Binding system and binding processing program

Abstract

Provided is a highly versatile binding system. A binding system (1C) binds, with a binding body W, an intersection point P at which reinforcing bars S intersect with respect to a workpiece B having the intersection point P, and comprises a control unit (77) capable of selecting a binding condition of the binding body W with respect to the intersection point P. The control unit (77) may be able to select the binding order of the binding body W with respect to a plurality of intersection points P as the binding condition. The control unit (77) may be able to select an operation mode for specifying the order of binding of the binding body W with respect to the plurality of intersection points P.

Description

Bundling system and bundling processing program

[0001] The present invention relates to a bundling system equipped with a bundling machine that binds reinforcing bars with wire, and a bundling processing program.

[0002] Reinforcing bars are used in concrete structures to improve their strength, and are bound with wire by a bundling machine to prevent the reinforcing bars from shifting from their designated positions during concrete pouring. In the case of a workpiece in which multiple reinforcing bars are arranged crosswise, multiple intersections of the reinforcing bars occur. For such workpieces, a conventional method has been proposed in which a bundling robot equipped with a bundling machine moves over the workpiece to bind the reinforcing bars at each intersection. This bundling robot acquires the intersections from a camera image of the work area, and then spirals around the work area to bind the intersections in order (see, for example, Patent Document 1).

[0003] Chinese Patent No. 110328662

[0004] Conventional bundling robots can acquire intersections from camera images and autonomously perform bundling work at each intersection within a work area. However, these bundling robots only perform control to spirally circumnavigate the work area and perform bundling at each intersection in order, which lacks versatility in their work.

[0005] The present invention has been made to solve the above problems, and has an object to provide a bundling system and a bundling processing program that are highly versatile for bundling work.

[0006] In order to solve the above-mentioned problems, the binding system of the present invention is a binding system that binds a workpiece having an intersection where reinforcing bars intersect with a binding body, and is equipped with a control unit that can select the binding conditions of the binding body for the intersection.

[0007] In addition, the binding processing program of the present invention enables a computer that controls a binding system that binds a workpiece having an intersection where multiple reinforcing bars intersect with a binding element to realize the function of selecting the binding conditions of the binding element for the intersection.

[0008] According to the present invention, since the binding conditions of the binding body for the intersection can be selected, binding work can be performed according to various requirements for the work, thereby improving the versatility of the binding system.

[0009] 1 is a perspective view of a device main body of a binding system according to an embodiment; FIG. 2 is a block diagram illustrating a schematic control configuration of the binding system according to an embodiment; FIG. 3 is a side view of the binding device in a posture when performing a binding operation; FIG. 4 is a schematic view of a workpiece on a holding table of a workpiece holding unit as viewed from above; FIG. 5 is a plan view showing an intersection where binding was performed in a first direction of the binding direction; FIG. 6 is a plan view showing an intersection where binding was performed in a second direction of the binding direction; FIG. 7 is a plan view showing an intersection where binding was performed with two bundling operations; FIG. 8 is a plan view showing an intersection where binding was performed with one bundling operation in the first direction and one bundling operation in the second direction; FIG. 9 is an explanatory diagram of operations when binding is performed in a (1) outer edge-first pattern; FIG. 10 is an explanatory diagram of operations when binding is performed in a (2) center-first pattern; FIG. 11 is an explanatory diagram of operations when binding is performed in a (3) horizontal feed pattern; FIG. 12 is an explanatory diagram of operations when binding is performed in a (4) vertical feed pattern; FIG. 13 is an explanatory diagram of operations when binding is performed in a (5) corner-first pattern. 1 is an explanatory diagram showing the distinction between "intersections located at corners," "intersections located on outer edges," and other intersections. FIG. 2 is a schematic diagram showing a workpiece viewed from above in a case where an area made up of intersections to be bound has an irregular shape. FIG. 3 is a flowchart showing the procedure when the binding system executes binding processing.

[0010] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0011] [Configuration of the bundling system] Fig. 1 is a perspective view of an apparatus main body 10C provided in a bundling system 1C according to this embodiment, and Fig. 2 is a block diagram showing a general control configuration of the bundling system 1C. As shown in these figures, the bundling system 1C binds a workpiece B, in which a plurality of reinforcing bars S are arranged in a lattice pattern, with wire W at intersections P (see Fig. 4) where the plurality of reinforcing bars S intersect to form a bundling body. Specifically, the bundling system 1C includes an apparatus main body 10C and a control device 7C.

[0012] The device main body 10C includes a workpiece holding unit 2, an overall photography unit 3, a robot arm 4, an individual photography unit 5, and a binding device 6C. Of these, the workpiece holding unit 2 is disposed inside a base 11 of the device main body 10C, and the overall photography unit 3, robot arm 4, individual photography unit 5, and binding device 6C are mounted on the base 11. In the following description, the X, Y, and Z directions refer to the directions shown in FIG. 1. The X, Y, and Z directions are mutually orthogonal, the XY plane is a substantially horizontal plane, and the Z direction is a direction substantially along the vertical. For convenience, the X, Y, and Z directions are assumed to coincide with the directions of the robot coordinate system of the robot arm 4, which will be described later.

[0013] The platform 11 is formed in the shape of a rectangular parallelepiped that is long in the X direction, and includes four support columns 12 erected at the four corners in the X and Y directions, and four beams 13 that are bridged in the X and Y directions at the upper ends of the support columns 12. Of the area inside the platform 11, approximately half on one side in the X direction (the right side in FIG. 1) is an imaging area E1 where imaging is performed by the overall imaging unit 3, and the half on the other side (the left side in FIG. 1) is a binding area E2 where binding work is performed by the robot arm 4 and binding device 6C.

[0014] <Workpiece Holding Unit> The workpiece holding unit 2 holds the workpiece B and moves the held workpiece B between the photography area E1 and the binding area E2. Specifically, the workpiece holding unit 2 includes a holding table 21 that holds the workpiece B, rails 22 that movably support the holding table 21, and a drive motor 23 that drives the rails 22. The holding table 21 is formed in the shape of a rectangular plate with four sides aligned along the X and Y directions. Support plates 211 that support multiple reinforcing bars S that constitute the workpiece B are erected on the four sides of the holding table 21. The support plate 211 has multiple U-shaped grooves 211a that open upward, and the reinforcing bars S are inserted into the U-shaped grooves 211a. The multiple reinforcing bars S are arranged in a grid pattern along the X and Y directions with their ends inserted into the U-shaped grooves 211a of the support plate 211. The rails 22 are laid along the X direction and guide the holding table 21 in the X direction. The rails 22 in this embodiment are laid so that the holding table 21 (workpieces B) can be moved at least between the photography area E1 and the binding area E2. However, the rails 22 may be extended to the outside of the frame 11 so that the workpieces B can be moved to work processes before and after binding. The drive motor 23 is a drive source that moves the holding table 21. The drive motor 23 moves the holding table 21 between the photography area E1 and the binding area E2 based on a drive command from the control device 7C.

[0015] <Overall Photography Unit> The overall photography unit 3 photographs the entire workpiece B in the photography area E1. Specifically, the overall photography unit 3 includes a first camera 31 disposed above the photography area E1 and a moving mechanism 32 that movably supports the first camera 31. The first camera 31 is disposed facing downward and photographs the workpiece B held by the workpiece holder 2 in the photography area E1 from above, acquiring signal information including distance information from the rebar and image information of the workpiece. Specifically, the first camera 31 in this embodiment is a compound-eye (e.g., four-eye) stereo camera (RGB-D camera) that acquires image information in the XY plane as well as distance information in the depth direction (up and down), and outputs the information to the control device 7C. The first camera 31 is an example of a second information acquisition unit according to the present invention. Note that the sensor type of the first camera 31 is not particularly limited as long as it can acquire distance information (depth information) along with image information. For example, a time-of-flight (TOF) sensor may be used. Furthermore, sensors such as a 3D laser scanner or LiDAR (Light Detection and Ranging) may be used instead of a camera. The movement mechanism 32 includes a Y-direction slider 33 extending along the Y direction. The Y-direction slider 33 is suspended on a beam 13 aligned along the X direction and supported on the beam 13 so as to be movable in the X direction. The first camera 31 is suspended from the Y-direction slider 33 so as to be movable in the Y direction. The movement mechanism 32 drives a drive source (not shown) based on a control command from the control device 7C to move the first camera 31 to a predetermined position (XY coordinates). The movement mechanism 32 is used to photograph the entire workpiece B multiple times in order to obtain an image of the workpiece B with the desired resolution. Therefore, depending on the performance of the first camera 31 and the shape of the workpiece B, the movement mechanism 32 may include an X-direction slider that moves the Y-direction slider 33 in the X direction, or may move the first camera 31 in only one of the X and Y directions, or may not be provided. Furthermore, if the shooting range of the first camera 31 is such that the entire holding table 21 or workpiece B located in the shooting area E1 can be photographed in one go, the first camera 31 may be configured to be fixed and supported at a fixed point.

[0016] The robot arm 4 is an example of a moving body according to the present invention, and is equipped with an individual photographing unit 5 and a binding device 6C, and moves the individual photographing unit 5 and the binding device 6C to desired positions in the binding area E2. The robot arm 4 of this embodiment includes a movement mechanism 46, a robot arm main body 40, and a controller 49.

[0017] The moving mechanism 46 moves the robot arm main body 40. The moving mechanism 46 in this embodiment includes a Y-direction slider 461 suspended on the beam 13 of the base 11. The Y-direction slider 461 moves the robot arm main body 40 in the Y direction. However, the specific configuration of the moving mechanism 46 is not particularly limited, and may include, for example, a mechanism for moving the robot arm main body 40 in the X direction. Furthermore, if the operating range of the robot arm main body 40 can cover the entire binding area E2 without relying on the moving mechanism 46, the moving mechanism 46 may not be provided.

[0018] The robot arm body 40 is a ceiling-suspended vertical articulated robot, and is installed facing downward on a Y-direction slider 461 suspended on a beam 13 in the binding area E2. Specifically, the robot arm body 40 includes a base unit 41, a plurality of arms 42, an end effector 43, and a plurality of joint units 44. Note that the robot arm body 40 is not limited to a vertical articulated robot, as long as it can move the mounted individual photographing unit 5 and binding device 6C.

[0019] The multiple arms 42 are connected in series with a base unit 41 as a base end. The base unit 41 is mounted on a Y-direction slider 461 of the movement mechanism 46 and supported so as to be movable in the Y direction. The multiple joint units 44 rotatably connect the base unit 41, the multiple arms 42, and the end effector 43. Each joint unit 44 is provided with a motor 441 that drives the arm 42 (or end effector 43) connected to the tip side of the joint unit 44, and an encoder 442 that detects the position (speed) of the motor 441 and outputs the position (speed) to the controller 49. The end effector 43 is connected to the tips of the multiple arms 42. The end effector 43 is equipped with an individual photographing unit 5 and a binding device 6C. Note that the specific configuration of the tip of the robot arm main body 40 is not particularly limited as long as it is equipped with the individual photographing unit 5 and the binding device 6C. For example, the individual photographing unit 5 may be fixed to the joint unit 44 on the most distal end side, and the binding device 6C may be connected as an end effector via a tool changer.

[0020] The controller 49 controls the operation of each part of the robot arm 4 based on a control command from the control device 7C. Specifically, the controller 49 operates each motor 441 and the moving mechanism 46, and outputs information acquired by each encoder 442 to the control device 7C. Note that the controller 49 may locally control the operation of the individual photographing unit 5 and binding device 6C mounted thereon based on a control command from the control device 7C.

[0021] <Individual Photography Unit> The individual photography unit 5 is mounted on the tip of the robot arm 4 and individually photographs the intersections P of the rebars S to be bundled in the binding area E2 with a higher resolution than that of the overall photography unit 3. Specifically, the individual photography unit 5 includes a second camera 51, an elevation motor 52, and a lighting unit 53. The second camera 51 is attached to the end effector 43 of the robot arm 4 facing downward and photographs the intersections P of the rebars S to be bundled from above. The second camera 51 is movable toward the tip (up and down) relative to the end effector 43. In this embodiment, the second camera 51 is, for example, an RGB camera that acquires image information (color images) of the intersections P to be bundled and outputs the image information to the control device 7C. The second camera 51 is an example of a second information acquisition unit according to the present invention. Note that the sensor type of the second camera 51 is not particularly limited as long as it can acquire an image of at least one intersection P (signal information of the rebar intersections including the image). The lifting motor 52 is a drive source that moves (lifts) the second camera 51 toward the tip (up and down) relative to the end effector 43. The lighting unit 53 is disposed slightly forward of the imaging direction of the second camera 51 and around the imaging range, and illuminates the object to be imaged by the second camera 51. The lighting unit 53 of this embodiment has multiple light sources (projectors, not shown) that can illuminate the object to be imaged by the second camera 51 from different angles. The lighting unit 53 may be configured to emit patterned light from multiple directions and to acquire three-dimensional information about the area around the intersection P in cooperation with the second camera 51.

[0022] 3 is a side view of the binding device 6C in a position when performing a binding operation. The binding device 6C is mounted on the tip of the robot arm 4. The binding device 6C includes a rebar binding machine 61C that binds the intersections P of the rebars S that constitute the workpiece B with wire W, a slack forming unit 62C that pulls out the wire W from a reel 63C and forms slack in the wire W between the binding machine 61C and the reel 63C, and a control unit 64C that causes the rebar binding machine 61C to perform the binding operation and the slack forming unit 62C to form slack in the wire W in accordance with an operation command from a control device 7C.

[0023] The rebar binding machine 61C has an entrance section 611C through which two wires W are fed from outside the housing along the feed direction F shown in the figure, and the two wires W fed into the interior from the entrance section 611C are wound around the rebar S, and the two wires W wound around the rebar S are fed in the reverse feed direction R to wrap around the rebar S and cut it, and then the wires W are twisted and the rebar S is bound with the wires W.

[0024] For this reason, the binding machine 61C is equipped with a wire feeding section that feeds the wire W, a wire guide 612C that guides the wire W, a curl guide 613C and a guide guide 614C that wind the wire W around the reinforcing bar S, a cutting section that cuts the wire W wound around the reinforcing bar S, and a binding section that twists the wire W wound around the reinforcing bar S.

[0025] The wire guide 612C is provided in front of the entrance 611C and guides the two wires W to enter the entrance 611C along the feed direction F.

[0026] The wire feeding unit is located inside the entrance portion 611C, and clamps two wires W between a pair of feed gears and feeds them in a feed direction F. The wire feeding unit is equipped with a feed motor 615C (see FIG. 2) that serves as a drive source. This feed motor 615C feeds the two wires W in the feed direction F by driving it in a forward rotation, and the wires W can be wound around the rebar S by the curl guide 613C and the induction guide 614C located at the end of the motor. In addition, the feed motor 615C feeds the two wires W in the reverse feed direction R by driving it in a reverse rotation, and the rebar S can be tightened by the wires W.

[0027] The cutting unit is located inside the entrance 611C, further back than the wire feed unit. The cutting unit has a movable blade and a fixed blade (not shown), and the movable blade shares a drive source with the bundling unit. The movable blade can be moved toward the fixed blade by a torsion motor 616C (see FIG. 2), which is the drive source for the bundling unit, to cut the two wires. The drive source for the cutting unit may be provided separately and independently.

[0028] 3 is supported by an end effector 43 at the tip of the robot arm 4, and performs the binding operation with the rotation axis Zr of the end effector 43 parallel to the Z direction (vertical up-down direction) described above. The binding device 6C is set so that the position where the wire W is bound to the rebar S is located on the axis of the rotation axis Zr, and during binding, the robot arm 4 positions the binding device 6C so that the intersection P of the rebar S is located on the axis of the rotation axis Zr.

[0029] The curl guide 613C and the leading guide 614C are located at the tip end (the lower end during the bundling operation) of the bundling machine 61C, and are arranged on both sides of the aforementioned pivot axis Zr. The base end of the curl guide 613C is located at the end of the inlet 611C in the feed direction F, and a guide path is formed inside the curl guide 613C to curl the wire W as it moves from the base end to the tip end.

[0030] The leading guide 614C is disposed opposite the curl guide 613C, and has a guide path formed inside that receives the wire W curled by the curl guide 613C from the tip end and guides the wire W to the base end while maintaining the curled state. The curl guide 613C and the leading guide 614C cooperate to deform the wire W into a loop and wind it around the reinforcing bar S.

[0031] The bundling unit has a locking member that captures the wire W wound around the reinforcing bar S between the base end of the induction guide 614C and the base end of the curl guide 613C. The locking member is rotatably supported inside the bundling machine 61C about a rotation axis that is concentric with the aforementioned pivot axis Zr, and a torque for rotational drive is applied to the locking member by the aforementioned torsion motor 616C. The locking member is rotationally driven by the torsion motor 616C after the wire W is cut by the cutting unit, and can twist both ends of the wire W to bind the reinforcing bar S.

[0032] Two reels 63C of the wire W are rotatably supported side by side on one side of the bundling machine 61C in the direction along the rotation axis Zr (the upper side during bundling operation). The two reels 63C are rotatable around an axis extending perpendicular to the plane of the paper in FIG. 3 and are arranged side by side in the same direction.

[0033] 3, the slack forming unit 62C is disposed on one side of the binding machine 61C and the two reels 63C in the orthogonal direction Xw that is perpendicular to the pivot axis Zr. The slack forming unit 62C has a first slack forming unit 621C and a second slack forming unit 622C that move past each other, and a slack forming motor 623C that serves as a drive source for these moving past each other.

[0034] The aforementioned feed direction F of the wire W is generally parallel to a plane parallel to the pivot axis Zr and the orthogonal direction Xw. Furthermore, the upstream side of the feed direction F of the wire W is inclined slightly upward in the plane of the paper in Figure 3 with respect to the orthogonal direction Xw. Both the first slack forming unit 621C and the second slack forming unit 622C hold rollers around which the two wires W are wound.

[0035] The first slack forming unit 621C and the second slack forming unit 622C pass each other generally along the feed direction F, thereby extending the path length of the wire W from the reel 63C to the inlet 611C of the binding machine 61C and pulling out the wire W from the reel 63C. Furthermore, the first slack forming unit 621C and the second slack forming unit 622C can impart slack to the wire W by the amount pulled out from the reel 63C by performing a return operation after the passing operation.

[0036] The two wires W are required to be fed into the entrance 611C of the binding machine 61C in a direction close to the feed direction F, i.e., at an incident angle close to the feed direction F. The feed direction F is a direction suitable for deforming the wire W into an appropriate loop shape using the curl guide 613C and the induction guide 614C located at the end of the wire W's travel direction. In order to supply the wire W to the entrance 611C of the binding machine 61C along the feed direction F, the slack forming unit 62C is disposed so that the path from the downstream second slack forming unit 622C to the entrance 611C of the binding machine 61C is along the feed direction F. During the passing operation, the second slack forming unit 622C moves away from the entrance 611C of the binding machine 61C along the feed direction F.

[0037] For this reason, the binding device 6C is disposed so that the slack forming portion 62C protrudes largely to one side (the right side of the paper in FIG. 3 ) in the direction perpendicular to the binding machine 61C (swivel axis Zr). Note that the second camera 51 and the lighting unit 53 of the individual photographing unit 5 are disposed on the left side of the binding machine 61C of the binding device 6C in FIG. 3 .

[0038] <Control Device> The control device 7C is a computer that comprehensively controls the bundling 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 operating means through which the user performs various operations to operate the control device 7C, and includes, for example, a pointing device such as a mouse and a keyboard. The display unit 73 is configured, for example, with a liquid crystal display, an organic EL display, or other display, and displays various information based on a display signal from the control unit 77C. Note that the display unit 73 may be a touch panel that also serves as part of the operation unit 72, or may output audio.

[0039] The storage unit 76C is a memory configured with RAM (Random Access Memory), ROM (Read Only Memory), etc., and stores various programs and data. It also functions as a work area for the control unit 77C. In this embodiment, a bundling processing program 761C for executing bundling processing, which will be described later, is pre-stored in the storage unit 76C. The storage unit 76C, which serves as a recording device, also stores image data 762C captured by the first camera 31 and the second camera 51, map data 763C containing information about the workpiece B, first bundling condition data 764C storing various bundling conditions selected and set by the user, which will be described later, second bundling condition data 765C storing various bundling conditions prepared in advance for executing multiple operation modes, which will be described later, machine body information data 766C indicating the three-dimensional position of the entire surface of the bundling device 6C, and surrounding information data 767C indicating the three-dimensional position of the entire surface of obstacles around the robot arm 4 deployed in the robot arm 4 coordinate system.

[0040] The control unit 77C is configured by, for example, a CPU (Central Processing Unit) and controls the operation of each unit of the control device 7C. Specifically, the control unit 77C operates each unit of the control device 7C based on the operation content of the operation unit 72, loads a program stored in advance in the storage unit 76C, and executes various processes in cooperation with the loaded program.

[0041] <Intersection Information Acquisition Process> The control unit 77C executes the bundling process program 761C described above, thereby functioning as an intersection information acquisition means for acquiring information about the intersection P where the multiple reinforcing bars S of the work B intersect. As described above, the control unit 77C controls the device main body 10C to perform bundling at the intersection P where the multiple reinforcing bars S of the work B intersect with the wire W as a bundling body.

[0042] 4 is a schematic diagram of the workpiece B held on the support plate 211 of the holder 21 of the workpiece holder 2, viewed from above in the Z direction. Note that in this schematic diagram, the number of reinforcing bars S on the workpiece B is shown to be fewer than in FIG. 1. Also, the multiple double circles in the figure are marks indicating the positions of the intersection points P, and do not represent objects that actually exist on the workpiece B. Furthermore, because there are so many reinforcing bars S and intersection points P in the figure, only some are labeled. The same applies to the other figures, Figures 9 to 15.

[0043] The workpiece B has a grid-like configuration in which a plurality of rebars S arranged in the Y direction are arranged on top of a plurality of rebars S arranged in the X direction. The rebars S arranged in the X direction and the rebars S arranged in the Y direction may be arranged upside down. While the plurality of rebars S arranged in each direction are illustrated as being arranged at equal intervals, the rebars S may be spaced apart unevenly. Furthermore, their lengths may also be uneven. The positions where the center lines of the plurality of rebars S arranged in the X direction and the plurality of rebars S arranged in the Y direction intersect as viewed from the Z direction are intersection points P, and the bundling system 1C can target these intersection points P for bundling.

[0044] The control of the bundling operation by the control unit 77C requires information about the intersections P to identify the positions of the multiple intersections P where the multiple rebars S of the work B intersect. For this reason, the control unit 77C, which functions as an intersection information acquisition means, executes a first acquisition process to acquire the positions of the intersections P from image data 762C captured by the first camera 31 or the second camera 51, and a second acquisition process to acquire map data 763C from outside the bundling system 1C.

[0045] The control unit 77C may be configured to be capable of executing only one of the first acquisition process and the second acquisition process. For example, if the control unit 77C is configured to be capable of executing only the first acquisition process, the storage unit 76C may be configured not to store the map data 763C.

[0046] In the first acquisition process performed by the control unit 77C, when the image data 762C of the workpiece B on the support table 21 photographed by the first camera 31 or the second camera 51 is two-dimensional planar image data, the position of the outline of each rebar S in the image is extracted using well-known image processing, the center line passing through the center of each rebar S is determined, and the positions where the center lines of each rebar S intersect are identified and acquired as the positions of the intersection points P. Furthermore, height information of the intersection points P may be obtained by photographing the workpiece B on the support table 21 two or more times while changing the relative positions of the first camera 31 or the second camera 51 and the workpiece B, and calculating the height of each position in the image using parallax. This provides three-dimensional position data of all intersection points P of the rebars S of the workpiece B, which is then expanded into the coordinate system of the robot arm 4 to acquire information about the intersection points P for identifying the positions of the intersection points P.

[0047] Furthermore, if the image data 762C of the first camera 31 or the second camera 51 is image data that includes three-dimensional position information, information regarding the intersection P is obtained to identify the position of the intersection P by expanding the position information indicated by the image data into the coordinate system of the robot arm 4.

[0048] The second acquisition process performed by the control unit 77C is a process in which the control device 7C is provided with a communication device (not shown) that communicates with the outside of the bundling system 1C, and requests and acquires the map data 763C from another external information processing terminal via a communication network, etc. Alternatively, the control device 7C may be provided with a reading device (not shown) that reads a storage medium that stores the map data 763C, and acquires the map data 763C by reading from the storage medium.

[0049] The map data 763C records design information of the work B and includes basic dimensions and three-dimensional position information of each rebar S, as well as three-dimensional position information of each intersection P. Therefore, the control unit 77C that executes the second acquisition process acquires information about the intersection P for identifying the position of the intersection P by expanding the three-dimensional position information of each intersection P obtained from the map data 763C into the coordinate system of the robot arm 4.

[0050] <Binding Condition Selection Process> The control unit 77C executes the above-described binding processing program 761C to receive a selection of binding conditions for the wire W at the intersections P of the multiple rebars S of the workpiece B, generate first binding condition data 764C, and store the data in the memory unit 76C. The control of the binding operation by the control unit 77C is based on various binding conditions. The user can set and input the various binding conditions from the operation unit 72, which serves as a condition input unit, and the control unit 77C selects the set various binding conditions and controls the binding operation. Here, various binding conditions will be described. Note that the binding conditions described below are merely examples and are not limited to these.

[0051] The bundling conditions included in the first bundling condition data 764C include "presence or absence of bundling," "bundling direction," "number of bundling times," and "bundling strength" for each intersection P. Further, the bundling condition includes "bundling order" for multiple intersections P of the work B. These bundling conditions will be explained individually.

[0052] The bundling condition "whether to bundle or not" is selected individually for all intersections P in work B. "whether to bundle or not" is a setting for whether each intersection P is to be bundled or not. In other words, it is possible to select whether to bundle or not for each intersection P in work B. For "whether to bundle or not," the user inputs a setting from the operation unit 72 for whether or not each intersection P of work B is to be bundled, and the control unit 77C selects the intersections P that are to be bundled and performs the bundling.

[0053] The "binding direction" as a binding condition is selected individually for each intersection P within the workpiece B that is the target of binding. The "binding direction" will be explained with reference to FIGS. 5 and 6. FIGS. 5 and 6 are plan views showing two types of binding directions for the intersection P. The wire W bound to the intersection P between the X-direction rebar S and the Y-direction rebar S is inclined at approximately 45° with respect to both the X and Y directions when viewed from above in the Z direction, either in the direction shown in FIG. 5 or in the direction shown in FIG. 6. Here, the binding direction extending diagonally upward to the right in FIG. 5 is defined as the first direction, and the binding direction extending diagonally upward to the left in FIG. 6 is defined as the second direction. The "binding direction" as a binding condition indicates whether the wire W will be oriented in the first or second direction. The "binding direction" here refers to the direction along which the wire W will be oriented after binding when viewed perpendicular to the planar workpiece B.

[0054] The binding device 6C of the binding system 1C is designed to use two wires W in one binding operation, and the two wires W shown in Figures 5 and 6 are shown in a state after one binding operation. The same applies to the subsequent figures. After binding, both ends of each wire W are twisted to form a wound portion, but the wound portion is not shown in Figure 5 and subsequent figures.

[0055] The "number of bundling times" as a bundling condition is selected individually for all intersections P targeted for bundling within the workpiece B. The "number of bundling times" will be explained with reference to FIG. 7. The "number of bundling times" is the number of bundling operations performed by the bundling device 6C for one intersection P. The number of wires W used for bundling is proportional to the number of bundling operations. FIG. 7 shows the bundling state when the "number of bundling times" is set to two. As mentioned above, two wires W are used for one bundling operation, so four wires W are used to bind the intersection P. The "number of bundling times" can be selected from one to multiple times. However, there is a limit to the number of times because if the number of times is repeated, the bundle of wires W bound at the intersection P becomes too large.

[0056] Furthermore, the "number of times of bundling" as a bundling condition may be selectable in combination with the aforementioned "bundling direction." For example, both the first direction and the second direction may be selected as the "bundling direction," and the "number of times of bundling" may be selected for each direction. FIG. 8 shows the bundling state when one bundling operation is selected for the first direction and one bundling operation is selected for the second direction. In this case, the order of the bundling operation in the first direction and the bundling operation in the second direction may also be selectable as a bundling condition.

[0057] The "binding strength" as a binding condition is selected individually for all intersections P to be bound within the workpiece B. The "binding strength" indicates the winding strength of the wire W that binds the intersections P. This "binding strength" may be selected numerically or by a level of strength (e.g., strong, medium, weak, etc.). As described above, the binding device 6C forms a winding portion by twisting both ends of the wire W. The "binding strength" can be determined by the magnitude of the torque generated by the torsion motor 616C of the binding device 6C, which twists the wire W. For example, if there is a correlation between the torque output by the torsion motor 616C and the current value flowing through the torsion motor 616C, the control unit 77C monitors the current value flowing through the torsion motor 616C of the binding device 6C and controls the torsion motor 616C to twist both ends of the wire W until the current value reaches a value that results in a torque corresponding to the selection of the "binding strength."

[0058] The "binding order" as a binding condition will now be described. The "binding order" can be selected from patterns such as (1) outer edge first, (2) center first, (3) horizontal feed (Y direction), (4) vertical feed (X direction), and (5) corner first. Note that these patterns are merely examples, and other patterns may also be selectable. For example, when the user selects and sets one of patterns (1) to (5) through the operation unit 72, the control unit 77C performs binding for the multiple intersections P in accordance with the order determined in one of the set patterns.

[0059] 9 shows the order of progress for each intersection P in the (1) outer edge first pattern. When this (1) outer edge first pattern is selected, the control unit 77C performs bundling with priority to the intersections P located on the outer edge of the area where all the intersections P to be bundled of the work B exist. For example, if all the intersections P shown in FIG. 9 are to be bundled and the area where the intersections P exist is rectangular, the control unit 77C performs bundling with priority to the intersections P located on the outer edges along the four corners and four sides of the rectangular area.

[0060] In this (1) outer edge first pattern, bundling starts from an intersection P located at one of the four corners, and bundling is performed for each intersection P while going around the outer edge of the area where the intersection P is located in a predetermined direction. The user may select which of the four corners to start bundling from using the operation unit 72, or a corner located in a predetermined position may be predetermined as the start position. Also, while FIG. 9 illustrates an example in which bundling is performed by going around in a clockwise direction on the paper surface of the figure, this is not limiting and may also be counterclockwise. The direction of the rounding may be selected by the user using the operation unit 72, or a predetermined direction of the rounding may be predetermined.

[0061] Furthermore, in the (1) outer edge-first pattern, for intersections P other than the outer edge, as shown in the example of Figure 9, the robot may circle the outer edge of the region consisting of the remaining intersections P in a predetermined direction, performing bundling for each intersection P, and then repeating the same circle inward until bundling is completed for all intersections P. In this case, it is preferable that the direction of each circle is reversed from the previous circle. The robot arm main body 40 of the robot arm 4 that moves the bundling device 6C performs the bundling operation while rotating with its rotation axis about an axis along the Z direction aligned with the center position of the workpiece B. However, the rotation angle range of the robot arm main body 40 about the axis along the Z direction may be limited to approximately 360°. When performing bundling by circle as described above, alternating the rotation direction can reduce the impact of the limited rotation angle range of the robot arm main body 40. Note that if the rotation angle range of the robot arm main body 40 is sufficiently wide, it may also be continuously rotated in a fixed direction.

[0062] 10 shows the order of progress for each intersection P in the (2) center-first pattern. When this (2) center-first pattern is selected, the control unit 77C starts bundling from the intersection P that is closest to the center of the area in which all of the intersections P to be bound of the workpieces B exist. The center of the area may be defined as, for example, the geometric center (center of gravity). Also, if the area in which all of the intersections P to be bound of the workpieces B exist is not rectangular, the center of gravity of the rectangle in which the area is inscribed may be defined as the center of the area.

[0063] For example, if all the intersections P shown in Figure 10 are targets of bundling and the area in which the intersections P exist is rectangular, the control unit 77C, when (2) selecting a center-first pattern, starts from the central intersection P, moves to the intersections P located around it, and performs bundling in order toward the outer intersections P while going around.

[0064] In this (2) center-first pattern, as shown in Figure 10, the rotation direction is alternately switched between clockwise and counterclockwise on the paper surface for each revolution. The reason for this is the same as the reason for alternately switching the rotation direction in the (1) outer edge-first pattern described above. Therefore, if the rotation angle range of the robot arm main body 40 is sufficiently wide, the robot may rotate continuously in a fixed direction.

[0065] 11 shows the order of progress for each intersection P in the (3) horizontal feed pattern. When the (3) horizontal feed pattern is selected, the control unit 77C starts binding from the row of intersection P closest to one side in the Y direction among the rows of intersection P lined up in the X direction in the area where all of the intersections P to be bound of the work B exist, and continues binding row by row in the Y direction.

[0066] The user may select and set from which end of the row in the Y direction among the rows of intersection points P aligned along the X direction the bundling should start, or from which end of the row of intersection points P aligned along the X direction the bundling should start, using the operation unit 72, or may decide this in advance. Also, Figure 11 illustrates an example in which the bundling progress direction in a row of intersection points P aligned along the X direction is opposite to that of the previous row. This reduces the amount of movement of the work B to all of the intersection points P, making it possible to perform the work quickly.

[0067] 11, the rows of intersections P aligned along the X direction are bound row by row in the Y direction, but this is not limiting. For example, among the rows of intersections P aligned along the X direction, binding may be performed alternately between the row on one end side in the Y direction and the row on the other end side, and binding may be completed at the middle row in the Y direction.

[0068] 12 shows the order of progress for each intersection P in the (4) vertical feed pattern. When the (4) vertical feed pattern is selected, the control unit 77C starts binding from the row of intersection P closest to one side in the X direction among the rows of intersection P lined up in the Y direction in the area where all of the intersections P to be bound of the work B exist, and continues binding row by row in the X direction.

[0069] The user may select and set from which end of the X-direction row of multiple rows of intersection points P aligned along the Y direction bundling should begin, or from which end of the row of intersection points P aligned along the Y direction bundling should begin, using the operation unit 72, or may decide this in advance. Also, Figure 12 illustrates an example in which the direction of bundling in a row of intersection points P aligned along the Y direction is opposite to that of the previous row. This reduces the amount of movement of the work B to all of the intersection points P, making it possible to perform the work quickly.

[0070] 12, the rows of intersections P aligned along the Y direction are bound row by row in the X direction, but this is not limiting. For example, among the rows of intersections P aligned along the Y direction, binding may be performed alternately between the row on one end side in the X direction and the row on the other end side, and binding may be completed at the middle row in the X direction.

[0071] 13 shows the order of progress for each intersection P in the (5) corner-first pattern. When this (5) corner-first pattern is selected, the control unit 77C first performs bundling on the intersections P located at the corners of the area where all the intersections P to be bundled of the work B exist. For example, if all the intersections P shown in FIG. 13 are to be bundled and the area where the intersections P exist is rectangular, the control unit 77C identifies the intersections P located at the corners of the rectangle and performs bundling first.

[0072] In this (5) corner-first pattern, bundling is performed for each intersection P located at the four corners in a predetermined order. The order in which bundling is performed for each intersection P at the four corners may be selectable and set by the user using the operation unit 72, or a default order may be determined in advance. For example, bundling may be performed in a circular manner starting from the first intersection P of the four corners, or bundling may be performed for the intersection P located diagonally opposite the first intersection P of the four corners, and similar bundling may be performed for the remaining two corner intersections P.

[0073] In addition, in this (5) corner-first pattern, any of the above-described patterns (1) to (4) may be executed for the bundling order for intersections P other than corners. Therefore, when selecting the (5) corner-first pattern, any of patterns (1) to (4) may be selectable for intersections P other than corners. This selection may be made selectable by the user via the operation unit 72, or any of patterns (1) to (4) may be preset as a default setting.

[0074] Incidentally, when a selection is made regarding the "order of bundling" as a bundling condition, the control unit 77C needs to identify "intersections P located at corners" and "intersections P located on outer edges" within the area where the intersections P exist. Fig. 14 is an explanatory diagram in which "intersections P located at corners" are labeled "A," "intersections P located on outer edges" are labeled "B," and other intersections P are labeled "C."

[0075] The control unit 77C identifies an intersection P with two adjacent intersections P, such as the intersection P marked with "A" in the region Ra surrounded by the two-dot chain line in Fig. 14, as an "intersection P located at a corner." The control unit 77C also identifies an intersection P with three or fewer adjacent intersections P, such as the intersection P marked with "B" in the region Rb surrounded by the two-dot chain line in Fig. 14, as an "intersection P located at an outer edge." The control unit 77C then identifies an intersection P with four adjacent intersections P, such as the intersection P marked with "C" in the region Rc surrounded by the two-dot chain line in Fig. 14, as an intersection P other than an "intersection P located at a corner" and an "intersection P located at an outer edge."

[0076] The above-mentioned "adjacent intersections P" refers to intersections adjacent to each other via a reinforcing bar S. In other words, it refers to intersections P adjacent to each other in the X or Y direction, and does not include intersections P diagonally adjacent to each other in the X or Y direction. Furthermore, the "intersection P located on the outer edge" refers to an intersection with three or fewer other adjacent intersections P, and therefore also includes an "intersection P located at a corner" with two other adjacent intersections P.

[0077] Furthermore, patterns (1) to (5) of the "binding order" have been explained using an example in which all intersections P are targets for binding and the area in which the intersections P exist is rectangular. However, there are cases in which some intersections P are not targets for binding, or in which the work B is not a rectangular planar grid but has a partially missing shape. For example, if the work B is installed in a location where there are obstacles such as pillars, a portion of the rebar S is removed to avoid the obstacle before or after the binding work for the intersections P, resulting in a partially missing shape. Furthermore, intersections P within an area where a portion of the rebar S is expected to be removed due to an obstacle may not be targets for binding.

[0078] 15 is a schematic diagram of the workpiece B on the support table 21 viewed from above, showing a case where some of the intersections P are not subject to binding or where part of the rebar S of the workpiece B has been removed, resulting in a missing part of the rectangle and an irregular shape of the area to be bound. Note that all of the intersections P indicated by double circle marks in this figure are considered to be subject to binding.

[0079] Even in the case of an area with such an irregular shape, the control unit 77C can perform binding in the order specified in the patterns (1) to (5) by identifying the "intersection P located at the corner," the "intersection P located at the outer edge," and other intersections P using the definitions described above.

[0080] For example, as shown in FIG. 15, all intersections P numbered on the inside are "intersections P located on the outer edge," and among these intersections P, the intersections P numbered "1," "7," "13," "17," and "21" are "intersections P located at the corners."

[0081] Therefore, in the (1) outer edge-first pattern, bundling can be performed starting with the intersections P numbered "1" to "33." In this case, bundling can be performed in numerical order, for example. In the (2) center-first pattern, the center of the area is found according to the definition described above, and bundling can be performed starting with the intersection P closest to the center. In the (3) horizontal feed pattern, bundling can be performed in the order described above for multiple rows of intersections P lined up along the X direction. In the (4) vertical feed pattern, bundling can be performed in the order described above for multiple rows of intersections P lined up along the Y direction. In the (5) corner-first pattern, bundling can be performed starting with the intersections P numbered "1," "7," "13," "17," and "21."

[0082] As described above, the bundling system 1C allows the user to select and set all of the above-mentioned bundling conditions, including "whether to bundle," "bundling direction," "number of bundling times," "bundling strength," and "bundling order," via the operation unit 72. When these selections are made, the control unit 77C generates first bundling condition data 764C that defines the bundling conditions according to the selections and records it in the storage unit 76C. The control unit 77C can read out this first bundling condition data 764C any number of times, and can read out the same first bundling condition data 764C for multiple workpieces B each time and control the bundling operation according to the same bundling conditions. Note that if the user selects and sets different binding conditions via the operation unit 72, new first bundling condition data 764C is generated and recorded in the storage unit 76C. In this case, each of the first bundling condition data 764C is recorded with identification information so that the existing first bundling condition data 764C and the new first bundling condition data 764C can be distinguished, and the configuration is such that individual first bundling condition data 764C can be selected to perform bundling operation control.

[0083] <Operation Modes as Binding Conditions> In addition, in order to reduce the user's workload of selecting and setting all of the binding conditions via the operation unit 72, the storage unit 76C stores a plurality of second binding condition data 765C, each of which includes predetermined content such as "whether or not to bind," "binding direction," "number of bindings," "binding strength," and "binding order." Each of the plurality of second binding condition data 765C is individually associated with a plurality of operation modes, and the control unit 77C can read out the corresponding second binding condition data 765C in accordance with the selected operation mode and execute the binding operation for each intersection P. Examples of the operation modes include a "standard mode," a "strength-priority mode," and a "speed-priority mode." These various operation modes will be described below.

[0084] The "standard mode" is a mode for performing standard bundling. In principle, this "standard mode" can be selected and executed by the user. Furthermore, even if the user inputs a bundling operation without selecting "whether to bundle," "bundling direction," "number of bundlings," "bundling strength," or "bundling order," and without selecting an operation mode, the "standard mode" is automatically selected and the bundling operation is executed. In the "standard mode," for example, the "whether to bundle" setting is configured so that all intersections P in workpiece B are targeted for bundling. Furthermore, the "bundling direction" setting is configured so that all intersections P in workpiece B are in either the first direction or the second direction, and all intersections P have a different "bundling direction" from other adjacent intersections P. In other words, bundling is performed in a staggered arrangement in which all intersections P in workpiece B are alternately arranged in the first direction and the second direction in the X direction, and all intersections P in workpiece B are alternately arranged in the first direction and the second direction in the Y direction. The "number of times of bundling" is set so that bundling is performed once for all intersections P in the work B. The "bundling strength" is set to a default standard value. The "bundling order" is set to (1) outer edge first.

[0085] "Strength Priority Mode" is a mode for performing binding with a higher binding strength than "Standard Mode." "Strength Priority Mode" has the same settings as "Standard Mode" except for "Binding Strength." "Strength Priority Mode" is set so that "Binding Strength" is a higher value than the default standard value (for example, about 1.2 to 2 times the standard value).

[0086] The "speed priority mode" is a mode for performing bundling more quickly than the "standard mode." The "speed priority mode" is the same as the "standard mode" in various setting conditions except for the "bundling direction" and "bundling order." In the "speed priority mode," the "bundling direction" is aligned in the first direction (or the second direction) for all intersections P within the workpiece B, reducing the frequency of the bundling device 6C's rotation around the axis along the Z direction to speed up consecutive bundling operations. Furthermore, in the "speed priority mode," either (1) outer edge first or (2) center first is set for the "bundling order." In either of these "bundling orders," the path from the first intersection P to the last intersection P does not pass through the same position twice, thereby speeding up the bundling operation. In addition, the distance between the first intersection P where binding begins and the last intersection P is closer than in (3) horizontal feed and (4) vertical feed, so when binding multiple works B in succession, the return operation to the starting position for binding the next work B can be made faster.

[0087] <Operation of the bundling system> Next, the operation of the bundling system 1C will be described. Fig. 16 is a flowchart showing the procedure when the bundling system 1C executes the bundling process. The CPU of the control unit 77C of the control device 7C executes the following bundling process in accordance with a bundling process program 761C.

[0088] By executing the bundling processing program 761C, the control unit 77C functions as an intersection information acquisition means, and executes processing to acquire information about the intersection P where multiple rebars S of the work B intersect. In this case, the control unit 77C determines whether or not the user has selected to use the map data 763C via the operation unit 72, for example (step S101).

[0089] 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, if the map data 763C is not prepared in the storage unit 76C, the control unit 77C acquires the map data 763C by external communication or by reading from a recording medium.

[0090] On the other hand, if the use of map data 763C is not selected, the control unit 77C photographs the entire work B on the holding table 21 of the work holding unit 2 arranged in the photographing area E1 of the stand 11 using the first camera 31 of the overall photographing unit 3 (step S105).

[0091] When the map data 763C is read or the workpiece B is photographed by the first camera 31, the control unit 77C acquires three-dimensional position data of all intersections P of the rebars S of the workpiece B from the map data 763C or image data 762C, and expands this data into the coordinate system of the robot arm 4. This makes it possible to identify the positions of all intersections P (step S107). Therefore, the control unit 77C functions as an intersection identification means.

[0092] Next, the control unit 77C drives the drive motor 23 of the workpiece holder 2 to move the holder 21 and the workpiece B to the bundling area E2 (step S109).

[0093] Next, the control unit 77C determines whether the user has selected to use the first bundling condition data 764C, which individually selects and sets each bundling condition (step S111). If the user has selected to use the first bundling condition data 764C, the control unit 77C further reads the first bundling condition data 764C from the storage unit 76C (step S113). If multiple pieces of first bundling condition data 764C are stored in the storage unit 76C, the control unit 77C reads a specific piece of first bundling condition data 764C selected by the user. The process then proceeds to step S121.

[0094] On the other hand, if the use of the first bundling condition data 764C is not selected, the control unit 77C determines whether an operation mode is selected (step S115). If an operation mode is selected, the control unit 77C determines whether the operation mode should be executed based on the user's selection: "standard mode," "strength priority mode," or "speed priority mode." Depending on the selected operation mode, the control unit 77C reads the setting conditions from the corresponding second bundling condition data 765C stored in the storage unit 76C. The process then proceeds to step S121.

[0095] Furthermore, if it is determined in step S115 that no operation mode has been selected, the control unit 77C selects the "standard mode" (step S119), reads the setting conditions from the corresponding second binding condition data 765C in the storage unit 76C, and then proceeds to step S121.

[0096] In step S121, the control unit 77C identifies the intersection P of the work B that will be first bound based on the selection of "whether to bind" and "order of binding" among the binding conditions acquired in step S113, step S117, or step S119. Furthermore, the control unit 77C calculates the position coordinates of the intersection P that will be first bound based on the information about the intersection P for identifying the position of the intersection P acquired in step S107.

[0097] Then, the control unit 77C controls the robot arm 4 to position the second camera 51 at the photographing position of the intersection P where binding will be performed first, and moves the second camera 51 closer to the intersection P by driving the lifting motor 52 (step S121).

[0098] Next, the control unit 77C causes the second camera 51 to photograph the intersection P (step S123). By photographing the intersection P closer to the second camera 51 than the first camera 31, the second camera 51 can determine the position of the intersection P with higher accuracy based on the image data 762C.

[0099] Therefore, the control unit 77C recalculates the position of the intersection P based on the image data 762C captured by the second camera 51 (step S125), and positions the binding position of the binding device 6C by moving it closer to the newly obtained position of the intersection P (step S127). At this time, the control unit 77C determines the orientation of the binding device 6C around the axis along the Z direction in accordance with the "binding direction" included in the binding conditions acquired in step S113, step S117, or step S119.

[0100] Then, the control unit 77C activates the binding device 6C to bind the intersection P with the wire W (step S129). At this time, the control unit 77C binds the intersection P with the wire W in accordance with the "number of times of binding" and "binding strength" (including "binding direction" when "number of times of binding" and "binding direction" are selected in combination) of the binding conditions acquired in step S113, step S117, or step S119.

[0101] Then, the control unit 77C determines whether the intersection P where bundling was performed is the last intersection P or not (step S131), based on the positions of all intersections P based on the information about intersections P for identifying the positions of intersections P acquired in step S107, and the selection of "whether or not to bundle" and "order of bundling" among the bundling conditions acquired in step S113, step S117, or step S119. As a result, if the intersection P where bundling was performed is not the last intersection P, the control unit 77C identifies the next intersection P to be bundled (step S133) and repeats the processes from step S121 to step S133. On the other hand, if the intersection P where bundling was performed is the last intersection P, the control unit 77C ends the bundling process for the work B.

[0102] <Technical Effects of the Invention> The control device 7C of the binding system 1C is equipped with a control unit 77C that can select the binding conditions for the wire W at the intersections P of the reinforcing bars S of the workpieces B. Therefore, by appropriately selecting the binding conditions, it is possible to perform appropriate binding processing with the wire W for various workpieces B, and it is possible to provide a highly versatile binding system 1C.

[0103] Furthermore, the control unit 77C of the control device 7C of the binding system 1C can select from a plurality of patterns the order of binding of the wire W to the plurality of intersections P of the workpieces B as a binding condition. This makes it possible to achieve strong binding of the workpieces B and rapid binding.

[0104] In particular, the control unit 77C makes it possible to select from multiple operating modes that specify the order in which the wire W is bound to multiple intersections P of the work B, so that in the binding process of the work B, the wire W can be bound to each intersection P in the appropriate order depending on the purpose.

[0105] Furthermore, some or all of the selectable operating modes involve tying the wire W from the outer edge of the workpiece B to multiple intersections P. Because the multiple rebars S constituting the workpiece B are supported at both ends by the support plates 211 of the holding table 21 before tying, they are prone to bending in the center, which can lead to gaps in the center when the rebars S are stacked one on top of the other. In this case, tying the rebars S starting from the intersections P on the outer edge first reduces the gaps between the upper and lower rebars S before tying them in the center, thereby reducing the amount of bending of the rebars S when tying them in the center. This makes it possible to prevent misalignment of each part of the workpiece B after tying due to bending of the rebars S when tying them in the center. The outer edge, as used herein, refers to the outermost part of the overall area consisting of the inner and outer regions of the workpiece B, and the outside refers to the outermost part of the workpiece including a regularly-spaced group of intersections. In other words, tying from the outer edge refers to tying workpieces of various shapes from intersections facing the external space. The external space is a space that does not constitute a group of intersections, and includes the space around the workpiece and the space provided inside the workpiece.

[0106] Furthermore, the control device 7C of the binding system 1C includes an operation unit 72 for inputting binding conditions, and the control unit 77C executes binding with the wire W at the multiple intersections P in accordance with the binding conditions input from the operation unit 72. This makes it easy for the user to select binding conditions that correspond to the actual workpieces B, and it becomes possible to appropriately select binding conditions for various or irregular workpieces B to achieve strong, rapid, or smooth binding.

[0107] In addition, the control unit 77 of the control device 7C of the binding system 1C functions as an intersection information acquisition means for acquiring information regarding the intersection P and an intersection identification means for identifying the intersection P at which the wire W is to be bound from the acquired information regarding the intersection P of the work B, so that the binding work can be performed from a position corresponding to the intersection P of the work B to be bound, thereby optimizing the binding work and achieving good binding.

[0108] Furthermore, since the bundling system 1C has a storage unit 76C that can record map data 763C, which is information related to the intersections P acquired from the outside, it is possible to identify the positions of the intersections P from the map data 763C prepared externally. Therefore, it is possible to acquire the positions of all of the intersections P of the work B without performing processes such as photographing the work B, extracting the intersections from the image data obtained by photographing, and identifying the intersection positions, which makes it possible to speed up the bundling process and reduce the processing load.

[0109] Furthermore, since the control unit 77 of the control device 7C executes the bundling processing program 761C to realize the function of enabling the selection of bundling conditions, it becomes easy to obtain this function from an existing bundling system without adding new hardware resources, thereby enabling the development burden of hardware resources and the manufacturing costs of the system to be reduced.

[0110] <Use of Machine Information Data and Periphery Information Data> The memory unit 76C of the control device 7C of the binding system 1C stores machine information data 766C indicating the three-dimensional position of the entire surface of the binding device 6C and peripheral information data 767C indicating the three-dimensional position of the entire surface of obstacles around the robot arm 4. When the "binding direction" which is a binding condition is selected, the control unit 77C may use these data 766C, 767C to determine whether or not the selection is possible.

[0111] That is, since the machine information data 766C includes three-dimensional position data of the entire machine surface of the binding device 6C, it is possible to obtain each position on the surface of the binding device 6C when the binding device 6C is supported by the end effector 43 of the robot arm 4. When the binding device 6C is rotated around the rotation axis Zr in accordance with the selection of the "binding direction" during the binding operation of the binding device 6C, it is possible to determine the possibility of interference between the binding device 6C and an obstacle based on each position on the surface of the binding device 6C and the surrounding information data 767C indicating the three-dimensional position of the entire surface of the obstacle around the robot arm 4. Therefore, when the user selects the "binding direction" which is a binding condition from the operation unit 72, the control unit 77 determines the possibility of interference between the binding device 6C and the obstacle, and if there is a possibility of interference, the control unit 77 may perform a process of notifying the user of the possibility of interference via the display unit 73, etc., a process of rejecting the current selection of the "binding direction," a process of automatically changing the current selection of the "binding direction," etc. Furthermore, each of the above processes may be executed when the first bundling condition data 764C or the second bundling condition data 765C, the machine information data 766C, and the peripheral information data 767C are all stored in the storage unit 76C. Alternatively, the processes may be executed when the machine information data 766C and the peripheral information data 767C are stored in the storage unit 76C, and the first bundling condition data 764C or the second bundling condition data 765C, which may cause the above-mentioned interference, is selected by the user to perform the bundling process for the work B.

[0112] <Other Matters in the Present Embodiment> Each 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 from a single member may be replaced with a component divided into multiple members that are connected or fixed to each other. Furthermore, a component formed by connecting multiple members may be replaced with a component integrally formed from a single member. In addition, the details shown in the embodiments may be modified as appropriate without departing from the spirit of the invention.

[0113] Furthermore, in the present embodiment, the bundling system 1C has been exemplified as a case in which the user selects the bundling conditions using the operation unit 72, but this is not limiting. For example, a configuration may be adopted in which the user selects the setting conditions using an information processing terminal or the like that is not included in the bundling system 1C to create the first bundling condition data 764C, and the control device 7C of the bundling system 1C acquires the first bundling condition data 764C via communication or acquires a recording medium on which the first bundling condition data 764C is recorded via its reading device.

[0114] Furthermore, the bundling system 1C may be configured to acquire information about the intersections P that identify each intersection P of the workpiece B from only the map data 763C. In that case, the first camera 31 and the second camera 51 are not essential to the bundling system 1C. However, since the second camera 51 can more accurately position the bundling device 6C with respect to the intersections P, the bundling system 1C may be configured to include only the first camera 31 and the second camera 51. If the first camera 31 is omitted from the configuration of the bundling system 1C, the rails 22 and drive motor 23 of the workpiece holding unit 2 that move the workpiece B between the photography area E1 and the bundling area E2 may also be unnecessary.

[0115] In addition, in the binding system 1C of this embodiment, a binding device 6C that binds reinforcing bars S with two wires W is exemplified, but this is not limited to this, and a binding device that binds reinforcing bars S with one or three or more wires W may also be used.

[0116] Furthermore, in the binding system 1C, a configuration in which the binding device 6C and the individual photographing unit 5 are moved by the robot arm 4 is exemplified, but the present invention is not limited to this. For example, the binding device 6C and the individual photographing unit 5 may be mounted on the head of a gantry-type moving device in the XY directions, and the binding device 6C and the individual photographing unit 5 may be made capable of moving up and down from the head in the Z direction and swiveling around an axis along the Z direction. Alternatively, the binding device 6C and the individual photographing unit 5 may be mounted on a self-propelled moving device that moves relative to the workpieces B held in a lattice pattern.

[0117] Furthermore, the bundling system 1C of this embodiment is a stationary bundling system that is placed or fixedly installed in an indoor work space. Therefore, unlike outdoor work bundling systems, bundling work can be performed without being affected by weather or the outdoor environment. Furthermore, since there is no need for equipment that is waterproof, dustproof, high-temperature, low-temperature, or other measures to withstand harsh outdoor environments, it can be equipped with equipment for precision work indoors, making it possible to perform precise bundling work on workpiece B. However, it is also possible to eliminate these advantages and configure a bundling system equipped with the features of this embodiment for outdoor use.

[0118] This application is based on a Japanese patent application (Patent Application No. 2024-013041) filed on January 31, 2024, the contents of which are incorporated herein by reference.

[0119] A bundling system is provided that can select bundling conditions for a bundling body at an intersection and perform bundling work in accordance with various requirements for workpieces.

[0120] 1C Binding system 6C Binding device 61C Reinforcing bar binding machine 62C Slack forming unit 7C Control device 72 Operation unit (condition input unit) 76C Memory unit (recording device) 761C Binding processing program 77C Control unit (intersection information acquisition means, intersection identification means) P Intersection S Reinforcing bar B Work W Wire (binding body)

Claims

1. A binding system for binding a workpiece having an intersection where reinforcing bars intersect with a binding element, the binding system having a control unit that can select the binding conditions of the binding element for the intersection.

2. The bundling system according to claim 1, wherein the workpiece has a plurality of intersections, and the control unit is capable of selecting the order in which the bundling elements are to be bound at the plurality of intersections as the bundling condition.

3. The bundling system according to claim 2, wherein the control unit is capable of selecting an operation mode that specifies the order in which the bundling bodies are to be bound at the plurality of intersections.

4. The bundling system according to claim 3, wherein the operation mode performs bundling of the bundling body along the outer edge of the workpiece from the outer edge to the plurality of intersections.

5. A bundling system as described in claim 2, further comprising a condition input unit for the bundling conditions, wherein the control unit executes bundling of the bundling bodies for the plurality of intersections in accordance with the bundling conditions input from the condition input unit.

6. A bundling system as described in claim 1, comprising: an intersection information acquisition means for acquiring information about the intersections; and an intersection identification means for identifying the intersections at which the bundling body is to be bound from the acquired information about the intersections of the workpieces.

7. The bundling system according to claim 1, further comprising a recording device capable of recording information about intersections obtained from outside the bundling system.

8. A bundling processing program that enables a computer that controls a bundling system that uses bundling elements to bundle a workpiece having an intersection where multiple rebars intersect, to select the bundling conditions of the bundling elements for the intersection.

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