Binding system and binding program

Abstract

In the present invention, the shape of a reinforcing bar is favorably detected. A binding system (1) for binding using a binding device on the basis of signal information relating to a plurality of arranged reinforcing bars is provided with a second camera (51) for acquiring image data relating to the reinforcing bars S, and a control unit (77). The control unit (77) detects the shape of the reinforcement bars S on the basis of contrast information included in the image data of the reinforcement bars S.

Description

Cohesion Systems and Cohesion Programs

[0001] The present invention relates to a bundling system and a bundling program for bundling reinforcing bars.

[0002] Conventionally, there has been known a bundling system that automatically uses a wire to sequentially bundle the intersections of intersecting rebars in a workpiece that is made up of multiple rebars. In this type of bundling system, information on the bundling points, which are the intersections of the rebars, may be acquired using a sensor or a camera. For example, the technology described in Patent Literature 1 is applied to a self-propelled bundling device that travels over rebars arranged on a plane while bundling them. The technology acquires point cloud information in the vertical direction using a distance sensor, and detects the intersections of the rebars by converting the point cloud information into a straight-line model.

[0003] Japanese Patent Application Publication No. 2022-110556

[0004] However, the technology described in Patent Document 1 has low accuracy in detecting intersections, making it difficult to grasp the shape of the reinforcing bars, such as their diameters.

[0005] The present invention has been made in view of the above circumstances, and has an object to suitably detect the shape of a reinforcing bar.

[0006] In order to solve the above-mentioned problems, the present invention provides a bundling system that uses a bundling device to bundle reinforcing bars based on signal information relating to a plurality of installed reinforcing bars, the bundling system comprising: an information acquisition unit that acquires the signal information; and a detection unit that detects the shape of the reinforcing bars based on contrast information included in the signal information.

[0007] According to the present invention, the outline of the reinforcing bar is extracted based on the contrast information contained in the signal information of the reinforcing bar. Then, the shape of the reinforcing bar, such as its diameter, can be determined from the position of this outline. Therefore, the shape of the reinforcing bar can be suitably detected.

[0008] 8A is a perspective view of the device body of the bundling system according to the embodiment. FIG. 8B is a block diagram showing a schematic control configuration of the bundling system according to the embodiment. FIG. 8C is a side view of the bundling device according to the embodiment. FIG. 8D is a flowchart showing the procedure of the bundling process according to the embodiment. FIG. 8E is a flowchart showing the procedure of the bundling process according to the embodiment. FIG. 8F is a diagram showing an example of image data acquired by a first camera. FIG. 8G is a perspective view of the device body in a state where the workpiece has been moved to the bundling area. FIG. 8H is a diagram showing an example of image data acquired by a second camera. FIG. 8H is a diagram showing an example of image data in which height information of the rebar and other positions has been added to the image data of FIG. 8A. FIG. 8I is a diagram for explaining the shape of the rebar detected from the image data. FIG. 8I is a flowchart showing the procedure of a modified example of the bundling process according to the embodiment.

[0009] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0010] [Configuration of the bundling system] Fig. 1 is a perspective view of an apparatus main body 10 provided in a bundling system 1 according to this embodiment, and Fig. 2 is a block diagram showing a general control configuration of the bundling system 1. As shown in these figures, the bundling system 1 binds a workpiece B made up of a plurality of reinforcing bars S arranged in a lattice pattern at the intersections where the plurality of reinforcing bars S intersect. Specifically, the bundling system 1 includes an apparatus main body 10 and a control device 7.

[0011] The device main body 10 includes a workpiece holding unit 2, an overall photographing unit 3, a robot arm 4, an individual photographing unit 5, and a binding device 6. Of these, the workpiece holding unit 2 is disposed inside a stand 11 of the device main body 10, and the overall photographing unit 3, the robot arm 4, the individual photographing unit 5, and the binding device 6 are mounted on the stand 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 perpendicular to each other, the XY plane is a substantially horizontal plane, and the Z direction is a direction substantially along the vertical.

[0012] 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 from 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 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 6.

[0013] <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 (work B) can be moved at least between the photography area E1 and the bundling area E2. However, the rails 22 may be extended to the outside of the frame 11 so that the work B can be moved to work processes before and after bundling. 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 bundling area E2 based on a drive command from the control device 7. It is sufficient that the work holding unit 2 is at least capable of moving the holding table 21 (work B) from the photography area E1 to the bundling area E2.

[0014] <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 arranged above the photography area E1 and a moving mechanism 32 that movably supports the first camera 31. The first camera 31 is arranged facing downward and photographs the workpiece B held by the workpiece holder 2 in the photography area E1 from above. In this embodiment, the first camera 31 is a compound-eye (e.g., four-eye) stereo camera that acquires image information (monochrome image) in the XY plane as well as distance information in the depth direction (up and down), and outputs the acquired information to the control device 7. The first camera 31 is an example of an 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 TOF (Time of Flight) sensor may be used. The moving mechanism 32 includes a Y-direction slider 33 extending along the Y direction. The Y-direction slider 33 is suspended on the beam 13 along the X direction and is supported by 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 7 to move the first camera 31 to a predetermined position (XY coordinates). As will be described later, 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 a desired resolution. Therefore, depending on the performance of the first camera 31 and the shape of the workpiece B, the movement mechanism 32 may move the first camera 31 in only one of the X and Y directions, or may not be provided at all.

[0015] <Robot Arm> The robot arm 4 is equipped with the individual photographing unit 5 and the binding device 6, and moves the individual photographing unit 5 and the binding device 6 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.

[0016] 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.

[0017] 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 individual photographing unit 5 and binding device 6 mounted thereon.

[0018] 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 6. 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 6. 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 6 may be connected as an end effector via a tool changer.

[0019] The controller 49 controls the operation of each part of the robot arm 4 based on a control command from the control device 7. 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 7. Note that the controller 49 may locally control the operation of the individual photographing unit 5 and binding device 6 mounted thereon based on a control command from the control device 7.

[0020] <Individual Photography Unit> The individual photography unit 5 is mounted on the tip of the robot arm main body 40 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 7. The second camera 51 is an example of an information acquisition unit according to the present invention. Note that the type of sensor of the second camera 51 is not particularly limited as long as it can acquire an image (signal information) of at least one intersection P. The lifting motor 52 is a drive source that moves (lifts and lowers) 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 second camera 51 and around the periphery of the imaging range, and illuminates the subject being imaged by the second camera 51. The lighting unit 53 in this embodiment has multiple light sources (projectors, not shown) that can illuminate the subject being imaged by the second camera 51 from different angles.

[0021] <Binding Device> Figure 3 is a side view of the binding device 6. As shown in this figure, the binding device 6 is mounted on the tip of the robot arm main body 40. The binding device 6 includes a rebar binding machine 61 that binds the intersections P of the rebars S that make up the workpiece B with wire W, a slack forming unit 62 that pulls out the wire W from a reel 63 and forms slack in the wire W between the binding machine 61 and the reel 63, and a control unit 64 (see Figure 2) that causes the rebar binding machine 61 to perform the binding operation and the slack forming unit 62 to form slack in the wire W in accordance with operation commands from the control device 7.

[0022] The rebar binding machine 61 has an entrance section 611 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 611 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 be wrapped around the rebar S and cut, and then the wires W are twisted and the rebar S is bound with the wires W.

[0023] For this reason, the binding machine 61 is equipped with a wire feeding section that feeds the wire W, a wire guide 612 that guides the wire W, a curl guide 613 and a guide guide 614 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.

[0024] The wire guide 612 is provided in front of the entrance portion 611 and guides the two wires W so that they enter the entrance portion 611 along the feed direction F.

[0025] The wire feeding unit is located inside the entrance 611, 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 615 (see FIG. 2 ) that serves as a drive source. This feed motor 615 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 613 and the induction guide 614 located at the end of the motor. In addition, the feed motor 615 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.

[0026] The cutting unit is located inside the entrance 611, further back than the wire feeding 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 616 (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.

[0027] 3 is supported by an end effector 43 at the tip of the robot arm 4, and performs binding operations with the rotation axis Zr of the end effector 43 parallel to the Z direction (vertical up-down direction) described above. The binding device 6 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 6 so that the intersection P of the rebar S is located on the axis of the rotation axis Zr.

[0028] The curl guide 613 and the induction guide 614 are located at the tip end (the lower end during the bundling operation) of the bundling machine 61, and are arranged on both sides of the aforementioned pivot axis Zr. The base end of the curl guide 613 is located at the end of the entrance 611 in the feed direction F, and a guide path is formed inside the curl guide 613 to curl the wire W as it moves from the base end to the tip end.

[0029] The leading guide 614 is disposed opposite the curl guide 613, and has a guide path formed inside that receives the wire W curled by the curl guide 613 from the tip end and guides the wire W to the base end while maintaining the curled state. The curl guide 613 and the leading guide 614 cooperate to deform the wire W into a loop and wind it around the reinforcing bar S.

[0030] The bundling unit has a locking member that captures the wire W while it is wound around the reinforcing bar S between the base end of the induction guide 614 and the base end of the curl guide 613. The locking member is rotatably supported inside the bundling machine 61 around a rotation axis that is concentric with the aforementioned pivot axis Zr, and torque for rotational drive is applied to the locking member by the aforementioned torsion motor 616. The locking member is rotationally driven by the torsion motor 616 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.

[0031] Two reels 63 of the wire W are rotatably supported side by side on one side in the direction along the rotation axis Zr of the binding machine 61 (the upper side during the binding operation). The two reels 63 are each rotatable around an axis extending perpendicular to the paper surface of FIG. 3 and are arranged side by side on the axis.

[0032] The slack forming unit 62 is disposed on one side in the orthogonal direction Xw perpendicular to the pivot axis Zr with respect to the binding machine 61 and the two reels 63. The slack forming unit 62 has a first slack forming unit 621 and a second slack forming unit 622 that move past each other, and a slack forming motor 623 that serves as a drive source for these moving past each other.

[0033] 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 621 and the second slack forming unit 622 hold rollers around which the two wires W are wound.

[0034] The first slack forming unit 621 and the second slack forming unit 622 perform a passing operation generally along the feed direction F, thereby extending the path length of the wire W from the reel 63 to the inlet 611 of the binding machine 61 and pulling out the wire W from the reel 63. Furthermore, the first slack forming unit 621 and the second slack forming unit 622 perform a returning operation after the passing operation, thereby imparting slack to the wire W by the amount pulled out from the reel 63. Note that the slack forming unit 62 does not necessarily have to be provided.

[0035] The two wires W are required to be fed into the inlet 611 of the binding machine 61 from 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 by the curl guide 613 and the induction guide 614 located at the end of the wire W's travel direction. In order to supply the wire W to the inlet 611 of the binding machine 61 along the feed direction F, the slack forming unit 62 is disposed so that the path from the downstream second slack forming unit 622 to the inlet 611 of the binding machine 61 follows the feed direction F. During the passing operation, the second slack forming unit 622 moves away from the inlet 611 of the binding machine 61 along the feed direction F.

[0036] For this reason, the binding device 6 is disposed so that the slack forming portion 62 protrudes largely to one side (the right side of the paper in FIG. 3 ) in the direction Xw perpendicular to the binding machine 61 (swivel axis Zr). Note that the second camera 51 and the lighting unit 53 of the individual photographing portion 5 are disposed on the left side of the binding machine 61 of the binding device 6 in FIG. 3 .

[0037] <Control Device> As shown in Fig. 2, the control device 7 is a computer that performs overall control of the bundling 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 operating means through which a user performs various operations to operate the control device 7, 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 77. 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.

[0038] The storage unit 76 is a memory configured from RAM (Random Access Memory), ROM (Read Only Memory), etc., and stores various programs and data, and also functions as a work area for the control unit 77. In this embodiment, the storage unit 76 pre-stores a bundling program 761 and a rebar arrangement model 764 for executing the bundling process described below, as well as image data 762 and work information 763 acquired in the bundling process.

[0039] The image data 762 is image information of the workpiece B (reinforcing bars S) acquired by the first camera 31 and the second camera 51 during the bundling process described below. The work information 763 is various information related to the bundling work. Specific details of the work information 763 will be described later. The reinforcing bar arrangement model 764 is arrangement information of multiple reinforcing bars S in the workpiece B to be worked on, and includes, for example, information on the number of reinforcing bars S arranged in each of the X, Y, and Z directions. It may also include other information such as the spacing between the reinforcing bars S in each of the X, Y, and Z directions, and, if the reinforcing bars S are inclined, information on the angle of the inclined reinforcing bars S. The storage unit 76 may also store various data other than those described above that are acquired during the bundling process described below.

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

[0041] [Operation of the bundling system] Next, we will explain the operation of the bundling system 1 when executing the bundling process to bundling the workpieces B. Figures 4 and 5 are flowcharts showing the steps of the bundling process, and Figures 6 to 9 are diagrams for explaining the bundling process, with Figure 6 being an example of image data of the workpieces B acquired by the first camera 31, Figure 7 being a perspective view of the device main body 10 in a state where the workpieces B have been moved to the bundling area E2, Figure 8A being an example of image data of the target intersection Pa acquired by the second camera 51, Figure 8B being an example of image data in which height information of the reinforcing bars S and other positions has been added to Figure 8A, and Figure 9 being a diagram for explaining the shape of the reinforcing bars S detected from the image data.

[0042] In the bundling process, a plurality of reinforcing bars S arranged in a grid pattern along each of the X and Y directions are bundled at intersections P (see FIG. 6 ) where the plurality of reinforcing bars S intersect. This bundling process is executed by the control unit 77 of the control device 7 reading and executing the bundling program 761 from the storage unit 76. Here, it is assumed that the workpiece B is placed in the photography area E1 in a state where it is placed on the support table 21 in advance (see FIG. 1 ). Note that, although it is assumed below that each step is executed solely by the control device 7 (control unit 77 thereof), the entity that controls the bundling process is not particularly limited. For example, the bundling process may be executed by each component (control unit) of the bundling system 1, or may be executed by the control device 7 and each component working together.

[0043] As shown in FIG. 4 , when the bundling process is executed, the control unit 77 of the control device 7 first photographs the workpiece B in the photographing area E1 using the first camera 31 of the overall photographing unit 3 (step S1). Here, the control unit 77 acquires image data (monochrome image) of the entire workpiece B in the XY plane, including distance information, using the first camera 31, which is a stereo camera, and stores the image in the memory unit 76. More specifically, the control unit 77 controls the movement mechanism 32 to move the first camera 31 in the XY plane according to the size of the workpiece B and the angle of view of the first camera 31, etc., to photograph the entire workpiece B by dividing it into multiple overlapping parts (e.g., 2 x 2, 4 parts in each of the X and Y directions). The control unit 77 then combines the acquired images to generate an image of the entire workpiece B and stores the image in the memory unit 76. As a result, image data 762a including the entire workpiece B, as shown in FIG. 6 , is acquired.

[0044] In step S1, it is sufficient to acquire signal information related to the multiple reinforcing bars S to be bundled. Here, "signal information related to the reinforcing bars S" refers to data including at least one of position information of the reinforcing bars S and position information of obstacles that may hinder the bundling of the reinforcing bars S. The data format of the signal information is not limited to image data, but broadly includes electromagnetic data including optical signals.

[0045] Next, the control unit 77 calculates the positions of all intersections P included in the workpiece B based on the image data acquired in step S1 (step S2). Here, the control unit 77 calculates three-dimensional position information including X, Y, and Z coordinates for each intersection P. In this step, it is sufficient to calculate the positions of multiple intersections P out of all intersections P included in the workpiece B. Here, when calculating the positions of the intersections P, the positions may be calculated using a rebar array model (the intersection shape of intersecting rebars). In this case, when the shape matches the rebar array model, it is considered to be an intersection P, making it easier to calculate the position.

[0046] Next, as shown in FIG. 7, the control unit 77 drives the drive motor 23 of the workpiece holder 2 to operate the holder table 21, thereby moving the workpiece B to the bundling area E2 (step S3).

[0047] Next, the control unit 77 selects an intersection P to be bound from among the plurality of intersections P included in the work B (step S4). Here, the control unit 77 selects one intersection P to be bound next from the plurality of intersections P excluding intersections P that have already been bound (recognized as having been bound), for example, based on a predetermined bundling order. Hereinafter, the intersection P to be bound next as selected here will be referred to as the "target intersection Pa."

[0048] Next, in the bundling area E2, the control unit 77 moves the second camera 51 of the individual photographing unit 5 mounted on the robot arm 4 closer to the target intersection Pa selected in step S4 (step S5). Here, the control unit 77 controls the operation of the robot arm 4 based on the position information of the target intersection Pa calculated in step S2 and the amount of movement in the X direction of the workpiece B moved in step S3, to move the second camera 51 directly above the target intersection Pa. Then, the control unit 77 controls the operation of the lifting motor 52 to lower the second camera 51 and move it closer to the target intersection Pa by a predetermined distance. As a result, the target intersection Pa is positioned immediately in front of the downward-facing second camera 51, and, for example, only the target intersection Pa falls within the angle of view of the second camera 51 (intersections P other than the target intersection Pa are outside the angle of view).

[0049] Next, the control unit 77 photographs the target intersection Pa using the second camera 51 that was approached in step S5 and acquires the image data (step S6). Here, the control unit 77 acquires image data (color image) of the target intersection Pa using the second camera 51 and stores it in the storage unit 76. As a result, as shown in FIG. 8A, for example, image data 762b of the target intersection Pa with higher resolution than the image data acquired by the first camera 31 in step S1 is obtained. Note that in this step, it is sufficient to acquire traffic light information for at least one of the multiple intersections P. More specifically, it is sufficient to acquire traffic light information for a smaller number of intersections P than the multiple intersections P for which traffic light information was acquired by the first camera 31 in step S1. Also, in this step, the control unit 77 may control the lighting unit 53 to photograph the target intersection Pa using multiple different lighting patterns. This allows a three-dimensional image to be generated based on changes in the patterns of projected and reflected light, and distance information to 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] To calculate the target intersection Pa, as shown in FIG. 5 , the control unit 77 first detects the edge of the reinforcing bar S, which is the outline of the image of the reinforcing bar S, based on the contrast information included in the image data of the reinforcing bar S (step S71). Here, the outline (edge) refers to the boundary between the target reinforcing bar S and other parts of the target image. The control unit 77 then binarizes the image data and performs edge detection by scanning the image data from the white side (bright part) to the black side (dark part) (i.e., from weak to strong signal parts). However, the image data may not be completely binarized, but may be grayscaled with a predetermined number of gradations. Specifically, in the case of the image data 762d shown in FIG. 9 , the control unit 77 examines the contrast value from one side to the other in the X direction. The control unit 77 then detects (extracts) the part where the contrast changes more than a predetermined threshold as the edge Se of the reinforcing bar S. Next, the control unit 77 similarly detects the edge Se from the other side to the other side in the X direction. At this time, based on the difference in contrast change from the previously detected edge Se, it is confirmed that they are both ends of the same reinforcing bar S. In this way, two edges Se along the Y direction are detected. In the same way, the control unit 77 detects edges Se along the Y direction this time, and detects two edges Se along the X direction.

[0052] Next, the control unit 77 calculates the rebar diameter (diameter of the rebar S) and the rebar center (central axis along the longitudinal direction of the rebar S) based on the position information of the edges Se (step S72). Here, since the rebar S is approximately cylindrical, the control unit 77 determines the distance between the edges Se as the rebar diameter D, and the line passing through the center of two edges Se in the same direction as the rebar center Ax. Here, detailed dimensions of the rebar S in the height direction (Z direction) can also be obtained.

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

[0054] Next, the control unit 77 calculates the distance from the second camera 51 to the target intersection Pa of the rebar S (step S74). Here, the control unit 77 acquires height information along the Z direction based on the image data and calculates the distance between the second camera 51 and the target intersection Pa. Regarding the distance, image data 762c in FIG. 8B is shown, in which height information of the rebars and each other position, including the target intersection Pa, is added to the image data 762b in FIG. 8A. In this way, the calculated height information can be used to obtain the distance at which the binding device 6 can approach the target intersection Pa. Here, the amount of gap in the Z direction between the two rebars S at the target intersection Pa can also be obtained.

[0055] Next, the control unit 77 compares the shape information of the reinforcing bars S obtained in the above steps with the reinforcing bar arrangement model 764 of the workpiece B (step S75). Here, the control unit 77 reads the reinforcing bar arrangement model 764 of the workpiece B previously stored in the storage unit 76 and compares it with the calculated shape information of the reinforcing bars S. This allows the control unit 77 to identify the target intersection Pa, which is the binding target, and confirm its reinforcing bar combination type. In addition to the above, the control unit 77 may also identify the target intersection Pa by comparing the information of other intersections P obtained in steps S1 and S6 with the information of the target intersection Pa. This indicates, for example, that an intersection formed by two reinforcing bars S in each of the X and Y directions may be mistakenly recognized as an intersection P where a single thick reinforcing bar S intersects with the results of other intersections P adjacent to the target intersection Pa or other intersections P present in the same workpiece B, thereby identifying the target intersection Pa and confirming the reinforcing bar combination type.

[0056] Next, the control unit 77 determines whether the target intersection Pa can be bound (step S76). Here, the control unit 77 determines whether a key part of the binding device 6 (such as the curl guide 613) can be inserted between the two rebars S from above, for example, based on the intersection angle of the two rebars S. If it determines that insertion is possible, it determines that binding is possible. If it determines that binding is not possible, the control unit 77 proceeds to other processing, such as suspending the work or issuing a warning. Alternatively, the robot arm 4 and the binding device 6 may be configured to be detachable, and multiple binding devices 6 with different sized insertion parts (portions to be inserted between the rebars S) may be prepared, and the binding device 6 corresponding to the target intersection Pa may be selected. That is, in this case, the control unit 77 selects one of the multiple binding devices 6 that can bind the target intersection Pa to be bound. In this case, a plurality of binding devices 6 may be arranged at predetermined positions within the movement range of the robot arm 4, and replacement of the binding devices 6 by the robot arm 4 may be automated. Here, the control unit 77 determines the binding direction based on the position and posture of the binding device 6 that allows the main part to be inserted between two rebars S.

[0057] Next, the control unit 77 calculates the wire length required for binding the target intersection Pa (step S77). Here, the control unit 77 calculates the length of the wire W required for binding (including the pull-back length) based on the reinforcing bar diameter D and the intersection angle of the two reinforcing bars S that make up the target intersection Pa. Here, the control unit 77 may also set the rotation amount of the wire feed unit (the operation amount of the feed motor 615) when binding (pulling back) the wire W by the binding device 6.

[0058] 4, the control unit 77 moves the binding device 6 closer to the target intersection Pa based on the position information of the target intersection Pa calculated in step S7 (S73) (step S8). Here, the control unit 77 controls the operation of the robot arm 4 to move the binding device 6 mounted on the end effector 43, instead of the second camera 51, closer to the target intersection Pa. At this time, the control unit 77 can position the relevant portion of the binding device 6 facing the target intersection Pa with high positional accuracy based on the more accurate position information of the target intersection Pa calculated in step S7.

[0059] Next, the control unit 77 operates the binding device 6 to bind the target intersection Pa with the wire W (step S9). At this time, the binding device 6 is positioned opposite the target intersection Pa with sufficiently high positional accuracy, so that the target intersection Pa can be suitably bound. At this time, the amount of wire W used to bind the target intersection Pa may be calculated and stored in the storage unit 76. The amount of wire W used may be estimated from the actual wire feed amount (not including the amount of retraction) in the wire feed unit. Furthermore, the wire length required for binding, estimated prior to binding in the above-mentioned step S77, may be used as the amount of wire W used.

[0060] Next, the control unit 77 determines whether or not to terminate the bundling process (step S10). If it determines not to terminate the bundling process (step S10; No), the control unit 77 proceeds to the above-mentioned step S4. As a result, the processes of steps S4 to S10 are repeated, for example, until all the necessary intersections P are bound. That is, the selection of the next intersection P to be bound (changing the target intersection Pa), and the photographing and bundling of the target intersection Pa are sequentially performed. Then, if it is determined in step S10 that the bundling process should be terminated, for example, because all the necessary intersections P have been bound (step S10; Yes), the control unit 77 terminates the bundling process.

[0061] [Technical Effects of the Present Embodiment] As described above, according to the present embodiment, the shape of the reinforcing bar S is detected based on contrast information contained in image data (signal information) of the reinforcing bar S. This makes it possible to grasp the position of the reinforcing bar S based on changes in contrast, and to obtain shape information of the reinforcing bar S, such as the reinforcing bar diameter D and the reinforcing bar center Ax. Therefore, the shape of the reinforcing bar S can be suitably detected. Furthermore, it is also possible to select an optimal binding device 6 based on, for example, the reinforcing bar diameter D.

[0062] Furthermore, according to this embodiment, the edges (contours) 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 from the image data of the reinforcing bars S. However, parts other than the edges Se may be used as long as the shape of the reinforcing bars S can be detected based on the contrast information.

[0063] Furthermore, according to this embodiment, the distance from the second camera 51 to the rebar S is calculated based on image data of the rebar S. This makes it possible to confirm the amount of movement of the binding device 6 required for binding the rebar S (target intersection Pa). Furthermore, compared to using a 3D sensor or the like, distance information (height information) can be obtained by simple processing of two-dimensional image data. Furthermore, the height gap between the two rebars S at the target intersection Pa can also be confirmed.

[0064] Furthermore, according to this embodiment, the length of the wire W required for bundling is calculated (estimated) based on the image data. As a result, for example, by comparing the calculated length with the remaining amount of wire, it is possible to detect a shortage of the wire W in advance of the actual bundling work.

[0065] Furthermore, according to this embodiment, the detection of the edges Se of the reinforcing bars S is performed from light to dark (from weak to strong signals) in the image data (signal information) of the reinforcing bars S. This makes it easy to detect the intersections P even when the types of reinforcing bars are different (for example, differences in thickness, number of reinforcing bars, etc.).

[0066] Furthermore, according to this embodiment, the amount of wire W used to bind the target intersection Pa may be calculated and stored. This allows the remaining amount of wire in the binding device 6 to be known.

[0067] Furthermore, according to this embodiment, image data (signal information) of the rebar S (target intersection Pa) after binding may be acquired, and the binding condition may be determined based on the image data. The image may be taken by either the second camera 51 or the first camera 31. Specifically, the protrusion of the wire W from the edge Se of the target intersection Pa may be detected, and if the protrusion is longer than a predetermined threshold, the binding condition of the target intersection Pa may be determined to be poor. This allows the binding condition to be determined easily.

[0068] [Modification] Although the above describes an embodiment of the present invention, the present invention is not limited to the above embodiment. For example, in the above embodiment, the shape of the rebar S is determined based on image data acquired by the second camera 51. However, if the target image data is of the rebar S, image data acquired by the first camera 31 may be used. In this case, the bundling process (steps S71 to S77) can be performed in a manner similar to the above embodiment. However, unlike the above embodiment, in this case, the image data includes multiple intersections P. Based primarily on this point, the following process may be performed after step S77, as shown in FIG. 10 . In this case, steps S71 to S77 are performed for each intersection P. In addition, in the processes of steps S71 to S77 in this case, the "target intersection Pa" is simply referred to as the "intersection P."

[0069] Specifically, after executing step S77, the control unit 77 acquires position information of the multiple intersections P (step S78a), and detects the ends of the workpiece B (multiple rebars S) based on the position information (step S78b). Here, the control unit 77 detects the intersections P located at the ends by determining whether the intersections P are continuous (whether adjacent intersections P exist). This makes it possible to grasp the overall shape and size of the workpiece B and determine the range of the work target. This in turn makes it possible to plan the movement path of, for example, the robot arm 4.

[0070] Next, the control unit 77 detects obstacles that may hinder bundling based on the image data of the rebars S (step S79a). Here, the control unit 77 determines that an obstacle exists at an intersection P if the height (Z direction) position of the intersection P differs from that of other intersections P by a predetermined threshold or more. This allows the worker to continue work while avoiding contact with the obstacle by taking measures such as moving around the obstacle or changing the bundling direction so as not to interfere with the obstacle.

[0071] Next, the control unit 77 selects one of the multiple intersections P based on predetermined selection conditions (step S80a). Here, the control unit 77 selects the intersection P that best meets the selection conditions, such as the shape of the intersections P that can be bound or the arrangement pattern of the multiple intersections P, stored in advance in the storage unit 76, as the preferred intersection P. The selected intersection P may be designated as the target intersection Pa. This allows the intersections P to be bound to be bound appropriately even if they have various patterns. Also, here, the possibility of binding the intersection P may be determined based on the selection conditions. In other words, an intersection P that does not meet the selection conditions may be determined to be unbindingable. This allows intersections P that are difficult to bind to be selected in advance, thereby reducing the occurrence of binding-unable errors during actual work.

[0072] If the image data includes multiple intersections P, the comparison with the rebar array model 764 in step S75 identifies the approximate positions of the intersections P for comparison and determination, thereby shortening the determination time. Furthermore, by comparing with the rebar array model 764, it is easier to identify the actual intersection locations.

[0073] [Other Modifications] In the above embodiment, work information related to the binding work performed by the binding device 6 may be stored in the storage unit 76. Here, "work information" refers to information related to the binding work performed in the binding area E2, and includes, for example, position information (XYZ coordinates), whether binding is possible, the binding direction (angle), the number of bindings, the binding strength, the binding order, etc. Furthermore, the "work information" may include work log information such as the operation details of the robot arm 4 and the binding device 6 in each binding operation. This allows work information related to the binding work to be recorded at any time and output as appropriate.

[0074] In the above embodiment, the photographing area E1 (first area) and the bundling area E2 (second area) are different from each other. However, the photographing area E1 and the bundling area E2 may partially overlap or may be integrated (identical).

[0075] Furthermore, it is preferable that the position of an obstacle can be grasped and the insertion direction of the binding device 6 (access route to the intersection P) can be set taking the obstacle into consideration, regardless of whether the signal information is acquired by the first camera 31 or 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, but if the signal information is image data, it is preferable that one is a monochrome image and the other is a color image. It is also preferable that the position information of the obstacle can be acquired in any of the X, Y, and Z directions. In other words, by grasping the position of the obstacle three-dimensionally, the robot arm 4 can perform work without coming into contact with the obstacle.

[0076] In the above embodiment, the workpiece holder 2 moves the workpiece B in the X direction, but it may also be possible to move or rotate the workpiece B in other directions. For example, if the workpiece holder 2 can rotate the workpiece B around a horizontal axis to invert the top and bottom surfaces, it can be used effectively for workpieces B with double reinforcement on the top and bottom.

[0077] Furthermore, the image information according to the present invention is not particularly limited to a particular data type (data format) as long as it is essentially image data having contrast information of the reinforcing bars that are the subject of imaging.

[0078] In the above embodiment, the present invention has been described as being applied to a robot arm system using a robot arm. However, the present invention can also be suitably applied to binding systems other than the robot arm system, such as a workpiece transport system in which a workpiece is transported, a gantry system in which an apparatus is moved by a gantry, or a self-propelled system in which the entire apparatus, including the binding apparatus, is self-propelled above the workpiece. However, the present invention is more suitably applied to a system in which the entire apparatus is installed (fixed) indoors, for example, and the workpiece is moved, as in the above embodiment. In the case of a freely moving mobile object such as a self-propelled robot or work outdoors, applying the structure of the above embodiment can cause problems such as an increased risk of collision with the information acquisition unit, distortion of the acquired signal (camera image) due to a collision, an increase in the size of the entire apparatus, and the need for waterproofing of the information acquisition unit.

[0079] In addition, the details shown in the above embodiment can be modified as appropriate without departing from the spirit of the invention.

[0080] This application is based on a Japanese patent application (Patent Application No. 2024-013039) filed on January 31, 2024, the contents of which are incorporated herein by reference.

[0081] A bundling system and a bundling program are provided that can suitably detect the shape of reinforcing bars.

[0082] DESCRIPTION OF SYMBOLS 1 Binding system 2 Workpiece holding section 3 Overall photography section 31 First camera (information acquisition section) 4 Robot arm 40 Robot arm body 5 Individual photography section 51 Second camera (information acquisition section) 6 Binding device 61 Rebar tying machine 611 Entrance section 613 Curl guide 7 Control device 76 Memory section 761 Binding program 762 Image data (image information) 764 Rebar arrangement model (arrangement information) 77 Control section (detection section, calculation section, comparison section, second comparison section, selection section, judgment section) E1 Photography area E2 Binding area B Work S Rebar Se Edge Ax Rebar center D Rebar diameter P Intersection Pa Target intersection W Wire

Claims

1. A bundling system that uses a bundling device to bundle reinforcing bars based on signal information relating to a plurality of installed reinforcing bars, comprising: an information acquisition unit that acquires the signal information; and a detection unit that detects the shape of the reinforcing bars based on contrast information included in the signal information.

2. The bundling system according to claim 1, wherein the detection unit detects the contour of the reinforcing bar based on the contrast information.

3. The bundling system according to claim 1, wherein the information acquisition unit calculates the distance to the reinforcing bar based on the signal information.

4. The bundling system according to claim 1, further comprising a calculation unit that calculates the wire length required for bundling based on the signal information.

5. The bundling system according to claim 1, wherein the detection unit detects position information of a plurality of intersections of a plurality of intersecting reinforcing bars based on the signal information.

6. The bundling system according to claim 1, wherein the detection unit detects an obstacle that may hinder bundling based on the signal information.

7. The binding system according to claim 1, comprising: a memory unit that stores arrangement information of a plurality of said reinforcing bars in advance; and a comparison unit that compares said signal information with said arrangement information stored in said memory unit.

8. The bundling system according to claim 2, wherein the detection unit detects the contour of the reinforcing bar from a portion of the signal information where the signal is weak to a portion where the signal is strong.

9. The bundling system according to claim 1, further comprising a second comparison unit that compares the signal information of a plurality of intersections of a plurality of intersecting reinforcing bars with the signal information of the intersection.

10. The bundling system according to claim 1, further comprising a selection unit that selects one of the bundling devices for a bundling object.

11. The bundling system according to claim 10, wherein the selection unit determines whether or not the bundling targets can be bundled based on the signal information.

12. The bundling system according to claim 1, comprising: a bundling device that binds the reinforcing bars with wire; and a memory unit that stores the amount of wire used.

13. The bundling system according to claim 1, wherein the information acquisition unit acquires the signal information after bundling, and the bundling system further comprises a determination unit that determines the bundling state based on the signal information after bundling.

14. A bundling program that causes a computer that controls a bundling system having an information acquisition unit that acquires signal information related to multiple installed reinforcing bars to function as a detection unit that detects the shape of the reinforcing bars based on contrast information included in the signal information.

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