Binding system

Abstract

The present invention suitably binds intersection points of a plurality of reinforcing bars. A binding system (1) comprises: a first camera (31) that acquires first information pertaining to a plurality of arranged reinforcing bars S; a second camera (51) that moves on the basis of the first information acquired by the first camera (31), and acquires second information pertaining to intersection points P of the plurality of reinforcing bars S; and a binding device (6) that binds the intersection points P on the basis of the second information acquired by the second camera (51).

Description

Binding System

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

[0002] Conventionally, there has been known a bundling system that sequentially binds the intersections of intersecting rebars with wire for a workpiece made up of multiple rebars. For example, a bundling system of this type is described in Patent Document 1, in which an information acquisition unit such as a sensor and a bundling machine are mounted on the tip of a robot arm. The information acquisition unit acquires information about the workpiece, such as the positions of the rebar intersections, and the bundling machine is controlled based on the information about the workpiece. Furthermore, a bundling system described in Patent Document 2 photographs the entire workpiece having multiple intersections with a camera fixed above, and determines the positions of each intersection from the image.

[0003] Japanese Patent Publication No. 2023-105958 Chinese Patent Publication No. 113264212

[0004] However, the technology described in Patent Document 1 does not allow for the appropriate acquisition of position information for each intersection point across the entire workpiece. Unless this position information for each intersection point can be acquired in advance, it is difficult to efficiently and sequentially bundle multiple intersection points. On the other hand, the technology described in Patent Document 2 allows for the acquisition of position information for each intersection point across the entire workpiece based on an image captured by an overhead camera. However, images captured by a camera spaced apart from each intersection point make it difficult to appropriately perform control such as position correction during bundling.

[0005] The present invention has been made in consideration of the above circumstances, and has as its object to suitably bind the intersections of multiple reinforcing bars.

[0006] In order to solve the above-mentioned problems, the binding system of the present invention comprises a first information acquisition unit that acquires first information regarding a plurality of installed reinforcing bars; a second information acquisition unit that moves based on the first information and acquires second information regarding the intersections of the plurality of reinforcing bars; and a binding device that binds the intersections based on the second information.

[0007] According to the present invention, information such as the positions of multiple intersections and the presence or absence of obstacles in a relatively wide area is obtained based on first information about multiple installed reinforcing bars. Then, a second information acquisition unit moves based on the first information, and more accurate second information in a more localized area is acquired by the second information acquisition unit. The intersections of the reinforcing bars are then bundled based on the second information. Therefore, the intersections of the multiple reinforcing bars can be bundled appropriately.

[0008] 8A . FIG. 8B is a perspective view of the device main body of the bundling system according to the first embodiment. FIG. 8C is a block diagram showing a schematic control configuration of the bundling system according to the first embodiment. FIG. 8D is a side view of the bundling device according to the first embodiment. FIG. 8E is a flowchart showing the procedure of the bundling process according to the first embodiment. FIG. 8F is a flowchart showing the procedure of the bundling process according to the first embodiment. FIG. 8G is a diagram showing an example of image data acquired by a first camera according to the first embodiment. FIG. 8H is a perspective view of the device main body in a state in which the workpiece has been moved to the bundling area according to the first embodiment. FIG. 8H is a diagram showing an example of image data acquired by a second camera according to the first embodiment. 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 according to the first embodiment. FIG. 8I is a flowchart showing the procedure of a modified example of the bundling process according to the first embodiment. FIG. 8I is a perspective view of the device main body of the bundling system according to the second embodiment. FIG. 8F is a block diagram showing a schematic control configuration of the bundling system according to the second embodiment. FIG. 8H is a side view of the bundling device according to the second embodiment in an attitude when performing a bundling operation. FIG. 8I is a schematic view of workpieces on the holding table of the work holding unit according to the second embodiment, as seen from above. FIG. 8I is a plan view showing an intersection where bundling has been performed in a first direction of the bundling direction according to the second embodiment. FIG. 8I is a plan view showing an intersection where bundling has been performed in a second direction of the bundling direction according to the second embodiment. 1 is a plan view showing an intersection where bundling was performed with two "bundling times" according to the second embodiment; FIG. 2 is a plan view showing an intersection where bundling was performed with one bundling time in the first direction and one bundling time in the second direction according to the second embodiment; FIG. 3 is an explanatory diagram of the operation when bundling is performed in the (1) outer edge-first pattern according to the second embodiment; FIG. 4 is an explanatory diagram of the operation when bundling is performed in the (2) center-first pattern according to the second embodiment; FIG. 5 is an explanatory diagram of the operation when bundling is performed in the (3) horizontal feed pattern according to the second embodiment; FIG. 6 is an explanatory diagram of the operation when bundling is performed in the (4) vertical feed pattern according to the second embodiment; FIG. 7 is an explanatory diagram of the operation when bundling is performed in the (5) corner-first pattern according to the second embodiment; and FIG. 8 is an explanatory diagram showing the distinction between "intersections located at corners," "intersections located at outer edges," and other intersections according to the second embodiment.14 is a schematic view of a workpiece viewed from above when a region consisting of intersections to be bound according to the second embodiment has an irregular shape. FIG. 15 is a flowchart showing the procedure when the binding system according to the second embodiment executes the binding process. FIG. 16 is a block diagram showing the general control configuration of the binding system according to the third embodiment. FIG. 17 is a plan view of a workpiece subjected to binding according to condition (1) in the process of determining the binding direction according to the third embodiment. FIG. 18 is a plan view of a workpiece subjected to binding according to condition (2) in the process of determining the binding direction according to the third embodiment. FIG. 19 is a plan view of a workpiece subjected to binding according to condition (3) in the process of determining the binding direction according to the third embodiment. FIG. 19 is a plan view of a workpiece subjected to binding according to condition (4) in the process of determining the binding direction according to the third embodiment. FIG. 19 is an enlarged plan view of an intersection of the workpiece subjected to binding according to condition (4) in the process of determining the binding direction according to the third embodiment. FIG. 19 is a plan view of the binding device of FIG. 13 viewed from one side of the pivot shaft. FIG. 19 is a plan view with some components of the device main body according to the third embodiment omitted. FIG. 19 is a flowchart showing the procedure when the binding system according to the third embodiment executes the binding process. FIG. 19 is a side view showing an example of a binding device according to a fourth embodiment. 1 is a side view showing an example of a binding device according to a fourth embodiment, with some components omitted; FIG. 2 is a perspective view showing an example of a binding device according to the fourth embodiment; FIG. 3 is a rear view showing an example of a binding device according to the fourth embodiment; FIG. 4 is a side view showing an example of a binding device according to the fourth embodiment, as viewed from the back; FIG. 5 is an internal configuration view showing an example of a reinforcing bar binding machine according to the fourth embodiment, as viewed from the side; FIG. 6 is a perspective view showing an example of a binding system according to the fourth embodiment; FIG. 7 is a perspective view showing an example of a binding system according to the fourth embodiment; FIG. 8 is a side view showing an example of an operation of the binding device according to the fourth embodiment; FIG. 9 is a side view showing an example of an operation of the binding device according to the fourth embodiment, with some components omitted; FIG. 10 is a side view showing an example of an operation of the binding device according to the fourth embodiment, with some components omitted;

[0009] First Embodiment A first embodiment of the present invention will be described below 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 the first 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 formed by 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, acquiring signal information including first information such as distance information from the rebar S and image information of the workpiece B. Specifically, the first camera 31 in this embodiment 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 a first 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. The moving 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 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 moving 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 moving 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 moving 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 an example of a moving body according to the present invention, and is equipped with an individual photographing unit 5 and a 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 main 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 main body 40 includes a base 41, a plurality of arms 42, an end effector 43, and a plurality of joints 44. Note that the robot arm main 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. Furthermore, it is preferable that the robot arm 4 can change the position on each of three orthogonal axes and the angle around at least one of the three orthogonal axes for at least one of the individual photographing unit 5 (second camera 51) and the binding device 6.

[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 toward the tip (downward) and photographs the intersections P of the rebars S to be bundled from above. The second camera 51 is provided so as to be movable toward the tip (up and down) relative to the end effector 43. The second camera 51 in this embodiment is, for example, an RGB camera and 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 a second information acquisition unit according to the present invention. The second camera 51 is not particularly limited in terms of the type of sensor, as long as it can acquire an image of at least one intersection P (signal information of the intersection P of the rebar S, which is the second information, including the image). The lifting motor 52 is a drive source that moves (raises 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 shooting range, and illuminates the target to be shot by the second camera 51. The lighting unit 53 in this embodiment has multiple light sources (projectors, not shown) that can illuminate the target to be shot 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.

[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 about the multiple intersections P to be bundled. Here, "signal information about intersections P" is data including at least one of position information about intersections P and position information about obstacles that may hinder the bundling work at intersections P. 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 (binding machines) that can bind the target intersection Pa. 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 First Embodiment] As described above, according to this embodiment, signal information (first information) regarding the plurality of installed reinforcing bars S is acquired by the first camera 31, and signal information (second information) regarding the intersections P of the plurality of reinforcing bars S is acquired by the second camera 51 based on the first information. That is, based on the first information acquired by the first camera 31, information such as the positions of the plurality of intersections P and the presence or absence of obstacles is grasped over a relatively wide area. Then, based on the first information, the second camera 51 or the binding device 6 approaches a specific intersection P, and the second camera 51 moves in a manner such as to avoid obstacles at that time. As a result, more accurate signal information (second information) over a more localized area is acquired by the second camera 51. Then, the intersections of the reinforcing bars are bound based on the second information. That is, the desired intersections P can be bound with high accuracy. Therefore, the intersections P of the plurality of reinforcing bars S can be bound suitably.

[0062] Furthermore, according to this embodiment, both the second camera 51 and the binding device 6 are mounted and moved integrally on the robot arm 4. This makes it possible to suppress relative positional deviation between the second camera 51 and the binding device 6, unlike when the second camera 51 and the binding device 6 are moved separately. Therefore, the binding operation of the binding device 6 based on the position information of the intersection P acquired by the second camera 51 can be controlled with higher precision. As a result, the intersection P can be bound with higher precision.

[0063] Furthermore, according to this embodiment, the robot arm 4 can change the position on each of the three orthogonal axes and the angle around at least one of the three orthogonal axes for at least one of the second camera 51 and the binding device 6. This allows the position and posture of the second camera 51 and / or the binding device 6 to be flexibly changed and adjusted to perform photography and binding. Therefore, photography and binding can be preferably performed even when the work B is upright or tilted, for example.

[0064] Furthermore, according to this embodiment, the photographing area E1 (first area) where the first camera 31 acquires the signal information (first information) is different from the bundling area E2 (second area) where the robot arm 4 can move. This allows the photographing work by the first camera 31, the photographing work by the second camera 51, and the bundling work by the bundling device 6 to be performed separately. This improves work efficiency.

[0065] Furthermore, according to this embodiment, the holder 21 that holds the work B (plurality of rebars S) can be moved from the photography area E1 to the bundling area E2. In other words, by moving the work B, work can be performed in each area without moving the equipment on the device side. Therefore, the occurrence of measurement errors and the like that accompany moving the equipment on the device side can be suppressed. Furthermore, the size of the movement can be kept small compared to when the equipment on the device side is moved.

[0066] Furthermore, according to this embodiment, the holder 21 that holds the workpieces B (plurality of rebars S) can be moved from the bundling area E2 to the photographing area E1. In other words, the workpieces B that have been bound in the bundling area E2 can be returned to the photographing area E1. Therefore, the workpieces B that have been bound in the bundling area E2 can be photographed again in the photographing area E1. This makes it possible to check the binding condition, including detecting binding defects, and compare the condition of the workpieces B before and after binding.

[0067] Furthermore, according to this embodiment, the second camera 51 may acquire signal information (second information) regarding the intersections P of the reinforcing bars S in a state where they have been bound by the binding device 6. This allows for a detailed understanding of the state of the intersections P after the binding work. In addition, the positions of the bound intersections P in the entire work B can be understood.

[0068] Furthermore, according to this embodiment, signal information regarding the intersections P of the rebars S is stored in the memory unit 76. That is, the intersections P of the rebars S and the position information of obstacles can be recorded at any time and output as appropriate. Note that the memory unit 76 only needs to store at least one of the signal information (first information) acquired by the first camera 31 and the signal information (second information) acquired by the second camera 51.

[0069] Furthermore, according to this 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.

[0070] Furthermore, according to this embodiment, a map (map information) including position information of each intersection P in the work B (plurality of rebars S) may be created based on the signal information (second information) acquired by the second camera 51. This allows, for example, the map (positions of the intersections P) based on the first information acquired by the first camera 31 to be updated with more detailed, up-to-date data acquired by the second camera 51. Furthermore, when creating a map of the intersections P based on the second information acquired by the second camera 51, the map may be created prior to the bundling work, and then bundling of the plurality of intersections P may be performed continuously based on the map.

[0071] Furthermore, according to this embodiment, the traffic light information (first information and second information) regarding the intersection P is image data acquired by the first camera 31 and the second camera 51. Therefore, the user can easily check the content of the traffic light information by simply visually checking the image data.

[0072] Furthermore, according to this embodiment, one of the first camera 31 and the second camera 51 captures a monochrome image, and the other captures a color image. This makes it possible to reduce errors caused by color mismatch when comparing image data captured by the first camera 31 and image data captured by the second camera 51.

[0073] [Other Technical Effects of the First Embodiment] Conventionally, a bundling system has been known that automatically binds the intersections of intersecting rebars with wire in a workpiece in which multiple rebars are combined. 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 JP 2022-110556 A is applied to a self-propelled bundling device that travels over rebars assembled on a plane while bundling them. The technology acquires vertical point cloud information using a distance sensor and converts the point cloud information into a linear model to detect the intersections of the rebars. However, the technology described in JP 2022-110556 A has low accuracy in detecting intersections, making it difficult to grasp the shape of the rebars, such as the rebar diameter. In this regard, according to the present embodiment, the shape of the rebar S is detected based on contrast information included in image data (signal information) of the rebar S. This allows the position of the rebar S to be grasped based on changes in contrast, and shape information of the rebar S, such as the rebar diameter D and the rebar center Ax, can be obtained. Therefore, the shape of the reinforcing bar S can be suitably detected. Furthermore, it is also possible to select an optimum binding device 6 based on, for example, the reinforcing bar diameter D. Note that the image data (signal information) in this case is not particularly limited to a particular type (data format) as long as it is substantial image data having contrast information of the reinforcing bar being photographed.

[0074] 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.

[0075] 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.

[0076] 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.

[0077] 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.).

[0078] 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.

[0079] 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.

[0080] [Modification of the First Embodiment] In the first embodiment, the shape of the reinforcing bar S is determined based on image data acquired by the second camera 51. However, if the target image data is image data of the reinforcing bar 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, in this case, unlike the above embodiment, the image data includes multiple intersections P. Based mainly on this point, the following process may be performed after step S77, as shown in FIG. 10. In this case, the processes of 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 interpreted as the "intersection P."

[0081] 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.

[0082] 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.

[0083] 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.

[0084] 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.

[0085] [Other Modifications of First Embodiment] In the first 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).

[0086] 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.

[0087] 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.

[0088] 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.

[0089] Second Embodiment A second embodiment of the present invention will be described below with reference to the drawings. In view of the low versatility of bundling work using a bundling robot that performs bundling at each intersection in sequence according to a predetermined orbital motion, as in the specification of Chinese Patent No. 110328662 exemplified as prior art, the second embodiment discloses a bundling system and a bundling processing program that are configured to solve this problem.

[0090] The binding system 1C disclosed in this second embodiment has a binding device 6C and a control device 7C that are partially different in configuration from the binding device 6 and the control device 7 of the binding system 1 disclosed in the first embodiment, but the other configurations are the same as those of the binding system 1. Therefore, in this second embodiment, the binding system 1C will be mainly described in terms of the configurations of the binding device 6C and the control device 7C that are different from those of the binding device 6 and the control device 7, and the same configurations as those of the binding system 1 will be assigned the same reference numerals as those of the binding system 1, and redundant explanations will be omitted.

[0091] [Configuration of the Binding System] Fig. 11 is a perspective view of an apparatus main body 10C included in a binding system 1C according to the second embodiment, and Fig. 12 is a block diagram showing a general control configuration of the binding system 1C. As shown in these figures, the binding system 1C binds a workpiece B, which is made up of a plurality of reinforcing bars S arranged in a lattice pattern, with wire W at intersections P (see Fig. 14) where the plurality of reinforcing bars S intersect to form a binding body. Specifically, the binding system 1C includes an apparatus main body 10C and a control device 7C. The apparatus main body 10C includes a workpiece holding unit 2, an overall photographing unit 3, a robot arm 4, an individual photographing unit 5, and a binding device 6C.

[0092] 13 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 the control device 7C.

[0093] 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.

[0094] 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.

[0095] 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.

[0096] 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. 12 ) 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.

[0097] 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. 12), 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.

[0098] 13 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.

[0099] 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.

[0100] 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.

[0101] 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.

[0102] 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 paper surface of FIG. 13 and are arranged side by side in the same direction.

[0103] 13, 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.

[0104] 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 13 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.

[0105] 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.

[0106] 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.

[0107] 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. 13 ) in the direction Xw 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. 13 .

[0108] <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.

[0109] 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.

[0110] 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.

[0111] <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.

[0112] Figure 14 is a schematic diagram of 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 workpiece B is shown to be fewer than in Figure 11. 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 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 19 to 25.

[0113] 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.

[0114] 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.

[0115] 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.

[0116] 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.

[0117] 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.

[0118] 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.

[0119] 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.

[0120] <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.

[0121] 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.

[0122] 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.

[0123] 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 described with reference to FIGS. 15 and 16. FIGS. 15 and 16 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. 15 or in the direction shown in FIG. 16. Here, the binding direction extending diagonally upward to the right in FIG. 15 is defined as the first direction, and the binding direction extending diagonally upward to the left in FIG. 16 is defined as the second direction. The "binding direction" as a binding condition indicates whether the wire W will be bound in the first or second direction. The "binding direction" here refers to the direction along which the wire W will be bound after binding, as viewed perpendicular to the planar workpiece B.

[0124] The binding device 6C of the binding system 1C is designed to bind two wires W in one binding operation, and the two wires W shown in Figures 15 and 16 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 15 and subsequent figures.

[0125] 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. 17. 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. 17 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.

[0126] 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. 18 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.

[0127] 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."

[0128] 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.

[0129] 19 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. 19 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.

[0130] 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. 19 illustrates a case where 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.

[0131] Furthermore, in the (1) outer edge-first pattern, for intersections P other than the outer edge, as shown in the example of Figure 19, 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 near 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.

[0132] 20 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 inscribed in the area may be defined as the center of the area.

[0133] For example, if all the intersections P shown in Figure 20 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.

[0134] In this (2) center-first pattern, as shown in Figure 20, 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.

[0135] 21 shows the order of progress for each intersection P in the (3) horizontal feed pattern. When this (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.

[0136] The user may select and set from which end of the row in the Y direction among multiple 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 21 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.

[0137] 21, 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.

[0138] 22 shows the order of progress for each intersection P in the (4) vertical feed pattern. When this (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.

[0139] 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 the setting may be predetermined. Also, Figure 22 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, enabling work to be performed quickly.

[0140] 22, 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.

[0141] 23 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. 23 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.

[0142] 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.

[0143] 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.

[0144] 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. 24 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."

[0145] 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. 24, 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. 24, 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. 24, as an intersection P other than an "intersection P located at a corner" and an "intersection P located at an outer edge."

[0146] 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.

[0147] 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.

[0148] 25 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 marked with double circles in this figure are considered to be subject to binding.

[0149] 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.

[0150] For example, as shown in FIG. 25, 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."

[0151] 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."

[0152] 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.

[0153] <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.

[0154] The "standard mode" is a mode for performing standard bundling. In principle, this "standard mode" can be selected 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 performed. 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.

[0155] "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).

[0156] 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.

[0157] <Operation of the bundling system> Next, the operation of the bundling system 1C will be described. Fig. 26 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.

[0158] 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).

[0159] When the use of the map data 763C is selected, the control unit 77C reads the map data 763C from the storage unit 76C (step S103). At this time, 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.

[0160] 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).

[0161] 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.

[0162] 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).

[0163] 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.

[0164] 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.

[0165] 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.

[0166] 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.

[0167] 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).

[0168] 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.

[0169] 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.

[0170] 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.

[0171] 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.

[0172] <Technical Effects of the Second Embodiment> The control device 7C of the binding system 1C includes a control unit 77C that can select 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.

[0173] 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.

[0174] 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.

[0175] 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.

[0176] 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.

[0177] In addition, the control unit 77C 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.

[0178] 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.

[0179] In addition, the control unit 77C of the control device 7C executes the bundling processing program 761C to realize the function of enabling selection of bundling conditions, so that it is easy to obtain that function from an existing bundling system without adding new hardware resources, thereby enabling reduction in the development burden of hardware resources and the manufacturing costs of the system.

[0180] <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.

[0181] 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 77C determines the possibility of interference between the binding device 6C and an obstacle, and if there is a possibility of interference, the control unit 77C 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.

[0182] <Other Matters in the Present Embodiment> The third embodiment of the present invention has been described above. However, the present invention is not limited to the above embodiment. For example, in the embodiment, 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 embodiment may be modified as appropriate without departing from the spirit of the invention.

[0183] 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.

[0184] 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.

[0185] 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.

[0186] 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.

[0187] 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.

[0188] The means for solving the problem in the second embodiment are as follows. [Solution 1] A bundling system for bundling a workpiece having intersections where reinforcing bars intersect with binders at the intersections, the bundling system comprising a control unit capable of selecting bundling conditions for the binders at the intersections. [Solution 2] The bundling system according to Solution 1, wherein the workpiece has a plurality of intersections, and the control unit is capable of selecting the order in which the binders are to be bundled at the plurality of intersections as the bundling condition. [Solution 3] The bundling system according to Solution 2, wherein the control unit is capable of selecting an operation mode that specifies the order in which the binders are to be bundled at the plurality of intersections. [Solution 4] The bundling system according to Solution 3, wherein the operation mode is to bundle the binders along the outer edge of the workpiece from the outer edge to the plurality of intersections. [Solution 5] The bundling system according to Solution 2, comprising a condition input unit for the bundling conditions, and the control unit executes bundling of the binders at the plurality of intersections in accordance with the bundling conditions input from the condition input unit. [Solution 6] The bundling system according to Solution 1, comprising: an intersection information acquisition means for acquiring information about the intersection; and an intersection identification means for identifying the intersection at which the bundling element will be bound from the acquired information about the intersection of the workpiece. [Solution 7] The bundling system according to Solution 1, comprising a recording device capable of recording information about the intersection acquired from outside the bundling system. [Solution 8] A bundling processing program that causes a computer controlling a bundling system that binds workpieces having intersections where multiple rebars intersect with bundling elements to realize a function of enabling selection of bundling conditions for the bundling element for the intersection.

[0189] Third Embodiment A third embodiment of the present invention will be described below with reference to the drawings. This third embodiment, in consideration of the prior art techniques described in Japanese Patent Application Publication No. 2013-35052 and Japanese Patent Application Publication No. 6-219420, in which a single rebar constituting a workpiece is bound by a binding element in the same uniform direction, resulting in a decrease in binding strength, discloses a binding system and a binding processing program having a configuration that can solve this problem. The binding system 1D disclosed in this third embodiment includes a control device 7D that differs in part from the control device 7C of the binding system 1C disclosed in the second embodiment, while the configuration of the device main body 10C is identical to that of the binding system 1C. Therefore, in this third embodiment, the binding system 1D will be described primarily with respect to the configuration of the control device 7D that differs from the control device 7C. Components identical to those of the binding system 1C are designated by the same reference numerals as those of the binding system 1C, and redundant description will be omitted.

[0190] [Configuration of the bundling system] Fig. 27 is a block diagram showing a schematic control configuration of the bundling system 1D. The bundling system 1D 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. 14) where the plurality of reinforcing bars S intersect to form a bundling body. Specifically, the bundling system 1D includes an apparatus main body 10C and a control device 7D.

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

[0192] The storage unit 76D is a memory configured with 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 77D. The storage unit 76D, which serves as a recording device, stores image data 762D captured by the first camera 31 and the second camera 51, map data 763D in which information about the workpiece B is recorded, binding direction data 764D generated in a binding direction determination process described below, machine body information data 766D indicating the three-dimensional position of the entire surface of the binding device 6C, and surrounding information data 767D indicating the three-dimensional position of the entire surface of obstacles around the robot arm 4 deployed in the coordinate system of the robot arm 4.

[0193] The control unit 77D is configured by, for example, a CPU (Central Processing Unit) and controls the operation of each unit of the control device 7D. Specifically, the control unit 77D operates each unit of the control device 7D based on the operation content of the operation unit 72, loads a program stored in advance in the storage unit 76D, and executes various processes in cooperation with the loaded program.

[0194] <Intersection Information Acquisition Process> The control unit 77D executes the bundling process program 761D described above to acquire information about the intersection P where the multiple reinforcing bars S of the workpiece B intersect. As described above, the control unit 77D controls the device main body 10C to perform bundling at the intersection P where the multiple reinforcing bars S of the workpiece B intersect with the wire W as a bundling body.

[0195] As with the bundling system 1C described above, the workpiece B has a grid-like configuration in which multiple rebars S aligned in the Y direction are arranged on top of multiple rebars S aligned in the X direction (FIG. 14). The positions where the center lines of the multiple rebars S aligned in the X direction and the multiple rebars S aligned in the Y direction intersect as viewed from the Z direction are intersection points P, and the bundling system 1D can target these intersection points P for bundling.

[0196] The control of the bundling operation by the control unit 77D 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 77D executes an intersection information acquisition process to acquire information about the intersections P to identify the positions of all of the intersections P of the work B. This intersection information acquisition process consists of a first acquisition process to acquire the positions of each intersection P from image data 762D captured by the first camera 31 or the second camera 51 functioning as the intersection information acquisition means, and a second acquisition process to acquire map data 763D from outside the bundling system 1D.

[0197] The control unit 77D 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 77D is configured to be capable of executing only the first acquisition process, the storage unit 76D may be configured not to store the map data 763D.

[0198] In the first acquisition process performed by the control unit 77D, when the image data 762D of the workpiece B on the 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.

[0199] Furthermore, if the image data 762D 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.

[0200] The second acquisition process performed by the control unit 77D is a process in which the control device 7D includes a communication device (not shown) that communicates with the outside of the bundling system 1D, requests and acquires the map data 763D from another external information processing terminal via a communication network, etc. Alternatively, the control device 7D may include a reading device (not shown) that reads a storage medium that stores the map data 763D, and acquires the map data 763D by reading from the storage medium.

[0201] The map data 763D 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 77D 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 763D into the coordinate system of the robot arm 4.

[0202] <Binding Direction Determination Process> The control unit 77D executes the bundling processing program 761D described above to perform processing to determine the bundling direction for the intersections P of the reinforcing bars S of the workpiece B. The processing to determine the bundling direction for each intersection P of the workpiece B is performed for all intersections P of the workpiece B based on the intersections P for identifying the positions of all intersections P of the workpiece B acquired by the intersection information acquisition process. Below, a method used by the control unit 77D to determine the bundling direction for the intersections P of the reinforcing bars S of the workpiece B will be described.

[0203] The "binding direction" with respect to the intersections P of the workpiece B is as described in the second embodiment. That is, referring to FIGS. 15 and 16 , the wire W bound to the intersections P of the X-direction rebars S and the Y-direction rebars S is in either the first direction shown in FIG. 15 or the second direction shown in FIG. 16 , which is inclined at approximately 45° with respect to both the X and Y directions, when viewed from above in the Z direction. In the process of determining the binding direction, the control unit 77D determines the "binding direction" for all intersections P of the workpiece B to be either the first direction or the second direction. The "binding direction" here refers to the direction in which the wire W is aligned after binding when viewed perpendicular to the planar workpiece B.

[0204] The binding device 6C of the binding system 1D is designed to use two wires W in one binding operation, and the two wires W shown in Figures 15 and 16 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 portions are not shown in the figures of this embodiment.

[0205] In the bundling direction determination process, the control unit 77D determines the bundling direction of each intersection P in accordance with the following bundling direction conditions (1) to (5): [Condition (1)] For each of all intersections P of the workpiece B, at least one other intersection P different from the intersection P formed by one reinforcing bar S and the other reinforcing bar S in the one reinforcing bar S and at least one other intersection P different from the intersection P formed by one reinforcing bar S and the other reinforcing bar S in the other reinforcing bar S is bound with wire W in a direction different from the intersection P formed by the one reinforcing bar S and the other reinforcing bar S. [Condition (2)] Based on condition (1), for all intersections P within the work area for the workpiece B, for intersections P located at corners of the work area, the direction in which wire W is bound is set to be as close to parallel as possible to the line connecting the intersection P and the center of the work area. [Condition (3)] Assuming condition (2), of all intersections P within the working area for work B, for at least one of two intersections P adjacent to an intersection P located at a corner of the working area, the bundling direction is set to be the same as the bundling direction of the intersection P located at the corner of the working area. [Condition (4)] Assuming condition (2), of all intersections P within the working area for work B, for an intersection P located at the outer edge of the working area, the bundling direction is set to be closer to parallel to the line connecting the intersection P and the center of the working area of ​​work B. [Condition (5)] Assuming condition (1), for each of all intersections P of work B, the bundling direction is set to be different from the bundling direction of all other adjacent intersections P.

[0206] When determining the binding direction of each intersection P according to the binding direction conditions (1) to (5), the control unit 77D needs to identify "intersection P located at a corner" and "intersection P located at an outer edge" within the working area. The definitions of "intersection P located at a corner" and "intersection P located at an outer edge" are the same as those described in FIG. 24 of the second embodiment. The "working area" in the binding direction conditions (2) to (4) refers to the narrower of the outer edge of the range of motion (the range within which the binding device 6C can move) of the binding device 6C, which is set when the robot arm 4 holding the binding device 6C performs binding work on the work B, and the outer edge of the area in which all of the intersections P of the work B exist. It may be assumed that both the range of motion of the binding device 6C and the area in which all of the intersections P of the work B exist are rectangular. 14 , in this embodiment, the area inside the four support plates 211 of the holder 21 is a rectangular movable area, which coincides with the rectangular area in which all of the intersection points P of the workpiece B exist. In this case, the area inside the four support plates 211 of the holder 21 is a rectangular "working area."

[0207] Within the above-described work area, as shown in FIG. 24 , the control unit 77D identifies, among all intersections P within the work area, an intersection P with two adjacent intersections P, such as the intersection P marked "A" in the area Ra surrounded by a two-dot chain line, as an "intersection P located at the corner of the work area." The control unit 77D also identifies, as an intersection P with three or fewer adjacent intersections P, such as the intersection P marked "B" in the area Rb surrounded by a two-dot chain line in FIG. 24 , as an "intersection P located at the outer edge of the work area." The control unit 77D then identifies, as an intersection P with four adjacent intersections P, such as the intersection P marked "C" in the area Rc surrounded by a two-dot chain line in FIG. 24 , as an intersection P other than an "intersection P located at the corner of the work area" and an "intersection P located at the outer edge of the work area."

[0208] Note that the above-mentioned "adjacent intersections P" refers to intersections adjacent via rebar S. In other words, it refers to intersections P adjacent in the X or Y direction, and does not include intersections P adjacent in a direction diagonal to either the X or Y direction. Furthermore, the "intersection P located on the outer edge of the work area" refers to an intersection with three or fewer other adjacent intersections P, and therefore also includes an "intersection P located at the corner of the work area" with two other adjacent intersections P.

[0209] The above-mentioned condition (1) will be explained based on Figure 28. As shown in the figure, one reinforcing bar S and the other reinforcing bar S that form an intersection P are designated Sx and Sy, respectively, and these intersections P are designated Po. This condition (1) requires that, with regard to the bundling direction of the wire W, at least one of the intersections P other than the intersection Po on one reinforcing bar Sx is in a direction different from the intersection Po, and at least one of the intersections P other than the intersection Po on the other reinforcing bar Sy is in a direction different from the intersection Po. Note that, since the bundling direction of the wire W can only be either the first direction or the second direction described above, "different bundling directions" means that one intersection P is in the first direction and the other intersection P is in the second direction.

[0210] Condition (1) requires that when bundling is performed at intersection Po along the second direction, the reinforcing bar Sx be bundled with the wire W along the first direction at any other intersection P other than intersection Po. Similarly, the reinforcing bar Sy is also required to be bundled with the wire W along the first direction at any other intersection P other than intersection Po. All intersections P of the workpiece B are required to be the same as intersection Po. Note that, in this embodiment, condition (1) exemplifies a case in which all intersections P of the workpiece B are required to be the same as intersection Po, but is not limited to this. For example, condition (1) may require only one intersection P or some intersections P of the workpiece B to be the same as intersection Po.

[0211] The aforementioned condition (2) will be explained with reference to FIGS. 29 and 32. This condition (2) is based on the premise that condition (1) is satisfied. Here, as shown in the figure, among all the intersection points P within the working area U relative to the workpiece B, the intersection points Pc located at the corners of the working area U are designated as Pc. The control unit 77D can identify the working area U according to the definition described above and determine the center C of the working area U. The center C of the working area U can be determined, for example, from the center of gravity (centroid) of the working area U. Furthermore, the control unit can identify all the intersection points P located at the corners of the working area U according to the definition described above in FIG. 24. In the example of FIG. 29, the intersection points P where the rebars S1 and S2 located at both ends of the working area U in the Y direction intersect with the rebars S3 and S4 located at both ends of the working area U in the X direction are the four intersection points Pc located at the corners of the working area U. Then, as shown in FIG. 29, a straight line Lc passing through the center C and each of the intersection points Pc located at the corners can be identified. Then, as shown in FIG. 32 , the intersection angle between the wire W facing in the first direction and the straight line Lc at an intersection point Pc located at a corner and the intersection angle between the wire W facing in the second direction and the straight line Lc at the same intersection point Pc are calculated. The direction with the smaller intersection angle between the first direction and the second direction is determined as the “direction closer to being parallel” to the straight line Lc and is determined as the bundling direction at the intersection point Pc. Note that in both cases, the line of sight is assumed to be from the Z direction. In the above case, the intersection angle between the wire W and the straight line Lc can be either an acute angle or an obtuse angle, and the acute angle is used for comparison. Depending on the shape of the work area, the intersection angle between the wire W facing in the first direction and the straight line Lc and the straight line Lc may both be equal. In such cases, the control unit 77D may select either the first direction or the second direction for the intersection point Pc. In this case, the control unit 77D may predetermine whether to decide on the "first direction" or the "second direction."

[0212] The above-mentioned condition (3) will be explained with reference to FIG. 30 . This condition (3) is based on the premise that condition (2) is satisfied. Here, as shown in the figure, the intersection Pn adjacent to the intersection Pc located at a corner of the work area U is designated as an intersection Pn on one side. The intersection Pn adjacent to the four intersections Pc located at the corners of the work area U is required to be bound with the wire W in the same direction as the intersection Pc. Therefore, in the case of FIG. 30 , the wire W is bound along the second direction at the intersection Pn adjacent to the intersection Pc located at the upper left corner of the figure, the wire W is bound along the first direction at the intersection Pn adjacent to the intersection Pc located at the upper right corner of the figure, the wire W is bound along the first direction at the intersection Pn adjacent to the intersection Pc located at the lower left corner of the figure, and the wire W is bound along the second direction at the intersection Pn adjacent to the intersection Pc located at the lower right corner of the figure. It should be noted that the intersection Pc located at the corner of the work area U has two adjacent intersections P, and both of these intersections P may be bound in the same direction as the intersection Pc located at the corner.

[0213] The above-mentioned condition (4) will be explained with reference to FIGS. 31 and 32. This condition (4) is based on the premise that condition (2) is satisfied. The control unit 77D can identify the center C of the working area U and all of the intersection points P located on the outer edge of the working area U according to the above-mentioned definition, and can therefore identify the line Lc passing through the center C and each of the intersection points P located on the outer edge, as shown in FIG. 31. Then, as shown in FIG. 32, the control unit 77D calculates the intersection angle between the wire W facing in the first direction and the line Lc at the intersection point P located on the outer edge, and the intersection angle between the wire W facing in the second direction and the line Lc at the same intersection point P. The direction with the smaller intersection angle between the first direction and the second direction is determined to be "more parallel" to the line Lc, and is determined as the bundling direction at the intersection point P. Note that in both cases, it is assumed that the line of sight is from the Z direction.

[0214] In the above case, the intersection angle between the wire W and the straight line Lc can be either an acute or obtuse angle, but the acute intersection angle will be compared. Furthermore, the intersection angle between the wire W facing the first direction and the straight line Lc and the wire W facing the second direction may both be equal. For example, a wire W that performs bundling at an intersection point P located on the outer edge of a rebar S that passes through the center C of the work area U and is parallel to the X direction, or a wire W that performs bundling at an intersection point P located on the outer edge of a rebar S that passes through the center C of the work area U and is parallel to the Y direction, has the same intersection angle in the first direction as the intersection angle in the second direction. In such a case, the control unit 77D may select either the first direction or the second direction for the intersection point P. In this case, the control unit 77D may predetermine whether to select the "first direction" or the "second direction."

[0215] The above-mentioned condition (5) will be explained with reference to Figure 33. This condition (5) is based on the premise that condition (1) is satisfied. This condition (5) specifies that the wire W is bound to each of all intersections P of the workpiece B in a direction different from that of all other adjacent intersections P. Therefore, as shown in Figure 33, the wire W bound to each intersection P is arranged in a so-called staggered configuration in which the first direction and the second direction are alternately arranged for all rows of intersections lined up in the X direction, and the first direction and the second direction are alternately arranged for all rows of intersections lined up in the Y direction.

[0216] The bundling direction of each intersection P that satisfies condition (5) can be the case shown in the example of FIG. 33 or the case where the bundling direction of the wire W is reversed between the first direction and the second direction for all intersections P in FIG. 33 . Therefore, it is preferable for the control unit 77D to define a condition for selecting either the pattern shown in FIG. 33 or the pattern opposite to that shown in FIG. 33 for each intersection P of the workpiece B. For example, it is preferable to define a condition such that the bundling direction of the wire W is the first direction (or the second direction) for intersections P located at specific positions on the workpiece B (e.g., intersections P located at specific corners). This enables the control unit 77D to uniquely determine the bundling direction of the wire W for all intersections P for the workpiece B. Note that in this embodiment, the condition (5) is exemplified as a case where the bundling direction of the wire W for all intersections P of the workpiece B must be different from that for all neighboring intersections P, but is not limited thereto. For example, condition (5) may require that the direction in which the wire W is bound is different from that of all other adjacent intersections P only for one intersection P or some intersections P of the work B.

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

[0218] Here, we will explain the usefulness of the bundling direction of the wire W relative to the intersection P of the workpiece B based on each of conditions (1) to (5). In the case of condition (1), if the control unit 77D determines the bundling direction of the wire W at each intersection P so as to satisfy this condition, all of the intersections P of all of the rebars S that make up the workpiece B will not be bundled in the same direction. If all of the intersections on a rebar S are bundled with other rebars S in the same bundling direction, stress will be applied in the same direction from each intersection P, making it more likely that gaps will occur between the rebars S and reducing the bundling strength. However, if the bundling direction for each intersection P of the workpiece B is determined according to condition (1), it is possible to avoid a reduction in bundling strength and achieve strong bundling of the workpiece B.

[0219] In the case of condition (5), when the control unit 77D determines the bundling direction of the wire W at each intersection P so as to satisfy this condition, bundling is performed alternately in the first direction and the second direction for multiple intersections P on a single rebar S. This distributes the direction of stress for each intersection P lined up along the rebar S, further reducing the gaps between the rebars S and enabling stronger bundling to the workpiece B more effectively.

[0220] The cases of conditions (2) to (4) will be described with reference to Figures 34 and 35 in addition to Figures 13 and 31. Figure 34 is a plan view of the binding device 6C in Figure 13 as seen from one side of the pivot axis Zr (for example, from above during the binding operation), and Figure 35 is a plan view with some of the configuration of the device main body 10C omitted.

[0221] As described above, the binding device 6C is configured such that the slack forming portion 62C is disposed on one side of the rebar binding machine 61C in the orthogonal direction Xw, which is the alignment direction of the curl guide 613C and the guiding guide 614C, in order to properly deform the wire W into a loop using the curl guide 613C and the guiding guide 614C. As shown in FIG. 34 , the binding device 6C protrudes most significantly from the pivot axis Zr toward the slack forming portion 62C in the orthogonal direction Xw. When binding the wire W in a predetermined binding direction, the robot arm main body 40 rotates the binding device 6C around the pivot axis Zr. In this case, if there is a portion protruding toward the orthogonal direction Xw around the pivot axis Zr, there is a risk of contact with an object standing in the Z direction around the binding device 6C or an object located higher than the workpiece B in the Z direction. 35, in the device main body 10C, there is a particular concern that the support columns 12 of the stand 11 may come into contact with the binding device 6C. The device main body 10C only has one support column 12 at each of the four corners, but if the overall weight of the device main body 10C increases, more support columns 12 may be provided along each beam 13. Furthermore, depending on the installation environment of the device main body 10C, obstacles other than the support columns may arise.

[0222] For this reason, when the wire W is tied to the workpiece B, it is preferable that the protruding portions of the binding device 6C, particularly the slack forming portion 62C, do not protrude outside the working area U. In Figure 31, the silhouette of the binding device 6C in a plan view is depicted by a two-dot chain line when the pivot axis Zr, which is the binding position of the binding device 6C, is positioned with respect to the multiple intersections P. In the silhouette of the binding device 6C in a plan view, the end that forms a semicircle in the longitudinal direction is the end on the individual photographing unit 5 side in the orthogonal direction Xw, and the end that forms a rectangle in the longitudinal direction is the end on the slack forming portion 62C side.

[0223] 31 , when conditions (2) to (4) are satisfied, a bundling direction that intersects with the outer edge of the work area U is selected at intersection P, which is a corner within the work area U. This allows the bundling operation to be performed with the slack forming part 62C, which is the most protruding part of the bundling device 6C, facing the inside of the work area U, reducing the possibility of contact between obstacles around the work area U and the slack forming part 62C, which is the most protruding part of the bundling device 6C. If a direction that does not satisfy conditions (2) to (4) is selected at intersection P of a corner, for example, if the first direction is selected at intersection P, which is the upper left corner of the page in FIG. 31 , the slack forming part 62C will protrude outward from the work area U to the left or top of the page in FIG. 31 , potentially causing contact with obstacles around the work area U. If conditions (2) to (4) are met, it is possible to eliminate the selection of a binding direction that may unavoidably cause the slack forming portion 62C to protrude outside the working area U, thereby reducing the possibility of contact between the slack forming portion 62C and an obstacle.

[0224] Furthermore, in the case of condition (3), the binding operation is performed on the intersection P adjacent to the corner intersection P in the same direction as the corner intersection P. If the binding direction is not properly selected for an intersection P near a corner, there is a possibility that the slack forming part 62C will protrude outward outside the working area U, just like the corner. Therefore, even in the case of condition (3), it is possible to reduce the possibility of contact between the slack forming part 62C and an obstacle. Furthermore, since the binding operation is performed on the intersection P adjacent to the corner intersection P in the same direction as the corner intersection P, it is possible to reduce the frequency of pivoting operations of the binding device 6C and speed up the binding operation.

[0225] Furthermore, in the case of condition (4), the bundling direction at intersection P located on the outer edge including the corner is selected to be nearly parallel to the line connecting the center C of the working area U and intersection P, so that the bundling operation can be performed with the slack forming part 62C, which is the most protruding part of the bundling device 6C, facing the inside of the working area U, thereby reducing the possibility of contact between the slack forming part 62C and obstacles outside the working area U. In particular, among intersections P located on the outer edge, the closer to a corner one is, the more likely it is that the bundling direction will unavoidably cause the slack forming part 62C to protrude outside the working area U. However, if condition (4) is satisfied, this possibility can be reduced, and the possibility of contact between the slack forming part 62C and obstacles can be reduced.

[0226] If the bundling directions of all the intersections P of the workpiece B are determined only according to condition (1), the number of combinations will be extremely large, so it is preferable to determine the conditions for narrowing down the options in advance. The conditions for narrowing down the options include, for example, the ratio of the number of intersections P in the first direction to the number of intersections P in the second direction for each rebar S, the lower limit of the number of intersections P in the first direction or the lower limit of the number of intersections P in the second direction for each rebar S, the ratio of the number of intersections P in the first direction to the number of intersections P in the second direction for all the intersections P of the workpiece B, and the degree of dispersion of the intersections P in the first direction and the intersections P in the second direction in the arrangement of all the intersections P of the workpiece B (for example, dividing the area where all the intersections P of the workpiece B exist into multiple areas and making the number of intersections P in the first direction and the number of intersections P in the second direction in each divided area closer to equal). Furthermore, for intersections P for which the binding direction cannot be determined even when taking into consideration condition (1) and the narrowing down conditions, it is more preferable to decide in advance whether to make all of them the first direction, all of them the second direction, or to make the ratio of the first direction to the second direction more equal.

[0227] Furthermore, since the number of possible combinations for determining the binding directions of all intersections P of the workpiece B based solely on condition (2) is extremely large, it is preferable to predetermine narrowing-down conditions. For example, within the work area U, intersections P other than those located at each corner may be set to the same binding direction as the intersection P located at the nearest corner. Other narrowing-down conditions, such as those in condition (1), may also be added. Furthermore, for intersections P whose binding directions cannot be determined even after considering condition (2) and the narrowing-down conditions, it is more preferable to predetermine that all intersections P be in the first direction, all be in the second direction, or that the ratio of the first and second directions be more equal.

[0228] Furthermore, since the number of combinations is extremely large when determining the binding direction of all intersections P of the workpiece B according to condition (3) alone, it is preferable to predetermine narrowing-down conditions. For example, within the work area U, intersections P other than those located at each corner and their adjacent intersections P may be set to the same binding direction as the intersection P located at the nearest corner. Other narrowing-down conditions, such as those in condition (1), may also be added. Furthermore, for intersections P whose binding direction cannot be determined even after considering condition (3) and the narrowing-down conditions, it is more preferable to predetermine that all intersections P be in the first direction, all be in the second direction, or that the ratio of the first direction to the second direction be more equal.

[0229] Furthermore, since the number of possible combinations for determining the binding directions of all intersections P of the workpiece B based solely on condition (4) is extremely large, it is preferable to predetermine narrowing-down conditions. For example, within the work area U, intersections P other than those located at each corner and on the outer edge may be set to the same binding direction as the intersection P located at the nearest corner or on the outer edge. Other narrowing-down conditions, such as those in condition (1), may also be added. Furthermore, for intersections P whose binding directions cannot be determined even after considering condition (4) and the narrowing-down conditions, it is more preferable to predetermine that all intersections P be in the first direction, all be in the second direction, or that the ratio of the first and second directions be more equal.

[0230] Furthermore, when determining the binding direction of all intersections P of work B according to condition (5) alone, there are only two possible combinations, so as mentioned above, it is sufficient to predetermine whether a specific intersection P will be in the first direction or the second direction.

[0231] <Operation of the bundling system> Next, the operation of the bundling system 1D will be described. Fig. 36 is a flowchart showing the procedure when the bundling system 1D executes the bundling process. The CPU of the control unit 77D of the control device 7D executes the following bundling process in accordance with the bundling process program 761D.

[0232] By executing the bundling processing program 761D, the control unit 77D executes an intersection information acquisition process to acquire information about the intersection P where the multiple rebars S of the work B intersect. In this case, the control unit 77D determines whether or not the user has selected to use the map data 763D via the operation unit 72, for example (step S201).

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

[0234] On the other hand, if the use of map data 763D is not selected, the control unit 77D 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 S205).

[0235] When the map data 763D is read or the workpiece B is photographed by the first camera 31, the control unit 77D obtains three-dimensional position data of all intersections P of the rebars S of the workpiece B from the map data 763D or image data 762D, 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 S207). Therefore, the control unit 77D functions as an intersection identification means.

[0236] Next, the control unit 77D 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 S209).

[0237] Next, the control unit 77D determines the bundling directions for the workpiece B or all of the intersections P within the work area U based on the determined bundling direction determination condition (any of the above-mentioned conditions (1) to (5)). In this case, the narrowing conditions described above for each of the conditions (1) to (5) may also be taken into consideration (step S211). After determining the bundling directions for the workpiece B or all of the intersections P within the work area U, the control unit 77D generates and records bundling direction data 764D in the storage unit 76D. This bundling direction data 764D may be used without performing the processing of step S211 when performing a bundling operation on another workpiece B with the same design conditions.

[0238] Then, the control unit 77D controls the robot arm 4 to position the second camera 51 at the photographing position of the intersection P where bundling will be performed first, and drives the lifting motor 52 to move the second camera 51 closer to the intersection P (step S213). Note that the bundling order for each intersection P is determined according to predetermined operating conditions, etc.

[0239] Next, the control unit 77D causes the second camera 51 to capture an image of the intersection P (step S215). By capturing an image of the intersection P closer to the intersection P 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 762D.

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

[0241] Then, the control unit 77D activates the binding device 6C to bind the intersection P with the wire W (step S221). Thereafter, the control unit 77D again controls the robot arm 4 to position the second camera 51 at the image capturing position of the intersection P, and drives the lift motor 52 to move the second camera 51 closer to the intersection P (step S223), thereby capturing an image (step S225).

[0242] The control unit 77D then determines whether the bundling is being performed in the same direction as determined in step S211 based on the captured image data 762D (step S227). If the result is that the bundling direction is not the direction determined in step S211, an error is reported (step S229) and the bundling operation is terminated. The error may be reported by a dedicated reporting device such as a reporting lamp or buzzer, or by displaying a report on the display unit 73. If the control unit 7D is equipped with a device for communicating with the outside, the error may be reported to the outside via communication.

[0243] On the other hand, if it is determined in step S227 that the binding has been performed in the binding direction determined in step S211, the control unit 77D determines whether the intersection P at which binding has been performed is the last intersection P or not, based on the information about the intersection P for identifying the position of the intersection P obtained in step S207 (step S231). If the intersection P at which binding has been performed is not the last intersection P, the control unit 77D identifies the next intersection P at which binding will be performed (step S233) and repeats the processes from step S213 to step S233. On the other hand, if the intersection P at which binding has been performed is the last intersection P, the control unit 77D ends the binding process for the work B.

[0244] As shown in step S229, an example of processing has been given in which an error is reported and the bundling operation is terminated if the bundling direction is not as determined, but it is also possible to report the occurrence of an error, record the error content, proceed to step S231, and continue the bundling operation for the subsequent intersection P.

[0245] <Technical Effects of the Third Embodiment> The control device 7D of the binding system 1D is equipped with a control unit 77D that binds, with respect to one reinforcing bar S and the other reinforcing bar S that form an intersection P, at least one other intersection P different from the intersection P formed by one reinforcing bar S and the other reinforcing bar S in one reinforcing bar S and at least one other intersection P different from the intersection P formed by one reinforcing bar S and the other reinforcing bar S in the other reinforcing bar S, with wire W along a direction different from the intersection P formed by the one reinforcing bar S and the other reinforcing bar S. This reduces the gaps between the reinforcing bars S that make up the workpiece B, making it possible to bind the workpiece B firmly.

[0246] Furthermore, the control unit 77D binds the wire W at the intersections P located at the corners of all the intersections P within the working area U for the workpiece B along a direction nearly parallel to the straight line Lc connecting the intersections P and the center C of the working area U. Therefore, it is possible to reduce the possibility of contact between the slack forming portion 62C, which is a protruding part of the binding device 6C, and an obstacle outside the working area U during the binding operation at the intersections P located at the corners.

[0247] Furthermore, the control unit 77D binds at least one of the intersections P adjacent to an intersection P located at a corner of the work area U with the wire W in the same direction as the intersection P located at the corner, among the multiple intersections P within the work area U for the work B. This makes it possible to reduce the possibility of contact between the slack forming portion 62C, which is a protruding portion of the binding device 6C, and an obstacle outside the work area U during the binding operation of the intersection P adjacent to the intersection P located at the corner. Furthermore, this reduces the frequency of the pivoting operation of the binding device 6C, making it possible to speed up the binding operation.

[0248] Furthermore, the control unit 77D binds the intersection P located on the outer edge of the working area U with the wire W in a direction more nearly parallel to the line Lc connecting the intersection P and the center of the working area U. This makes it possible to reduce the possibility of contact between the slack forming portion 62C, which is a protruding part of the binding device 6C, and an obstacle outside the working area U during the binding operation of the intersection P located on the outer edge.

[0249] Furthermore, the control unit 77D binds each of all intersections P of the workpiece B with wire W in a direction different from that of all other adjacent intersections P. This distributes the direction of stress at each intersection P aligned along the rebar S, further reducing the gaps between the rebars S and enabling the workpiece B to be bound more effectively and firmly.

[0250] In addition, the binding system 1D is provided with a second camera 51, which is installed next to the binding device 6C and serves as an intersection information acquisition means for acquiring information regarding the intersection P. Therefore, during the binding operation, it is possible to determine whether the binding direction of the bound wire W is appropriate, and to detect the occurrence of improper binding.

[0251] In addition, the control unit 77D of the control device 7D executes the binding processing program 761D to realize the function of controlling the binding of the wire W along a predetermined binding direction relative to the intersection P of the work B, so that this function can be obtained from an existing binding system without adding new hardware resources, making it possible to reduce the development burden of hardware resources and the manufacturing costs of the system.

[0252] <Use of Machine Information Data and Periphery Information Data> The memory unit 76D of the control device 7D of the binding system 1D stores machine information data 766D indicating the three-dimensional position of the entire surface of the binding device 6C and peripheral information data 767D indicating the three-dimensional position of the entire surface of obstacles around the robot arm 4. The control unit 77D may use these pieces of data 766D and 767D to determine whether or not the "binding direction" determined for each intersection P of the workpiece B is acceptable.

[0253] That is, since the machine information data 766D 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. In the binding operation of the binding device 6C, when the binding device 6C is rotated around the rotation axis Zr in accordance with the determination of the "binding direction," 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 767D that indicates the three-dimensional position of the entire surface of the obstacle around the robot arm 4. Therefore, when the control unit 77D determines the "binding direction," it determines the possibility of interference between the binding device 6C and an obstacle, and if there is a possibility of interference, the control unit 77D may perform processing such as notifying the user of the possibility of interference via the display unit 73 or the like, or automatically changing the currently determined "binding direction."

[0254] <Other Matters in the Present Embodiment> The third embodiment of the present invention has been described above. However, the present invention is not limited to the above embodiment. For example, in the embodiment, 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 embodiment may be modified as appropriate without departing from the spirit of the invention.

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

[0256] In the above embodiment, when describing the conditions (1) to (5) by which the control unit 77D determines the bundling direction, the example was given in which the work area U is a rectangular area with no missing parts. However, the bundling direction can also be effectively determined for work area U with other shapes. For example, even if the work area U has a rectangular shape with missing parts in various parts, the bundling direction of each intersection P can be determined according to the conditions (1) to (5) by identifying "intersections P located at corners" and "intersections P located on the outer edge" according to the definitions shown in Figure 24. Furthermore, if there is a missing part, such as a hole, inside the work area U, the area around the hole is also recognized as the outer edge of the work area U, and the bundling direction of each intersection P can be determined according to the conditions (1) to (5).

[0257] It is also possible to determine which direction the slack forming portion 62C, which is a protruding portion of the binding device 6C, should face relative to the pivot axis Zr for the irregular working area U described above. For example, in the case of a working area U that has a missing portion such as a hole, the slack forming portion 62C can be determined to face the opposite side relative to the pivot axis Zr from the outer edge of the working area U around the hole, where the intersection point P is closest.

[0258] Furthermore, in the present embodiment, the case has been exemplified where the outer edge of the range of motion of the binding device 6C, which is set when the robot arm 4 performs the binding operation on the workpiece B, coincides with the outer edge of the area in which all of the intersections P of the workpiece B exist, but these do not have to coincide. For example, if the area in which all of the intersections P of the workpiece B exist is larger than the range of motion of the binding device 6C, the area in which all of the intersections P of the workpiece B exist may be divided into multiple areas, and the robot arm 4 and the workpiece B may be moved hypothetically to perform the binding operation for each of the divided areas.

[0259] Furthermore, in the present embodiment, the control unit 77D of the bundling system 1D performs the process of determining the bundling direction of the wire W for each intersection P of the workpiece B, but this is not limiting. For example, the control unit 77D may not make a determination as to the bundling direction of the wire W for each intersection P of the workpiece B, but may instead use bundling direction data created by a user using the operation unit 72 to determine a bundling direction for each intersection P of the workpiece B so as to satisfy any one of the bundling direction conditions (1) to (5) described above, and the control unit 77D may perform the bundling operation in accordance with the bundling direction data. Alternatively, the control unit 77D may obtain bundling direction data, in which the bundling direction for each intersection P of the workpiece B is determined so as to satisfy any one of the bundling direction conditions (1) to (5) described above, from outside the bundling system 1D via communication or the like, and the control unit 77D may perform the bundling operation in accordance with the bundling direction data. In addition, a recording medium reading device may read a recording medium containing bundling direction data in which the bundling direction is determined for each intersection P of the work B so as to satisfy one of the bundling direction conditions (1) to (5) described above using an information processing terminal or the like not included in the bundling system 1D, and the control unit 77D may perform the bundling operation in accordance with the bundling direction data.

[0260] Furthermore, the bundling system 1D may be configured to acquire information about the intersections P that identify each intersection P of the workpiece B from only the map data 763D. In that case, the first camera 31 and the second camera 51 are not essential to the bundling system 1D. However, since the second camera 51 can more accurately position the bundling device 6C with respect to the intersections P, the bundling system 1D may be configured to omit only the first camera 31 and include the second camera 51. If the first camera 31 is omitted from the configuration of the bundling system 1D, the moving mechanism 32 that moves the workpiece B between the photography area E1 and the bundling area E2 may also be unnecessary.

[0261] In addition, in the binding system 1D 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.

[0262] Furthermore, in the bundling system 1D, a configuration in which the bundling 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 bundling 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 bundling 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 bundling 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.

[0263] Furthermore, the bundling system 1D 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, and precise bundling work can be performed on the workpiece B. However, it is also possible to eliminate these advantages and configure a bundling system equipped with the features of this embodiment for an outdoor-use bundling system.

[0264] The means for solving the problems in the third embodiment are as follows: [Solution 1] A binding system for a workpiece in which a plurality of reinforcing bars intersect with a plurality of reinforcing bars to form a plurality of intersections with a binding element using a moving binding device, the binding system including a control unit that binds, for one reinforcing bar and another reinforcing bar forming the intersections, at least one other intersection different from the intersection formed by the one reinforcing bar and the other reinforcing bar in the one reinforcing bar, and at least one other intersection different from the intersection formed by the one reinforcing bar and the other reinforcing bar in the other reinforcing bar, with the binding element along a direction different from the intersection formed by the one reinforcing bar and the other reinforcing bar. [Solution 2] The binding system described in Solution 1, wherein the control unit, when an intersection having two other adjacent intersections among all the intersections within the working area in which the binding device can move is an intersection located at a corner of the working area, binds the intersection located at the corner along a direction that is more nearly parallel to a line connecting the intersection and the center of the working area. [Solution 3] The binding system described in Solution 2, wherein the control unit, for at least one of the two intersections adjacent to the intersection located at a corner of the working area among the multiple intersections within the working area for the work, binds the binder along the same direction as the intersection located at the corner of the working area. [Solution 4] The bundling system described in Solution 2, wherein the control unit, when an intersection of the plurality of intersections within the working area for the workpiece that has three or fewer adjacent intersections is defined as an intersection located on the outer edge of the working area, binds the intersection located on the outer edge of the working area with the binder in a direction that is more nearly parallel to a line connecting the intersection and the center of the working area. [Solution 5] The bundling system described in Solution 1, wherein the control unit binds the intersection with the binder in a direction different from that of all other adjacent intersections. [Solution 6] The bundling system described in Solution 1, comprising: a bundling device that binds the intersection with the binder; and intersection information acquisition means that is provided in addition to the bundling device and acquires information about the intersection.[Solution 7] A binding processing program that causes a computer to control a binding system that uses a moving binding device to bind multiple intersections of a workpiece where multiple reinforcing bars intersect with each other, the binding system controlling the system binding the multiple intersections with binding elements using a moving binding device, the binding processing program causing a computer to control the binding of at least one other intersection different from the intersection formed by the one reinforcing bar and the other reinforcing bar in one of the reinforcing bars and at least one other intersection different from the intersection formed by the one reinforcing bar and the other reinforcing bar in the other reinforcing bar, along a direction different from the intersection formed by the one reinforcing bar and the other reinforcing bar.

[0265] Fourth Embodiment A fourth embodiment of the present invention will be described below with reference to the drawings. In the fourth embodiment, in consideration of the fact that the load on the wire feed section of the reinforcing bar binding machine fluctuates because the reinforcing bar binding machine rises and falls independently of the wire pull-out mechanism as in JP 2023-105958 A , which is exemplified as prior art, the fourth embodiment discloses a binding device and a binding system that can reliably pull out the amount of wire required for binding reinforcing bars and can suppress changes in the direction of the wire entering the binding machine.

[0266] <Configuration example of the binding device of this embodiment> Fig. 37A is a side view showing an example of the binding device of this embodiment, Fig. 37B is a side view showing an example of the binding device of this embodiment with some components omitted, Fig. 37C is a perspective view showing an example of the binding device of this embodiment, Fig. 37D is a rear view showing an example of the binding device of this embodiment, and Fig. 37E is a side view of the example of the binding device of this embodiment as seen from the back.

[0267] The binding device 100 includes a reinforcing bar binding machine 1E that binds the intersections of reinforcing bars S arranged in a lattice pattern with wire W, a slack forming unit 2E that pulls out the wire W from a reel 20E and forms slack in the wire W between the reinforcing bar binding machine 1E and the reel 20E, and a reel housing unit 200 that houses the reel 20E. Note that the slack forming unit 2E does not need to have the function of pulling out the wire W from the reel 20E as long as it can form slack.

[0268] 38 is a side view of the internal configuration of an example of a reinforcing bar binding machine. The reinforcing bar binding machine 1E is an example of a binding machine in which a wire W is fed in the forward direction indicated by an arrow F to wind it around a reinforcing bar S, and the wire W wound around the reinforcing bar S is fed in the reverse direction indicated by an arrow R to wind it around the reinforcing bar S and cut it, and then the wire W is twisted and the reinforcing bar S is bound with the wire W.

[0269] To achieve the above-described functions, the reinforcing bar binding machine 1E includes a wire feeding unit 3E that feeds the wire W and a wire guide 4E that guides the wire W. The reinforcing bar binding machine 1E also includes a curl forming unit 5E that forms a path for winding the wire W fed by the wire feeding unit 3E around the reinforcing bar S, and a cutting unit 6E that cuts the wire W wound around the reinforcing bar S. The reinforcing bar binding machine 1E further includes a binding unit 7E that twists the wire W wound around the reinforcing bar S, and a drive unit 8E that drives the binding unit 7E.

[0270] The wire feeding unit 3E includes a pair of feed gears 30 that sandwich and feed the wire W. The wire feeding unit 3E rotates the feed gears 30 by transmitting the rotational motion of a feed motor (not shown). As a result, the wire feeding unit 3E feeds the wire W sandwiched between the pair of feed gears 30 along the extension direction of the wire W. In a configuration in which multiple pieces of wire W, for example, two pieces of wire W, are fed to bind the reinforcing bars S, the two pieces of wire W are fed in a parallel state.

[0271] The wire feed unit 3E switches the rotation direction of the feed motor (not shown) between forward and reverse, thereby switching the rotation direction of the feed gear 30 and switching the feed direction of the wire W between forward and reverse, either feeding the wire W in the forward direction indicated by arrow F or feeding the wire W in the reverse direction indicated by arrow R.

[0272] The wire guides 4E are provided at predetermined positions upstream and downstream of the wire feeding unit 3E with respect to the feeding direction in which the wire W is fed in the forward direction. In a configuration in which two wires W are fed to bind reinforcing bars S, the wire guide 4E provided upstream of the wire feeding unit 3E regulates the radial orientation of the two wires W, aligns the two incoming wires W in parallel, and guides them between a pair of feed gears 30. The wire guide 4E provided downstream of the wire feeding unit 3E regulates the radial orientation of the two wires W, aligns the two incoming wires W in parallel, and guides them to the cutting unit 6E and the curl forming unit 5E. Note that the wire guide upstream of the wire feeding unit 3E is not shown in Figure 38.

[0273] The curl forming unit 5E includes a curl guide 50 that curls the wire W fed by the wire feeding unit 3E, and a guide 51E that guides the wire W curled by the curl guide 50 to the bundling unit 7E. In the reinforcing bar bundling machine 1E, the path of the wire W fed by the wire feeding unit 3E is regulated by the curl forming unit 5E, so that the trajectory of the wire W forms a loop Ru as shown by the two-dot chain line in Figure 38, and the wire W is wound around the reinforcing bar S.

[0274] The cutting unit 6E includes a fixed blade unit 60 and a movable blade unit 61E that cuts the wire W in cooperation with the fixed blade unit 60. The cutting unit 6E cuts the wire W by the rotational movement of the movable blade unit 61E around the fixed blade unit 60 as a fulcrum axis. In the cutting unit 6E, the movement of the binding unit 7E is transmitted to the movable blade unit 61E.

[0275] The binding unit 7E includes a locking member 70 that locks the wire W, and a sleeve 71 that operates the locking member 70. The driving unit 8E includes a torsion motor 80 and a reducer 81 that reduces speed and amplifies torque.

[0276] When the binding unit 7E is driven by the drive unit 8E, the sleeve 71 activates the locking member 70 to lock the wire W. After the cutting unit 6E cuts the wire W in conjunction with the operation of the sleeve 71, the binding unit 7E twists the wire W by rotating the locking member 70 and the sleeve 71 to bind the reinforcing bar S.

[0277] In the reinforcing bar binding machine 1E, the binding unit 7E is provided on an imaginary straight line 10L that is along the axial direction of the torsion motor 80, as shown by the dashed line in Figure 38. In addition, when the imaginary straight line 10L of the reinforcing bar binding machine 1E is oriented in the vertical direction, a curl guide 50 and an induction guide 51E are provided at the lower end of the machine in a form that protrudes from the main body 10E.

[0278] In addition, the reinforcing bar binding machine 1E has a wire feeding unit 3E provided on one side along a direction intersecting with the imaginary line 10L, which is a direction intersecting with the axial direction of the torsion motor 80.

[0279] Furthermore, in the binding device 100, a slack forming unit 2E is provided on the side of the reinforcing bar binding machine 1E where the wire feeding unit 3E is provided, i.e., on one side of the reinforcing bar binding machine 1E along a direction intersecting with the imaginary line 10L, which in turn intersects with the axial direction of the torsion motor 80. The slack forming unit 2E forms slack in the wire W between the reinforcing bar binding machine 1E and the reel 20E.

[0280] Furthermore, in the binding device 100, a reel storage section 200 is provided above the reinforcing bar binding machine 1E, along the direction in which the imaginary straight line 10L, which is the direction along the axial direction of the torsion motor 80, extends.

[0281] The reel housing 200 rotatably and detachably houses a reel 20E around which a long wire W is wound so as to be able to be unwound. The wire W is a wire made of a metal wire that can be plastically deformed, a wire made of a metal wire coated with resin, or a twisted wire.

[0282] When the reinforcing bar binding machine 1E is configured to bind reinforcing bars S with one wire W, the reel storage unit 200 stores one reel 20E around which one wire W is wound, and the reel 20E is configured to rotate and pull out one wire W. When the reinforcing bar binding machine 1E is configured to bind reinforcing bars S with multiple wires W, the reel storage unit 200 stores multiple reels 20E corresponding to the number of wires W, and each reel 20E is configured to rotate and pull out multiple wires W. For example, when the reinforcing bar binding machine 1E is configured to bind reinforcing bars S with two wires W, the reel storage unit 200 stores two reels 20E around which one wire W is wound, and each reel 20E is configured to rotate and pull out two wires W.

[0283] The reel accommodating section 200 may be provided with a braking section that allows rotation of the reel 20E in the direction in which the wire W is pulled out, but restricts rotation of the reel 20E in the opposite direction.

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

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

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

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

[0288] The guide member 21c is provided in a path of the wire W entering the first slack forming section 21E from the first guide section 23E, facing the guide surface 21f of the first slack forming roller 21a. The guide member 21c is provided between the pair of guide plates 21b, for example, in the form of a cylindrical member extending in a direction intersecting the guide plates 21b.

[0289] The guide member 21d is provided on the path of the wire W exiting the first slack forming portion 21E. The guide member 21d is, for example, a roller that is rotatable about a shaft 21h as a fulcrum and is provided between the pair of guide plates 21b.

[0290] The shafts 21h of the guide members 21c and 21d also function as spacers that define the gap between the pair of guide plates 21b.

[0291] The guide plate 21b is shaped to cover at least a portion of the side of the first slack forming roller 21a and at least a portion of the side of the guide members 21c and 21d, and to support the first slack forming roller 21a and the guide members 21c and 21d.

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

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

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

[0295] The guide member 22c is provided on the path of the wire W that enters the second slack forming portion 22E from the first slack forming portion 21E. The guide member 22c is, for example, a roller that is rotatable about a shaft 22h and is provided between the pair of guide plates 22b.

[0296] The guide member 22d is provided in the path of the wire W exiting the second slack forming section 22E, facing the guide surface 22f of the second slack forming roller 22a. The guide member 22d is, for example, a cylindrical member extending in a direction intersecting with the guide plates 22b, and is provided between the pair of guide plates 22b.

[0297] The shafts 22h of the guide members 22c and 22d also function as spacers that define the gap between the pair of guide plates 22b.

[0298] The guide plate 22b is shaped to cover at least a portion of the side of the second slack forming roller 22a and at least a portion of the side of the guide members 22c and 22d, and to support the second slack forming roller 22a and the guide members 22c and 22d.

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

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

[0301] The second guide portion 24E is provided between the second slack forming portion 22E and the rebar binding machine 1E. The second guide portion 24E may be provided with a braking portion that allows the wire W to pass through when the wire feeding portion 3E feeds the wire W, and that restricts the passage of the wire W when the slack forming portion 2E forms slack in the wire W.

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

[0303] The first guide portion 21i movably guides the first slack forming portion 21E in a direction along the feed path WL of the wire W entering the rebar binding machine 1E, which is defined by the wire feeding portion 3E, the wire guide 4E, etc. The second guide portion 22i movably guides the second slack forming portion 22E in a direction along the feed path WL of the wire W entering the rebar binding machine 1E. The second guide portion 22i supports the second slack forming portion 22E so that the guide surface 22f of the second slack forming roller 22a is positioned on an extension of the feed path WL of the wire W entering the rebar binding machine 1E, which is defined by the wire feeding portion 3E, the wire guide 4E, etc.

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

[0305] Pulley 25a is provided on the side closer to the rebar binding machine 1E along the movement direction of first slack forming unit 21E and second slack forming unit 22E. Pulley 25b is provided on the side farther from the rebar binding machine 1E along the movement direction of first slack forming unit 21E and second slack forming unit 22E. Belt 25c extends along the movement direction of first slack forming unit 21E and second slack forming unit 22E. First connecting portion 25e is connected to one side of belt 25c extending between the pair of pulleys 25a, 25b, and second connecting portion 25f is connected to the other side of belt 25c extending between the pair of pulleys 25a, 25b.

[0306] One side and the other side of the belt 25c stretching between the pair of pulleys 25a, 25b move in the opposite direction as the pulley 25a is driven by the motor 25d to rotate, whereby the first slack forming portion 21E and the second slack forming portion 22E move relatively toward or away from each other depending on the direction of rotation of the motor 25d.

[0307] The wire W unwound from the reel 20E extends laterally relative to the rebar binding machine 1E, intersecting with the axial direction of the torsion motor 80, and its path is changed by the first guide unit 23E toward the slack forming unit 2E. The wire W passing through the slack forming unit 2E has its path changed by the second slack forming roller 22a toward the wire feed unit 3E of the rebar binding machine 1E.

[0308] In the binding device 100, the rebar binding machine 1E is attached to the binding machine support portion 101, and the reel storage portion 200 is attached to the storage portion support portion 102. In addition, the binding machine support portion 101 is attached to the storage portion support portion 102. Furthermore, in the binding device 100, the slack forming portion 2E is attached to the slack forming portion support portion 103. In addition, in the binding device 100, the storage portion support portion 102 and the slack forming portion support portion 103 are attached to the support portion 104.

[0309] The binding device 100 has a support part 104 provided above the rebar binding machine 1E and the reel storage part 200 along the axial direction of the torsion motor 80, and an attachment part 105 to which the robot arm 300 is attached is provided on the support part 104.

[0310] Furthermore, the slack forming unit 2E has a first slack forming unit 21E, a second slack forming unit 22E, and a drive unit 25 provided on one side of the slack forming unit support unit 103, and a control unit 250 for the drive unit 25 and the like provided on the other side of the slack forming unit support unit 103. The control unit 250 includes a control board (not shown), a board accommodating unit 250a for accommodating the control board, and the like.

[0311] As shown in Fig. 38 , in the reinforcing bar binding machine 1E, the binding unit 7E is provided on an imaginary line 10L that is aligned with the axial direction of the torsion motor 80. Furthermore, as shown in Fig. 37A , in the binding device 100, the attachment unit 105 is provided on the imaginary line 10L. As a result, in the binding device 100, the binding unit 7E and the attachment unit 105 are provided on the same imaginary line 10L. Therefore, when the orientation of the reinforcing bar binding machine 1E is oriented in the up-down direction so that the curl forming unit 5E faces downward, the binding unit 7E is provided vertically below the attachment unit 105.

[0312] Furthermore, when the binding device 100 is viewed from the side, the reel accommodating section 200 accommodates the reel 20E so that the axis of rotation of the reel 20E is located on an imaginary line 10L that passes through the binding section 7E and the attachment section 105. When the binding device 100 is viewed from a direction perpendicular to the imaginary line 10L, the position of the axis of rotation of each reel deviates from the imaginary line 10L depending on the number of reels used, but it is sufficient that the reels are arranged so that the center of the line connecting the axes of rotation of all the reels used is located on the imaginary line 10L; in other words, it is sufficient that the line connecting the axes of rotation of multiple reels used is located on the imaginary line 10L.

[0313] 39A and 39B are perspective views showing an example of a binding system according to this embodiment. The binding system 301 includes the binding device 100 described above and a robot arm 300. The binding system 301 also includes an overall photographing unit 303, an individual photographing unit 305 provided in the binding device 100, and a stand 311 on which the robot arm 300 and the overall photographing unit 303 are provided.

[0314] In the description of the binding system 301, the X, Y, and Z directions refer to the directions shown in Figures 39A and 39B. 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.

[0315] The stand 311 is formed in the shape of a rectangular parallelepiped that is long in the X direction, and is equipped with four pillars 312 erected at the four corners in the X and Y directions, and multiple beams 313 that are bridged in the X and Y directions at the upper ends of the pillars 312.

[0316] Of the area inside the stand 311, approximately half on one side in the X direction (the right side in Figures 39A and 39B) is the photography area E1 where photography is performed by the overall photography unit 303, and the half on the other side (the left side in Figures 39A and 39B) is the binding area E2 where binding operations are performed by the robot arm 300 and the binding device 100.

[0317] In the bundling system 301, a workpiece B, which is made up of a plurality of reinforcing bars S arranged in a lattice pattern, is held by a workpiece holding unit 302. The workpiece holding unit 302 holds the workpiece B and moves the held workpiece B between a photography area E1 shown in Fig. 39A and a bundling area E2 shown in Fig. 39B. Specifically, the workpiece holding unit 302 includes a holding table 321 that holds the workpiece B, rails 322 that movably support the holding table 321, a drive motor (not shown) that drives the rails 322, and the like.

[0318] The holding base 321 is formed in the shape of a rectangular plate with four sides aligned along the X and Y directions. Support plates 321a are provided on the four sides of the holding base 321 to support a plurality of reinforcing bars S that constitute the workpiece B. The support plates 321a have a plurality of U-shaped grooves 321b that open upward, and the reinforcing bars S are inserted into the U-shaped grooves 321b. The multiple reinforcing bars S are arranged in a lattice pattern along the X and Y directions with their ends inserted into the U-shaped grooves 321b of the support plates 321a.

[0319] The rails 322 are laid along the X direction and guide the holder 321 in the X direction. The rails 322 in this embodiment are laid so that the holder 321 (work B) can move at least between the photography area E1 and the bundling area E2. However, the rails 322 may be configured to extend to the outside of the stand 311 so that the work B can be moved to a work process before or after bundling.

[0320] The overall photographing unit 303 photographs the entire workpiece B at once or for each of the divided areas. Specifically, the overall photographing unit 303 includes a first camera 331 disposed above the photographing area E1, and a moving mechanism 332 that movably supports the first camera 331.

[0321] The first camera 331 is disposed facing downward and photographs the workpiece B held by the workpiece holder 302 from above in the photographing area E1. The first camera 331 is a compound eye (for example, four-eye) stereo camera and is capable of acquiring distance information in the depth direction (up and down direction) along with image information (monochrome image) in the XY plane. Note that the sensor type of the first camera 331 is not particularly limited as long as it can acquire distance information (depth information) along with image information.

[0322] The movement mechanism 332 includes a Y-direction slider 333 extending along the Y direction. The Y-direction slider 333 is suspended on a beam 313 extending along the X direction and supported by the beam 313 so as to be movable in the X direction. The first camera 31 is suspended from the Y-direction slider 333 so as to be movable in the Y direction. The movement mechanism 332 is driven by a drive source (not shown) and moves the first camera 331 to a predetermined position (XY coordinates).

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

[0324] The moving mechanism 346 includes a Y-direction slider 346a suspended on the beam 313 of the stand 311. The Y-direction slider 346a moves the robot arm 300 in the Y direction. Note that the moving mechanism 346 may include, for example, a mechanism for moving the robot arm 300 in the X direction. Furthermore, if the operating range of the robot arm 300 can cover the entire binding area E2 without relying on the moving mechanism 346, the moving mechanism 346 does not need to be provided.

[0325] The robot arm 300 is a ceiling-suspended articulated robot, and is installed facing downward on a Y-direction slider 346a suspended on a beam 313 in the binding area E2. Specifically, the robot arm 300 includes a base 341, a plurality of arms 342, an end effector 343, and a plurality of joints 344. Note that the robot arm 300 is not limited to an articulated robot.

[0326] The arms 342 are connected in series with the base portion 341 as a base end portion. The base portion 341 is supported by a Y-direction slider 346a of a movement mechanism 346 and is movable in the Y direction.

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

[0328] The end effector 343 is connected to the tips of the multiple arms 342. The end effector 343 supports the individual photographing unit 305 and also supports the binding device 100 via the attachment unit 105.

[0329] The individual photographing unit 305 is mounted on the tip of the robot arm 300, and photographs the intersections of the rebars S to be bundled individually in the binding area E2 with a higher resolution than that of the overall photographing unit 303. Specifically, the individual photographing unit 305 includes a second camera 351, a lighting unit 353, an elevator motor (not shown), and the like.

[0330] The second camera 351 is attached to the end effector 343 of the robot arm 300 facing downward and photographs the intersections of the rebars S to be bundled from above. The second camera 351 is driven by an elevator motor (not shown) and moves up and down relative to the end effector 343. The second camera 351 is, for example, an RGB camera and acquires image information (color images) of the intersections to be bundled. Note that the type of sensor of the second camera 351 is not particularly limited as long as it can acquire an image (signal information) of at least one intersection.

[0331] The lighting unit 353 illuminates the subject to be photographed by the second camera 351 .

[0332] The bundling system 301 moves the work B to the photographing area E1, photographs the entire work B with the first camera 331 of the overall photographing unit 303, and acquires position information and the like of each intersection of the rebars S. After acquiring the position information and the like of each intersection of the rebars S, the bundling system 301 moves the work B to the bundling area E2, and based on the position information and the like of each intersection of the rebars S, moves the bundling device 100 with the robot arm 300 to the position of the intersection to be bound.

[0333] When the binding system 301 moves the binding device 100 to the position of the intersection of the binding target, the second camera 351 of the individual photographing unit 305 photographs the intersection of the binding target and acquires image information of the intersection of the binding target. Then, the binding system 301 obtains position information with higher accuracy than the position information of each intersection acquired by the overall photographing unit 303 from the image information acquired by the individual photographing unit 305, and moves the binding device 100 with the robot arm 300 to perform the binding operation.

[0334] <Example of operation of the binding device of this embodiment> Figures 40A and 41A are side views showing an example of operation of the binding device of this embodiment, and Figures 40B and 41B are side views with some parts omitted showing an example of operation of the binding device of this embodiment.

[0335] In the binding device 100, depending on the direction of rotation of the motor 25d, the first slack forming unit 21E and the second slack forming unit 22E move relatively away from each other from the standby position shown in Figures 37A, 37B, etc. to the slack forming position shown in Figures 40A and 40B, and also move relatively closer to each other from the slack forming position shown in Figures 40A and 40B to the standby position shown in Figures 41A and 41B.

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

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

[0338] The wire W entering the rebar binding machine 1E is clamped between a pair of feed gears 30. The pair of feed gears 30 are prevented from rotating due to an external force while the drive of a feed motor (not shown) is stopped. This prevents the wire W from being pulled out from between the pair of feed gears 30, even if the second slack forming roller 22a moves in a direction away from the rebar binding machine 1E and a force is applied to the portion of the wire W in contact with the guide surface 22f in a direction away from the rebar binding machine 1E.

[0339] The path of the wire W pulled out from the reel 20E is changed by the first guide portion 23E between the reel 20E and the first slack forming roller 21a toward the slack forming portion 2E. As a result, the first slack forming roller 21a moves in a direction approaching the rebar binding machine 1E, and the portion of the wire W in contact with the guide surface 21f is pulled in a direction approaching the rebar binding machine 1E, applying a force to pull the wire W out from the reel 20E.

[0340] In addition, as the second slack forming roller 22a moves in a direction away from the rebar binding machine 1E, the wire W in contact with the guide surface 22f is pulled in a direction away from the rebar binding machine 1E, and a force is applied via the first slack forming roller 21a to pull the wire W from the reel 20E.

[0341] The reel 20E can rotate when a force is applied to pull out the wire W. As a result, when the first slack forming roller 21a moves in a direction toward the rebar binding machine 1E and the second slack forming roller 22a moves in a direction away from the rebar binding machine 1E, the wire W is pulled out from the reel 20E.

[0342] In the binding device 100, when the first slack forming unit 21E moves from the slack forming position to the standby position, the first slack forming roller 21a moves in a direction away from the rebar binding machine 1E. When the first slack forming roller 21a moves in a direction away from the rebar binding machine 1E, the guide surface 21f moves away from the wire W. In addition, in the binding device 100, when the second slack forming unit 22E moves from the slack forming position to the standby position, the second slack forming roller 22a moves in a direction approaching the rebar binding machine 1E. When the second slack forming roller 22a moves in a direction approaching the rebar binding machine 1E, the guide surface 22f moves away from the wire W. As a result, a slack portion WB is formed in the wire W between the reel 20E and the rebar binding machine 1E.

[0343] The second slack forming unit 22E is supported by the second guide unit 22i so that the guide surface 22f is located on an extension of the feed path WL of the wire W entering the rebar binding machine 1E, which is defined by the wire feeding unit 3E, the wire guide 4E, etc. The second slack forming unit 22E is also guided by the second guide unit 22i so as to be movable in a direction along the feed path WL of the wire W entering the rebar binding machine 1E. This prevents the wire W entering the rebar binding machine 1E from significantly changing relative to the feed path WL when the second slack forming unit 22E moves from the standby position to the slack forming position, and vice versa.

[0344] When the first slack forming unit 21E moves from the slack forming position to the standby position, the guide member 22c guides the wire W between the pair of guide plates 21b. As a result, the pair of guide plates 21b prevent the wire W entering the first slack forming unit 21E from moving in the axial direction of the first slack forming roller 21a. This prevents the wire W entering the first slack forming unit 21E from becoming entangled with the first guide unit 23E, etc. Furthermore, in a configuration in which two wires W are used to bind the rebar S, the two wires W are prevented from becoming entangled in the slack forming unit 21E.

[0345] Furthermore, the wire W emerging from the first slack forming portion 21E is guided between a pair of guide plates 21b by guide member 21d. As a result, the pair of guide plates 21b prevent the wire W emerging from the first slack forming portion 21E from moving in the axial direction of the first slack forming roller 21a. Furthermore, guide member 21d prevents the wire W emerging from the first slack forming portion 21E from moving toward the second slack forming portion 22E. Therefore, the wire W emerging from the first slack forming portion 21E is prevented from becoming entangled with the second slack forming portion 22E, etc. Furthermore, in a configuration in which two wires W are used to bind the reinforcing bars S, the two wires W are prevented from becoming entangled in the slack forming portion 2E.

[0346] Furthermore, the wire W entering the second slack forming portion 22E is guided between a pair of guide plates 22b by guide member 22c. As a result, the pair of guide plates 22b prevent the wire W entering the second slack forming portion 22E from moving in the axial direction of the second slack forming roller 22a. Also, guide member 22c prevents the wire W entering the second slack forming portion 22E from moving toward the first slack forming portion 21E. Therefore, the wire W entering the second slack forming portion 22E is prevented from becoming tangled in the first slack forming portion 21E, etc. Furthermore, in a configuration in which two wires W are used to bind the rebar S, the two wires W are prevented from becoming tangled in the slack forming portion 2E.

[0347] Furthermore, the wire W coming out of the second slack forming portion 22E is guided between the pair of guide plates 22b by the guide member 22d. As a result, the pair of guide plates 22b prevent the wire W coming out of the second slack forming portion 22E from moving in the axial direction of the second slack forming roller 22a. Therefore, in a configuration in which the reinforcing bars S are bound with two wires W, entanglement of the two wires W in the slack forming portion 2E is prevented.

[0348] Figure 42 is a side view of a binding device showing an example of a binding operation, with some components omitted. In the reinforcing bar binding machine 1E, as shown in Figures 41A and 41B , when a slack WB is formed in the wire W by the slack forming unit 2E, the wire feeding unit 3E shown in Figure 38 feeds the wire W in the forward direction indicated by arrow F, and the curl forming unit 5E winds the wire W around the reinforcing bar S. When the wire feeding unit 3E feeds the wire W in the forward direction indicated by arrow F, the slack portion WB of the wire W is fed, as shown in Figure 42 . This eliminates the need to rotate the reel 20E with the force of the wire feeding unit 3E feeding the wire W in the forward direction indicated by arrow F, thereby reducing the load on the wire feeding unit 3E and suppressing the occurrence of wire feeding defects by the wire feeding unit 3E.

[0349] In order to wind the wire W wound around the reinforcing bar S onto the reinforcing bar S, the wire feeding unit 3E feeds the wire W in the reverse direction indicated by the arrow R, which creates slack in the wire W according to the amount of reverse feeding. This eliminates the need to rotate the reel 20E with the force of the wire feeding unit 3E feeding the wire W in the reverse direction indicated by the arrow R, thereby reducing the load on the wire feeding unit 3E and suppressing the occurrence of poor wire feeding by the wire feeding unit 3E.

[0350] In addition, in the binding device 100, the slack forming unit 2E forms a slack WB corresponding to the amount of wire W required in the operation of binding the reinforcing bar S with the reinforcing bar binding machine 1E, and then the operation of binding the reinforcing bar S with the reinforcing bar binding machine 1E is performed. Note that the slack forming unit 2E may be operated while the operation of binding the reinforcing bar S with the reinforcing bar binding machine 1E is being performed, and the slack forming unit 2E may form a slack WB corresponding to the amount of wire W required in the operation of binding the next reinforcing bar S.

[0351] The binding device 100 is configured so that the reinforcing bar binding machine 1E and the slack forming unit 2E can move as a single unit. As a result, the direction in which the slack portion WB of the wire W formed by the slack forming unit 2E enters the wire feeding unit 3E of the reinforcing bar binding machine 1E does not change when the binding device 100 is moved by the robot arm 300. Therefore, fluctuations in the load on the wire feeding unit 3E are suppressed, and poor wire feeding by the wire feeding unit 3E is suppressed.

[0352] Furthermore, compared to when the reinforcing bar binding machine 1E and the slack forming unit 2E are configured independently, the slack forming unit 2E can be located closer to the reinforcing bar binding machine 1E, thereby shortening the path length of the wire W. This eliminates factors that cause defects in wire feeding.

[0353] Furthermore, compared to when the rebar tying machine 1E and the slack forming unit 2E are configured independently, the tolerances when assembling the rebar tying machine 1E and the slack forming unit 2E together can be reduced, eliminating factors that cause defects in wire feeding due to the accuracy between the rebar tying machine 1E and the slack forming unit 2E.

[0354] Furthermore, the slack forming unit 2E includes a drive unit 25 that drives the first slack forming unit 21E and the second slack forming unit 22E that pull out the wire W wound on the reel 20E, so that the reinforcing bar binding machine 1E does not need to be raised or lowered, for example, in order to pull out the wire W from the reel 20E. As a result, the pulling out of the wire W does not depend on the distance between the reinforcing bar binding machine 1E and the surface on which the reinforcing bars S are placed.

[0355] Furthermore, the slack forming unit 2E has a first slack forming unit 21E, a second slack forming unit 22E, and a drive unit 25 provided on one side of the slack forming unit support unit 103, and a control unit 250 for the drive unit 25 and the like provided on the other side of the slack forming unit support unit 103. This prevents the wire W from coming into contact with the control unit 250 and the like when the slack forming unit 2E is activated to form slack in the wire W and when the wire feeding unit 3E feeds the wire W, thereby preventing malfunctions of the slack forming unit 2E and malfunctions in wire feeding.

[0356] In addition, the binding device 100 is provided with a storage section support section 102 that supports the reel storage section 200, a slack forming section support section 103 that supports the slack forming section 2E, and a support section 04 that supports the storage section support section 102 and the slack forming section support section 103, and by configuring the reel storage section 200 and the slack forming section 2E as a single unit, the binding device 100 can be made smaller.

[0357] Furthermore, the reinforcing bar binding machine 1E is provided with a binding machine support part 101, and the binding machine support part 101 is supported by the storage part support part 102, so that the relative positions of the reinforcing bar binding machine 1E and the reel 20E do not change, and inadvertent unwinding of the wire W is prevented. This prevents malfunction of the slack forming part 2E and wire feeding problems caused by excessive unwinding of the wire W.

[0358] Furthermore, the binding device 100 is provided with a slack forming unit 2E on the side of the reinforcing bar binding machine 1E where the wire feed unit 3E is provided. This prevents the path of the wire W entering the wire feed unit 3E from crossing the binding unit 7E, which is a movable part, and prevents the wire W from becoming entangled in the binding unit 7E, etc. Furthermore, space can be secured on the opposite side of the reinforcing bar binding machine 1E where the wire feed unit 3E is provided, so that even if there is an obstacle near the binding device 100, the reinforcing bar binding machine 1E can be moved to the position of the intersection of the reinforcing bars S to be bound. Furthermore, if a camera or the like is to be provided to photograph the intersection of the reinforcing bars S, a location for the camera can be secured.

[0359] Furthermore, the binding device 100 has a mounting portion 105 for mounting the binding device 100 to the robot arm 300 and the binding portion 7E of the rebar binding machine 1E, both of which are provided on an imaginary line 10L along the axial direction of the torsion motor 80. As a result, when the rebar binding machine 1E is oriented in the up-down direction with the curl forming portion 5E facing downward, the binding portion 7E is provided vertically below the mounting portion 105. This prevents the weight of the torsion motor 80, the binding portion 7E, and the like from being applied to the robot arm 300 via the mounting portion 105 at a position away from the imaginary line 10L along the axial direction of the torsion motor 80. This prevents the position of the rebar binding machine 1E from shifting from the intersection of the rebars S to be bound due to uneven load application to the robot arm 300.

[0360] Furthermore, when the binding device 100 is viewed from the side, the reel storage section 200 stores the reel 20E so that the axis of rotation of the reel 20E is located on an imaginary line 10L that passes through the binding section 7E and the attachment section 105. This prevents the weight of the reel 20E from being applied to the robot arm 300 via the attachment section 105 at a position away from the imaginary line 10L that runs along the axial direction of the torsion motor 80, and prevents the position of the reinforcing bar binding machine 1E from shifting from the intersection of the reinforcing bars S to be bound, due to uneven load being applied to the robot arm 300.

[0361] The slack forming unit 2E can ensure the amount of wire W pulled out while suppressing an increase in the amount of movement of the first slack forming unit 21E and the second slack forming unit 22E by moving the first slack forming unit 21E and the second slack forming unit 22E relative to each other. Note that, as long as the wire feed unit can sufficiently feed the wire to the bundling unit, that is, as long as the amount of wire W pulled out can be ensured or slack in the wire between the reel and the bundling machine can be ensured, the slack forming unit 2E may be configured such that one slack forming roller moves in a direction intersecting the path of the wire W. Also, the reel housing 200 may be configured to include a reel drive unit such as a motor that rotates the reel 20E, and slack in the wire W may be formed between the reel 20E and the rebar bundling machine 1E by rotating the reel 20E by driving the reel drive unit.

[0362] The means for solving the problems of the fourth embodiment are as follows. [Solution 1] A binding device comprising: a binding machine that binds a plurality of arranged reinforcing bars with wire; and a slack forming unit that forms slack in the wire between the binding machine and a reel around which wire supplied to the binding machine is wound, wherein the binding machine comprises a binding unit that binds the reinforcing bars with wire and a wire feeding unit that feeds wire to the binding unit, and the binding machine and the slack forming unit are configured to be movable as a unit. [Solution 2] The binding device described in Solution 1, wherein the slack forming unit comprises a slack forming mechanism that pulls out the wire wound on the reel and a drive unit that drives the slack forming mechanism. [Solution 3] A binding device described in Solution 2, wherein the slack forming unit support unit supports the slack forming unit, and the slack forming mechanism and the drive unit are provided on one side of the slack forming unit support unit and a control unit for the drive unit is provided on the other side. [Solution 4] The binding device according to Solution 3, comprising: a reel accommodating section for accommodating the reel; an accommodating section support section for supporting the reel accommodating section; and a support section for supporting the accommodating section support section and the slack forming section support section. [Solution 5] The binding device according to Solution 4, comprising: a binding machine support section for supporting the binding machine, the binding machine support section being supported by the accommodating section support section. [Solution 6] The binding device according to Solution 1, wherein the slack forming section comprises: a guide member for defining a path along which the wire passes between the reel and the binding machine. [Solution 7] The binding device according to Solution 1, wherein the slack forming section is provided on the side of the binding machine where the wire feed section is provided. [Solution 8] The binding device according to Solution 1, comprising: an attachment section that is attached to a moving body that moves the binding device in a direction along the arrangement surface of the placed reinforcing bars and in directions toward and away from the arrangement surface. [Solution 9] The binding device according to Solution 8, wherein the attachment portion is provided on an imaginary line passing through the binding portion, and when the orientation of the binding machine is in the up-down direction, the binding portion is provided vertically below the attachment portion. [Solution 10] The binding device according to Solution 8, further comprising a reel accommodating portion in which the reel is accommodated, wherein the reel accommodating portion accommodates the reel on an imaginary line passing through the attachment portion and the binding portion.[Solution 11] A binding system comprising: a binding device; and a moving body for moving the binding device; the binding device comprising: a binding machine for binding a plurality of arranged reinforcing bars with wire; a slack forming unit for forming slack in the wire between the binding machine and a reel around which wire supplied to the binding machine is wound; and a reel accommodating unit for accommodating the reel; the binding machine comprising: a binding unit for binding the reinforcing bars with wire; and a wire feeding unit for feeding wire to the binding unit; and the binding machine and the slack forming unit are configured to be movable as a unit.

[0363] This application is based on a Japanese patent application (Patent Application No. 2024-013038) filed on January 31, 2024, the contents of which are incorporated herein by reference.

[0364] To provide a bundling system capable of suitably bundling the intersections of a plurality of reinforcing bars.

[0365] REFERENCE SIGNS LIST 1 Binding system 2 Workpiece holding unit 3 Overall photographing unit 31 First camera (first information acquisition unit) 4 Robot arm (moving body) 40 Robot arm main body 5 Individual photographing unit 51 Second camera (second information acquisition unit) 6 Binding device 7 Control device 76 Memory unit 77 Control unit (map creation unit) 762 Image data 763 Work information B Work E1 Photographing area (first area) E2 Binding area (second area) P Intersection Pa Target intersection S Reinforcing bar W Wire

Claims

1. A bundling system comprising: a first information acquisition unit that acquires first information about a plurality of installed reinforcing bars; a second information acquisition unit that moves based on the first information and acquires second information about the intersections of the plurality of reinforcing bars; and a bundling device that bundles the intersections based on the second information.

2. The bundling system according to claim 1, further comprising a mobile body that integrally mounts and moves both the second information acquisition unit and the bundling device.

3. The binding system described in claim 2, wherein the moving body is capable of changing the position on each of three orthogonal axes and the angle around at least one of the three orthogonal axes for at least one of the second information acquisition unit and the binding device.

4. The bundling system according to claim 2, wherein a first area in which the first information acquisition unit acquires the first information is different from a second area in which the mobile object can move.

5. The binding system according to claim 4, further comprising a holding portion that holds the plurality of reinforcing bars, the holding portion being movable from the first region to the second region.

6. The binding system according to claim 5, wherein the holding portion is movable from the second region to the first region.

7. The bundling system according to claim 1, wherein the second information acquisition unit is capable of acquiring the second information relating to the intersections in a state bundling by the bundling device.

8. The bundling system according to claim 1, further comprising a storage unit that stores at least one of the first information and the second information.

9. A binding system as described in claim 1, comprising: a control unit that controls the operation of the binding device based on at least one of the first information and the second information; and a memory unit that stores work information related to the binding work performed by the binding device.

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

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

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

Images