行して、即ちリアルタイムで以下に示す処理を行ってもよい。
第2の閾値≦(着目領域のサイズ)/(着目領域を包含する矩形領域のサイズ)
着目領域のサイズが第2の閾値以上である場合、即ち、S1004にてYESの場合、画像分割部53の処理はS1007へ進む。一方、着目領域のサイズが第2の閾値より小さい場合、即ち、S1004にてNOの場合、画像分割部53の処理はS1008へ進む。
上記の構成において更に、計測時間を設定可能な構成であってもよい。例えば、所定時間の長さの動画像データにおいて、そのうちの測定対象となる時間帯を指定できるような構成であってもよい。そして、この時間帯において、ヒューム、スパッタ、アーク光の画素や輝度値をカウントし、各指標値を算出してもよい。これにより、例えば、所定の時間帯における溶接条件を踏まえながら、溶接挙動を確認するようなことが可能となる。
(1) 溶接関連情報に含まれる複数の計測項目のうちの少なくとも2つの計測項目を、時系列および位置情報の少なくとも一方に対応付けて同一のグラフ上にて表示する表示工程を有し、
前記少なくとも2つの計測項目それぞれは、前記グラフ上において色彩および線種の少なくとも一方を変更して表示され、
前記グラフの表示画面と、前記グラフに表示された計測項目に関連付けられた溶接の動画像の表示画面または当該計測項目にて検出されたエラーの履歴情報の表示画面のうちの少なくとも一方の画面とが切替可能に構成され、
前記溶接関連情報は、溶接設定情報、溶接状態情報、生産状況情報、補正情報、溶接現象情報のうちの少なくとも一つを含む、
ことを特徴とする溶接関連情報の表示方法。
この構成によれば、複数の溶接関連情報を作業者が迅速に認識できるとともに、溶接関連のより高度な問題を解決する際に有用な情報を容易に取得が可能となる。
ことを特徴とする(1)に記載の表示方法。
この構成によれば、1の画面上で、複数の計測項目の変動傾向を容易に把握することが可能となる。
前記矢印の向きにより、増加、減少、または変化なしが示され、かつ、前記矢印の色、色調、または大きさにより、変化量が示される、
ことを特徴とする(2)に記載の表示方法。
この構成によれば、1の画面上で、複数の計測項目の変動傾向を視覚的に容易に把握することが可能となる。
ことを特徴とする請求項2または3に記載の表示方法。
この構成によれば、着目するサンプリング点の周辺の値に基づいて、変動傾向を判定することが可能となる。
ことを特徴とする(1)~(4)のいずれかに記載の表示方法。
この構成によれば、過去データや参考データに基づいて行われた計測値の評価結果を容易に把握することが可能となる。
ことを特徴とする(1)~(5)のいずれかに記載の表示方法。
この構成によれば、過去データ、参考データ、または、設定値のいずれかに基づいて行われた判定結果を容易に把握することが可能となる。
ことを特徴とする(6)に記載の表示方法。
この構成によれば、判定処理の結果に基づいて色彩や線種を変更させることで、視覚的に容易に結果を把握することが可能となる。
ことを特徴とする(1)~(7)のいずれかに記載の表示方法。
この構成によれば、複数の情報の中からそれぞれ計測項目を選択して表示させることが可能となる。
ことを特徴とする(1)~(8)のいずれかに記載の表示方法。
この構成によれば、溶接設定情報として、複数の設定値を対象として表示画面に表示させることが可能となる。
ことを特徴とする(1)~(9)のいずれかに記載の表示方法。
この構成によれば、溶接状態情報として、複数の検出値を対象として表示画面に表示させることが可能となる。
ことを特徴とする(1)~(10)のいずれかに記載の表示方法。
この構成によれば、生産状況情報として、複数の検出値を対象として表示画面に表示させることが可能となる。
ことを特徴とする(1)~(11)のいずれかに記載の表示方法。
この構成によれば、補正情報として、複数の検出値を対象として表示画面に表示させることが可能となる。
ことを特徴とする(1)~(12)のいずれかに記載の表示方法。
この構成によれば、溶接現象情報として、複数の検出値を対象として表示画面に表示させることが可能となる。
ことを特徴とする(1)~(13)のいずれかに記載の表示方法。
この構成によれば、溶接現象情報の測定項目として、スパッタ、ヒューム、アーク長、アーク幅、溶接欠陥、溶融池幅、溶融池高さ、溶融池または溶滴の温度のうちの少なくとも一つを表示画面上に表示させることが可能となる。
前記少なくとも2つの計測項目それぞれは、前記グラフ上において色彩および線種の少なくとも一方を変更して表示され、
前記グラフの表示画面と、前記グラフに表示された計測項目に関連付けられた溶接の動画像の表示画面または当該計測項目にて検出されたエラーの履歴情報の表示画面のうちの少なくとも一方の画面とが切替可能に構成され、
前記溶接関連情報は、溶接設定情報、溶接状態情報、生産状況情報、補正情報、溶接現象情報のうちの少なくとも一つを含む、
ことを特徴とする溶接関連情報の表示装置。
この構成によれば、複数の溶接関連情報を作業者が迅速に認識できるとともに、溶接関連のより高度な問題を解決する際に有用な情報を容易に取得が可能となる。
センサと、
前記センサによって検出された値を用いて溶接関連情報を計測する計測装置と、
前記溶接関連情報を表示する表示装置と
を有する溶接システムであって、
前記表示装置は、
前記溶接関連情報に含まれる複数の計測項目のうちの少なくとも2つの計測項目を、時系列および位置情報の少なくとも一方に関連付けて同一のグラフ上にて表示する表示手段を有し、
前記少なくとも2つの計測項目それぞれは、前記グラフ上において色彩および線種の少なくとも一方を変更して表示され、
前記グラフの表示画面と、前記グラフに表示された計測項目に関連付けられた溶接の動画像の表示画面または当該計測項目にて検出されたエラーの履歴情報の表示画面のうちの少なくとも一方の画面とが切替可能に構成され、
前記溶接関連情報は、溶接設定情報、溶接状態情報、生産状況情報、補正情報、溶接現象情報のうちの少なくとも一つを含む、
ことを特徴とする溶接システム。
この構成によれば、複数の溶接関連情報を作業者が迅速に認識できるとともに、溶接関連のより高度な問題を解決する際に有用な情報を容易に取得が可能となる。
前記少なくとも2つの計測項目それぞれは、前記グラフ上において色彩および線種の少なくとも一方を変更して表示され、
前記グラフの表示画面と、前記グラフに表示された計測項目に関連付けられた溶着の動画像の表示画面または当該計測項目にて検出されたエラーの履歴情報の表示画面のうちの少なくとも一方の画面とが切替可能に構成され、
前記溶着関連情報は、溶着設定情報、溶着状態情報、生産状況情報、補正情報、溶着現象情報のうちの少なくとも一つを含む、
ことを特徴とする溶着関連情報の表示方法。
この構成によれば、複数の溶着関連情報を作業者が迅速に認識できるとともに、溶着関連のより高度な問題を解決する際に有用な情報を容易に取得が可能となる。
溶接関連情報に含まれる複数の計測項目のうちの少なくとも2つの計測項目を、時系列および位置情報の少なくとも一方に関連付けて同一のグラフ上にて表示する表示工程を実行させ、
前記少なくとも2つの計測項目それぞれは、前記グラフ上において色彩および線種の少なくとも一方を変更して表示され、
前記グラフの表示画面と、前記グラフに表示された計測項目に関連付けられた溶接の動画像の表示画面または当該計測項目にて検出されたエラーの履歴情報の表示画面のうちの少なくとも一方の画面とが切替可能に構成され、
前記溶接関連情報は、溶接設定情報、溶接状態情報、生産状況情報、補正情報、溶接現象情報のうちの少なくとも一つを含む、
ことを特徴とするプログラム。
この構成によれば、複数の溶接関連情報を作業者が迅速に認識できるとともに、溶接関連のより高度な問題を解決する際に有用な情報を容易に取得が可能となる。
前記少なくとも2つの計測項目それぞれは、前記グラフ上において色彩および線種の少なくとも一方を変更して表示され、
前記グラフの表示画面と、前記グラフに表示された計測項目に関連付けられた溶接の動画像の表示画面または当該計測項目にて検出されたエラーの履歴情報の表示画面のうちの少なくとも一方の画面とが切替可能に構成され、
前記溶接関連情報は、溶接設定情報、溶接状態情報、生産状況情報、補正情報、溶接現象情報のうちの少なくとも一つを含む、
ことを特徴とする溶接関連情報の表示画面。
この構成によれば、複数の溶接関連情報を作業者が迅速に認識できるとともに、溶接関連のより高度な問題を解決する際に有用な情報を容易に取得が可能となる。
10 溶接ロボット
11 溶接トーチ
12 ワイヤ送給装置
13 溶接ワイヤ
20 ロボット制御装置
30 電源装置
40 視覚センサ
41 レーザーセンサ
42 電流センサ
43 電圧センサ
50 データ処理装置
51 記憶部
52 画像処理部
53 画像分割部
54 算出部
55 表示制御部
56 表示部
57 センサ制御部
201 CPU(Central Processing Unit)
202 メモリ
202A 制御プログラム
203 操作パネル
204 教示ペンダント
205 ロボット接続部
206 通信部
Claims (19)
- 溶接関連情報に含まれる複数の計測項目のうちの少なくとも2つの計測項目を、時系列および位置情報の少なくとも一方に対応付けて同一のグラフ上にて表示する表示工程を有し、
前記少なくとも2つの計測項目それぞれは、前記グラフ上において色彩および線種の少なくとも一方を変更して表示され、
前記グラフの表示画面と、前記グラフに表示された計測項目に関連付けられた溶接の動画像の表示画面または当該計測項目にて検出されたエラーの履歴情報の表示画面のうちの少なくとも一方の画面とが切替可能に構成され、
前記溶接関連情報は、溶接設定情報、溶接状態情報、生産状況情報、補正情報、溶接現象情報のうちの少なくとも一つを含む、
ことを特徴とする溶接関連情報の表示方法。 - 前記グラフに表示される前記少なくとも2つの計測項目の時間または位置における変動傾向に対し、増加、減少、変化なしのうちの少なくとも2つの変動傾向が、記号または図形を用いて示される、
ことを特徴とする請求項1に記載の表示方法。 - 前記図形は矢印であり、
前記矢印の向きにより、増加、減少、または変化なしが示され、かつ、前記矢印の色、色調、または大きさにより、変化量が示される、
ことを特徴とする請求項2に記載の表示方法。 - 前記計測項目における変動傾向は、着目する時間または位置におけるサンプリング点を中心として、近傍の少なくとも2つの点の値に基づいて判定される、
ことを特徴とする請求項2または3に記載の表示方法。 - 前記計測項目の値と、当該計測項目の過去データまたは参考データのうち少なくとも一方とが対応付けて表示される、
ことを特徴とする請求項1から3のいずれか一項に記載の表示方法。 - 前記計測項目の値と、当該計測項目の過去データ、参考データ、または、設定値のいずれかに基づいて行われる判定処理の結果とが対応付けて表示される、
ことを特徴とする請求項1から3のいずれか一項に記載の表示方法。 - 前記判定処理において所定の判定がなされた場合、前記グラフ上において、前記所定の判定がなされた計測項目を示す範囲に対し、色彩および線種のうちの少なくとも一方を変更して表示される、
ことを特徴とする請求項6に記載の表示方法。 - 前記少なくとも2つの計測項目は、前記溶接関連情報に含まれる溶接設定情報、溶接状態情報、生産状況情報、補正情報、溶接現象情報のうちの少なくとも2つから選択して表示される、
ことを特徴とする請求項1から3のいずれか一項に記載の表示方法。 - 前記溶接設定情報に係る計測項目は、溶接電流、アーク電圧、送給速度、溶接速度、シールドガス流量、シールドガス圧力のうちの少なくとも一つの設定値を含む、
ことを特徴とする請求項1から3のいずれか一項に記載の表示方法。 - 前記溶接状態情報に係る計測項目は、溶接電流、アーク電圧、送給速度、溶接速度、シールドガス流量、シールドガス圧力のうちの少なくとも一つの検出値を含む、
ことを特徴とする請求項1から3のいずれか一項に記載の表示方法。 - 前記生産状況情報に係る計測項目は、ワイヤの消費量、ワイヤの消費率、アーク率、送給負荷、短絡回数のうちの少なくとも一つの検出値を含む、
ことを特徴とする請求項1から3のいずれか一項に記載の表示方法。 - 前記補正情報に係る計測項目は、センシング補正量、アークセンサ補正量のうちの少なくとも一つの検出値を含む、
ことを特徴とする請求項1から3のいずれか一項に記載の表示方法。 - 前記溶接現象情報に係る計測項目は、スパッタ、ヒューム、アーク長、アーク幅、溶接欠陥、溶融池幅、溶融池高さ、溶融池または溶滴の温度のうちの少なくとも一つの検出値を含む、
ことを特徴とする請求項1から3のいずれか一項に記載の表示方法。 - 前記溶接現象情報として、スパッタ、ヒューム、アーク長、アーク幅、溶接欠陥、溶融池幅、溶融池高さ、溶融池または溶滴の温度のうちの少なくとも一つの計測項目が表示画面上に表示される、
ことを特徴とする請求項1から3のいずれか一項に記載の表示方法。 - 溶接関連情報に含まれる複数の計測項目のうちの少なくとも2つの計測項目を、時系列および位置情報の少なくとも一方に対応付けて同一のグラフ上にて表示する表示手段を有し、
前記少なくとも2つの計測項目それぞれは、前記グラフ上において色彩および線種の少なくとも一方を変更して表示され、
前記グラフの表示画面と、前記グラフに表示された計測項目に関連付けられた溶接の動画像の表示画面または当該計測項目にて検出されたエラーの履歴情報の表示画面のうちの少なくとも一方の画面とが切替可能に構成され、
前記溶接関連情報は、溶接設定情報、溶接状態情報、生産状況情報、補正情報、溶接現象情報のうちの少なくとも一つを含む、
ことを特徴とする溶接関連情報の表示装置。 - 溶接装置と、
センサと、
前記センサによって検出された値を用いて溶接関連情報を計測する計測装置と、
前記溶接関連情報を表示する表示装置と
を有する溶接システムであって、
前記表示装置は、
前記溶接関連情報に含まれる複数の計測項目のうちの少なくとも2つの計測項目を、時系列および位置情報の少なくとも一方に関連付けて同一のグラフ上にて表示する表示手段を有し、
前記少なくとも2つの計測項目それぞれは、前記グラフ上において色彩および線種の少なくとも一方を変更して表示され、
前記グラフの表示画面と、前記グラフに表示された計測項目に関連付けられた溶接の動画像の表示画面または当該計測項目にて検出されたエラーの履歴情報の表示画面のうちの少なくとも一方の画面とが切替可能に構成され、
前記溶接関連情報は、溶接設定情報、溶接状態情報、生産状況情報、補正情報、溶接現象情報のうちの少なくとも一つを含む、
ことを特徴とする溶接システム。 - 溶着関連情報に含まれる複数の計測項目のうちの少なくとも2つの計測項目を、時系列および位置情報の少なくとも一方に関連付けて同一のグラフ上にて表示する表示工程を有し、
前記少なくとも2つの計測項目それぞれは、前記グラフ上において色彩および線種の少なくとも一方を変更して表示され、
前記グラフの表示画面と、前記グラフに表示された計測項目に関連付けられた溶着の動画像の表示画面または当該計測項目にて検出されたエラーの履歴情報の表示画面のうちの少なくとも一方の画面とが切替可能に構成され、
前記溶着関連情報は、溶着設定情報、溶着状態情報、生産状況情報、補正情報、溶着現象情報のうちの少なくとも一つを含む、
ことを特徴とする溶着関連情報の表示方法。 - コンピュータに、
溶接関連情報に含まれる複数の計測項目のうちの少なくとも2つの計測項目を、時系列および位置情報の少なくとも一方に関連付けて同一のグラフ上にて表示する表示工程を実行させ、
前記少なくとも2つの計測項目それぞれは、前記グラフ上において色彩および線種の少なくとも一方を変更して表示され、
前記グラフの表示画面と、前記グラフに表示された計測項目に関連付けられた溶接の動画像の表示画面または当該計測項目にて検出されたエラーの履歴情報の表示画面のうちの少なくとも一方の画面とが切替可能に構成され、
前記溶接関連情報は、溶接設定情報、溶接状態情報、生産状況情報、補正情報、溶接現象情報のうちの少なくとも一つを含む、
ことを特徴とするプログラム。 - 溶接関連情報に含まれる複数の計測項目のうちの少なくとも2つの計測項目を、時系列および位置情報の少なくとも一方に対応付けて同一のグラフ上にて表示する表示工程にて生成される溶接関連情報の表示画面であって、
前記少なくとも2つの計測項目それぞれは、前記グラフ上において色彩および線種の少なくとも一方を変更して表示され、
前記グラフの表示画面と、前記グラフに表示された計測項目に関連付けられた溶接の動画像の表示画面または当該計測項目にて検出されたエラーの履歴情報の表示画面のうちの少なくとも一方の画面とが切替可能に構成され、
前記溶接関連情報は、溶接設定情報、溶接状態情報、生産状況情報、補正情報、溶接現象情報のうちの少なくとも一つを含む、
ことを特徴とする溶接関連情報の表示画面。
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JPH1147950A (ja) * | 1997-07-28 | 1999-02-23 | Miyachi Technos Corp | 遠隔溶接管理装置 |
JP2006026640A (ja) * | 2004-07-12 | 2006-02-02 | Matsushita Electric Ind Co Ltd | アーク溶接ロボット |
JP2021016870A (ja) * | 2019-07-17 | 2021-02-15 | 株式会社日立製作所 | 溶接作業データ蓄積装置、溶接作業支援システムおよび溶接ロボット制御装置 |
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JP6050004B2 (ja) | 2012-02-07 | 2016-12-21 | 株式会社ダイヘン | アーク溶接モニタ装置 |
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JPH1147950A (ja) * | 1997-07-28 | 1999-02-23 | Miyachi Technos Corp | 遠隔溶接管理装置 |
JP2006026640A (ja) * | 2004-07-12 | 2006-02-02 | Matsushita Electric Ind Co Ltd | アーク溶接ロボット |
JP2021016870A (ja) * | 2019-07-17 | 2021-02-15 | 株式会社日立製作所 | 溶接作業データ蓄積装置、溶接作業支援システムおよび溶接ロボット制御装置 |
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