Binding system

Abstract

    The intersection of a plurality of reinforcing bars is suitably bound. A binding system (1) includes: a first camera (31) configured to acquire first information on a plurality of arranged reinforcing bars (S); a second camera (51) configured to move based on the first information acquired by the first camera (31) and acquire second information on an intersection (P) of the plurality of reinforcing bars (S); and a binding device (6) configured to bind the intersection (P) based on the second information acquired by the second camera (51).

Description

DESCRIPTION TITLE OF INVENTION:BINDING SYSTEM TECHNICAL FIELD

[0001] The present invention relates to a binding system used for binding reinforcing bars. BACKGROUND ART

[0002] In the related art, regarding a workpiece in which a plurality of reinforcing bars are combined, a binding system is known that sequentially binds intersections of intersecting reinforcing bars with wires. As an example of such a binding system, Patent Literature 1 discloses a binding system in which an information acquisition unit such as a sensor and a binding machine are mounted on the tip of a robotic arm. The information on the workpiece, such as the position of the intersections of the reinforcing bars, is acquired by the information acquisition unit, and the binding machine is controlled based on the information on the workpiece. In the binding system disclosed in Patent Literature 2, the entire workpiece having a large number of intersections is imaged by a camera fixed above the workpiece, and the positions of the intersections are determined from the image. CITATION LISTPATENT LITERATURE

[0003] Patent Literature 1: JP2023-105958A Patent Literature 2: CN113264212A SUMMARY OF INVENTIONTECHNICAL PROBLEM

[0004] However, in the technique described in the above-mentioned Patent Literature 1, the position information on each intersection in the entire workpiece cannot be suitably acquired. If the position information on each intersection cannot be acquired in advance, it is difficult to efficiently bind the plurality of intersections in sequence. On the other hand, in the technique disclosed in the above-mentioned Patent Literature 2, the position information on each intersection in the entire workpiece can be obtained based on the image taken by the upper camera. However, in an image taken by a camera away from the intersection, the control at the time of binding, such as position correction, cannot be suitably performed.

[0005] The present invention has been made in view of the above circumstances, and an object thereof is to suitably bind intersections of a plurality of reinforcing bars. SOLUTION TO PROBLEM

[0006] In order to solve the above-described problem, a binding system of the present invention includes: a first information acquisition unit configured to acquire first information on a plurality of arranged reinforcing bars; a second information acquisition unit configured to move based on the first information and acquire second information on an intersection of the plurality of reinforcing bars; and a binding device configured to bind the intersection based on the second information. ADVANTAGEOUS EFFECTS OF INVENTION

[0007] According to the present invention, information such as the positions of a plurality of intersections and the presence or absence of obstacles in a relatively wide range is grasped based on the first information on the arranged reinforcing bars. Then, the second information acquisition unit moves based on the first information, and the second information acquisition unit acquires more accurate second information in a more local range. Then, the intersections of the reinforcing bars are bound based on the second information. Therefore, the intersections of the plurality of reinforcing bars can be suitably bound. BRIEF DESCRIPTION OF DRAWINGS

[0008] [FIG. 1] FIG. 1 is a perspective view illustrating a device body of a binding system according to a first embodiment; [FIG. 2] FIG. 2 is a block diagram illustrating a schematic control configuration of the binding system according to the first embodiment; [FIG. 3] FIG. 3 is a side view of a binding device according to the first embodiment; [FIG. 4] FIG. 4 is a flow chart illustrating procedures of the binding process according to the first embodiment; [FIG. 5] FIG. 5 is a flow chart illustrating procedures of the binding process according to the first embodiment; [FIG. 6] FIG. 6 is a diagram illustrating an example of image data acquired by a first camera according to the first embodiment; [FIG. 7] FIG. 7 is a perspective view of the device body in a state where a workpiece is moved into a binding area according to the first embodiment; [FIG. 8A] FIG. 8A is a diagram illustrating an example of image data acquired by a second camera according to the first embodiment; [FIG. 8B] FIG. 8B is a diagram illustrating an example of image data obtained by providing height information on reinforcing bars and other positions to the image data in FIG. 8A; [FIG. 9] FIG. 9 is a diagram for explaining a shape of the reinforcing bars detected based on the image data according to the first embodiment; [FIG. 10] FIG. 10 is a flow chart illustrating procedures according to a modification of the binding process of the first embodiment; [FIG. 11] FIG. 11 is a perspective view illustrating a device body of a binding system according to a second embodiment; [FIG. 12] FIG. 12 is a block diagram illustrating a schematic control configuration of the binding system according to the second embodiment; [FIG. 13] FIG. 13 is a side view of the binding device according to the second embodiment in a posture when performing a binding operation; [FIG. 14] FIG. 14 is a schematic diagram illustrating a workpiece on a holding table of a workpiece holding unit as viewed from above according to the second embodiment; [FIG. 15] FIG. 15 is a plan view illustrating an intersection at which binding is performed in a first direction of a binding direction according to the second embodiment; [FIG. 16] FIG. 16 is a plan view illustrating an intersection at which binding is performed in a second direction of the binding direction according to the second embodiment; [FIG. 17] FIG. 17 is a plan view illustrating an intersection at which the binding is performed with the "number of times of binding" being two according to the second embodiment; [FIG. 18] FIG. 18 is a plan view illustrating an intersection at which the binding is performed with the number of times of binding in the first direction being one and the number of times of binding in the second direction being one according to the second embodiment; [FIG. 19] FIG. 19 is a diagram illustrating an operation when the binding is performed in a binding order in an (1) outer edge first pattern according to the second embodiment; [FIG. 20] FIG. 20 is a diagram illustrating an operation when the binding is performed in a binding order in a (2) center first pattern according to the second embodiment; [FIG. 21] FIG. 21 is a diagram illustrating an operation when the binding is performed in a binding order in a (3) transverse feed pattern according to the second embodiment; [FIG. 22] FIG. 22 is a diagram illustrating an operation when the binding is performed in a binding order in a (4) longitudinal feed pattern according to the second embodiment; [FIG. 23] FIG. 23 is a diagram illustrating an operation when the binding is performed in a binding order in a (5) corner first pattern according to the second embodiment; [FIG. 24] FIG. 24 is a diagram illustrating the distinction among an "intersection located at a corner", an "intersection located on an outer edge", and the other intersections according to the second embodiment; [FIG. 25] FIG. 25 is a schematic diagram of a workpiece as viewed from above when an area including intersections serving as binding objects has an irregular shape according to the second embodiment; [FIG. 26] FIG. 26 is a flow chart illustrating a procedure when the binding system performs a binding process according to the second embodiment; [FIG. 27] FIG. 27 is a block diagram illustrating a schematic control configuration of the binding system according to a third embodiment; [FIG. 28] FIG. 28 is a plan view illustrating the workpiece that has been subjected to the binding direction determination process under a condition (1) according to the third embodiment; [FIG. 29] FIG. 29 is a plan view illustrating the workpiece that has been subjected to the binding direction determination process under a condition (2) according to the third embodiment; [FIG. 30] FIG. 30 is a plan view illustrating the workpiece that has been subjected to the binding direction determination process under a condition (3) according to the third embodiment; [FIG. 31] FIG. 31 is a plan view illustrating the workpiece that has been subjected to the binding direction determination process under a condition (4) according to the third embodiment; [FIG. 32] FIG. 32 is an enlarged plan view illustrating the workpiece at the intersection that has been subjected to the binding direction determination process under the condition (4) according to the third embodiment; [FIG. 33] FIG. 33 is a plan view illustrating the workpiece that has been subjected to the binding direction determination process under a condition (5) according to the third embodiment; [FIG. 34] FIG. 34 is a plan view illustrating a binding device in FIG. 13 viewed from one side of a turning axis; [FIG. 35] FIG. 35 is a plan view of a part of a device body according to the third embodiment, with a part of the structure thereof omitted; [FIG. 36] FIG. 36 is a flow chart illustrating a procedure when the binding system performs a binding process according to the third embodiment; [FIG. 37A] FIG. 37A is a side view illustrating an example of the binding device according to a fourth embodiment; [FIG. 37B] FIG. 37B is a side view illustrating an example of the binding device according to the fourth embodiment, with some components omitted from illustration; [FIG. 37C] FIG. 37C is a perspective view illustrating an example of the binding device according to the fourth embodiment; [FIG. 37D] FIG. 37D is a rear view illustrating an example of the binding device according to the fourth embodiment; [FIG. 37E] FIG. 37E is a side view viewed from a back surface illustrating an example of the binding device according to the fourth embodiment; [FIG. 38] FIG. 38 is an internal configuration diagram illustrating an example of a reinforcing bar binding machine according to the fourth embodiment, viewed from a side; [FIG. 39A] FIG. 39A is a perspective view illustrating an example of the binding system according to the fourth embodiment; [FIG. 39B] FIG. 39B is a perspective view illustrating an example of the binding system according to the fourth embodiment; [FIG. 40A] FIG. 40A is a side view illustrating an example of an operation of the binding device according to the fourth embodiment; [FIG. 40B] FIG. 40B is a side view illustrating the example of the operation of the binding device according to the fourth embodiment, with some components omitted from illustration; [FIG. 41A] FIG. 41A is a side view illustrating an example of an operation of the binding device according to the fourth embodiment; [FIG. 41B] FIG. 41B is a side view illustrating the example of the operation of the binding device according to the fourth embodiment, with some components omitted from illustration; and [FIG. 42] FIG. 42 is a side view illustrating an example of a binding operation of the binding device according to the fourth embodiment, with some components omitted from illustration. DESCRIPTION OF EMBODIMENTS

[0009] <<First Embodiment>> Hereinafter, a first embodiment of the present invention will be described with reference to the drawings.

[0010] [Configuration of Binding System] FIG. 1 is a perspective view illustrating a device body 10 included in a binding system 1 according to the first embodiment, and FIG. 2 is a block diagram illustrating a schematic control configuration of the binding system 1. As illustrated in these drawings, the binding system 1 binds a workpiece B, in which a plurality of reinforcing bars S are arranged in a grid pattern, at intersections P at which the plurality of reinforcing bars S intersect. Specifically, the binding system 1 includes the device body 10 and a control device 7.

[0011] The device body 10 includes a workpiece holding unit 2, an entire imaging unit 3, a robotic arm 4, an individual imaging unit 5, and a binding device 6. Of these, the workpiece holding unit 2 is disposed inside a gantry 11 of the device body 10, and the entire imaging unit 3, the robotic arm 4, the individual imaging unit 5, and the binding device 6 are mounted on the gantry 11. In the following description, X, Y, and Z directions refer to directions illustrated in FIG. 1. The X, Y, and Z directions are orthogonal to each other, an XY plane is a substantially horizontal plane, and the Z direction is a direction substantially along a vertical direction.

[0012] The gantry 11 is formed in a rectangular parallelepiped shape elongated in the X direction, and includes four support columns 12 erected at four corners in the X direction and the Y direction, and four beams 13 bridged in the X direction and the Y direction at upper ends of the support columns 12. In an area inside the gantry 11, a substantially half portion on one side (right side in FIG. 1) in the X direction is an imaging area E1 in which imaging by the entire imaging unit 3 is performed, and a half portion on the other side (left side in FIG. 1) is a binding area E2 in which a binding work by the robotic arm 4 and the binding device 6 is performed.

[0013] <Workpiece Holding Unit> The workpiece holding unit 2 holds the workpiece B and moves the held workpiece B between the imaging area E1 and the binding area E2. Specifically, the workpiece holding unit 2 includes a holding table 21 that holds the workpiece B, a rail 22 that movably supports the holding table 21, and a driving motor 23 that drives the rail 22. The holding table 21 is formed in a rectangular plate shape having four sides along the X direction and the Y direction. Support plates 211 that support the plurality of reinforcing bars S constituting the workpiece B are erected on the four sides of the holding table 21. Each of the support plates 211 has a plurality of U-shaped grooves 211a opening upward, and the reinforcing bars S are inserted into the U-shaped grooves 211a. The plurality of reinforcing bars S are arranged in a grid pattern along the X direction and the Y direction in a state where ends of the reinforcing bars S are inserted into the U-shaped grooves 211a of the support plates 211. The rail 22 is laid along the X direction and guides the holding table 21 in the X direction. The rail 22 according to the present embodiment is laid such that the holding table 21 (workpiece B) is movable at least between the imaging area E1 and the binding area E2. However, the rail 22 may be extended to an outside of the gantry 11, and the workpiece B may be movable to a work process before and after binding. The driving motor 23 is a driving source that causes the holding table 21 to move. The driving motor 23 causes the holding table 21 to move to the imaging area E1 and the binding area E2 based on a driving command from the control device 7. The workpiece holding unit 2 only needs to move the holding table 21 (workpiece B) from the imaging area E1 to the binding area E2 at least.

[0014] <Entire Imaging Unit> The entire imaging unit 3 images the entire workpiece B in the imaging area E1. Specifically, the entire imaging unit 3 includes a first camera 31 disposed above the imaging area E1 and a movement mechanism 32 that movably supports the first camera 31. The first camera 31 is disposed to face downward, images the workpiece B held by the workpiece holding unit 2 from above in the imaging area E1, and acquires signal information including information on distances to the reinforcing bars S as first information and image information of the workpiece B. Specifically, the first camera 31 according to the present embodiment is a compound-eye (for example, four-eye) stereo camera, acquires distance information in a depth direction (upper-lower direction) together with image information (monochrome image) on the XY plane, and outputs the distance information and the image information to the control device 7. The first camera 31 is an example of a first information acquisition unit according to the present invention. A sensor type or the like of the first camera 31 is not particularly limited as long as the first camera 31 can acquire the distance information (depth information) together with the image information, and may be a time of flight (TOF) sensor or the like. The movement mechanism 32 includes a Y direction slider 33 extending along the Y direction. The Y direction slider 33 is bridged over the beams 13 along the X direction and is supported by the beams 13 to be movable in the X direction. The first camera 31 is suspended from the Y direction slider 33 to be movable in the Y direction. The movement mechanism 32 drives a driving source (not illustrated) based on a control command from the control device 7 to cause the first camera 31 to move to a predetermined position (XY coordinates). As will be described later, the movement mechanism 32 is for imaging the entire workpiece B a plurality of times in order to obtain an image of the workpiece B with a desired resolution. Therefore, depending on the performance of the first camera 31, a shape of the workpiece B, and the like, the movement mechanism 32 may move the first camera 31 only in one of the X and Y directions, or may not be provided.

[0015] <Robotic Arm> The robotic arm 4 is an example of a moving body according to the present invention, is mounted with the individual imaging unit 5 and the binding device 6, and causes the individual imaging unit 5 and the binding device 6 to move to desired positions in the binding area E2. The robotic arm 4 according to the present embodiment includes a movement mechanism 46, a robotic arm body 40, and a controller 49.

[0016] The movement mechanism 46 causes the robotic arm body 40 to move. The movement mechanism 46 according to the present embodiment includes Y direction sliders 461 bridged over the beams 13 of the gantry 11. The Y direction sliders 461 cause the robotic arm body 40 to move in the Y direction. However, a specific configuration of the movement mechanism 46 is not particularly limited, and may include, for example, a mechanism that causes the robotic arm body 40 to move in the X direction. In addition, when an operation range of the robotic arm body 40 can cover the entire binding area E2 without depending on the movement mechanism 46, the movement mechanism 46 may not be provided.

[0017] The robotic arm body 40 is a suspended vertical multi-joint robot, and is installed downward on the Y direction sliders 461 bridged over the beams 13 in the binding area E2. Specifically, the robotic arm body 40 includes a base 41, a plurality of arms 42, an end effector 43, and a plurality of joints 44. The robotic arm body 40 is not limited to the vertical multi-joint robot as long as the robotic arm body 40 can move the individual imaging unit 5 and the binding device 6 mounted thereon. Further, it is preferable that the robotic arm 4 can change the position on each axis of the three orthogonal axes and the angle around at least one axis of the three orthogonal axes for at least one of the individual imaging unit 5 (the second camera 51) and the binding device 6.

[0018] The plurality of arms 42 are coupled in series to each other with the base 41 as a proximal end. The base 41 is mounted on the Y direction sliders 461 of the movement mechanism 46 and is supported to be movable in the Y direction. The plurality of joints 44 pivotably couple the base 41, the plurality of arms 42, and the end effector 43. Each joint 44 is provided with a motor 441 that drives the arm 42 (or the end effector 43) coupled to a distal end side of the joint 44, and an encoder 442 that detects a position (speed) of the motor 441 and outputs the position (speed) to the controller 49. The end effector 43 is coupled to distal ends of the plurality of arms 42. The individual imaging unit 5 and the binding device 6 are mounted on the end effector 43. A specific configuration of the robotic arm body 40 is not particularly limited as long as the individual imaging unit 5 and the binding device 6 are mounted on a distal end of the robotic arm body 40. For example, the individual imaging unit 5 may be fixed to the joint 44 on the most distal end side, and the binding device 6 may be coupled as an end effector via a tool changer.

[0019] The controller 49 controls an operation of each part of the robotic arm 4 based on a control command from the control device 7. Specifically, the controller 49 causes each motor 441 and the movement mechanism 46 to operate, and outputs information acquired by each encoder 442 to the control device 7. The controller 49 may locally control an operation of the mounted individual imaging unit 5 or binding device 6 based on a control command from the control device 7.

[0020] <Individual Imaging Unit> The individual imaging unit 5 is mounted on the distal end of the robotic arm body 40, and individually images the intersections P of the reinforcing bars S as binding objects in the binding area E2 with a resolution higher than that of the imaging by the entire imaging unit 3. Specifically, the individual imaging unit 5 includes a second camera 51, an elevator motor 52, and an illumination unit 53. The second camera 51 is attached to the end effector 43 of the robotic arm 4 in a distal end (downward) direction, and images the intersections P of the reinforcing bars S as binding objects from above. The second camera 51 is provided to be movable in a distal direction (upper-lower direction) relative to the end effector 43. The second camera 51 according to the present embodiment is, for example, an RGB camera, acquires image information (color image) of the intersections P as the binding objects, and outputs the image information to the control device 7. The second camera 51 is an example of a second information acquisition unit according to the present invention. A sensor type and the like of the second camera 51 are not particularly limited as long as the second camera 51 can acquire an image of at least one intersection P (signal information of an intersection P of reinforcing bars S including an image as second information). The elevator motor 52 is a driving source that causes the second camera 51 to move (lift and lower) in the distal direction (upper-lower direction) relative to the end effector 43. The illumination unit 53 is disposed slightly in front of the second camera 51 and around an imaging range thereof, and illuminates an imaging object of the second camera 51. The illumination unit 53 according to the present embodiment includes a plurality of light sources (light projectors, not illustrated) capable of illuminating the imaging object of the second camera 51 from different angles.

[0021] <Binding Device> FIG. 3 is a side view of the binding device 6. As illustrated in FIG. 3, the binding device 6 is mounted on the distal end of the robotic arm body 40. The binding device 6 includes a reinforcing bar binding machine 61 that uses wires W to bind the intersections P of the reinforcing bars S constituting the workpiece B, a slack forming unit 62 that draws the wires W from reels 63 and forms a slack in the wires W between the binding machine 61 and the reels 63, and a control unit 64 (see FIG. 2) that causes the reinforcing bar binding machine 61 to perform a binding operation and causes the slack forming unit 62 to perform a slack forming operation of the wires W according to operation commands from the control device 7.

[0022] The reinforcing bar binding machine 61 has an entry portion 611 through which two wires W are fed in from the outside of a case along a feed direction F illustrated in the drawing, winds the two wires W fed in from the entry portion 611 around the reinforcing bars S, feeds the two wires W wound around the reinforcing bars S in a reverse feed direction R to wind the wires W on the reinforcing bars S, cuts off the wires W, and then twists the wires W, thereby binding the reinforcing bars S with the wires W.

[0023] Therefore, the binding machine 61 includes a wire feeder that feeds the wires W, a wire guide 612 that guides the wires W, a curl guide 613 and an inducing guide 614 that wind the wires W around the reinforcing bars S, a cut unit that cuts the wires W wound on the reinforcing bars S, and a binding unit that twists the wires W wound on the reinforcing bars S.

[0024] The wire guide 612 is provided in front of the entry portion 611, and guides the two wires W to enter the entry portion 611 along the feed direction F.

[0025] The wire feeder is located inside the entry portion 611, and feeds the two wires W along the feed direction F while clamping the two wires W with a pair of feed gears. The wire feeder includes a feeding motor 615 (see FIG. 2) serving as a driving source. The feeding motor 615 can feed the two wires W in the feed direction F by forward rotation driving to wind the wires W around the reinforcing bars S by the curl guide 613 and the inducing guide 614 located ahead. In addition, the feeding motor 615 can feed the two wires W in the reverse feed direction R by reverse rotation driving to tighten the reinforcing bars S with the wires W.

[0026] The cut unit is located inside the entry portion 611 and on a further inner side relative to the wire feeder. The cut unit includes a movable blade and a fixed blade (not illustrated), and shares a driving source of the movable blade with the binding unit. The movable blade can be moved toward the fixed blade by a twisting motor 616 (see FIG. 2) serving as a driving source of the binding unit, to cut the two wires. The driving source of the cut unit may be separately provided.

[0027] The binding device 6 of FIG. 3 is supported by the end effector 43 on the distal end of the robotic arm 4, and performs the binding operation in a state where a turning axis Zr of the end effector 43 is parallel to the Z direction (vertically upper-lower direction). Further, the binding device 6 is set such that a position at which binding of the reinforcing bars S with the wires W is performed is located on an axis of the turning axis Zr, and the robotic arm 4 positions the binding device 6 during the binding such that each of the intersections P of the reinforcing bars S is on the axis of the turning axis Zr.

[0028] The curl guide 613 and the inducing guide 614 are located at a distal end (a lower end during the binding operation) of the binding machine 61, and are respectively disposed on both sides of the turning axis Zr while sandwiching the turning axis Zr. A proximal end of the curl guide 613 is disposed ahead of the entry portion 611 in the feed direction F, and a guide path for curling the wires W in a process from the proximal end toward a distal end of the curl guide 613 is formed inside the curl guide 613.

[0029] The inducing guide 614 is disposed to face the curl guide 613, and a guide path for receiving the wires W curled by the curl guide 613 from a distal end and guiding the wires W toward a proximal end side while maintaining the curled state is formed inside the inducing guide 614. The curl guide 613 and the inducing guide 614 cooperate with each other to deform the wires W into a loop shape, and then wind the wires W around the reinforcing bars S.

[0030] The binding unit includes a locking member that captures the wires W in a state of being wound around the reinforcing bars S between the proximal end of the inducing guide 614 and the proximal end of the curl guide 613. The locking member is supported inside the binding machine 61 to be rotatable around a rotational axis coaxial with the above-described turning axis Zr, and receives torque for performing rotational driving by the above-described twisting motor 616. The locking member can be subjected to the rotational driving by the above-described twisting motor 616 after the wires W are cut by the cut unit, and can twist both ends of the wires W to bind the reinforcing bars S.

[0031] The two reels 63 of the wires W are rotatably supported side by side on one side (upper side at the time of the binding operation) in a direction along the turning axis Zr of the binding machine 61. The two reels 63 are rotatable around an axis along a direction perpendicular to the page in FIG. 3, and are arranged side by side along the axis.

[0032] The slack forming unit 62 is disposed on one side of an orthogonal direction Xw orthogonal to the turning axis Zr relative to the binding machine 61 and the two reels 63. The slack forming unit 62 includes a first slack forming unit 621 and a second slack forming unit 622 that perform mutual crossing operations, and a slack forming motor 623 that is a driving source of the mutual crossing operations.

[0033] The above-described feed direction F of the wires W is substantially parallel to a plane that is parallel to both the turning axis Zr and the orthogonal direction Xw. Further, an upstream side of the feed direction F of the wires W is slightly inclined upward in the paper of FIG. 3 with respect to the orthogonal direction Xw. Each of the first slack forming unit 621 and the second slack forming unit 622 holds a roller over which the two wires W are stretched.

[0034] Further, since the first slack forming unit 621 and the second slack forming unit 622 perform the crossing operation substantially along the feed direction F, a path length for the wires W from the reels 63 to the entry portion 611 of the binding machine 61 is extended, and the wires W are drawn from the reels 63. The first slack forming unit 621 and the second slack forming unit 622 can form a slack corresponding to the drawing from the reels 63 on the wires W by performing a restoration operation after the crossing operation.

[0035] The two wires W are required to be fed to the entry portion 611 of the binding machine 61 from a direction close to the feed direction F (that is, at an incident angle close to the feed direction F). The feed direction F is a direction suitable for deforming the wires W into an appropriate loop shape by the curl guide 613 and the inducing guide 614 located ahead in an advance direction of the feed direction F. In order to supply the wires W to the entry portion 611 of the binding machine 61 along the feed direction F, the slack forming unit 62 is disposed such that a path from the second slack forming unit 622 on a downstream side to the entry portion 611 of the binding machine 61 follows the feed direction F. Then, during the crossing operation, the second slack forming unit 622 performs a separation movement in a direction away from the entry portion 611 of the binding machine 61 along the feed direction F.

[0036] Therefore, the binding device 6 is disposed such that the slack forming unit 62 greatly protrudes on one side (right side of the page in FIG. 3) of the orthogonal direction Xw relative to the binding machine 61 (turning axis Zr). The second camera 51 and the illumination unit 53 of the individual imaging unit 5 are disposed on the left side of the page in FIG. 3 relative to the binding machine 61 of the binding device 6.

[0037] <Control Device> As illustrated in FIG. 2, the control device 7 is a computer that integrally controls the binding system 1. Specifically, the control device 7 includes an operation unit 72, a display unit 73, a storage unit 76, and a control unit 77. The operation unit 72 is an operation unit for a user to perform various operations for operating the control device 7, and includes, for example, a keyboard and a pointing device such as a mouse. The display unit 73 includes, for example, a liquid crystal display, an organic EL display, or other displays, and displays various information based on a display signal from the control unit 77. The display unit 73 may be a touch panel that also serves as a part of the operation unit 72, or may perform sound output.

[0038] The storage unit 76 is a memory including a RAM (random access memory), a ROM (read only memory), and the like, stores various programs and data, and also functions as a work area of the control unit 77. The storage unit 76 according to the present embodiment stores a binding program 761 for executing a binding process to be described later and a reinforcing bar arrangement model 764 in advance, and also stores image data 762 acquired in the binding process and work information 763.

[0039] The image data 762 refers to image information on the workpiece B (reinforcing bars S) acquired by the first camera 31 and the second camera 51 during the execution of the binding process to be described later. The work information 763 refers to various information on the binding work. Specific contents of the work information 763 will be described later. The reinforcing bar arrangement model 764 refers to arrangement information on the plurality of reinforcing bars S in the workpiece B serving as a work object, and includes, for example, information on the number of reinforcing bars S arranged in each of the X, Y, and Z directions. In addition, the reinforcing bar arrangement model 764 may also include information on an interval between the reinforcing bars S in each of the X, Y, and Z directions, information on an angle when the reinforcing bars S are inclined, and the like. The storage unit 76 may store various data other than the above data acquired during the execution of the binding process to be described later, as needed.

[0040] The control unit 77 includes, for example, a CPU (central processing unit) and controls an operation of each unit of the control device 7. Specifically, the control unit 77 causes each unit of the control device 7 to operate based on an operation content of the operation unit 72 or the like, loads the programs stored in the storage unit 76 in advance, and executes various processes in cooperation with the loaded programs.

[0041] [Operations of Binding System] Next, operations of the binding system 1 at the time of executing the binding process for binding the workpiece B will be described. FIGS. 4 and 5 are flow charts each illustrating procedures of the binding process, FIGS. 6 to 9 are diagrams for explaining the binding process, FIG. 6 is a diagram for explaining an example of image data of the workpiece B acquired by the first camera 31, FIG. 7 is a diagram for explaining a perspective view of the device body 10 in a state where the workpiece B is moved into the binding area E2, FIG. 8A is a diagram for explaining an example of image data of a target intersection Pa acquired by the second camera 51, FIG. 8B is a diagram for explaining an example of image data obtained by providing height information on the reinforcing bars S and other positions in FIG. 8A, and FIG. 9 is a diagram for explaining a shape of the reinforcing bars S detected based on the image data.

[0042] In the binding process, the plurality of reinforcing bars S arranged in a grid pattern along the X and Y directions are bound at the intersections P (see FIG. 6) where the plurality of reinforcing bars S intersect with one another. This binding process is executed by the control unit 77 of the control device 7 reading out and loading the binding program 761 from the storage unit 76. Here, it is assumed that the workpiece B is disposed in the imaging area E1 in a state of being placed on the holding table 21 in advance (see FIG. 1). In the following description, it is assumed that only the control device 7 (the control unit 77 thereof) executes each step, but a control entity of the binding process is not particularly limited. For example, the respective components (control units thereof) of the binding system 1 may execute the binding process, or the control device 7 and the respective components may cooperate to execute the binding process.

[0043] As illustrated in FIG. 4, when the binding process is executed, first, the control unit 77 of the control device 7 images the workpiece B by the first camera 31 of the entire imaging unit 3 in the imaging area E1 (Step S1). Here, regarding the entire workpiece B, the control unit 77 acquires the image data (monochrome image) of the XY plane including the distance information by the first camera 31 as the stereo camera, and stores the image data in the storage unit 76. More specifically, the control unit 77 controls the movement mechanism 32 to move the first camera 31 into the XY plane in accordance with the size of the workpiece B, an angle of view of the first camera 31, and the like, and images by dividing the entire workpiece B into a plurality of parts (for example, 4 parts of 2 × 2 in the X and Y directions) while partially overlapping a part thereof. Then, the control unit 77 combines a plurality of acquired images to generate an image of the entire workpiece B, and stores the image in the storage unit 76. Accordingly, for example, image data 762a including the entire workpiece B as illustrated in FIG. 6 is acquired.

[0044] In Step S1, it is sufficient to acquire the signal information on the plurality of intersections P as the binding objects. Here, the "signal information on the plurality of intersections P" refers to data including at least one of position information on the intersections P and position information on an obstacle capable of interfering with the binding work of the intersections P. Further, a data format of the signal information is not limited to the image data, and may broadly include electromagnetic data including an optical signal.

[0045] Next, the control unit 77 calculates positions of all the intersections P included in the workpiece B based on the image data acquired in Step S1 (Step S2). Here, the control unit 77 calculates a three-dimensional position information including XYZ coordinates, for each intersection P. In this step, it is sufficient to calculate positions of a plurality of intersections P among all the intersections P included in the workpiece B. Here, at the time of calculating the positions of the intersections P, the positions may be calculated by using a reinforcing bar arrangement model 764 (a shape of the intersections of the intersecting reinforcing bars). In this case, when the shape matches the reinforcing bar arrangement model 764, the intersections are regarded as the intersections P, and thus the calculation of the positions becomes easy.

[0046] Next, as illustrated in FIG. 7, the control unit 77 drives the driving motor 23 of the workpiece holding unit 2 to operate the holding table 21, and causes the workpiece B to move into the binding area E2 (Step S3).

[0047] Next, the control unit 77 selects the intersection P to be bound among the plurality of intersections P included in the workpiece B (Step S4). Here, the control unit 77 selects one intersection P to be bound next among the plurality of intersections P excluding the intersection P that has already been bound (is recognized as a bound intersection) based on a predetermined binding order, for example. Hereinafter, the intersection P as the next binding object due to the above selection is referred to as a "target intersection Pa".

[0048] Next, the control unit 77 causes the second camera 51 of the individual imaging unit 5 mounted on the robotic arm 4 to approach the target intersection Pa selected in Step S4 in the binding area E2 (Step S5). Here, the control unit 77 controls the operation of the robotic arm 4 based on the position information on the target intersection Pa calculated in Step S2 and a movement amount in the X direction of the workpiece B moved in Step S3, to move the second camera 51 to a position directly above the target intersection Pa. Then, the control unit 77 controls the operation of the elevator motor 52 to lower the second camera 51 so as to approach the target intersection Pa by a predetermined distance. Accordingly, the target intersection Pa is positioned immediately near the second camera 51 facing downward, for example, a state is achieved where only the target intersection Pa is positioned within the angle of view of the second camera 51 (the intersections P other than the target intersection Pa are positioned outside the angle of view).

[0049] Next, the control unit 77 images the target intersection Pa and acquires image data thereof by using the second camera 51 brought close in Step S5 (Step S6). Here, the control unit 77 acquires the image data (color image) of the target intersection Pa by the second camera 51 and stores the image data in the storage unit 76. Accordingly, for example, as illustrated in FIG. 8A, image data 762b of the target intersection Pa with a resolution higher than that of the image data acquired by the first camera 31 in Step S1 is acquired. In this step, it is sufficient to acquire the signal information on at least one intersection P among the plurality of intersections P. More specifically, it is sufficient to acquire the signal information on the intersections P whose number is smaller than that of the plurality of intersections P for which the signal information is acquired by the first camera 31 in Step S1. In this step, the control unit 77 may control the illumination unit 53 to image the target intersection Pa with different illumination patterns. Accordingly, a three-dimensional image can be generated based on a change in patterns of light and reflected light, and the distance information can be acquired.

[0050] Next, the control unit 77 calculates the position of the target intersection Pa based on the image data acquired in Step S6 (Step S7).

[0051] In the calculation of the target intersection Pa, as illustrated in FIG. 5, first, the control unit 77 detects edges of the reinforcing bars S as a contour in the image of the reinforcing bars S based on contrast information included in the image data of the reinforcing bars S (step S71). Here, the contour (edges) indicates a boundary between the reinforcing bars S as the target and other parts in a target image. At this time, the control unit 77 binarizes the image data, and scans from a white side (bright part) to a black side (dark part) (that is, from a weak signal part to a strong signal part) of the image data, thereby detecting the edges. However, the image data may be gray-scaled with a predetermined gradation value instead of being completely binarized. Specifically, for example, in the case of image data 762d illustrated in FIG. 9, the control unit 77 acquires a contrast value from one side toward the other side of the X direction, for example. Then, a part where the contrast value changes to be larger than a predetermined threshold is detected (extracted) as an edge Se of the reinforcing bar S. Subsequently, the control unit 77 similarly detects an edge Se from the other side toward one side of the X direction. At this time, it is confirmed that these edges Se are both ends of the same reinforcing bar S based on a contrast change difference with the previously detected edge Se. Accordingly, the two edges Se along the Y direction are detected. Similarly, the control unit 77 performs the detection of edge Se along the Y direction, and detects two edges Se along the X direction.

[0052] Next, the control unit 77 calculates a reinforcing bar diameter (diameter of the reinforcing bar S) and a reinforcing bar center (center axis along a longitudinal direction of the reinforcing bar S) based on position information on the edges Se (Step S72). Here, since the reinforcing bar S has a substantially cylindrical shape, the control unit 77 sets a distance between the edges Se as a reinforcing bar diameter D, and sets a line passing through the center of the distance along the two edges Se in the same direction as a reinforcing bar center Ax. Further, it is also possible to acquire a detailed dimension of the reinforcing bar S in a height direction (Z direction).

[0053] Next, the control unit 77 calculates the position of the target intersection Pa (Step S73). Here, the control unit 77 obtains the position (coordinates) of the target intersection Pa as an intersection of the two reinforcing bar centers Ax. Further, dimensions of the target intersection Pa can also be acquired based on the dimensions of the reinforcing bar S in the X and Y directions. In this way, the position information on the target intersection Pa with higher accuracy than the position information calculated in Step S2 is obtained based on the high-resolution image data acquired by the second camera 51.

[0054] Next, the control unit 77 calculates the distance from the second camera 51 to the target intersection Pa of the reinforcing bars S (Step S74). Here, the control unit 77 acquires height information along the Z direction based on the image data, and obtains the distance between the second camera 51 and the target intersection Pa. Regarding the distance, image data 762c obtained by providing the height information on the reinforcing bars and other positions including the target intersection Pa to the image data 762b in FIG. 8A, is illustrated in FIG. 8B. In this way, based on the obtained height information, the distance by which the binding device 6 can approach the target intersection Pa can be obtained. In addition, a gap amount between the two reinforcing bars S at the target intersection Pa in the Z direction can also be obtained.

[0055] Next, the control unit 77 verifies shape information on the reinforcing bars S obtained in the step performed so far with the reinforcing bar arrangement model 764 of the workpiece B (Step S75). Here, the control unit 77 reads out the reinforcing bar arrangement model 764 of the workpiece B stored in the storage unit 76 in advance, and compares the reinforcing bar arrangement model 764 with the calculated shape information on the reinforcing bars S. Accordingly, the control unit 77 can identify the target intersection Pa as the binding object, and confirm a combination type of the reinforcing bars. In addition to the above, information on other intersections P acquired in Step S1 and Step S6 may be compared with the information on the target intersection Pa, thereby identifying the target intersection Pa. This indicates that, for example, although the intersection formed by the two reinforcing bars S along the X and Y directions may be erroneously recognized as an intersection P where one thick reinforcing bar S intersects another reinforcing bar S based on the image data, the target intersection Pa is identified by comparing with a result of another intersection P adjacent to the target intersection Pa or another intersection P existing in the same workpiece B, thereby confirming the combination type of the reinforcing bars.

[0056] Next, the control unit 77 determines whether to bind the target intersection Pa (Step S76). Here, the control unit 77 determines whether a main portion (for example, the curl guide 613) of the binding device 6 can be inserted between the two reinforcing bars S from above based on a cross angle of the two reinforcing bars S or the like, and when determining that the main portion can be inserted, the control unit 77 determines to bind the target intersection Pa. Here, when the control unit 77 cannot determine to bind the target intersection Pa, the control unit 77 proceeds to another process including, for example, interruption of the work or output of a warning. Alternatively, the robotic arm 4 and the binding device 6 may be configured to be detachable from each other, a plurality of binding devices 6 having insertion portions (portions to be inserted between the reinforcing bars S) with different sizes may be prepared in advance, and then the binding device 6 corresponding to the target intersection Pa may be selected. That is, in this case, the control unit 77 selects one binding device 6 capable of binding the target intersection Pa as the binding object, among the plurality of binding devices 6 (binding machines). Further, in this case, the plurality of binding devices 6 may be arranged at predetermined positions within a movement range of the robotic arm 4, and the exchange of the binding device 6 by the robotic arm 4 may be automated. Here, the control unit 77 determines a binding direction based on the position and an orientation of the binding device 6 capable of inserting the main portion between the two reinforcing bars S.

[0057] Next, the control unit 77 calculates a wire length necessary for the binding of the target intersection Pa (Step S77). Here, the control unit 77 calculates the length (including a retracting length) of the wires W necessary for the binding based on the reinforcing bar diameter D and the cross angle of the two reinforcing bars S constituting the target intersection Pa, or the like. In addition, the control unit 77 may set a rotation amount of the wire feeder (an operation amount of the feeding motor 615) in the binding (retracting) of the wires W by the binding device 6.

[0058] Next, as illustrated in FIG. 4, the control unit 77 causes the binding device 6 to approach the target intersection Pa based on the position information on the target intersection Pa calculated in Step S7 (S73) (Step S8). Here, the control unit 77 controls the operation of the robotic arm 4, and causes the binding device 6 mounted on the end effector 43 to approach the target intersection Pa instead of the second camera 51. At this time, the control unit 77 can cause the corresponding portion of the binding device 6 to face the target intersection Pa with high positional accuracy based on the position information with higher accuracy on the target intersection Pa obtained in Step S7.

[0059] Next, the control unit 77 causes the binding device 6 to operate and bind the target intersection Pa with the wires W (Step S9). At this time, the binding device 6 is disposed to face the target intersection Pa with sufficiently high positional accuracy, so that it is possible to preferably bind the target intersection Pa. Further, at this time, the amount of the wires W used to be bound at the target intersection Pa may be calculated and stored in the storage unit 76. The amount of the wires W used may be estimated based on a (substantial) wire feed amount (without including a retraction amount) in the wire feeder. The wire length necessary for the binding, which is estimated in the above Step S77 before the binding, may be the amount of the wires W used.

[0060] Next, the control unit 77 determines whether to end the binding process (Step S10), and when determining not to end the binding process (No in Step S10), the process proceeds to the above Step S4. Accordingly, the processes in Steps S4 to S10 are repeated until all the necessary intersections P are bound, for example. That is, the selection of the intersection P to be bound next (change of the target intersection Pa), and the imaging and binding of this target intersection Pa are sequentially executed. Then, for example, when determining to end the binding process due to completion of the binding of all the necessary intersections P in Step S10 (Yes in Step S10), the control unit 77 ends the binding process.

[0061] [Technical Effects of First Embodiment] As described above, according to the present embodiment, the signal information (first information) on the arranged plurality of reinforcing bars S is acquired by the first camera 31, and the signal information (second information) on the intersection P of the plurality of reinforcing bars S is acquired by the second camera 51 based on the first information. That is, information such as the positions of the plurality of intersections P and the presence or absence of an obstacle in a relatively wide range is grasped based on the first information acquired by the first camera 31. Then, the second camera 51 moves based on the first information in such a manner that the second camera 51 or the binding device 6 approaches the specific intersection P and avoids an obstacle at that time. Accordingly, the second camera 51 acquires more accurate signal information (second information) in a more local range. Then, the intersections of the reinforcing bars are bound based on the second information. That is, the desired intersections P can be bound with high accuracy. Therefore, the intersections P of the plurality of reinforcing bars S can be suitably bound.

[0062] According to the present embodiment, both the second camera 51 and the binding device 6 are mounted integrally on the robotic arm 4 and move together with the robotic arm 4. Accordingly, unlike the case where the second camera 51 and the binding device 6 move separately, the relative positional deviation between the second camera 51 and the binding device 6 can be prevented. Therefore, the binding operation of the binding device 6 can be controlled with higher accuracy based on the position information on the intersections P acquired by the second camera 51. Consequently, the intersection P can be bound with higher accuracy.

[0063] According to the present embodiment, the robotic arm 4 can change the position on each axis of the three orthogonal axes and the angle around at least one axis of the three orthogonal axes for at least one of the second camera 51 and the binding device 6. Accordingly, the imaging and the binding can be executed while flexibly changing and adjusting the position and orientation of the second camera 51 and / or the binding device 6. Accordingly, the imaging and the binding can be suitably performed when the workpiece B is either standing or inclined.

[0064] According to the present embodiment, an imaging area E1 (first area) in which the first camera 31 acquires the signal information (first information) is different from a binding area E2 (second area) in which the robotic arm 4 can move. Accordingly, the imaging work by the first camera 31, the imaging work by the second camera 51, and the binding work by the binding device 6 can be individually performed. Accordingly, the work efficiency can be improved.

[0065] According to the present embodiment, the holding table 21 that holds the workpiece B (the plurality of reinforcing bars S) can be moved from the imaging area E1 to the binding area E2. That is, by moving the workpiece B, the work in each area can be executed without moving the equipment on the device side. Therefore, the occurrence of measurement errors and the like due to the movement of the equipment on the device side can be prevented. Further, the scale of the movement can be reduced as compared with the case where the equipment on the device side is moved.

[0066] According to the present embodiment, the holding table 21 that holds the workpiece B (the plurality of reinforcing bars S) can be moved from the binding area E2 to the imaging area E1. That is, the workpiece B bound in the binding area E2 can be returned to the imaging area E1. Therefore, the workpiece B bound in the binding area E2 can be imaged again in the imaging area E1. Accordingly, the confirmation of the bound state including the detection of binding failure, the comparison of the state of the workpiece B before and after the binding, and the like can be performed.

[0067] According to the present embodiment, the second camera 51 may acquire signal information (second information) on the intersections P of the reinforcing bars S bound by the binding device 6. Accordingly, the state of the intersections P after the binding work can be grasped in detail. Further, the position of the bound intersections P in the entire workpiece B can be grasped.

[0068] According to the present embodiment, the signal information on the intersections P of the reinforcing bars S is stored in the storage unit 76. That is, the position information on the intersections P of the reinforcing bars S and the obstacle can be recorded at any time, and can be output as appropriate. At least one of the signal information acquired by the first camera 31 (first information) and the signal information acquired by the second camera 51 (second information) may be stored in the storage unit 76.

[0069] According to the present embodiment, the work information on the binding work by the binding device 6 may be stored in the storage unit 76. Here, the "work information" refers to information on the binding work executed in the binding area E2, and includes, for example, the position information (XYZ coordinates), whether to bind the intersection, the binding direction (angle), the number of times of binding, a binding strength, and a binding order. Further, the "work information" may include work log information such as operation contents of the robotic arm 4 and the binding device 6 in each binding operation. Accordingly, the work information on the binding work can be recorded as needed, and the work information can be output as appropriate.

[0070] According to the present embodiment, a map (map information) including the position information on the respective intersections P in the workpiece B (the plurality of reinforcing bars S) may be created based on the signal information acquired by the second camera 51 (second information). Accordingly, for example, the map (the positions of the intersections P) based on the first information acquired by the first camera 31 can be updated by more detailed and latest data acquired by the second camera 51. Further, when the map of the intersections P based on the second information acquired by the second camera 51 is created, the map may be created before the binding work, and then a plurality of intersection P may be bound continuously executed based on the map.

[0071] According to the present embodiment, the signal information on the intersections P (the first information and the second information) is image data acquired by the first camera 31 and the second camera 51. Therefore, the user can easily confirm the contents of the signal information by simply visually recognizing the image data.

[0072] According to the present embodiment, the first camera 31 and the second camera 51 acquire monochrome images and color images, respectively. Accordingly, errors caused by a color mismatch can be prevented by comparing the image data obtained by the first camera 31 and the image data obtained by the second camera 51.

[0073] [Other Technical Effects of First Embodiment] In the related art, regarding a workpiece in which a plurality of reinforcing bars are combined, a binding system is known that automatically and sequentially binds intersections of intersecting reinforcing bars with wires. According to this type of binding system, information on binding points as the intersections of the reinforcing bars may be acquired by a sensor or a camera. For example, the technique described in JP2022-110556A is applied to a self-propelled binding device that binds while propelling above reinforcing bars assembled on a plane, the technique acquires point group information in an upper-lower direction by using a distance sensor, and linearly models the point group information to detect intersections of the reinforcing bars. However, according to the technique described in JP2022-110556A, the detection accuracy of the intersections is low, and it is difficult to grasp a shape of the reinforcing bars such as a reinforcing bar diameter. Regarding this, according to the present embodiment, the shape of the reinforcing bars S is detected based on the contrast information included in the image data (signal information) of the reinforcing bars S. Accordingly, the positions of the reinforcing bars S can be grasped based on a contrast change, and the shape information on the reinforcing bars S such as the reinforcing bar diameter D and the reinforcing bar center Ax can be acquired. Therefore, the shape of the reinforcing bars S can be detected suitably. Further, for example, the optimal binding device 6 can also be selected based on the reinforcing bar diameter D. In addition, as long as the image data (signal information) in this case is substantial image data including the contrast information on the reinforcing bars as the imaging object, the data type (data format) thereof is not particularly limited.

[0074] According to the present embodiment, the edges (contour) Se of the reinforcing bars S are detected based on the contrast information of the image data. Therefore, the shape of the reinforcing bars S can be suitably detected based on the image data of reinforcing bars S. However, if the shape of the reinforcing bars S can be detected based on the contrast information, the parts other than the edges Se may be used.

[0075] Further, according to the present embodiment, the distance from the second camera 51 to the reinforcing bars S is calculated based on the image data of the reinforcing bars S. Accordingly, the movement amount of the binding device 6 necessary for the binding work of the reinforcing bars S (target intersection Pa) can be confirmed. As compared with a case of using a 3D sensor or the like, the distance information (height information) can be acquired by a simple process for two-dimensional image data. Further, a gap between the two reinforcing bars S at the target intersection Pa in the height direction can also be confirmed.

[0076] According to the present embodiment, the length of the wires W necessary for the binding is calculated (estimated) based on the image data. Accordingly, for example, shortage of the wires W before the actual binding work can be detected in advance by comparing with a wire remaining amount.

[0077] Further, according to the present embodiment, the detection of the edges Se of the reinforcing bars S is performed from the bright part to the dark part (from the weak signal part to the strong signal part) of the image data (signal information) of the reinforcing bars S. Accordingly, even when the types of the arranged reinforcing bars are different (for example, a difference in thickness or a difference in the number of the arranged reinforcing bars), it is easy to detect the intersections P.

[0078] Further, according to the present embodiment, the amount of the wires W used to be bound at the target intersection Pa may be calculated and stored. Accordingly, the wire remaining amount of the binding device 6 can be grasped.

[0079] According to the present embodiment, the image data (signal information) of the reinforcing bars S (target intersection Pa) after the binding may be acquired, and then a bound state may be determined based on the image data. The imaging may be performed by the second camera 51 or the first camera 31. Specifically, the drawing of the wires W from the edges Se at the target intersection Pa may be detected, and for example, when the wires W are drawn to exceed a predetermined threshold, it may be determined that the bound state of the target intersection Pa is not favorable. Accordingly, the bound state can be simply determined.

[0080] [Modifications of First Embodiment] For example, according to the first embodiment, the shape of the reinforcing bars S is obtained based on the image data acquired by the second camera 51. However, when the image data of the reinforcing bars S as the objects is used, the image data acquired by the first camera 31 may be used, and also in this case, the binding process (Step S71 to S77) can be executed in substantially the same manner as the above embodiment. In this case, however, unlike the above embodiment, the plurality of intersections P are included in the image data, and thus mainly based on this matter, the following processes may be further executed after Step S77 as illustrated in FIG. 10. In this case, the processes in Steps S71 to S77 are executed for each intersection P. In the processes in Steps S71 to S77 in this case, the "target intersection Pa" is replaced with the simple "intersections P".

[0081] Specifically, after Step S77 is executed, the control unit 77 acquires the position information on the plurality of intersections P (Step S78a), and detects the ends (of the plurality of reinforcing bars S) in the workpiece B based on the position information (Step S78b). Here, the control unit 77 detects the intersections P positioned at the ends among the plurality of intersections P by determining whether the intersections P are continuous (whether there are adjacent intersections P). Accordingly, the overall shape and size of the workpiece B can be grasped, and the range of the work object can be determined. Further, a movement path of the robotic arm 4 or the like can be planned, for example.

[0082] Next, the control unit 77 detects the obstacle capable of interfering with the binding, based on the image data of the reinforcing bars S (Step S79a). Here, when one height (Z direction) position is different by a predetermined threshold or more relative to other intersections P based on the height positions of the intersections P, the control unit 77 determines that the obstacle exists in this intersection P. Accordingly, the work can be continued while avoiding contact with the obstacle by taking measures, for example, moving so as to avoid the obstacle, changing the binding direction so as not to interfere with the obstacle and then performing the binding, or the like.

[0083] Next, the control unit 77 selects one intersection P among the plurality of intersections P based on a predetermined selection condition (Step S80a). Here, based on the selection condition stored in the storage unit 76 in advance, such as the shape of the intersection P capable of being bound or an arrangement pattern of the plurality of intersections P, the control unit 77 selects the intersection most satisfying the selection condition as the preferable intersection P. The selected intersection may be the target intersection Pa. Accordingly, even when the intersections P as the binding objects have various patterns, the intersections P can be preferably bound. Here, whether to bind the intersection P may be determined based on the above selection condition. That is, it may be determined that the intersection P not satisfying the selection condition cannot be bound. Accordingly, it is possible to select in advance the intersection P that is difficult to be bound, and to restrain the occurrence of an error indicating that the binding cannot be performed in the actual work.

[0084] When the plurality of intersections P are included in the image data, approximate positions of the intersections P are specified and then compared and determined in the comparison with the reinforcing bar arrangement model 764 in Step S75, and thus a determination time can be shortened. Further, the actual positions of the intersections are easily grasped by comparing with the reinforcing bar arrangement model 764.

[0085] [Other Modifications of First Embodiment] According to the first embodiment, it is assumed that the imaging area E1 (first area) and the binding area E2 (second area) are different. However, the imaging area E1 and the binding area E2 may partially overlap with each other, or may be integrated with each other (the same).

[0086] Further, it is preferable that the position of the obstacle and setting of an insertion direction (an access path to the intersection P) of the binding device 6 in consideration of the obstacle can be performed depending on the signal information acquired by one of the first camera 31 and the second camera 51. The data format of the signal information acquired by the first camera 31 and the second camera 51 is not particularly limited, and in the case of the image data, it is preferable that the signal information acquired by one of the first camera 31 and the second camera 51 is a monochrome image, the signal information acquired by the other one thereof is a color image. Further, it is preferable that the position information on the obstacle can be acquired in any direction among the X, Y, and Z directions. That is, by three-dimensionally grasping the position of the obstacle, the work can be executed without causing the robotic arm 4 to come into contact with the obstacle.

[0087] According to the above embodiment, the workpiece holding unit 2 moves the workpiece B in the X direction, but the workpiece holding unit 2 may further move or rotate the workpiece B in another direction. For example, when the workpiece holding unit 2 can rotate the workpiece B around a horizontal axis to reverse upper and lower surfaces thereof, the workpiece holding unit 2 can suitably cope with a workpiece B including reinforcing bars arranged in upper and lower two layers, or the like.

[0088] According to the above embodiment, an example in which the present invention is applied to a robotic arm system using a robotic arm has been described. However, the present invention can also be suitably applied to binding systems other than the robotic arm system, such as a workpiece conveyance system for conveying a workpiece, a gantry system for moving a device by a gantry, and a self-propelled system for causing an entire apparatus provided with a binding device to self-propel above a workpiece. Further, the present invention can be more preferably applied to a system in which an entire device is installed (fixed), for example, indoors and causes a workpiece to move, as in the above embodiment. When the structure according to the above embodiment is applied in a case of a moving body such as a self-propelled robot that moves freely, a case of an outdoor work, or the like, there may be problems that risk of collision of the information acquisition unit increases, the acquired signal (camera image) is disturbed due to a collision or the like, the size of the entire device increases, and waterproofing of the information acquisition unit is necessary.

[0089] <<Second Embodiment>> Hereinafter, a second embodiment of the present invention will be described with reference to the drawings. The second embodiment discloses a binding system and a binding processing program having a configuration capable of solving the problem that the binding robot has low versatility in the binding work of sequentially binding each intersection according to a predetermined circling operation as exemplified in CN110328662B as a related art.

[0090] The binding system 1C disclosed in the second embodiment includes a binding device 6C and a control device 7C whose configuration is different in part from the binding device 6 and the control device 7 of the binding system 1 disclosed in the first embodiment, and the other configurations are the same as those of the binding system 1. Accordingly, in the second embodiment, the binding system 1C is mainly described with respect to the configuration in the binding device 6C and the control device 7C that is different from that of the binding device 6 and the control device 7, and the same components as those of the binding system 1 are denoted by the same signs as those of the binding system 1, and the description thereof is omitted.

[0091] [Configuration of Binding System] FIG. 11 is a perspective view illustrating a device body 10C in a binding system 1C according to the second embodiment, and FIG. 12 is a block diagram illustrating a schematic control configuration of the binding system 1C. As illustrated in these drawings, the binding system 1C binds, with a wire W as a binding body, a workpiece B in which a plurality of reinforcing bars S are arranged in a grid pattern at intersections P (see FIG. 14) at which the plurality of reinforcing bars S intersect. Specifically, the binding system 1C includes the device body 10C and a control device 7C. The device body 10C includes a workpiece holding unit 2, an entire imaging unit 3, a robotic arm 4, an individual imaging unit 5, and a binding device 6C.

[0092] <Binding Machine> FIG. 13 is a side view of the binding device 6C in a posture when performing a binding operation. The binding device 6C is mounted on the distal end of the robotic arm 4. The binding device 6C includes a reinforcing bar binding machine 61C that uses the wires W to bind the intersections P of the reinforcing bars S constituting the workpiece B, a slack forming unit 62C that draws the wires W from reels 63C and forms a slack in the wires W between the binding machine 61C and the reels 63C, and a control unit 64C that causes the reinforcing bar binding machine 61C to perform a binding operation and causes the slack forming unit 62C to perform a slack forming operation of the wires W according to operation commands from the control device 7C.

[0093] The reinforcing bar binding machine 61C has an entry portion 611C through which two wires W are fed in from the outside of a case along a feed direction F illustrated in the drawing, winds the two wires W fed in from the entry portion 611C around the reinforcing bars S, feeds the two wires W wound around the reinforcing bars S in a reverse feed direction R to wind the wires W on the reinforcing bars S, cuts off the wires W, and then twists the wires W, thereby binding the reinforcing bars S with the wires W.

[0094] Therefore, the binding machine 61C includes a wire feeder that feeds the wires W, a wire guide 612C that guides the wires W, a curl guide 613C and an inducing guide 614C that wind the wires W around the reinforcing bars S, a cut unit that cuts the wires W wound on the reinforcing bars S, and a binding unit that twists the wires W wound on the reinforcing bars S.

[0095] The wire guide 612C is provided in front of the entry portion 611C and guides the two wires W to enter the entry portion 611C along the feed direction F.

[0096] The wire feeder is located inside the entry portion 611C and feeds the two wires W along the feed direction F while clamping the two wires W with a pair of feed gears. The wire feeder includes a feeding motor 615C (see FIG. 12) serving as a driving source. The feeding motor 615C can feed the two wires W in the feed direction F by forward rotation driving to wind the wires W around the reinforcing bars S by the curl guide 613C and the inducing guide 614C located ahead. In addition, the feeding motor 615C can feed the two wires W in the reverse feed direction R by reverse rotation driving to tighten the reinforcing bars S with the wires W.

[0097] The cut unit is located inside the entry portion 611C and on a further inner side relative to the wire feeder. The cut unit includes a movable blade and a fixed blade (not illustrated), and shares a driving source of the movable blade with the binding unit. The movable blade can be moved toward the fixed blade by a twisting motor 616C (see FIG. 12) serving as a driving source of the binding unit, to cut the two wires. The driving source of the cut unit may be separately provided.

[0098] The binding device 6C of FIG. 13 is supported by the end effector 43 on the distal end of the robotic arm 4, and performs the binding operation in a state where a turning axis Zr of the end effector 43 is parallel to the Z direction (vertically upper-lower direction). Further, the binding device 6C is set such that a position at which binding of the reinforcing bars S with the wires W is performed is located on an axis of the turning axis Zr, and the robotic arm 4 positions the binding device 6C during the binding such that each of the intersections P of the reinforcing bars S is on the axis of the turning axis Zr.

[0099] The curl guide 613C and the inducing guide 614C are located at a distal end (a lower end during the binding operation) of the binding machine 61C, and are respectively disposed on both sides of the turning axis Zr while sandwiching the turning axis Zr. A proximal end of the curl guide 613C is disposed ahead of the entry portion 611C in the feed direction F, and a guide path for curling the wires W in a process from the proximal end toward a distal end of the curl guide 613C is formed inside the curl guide 613C.

[0100] The inducing guide 614C is disposed to face the curl guide 613C, and a guide path for receiving the wires W curled by the curl guide 613C from a distal end and guiding the wires W toward a proximal end while maintaining the curled state is formed inside the inducing guide 614C. The curl guide 613C and the inducing guide 614C cooperate with each other to deform the wires W into a loop shape, and then wind the wires W around the reinforcing bars S.

[0101] The binding unit includes a locking member that captures the wires W in a state of being wound around the reinforcing bars S between the proximal end of the inducing guide 614C and the proximal end of the curl guide 613C. The locking member is supported inside the binding machine 61C to be rotatable around a rotational axis coaxial with the above-described turning axis Zr, and receives the torque for performing rotational driving by the above-described twisting motor 616C. The locking member can be subjected to the rotational driving by the above-described twisting motor 616C after the wires W are cut by the cut unit, and can twist both ends of the wires W to bind the reinforcing bars S.

[0102] The two reels 63C of the wires W are rotatably supported side by side on one side (upper side at the time of the binding operation) in a direction along the turning axis Zr of the binding machine 61C. The two reels 63C are rotatable around an axis along a direction perpendicular to the page in FIG. 13 and are arranged side by side along the same direction.

[0103] As illustrated in FIG. 13, the slack forming unit 62C is disposed on one side in an orthogonal direction Xw orthogonal to the turning axis Zr with respect to the binding machine 61C and the two reels 63C. The slack forming unit 62C includes a first slack forming unit 621C and a second slack forming unit 622C that perform mutual crossing operations, and a slack forming motor 623C that is a driving source of the mutual crossing operations.

[0104] The above-described feed direction F of the wires W is substantially parallel to a plane that is parallel to both the turning axis Zr and the orthogonal direction Xw. Further, an upstream side of the feed direction F of the wires W is inclined slightly toward the upper side of the page in FIG. 13 relative to the orthogonal direction Xw. Each of the first slack forming unit 621C and the second slack forming unit 622C holds a roller over which the two wires W are stretched.

[0105] Further, since the first slack forming unit 621C and the second slack forming unit 622C perform the crossing operation substantially along the feed direction F, a path length for the wires W from the reels 63C to the entry portion 611C of the binding machine 61C is extended, and the wires W are drawn from the reels 63C. The first slack forming unit 621C and the second slack forming unit 622C can form a slack corresponding to the drawing from the reels 63C on the wires W by performing a restoration operation after the crossing operation.

[0106] The two wires W are required to be fed to the entry portion 611C of the binding machine 61C from a direction close to the feed direction F, that is, at an incident angle close to the feed direction F. The feed direction F is a direction suitable for deforming the wires W into an appropriate loop shape by the curl guide 613C and the inducing guide 614C located ahead in an advance direction of the feed direction F. In order to supply the wires W to the entry portion 611C of the binding machine 61C along the feed direction F, the slack forming unit 62C is disposed such that a path from the second slack forming unit 622C on a downstream side to the entry portion 611C of the binding machine 61C follows the feed direction F. Then, during the crossing operation, the second slack forming unit 622C performs a separation movement in a direction away from the entry portion 611C of the binding machine 61C along the feed direction F.

[0107] Therefore, the binding device 6C is disposed such that the slack forming unit 62C greatly protrudes on one side (right side of the page in FIG. 13) of the orthogonal direction Xw relative to the binding machine 61C (turning axis Zr). The second camera 51 and the illumination unit 53 of the individual imaging unit 5 are disposed on the left side of the page in FIG. 13 relative to the binding machine 61C of the binding device 6C.

[0108] <Control Device> The control device 7C is a computer that integrally controls the binding system 1C. Specifically, the control device 7C includes an operation unit 72, a display unit 73, a storage unit 76C, and a control unit 77C. The operation unit 72 is an operation unit for a user to perform various operations for operating the control device 7C, and includes, for example, a keyboard and a pointing device such as a mouse. The display unit 73 includes, for example, a liquid crystal display, an organic EL display, or other displays, and displays various information based on a display signal from the control unit 77C. The display unit 73 may be a touch panel that also serves as a part of the operation unit 72, or may perform sound output.

[0109] The storage unit 76C is a memory including a RAM (random access memory), a ROM (read only memory), and the like, stores various programs and data, and also functions as a work area of the control unit 77C. In the storage unit 76C of the present embodiment, a binding processing program 761C for executing a process related to binding to be described later is stored in advance. Further, the storage unit 76C as a recording device stores image data 762C captured by the first camera 31 and the second camera 51, map data 763C in which information on the workpiece B is recorded, first binding condition data 764C that stores various to-be-described binding conditions selectively set by the user, second binding condition data 765C that stores various binding conditions prepared in advance for executing a plurality of operation modes to be described later, device information data 766C indicating a three-dimensional position of an entire surface of the binding device 6C, and peripheral information data 767C indicating a three-dimensional position of an entire surface of an obstacle around the robotic arm 4 developed in the coordinate system of the robotic arm 4.

[0110] The control unit 77C includes, for example, a CPU (central processing unit) and controls an operation of each unit of the control device 7C. Specifically, the control unit 77C causes each unit of the control device 7C to operate based on an operation content of the operation unit 72 or the like, loads the programs stored in the storage unit 76C in advance, and executes various processes in cooperation with the loaded programs.

[0111] <Intersection Information Acquisition Process> By executing the binding processing program 761C described above, the control unit 77C functions as an intersection information acquisition unit that acquires information on the intersections P at which the plurality of reinforcing bars S of the workpiece B intersect. As described above, the control unit 77C controls the device body 10C to perform binding with the wires W serving as the binding body at each of the intersections P at which the plurality of reinforcing bars S of the workpiece B intersect.

[0112] FIG. 14 is a schematic diagram of the workpiece B held by the support plate 211 of the holding table 21 of the workpiece holding unit 2 as viewed from above in the Z direction. In this schematic diagram, the number of reinforcing bars S of the workpiece B is illustrated to be smaller than that in FIG. 11. Further, a plurality of double circles in the drawing are marks indicating the positions of the intersections P, and do not indicate an object existing on the actual workpiece B. Further, since the number of reinforcing bars S and intersections P in the drawing is large, only some of them are denoted by reference numerals. The same also applies to FIGS. 19 to 25.

[0113] The workpiece B has a grid pattern in which a plurality of reinforcing bars S along the Y direction are arranged on a plurality of reinforcing bars S along the X direction. The reinforcing bars S along the X direction and the reinforcing bars S along the Y direction may be upside down. Further, the plurality of reinforcing bars S along each direction are illustrated in a state of being arranged at uniform intervals, but the inter-intervals between the reinforcing bars S may not be uniform. Further, a length may not be uniform. Positions where center lines of the plurality of reinforcing bars S along the X direction and the plurality of reinforcing bars S along the Y direction intersect when viewed from the Z direction are the intersections P, and the binding system 1C can set each of the intersections P as a binding object.

[0114] For a binding operation control of the control unit 77C, the information on the intersections P for specifying the positions of the intersections P at which the reinforcing bars S of the workpiece B intersect is necessary. Therefore, the control unit 77C functioning as the intersection information acquisition unit performs a first acquisition process of acquiring the position of each intersection P from the image data 762C captured by the first camera 31 or the second camera 51, and a second acquisition process of acquiring the map data 763C from an outside of the binding system 1C.

[0115] The control unit 77C may be configured to perform only one of the first acquisition process and the second acquisition process. For example, when the control unit 77C is configured to perform only the first acquisition process, the storage unit 76C may be configured not to hold the map data 763C.

[0116] In the first acquisition process performed by the control unit 77C, when the image data 762C of the workpiece B on the holding table 21 captured by the first camera 31 or the second camera 51 is two-dimensional planar image data, a position of a contour of each of the reinforcing bars S in the image is extracted by known image processing, the center line passing through a center of each reinforcing bar S is obtained, and a position at which the center lines of the reinforcing bars S intersect each other is specified, and is acquired as the position of the intersection P. Further, height information of the intersection P may be obtained by performing imaging two or more times while changing a relative position between the first camera 31 or the second camera 51 and the workpiece B on the holding table 21, and calculating a height of each position in the image by parallax. Since three-dimensional position data of all the intersections P of the reinforcing bars S of the workpiece B is obtained in this way, by developing the three-dimensional position data in the coordinate system of the robotic arm 4, the information on the intersections P for specifying the positions of the intersections P is acquired.

[0117] When the image data 762C of the first camera 31 or the second camera 51 is image data including three-dimensional position information, the position information indicated by the image data is developed in the coordinate system of the robotic arm 4 to acquire the information on the intersections P for specifying the positions of the intersections P.

[0118] The control device 7C includes a communication device (not illustrated) that communicates with the outside of the binding system 1C, and the second acquisition process performed by the control unit 77C is a process of requesting and acquiring the map data 763C from another external information processing terminal via a communication network. Further, the control device 7C may include a reading device (not illustrated) that reads a storage medium storing the map data 763C, and may acquire the map data 763C by reading from the storage medium.

[0119] The map data 763C records design information of the workpiece B and the like, and includes basic dimensions and three-dimensional position information of each reinforcing bar S and the three-dimensional position information of each intersection P. Therefore, the control unit 77C that performs the second acquisition process develops the three-dimensional position information of the respective intersections P obtained from the map data 763C in the coordinate system of the robotic arm 4 to acquire the information on the intersections P for specifying the positions of the intersections P.

[0120] <Binding Condition Selection Process> By executing the binding processing program 761C described above, the control unit 77C performs a process of receiving a selection of the binding condition of the wire W for each of the intersections P of the plurality of reinforcing bars S of the workpiece B, generating the first binding condition data 764C, and storing the first binding condition data 764C in the storage unit 76C. The binding operation control of the control unit 77C follows various binding conditions. The user can set and input various binding conditions via the operation unit 72 serving as a condition input unit, and the control unit 77C selects various set binding conditions and performs an operation control on the binding work. Here, the various binding conditions will be described. Each of the binding conditions to be described below is an example and is not limited thereto.

[0121] The binding conditions included in the first binding condition data 764C include a "presence or absence of binding", a "binding direction", the "number of times of binding", and a "binding strength" for each of the intersections P. The binding conditions further include a "binding order" for the plurality of intersections P of the workpiece B. These binding conditions will be individually described.

[0122] The "presence or absence of binding" as the binding condition is individually selected for all the intersections P in the workpiece B. The "presence or absence of binding" is a setting on whether each of the intersections P is the binding object. That is, it is possible to select whether to perform binding for each of the intersections P in the workpiece B. In the "presence or absence of binding", the user sets and inputs, via the operation unit 72, whether each of the intersections P of the workpiece B is individually set as the binding object, and the control unit 77C selects the intersection P set as the binding object and performs binding.

[0123] The "binding direction" as the binding condition is individually selected for all the intersections P set as the binding objects in the workpiece B. The "binding direction" will be described with reference to FIGS. 15 and 16. FIGS. 15 and 16 are plan views illustrating two types of binding directions for the intersection P. The wires W bound at the intersection P of the reinforcing bar S in the X direction and the reinforcing bar S in the Y direction is in one of a direction illustrated in FIG. 15 and a direction illustrated in FIG. 16 inclined by approximately 45° with respect to both the X direction and the Y direction when viewed from above in the Z direction. Here, a binding direction along an upper right direction on the page of FIG. 15 is set as a first direction, and a binding direction along an upper left direction on the page of FIG. 16 is set as a second direction. The "binding direction" as the binding condition indicates whether the binding with the wires W is performed along the first direction or the second direction. The "binding direction" referred to here indicates a direction along which the wires W after binding extend, as viewed from a vertical direction of the planar workpiece B.

[0124] The binding device 6C of the binding system 1C has a specification of performing binding with two wires W by one binding operation, and the two wires W illustrated in FIGS. 15 and 16 illustrate a state after one binding operation. The same applies to the subsequent drawings. Both ends of each wire W after binding are formed with a wound portion by a twisting operation, but the wound portion is not illustrated in FIG. 15 and the subsequent drawings.

[0125] The "number of times of binding" as the binding condition is individually selected for all the intersections P set as the binding objects in the workpiece B. The "number of times of binding" will be described with reference to FIG. 17. The "number of times of binding" is the number of times the binding operation is performed by the binding device 6C on one intersection P. The number of wires W used for the binding is proportional to the number of times of binding operations. FIG. 17 illustrates a bound state when the "number of times of binding" is two. As described above, since two wires W are used in one binding operation, the binding is performed with four wires W at the intersection P. The "number of times of binding" can be selected from one to a plurality of times. However, when the number of times of binding is repeated, a bundle of the wires W wound at the intersection P becomes too large, and thus there is a limit for the number of times.

[0126] Further, the "number of times of binding" as the binding condition may be selectable in combination with the "binding direction". For example, both the first direction and the second direction may be selected as the "binding direction", and the "number of times of binding" may be selected for each of the directions. FIG. 18 illustrates a bound state when the number of times of binding is selected as one for the first direction and the number of times of binding is selected as one for the second direction. In this case, an order of the binding operation in the first direction and the binding operation in the second direction may also be selectable as the binding condition.

[0127] The "binding strength" as the binding condition is individually selected for all the intersections P set as the binding objects in the workpiece B. The "binding strength" indicates a winding strength of the wire W for binding the intersection P. The "binding strength" may be selected as a numerical value or may be selected as a level of strength (for example, strong, medium, weak, or the like). As described above, the binding device 6C forms a wound portion by the twisting operation on both ends of the wire W. The "binding strength" can be determined by the magnitude of the torque generated by the twisting motor 616C of the binding device 6C that performs the twisting operation of the wire W. For example, when there is a correlation between the torque output by the twisting motor 616C and a value of a current flowing through the twisting motor 616C, the control unit 77C monitors the value of the current flowing through the twisting motor 616C of the binding device 6C and controls the twisting motor 616C to perform the twisting operation on both ends of the wire W until the value of the current reaches a current value corresponding to the torque corresponding to the selection of the "binding strength".

[0128] The "binding order" as the binding condition will be described. The "binding order" can be selected from patterns such as (1) outer edge first, (2) center first, (3) transverse feed (Y direction), (4) longitudinal feed (X direction), and (5) corner first. These patterns are examples, and other patterns may be selectable. For example, when a certain one of these patterns (1) to (5) is selectively set by the user via the operation unit 72, the control unit 77C performs binding for the plurality of intersections P according to an order determined in the set pattern.

[0129] FIG. 19 illustrates an order of advancing for each intersection P in the (1) outer edge first pattern. When the (1) outer edge first pattern is selected, the control unit 77C preferentially performs binding at the intersections P located on an outer edge of an area where all the intersections P set as the binding objects of the workpiece B are present. For example, when all the intersections P illustrated in FIG. 19 are binding objects and an area where the intersections P are present is a rectangle, the control unit 77C performs the binding first at the intersections P located at four corners of the rectangular area and on an outer edge along four sides.

[0130] In the (1) outer edge first pattern, the binding is started from the intersection P located at any one of the four corners, and the binding is performed for each of the intersections P while circling in a predetermined direction around the outer edge of the area where the intersections P are present. From which of the four corners the binding is started can be selectively set via the operation unit 72 by the user, or it may be determined in advance that a corner at a predetermined position is a start position. Further, in FIG. 19, a case where the binding is performed by circling in a clockwise direction on the page of the drawing is illustrated, but the binding is not limited thereto, and may be performed in a counterclockwise direction. The circling direction can be selectively set by the user via the operation unit 72, or a predetermined circling direction may be determined in advance.

[0131] Further, in the (1) outer edge first pattern, for the intersections P other than those on the outer edge, as in the example of FIG. 19, the binding for each of the intersections P may be performed while circling in a predetermined direction around an outer edge of an area including the remaining intersections P, and the circling may be similarly repeated inward until the binding is completed for all the intersections P. In this case, regarding a direction of circling in each round, it is preferable that the circling is performed in a reverse direction of circling in a previous round every time one round of circling is performed. The robotic arm body 40 of the robotic arm 4 that moves the binding device 6C performs the binding operation while performing a turning operation in a state where the turning axis around the axis along the Z direction is aligned with the vicinity of a center position of the workpiece B, and a turning angle range around the axis along the Z direction of the robotic arm body 40 may be limited to a range around 360°. This is because, when the binding is performed by circling as described above, it is possible to reduce an influence of a limitation on the turning angle range of the robotic arm body 40 by alternately switching a turning direction. When the turning angle range of the robotic arm body 40 is sufficiently wide, circling in a certain direction may be continuously performed.

[0132] FIG. 20 illustrates an order of advancing for each intersection P in the (2) center first pattern. When the (2) center first pattern is selected, the control unit 77C starts the binding from the intersection P closest to a center of the area where all the intersections P set as the binding objects of the workpiece B are present. The center of the area may be defined as, for example, a geometric center (centroid). Further, when the area in which all the intersections P set as the binding objects of the workpiece B are present is not a rectangle, a centroid of a rectangle in which the area is inscribed may be defined as the center of the area.

[0133] For example, in a case where all the intersections P illustrated in FIG. 20 are binding objects and an area where the intersections P are present is a rectangle, when the (2) center first pattern is selected, the control unit 77C performs the binding in order starting from the intersection P at the center, shifting to the intersection P located therearound and advancing toward the intersections P on an outer side while circling.

[0134] In the (2) center first pattern, as illustrated in FIG. 20, the circling direction is alternately switched between the clockwise direction and the counterclockwise direction on the page of the drawing every time one round of circling is performed. A reason is the same as the reason for alternately switching the circling direction in the (1) outer edge first pattern described above. Therefore, when the turning angle range of the robotic arm body 40 is sufficiently wide, circling in a certain direction may be continuously performed.

[0135] FIG. 21 illustrates an order of advancing for each intersection P in the (3) transverse feed pattern. When the (3) transverse feed pattern is selected, the control unit 77C starts the binding from a row of intersections P closest to one side in the Y direction among rows of the intersections P arranged along the X direction in the area where all the intersections P set as the binding objects of the workpiece B are present, and performs the binding row by row in order in the Y direction.

[0136] From which row on both ends in the Y direction among a plurality of rows of the intersections P arranged along the X direction the binding is started, or from which intersection P on both ends of the row of intersections P arranged along the X direction the binding is started, may be selectively set by the user via the operation unit 72, or may be determined in advance. FIG. 21 illustrates a case where the advance direction of the binding in a row of intersections P arranged along the X direction is a reverse direction of an immediately preceding row. Thus, a movement amount for each of the intersections P of the workpiece B can be reduced, and the work can be quickly performed.

[0137] In the example of FIG. 21, the binding is performed for the rows of the intersections P arranged along the X direction row by row in order in the Y direction, but the present disclosure is not limited thereto. For example, the binding may be alternately advanced in a row on one end side and a row on the other end side in the Y direction among the rows of the intersections P arranged along the X direction, and the binding may be completed at a row in the middle in the Y direction.

[0138] FIG. 22 illustrates an order of advancing for each intersection P in the (4) longitudinal feed pattern. When the (4) longitudinal feed pattern is selected, the control unit 77C starts the binding from a row of intersections P closest to one side in the X direction among rows of the intersections P arranged along the Y direction in the area where all the intersections P set as the binding objects of the workpiece B are present, and performs the binding row by row in order in the X direction.

[0139] From which row on both ends in the X direction among a plurality of rows of the intersections P arranged along the Y direction the binding is started, or from which intersection P on both ends of the row of intersections P arranged along the Y direction the binding is started, may be selectively set by the user via the operation unit 72, or may be determined in advance. FIG. 22 illustrates a case where the advance direction of the binding in a row of intersections P arranged along the Y direction is a reverse direction of an immediately preceding row. Thus, a movement amount for each of the intersections P of the workpiece B can be reduced, and the work can be quickly performed.

[0140] In the example of FIG. 22, the binding is performed for the rows of the intersections P arranged along the Y direction row by row in order in the X direction, but the present disclosure is not limited thereto. For example, the binding may be alternately advanced in a row on one end side and a row on the other end side in the X direction among the rows of the intersections P arranged along the Y direction, and the binding may be completed at a row in the middle in the X direction.

[0141] FIG. 23 illustrates an order of advancing for each intersection P in the (5) corner first pattern. When the (5) corner first pattern is selected, the control unit 77C first performs the binding at the intersection P located at a corner of the area where all the intersections P set as the binding objects of the workpiece B are present. For example, when all the intersections P illustrated in FIG. 23 are binding objects and an area where the intersections P are present is a rectangle, the control unit 77C specifies the intersection P located at the corner of the rectangle and performs binding first at the intersection P.

[0142] In the (5) corner first pattern, the binding is performed in a predetermined order for each of the intersections P located at four corners. The order in which the binding is performed for each of the intersections P at the four corners may be selectively set by the user via the operation unit 72, or a predetermined order may be determined in advance. For example, the binding may be performed to circle from a first intersection P among the intersections P at the four corners, the binding may be performed for a next intersection P located diagonally with respect to the first intersection P among the intersections P at the four corners, and the binding may be similarly performed at the intersections P at the remaining two corners.

[0143] Further, in the (5) corner first pattern, any one of the patterns (1) to (4) described above may be performed for a binding order at the intersections P other than those at the corners. Therefore, when the (5) corner first pattern is selected, any one of the patterns (1) to (4) may be selectable for the intersections P other than those at the corners. The selection may be selectively set by the user via the operation unit 72, or any one of the patterns (1) to (4) may be determined in advance as a predetermined setting.

[0144] When the "binding order" as the binding condition is selected, the control unit 77C needs to specify the "intersections P located at the corners" and the "intersections P located on the outer edge" in the area where the intersections P are present. FIG. 24 is a diagram in which the "intersection P located at the corner" is indicated by "A", the "intersection P located on the outer edge" is indicated by "B", and the other intersection P is indicated by "C".

[0145] In FIG. 24, the control unit 77C specifies the intersections P each having two other adjacent intersections P as the "intersections P located at the corners", such as the intersections P denoted by "A" in an area Ra surrounded by a two-dot chain line. In FIG. 24, the control unit 77C specifies the intersections P each having three or less other adjacent intersections P as the "intersections P located on the outer edge", such as the intersections P denoted by "B" in an area Rb surrounded by a two-dot chain line. In FIG. 24, the control unit 77C specifies the intersections P each having four other adjacent intersections P as the intersections P other than the "intersections P located at the corners" and the "intersections P located on the outer edge", such as the intersections P denoted by "C" in an area Rc surrounded by a two-dot chain line.

[0146] The "adjacent intersections P" indicate a case of being adjacent via the reinforcing bar S. That is, the adjacent intersections P indicate intersections P adjacent in the X direction or the Y direction, and do not include intersections P adjacent in a direction oblique to both the X direction and the Y direction. Since the "intersections P located on the outer edge" are intersections each having three or less other adjacent intersections P, the "intersections P located at the corners" each having two other adjacent intersections P are also included.

[0147] Further, regarding the patterns (1) to (5) in the "binding order", the case where all the intersections P are the binding objects and the area where the intersections P are present is a rectangle has been described as an example, but a part of the intersections P may not be the binding objects or the workpiece B may not have a rectangular planar grid shape but have a partially missing shape. For example, when the workpiece B is installed in a place where an obstacle, such as a support column, is present, a part of the reinforcing bars S is removed to avoid the obstacle in advance or after the binding work at the intersections P, and the workpiece B has a missing shape. Further, the intersections P within a range in which a part of the reinforcing bars S are scheduled to be removed due to the obstacle may not be the binding object.

[0148] FIG. 25 is a schematic diagram of the workpiece B on the holding table 21 as viewed from above, illustrating a case where a part of the intersections P is not the binding object or a part of the reinforcing bars S of the workpiece B is removed and a part of the rectangle is lost, and an area in which the binding object is set has an irregular shape. It is assumed that all the intersections P indicated by double-circle marks illustrated in the drawing are the binding objects.

[0149] In a case of the area having such an irregular shape, the control unit 77C can also perform the binding according to an order determined in the patterns (1) to (5) by specifying the "intersections P located at the corners", the "intersections P located on the outer edge", and other intersections P according to the above definition.

[0150] For example, as illustrated in FIG. 25, all the intersections P numbered inside are the "intersections P located on the outer edge", and among these intersections P, the intersections P numbered "1", "7", "13", "17", and "21" are the "intersections P located at the corners".

[0151] Therefore, in the (1) outer edge first pattern, the binding may be performed first at the intersections P numbered "1" to "33". In this case, for example, the binding may be performed in numerical order. Further, in the (2) center first pattern, a center of the area may be obtained according to the above definition, and the binding may be performed from the intersection P close to the center. Further, in the (3) transverse feed pattern, the binding may be performed in the order described above for a plurality of rows of the intersections P arranged along the X direction. Further, in the (4) longitudinal feed pattern, the binding may be performed in the order described above for a plurality of rows of the intersections P arranged along the Y direction. Further, in the (5) corner first pattern, the binding may be performed first at the intersections P numbered "1", "7", "13", "17", and "21".

[0152] In the binding system 1C, as described above, the "presence or absence of binding", the "binding direction", the "number of times of binding", the "binding strength", and the "binding order" serving as the binding conditions can all be selectively set by the user via the operation unit 72. When these conditions are selected, the control unit 77C generates the first binding condition data 764C defining the binding conditions according to the selective setting, and records the first binding condition data 764C in the storage unit 76C. The control unit 77C can read the first binding condition data 764C many times, read the same first binding condition data 764C every time for a plurality of workpieces B, and perform the binding operation control according to the same binding conditions. When the user selectively sets another content for each binding condition via the operation unit 72, new first binding condition data 764C is generated and recorded in the storage unit 76C. In this case, the already existing first binding condition data 764C and the new first binding condition data 764C are recorded to include identification information so as to be able to be identified from each other, and the individual first binding condition data 764C can be selected to perform the binding operation control.

[0153] <Operation Mode as Binding Condition> Further, in the storage unit 76C, in order to reduce a workload of the user selectively setting all the binding conditions via the operation unit 72, a plurality of pieces of second binding condition data 765C in which contents of the "presence or absence of binding", the "binding direction", the "number of times of binding", the "binding strength", and the "binding order" are determined in advance are prepared in the storage unit 76C. The plurality of pieces of second binding condition data 765C are individually associated with a plurality of operation modes, respectively, and the control unit 77C can read the corresponding second binding condition data 765C according to the selected operation mode and perform the binding operation on each intersection P. Examples of the operation mode include a "normal mode", a "strength prioritized mode", and a "speed prioritized mode". Hereinafter, these various operation modes will be described.

[0154] The "normal mode" is a mode for performing normal binding. In principle, the "normal mode" can be selected by the user. Further, even in a case where the user inputs execution of the binding operation without selecting the "presence or absence of binding", the "binding direction", the "number of times of binding", the "binding strength", and the "binding order", and selecting the operation mode, the "normal mode" is automatically selected, and the binding operation is executed. For example, the "normal mode" is set such that, regarding the "presence or absence of binding", all the intersections P in the workpiece B are set as binding objects. Further, the "binding direction" is set such that all the intersections P in the workpiece B are in either the first direction or the second direction, and each of the intersections P is different in the "binding direction" from another adjacent intersection P. That is, the binding is performed in a staggered arrangement in which the binding in the first direction and the binding in the second direction are alternately performed in the X direction for all the intersections P in the workpiece B, and the binding in the first direction and the binding in the second direction are alternately performed in the Y direction for all the intersections P in the workpiece B. Further, the "number of times of binding" is set such that the binding is performed once for all the intersections P in the workpiece B. The "binding strength" is set to a predetermined standard value. Further, the "binding order" is set to the (1) outer edge first.

[0155] The "strength prioritized mode" is a mode for performing the binding with a higher binding strength than in the "normal mode". The "strength prioritized mode" is the same as the "normal mode" except for the "binding strength" among the various setting conditions. The "strength prioritized mode" is set such that the "binding strength" is a numerical value higher than a predetermined standard value (for example, about 1.2 times to 2 times the standard value).

[0156] The "speed prioritized mode" is a mode for performing the binding more quickly than in the "normal mode". The "speed prioritized mode" is the same as the "normal mode" except for the "binding direction" and the "binding order" among the various setting conditions. In the "speed prioritized mode", regarding the "binding direction", all the intersections P in the workpiece B are aligned in the first direction (or the second direction), and a frequency of the turning operation of the binding device 6C around the axis along the Z direction is reduced to accelerate a continuous binding operation. In the "speed prioritized mode", either the (1) outer edge first or the (2) center first is set for the "binding order". In any "binding order", a path from a first intersection P to a last intersection P does not pass through the same position in an overlapping manner, and the binding work can be accelerated. Further, since a distance between the first intersection P at which the binding is started and the last intersection P is shorter than that in the (3) transverse feed or the (4) longitudinal feed, it is possible to accelerate a restoration operation to a start position of binding for the next workpiece B when the binding is continuously performed for a plurality of workpieces B.

[0157] <Operation of Binding System> Subsequently, an operation of the binding system 1C will be described. FIG. 26 is a flow chart illustrating a procedure when the binding system 1C performs a binding process. The CPU of the control unit 77C of the control device 7C performs the following binding process according to the binding processing program 761C.

[0158] By executing the binding processing program 761C, the control unit 77C functions as the intersection information acquisition unit, and performs a process of acquiring the information on the intersections P at which the plurality of reinforcing bars S of the workpiece B intersect. In this case, the control unit 77C determines whether use of the map data 763C is selected by the user through the operation unit 72, for example (step S101).

[0159] When the use of the map data 763C is selected, the control unit 77C reads the map data 763C from the storage unit 76C (step S103). At this time, when the map data 763C is not prepared in the storage unit 76C, the map data 763C is acquired by communicating with the outside or reading a recording medium.

[0160] On the other hand, when the use of the map data 763C is not selected, the control unit 77C causes the first camera 31 of the entire imaging unit 3 to image the entire workpiece B on the holding table 21 of the workpiece holding unit 2 disposed in the imaging area E1 of the gantry 11 (step S105).

[0161] When the map data 763C is read or the workpiece B is imaged by the first camera 31, the control unit 77C acquires three-dimensional position data of all the intersections P of the reinforcing bars S of the workpiece B based on the map data 763C or the image data 762C, and develops the three-dimensional position data in the coordinate system of the robotic arm 4. Accordingly, the positions of all the intersections P can be specified (step S107). Therefore, the control unit 77C functions as an intersection specifying unit.

[0162] Next, the control unit 77C drives the driving motor 23 of the workpiece holding unit 2 to cause the holding table 21 and the workpiece B to move to the binding area E2 (step S109).

[0163] Next, the control unit 77C determines whether use of the first binding condition data 764C in which the user individually selectively sets each of the binding conditions is selected (step S111). When the use of the first binding condition data 764C is selected, the first binding condition data 764C in the storage unit 76C is further read (step S113). At this time, when a plurality of pieces of first binding condition data 764C are held in the storage unit 76C, a specific piece of first binding condition data 764C is read according to the selection of the user. Then, the process proceeds to step S121.

[0164] On the other hand, when the use of the first binding condition data 764C is not selected, the control unit 77C determines whether the operation mode is selected (step S115). Then, when the operation mode is selected, the control unit 77C determines which of the "normal mode", the "strength prioritized mode", and the "speed prioritized mode" is to be executed in response to the selection of the user, and reads the setting conditions from a corresponding piece of the second binding condition data 765C in the storage unit 76C according to the selected operation mode. Then, the process proceeds to step S121.

[0165] Further, in step S115, when it is determined that the operation mode is not selected, the control unit 77C selects the "normal mode" (step S119), and reads the setting conditions from a corresponding piece of the second binding condition data 765C in the storage unit 76C. Then, the process proceeds to step S121.

[0166] In step S121, the control unit 77C specifies the intersection P at which the binding is to be performed first on the workpiece B based on the selection of the "presence or absence of binding" and the "binding order" in the binding conditions acquired in step S113, step S117, or step S119. Further, the control unit 77C obtains position coordinates of the intersection P at which the binding is to be performed first, based on the information on the intersections P for specifying the positions of the intersections P acquired in step S107.

[0167] The control unit 77C controls the robotic arm 4 to position the second camera 51 at an imaging position of the intersection P at which the binding is to be performed first, and moves the second camera 51 closer to the intersection P by driving the elevator motor 52 (step S121).

[0168] Next, the control unit 77C images the intersection P by the second camera 51 (step S123). The second camera 51 can obtain a position of the intersection P with higher accuracy based on the image data 762C by imaging the intersection P closer to the intersection P than the first camera 31.

[0169] Therefore, the control unit 77C newly calculates a position of the intersection P based on the image data 762C obtained by the second camera 51 (step S125), and positions the binding position of the binding device 6C closer to the newly obtained position of the intersection P (step S127). At this time, the control unit 77C determines an orientation of the binding device 6C around the axis along the Z direction according to the "binding direction" included in the binding conditions acquired in step S113, step S117, or step S119.

[0170] The control unit 77C operates the binding device 6C to perform binding with the wires W at the intersection P (step S129). At this time, the control unit 77C performs the binding with the wires W according to the "number of times of binding" and the "binding strength" (also including the "binding direction" when the "number of times of binding" and the "binding direction" are selected in combination) in the binding conditions acquired in step S113, step S117, or step S119.

[0171] Then, the control unit 77C determines whether the intersection P at which the binding is performed is a last intersection P based on the positions of all the intersections P from the information on the intersections P for specifying the positions of the intersections P acquired in step S107 and the selection of the "presence or absence of binding" and the "binding order" in the binding conditions acquired in step S113, step S117, or step S119 (step S131). Thereby, when the intersection P at which the binding is performed is not the last intersection P, the control unit 77C specifies the intersection P at which binding is to be performed next (step S133), and repeats the processes from step S121 to step S133. On the other hand, when the intersection P at which the binding is performed is the last intersection P, the control unit 77C ends the binding process on the workpiece B.

[0172] <Technical Effects of Second Embodiment> The control device 7C of the binding system 1C includes the control unit 77C that allows selection of the binding condition of the wire W at each of the intersections P of the reinforcing bars S of the workpiece B. Therefore, by appropriately selecting a content of the binding condition, an appropriate binding process of the wire W can be performed for various workpieces B, and the binding system 1C with high versatility can be provided.

[0173] Further, the control unit 77C of the control device 7C of the binding system 1C allows a binding order of the wire W at the plurality of intersections P of the workpiece B to be selected from among a plurality of patterns, as the binding condition. Therefore, it is possible to implement strong binding and binding with a quick work speed for the workpiece B.

[0174] In particular, since the control unit 77C allows selection of a plurality of operation modes in each of which the binding order of the wire W at the plurality of intersections P of the workpiece B is specified, in the binding process of the workpiece B, the binding with the wire W at the respective intersections P can be performed in an appropriate order according to a purpose.

[0175] Further, in a part or all of the selectable operation modes, the binding with the wire W at the plurality of intersections P is performed from an outer edge of the workpiece B along the outer edge. Since both ends of each of the plurality of reinforcing bars S constituting the workpiece B are supported by the support plate 211 of the holding table 21 in a state before binding, deflection is likely to occur in a central portion, and a gap is likely to be generated in the central portion in a state where the reinforcing bars S are vertically stacked. In this case, by performing the binding first from the intersections P on the outer edge, the gap between the upper and lower reinforcing bars S before performing the binding at the central portion of the reinforcing bars S can be reduced, and a deflection amount of each of the reinforcing bars S when performing the binding at the central portion can be reduced. Therefore, a deviation after binding generated in each part of the workpiece B due to the deflection of the reinforcing bars S caused by the binding at the central portion can be prevented. The outer edge described here indicates an outermost side of an entire area including an area close to an inner side and an area close to an outer side of the workpiece B, and the outer side indicates an outermost side of the workpiece including a regularly continuous intersection group. That is, the binding from the outer edge indicates binding from intersections facing an external space for workpieces having various shapes. The external space is a space that does not constitute the intersection group, and includes a space around the workpiece and a space provided inside the workpiece.

[0176] Further, the control device 7C of the binding system 1C includes the operation unit 72 for inputting the binding condition, and the control unit 77C performs the binding with the wire W at the plurality of intersections P according to the binding condition input from the operation unit 72. Therefore, a user can easily select the binding condition corresponding to the actual workpiece B, and can appropriately select the binding condition for various workpieces B or irregular workpieces B to implement strong binding, quick binding, or smooth binding.

[0177] Further, since the control unit 77C of the control device 7C of the binding system 1C functions as the intersection information acquisition unit for acquiring information on the intersections P and the intersection specifying unit for specifying the intersection P at which the binding with the wire W is to be performed, based on the acquired information on the intersections P of the workpiece B, the binding work can be performed from a position corresponding to the intersection P of the workpiece B at which the binding is to be performed, the binding work can be optimized, and good binding can be provided.

[0178] Further, since the binding system 1C includes the storage unit 76C capable of recording the map data 763C which is acquired from an outside and is the information on the intersections P, the position of the intersection P can be specified from the map data 763C prepared outside. Therefore, the positions of all the intersections P of the workpiece B can be acquired without performing processing such as imaging the workpiece B, extracting the intersections from image data obtained by the imaging, specifying positions of the intersections, and the like, the binding process can be accelerated, and a processing load and the like can be reduced.

[0179] Since the control unit 77C of the control device 7C executes the binding processing program 761C to implement the function of allowing the selection of the binding conditions, the function can be easily obtained from the existing binding system without increasing new hardware resources, and it is possible to reduce a development burden of hardware resources or a manufacturing cost of the system.

[0180] <Use of Device Information Data and Peripheral Information Data> The storage unit 76C of the control device 7C of the binding system 1C stores the device information data 766C indicating the three-dimensional position of the entire surface of the binding device 6C and the peripheral information data 767C indicating the three-dimensional position of the entire surface of an obstacle around the robotic arm 4. When the "binding direction" which is the binding condition is to be selected, the control unit 77C may determine whether the selection is possible by using the data 766C and 767C.

[0181] That is, since the device information data 766C includes the three-dimensional position data of the entire device surface of the binding device 6C, it is possible to acquire each position of the surface of the binding device 6C in a state where the binding device 6C is supported by the end effector 43 of the robotic arm 4. In the binding operation of the binding device 6C, when the binding device 6C is turned around the turning axis Zr according to the selection of the "binding direction", the possibility of interference between the binding device 6C and the obstacle can be determined based on each position on the surface of the binding device 6C and the peripheral information data 767C indicating the three-dimensional position of the entire surface of the obstacle around the robotic arm 4. Therefore, when the user selects the "binding direction" which is the binding condition via the operation unit 72, the control unit 77C may determine the possibility of interference between the binding device 6C and the obstacle, and when there is a possibility of interference, the control unit 77C may perform a process of notifying that there is a possibility of interference via the display unit 73 or the like, a process of refusing the current selection of the "binding direction", or a process of automatically changing the current selection of the "binding direction". Further, each of the above processes may be performed at a time point when the first binding condition data 764C or the second binding condition data 765C, the device information data 766C, and the peripheral information data 767C are prepared in the storage unit 76C. Alternatively, the device information data 766C and the peripheral information data 767C may be prepared in the storage unit 76C, and the above process may be performed at a time point when the first binding condition data 764C or the second binding condition data 765C that may cause the interference is selected by the user to perform the binding process of the workpiece B.

[0182] <Other Matters in Present Embodiment> The second embodiment of the present invention has been described above. However, the present invention is not limited to the above-described embodiments. For example, in the embodiments, a component integrally formed by a single member may be replaced with a component divided into a plurality of members and coupled or fixed to each other. A component formed by coupling a plurality of members may be replaced with a component formed integrally by a single member. In addition, the details described in the embodiments can be appropriately changed without departing from the gist of the invention.

[0183] Further, in the present embodiment, in the binding system 1C, the user selects the binding conditions by the operation unit 72, but the present invention is not limited thereto. For example, the user may select the setting conditions using an information processing terminal or the like not included in the binding system 1C to create the first binding condition data 764C, and the control device 7C of the binding system 1C may be configured to acquire the first binding condition data 764C by communication or acquire the recording medium on which the first binding condition data 764C is recorded through the reading device.

[0184] The binding system 1C may be configured to acquire the information on the intersections P for specifying the respective intersections P of the workpiece B only from the map data 763C. In that case, in the binding system 1C, the first camera 31 and the second camera 51 are not essential. However, since the binding device 6C can be more accurately positioned with respect to the intersection P by the second camera 51, only the first camera 31 may be omitted, and the second camera 51 may be provided. When the first camera 31 is omitted from the configuration of the binding system 1C, the rail 22 and the driving motor 23 of the workpiece holding unit 2 that cause the workpiece B to move between the imaging area E1 and the binding area E2 can also be omitted.

[0185] In the binding system 1C according to the present embodiment, the binding device 6C that binds the reinforcing bars S with two wires W has been exemplified, but the present invention is not limited thereto, and a binding device that binds the reinforcing bars S with one or three or more wires W may be used.

[0186] In the binding system 1C, a configuration in which the binding device 6C and the individual imaging unit 5 are moved by the robotic arm 4 has been exemplified, but the present invention is not limited thereto. For example, the binding device 6C and the individual imaging unit 5 may be mounted on a head of a gantry-type mobile apparatus in the X-Y direction, and then the binding device 6C and the individual imaging unit 5 may be lifted and lowered along the Z direction from the head and may be turned around the axis along the Z direction. Alternatively, the binding device 6C and the individual imaging unit 5 may be mounted on a self-propelled mobile apparatus that moves the workpiece B held in a grid pattern.

[0187] In addition, the binding system 1C according to the present embodiment is a stationary binding system disposed or fixedly installed in an indoor work space. Therefore, it is possible to perform the binding work without being affected by the weather or the outdoor environment, unlike an outdoor work-type binding system. Since a need for a device treated with waterproof, dustproof, high-temperature, and low-temperature countermeasures to withstand a severe outdoor environment is eliminated, it is possible to mount a device that performs precise work indoors, and to perform precise binding work on the workpiece B. However, by excluding these advantages, it is also possible to configure a binding system having features in the present embodiment with respect to an outdoor use-type binding system.

[0188] The solution to the problem of the second embodiment will be described below.[Solution 1] A binding system for performing binding on a workpiece, having an intersection at which reinforcing bars intersect, at the intersection with a binding body, the binding system including: a control unit configured to allow selection of a binding condition of the binding body at the intersection.[Solution 2] The binding system according to solution 1, in which the workpiece has a plurality of the intersections, and the control unit allows a binding order of the binding body at the plurality of intersections to be selected as the binding condition.[Solution 3] The binding system according to solution 2, in which the control unit allows selection of an operation mode for specifying the binding order of the binding body at the plurality of intersections.[Solution 4] The binding system according to solution 3, in which in the operation mode, binding with the binding body at the plurality of intersections is performed from an outer edge of the workpiece along the outer edge.[Solution 5] The binding system according to solution 2, further including: a condition input unit for the binding condition, in which the control unit performs binding with the binding body at the plurality of intersections according to the binding condition input from the condition input unit.[Solution 6] The binding system according to solution 1, further including: an intersection information acquisition unit configured to acquire information on the intersection; and an intersection specifying unit configured to specify the intersection at which binding with the binding body is to be performed, based on the acquired information on the intersection of the workpiece.[Solution 7] The binding system according to solution 1, further including: a recording device configured to record information on the intersection acquired from an outside of the binding system.[Solution 8] A binding processing program for causing a computer that controls a binding system that performs binding on a workpiece, having an intersection at which a plurality of reinforcing bars intersect, at the intersection with a binding body, to implement a function of allowing selection of a binding condition of the binding body at the intersection.

[0189] <<Third Embodiment>> Hereinafter, a third embodiment of the present invention will be described with reference to the drawings. The third embodiment discloses a binding system and a binding processing program having a configuration capable of solving the problem that the binding strength is lowered by binding the binding body in the same direction uniformly for each of the reinforcing bars constituting the workpiece, as exemplified in JP2013-035052A and JPH06-219420A as a related art. The binding system 1D disclosed in the third embodiment includes a control device 7D whose configuration is different in part from the control device 7C of the binding system 1C disclosed in the second embodiment, and the configuration of the device body 10C is the same as that of the binding system 1C. Accordingly, in the third embodiment, the binding system 1D is mainly described with respect to the configuration different from that of the control device 7C in the control device 7D, and the same components as those of the binding system 1C are denoted by the same signs as those of the binding system 1C, and the description thereof is omitted.

[0190] [Configuration of Binding System] FIG. 27 is a block diagram illustrating a schematic control configuration of the binding system 1D. The binding system 1D binds, with a wire W as a binding body, a workpiece B in which a plurality of reinforcing bars S are arranged in a grid pattern at intersections P (see FIG. 14) at which the plurality of reinforcing bars S intersect. Specifically, the binding system 1D includes the device body 10C and a control device 7D.

[0191] <Control Device> The control device 7D is a computer that integrally controls the binding system 1D. Specifically, the control device 7D includes an operation unit 72, a display unit 73, a storage unit 76D, and a control unit 77D.

[0192] The storage unit 76D is a memory including a RAM (random access memory), a ROM (read only memory), and the like, stores various programs and data, and also functions as a work area of the control unit 77D. The storage unit 76D serving as a recording device stores image data 762D captured by the first camera 31 and the second camera 51, map data 763D in which information on the workpiece B is recorded, binding direction data 764D generated by a binding direction determination process to be described later, device information data 766D indicating a three-dimensional position of an entire surface of the binding device 6C, and peripheral information data 767D indicating a three-dimensional position of an entire surface of an obstacle around the robotic arm 4 developed in a coordinate system of the robotic arm 4.

[0193] The control unit 77D includes, for example, a CPU (central processing unit) and controls an operation of each unit of the control device 7D. Specifically, the control unit 77D causes each unit of the control device 7D to operate based on an operation content of the operation unit 72 or the like, loads the programs stored in the storage unit 76D in advance, and executes various processes in cooperation with the loaded programs.

[0194] <Intersection Information Acquisition Process> By executing the binding processing program 761D described above, the control unit 77D acquires information on the intersections P at which the plurality of reinforcing bars S of the workpiece B intersect. As described above, the control unit 77D controls the device body 10C to perform binding with the wires W serving as the binding body at each of the intersections P at which the plurality of reinforcing bars S of the workpiece B intersect.

[0195] As in the binding system 1C described above, the workpiece B has a grid pattern in which a plurality of reinforcing bars S along the Y direction are arranged on a plurality of reinforcing bars S along the X direction (FIG. 14). Positions where center lines of the plurality of reinforcing bars S along the X direction and the plurality of reinforcing bars S along the Y direction intersect when viewed from the Z direction are the intersections P, and the binding system 1D can set each of the intersections P as a binding object.

[0196] For a binding operation control of the control unit 77D, the information on the intersections P for specifying the positions of the intersections P at which the reinforcing bars S of the workpiece B intersect is necessary. Therefore, the control unit 77D performs an intersection information acquisition process of acquiring the information on the intersections P for specifying the positions of all the intersections P of the workpiece B. The intersection information acquisition process includes a first acquisition process of acquiring a position of each intersection P from the image data 762D captured by the first camera 31 or the second camera 51 functioning as an intersection information acquisition unit, and a second acquisition process of acquiring the map data 763D from the outside of the binding system 1D.

[0197] The control unit 77D may be configured to perform only one of the first acquisition process and the second acquisition process. For example, when the control unit 77D is configured to perform only the first acquisition process, the storage unit 76D may be configured not to hold the map data 763D.

[0198] In the first acquisition process performed by the control unit 77D, when the image data 762D of the workpiece B on the holding table 21 captured by the first camera 31 or the second camera 51 is two-dimensional planar image data, a position of a contour of each of the reinforcing bars S in the image is extracted by known image processing, a center line passing through a center of each reinforcing bar S is obtained, and a position at which the center lines of the reinforcing bars S intersect each other is specified, and is acquired as a position of the intersection P. Further, height information of the intersection P may be obtained by performing imaging two or more times while changing a relative position between the first camera 31 or the second camera 51 and the workpiece B on the holding table 21, and calculating a height of each position in the image by parallax. Since three-dimensional position data of all the intersections P of the reinforcing bars S of the workpiece B is obtained in this way, by developing the three-dimensional position data in the coordinate system of the robotic arm 4, the information on the intersections P for specifying the positions of the intersections P is acquired.

[0199] When the image data 762D of the first camera 31 or the second camera 51 is image data including three-dimensional position information, position information indicated by the image data is developed in the coordinate system of the robotic arm 4 to acquire the information on the intersections P for specifying the positions of the intersections P.

[0200] The control device 7D includes a communication device (not illustrated) that communicates with the outside of the binding system 1D, and the second acquisition process performed by the control unit 77D is a process of requesting and acquiring the map data 763D from another external information processing terminal via a communication network. Further, the control device 7D may include a reading device (not illustrated) that reads a storage medium storing the map data 763D, and may acquire the map data 763D by reading from the storage medium.

[0201] The map data 763D records design information of the workpiece B and the like, and includes basic dimensions and three-dimensional position information of each reinforcing bar S and the three-dimensional position information of each intersection P. Therefore, the control unit 77D that performs the second acquisition process develops the three-dimensional position information of the respective intersections P obtained from the map data 763D in the coordinate system of the robotic arm 4 to acquire the information on the intersections P for specifying the positions of the intersections P.

[0202] <Binding Direction Determination Process> The control unit 77D executes the binding processing program 761D to execute the binding direction determination process on the intersections P of the reinforcing bars S of the workpiece B. The binding direction determination process on the intersections P of the workpiece B is executed for all the intersections P of the workpiece B, based on information related to the intersections P for specifying positions of all the intersections P of the workpiece B acquired by the intersection information acquisition process. Hereinafter, a method for the control unit 77D to determine a binding direction for each of the intersections P of the reinforcing bars S of the workpiece B will be described.

[0203] The "binding direction" with respect to the intersections P of the workpiece B is as described in the second embodiment. That is, referring to the above-described FIG. 15 and FIG. 16, the wires W bound at the intersection P of the reinforcing bar S in the X direction and the reinforcing bar S in the Y direction is in either a first direction illustrated in FIG. 15 or a second direction illustrated in FIG. 16 inclined by approximately 45° with respect to both the X direction and the Y direction when viewed from above in the Z direction. In the binding direction determination process, the control unit 77D determines either the first direction or the second direction as the "binding direction" for each of all the intersections P of the workpiece B. The "binding direction" referred to here indicates a direction along which the wires W after binding extend, as viewed from a vertical direction of the planar workpiece B.

[0204] The binding device 6C of the binding system 1D has a specification of performing binding with two wires W by one binding operation, and the two wires W illustrated in FIGS. 15 and 16 illustrate a state after one binding operation. The same applies to the subsequent drawings. Both ends of each wire W after binding are formed with a wound portion by a twisting operation, but the wound portion is not illustrated in the drawings of the present embodiment.

[0205] In the binding direction determination process, the control unit 77D determines a binding direction for each intersection P according to the following binding direction conditions (1) to (5). [Condition (1)] For each of all the intersections P of the workpiece B, one reinforcing bar S and another reinforcing bar S that form the intersection P are bound with the wires W along a direction different from that of at least one other intersection P in the one reinforcing bar S, which is different from the intersection P formed by the one reinforcing bar S and the other reinforcing bar S, and at least one other intersection P in the other reinforcing bar S, which is different from the intersection P formed by the one reinforcing bar S and the other reinforcing bar S. [Condition (2)] Based on the condition (1), with respect to a direction for each of the intersections P located at corners of a work area of the workpiece B among all the intersections P within the work area, binding is performed with the wires W in a direction that is closer to parallel to a straight line connecting the intersection P and a center of the work area. [Condition (3)] Based on the condition (2), with respect to a binding direction for at least one of two intersections P adjacent to the intersection P located at the corner of the work area of the workpiece B among all the intersections P in the work area, binding is performed with the wires W along the same direction as the intersection P located at the corner of the work area. [Condition (4)] Based on the condition (2), with respect to a binding direction for each of the intersections P located on an outer edge of the work area of the workpiece B among all the intersections P within the work area, binding is performed with the wires W in a direction that is closer to parallel to a straight line connecting the intersection P and the center of the work area of the workpiece B. [Condition (5)] Based on the condition (1), with respect to a direction for each of all the intersections P of the workpiece B, binding is performed with the wires W in a direction different from a direction at all other adjacent intersections P.

[0206] Here, when the binding direction for each intersection P is determined according to the binding direction conditions (1) to (5), the control unit 77D needs to specify the "intersection P located at the corner" and the "intersection P located on the outer edge" in the work area. The definitions of "the intersections P located at the corner" and "the intersection P located at the outer edge" are the same as those described in FIG. 24 of the second embodiment. The "work area" in the binding direction conditions (2) to (4) indicates the narrower one of an area of an outer edge of a movable range (range in which the binding device 6C can move) of the binding device 6C set when the robotic arm 4 holding the binding device 6C performs a binding work on the workpiece B in the binding system 1D and an outer edge of an area where all the intersections P of the workpiece B are present. The movable range of the binding device 6C and the area where all the intersections P of the workpiece B are present may be assumed to be rectangular. In the present embodiment, referring to FIG. 14, a case where the inside of the support plates 211 on the four sides of the holding table 21 is a rectangular movable range and coincides with a rectangular area where all the intersections P of the workpiece B are present is exemplified. In this case, the inside of the support plates 211 on the four sides of the holding table 21 is a rectangular "work area".

[0207] In the above-described work area, as illustrated in FIG. 24, the control unit 77D specifies the intersection P having two other adjacent intersections P as the "intersection P located at the corner of the work area", such as the intersection P denoted by "A" in an area Ra surrounded by a two-dot chain line, at all the intersections P in the work area. In FIG. 24, the control unit 77D specifies the intersection P having three or less other adjacent intersections P as the "intersection P located at the outer edge of the work area", such as the intersection P denoted by "B" in an area Rb surrounded by a two-dot chain line. In FIG. 24, the control unit 77D specifies the intersection P having four other adjacent intersections P as the intersection P other than the "intersection P located at the corner of the work area" and the "intersection P located on the outer edge of the work area", such as the intersection P denoted by "C" in an area Rc surrounded by a two-dot chain line.

[0208] The "adjacent intersections P" indicate a case of being adjacent via the reinforcing bar S. That is, the adjacent intersections P indicate intersections P adjacent in the X direction or the Y direction, and do not include intersections P adjacent in a direction oblique to both the X direction and the Y direction. Since the "intersections P located on the outer edge of the work area" are intersections each having three or less other adjacent intersections P, the "intersections P located at the corners of the work area" each having two other adjacent intersections P are also included.

[0209] The above-described condition (1) will be described with reference to FIG. 28. As illustrated, one reinforcing bar S and the other reinforcing bar S that form the intersection P are defined as Sx and Sy, respectively, and the intersection P is defined as Po. In this condition (1), with respect to a binding direction with the wires W, it is required that at least one of the intersections P other than the intersection Po in one reinforcing bar Sx is in a direction different from the intersection Po, and at least one of the intersections P other than the intersection Po in the other reinforcing bar Sy is in a direction different from the intersection Po. Since the binding direction with the wires W is only one of the first direction and the second direction described above, and "the binding directions are different" means that one intersection P is the first direction and the other intersection P is the second direction.

[0210] In the condition (1), when the binding is performed along the second direction at the intersection Po, the reinforcing bar Sx is required to be bound with the wires W along the first direction at any intersection P other than the intersection Po. Similarly, the reinforcing bar Sy is also required to be bound with the wires W along the first direction at any other intersection P than the intersection Po. All the intersections P of the workpiece B are required to be the same as the intersection Po. In the present embodiment, as the condition (1), a case where all the intersections P of the workpiece B are required to be the same as the intersection Po is exemplified, but the present invention is not limited thereto. For example, as the condition (1), only one intersection P or some of the intersections P of the workpiece B may be required to be the same as the intersection Po.

[0211] The above-described condition (2) will be described with reference to FIGS. 29 and 32. The condition (2) is based on the premise that the condition (1) is satisfied. Here, as illustrated, among all the intersections P in a work area U of the workpiece B, an intersection located at a corner of the work area U is defined as Pc. The control unit 77D can specify the work area U according to the definition described above, and can obtain a center C of the work area U. The center C of the work area U can be obtained from the center of gravity (centroid) of the work area U, for example. Further, the control unit 77D can specify all the intersections P located at the corners of the work area U according to the definition in FIG. 24 described above. In the case of the example of FIG. 29, the intersections P at which reinforcing bars S1 and S2 located at both ends of the work area U in the Y direction and reinforcing bars S3 and S4 located at both ends of the work area U in the X direction intersect are four intersections Pc located at corners of the work area U. As illustrated in FIG. 29, straight lines Lc passing through the center C and the intersections Pc located at the corners can be specified. As illustrated in FIG. 32, a cross angle between the wires W facing the first direction at the intersection Pc located at the corner and the straight line Lc and a cross angle between the wires W facing the second direction at the same intersection Pc and the straight line Lc are obtained, and a direction in which the cross angle in the first direction or the second direction is smaller is determined as a "direction closer to parallel" to the straight line Lc, and is determined as a binding direction at the intersection Pc. In any case, it is assumed that the line of sight is from the Z direction. In the above case, the cross angle between the wires W and the straight line Lc includes an acute cross angle and an obtuse cross angle, and the acute cross angle is compared. Depending on a shape of the work area, the cross angle between the wires W facing the first direction and the straight line Lc may be equal to the cross angle between the wires W facing the second direction and the straight line Lc. In such a case, the control unit 77D may select either the first direction or the second direction for the intersection Pc. In this case, the control unit 77D may determine in advance either the "first direction" or the "second direction".

[0212] The above-described condition (3) will be described with reference to FIG. 30. The condition (3) is based on the premise that the condition (2) is satisfied. Here, as illustrated, an intersection adjacent to the intersection Pc located at the corner of the work area U on one side is defined as Pn. Binding at the intersections Pn adjacent to the four intersections Pc located at the corners of the work area U are required to be performed with the wires W in the same direction as the intersections Pc. Therefore, in the case of FIG. 30, binding is performed with the wires W along the second direction at the intersection Pn adjacent to the intersection Pc located at an upper left corner in the drawing, binding is performed with the wires W along the first direction at the intersection Pn adjacent to the intersection Pc located at an upper right corner in the drawing, binding is performed with the wires W along the first direction at the intersection Pn adjacent to the intersection Pc located at a lower left corner in the drawing, and binding is performed with the wires W along the second direction at the intersection Pn adjacent to the intersection Pc located at a lower right corner in the drawing. The intersection Pc located at the corner of the work area U has two adjacent intersections P, but binding may be performed at both of these intersections P in the same direction as the intersection Pc located at the corner.

[0213] The above-described condition (4) will be described with reference to FIGS. 31 and 32. This condition (4) is based on the premise that the condition (2) is satisfied. Since the control unit 77D can specify all the intersections P located at the center C of the work area U and located on the outer edges of the work area U according to the definition described above, the control unit 77D can specify the straight lines Lc passing through the center C and the intersections P located on the outer edges as illustrated in FIG. 31. As illustrated in FIG. 32, a cross angle between the wires W facing the first direction at the intersection P located on the outer edge and the straight line Lc and a cross angle between the wires W facing the second direction at the same intersection P and the straight line Lc are obtained, and a direction in which the cross angle in the first direction or the second direction is smaller is determined as a "direction closer to parallel" to the straight line Lc, and is determined as a binding direction at the intersection P. In any case, it is assumed that the line of sight is from the Z direction.

[0214] In the above case, the cross angle between the wires W and the straight line Lc includes an acute cross angle and an obtuse cross angle, and the acute cross angle is compared. The cross angle between the wires W facing the first direction and the straight line Lc may be equal to the cross angle between the wires W facing the second direction and the straight line Lc. For example, a cross angle in the first direction and a cross angle in the second direction are equal to each other for the wires W bound at the intersection P located on the outer edge on the reinforcing bar S that passes through the center C of the work area U and is parallel to the X direction, or the wires W bound at the intersection P located on the outer edge on the reinforcing bar S that passes through the center C of the work area U and is parallel to the Y direction. In such a case, the control unit 77D may select either the first direction or the second direction for the intersection P. In this case, the control unit 77D may determine in advance either the "first direction" or the "second direction".

[0215] The above-described condition (5) will be described with reference to FIG. 33. This condition (5) is based on the premise that the condition (1) is satisfied. Under this condition (5), the direction in which binding with the wires W is performed at each of all the intersections P of the workpiece B is different from the direction in which binding with the wires W is performed at all other adjacent intersections P. Therefore, as illustrated in FIG. 33, the wires W bound at the respective intersections P have a so-called staggered arrangement in which the first direction and the second direction are alternately arranged in all rows of the intersections arranged in the X direction, and the first direction and the second direction are alternately arranged in all rows of the intersections arranged in the Y direction.

[0216] With respect to the binding direction for each intersection P that satisfies the condition (5), there are a case illustrated in the example of FIG. 33 and a case where the binding direction with the wires W is reversed between the first direction and the second direction for all the intersections P in FIG. 33. Therefore, it is preferable that the control unit 77D determines a condition for selecting one of a pattern in FIG. 33 and a pattern opposite to FIG. 33 for each of the intersections P of the workpiece B. For example, it is preferable to determine a condition that the binding direction with the wires W is the first direction (or the second direction) at the intersection P at a specific position of the workpiece B (for example, the intersection P located at a specific corner). Thus, the control unit 77D can uniquely determine the binding direction with the wires W for each of all the intersections P of the workpiece B. In the present embodiment, as the condition (5), a case where binding with the wires W at all the intersections P of the workpiece B are required to be performed in a direction different from those of all the other adjacent intersections P is exemplified, but the present embodiment is not limited thereto. For example, as the condition (5), a direction in which binding with the wires W is performed at only one intersection P or some intersections P of the workpiece B may be required to be different from the direction in which binding with the wires W is performed at all other adjacent intersections P.

[0217] The binding system 1D may be implemented such that the user can select some or all of the conditions (1) to (5) described above from, for example, the operation unit 72. In this case, the control unit 77D determines a direction in which binding with the wires W is performed at all the intersections P of the workpiece B based on any of the conditions (1) to (5) selected by the user. In addition, in the binding system 1D, the control unit 77D may be configured to determine the direction in which the binding with the wires W is performed at all the intersections P of the workpiece B based on only one of the conditions (1) to (5).

[0218] Here, the usefulness of the binding direction with the wires W for the intersection P of the workpiece B based on each of the conditions (1) to (5) will be described. In the case of the condition (1), when the control unit 77D determines a binding direction with the wires W for each intersection P to satisfy this condition, all the intersections P of all the reinforcing bars S constituting the workpiece B are not bound in the same direction. When binding is performed at all intersections on a certain reinforcing bar S with another reinforcing bar S in the same binding direction, stress is received from each intersection P in the same direction, so that a gap between the reinforcing bars S is likely to be generated, and the binding strength can be reduced. However, when a binding direction for each intersection P of the workpiece B is determined according to the condition (1), it is possible to perform strong binding to the workpiece B while avoiding a reduction in binding strength.

[0219] In the case of the condition (5), when the control unit 77D determines the binding direction with the wires W for each intersection P to satisfy this condition, the binding is performed alternately in the first direction and the second direction for the plurality of intersections P in one reinforcing bar S. Therefore, since a direction of the stress is dispersed for each of the intersections P arranged along the reinforcing bars S, it is possible to further reduce the gap between the reinforcing bars S and to more effectively perform strong binding to the workpiece B.

[0220] The cases of the conditions (2) to (4) will be described with reference to FIGS. 34 and 35 in addition to FIGS. 13 and 31 described above. FIG. 34 is a plan view of the binding device 6C in FIG. 13 viewed from one side of the turning axis Zr (for example, an upper side in the binding operation), and FIG. 35 is a plan view in which a configuration of a part of the device body 10C is omitted.

[0221] As described above, the binding device 6C has a structure in which the slack forming unit 62C is disposed on one side of the reinforcing bar binding machine 61C in the orthogonal direction Xw, which is an arrangement direction of the curl guide 613C and the inducing guide 614C, to deform the wire W into an appropriate loop shape by the curl guide 613C and the inducing guide 614C. As illustrated in FIG. 34, the binding device 6C protrudes most toward one side in the orthogonal direction Xw, which is a slack forming unit 62C side, around the turning axis Zr. When the binding with the wires W is performed in the determined binding direction, the robotic arm body 40 turns the binding device 6C around the turning axis Zr. In this case, when there is a portion protruding toward one side in the orthogonal direction Xw around the turning axis Zr, there is a concern that the portion may come into contact with an object standing in the Z direction around the binding device 6C or an object at a position higher than the workpiece B in the Z direction. As illustrated in FIG. 35, in the device body 10C, there is a concern that each support column 12 of the gantry 11 may come into contact with the binding device 6C. Although only one support column 12 is provided at each of the four corners of the device body 10C, if the total weight of the device body 10C increases, more support columns 12 may be provided along each beam 13. Further, depending on the installation environment of the device body 10C, an obstacle other than the support column may occur.

[0222] Therefore, when the binding operation with the wires W is performed on the workpiece B, it is preferable that a protruding portion of the binding device 6C, particularly, the slack forming unit 62C does not protrude to the outside of the work area U. In FIG. 31, a silhouette of the binding device 6C in a plan view when the turning axis Zr at a binding position of the binding device 6C is positioned with respect to the plurality of intersections P is indicated by a two-dot chain line. In the silhouette of the binding device 6C in a plan view, an end having a semicircular shape in a longitudinal direction is an end on an individual imaging unit 5 side in the orthogonal direction Xw, and an end having a rectangular shape in the longitudinal direction is an end on the slack forming unit 62C side.

[0223] For example, as illustrated in FIG. 31, in a case where the conditions (2) to (4) are satisfied, for example, a binding direction intersecting with the outer edge of the work area U at the intersection P which is at a corner in the work area U is selected, so that the binding operation can be performed in a state where the slack forming unit 62C, which is the most protruding portion of the binding device 6C, faces the inside of the work area U, and it is possible to reduce the possibility of contact between an obstacle around the work area U and the slack forming unit 62C which is the most protruding portion of the binding device 6C. If a direction that does not satisfy the conditions (2) to (4) is selected at the intersection P at the corner, for example, if the first direction is selected at the intersection P at the upper left corner of the page of FIG. 31, the slack forming unit 62C protrudes to the left side or the upper side of the page of FIG. 31 toward the outside of the work area U, and the possibility of contact with the obstacle around the work area U occurs. In a case where the conditions (2) to (4) are satisfied, it is possible to exclude the selection of the binding direction in which there is a possibility that the slack forming unit 62C protrudes to the outside of the work area U, and it is possible to reduce the possibility of contact between the slack forming unit 62C and an obstacle.

[0224] In the case of the condition (3), the binding operation is also performed at the intersection P adjacent to the intersection P at the corner in the same direction as the intersection P at the corner. In the case of the intersection P in the vicinity of the corner, if the binding direction is not appropriately selected, there is a possibility that the slack forming unit 62C protrudes to the outside of the work area U similarly to that at the corner. Therefore, it is possible to reduce the possibility of contact between the slack forming unit 62C and an obstacle even in the case of the condition (3). Further, since the binding operation is performed at the intersection P adjacent to the intersection P at the corner in the same direction as the intersection P at the corner, it is possible to reduce the frequency of a turning operation of the binding device 6C and to accelerate the binding operation.

[0225] In the case of the condition (4), since a direction closer to parallel to a straight line connecting the center C of the work area U and the intersections P is selected as the binding direction at the intersection P located on the outer edge including the corner, the binding operation can be performed in a state where the slack forming unit 62C, which is the most protruding portion of the binding device 6C, faces the inside of the work area U, and the possibility of contact between the obstacle outside the work area U and the slack forming unit 62C can be reduced. In particular, among the intersections P located on the outer edge, the intersection P closer to the corner may have a binding direction in which the slack forming unit 62C cannot be prevented from protruding to the outside of the work area U. However, in a case where the condition (4) is satisfied, the possibility of protruding to the outside can be reduced, and the possibility of contact between the slack forming unit 62C and the obstacle can be reduced.

[0226] In a case where the binding directions for all the intersections P of the workpiece B are determined according to only the condition (1), since the number of combinations thereof is very large, it is preferable to determine a filtering condition in advance. The filtering condition includes, for example, a ratio of the number of intersections P in the first direction and the number of intersections P in the second direction in each reinforcing bar S, a lower limit value of the number of intersections P in the first direction or a lower limit value of the number of intersections P in the second direction in each reinforcing bar S, a ratio of the number of intersections P in the first direction and the number of intersections P in the second direction in all the intersections P of the workpiece B, and a degree of dispersion of the intersections P in the first direction and the intersections P in the second direction in the arrangement of all the intersections P of the workpiece B (for example, the area where all the intersections P of the workpiece B are present is divided into a plurality of areas, and the number of intersections P in the first direction and the number of intersections P in the second direction in each divided area are made close to equal). In addition, for the intersections P for which the binding direction cannot be determined even in consideration of the condition (1) and the filtering condition, it is more preferable to determine in advance that all of the intersections P are set to the first direction, all of the intersections P are set to the second direction, a ratio between the first direction and the second direction is more uniform, or the like.

[0227] In a case where the binding directions for all the intersections P of the workpiece B are determined according to only the condition (2), since the number of combinations thereof is very large, it is preferable to determine a filtering condition in advance. For example, in the work area U, the intersections P other than the intersections P located at the corners are set to the same binding direction as the intersection P located at the closest corner. In addition, the same filtering condition as the condition (1) may be added. In addition, for the intersections P for which the binding direction cannot be determined even in consideration of the condition (2) and the filtering condition, it is more preferable to determine in advance that all of the intersections P are set to the first direction, all of the intersections P are set to the second direction, a ratio between the first direction and the second direction is more uniform, or the like.

[0228] In a case where the binding directions for all the intersections P of the workpiece B are determined according to only the condition (3), since the number of combinations thereof is very large, it is preferable to determine a filtering condition in advance. For example, in the work area U, the intersections P other than the intersections P located at the corners and the intersections P adjacent thereto are set to the same binding direction as the intersection P located at the closest corner. In addition, the same filtering condition as the condition (1) may be added. In addition, for the intersections P for which the binding direction cannot be determined even in consideration of the condition (3) and the filtering condition, it is more preferable to determine in advance that all of the intersections P are set to the first direction, all of the intersections P are set to the second direction, a ratio between the first direction and the second direction is more uniform, or the like.

[0229] In a case where the binding directions for all the intersections P of the workpiece B are determined according to only the condition (4), since the number of combinations thereof is very large, it is preferable to determine a filtering condition in advance. For example, in the work area U, the intersections P other than the intersections P located at the corners and the intersections P located on the outer edges are set to the same binding direction as the intersection P located at the closest corner or the intersections P located on the outer edges. In addition, the same filtering condition as the condition (1) may be added. In addition, for the intersections P for which the binding direction cannot be determined even in consideration of the condition (4) and the filtering condition, it is more preferable to determine in advance that all of the intersections P are set to the first direction, all of the intersections P are set to the second direction, a ratio between the first direction and the second direction is more uniform, or the like.

[0230] In a case where the binding directions for all the intersections P of the workpiece B are determined according to only the condition (5), since there are only two types of combinations thereof, as described above, the first direction or the second direction may be determined in advance for a specific intersection P.

[0231] <Operation of Binding System> Subsequently, an operation of the binding system 1D will be described. FIG. 36 is a flow chart illustrating a procedure when the binding system 1D performs a binding process. The CPU of the control unit 77D of the control device 7D performs the following binding process according to the binding processing program 761D.

[0232] By executing the binding processing program 761D, the control unit 77D performs the intersection information acquisition process, and performs a process of acquiring information on the intersections P at which the plurality of reinforcing bars S of the workpiece B intersect. In this case, the control unit 77D determines whether the use of the map data 763D is selected by the user through the operation unit 72, for example (step S201).

[0233] When the use of the map data 763D is selected, the control unit 77D reads the map data 763D from the storage unit 76D (step S203). At this time, when the map data 763D is not prepared in the storage unit 76D, the map data 763D is acquired by communicating with the outside or reading a recording medium.

[0234] On the other hand, when the use of the map data 763D is not selected, the control unit 77D causes the first camera 31 of the entire imaging unit 3 to image the entire workpiece B on the holding table 21 of the workpiece holding unit 2 disposed in the imaging area E1 of the gantry 11 (step S205).

[0235] When the map data 763D is read or the workpiece B is imaged by the first camera 31, the control unit 77D acquires three-dimensional position data of all the intersections P of the reinforcing bars S of the workpiece B based on the map data 763D or the image data 762D, and develops the three-dimensional position data in the coordinate system of the robotic arm 4. Accordingly, the positions of all the intersections P can be specified (step S207). Therefore, the control unit 77D functions as an intersection specifying unit.

[0236] Next, the control unit 77D drives the driving motor 23 of the workpiece holding unit 2 to cause the holding table 21 and the workpiece B to move to the binding area E2 (step S209).

[0237] Next, the control unit 77D determines a binding direction for all the intersections P in the workpiece B or the work area U based on the determined binding direction determination condition (any one of the above-described conditions (1) to (5)). In this case, the filtering conditions described above for the conditions (1) to (5) may also be considered (step S211). When the binding direction for all the intersections P in the workpiece B or the work area U is determined, the control unit 77D generates and records the binding direction data 764D in the storage unit 76D. The binding direction data 764D may be used by omitting the process of step S211 when the binding operation is performed on another workpiece B having the same design condition.

[0238] The control unit 77D controls the robotic arm 4 to position the second camera 51 at an imaging position of the intersection P at which the binding is to be performed first, and moves the second camera 51 closer to the intersection P by driving the elevator motor 52 (step S213). The binding order for each intersection P is determined according to a predetermined operation condition or the like.

[0239] Next, the control unit 77D images the intersection P by the second camera 51 (step S215). The second camera 51 can obtain a position of the intersection P with higher accuracy based on the image data 762D by imaging the intersection P closer to the intersection P than the first camera 31.

[0240] Therefore, the control unit 77D newly calculates a position of the intersection P based on the image data 762D obtained by the second camera 51 (step S217), and positions the binding position of the binding device 6C closer to the newly obtained position of the intersection P (step S219). At this time, the control unit 77D determines an orientation of the binding device 6C around the axis along the Z direction according to the binding direction determined in step S211 for the intersection P.

[0241] The control unit 77D operates the binding device 6C to perform binding with the wires W at the intersection P (step S221). Thereafter, the control unit 77D controls the robotic arm 4 again to position the second camera 51 at the imaging position of the intersection P, moves the second camera 51 closer to the intersection P by driving the elevator motor 52 (step S223), and images the intersection P (step S225).

[0242] The control unit 77D determines whether the binding is performed in the binding direction determined in step S211 based on the image data 762D obtained by the imaging (step S227). As a result, when the binding direction is not the binding direction determined in step S211, the occurrence of an error is notified (step S229), and the binding operation is ended. As a method of notifying the occurrence of the error, a dedicated notification device such as a notification lamp or a buzzer may be prepared and operated, or the notification may be displayed on the display unit 73. When the control device 7D includes a communication device with the outside, the notification may be provided to the outside through communication.

[0243] On the other hand, in step S227, when it is determined that the binding is performed in the binding direction determined in step S211, the control unit 77D determines whether the intersection P at which the binding is performed is the last intersection P based on information on the intersection P for specifying the position of the intersection P acquired in step S207 (step S231). Thereby, when the intersection P at which the binding is performed is not the last intersection P, the control unit 77D specifies the intersection P at which binding is to be performed next (step S233), and repeats the processes from step S213 to step S233. On the other hand, when the intersection P at which the binding is performed is the last intersection P, the control unit 77D ends the binding process on the workpiece B.

[0244] As illustrated in step S229, the process of notifying the occurrence of the error and ending the binding operation in a case where the binding direction is not the determined binding direction has been exemplified, but the occurrence of the error may be notified, the error content may be further recorded, the process may proceed to step S231, and the binding operation for the subsequent intersection P may be continued.

[0245] <Technical Effects of the Present Embodiment> The control device 7D of the binding system 1D includes the control unit 77D that binds one reinforcing bar S and another reinforcing bar S that form the intersection P with the wires W along a direction different from that of at least one other intersection P in the one reinforcing bar S, which is different from the intersection P formed by the one reinforcing bar S and the other reinforcing bar S, and at least one other intersection P in the other reinforcing bar S, which is different from the intersection P formed by the one reinforcing bar S and the other reinforcing bar S. Therefore, it is possible to reduce the gap between the reinforcing bars S constituting the workpiece B and to perform strong binding to the workpiece B.

[0246] The control unit 77D performs binding with the wires W along a direction closer to parallel to the straight line Lc connecting the intersection P and the center C of the work area U at the intersection P located at the corner among all the intersections P within the work area U of the workpiece B. Therefore, it is possible to reduce the possibility of contact between the slack forming unit 62C, which is a protruding portion of the binding device 6C, and an obstacle outside the work area U during the binding operation at the intersection P located at the corner.

[0247] The control unit 77D performs binding with the wires W at least one intersection P adjacent to the intersection P located at the corner of the work area U among the plurality of intersections P in the work area U of the workpiece B along the same direction as the intersection P located at the corner. Therefore, it is possible to reduce the possibility of contact between the slack forming unit 62C, which is a protruding portion of the binding device 6C, and an obstacle outside the work area U during the binding operation at the intersection P adjacent to the intersection P located at the corner. Furthermore, it is possible to reduce the frequency of the turning operation of the binding device 6C and to accelerate the binding operation.

[0248] The control unit 77D performs binding with the wires W at the intersection P located on the outer edge of the work area U in a direction closer to parallel to the straight line Lc connecting the intersection P and the center of the work area U. Therefore, it is possible to reduce the possibility of contact between the slack forming unit 62C, which is a protruding portion of the binding device 6C, and the obstacle outside the work area U during the binding operation at the intersection P located on the outer edge.

[0249] Further, the control unit 77D performs binding with the wires W at each of all the intersections P of the workpiece B in a direction different from those of all the other adjacent intersections P. Therefore, since a direction of the stress is dispersed for each of the intersections P arranged along the reinforcing bars S, it is possible to further reduce the gap between the reinforcing bars S and to more effectively perform strong binding to the workpiece B.

[0250] Since the binding system 1D includes the second camera 51 as the intersection information acquisition unit that is provided together with the binding device 6C and acquires information on the intersection P, it is possible to determine whether the binding direction with the bound wires W is appropriate during the binding operation, and it is possible to detect the occurrence of inappropriate binding.

[0251] Since the control unit 77D of the control device 7D executes the binding processing program 761D to realize a function of performing the control of performing binding with the wires W along a predetermined binding direction at the intersection P of the workpieces B, it is possible to obtain the function from the existing binding system without increasing new hardware resources, and it is possible to reduce a development burden of hardware resources or a manufacturing cost of the system.

[0252] <Use of Device Information Data and Peripheral Information Data> The storage unit 76D of the control device 7D of the binding system 1D stores the device information data 766D indicating a three-dimensional position of the entire surface of the binding device 6C and the peripheral information data 767D indicating a three-dimensional position of the entire surface of an obstacle around the robotic arm 4. The control unit 77D may determine whether the "binding direction" determined for each intersection P of the workpiece B can be determined using these data 766D and 767D.

[0253] That is, since the device information data 766D includes the three-dimensional position data of the entire device surface of the binding device 6C, it is possible to acquire each position of the surface of the binding device 6C in a state where the binding device 6C is supported by the end effector 43 of the robotic arm 4. In the binding operation of the binding device 6C, when the binding device 6C is turned around the turning axis Zr according to the determination of the "binding direction", the possibility of interference between the binding device 6C and the obstacle can be determined based on each position on the surface of the binding device 6C and the peripheral information data 767D indicating the three-dimensional position of the entire surface of the obstacle around the robotic arm 4. Therefore, when the control unit 77D determines the "binding direction", the control unit 77D may determine the possibility of interference between the binding device 6C and the obstacle, and when there is the possibility of interference, the control unit 77D may perform a process of notifying that there is the possibility of interference through the display unit 73 or the like, a process of automatically changing the current determination of the "binding direction", or the like.

[0254] <Other Matters in Present Embodiment> The third embodiment of the present invention has been described above. However, the present invention is not limited to the above-described embodiments. For example, in the embodiments, a component integrally formed by a single member may be replaced with a component divided into a plurality of members and coupled or fixed to each other. A component formed by coupling a plurality of members may be replaced with a component formed integrally by a single member. In addition, the details described in the embodiments can be appropriately changed without departing from the gist of the invention.

[0255] For example, the control unit 77D performs a process of determining a binding direction for each intersection P of the workpiece B, but in addition to the determination of the binding direction, the control unit 77D may determine which direction the slack forming unit 62C, which is a protruding portion of the binding device 6C, faces with respect to the turning axis Zr. In this case, it is preferable that the slack forming unit 62C, which is a protruding portion of the binding device 6C, is determined to face the inside of the work area U (opposite side to the outer edge of the work area U) with respect to the turning axis Zr.

[0256] In the above embodiments, when each of the conditions (1) to (5) for the control unit 77D to determine the binding direction is described, a case where the work area U is a rectangular area without a defective portion has been exemplified, but the binding direction can be effectively determined even when the work area U has another shape. For example, even in a case where the work area U has a shape in which there is a defective portion in each portion with respect to a rectangle, a binding direction for each intersection P can be determined according to each of the conditions (1) to (5) by specifying the "intersection P located at the corner" and the "intersection P located on the outer edge" according to the definition illustrated in FIG. 24. Further, when there is a defective portion such as a hole inside the work area U, the periphery of the hole is also recognized as the outer edge of the work area U, and the binding direction for each intersection P can be determined according to each of the conditions (1) to (5).

[0257] With respect to the irregular work area U as described above, it is possible to determine in which direction the slack forming unit 62C, which is a protruding portion of the binding device 6C, faces with respect to the turning axis Zr. For example, in the case of the work area U having a defective portion such as a hole, the slack forming unit 62C may be determined to face the opposite side to the outer edge of the work area U around the hole where the intersection P is closest to the turning axis Zr.

[0258] In the present embodiment, a case where the outer edge of the movable range of the binding device 6C set when the robotic arm 4 performs the binding work on the workpiece B coincides with the outer edge of the area where all the intersections P of the workpiece B are present has been exemplified, but these outer edges may not coincide with each other. For example, when the area where all the intersections P of the workpiece B are present is larger than the movable range of the binding device 6C, the area where all the intersections P of the workpiece B are present may be divided into a plurality of areas, and the robotic arm 4 and the workpiece B may be assumed to be moved to perform the binding operation for each divided area.

[0259] In the present embodiment, in the binding system 1D, the control unit 77D performs the binding direction determination process of the wire W with respect to each intersection P of the workpiece B, but the present invention is not limited thereto. For example, the control unit 77D may use binding direction data created by the user by determining a binding direction for each intersection P of the workpiece B to satisfy any one of the above-described binding direction conditions (1) to (5) from the operation unit 72, and the control unit 77D may perform the binding operation according to the binding direction data without performing the determination of determining the binding direction of the wire W for each intersection P of the workpiece B. Alternatively, the control unit 77D may acquire, from the outside of the binding system 1D, binding direction data in which the binding direction for each intersection P of the workpiece B is determined to satisfy any one of the above-described binding direction conditions (1) to (5), and perform the binding operation according to the binding direction data. In addition, a recording medium on which the binding direction data in which the binding direction for each intersection P of the workpiece B is determined to satisfy any one of the binding direction conditions (1) to (5) is recorded by an information processing terminal or the like not included in the binding system 1D may be read by a reading device of the recording medium, and the control unit 77D may perform the binding operation according to the binding direction data.

[0260] The binding system 1D may be configured to acquire the information on the intersections P for specifying the respective intersections P of the workpiece B only from the map data 763D. In that case, in the binding system 1D, the first camera 31 and the second camera 51 are not essential. However, since the binding device 6C can be more accurately positioned with respect to the intersection P by the second camera 51, only the first camera 31 may be omitted, and the second camera 51 may be provided. When the first camera 31 is omitted from the configuration of the binding system 1D, the movement mechanism 32 that causes the first camera 31 to move between the imaging area E1 and the binding area E2 can also be omitted.

[0261] In the binding system 1D according to the present embodiment, the binding device 6C that binds the reinforcing bars S with two wires W has been exemplified, but the present invention is not limited thereto, and a binding device that binds the reinforcing bars S with one or three or more wires W may be used.

[0262] In the binding system 1D, a configuration in which the binding device 6C and the individual imaging unit 5 are moved by the robotic arm 4 has been exemplified, but the present invention is not limited thereto. For example, the binding device 6C and the individual imaging unit 5 may be mounted on a head of a gantry-type mobile apparatus in the X-Y direction, and then the binding device 6C and the individual imaging unit 5 may be lifted and lowered along the Z direction from the head and may be turned around the axis along the Z direction. Alternatively, the binding device 6C and the individual imaging unit 5 may be mounted on a self-propelled mobile apparatus that moves the workpiece B held in a grid pattern.

[0263] In addition, the binding system 1D according to the present embodiment is a stationary binding system disposed or fixedly installed in an indoor work space. Therefore, it is possible to perform the binding work without being affected by the weather or the outdoor environment as in an outdoor work type binding system. Since a need for a device treated with waterproof, dustproof, high-temperature, and low-temperature countermeasures to withstand a severe outdoor environment is eliminated, it is possible to mount a device that performs precise work indoors, and to perform precise binding work on the workpiece B. However, by excluding these advantages, it is also possible to configure a binding system having features in the present embodiment with respect to an outdoor use-type binding system.

[0264] The solution to the problem of the third embodiment will be described below.[Solution 1] A binding system for binding a workpiece, in which a plurality of reinforcing bars and a plurality of reinforcing bars intersect to form a plurality of intersections, with a binding body by a moving binding device at each of the plurality of intersections, the binding system including: a control unit configured such that, with respect to one reinforcing bar and another reinforcing bar that form the intersection, at least one other intersection in the one reinforcing bar, which is different from the intersection formed by the one reinforcing bar and the other reinforcing bar, and at least one other intersection in the other reinforcing bar, which is different from the intersection formed by the one reinforcing bar and the other reinforcing bar, are bound with the binding body along a direction different from a direction in which the intersection formed by the one reinforcing bar and the other reinforcing bar is bound with the binding body.[Solution 2] The binding system according to solution 1, in which when an intersection having two other adjacent intersections among all the intersections in a work area in which the binding device is movable is set as an intersection located at a corner of the work area, the control unit performs binding with the binding body at the intersection located at the corner along a direction closer to parallel to a straight line connecting the intersection located at the corner and a center of the work area.[Solution 3] The binding system according to solution 2, in which the control unit performs binding with the binding body at at least one of two intersections adjacent to the intersection located at the corner of the work area among the plurality of intersections in the work area of the workpiece along the same direction as the intersection located at the corner of the work area.[Solution 4] The binding system according to solution 2, in which when an intersection having three or less other adjacent intersections among the plurality of intersections in the work area of the workpiece is set as an intersection located on an outer edge of the work area, the control unit performs binding with the binding body at the intersection located on the outer edge of the work area in a direction closer to parallel to a straight line connecting the intersection and the center of the work area.[Solution 5] The binding system according to solution 1, in which the control unit performs binding with the binding body at the intersection in a direction different from a direction in which all other adjacent intersections are bound with the binding body.[Solution 6] The binding system according to solution 1, further including: a binding device configured to perform binding with the binding body at the intersection; and an intersection information acquisition unit provided together with the binding device and configured to acquire information on the intersection.[Solution 7] A binding processing program for causing a computer that controls a binding system for binding a workpiece, in which a plurality of reinforcing bars and a plurality of reinforcing bars intersect to form a plurality of intersections, with a binding body by a moving binding device at each of the plurality of intersections, to realize a function of performing control of binding, with respect to one reinforcing bar and another reinforcing bar that form the intersection, at least one other intersection in the one reinforcing bar, which is different from the intersection formed by the one reinforcing bar and the other reinforcing bar, and at least one other intersection in the other reinforcing bar, which is different from the intersection formed by the one reinforcing bar and the other reinforcing bar, with the binding body along a direction different from a direction in which the intersection formed by the one reinforcing bar and the other reinforcing bar is bound with the binding body.

[0265] <<Fourth Embodiment>> Hereinafter, a fourth embodiment of the present invention will be described with reference to the drawings. The fourth embodiment discloses a binding device and a binding system that can reliably draw out a required amount of wire for binding reinforcing bars and can prevent a change in the direction of the wire entering the binding machine, in view of the fact that the load applied to the wire feeder of the reinforcing bar binding machine varies when the reinforcing bar binding machine is raised and lowered independently of the wire drawing mechanism, as exemplified in JP2023-105958A as a related art.

[0266] <Configuration Example of Binding Device According to Present Embodiment> FIG. 37A is a side view illustrating an example of a binding device according to the present embodiment, and FIG. 37B is a side view illustrating the example of the binding device according to the present embodiment, with some components omitted from illustration. FIG. 37C is a perspective view illustrating the example of the binding device according to the present embodiment, FIG. 37D is a rear view illustrating the example of the binding device according to the present embodiment, and FIG. 37E is a side view viewed from a back surface illustrating the example of the binding device according to the present embodiment.

[0267] A binding device 100 includes a reinforcing bar binding machine 1E that binds intersections of reinforcing bars S arranged in a grid pattern with a wire W, a slack forming unit 2E that draws the wire W from a reel 20E and forms a slack in the wire W between the reinforcing bar binding machine 1E and the reel 20E, and a reel housing unit 200 that houses the reel 20E. The slack forming unit 2E may not have a function of drawing the wire W from the reel 20E, as long as the slack can be formed.

[0268] FIG. 38 is an internal configuration diagram illustrating an example of a reinforcing bar binding machine as viewed from a side. The reinforcing bar binding machine 1E is an example of a binding machine, feeds the wire W in a forward direction indicated by an arrow F, winds the wire W around the reinforcing bars S, feeds the wire W wound around the reinforcing bars S in a reverse direction indicated by an arrow R to wind the wire W around the reinforcing bars S and cut the wire W, and then twists the wire W to bind the reinforcing bars S with the wire W.

[0269] In order to implement the above functions, the reinforcing bar binding machine 1E includes a wire feeder 3E that feeds the wire W, and wire guides 4E that guide the wire W. The reinforcing bar binding machine 1E includes a curl forming unit 5E that constitutes a path for winding the wire W fed by the wire feeder 3E around the reinforcing bars S, and a cut unit 6E that cuts the wire W wound around the reinforcing bars S. The reinforcing bar binding machine 1E further includes a binding unit 7E that twists the wire W wound around the reinforcing bars S, and a driving unit 8E that drives the binding unit 7E.

[0270] The wire feeder 3E includes a pair of feed gears 30 that sandwich and feed the wire W. The wire feeder 3E receives a rotation operation of a feeding motor (not illustrated), causing the feed gears 30 to rotate. Accordingly, the wire feeder 3E feeds the wire W clamped between the pair of feed gears 30 along an extending direction of the wire W. In a configuration in which a plurality of, for example, two wires W are fed to bind the reinforcing bars S, the two wires W are fed in parallel.

[0271] In the wire feeder 3E, rotational directions of the feed gears 30 are switched by switching forward and reverse rotational directions of the feeding motor (not illustrated), and forward and reverse feed directions of the wires W are switched such that the wires W are fed in the forward direction indicated by the arrow F or in the reverse direction indicated by the arrow R.

[0272] The wire guides 4E are provided at predetermined positions upstream and downstream of the wire feeder 3E with respect to the feed direction in which the wires W are fed in the forward direction. In the configuration in which two wires W are fed to bind the reinforcing bars S, the wire guide 4E provided upstream of the wire feeder 3E regulates an orientation of the two wires W in a radial direction, arranges the two incoming wires W in parallel, and guides the two wires W between the pair of feed gears 30. The wire guide 4E provided downstream of the wire feeder 3E regulates the orientation of the two wires W in the radial direction, arranges the two incoming wires W in parallel, and guides the two wires W into the cut unit 6E and the curl forming unit 5E. In FIG. 38, the wire guide 4 provided on the upstream side of the wire feeder 3E is not illustrated.

[0273] The curl forming unit 5E includes a curl guide 50 that curls the wire W fed by the wire feeder 3E, and a inducing guide 51E that leads the wire W curled by the curl guide 50 to the binding unit 7E. In the reinforcing bar binding machine 1E, since a feeding path of the wire W fed by the wire feeder 3E is regulated by the curl forming unit 5E, a trajectory of the wire W becomes a loop Ru as illustrated by a two-dot chain line in FIG. 38, and the wire W is wound around the reinforcing bars S.

[0274] The cut unit 6E includes a fixed blade portion 60 and a movable blade portion 61E that cuts the wire W in cooperation with the fixed blade portion 60. The cut unit 6E cuts the wires W by rotation of the movable blade portion 61E with the fixed blade portion 60 as a fulcrum shaft. An operation of the binding unit 7E is transmitted to the movable blade portion 61E via the cut unit 6E.

[0275] The binding unit 7E includes a locking member 70 that locks the wire W and a sleeve 71 that actuates the locking member 70. The driving unit 8E includes a twisting motor 80 and a speed reducer 81 that performs speed reduction and torque amplification.

[0276] The binding unit 7E is driven by the driving unit 8E, causing the sleeve 71 to actuate the locking member 70 to lock the wire W. After the wire W is cut by the cut unit 6E in conjunction with the operation of the sleeve 71, the binding unit 7E twists the wire W by the rotation operation of the locking member 70 and the sleeve 71 to bind the reinforcing bars S.

[0277] The reinforcing bar binding machine 1E is provided with the binding unit 7E on a virtual straight line 10L along an axial direction of the twisting motor 80 illustrated by a one-dot chain line in FIG. 38. The reinforcing bar binding machine 1E is provided with the curl guide 50 and the inducing guide 51E at a lower end thereof, protruding from a main body 10E, when an orientation of the virtual straight line 10L is set to be along an upper-lower direction.

[0278] The reinforcing bar binding machine 1E is provided with the wire feeder 3E on one side in a direction intersecting the virtual straight line 10L, which is a direction intersecting the axial direction of the twisting motor 80.

[0279] Further, the binding device 100 is provided with the slack forming unit 2E on a side of the reinforcing bar binding machine 1E where the wire feeder 3E is disposed, that is, on one side of the reinforcing bar binding machine 1E in the direction intersecting the virtual straight line 10L, which is the direction intersecting the axial direction of the twisting motor 80. The slack forming unit 2E forms a slack in the wire W between the reinforcing bar binding machine 1E and the reel 20E.

[0280] The binding device 100 is provided with the reel housing unit 200 above the reinforcing bar binding machine 1E in a direction along which the virtual straight line 10L extends, which is a direction along the axial direction of the twisting motor 80.

[0281] The reel housing unit 200 houses the reel 20 such that the reel 20E is rotatable and detachable, on which the elongated wire W is wound to be fed out. Examples of the wire W include a wire formed of a plastically deformable metal wire, a wire having a metal wire covered with resin, or a stranded wire.

[0282] In a configuration in which the reinforcing bar binding machine 1E binds the reinforcing bars S with one wire W, the reel housing unit 200 houses one reel 20E wound with one wire W and is configured to allow the reel 20E to draw one wire W while rotating. In a configuration in which the reinforcing bar binding machine 1E binds the reinforcing bars S with a plurality of wires W, the reel housing unit 200 houses a plurality of reels 20E corresponding to the number of the wires W and is configured to allow the reels 20E to draw a plurality of wires W while rotating. For example, in a configuration in which the reinforcing bar binding machine 1E binds the reinforcing bars S with two wires W, the reel housing unit 200 houses two reels 20E each wound with one wire W and is configured to allow the reels 20E to draw two wires W while rotating.

[0283] The reel housing unit 200 may include a brake portion that allows rotation of the reel 20E in a direction in which the wire W is drawn, and regulates the rotation of the reel 20E to a reverse direction.

[0284] The slack forming unit 2E includes a first slack forming unit 21E, a second slack forming unit 22E, a first guide portion 23E, and a second guide portion 24E.

[0285] The first slack forming unit 21E is an example of a slack forming mechanism part and includes a first slack forming roller 21a, a guide plate 21b, and guide members 21c and 21d.

[0286] The first slack forming roller 21a has a disk shape with a thickness greater than a diameter of the wire W, and has a guide surface 21f in contact with the wire W on an outer periphery of the disk. The first slack forming roller 21a is rotatably supported between a pair of guide plates 21b with a shaft 21g as a fulcrum.

[0287] The guide plates 21b are provided on both sides in an axial direction of the first slack forming roller 21a with the first slack forming roller 21a interposed therebetween. In the configuration in which the reinforcing bars S are bound with two wires W, the first slack forming rollers 21a are provided on both sides of one guide plate 21b, and the guide plate 21b is provided on an outer side of each of the first slack forming rollers 21a.

[0288] The guide member 21c is provided to face the guide surface 21f of the first slack forming roller 21a in a path of the wire W entering the first slack forming unit 21E from the first guide portion 23E. The guide member 21c is provided between the pair of guide plates 21b, for example, in a form of a cylindrical member that extends in a direction intersecting the guide plate 21b.

[0289] The guide member 21d is provided in a path of the wire W coming out of the first slack forming unit 21E. The guide member 21d is provided between the pair of guide plates 21b, for example, in a form of a roller rotatable around a shaft 21h as a fulcrum.

[0290] The guide member 21c and the shaft 21h of the guide member 21d also function as a spacer that defines an interval between the pair of guide plates 21b.

[0291] The guide plate 21b covers at least a part of the side of the first slack forming roller 21a and at least a part of the sides of the guide members 21c and 21d, and has a shape capable of supporting the first slack forming roller 21a and the guide members 21c and 21d.

[0292] The second slack forming unit 22E is an example of the slack forming mechanism part and includes a second slack forming roller 22a, a guide plate 22b, and guide members 22c and 22d.

[0293] The second slack forming roller 22a has a disk shape with a thickness greater than the diameter of the wire W, and has a guide surface 22f in contact with the wire W on an outer periphery of the disk. The second slack forming roller 22a is rotatably supported between a pair of guide plates 22b with a shaft 22g as a fulcrum.

[0294] The guide plates 22b are provided on both sides in an axial direction of the second slack forming roller 22a with the second slack forming roller 22a interposed therebetween. In the configuration in which the reinforcing bars S are bound with two wires W, the second slack forming rollers 22a are provided on both sides of one guide plate 22b, and the guide plate 22b is provided on an outer side of each of the second slack forming rollers 22a.

[0295] The guide member 22c is provided in a path of the wire W entering the second slack forming unit 22E from the first slack forming unit 21E. The guide member 22c is provided between the pair of guide plates 22b, for example, in a form of a roller rotatable around a shaft 22h as a fulcrum.

[0296] The guide member 22d is provided to face the guide surface 22f of the second slack forming roller 22a in a path of the wire W coming out of the second slack forming unit 22E. The guide member 22d is provided between the pair of guide plates 22b, for example, in a form of a cylindrical member that extends in a direction intersecting the guide plate 22b.

[0297] The guide member 22c and the shaft 22h of the guide member 22d also function as a spacer that defines an interval between the pair of guide plates 22b.

[0298] The guide plate 22b covers at least a part of the side of the second slack forming roller 22a and at least a part of the sides of the guide members 22c and 22d, and has a shape capable of supporting the second slack forming roller 22a and the guide members 22c and 22d.

[0299] The first guide portion 23E is provided between the reel 20E and the first slack forming unit 21E. In the first guide portion 23E, the wire W passes between a pair of guide plates 23a, and a path through which the wire W drawn from the reel 20E passes is directed toward the first slack forming unit 21E.

[0300] The binding device 100 may include a guide portion 26 that forms a path through which the wire W passes between the reel 20E and the first guide portion 23E. In the configuration in which the reinforcing bars S are bound with two wires W, the first guide portion 23E and the guide portion 26 are provided corresponding to each reel 20E. The guide portion 26 guides the two wires W such that a distance between the paths through which the two wires W pass gradually narrows from each reel 20E toward the first guide portions 23E, in order to accommodate a difference between a distance between the two reels 20E and a distance between the two first guide portions 23E.

[0301] The second guide portion 24E is provided between the second slack forming unit 22E and the reinforcing bar binding machine 1E. The second guide portion 24E may include a brake portion that allows passage of the wire W during the operation of feeding the wire W by the wire feeder 3E, and regulates the passage of the wire W during the operation of forming a slack in the wire W by the slack forming unit 2E.

[0302] The binding device 100 includes a first guide portion 21i that guides movement of the first slack forming unit 21E, a second guide portion 22i that guides movement of the second slack forming unit 22E, and a driving unit 25 that moves the first slack forming unit 21E and the second slack forming unit 22E.

[0303] The first guide portion 21i guides the first slack forming unit 21E to be movable in a direction along a feed path WL of the wire W entering the reinforcing bar binding machine 1E, which is defined by the wire feeder 3E, the wire guide 4E, and the like. The second guide portion 22i guides the second slack forming unit 22E to be movable in the direction along the feed path WL of the wire W entering the reinforcing bar binding machine 1E. The second guide portion 22i supports the second slack forming unit 22E such that the guide surface 22f of the second slack forming roller 22a is positioned on an extension line of the feed path WL of the wire W entering the reinforcing bar binding machine 1E, which is defined by the wire feeder 3E, the wire guide 4E, and the like.

[0304] The driving unit 25 includes a pair of pulleys 25a and 25b, a belt 25c wound around the pulleys 25a and 25b, and a motor 25d that drives the pulley 25a. The driving unit 25 includes a first connecting portion 25e that connects the first slack forming unit 21E and the belt 25c, and a second connecting portion 25f that connects the second slack forming unit 22E and the belt 25c.

[0305] The pulley 25a is provided on a side closer to the reinforcing bar binding machine 1E in the movement direction of the first slack forming unit 21E and the second slack forming unit 22E. The pulley 25b is provided on a side away from the reinforcing bar binding machine 1E in the movement direction of the first slack forming unit 21E and the second slack forming unit 22E. The belt 25c extends in the movement direction of the first slack forming unit 21E and the second slack forming unit 22E. The first connecting portion 25e is connected to one side of the belt 25c extending between the pair of pulleys 25a and 25b, and the second connecting portion 25f is connected to the other side of the belt 25c extending between the pair of pulleys 25a and 25b.

[0306] One side and the other side of the belt 25c extending between the pair of pulleys 25a and 25b move in opposite directions to each other when the pulley 25a is rotated by being driven by the motor 25d. Accordingly, depending on the direction of rotation of the motor 25d, the first slack forming unit 21E and the second slack forming unit 22E move in a direction toward each other and a direction away from each other.

[0307] The wire W drawn from the reel 20E extends laterally with respect to the reinforcing bar binding machine 1E in the direction intersecting the axial direction of the twisting motor 80, and the path thereof is changed toward the slack forming unit 2E by the first guide portion 23E. The path of the wire W passing through the slack forming unit 2E is changed toward the wire feeder 3E of the reinforcing bar binding machine 1E by the second slack forming roller 22a.

[0308] In the binding device 100, the reinforcing bar binding machine 1E is attached to a binding machine support portion 101, and a reel housing unit 200 is attached to a housing unit support portion 102. The binding machine support portion 101 is attached to the housing unit support portion 102. Further, in the binding device 100, the slack forming unit 2E is attached to a slack forming unit support portion 103. In the binding device 100, the housing unit support portion 102 and the slack forming unit support portion 103 are attached to a support portion 104.

[0309] In the binding device 100, the support portion 104 is provided above the reinforcing bar binding machine 1E and the reel housing unit 200 in the axial direction of the twisting motor 80, and an attachment portion 105 to which the robotic arm 300 is attached is provided on the support portion 104.

[0310] In the slack forming unit 2E, the first slack forming unit 21E, the second slack forming unit 22E, and the driving unit 25 are provided on one side of the slack forming unit support portion 103, and a control unit 250 of the driving unit 25 and the like are provided on the other side of the slack forming unit support portion 103. The control unit 250 includes a control board (not illustrated), a board housing unit 250a that houses the control board, and the like.

[0311] As illustrated in FIG. 38, the reinforcing bar binding machine 1E is provided with the binding unit 7E on the virtual straight line 10L along the axial direction of the twisting motor 80. In the binding device 100, as illustrated in FIG. 37A, the attachment portion 105 is provided on the virtual straight line 10L. Accordingly, in the binding device 100, the binding unit 7E and the attachment portion 105 are provided on the same virtual straight line 10L. Therefore, when the orientation of the reinforcing bar binding machine 1E is set along an upper-lower direction such that the curl forming unit 5E faces downward, the binding unit 7E is provided vertically below the attachment portion 105.

[0312] Further, the reel housing unit 200 houses the reel 20E such that the rotation axis of the reel 20E is located on the virtual straight line 10L passing through the binding unit 7E and the attachment portion 105 when the binding device 100 is viewed from the side. When the binding device 100 is viewed from a direction orthogonal to the virtual straight line 10L, a position of the rotation axis of each reel deviates from the virtual straight line 10L depending on the number of reels to be used, but it is sufficient that a center of a line connecting rotation axes of all the reels to be used is located on the virtual straight line 10L, that is, the line connecting the rotation axes of the plurality of reels to be used is located on the virtual straight line 10L.

[0313] <Configuration Example of Binding System According to Present Embodiment> FIGS. 39A and 39B are perspective views illustrating examples of a binding system according to the present embodiment. A binding system 301 includes the binding device 100 and the robotic arm 300. The binding system 301 includes an entire imaging unit 303, an individual imaging unit 305 provided in the binding device 100, and a gantry 311 on which the robotic arm 300 and the entire imaging unit 303 are provided.

[0314] In the description of the binding system 301, X, Y, and Z directions refer to directions illustrated in FIGS. 39A and 39B. The X, Y, and Z directions are orthogonal to each other, an XY plane is a substantially horizontal plane, and the Z direction is a direction substantially along a vertical direction.

[0315] The gantry 311 is formed in a rectangular parallelepiped shape elongated in the X direction, and includes four support columns 312 erected at four corners in the X direction and the Y direction, and a plurality of beams 313 bridged in the X direction and the Y direction at upper ends of the support columns 312.

[0316] In an area inside the gantry 311, a substantially half portion on one side (right side in FIGS. 39A and 39B) in the X direction is an imaging area E1 in which imaging by the entire imaging unit 303 is performed, and a half portion on the other side (left side in FIGS. 39A and 39B) is a binding area E2 in which a binding operation by the robotic arm 300 and the binding device 100 is performed.

[0317] In the binding system 301, a workpiece B in which a plurality of reinforcing bars S are arranged in a grid pattern is held by a workpiece holding unit 302. The workpiece holding unit 302 holds the workpiece B and moves the held workpiece B between the imaging area E1 illustrated in FIG. 39A and the binding area E2 illustrated in FIG. 39B. Specifically, the workpiece holding unit 302 includes a holding table 321 that holds the workpiece B, a rail 322 that movably supports the holding table 321, and a driving motor (not illustrated) that drives the rail 322.

[0318] The holding table 321 is formed in a rectangular plate shape having four sides along the X direction and the Y direction. Support plates 321a that support the plurality of reinforcing bars S constituting the workpiece B are erected on the four sides of the holding table 321. Each of the support plates 321a has a plurality of U-shaped grooves 321b opening upward, and the reinforcing bars S are inserted into the U-shaped grooves 321b. The plurality of reinforcing bars S are arranged in a grid pattern along the X direction and the Y direction in a state where ends of the reinforcing bars S are inserted into the U-shaped grooves 321b of the support plates 321a.

[0319] The rail 322 is laid along the X direction and guides the holding table 321 in the X direction. The rail 322 according to the present embodiment is laid such that the holding table 321 (workpiece B) is movable at least between the imaging area E1 and the binding area E2. However, the rail 322 may be extended to an outside of the gantry 311, and the workpiece B may be movable to a work process before and after binding.

[0320] The entire imaging unit 303 images the entire workpiece B at once or images each of a plurality of divided areas. Specifically, the entire imaging unit 303 includes a first camera 331 disposed above the imaging area E1 and a movement mechanism 332 that movably supports the first camera 331.

[0321] The first camera 331 is disposed to face downward, and images the workpiece B held by the workpiece holding unit 302 from above in the imaging area E1. The first camera 331 is a compound-eye (for example, four-eye) stereo camera, and can acquire distance information in a depth direction (upper-lower direction) together with image information (monochrome image) on the XY plane. A sensor type or the like of the first camera 331 is not particularly limited as long as the first camera 331 can acquire the distance information (depth information) together with the image information.

[0322] The movement mechanism 332 includes a Y direction slider 333 extending along the Y direction. The Y direction slider 333 is bridged over the beams 313 along the X direction and is supported by the beams 313 to be movable in the X direction. The first camera 331 is suspended from the Y direction slider 333 to be movable in the Y direction. The movement mechanism 332 is driven by a driving source (not illustrated) to cause the first camera 331 to move to a predetermined position (XY coordinates).

[0323] The robotic arm 300 is an example of a moving body, is supported by the movement mechanism 346, and causes the binding device 100 and the individual imaging unit 305 to move to desired positions in the binding area E2.

[0324] The movement mechanism 346 includes Y direction sliders 346a bridged over the beams 313 of the gantry 311. The Y direction sliders 346a cause the robotic arm 300 to move in the Y direction. The movement mechanism 346 may include, for example, a mechanism that causes the robotic arm 300 to move in the X direction. In addition, when an operation range of the robotic arm 300 can cover the entire binding area E2 without depending on the movement mechanism 346, the movement mechanism 346 may not be provided.

[0325] The robotic arm 300 is a suspended multi-joint robot, and is installed downward on the Y direction sliders 346a bridged over the beams 313 in the binding area E2. Specifically, the robotic arm 300 includes a base 341, a plurality of arms 342, an end effector 343, and a plurality of joints 344. The robotic arm 300 is not limited to the multi-joint robot.

[0326] The plurality of arms 342 are coupled in series to each other with the base 341 as a proximal end. The base 341 is supported by the Y direction sliders 346a of the movement mechanism 346 and is movable in the Y direction.

[0327] The plurality of joints 344 pivotably couple the base 341, the plurality of arms 342, and the end effector 343. Each joint 344 is provided with a motor (not illustrated), and is driven by the motor to rotate.

[0328] The end effector 343 is coupled to distal ends of the plurality of arms 342. The end effector 343 supports the individual imaging unit 305 and also supports the binding device 100 via the attachment portion 105.

[0329] The individual imaging unit 305 is mounted on a distal end of the robotic arm 300 and individually images the intersections of the reinforcing bars S as binding objects in the binding area E2 with a resolution higher than that of the imaging by the entire imaging unit 303. Specifically, the individual imaging unit 305 includes a second camera 351, an illumination unit 353, and an elevator motor (not illustrated).

[0330] The second camera 351 is attached downward to the end effector 343 of the robotic arm 300, and images the intersections of the reinforcing bars S as the binding objects from above. The second camera 351 is driven by an elevator motor (not illustrated), and moves in the upper-lower direction with respect to the end effector 343. The second camera 351 is, for example, an RGB camera, and acquires image information (color image) of the intersections as the binding objects. A sensor type and the like of the second camera 351 are not particularly limited as long as the second camera 351 can acquire an image (signal information) of at least one intersection.

[0331] The illumination unit 353 illuminates an imaging object of the second camera 351.

[0332] The binding system 301 moves the workpiece B to the imaging area E1, images the entire workpiece B with the first camera 331 of the entire imaging unit 303, and acquires the position information of the intersections of the reinforcing bars S. When the binding system 301 acquires the position information of the intersections of the reinforcing bars S and the like, the binding system 301 moves the workpiece B to the binding area E2 and moves the binding device 100 to positions of the intersections of the binding objects by the robotic arm 300 based on the position information of the intersections of the reinforcing bars S and the like.

[0333] When the binding device 100 is moved to the positions of the intersections of the binding objects, the binding system 301 images the intersections of the binding objects with the second camera 351 of the individual imaging unit 305 and acquires the image information of the intersections of the binding objects. Then, the binding system 301 acquires position information or the like with higher accuracy than the position information of the intersections acquired by the entire imaging unit 303 from the image information acquired by the individual imaging unit 305, moves the binding device 100 by the robotic arm 300, and performs the binding operation.

[0334] <Operation Example of Binding Device According to Present Embodiment> FIGS. 40A and 41A are side views illustrating examples of an operation of the binding device according to the present embodiment, and FIGS. 40B and 41B are side views illustrating the examples of the operation of the binding device according to the present embodiment, with some components omitted from illustration.

[0335] In the binding device 100, depending on the direction of rotation of the motor 25d, the first slack forming unit 21E and the second slack forming unit 22E move from a standby position illustrated in FIGS. 37A and 37B and the like to a slack formation position illustrated in FIGS. 40A and 40B in the direction away from each other, and move from the slack formation position illustrated in FIGS. 40A and 40B to the standby position illustrated in FIGS. 41A and 41B in the direction toward each other.

[0336] In the binding device 100, when the first slack forming unit 21E moves from the standby position to the slack formation position, the first slack forming roller 21a moves in a direction toward the reinforcing bar binding machine 1E. When the first slack forming roller 21a moves in the direction toward the reinforcing bar binding machine 1E, the guide surface 21f comes into contact with the wire W, and pulls the wire W at a portion in contact with the guide surface 21f in the direction toward the reinforcing bar binding machine 1E.

[0337] In the binding device 100, when the second slack forming unit 22E moves from the standby position to the slack formation position, the second slack forming roller 22a moves in a direction away from the reinforcing bar binding machine 1E. When the second slack forming roller 22a moves in the direction away from the reinforcing bar binding machine 1E, the guide surface 22f comes into contact with the wire W, and pulls the wire W at a portion in contact with the guide surface 22f in the direction away from the reinforcing bar binding machine 1E.

[0338] The wire W entering the reinforcing bar binding machine 1E is clamped by the pair of feed gears 30. The pair of feed gears 30 are prevented from being rotated by an external force while driving of the feeding motor (not illustrated) is stopped. Accordingly, even when the second slack forming roller 22a moves in the direction away from the reinforcing bar binding machine 1E and a force for pulling the wire W at the portion in contact with the guide surface 22f in the direction away from the reinforcing bar binding machine 1E is applied, the wire W is prevented from being drawn in the direction in which the wire W comes out from between the pair of feed gears 30.

[0339] The path of the wire W drawn from the reel 20E is changed toward the slack forming unit 2E by the first guide portion 23E between the reel 20E and the first slack forming roller 21a. Accordingly, the first slack forming roller 21a moves in the direction toward the reinforcing bar binding machine 1E, and the wire W at the portion in contact with the guide surface 21f is pulled in the direction toward the reinforcing bar binding machine 1E, so that a force for drawing the wire W from the reel 20E is applied.

[0340] In addition, the second slack forming roller 22a moves in the direction away from the reinforcing bar binding machine 1E, and the wire W at the portion in contact with the guide surface 22f is pulled in the direction away from the reinforcing bar binding machine 1E, so that the force for drawing the wire W from the reel 20E is applied via the first slack forming roller 21a.

[0341] The reel 20E is rotatable when the force for drawing the wire W is applied. Accordingly, when the first slack forming roller 21a moves in the direction toward the reinforcing bar binding machine 1E and the second slack forming roller 22a moves in the direction away from the reinforcing bar binding machine 1E, the wire W is drawn from the reel 20E.

[0342] In the binding device 100, when the first slack forming unit 21E moves from the slack formation position to the standby position, the first slack forming roller 21a moves in the direction away from the reinforcing bar binding machine 1E. When the first slack forming roller 21a moves in the direction away from the reinforcing bar binding machine 1E, the guide surface 21f separates from the wire W. Further, in the binding device 100, when the second slack forming unit 22E moves from the slack formation position to the standby position, the second slack forming roller 22a moves in the direction toward the reinforcing bar binding machine 1E. When the second slack forming roller 22a moves in the direction toward the reinforcing bar binding machine 1E, the guide surface 22f separates from the wire W. Accordingly, a slack portion WB is formed in the wire W between the reel 20E and the reinforcing bar binding machine 1E.

[0343] The second slack forming unit 22E is supported by the second guide portion 22i such that the guide surface 22f is positioned on the extension line of the feed path WL of the wire W entering the reinforcing bar binding machine 1E, which is defined by the wire feeder 3E, the wire guide 4E, and the like. Further, the second slack forming unit 22E is guided by the second guide portion 22i to be movable in the direction along the feed path WL of the wire W entering the reinforcing bar binding machine 1E. Accordingly, the wire W entering the reinforcing bar binding machine 1E is prevented from being largely changed with respect to the feed path WL by the operation of the second slack forming unit 22E moving from the standby position to the slack formation position and the operation of moving from the slack formation position to the standby position.

[0344] When the first slack forming unit 21E moves from the slack formation position to the standby position, the guide member 22c guides the wire W between the pair of guide plates 21b. Accordingly, the movement of the wire W entering the first slack forming unit 21E in the axial direction of the first slack forming roller 21a is prevented by the pair of guide plates 21b. Therefore, the wire W entering the first slack forming unit 21E is prevented from being entangled with the first guide portion 23E or the like. In the configuration in which the reinforcing bars S are bound with two wires W, the two wires W are prevented from being entangled with each other in the slack forming unit 2E.

[0345] The wire W coming out of the first slack forming unit 21E is guided between the pair of guide plates 21b by the guide member 21d. Accordingly, the movement of the wire W coming out of the first slack forming unit 21E in the axial direction of the first slack forming roller 21a is prevented by the pair of guide plates 21b. In addition, the movement of the wire W coming out of the first slack forming unit 21E toward the second slack forming unit 22E is prevented by the guide member 21d. Therefore, the wire W coming out of the first slack forming unit 21E is prevented from being entangled with the second slack forming unit 22E or the like. In the configuration in which the reinforcing bars S are bound with two wires W, the two wires W are prevented from being entangled with each other in the slack forming unit 2E.

[0346] Further, the wire W entering the second slack forming unit 22E is guided between the pair of guide plates 22b by the guide member 22c. Accordingly, the movement of the wire W entering the second slack forming unit 22E in the axial direction of the second slack forming roller 22a is prevented by the pair of guide plates 22b. In addition, the movement of the wire W entering the second slack forming unit 22E toward the first slack forming unit 21E is prevented by the guide member 22c. Therefore, the wire W entering the second slack forming unit 22E is prevented from being entangled with the first slack forming unit 21E or the like. In the configuration in which the reinforcing bars S are bound with two wires W, the two wires W are prevented from being entangled with each other in the slack forming unit 2E.

[0347] The wire W coming out of the second slack forming unit 22E is guided between the pair of guide plates 22b by the guide member 22d. Accordingly, the movement of the wire W coming out of the second slack forming unit 22E in the axial direction of the second slack forming roller 22a is prevented by the pair of guide plates 22b. Therefore, in the configuration in which the reinforcing bars S are bound with two wires W, the two wires W are prevented from being entangled with each other in the slack forming unit 2E.

[0348] FIG. 42 is a side view illustrating an example of a binding operation, with some components of the binding device omitted from illustration. As illustrated in FIGS. 41A and 41B, in the reinforcing bar binding machine 1E, when a slack portion WB is formed in the wire W by the slack forming unit 2E, the wire W is fed in the forward direction indicated by the arrow F by the wire feeder 3E illustrated in FIG. 38 and is wound around the reinforcing bars S by the curl forming unit 5E. In the operation of feeding the wire W in the forward direction indicated by the arrow F by the wire feeder 3E, as illustrated in FIG. 42, the slack portion WB of the wire W is fed. Accordingly, it is not necessary to rotate the reel 20E by the force for feeding the wire W in the forward direction indicated by the arrow F by the wire feeder 3E, the load applied to the wire feeder 3E is reduced, and the occurrence of a failure in wire feeding by the wire feeder 3E is prevented.

[0349] In order to wind the wire W wound around the reinforcing bars S on the reinforcing bars S, in the operation of feeding the wire W in the reverse direction indicated by the arrow R by the wire feeder 3E, a slack corresponding to the feed amount of the wire W in the reverse direction is formed. Accordingly, it is not necessary to rotate the reel 20E by the force for feeding the wire W in the reverse direction indicated by the arrow R by the wire feeder 3E, the load applied to the wire feeder 3E is reduced, and the occurrence of a failure in wire feeding by the wire feeder 3E is prevented.

[0350] In the binding device 100, after the slack forming unit 2E forms the slack portion WB corresponding to the amount of the wire W necessary for the operation of binding the reinforcing bars S by the reinforcing bar binding machine 1E, the operation of binding the reinforcing bars S by the reinforcing bar binding machine 1E is performed. The slack forming unit 2E may be actuated during the operation of binding the reinforcing bars S by the reinforcing bar binding machine 1E, and the slack portion WB corresponding to the amount of the wire W necessary for the next operation of binding the reinforcing bars S may be formed by the slack forming unit 2E.

[0351] The binding device 100 is configured such that the reinforcing bar binding machine 1E and the slack forming unit 2E are integrally movable. Accordingly, the direction in which the slack portion WB of the wire W formed by the slack forming unit 2E enters the wire feeder 3E of the reinforcing bar binding machine 1E does not change in the operation of moving the binding device 100 by the robotic arm 300. Therefore, the fluctuation of the load applied to the wire feeder 3E is prevented, and the occurrence of the failure in the wire feeding by the wire feeder 3E is prevented.

[0352] In addition, as compared with a case where the reinforcing bar binding machine 1E and the slack forming unit 2E are independently configured, the slack forming unit 2E can be provided closer to the reinforcing bar binding machine 1E, and a path length through which the wire W passes can be reduced. Accordingly, it is possible to eliminate factors that cause the failure in the wire feeding.

[0353] Further, as compared with the case where the reinforcing bar binding machine 1E and the slack forming unit 2E are independently configured, it is possible to reduce a tolerance when the reinforcing bar binding machine 1E and the slack forming unit 2E are integrally assembled, and it is possible to eliminate factors that cause the failure in wire feeding due to accuracy between the reinforcing bar binding machine 1E and the slack forming unit 2E.

[0354] In addition, since the slack forming unit 2E includes the driving unit 25 that drives the first slack forming unit 21E and the second slack forming unit 22E drawing the wire W wound on the reel 20E, it is not necessary to, for example, raise and lower the reinforcing bar binding machine 1E in the operation of drawing the wire W from the reel 20E. Accordingly, the drawing of the wire W does not depend on a distance between the reinforcing bar binding machine 1E and an arrangement surface of the reinforcing bars S.

[0355] Further, in the slack forming unit 2E, the first slack forming unit 21E, the second slack forming unit 22E, and the driving unit 25 are provided on one side of the slack forming unit support portion 103, and the control unit 250 of the driving unit 25 and the like are provided on the other side of the slack forming unit support portion 103. Accordingly, by the operation of actuating the slack forming unit 2E to form the slack in the wire W and the operation of feeding the wire W by the wire feeder 3E, the wire W is prevented from coming into contact with the control unit 250 or the like, and the occurrence of malfunction of the slack forming unit 2E and the occurrence of the failure in wire feeding are prevented.

[0356] In addition, since the housing unit support portion 102 that supports the reel housing unit 200, the slack forming unit support portion 103 that supports the slack forming unit 2E, and the support portion 104 that supports the housing unit support portion 102 and the slack forming unit support portion 103 are provided, and the reel housing unit 200 and the slack forming unit 2E are integrally configured, it is possible to reduce the size of the binding device 100.

[0357] Further, since the binding machine support portion 101 that supports the reinforcing bar binding machine 1E is provided, and the binding machine support portion 101 is supported by the housing unit support portion 102, a relative position between the reinforcing bar binding machine 1E and the reel 20E does not change, and the wire W is not inadvertently drawn. Accordingly, the occurrence of the malfunction of the slack forming unit 2E and the occurrence of the failure in wire feeding due to excessive drawing of the wire W are prevented.

[0358] Further, in the binding device 100, the slack forming unit 2E is provided on a side where the wire feeder 3E is provided with respect to the reinforcing bar binding machine 1E. Accordingly, the path of the wire W entering the wire feeder 3E from the slack forming unit 2E is prevented from crossing the binding unit 7E which is a movable component, and the wire W is prevented from being entangled with the binding unit 7E or the like. A space can be secured on a side opposite the side where the wire feeder 3E is provided with respect to the reinforcing bar binding machine 1E, and even when there is an obstacle in the vicinity of the binding device 100, the reinforcing bar binding machine 1E can be moved to a position of an intersection of the reinforcing bars S as the binding objects. When a camera or the like that images an intersection of the reinforcing bars S is provided, an installation location thereof can be secured.

[0359] Further, in the binding device 100, the attachment portion 105 for attaching the binding device 100 to the robotic arm 300 and the binding unit 7E of the reinforcing bar binding machine 1E are provided on the virtual straight line 10L along the axial direction of the twisting motor 80. Accordingly, when the orientation of the reinforcing bar binding machine 1E is set along the upper-lower direction such that the curl forming unit 5E faces downward, the binding unit 7E is provided vertically below the attachment portion 105. Therefore, at the position separated in the direction intersecting the virtual straight line 10L along the axial direction of the twisting motor 80, the weight of the twisting motor 80, the binding unit 7E, and the like is prevented from being applied to the robotic arm 300 via the attachment portion 105, and the position of the reinforcing bar binding machine 1E is prevented from being deviated from the intersection of the reinforcing bars S as the binding objects due to the load being biasedly applied to the robotic arm 300.

[0360] Further, the reel housing unit 200 houses the reel 20E such that the rotation axis of the reel 20E is located on the virtual straight line 10L passing through the binding unit 7E and the attachment portion 105 when the binding device 100 is viewed from the side. Accordingly, at the position separated in the direction intersecting the virtual straight line 10L along the axial direction of the twisting motor 80, the weight of the reel 20E is prevented from being applied to the robotic arm 300 via the attachment portion 105, and the position of the reinforcing bar binding machine 1E is prevented from being deviated from the intersection of the reinforcing bars S as the binding objects due to the load being biasedly applied to the robotic arm 300.

[0361] Since the first slack forming unit 21E and the second slack forming unit 22E move relative to each other, the slack forming unit 2E can secure the drawing amount of the wire W while preventing an increase in the movement amount of the first slack forming unit 21E and the second slack forming unit 22E. If the wire can be sufficiently fed to the binding unit by the wire feeder, that is, if the drawing amount of the wire W can be secured or the slack of the wire between the reel and the binding machine can be secured, the slack forming unit 2E may be configured such that one slack forming roller moves in a direction intersecting the path through which the wire W passes. In addition, since the reel housing unit 200 is provided with a reel driving unit such as a motor that rotates the reel 20E, and the reel 20E is rotated by the driving of the reel driving unit, the slack forming unit 2E may be configured to form a slack in the wire W between the reel 20E and the reinforcing bar binding machine 1E.

[0362] The solution to the problem of the fourth embodiment will be described below.[Solution 1] A binding device including: a binding machine configured to bind a plurality of arranged reinforcing bars with a wire; and a slack forming unit configured to form a slack in a wire between a reel around which the wire supplied to the binding machine is wound and the binding machine, in which the binding machine includes a binding unit configured to bind the reinforcing bars with the wire and a wire feeder configured to feed the wire to the binding unit, and the binding machine and the slack forming unit are configured to be integrally movable.[Solution 2] The binding device according to solution 1, in which the slack forming unit includes a slack forming mechanism part configured to draw the wire wound around the reel, and a driving unit configured to drive the slack forming mechanism part.[Solution 3] The binding device according to solution 2, further including: a slack forming unit support portion configured to support the slack forming unit, in which the slack forming unit support portion is provided with the slack forming mechanism part and the driving unit on one side and is provided with a control unit of the driving unit on the other side.[Solution 4] The binding device according to solution 3, further including: a reel housing unit housing the reel; a housing unit support portion configured to support the reel housing unit; and a support portion configured to support the housing unit support portion and the slack forming unit support portion.[Solution 5] The binding device according to solution 4, further including: a binding machine support portion configured to support the binding machine, in which the binding machine support portion is supported by the housing unit support portion.[Solution 6] The binding device according to solution 1, in which the slack forming unit includes a guide member configured to define a path through which the wire passes between the reel and the binding machine.[Solution 7] The binding device according to solution 1, in which the slack forming unit is provided on a side of the binding machine on which the wire feeder is provided.[Solution 8] The binding device according to solution 1, further including: an attachment portion attached to a moving body configured to move the binding device in a direction along an arrangement surface of the plurality of arranged reinforcing bars and in a direction toward and a direction away from the arrangement surface.[Solution 9] The binding device according to solution 8, in which the attachment portion is provided on a virtual straight line passing through the binding unit, and the binding unit is provided vertically below the attachment portion when an orientation of the binding machine is set along an upper-lower direction.[Solution 10] The binding device according to solution 8, further including: a reel housing unit configured to house the reel, in which the reel housing unit houses the reel on a virtual straight line passing through the attachment portion and the binding unit.[Solution 11] A binding system including: a binding device; and a moving body configured to move the binding device, in which the binding device includes: a binding machine configured to bind a plurality of arranged reinforcing bars with a wire; a slack forming unit configured to form a slack in a wire between a reel around which the wire supplied to the binding machine is wound and the binding machine; and a reel housing unit housing the reel, the binding machine includes a binding unit configured to bind the reinforcing bars with the wire and a wire feeder configured to feed the wire to the binding unit, and the binding machine and the slack forming unit are configured to be integrally movable.

[0363] The present application is based on Japanese Patent Application No. 2024-013038 filed on January 31, 2024, the contents of which are incorporated herein by reference. INDUSTRIAL APPLICABILITY

[0364] A binding system capable of suitably binding an intersection of a plurality of reinforcing bars is provided. REFERENCE SIGNS LIST

[0365] 1 binding system 2 workpiece holding unit 3 entire imaging unit 31 first camera (first information acquisition unit) 4 robotic arm (moving body) 40 robotic arm body 5 individual imaging unit 51 second camera (second information acquisition unit) 6 binding device 7 control device 76 storage unit 77 control unit (map creation unit) 762 image data 763 work information B workpiece E1 imaging area (first area) E2 binding area (second area) P intersection Pa target intersection S reinforcing bar W wire

Claims

1. <p> A binding system comprising: a first information acquisition unit configured to acquire first information on a plurality of arranged reinforcing bars; a second information acquisition unit configured to move based on the first information and acquire second information on an intersection of the plurality of reinforcing bars; and a binding device configured to bind the intersection based on the second information.

2. The binding system according to claim 1, further comprising: a moving body configured to integrally carry and move the second information acquisition unit and the binding device.

3. The binding system according to claim 2, wherein the moving body is configured to change a position on each of three orthogonal axes and an angle around at least one of the three orthogonal axes for at least one of the second information acquisition unit and the binding device.

4. The binding system according to claim 2, wherein a first area in which the first information acquisition unit acquires the first information and a second area in which the moving body configured to move are different.

5. The binding system according to claim 4, further comprising: a holding unit for holding the plurality of reinforcing bars, wherein the holding unit is configured to move from the first area to the second area.

6. The binding system according to claim 5, wherein the holding unit is configured to move from the second area to the first area.

7. The binding system according to claim 1, wherein the second information acquisition unit is configured to acquire the second information on the intersection in a state bound by the binding device.

8. The binding system according to claim 1, further comprising: a storage unit configured to store at least one of the first information and the second information.

9. <p> The binding system according to claim 1, further comprising: a control unit configured to control an operation of the binding device based on at least one of the first information and the second information; and a storage unit configured to store work information related to a binding work by the binding device.

10. The binding system according to claim 1, further comprising: a map creation unit configured to create map information including position information on each intersection of the plurality of reinforcing bars based on the second information.

11. The binding system according to claim 1, wherein the first information acquisition unit and the second information acquisition unit are cameras, and the first information and the second information are image data.

12. The binding system according to claim 11, wherein one of the first information acquisition unit and the second information acquisition unit acquires a monochrome image, and the other of the first information acquisition unit and the second information acquisition unit acquires a color image. 

Images