Work robot system, marker member for work robot system, work robot system control method, travel program generation device, travel program generation method, and program

Abstract

This work robot system comprises: a work robot including a wagon capable of traveling on a floor surface, a manipulator mounted on the wagon and capable of arbitrarily changing the position and attitude of the fore end thereof, and a vision sensor attached to the fore end of the manipulator; and a marker member provided in a predetermined position on the floor surface. The marker member includes a post extending upright from the floor surface, and a marker which is provided at the upper end of the post and includes information related to position on the floor surface. The work robot includes a control device that controls travel of the wagon on the basis of the marker included in an image captured by the vision sensor.

Description

Title of Invention WORK ROBOT SYSTEM, MARKER MEMBER FOR WORK ROBOT SYSTEM, WORK ROBOT SYSTEM CONTROL METHOD, TRAVEL PROGRAM GENERATION DEVICE, TRAVEL PROGRAM GENERATION METHOD, AND PROGRAM Technical Field

[0001] The present disclosure relates to a work robot system, a marker member for a work robot system, a control method for a work robot system, a travel program generation device, a travel program generation method, and a program. The present application claims priority based on Japanese Patent Application No. 2024-148420 filed on August 30, 2024, the contents of which are incorporated herein by reference. Background Art

[0002] It is considered to mount a robot (manipulator) on an automated guided vehicle (AGV) and automatically transport the robot to a working position (for example, refer to PTL 1). In addition, a system in which a robot is mounted on a base and a movement of the base is controlled by a control device of the robot is considered (for example, refer to PTL 2). Citation List Patent Literatures

[0003] [PTL 1] Japanese Patent No. 2680298 [PTL 2] Japanese Patent No. 7395877 Summary of Invention Technical Problem

[0004] Meanwhile, an AGV on which a robot is mounted autonomously travels by a guidance system such as a magnetic guidance type or an optical guidance type. In general, a commercially available AGV in the related art is equipped with a dedicated sensor corresponding to the guidance system and various dedicated functions for autonomous travel control in a dedicated manner, and is highly functional and expensive. Therefore, for example, in a case where a commercially available AGV is introduced into a factory, there is a case where a function that is not used in the factory (for example, an automatic transport scheduling function or a map creation function) is included, and there is a possibility that a device configuration or a cost may be excessive for an application.

[0005] In addition, in a case where the AGV cannot precisely move to a correct working position, a relative position between the robot and the workpiece is deviated, and it is difficult for the robot to move the tool to a correct working point on the workpiece to perform work. Then, the accuracy of the work by the robot is reduced.

[0006] In addition, for example, PTL 2 discloses that, in a case where an operator determines that a deviation between a target position and an actual stop position is large, the robot is returned to an original position and the movement to the target position is retried. Therefore, in the system disclosed in PTL 2, the operator needs to always monitor the robot that is moving and perform an operation for the robot to move again, and thus the work cost of the operator increases accordingly.

[0007] The present disclosure has been made to solve the above-described problems, and an object of the present disclosure is to provide a work robot system, a marker member for a work robot system, a control method for a work robot system, a travel program generation device, a travel program generation method, and a program, which can cause a work robot to move with a simple and low-cost configuration. Solution to Problem

[0008] In order to solve the above-described problems, according to the present disclosure, there is provided a work robot system including a work robot including a carriage configured to travel on a floor surface, a manipulator mounted on the carriage and configured to freely change a position and an orientation of a distal end of the manipulator, and a vision sensor attached to the distal end of the manipulator, and a marker member provided at a predetermined position on the floor surface, in which the marker member includes a post that stands upward from the floor surface, and a marker that is provided at an upper end portion of the post and includes information related to a position on the floor surface, and the work robot includes a robot control device (control device) 10 that controls traveling of the carriage based on the marker included in an image captured by the vision sensor.

[0009] According to the present disclosure, there is provided a marker member for a work robot system including a work robot including a carriage configured to travel on a floor surface, a manipulator mounted on the carriage and configured to freely change a position and an orientation of a distal end of the manipulator, and a vision sensor attached to the distal end of the manipulator, the marker member including a post that is provided at a predetermined position on the floor surface and stands upward from the floor surface, and a marker that is provided at an upper end portion of the post and includes information related to a position on the floor surface.

[0010] According to the present disclosure, there is provided a control method for a work robot system, the control method including a step of causing the carriage to travel along a designated route, a step of capturing the marker by the vision sensor, and a step of controlling traveling of the carriage based on the marker included in an image captured by the vision sensor. Advantageous Effects of Invention

[0011] According to the work robot system, the marker member for the work robot system, and the control method for the work robot system of the present disclosure, the work robot can be moved with a simple and low-cost configuration. Brief Description of Drawings

[0012] FIG. 1 is a diagram showing an overall configuration of a robot system according to a first embodiment. FIG. 2 is a diagram showing a work robot according to the first embodiment as viewed from a direction different from that in FIG. 1. FIG. 3 is a perspective view showing a marker member according to the first embodiment. FIG. 4 is a block diagram showing a functional configuration of a robot control device and a travel control device according to the first embodiment. FIG. 5 is a flowchart showing an example of traveling processing of a carriage by the robot system according to the first embodiment. FIG. 6 is a diagram showing an example of route information according to the first embodiment. FIG. 7 is a diagram for describing the traveling processing of the robot system according to the first embodiment. FIG. 8 is a diagram showing an example of a hardware configuration of the robot control device and the travel control device. FIG. 9 is a block diagram showing a functional configuration of a travel program generation device and a robot control device according to a second embodiment. FIG. 10 is a flowchart showing an example of a process of the travel program generation device according to the second embodiment. FIG. 11 is a diagram for describing a process of the travel program generation device according to the second embodiment. FIG. 12 is a flowchart showing an example of traveling processing of a carriage by the robot system according to the second embodiment. FIG. 13 is a diagram for describing a process of the travel program generation device according to a third embodiment. FIG. 14 is a first diagram for describing a process of a travel program generation device according to a fourth embodiment. FIG. 15 is a second diagram for describing a process of a travel program generation device according to the fourth embodiment. Description of Embodiments

[0013] Hereinafter, embodiments for carrying out a work robot system, a marker member for a work robot system, and a control method for a work robot system according to the present disclosure will be described with reference to the accompanying drawings. However, the present disclosure is not limited only to the embodiments.

[0014] <First Embodiment> (Overall Configuration of Work Robot System) FIG. 1 is a diagram showing an overall configuration of a work robot system according to a first embodiment. As shown in FIG. 1, a work robot system 100 includes a work robot 1, a marker member 7, and an operation PC 3. The work robot 1 automatically performs work instructed by an operator in a working space such as a factory or a warehouse. The work robot 1 includes a carriage 2, a manipulator 11, a vision sensor 12, and a robot control device 10.

[0015] (Configuration of Carriage) FIG. 2 is a diagram of the work robot according to the first embodiment as viewed from a direction different from that in FIG. 1. The carriage 2 is, for example, an automated guided vehicle (AGV). In the present embodiment, the carriage 2 is formed in a rectangular shape in a plan view. As shown in FIGS. 1 and 2, the carriage 2 has a top plate 2t and a side surface 2s. The top plate 2t faces upward, and an article or the like to be transported by the work robot 1 may be mountable thereon. A height of the top plate 2t from a floor surface F is set in a range of, for example, about 10 cm to 30 cm. The side surfaces 2s extend downward from four sides of the top plate 2t. As shown in FIG. 1, the carriage 2 includes a travel control device 20, a drive device 21, wheels 23, and a stopper 24.

[0016] As will be described in detail later, the travel control device 20 controls the drive device 21 such that the carriage 2 moves (travels), stops, changes speed, and the like in accordance with a travel instruction of the robot control device 10.

[0017] The drive device 21 is a travel motor that operates the wheels 23 of the carriage 2. In the present embodiment, the wheels 23 are Mecanum wheels (registered trademark) having a plurality of rollers, and the drive device 21 has one travel motor for one wheel 23. The drive device 21 changes a combination of the wheels 23 to be rotated and a rotation speed and a rotation direction of each wheel 23 in accordance with a control command of the travel control device 20. Accordingly, the carriage 2 can move in any direction. In another embodiment, the wheels 23 may be general wheels instead of the Mecanum wheels. In this case, the drive device 21 has a travel motor that rotates the wheels and a steering mechanism that changes a direction of a wheel axle. In the following description, a main traveling direction of the carriage 2 by the plurality of wheels 23 (Mecanum wheels) may be referred to as an X-axis direction, and a width direction of the carriage 2 intersecting the X-axis direction in a horizontal plane may be referred to as a Y-axis direction.

[0018] The stopper 24 is a tool for fixing the carriage 2 so as not to move after the carriage 2 moves to a designated position.

[0019] The carriage 2 may further include a travel assist sensor (not shown). The travel assist sensor is a sensor for detecting the position and the traveling direction of the carriage 2 so that the carriage 2 can autonomously travel in a case where there is no travel instruction from the robot control device 10 to be described later. In the present embodiment, the travel assist sensor includes a position detection sensor that detects the movement amount of the carriage 2 in the horizontal direction (X-axis direction and Y-axis direction). The position detection sensor is a sensor using the same technique as a so-called optical mouse, and reads a pattern or the like of the floor surface to detect the movement amount of the carriage 2 in the X-axis direction and the Y-axis direction. In addition, the travel assist sensor may further include a gyrocompass that detects the traveling direction of the carriage 2.

[0020] In addition, the carriage 2 is provided with an obstacle detection sensor 26. The obstacle detection sensor 26 detects an obstacle around the carriage 2. The carriage 2 is configured to decelerate or stop in a case where the obstacle is detected to be present within a preset range by the obstacle detection sensor 26 during traveling under the control of the travel control device 20. In the present embodiment, the obstacle detection sensor 26 is provided at, for example, two corner portions located in a diagonal line shape of the carriage 2 having a rectangular shape in a plan view. The number of the obstacle detection sensors 26 to be installed and the installation positions can be appropriately changed.

[0021] (Configuration of Manipulator and Vision Sensor) As shown in FIGS. 1 and 2, the manipulator 11 is mounted on the carriage 2. In the present embodiment, the manipulator 11 is provided outward of the top plate 2t of the carriage 2 in a plan view. In the present embodiment, the work robot 1 has a support table 15 that supports the manipulator 11. The support table 15 is provided to protrude outward of the top plate 2t of the carriage 2 in a plan view. The support table 15 is provided to protrude from an upper end portion of a side surface 2s on one side in the width direction of the carriage 2 to one side in the width direction.

[0022] The manipulator 11 is provided on the support table 15. The manipulator 11 is an articulated robot arm having a plurality of joints. The manipulator 11 can change the position and the orientation of a distal end 11a in any way by rotating each joint. The configuration of the manipulator 11, such as the number of the joints of the manipulator 11, is not limited, and any configuration may be used.

[0023] A tool 13 is detachably attached to the distal end 11a of the manipulator 11. The tool 13 is an instrument for performing various types of work. The work performed by the work robot 1 is, for example, welding work, assembly work such as screw tightening or drilling, pick work such as gripping and moving of a component, finishing work, ultrasonic inspection work, appearance inspection work, or the like. The tool 13 corresponding to the work is attached to the distal end 11a of the manipulator 11.

[0024] The vision sensor 12 is attached to the distal end 11a of the manipulator 11. The vision sensor 12 is a camera that images the periphery of the work robot 1. FIG. 1 shows an example in which the vision sensor 12 includes a CCD camera 12A and a 3D camera 12B. The vision sensor 12 can image a landmark L provided in an area where the work robot 1 travels and moves. In the present embodiment, a guide line L1 and a marker L2 are provided as the landmark L.

[0025] (Configuration of Guide Line) The guide line L1 is provided on a floor surface F of an area where the work robot 1 travels and moves. The guide line L1 extends in a predetermined direction on the floor surface F in order to guide the traveling direction of the work robot 1.

[0026] (Configuration of Marker Member) FIG. 3 is a perspective view showing a marker member according to the first embodiment. As shown in FIGS. 1 to 3, the marker member 7 is provided at a predetermined position on the floor surface F. A plurality of the marker members 7 are provided, for example, at a position overlapping the guide line L1, a position along the route of the work robot 1, a stop position of the work robot 1, a position where the traveling direction of the work robot 1 is changed, and the like. In the present embodiment, for example, a plurality of the marker members 7 are provided at preset intervals in the extending direction of the guide line L1. Each of the plurality of marker members 7 includes a post 71 and a marker L2.

[0027] The post 71 stands upward from the floor surface F. The post 71 is formed in, for example, a columnar shape extending in the up-down direction. The post 71 may be formed in, for example, a wall shape (plate shape) extending in the up-down direction. The post 71 has an upward-facing surface 71t facing upward. In addition, the post 71 has a rectangular shape or a polygonal shape when viewed from above, and has a plurality of side surfaces 71s facing a side, which is a direction intersecting the up-down direction.

[0028] The marker L2 is provided at an upper end portion of the post 71. The marker L2 includes information related to the position on the floor surface F. In the present embodiment, the marker L2 is, for example, a QR code (registered trademark). In the present embodiment, the marker L2 includes an upper marker L2a and a side marker L2b. The upper marker L2a is provided on an upward-facing surface 71t of the post 71. The side marker L2b is provided on at least one side surface 71s of the plurality of side surfaces 71s of the post 71.

[0029] It is preferable that such a marker member 7 is provided at a height that can be detected by an obstacle detection sensor 16. That is, it is preferable that the marker member 7 is provided to extend above the obstacle detection sensor 16. Accordingly, the traveling carriage 2 is prevented from colliding with the marker member 7. In addition, it is preferable that the marker member 7 is lower than the support table 15. Accordingly, even in a case where the traveling carriage 2 deviates from the route, the support table 15 is prevented from colliding with the marker member 7. In addition, the marker member 7 preferably has a height of, for example, 5 cm or more in order to prevent a worker or the like who walks on the floor surface F from stumbling.

[0030] (Configuration of Robot Control Device) The robot control device 10 is mounted on the work robot 1. The robot control device 10 controls the operation of each part of the work robot 1. In addition, in the present embodiment, the robot control device 10 causes the carriage 2 to travel to a designated position. The designated position is, for example, a working position where the work robot 1 performs work, a storage position of the work robot 1, or the like. The designated position is designated by the operator of the work robot 1 via the operation PC 3.

[0031] (Configuration of Operation PC) The operation PC 3 is a computer operated by the operator of the work robot 1. The operation PC 3 performs wireless communication with the work robot 1. The operation PC 3 receives an operation of the operator and instructs the work robot 1 on the designated position as a destination and a route (passing position or the like) to the designated position.

[0032] (Functional Configuration of Robot Control Device) FIG. 4 is a block diagram showing a functional configuration of a robot control device and a travel control device according to the first embodiment. As shown in FIG. 4, the robot control device 10 includes a route acquisition unit 101, a sensor information acquisition unit 102, a detection unit 103, a travel instruction unit 104, and a manipulator control unit 105.

[0033] The route acquisition unit 101 acquires route information D1 indicating a route from the current position of the carriage 2 to the designated position from the operation PC 3.

[0034] The sensor information acquisition unit 102 acquires an image D2 captured by the vision sensor 12. For example, in the present embodiment, the sensor information acquisition unit 102 acquires the image D2 captured by the CCD camera 12A of the vision sensor 12 when the carriage 2 is moved.

[0035] The detection unit 103 detects a deviation amount of a traveling position or a traveling direction (angle) of the carriage 2 with respect to a designated route based on the guide line L1 and the marker L2 (the upper marker L2a and the side marker L2b) included in the image captured by the vision sensor 12 (the CCD camera 12A).

[0036] The travel instruction unit 104 outputs a travel instruction D4 to the carriage 2 (travel control device 20) to instruct the traveling position, stop, speed, and the like. For example, the travel instruction unit 104 instructs the carriage 2 to control the traveling direction (angle) of the carriage 2, based on the traveling direction of the carriage 2 detected by the detection unit 103 based on the guide line L1. In addition, the travel instruction unit 104 instructs the carriage 2 to correct the traveling position or the traveling direction (angle) of the carriage 2, based on the deviation amount of the carriage 2 detected by the detection unit 103 based on the marker L2.

[0037] The manipulator control unit 105 controls the manipulator 11 such that the vision sensor 12 and the tool 13 are in any position and orientation. The manipulator control unit 105 controls the manipulator 11 such that the vision sensor 12 takes a first orientation facing downward as shown in FIG. 1 during the movement of the carriage 2.

[0038] (Functional Configuration of Travel Control Device) As shown in FIG. 4, the travel control device 20 includes a motor control unit 201. The motor control unit 201 controls the drive device 21 to move, stop, or change the speed of the carriage 2. When there is no travel instruction from the robot control device 10, the motor control unit 201 may control the drive device 21 such that the carriage 2 autonomously travels to a designated position, based on a sensor value (the movement amount and the traveling direction of the carriage 2) of a travel assist sensor (not shown).

[0039] In a case where the carriage 2 is moved, the traveling position and the traveling direction of the carriage 2 may deviate from the designated route due to the influence of unevenness of the floor surface of a factory or the like, slipping of the wheels 23 on the floor surface F, inability to read the guide line L1, or the like. Therefore, in the present embodiment, in a case where the robot control device 10 of the work robot 1 captures the marker L2 with the vision sensor 12, the robot control device 10 detects the deviation amount of the carriage 2 from the route based on the captured marker L2, and gives a travel instruction to the travel control device 20 of the carriage 2 to correct the traveling position. The motor control unit 201 of the travel control device 20 controls the drive device 21 to adjust the traveling position of the carriage 2 in accordance with the travel instruction of the robot control device 10.

[0040] In addition, as described above, the wheels 23 of the carriage 2 of the present embodiment are Mecanum wheels. The motor control unit 201 may include a calculation unit 201A for calculating a control command value indicating the presence or absence of rotation, the rotation direction, the rotation speed, and the like of the travel motor of each wheel 23. For example, upon the coordinates of the movement destination being given, the calculation unit 201A calculates a control command value of each travel motor for the carriage 2 to move toward the coordinates of the movement destination. The motor control unit 201 controls the travel motor based on the control command value calculated by the calculation unit 201A.

[0041] (Traveling Processing of Carriage by Robot) FIG. 5 is a flowchart showing an example of a traveling process of a carriage by the robot according to the first embodiment. FIG. 6 is a diagram showing an example of route information according to the first embodiment. FIG. 7 is a diagram for describing traveling processing of the robot according to the first embodiment. Here, a flow of the traveling processing of the carriage 2 performed by the robot control device 10 of the work robot 1 will be described with reference to FIGS. 5 to 7.

[0042] The route acquisition unit 101 acquires the route information D1 (FIG. 4) indicating the route from the current position of the carriage 2 to the designated position from the operation PC 3 (step S101). The designated position is, for example, the working position of the work robot 1. The designated position and the route are input by the operator via the operation PC 3. As shown in FIG. 6, the route information D1 is represented by coordinates (X, Y, Z) of each of the start position (current position), the passing position, and the designated position (destination), and the orientation (R) of the carriage 2 at each position.

[0043] Upon acquisition of the route information D1, the robot control device 10 causes the carriage 2 to start traveling in accordance with the route information D1 (step S102). After the carriage 2 starts traveling, the robot control device 10 acquires the image D2 captured by the vision sensor 12 (step S103). As shown in FIGS. 1 and 7, in the present embodiment, first, the work robot 1 captures the image D2 in an orientation (first orientation) in which the vision sensor 12 is directed downward (floor surface) in the vertical direction.

[0044] In a case where the detection unit 103 detects the guide line L1 from the acquired image D2 (step S104; YES), the detection unit 103 detects a deviation amount of the traveling direction of the carriage 2 and a deviation amount of the carriage 2 in the Y-direction based on detection information D3 of the guide line L1 (step S105). The detection unit 103 detects the deviation amount indicating how much the position of the carriage 2 deviates in the Y-direction, for example, based on the position of the guide line L1 in the image D2. In addition, the detection unit 103 detects the deviation amount indicating how much the traveling direction of the carriage 2 deviates, for example, based on the angle of the guide line L1 in the image D2.

[0045] In addition, in a case where the detection unit 103 detects the upper marker L2a from the image D2 (step S104; YES), the detection unit 103 detects the coordinates (X, Y) and the angle (angle R around the Z-axis) of the detection position of the upper marker L2a in the image D2. The detection unit 103 detects a deviation amount indicating how much the position and the traveling direction of the carriage 2 deviate based on the coordinates and the angle of the upper marker L2a (step S105).

[0046] In a case where the detection unit 103 cannot detect the upper marker L2a in the first orientation (step S104; NO), the manipulator control unit 105 changes the position and the orientation of the manipulator 11 such that the manipulator 11 takes a second orientation in which the vision sensor 12 is directed forward in the traveling direction. Thereafter, in a case where the detection unit 103 detects the side marker L2b from the image D2 captured in the second orientation (step S104; YES), the detection unit 103 detects the coordinates (X, Y) and the angle (angle R around the Z-axis) of the detection position of the side marker L2b in the image D2. The detection unit 103 detects, based on the coordinates and the angle of the side marker L2b, a deviation amount indicating how much the position and the traveling direction of the carriage 2 deviate (step S105).

[0047] Next, the travel instruction unit 104 outputs the travel instruction D4 to the carriage 2 such that the deviation amount of the carriage 2 is reduced, based on the detected deviation amount and traveling position (step S106).

[0048] For example, as shown in (7) in FIG. 5, in a case where the deviation amount in the Y direction from the guide line L1 is detected, the travel instruction unit 104 outputs the travel instruction D4 to correct the position of the carriage 2 in the Y-direction. This travel instruction is represented by, for example, relative coordinates (X, Y) of the corrected position with respect to the current position of the carriage 2. In a case where the carriage 2 can change the traveling direction by the steering mechanism, a relative angle (R) of the corrected traveling direction with respect to the current traveling direction may be included in the travel instruction D4. The travel instruction unit 104 may output the travel instruction D4 to correct the traveling position of the carriage 2 in a case where the deviation amount is equal to or greater than a preset allowable value. That is, in a case where the deviation amount is less than the allowable value, the position of the carriage 2 need not be corrected.

[0049] In addition, as shown in (b) in FIG. 5, in a case where the traveling position of the carriage 2 is detected from the marker L2, the travel instruction unit 104 outputs the travel instruction D4 including coordinates indicating the next movement destination of the carriage 2, stop, speed change, or the like, based on the traveling position of the carriage 2 and the route information D1. For example, it is assumed that the route information D1 includes a route along which the carriage 2, after moving in the X-direction, moves in the Y-direction upon reaching a certain work area (area 3). At this time, upon detecting the carriage 2 has reached the work area (area 3) from a reading result of the marker L2, the travel instruction unit 104 outputs the travel instruction D4 designating coordinates of the next movement destination to the carriage 2. In a case where the reading result of the marker L2 includes information indicating "stop", "90° turn", or "traveling speed", the travel instruction unit 104 may include an instruction such as stop, 90° turn, or change (acceleration or deceleration) of the traveling speed in the travel instruction D4 according to the reading result. In addition, when causing the carriage 2 to stop, the travel instruction unit 104 may detect the deviation amount of the detection position of the marker L2, output the travel instruction D4 for adjusting the position and the orientation of the carriage 2, and output the travel instruction D4 indicating stop after the position and the orientation of the carriage 2 are adjusted.

[0050] Thereafter, the robot control device 10 determines whether or not the carriage 2 has stopped at the designated position (step S107). For example, in a case where the robot control device 10 has instructed the carriage 2 to stop at the stop position for the designated position (within the work area that is the destination) in step S105 (step S107; YES), the robot control device 10 stops the carriage 2. On the other hand, in a case where the robot control device 10 has not instructed the carriage 2 to stop at the stop position for the designated position in step S105 (step S107; NO), the robot control device 10 returns to step S102 and continues the traveling processing (steps S102 to S107) of the carriage 2.

[0051] In step S107, in a case where the carriage 2 has stopped at the designated position (step S107; YES), the work robot 1 reads the marker L2 (upper marker L2a) with the vision sensor 12 (step S108). The work robot 1 executes predetermined processing such as self-localization or interlock before the next operation, for example, based on the information included in the read marker L2 (QR code).

[0052] (Operations and Effects) As described above, the work robot system 100 according to the present embodiment includes the work robot 1 including the carriage 2 configured to travel on the floor surface F, the manipulator 11 mounted on the carriage 2 and configured to freely change the position and the orientation of the distal end of the manipulator 11, and the vision sensor 12 attached to the distal end 11a of the manipulator 11, and the marker member 7 provided at the predetermined position on the floor surface F, in which the marker member 7 includes the post 71 that stands upward from the floor surface F, and the marker L2 that is provided at the upper end portion of the post 71 and includes the information related to the position on the floor surface F, and the work robot 1 includes the robot control device 10 that controls the traveling of the carriage 2 based on the marker L2 included in the image captured by the vision sensor 12.

[0053] By guiding the carriage 2 using the vision sensor 12 attached to the manipulator 11, the work robot system 100 eliminates the need to separately provide a mechanism for guiding the carriage 2, and can realize both the configuration of the carriage 2 with a minimum amount of equipment and cost and the accurate movement of the carriage 2 along the route. In addition, the marker L2 is provided at the upper end portion of the post 71 that stands upward from the floor surface F. Therefore, compared to a case where the marker L2 is provided on the floor surface F, the marker L2 is less likely to be contaminated or damaged. Therefore, when the marker L2 is imaged by the vision sensor 12 attached to the distal end 11a of the manipulator 11 of the work robot 1, the vision sensor 12 can be easily brought close to the marker L2. As a result, the marker L2 can be easily and satisfactorily imaged, and the traveling control of the carriage 2 can be efficiently performed. In addition, the post 71 also functions as a protective member that prevents the carriage 2 from colliding with surrounding workers in a case where the carriage 2 deviates from the route.

[0054] In addition, the post 71 has the upward-facing surface 71t facing upward, and the marker L2 has the upper marker L2a provided on the upward-facing surface 71t. Accordingly, during the traveling of the carriage 2, the upper marker L2a provided on the upward-facing surface 71t of the post 71 can be satisfactorily imaged by performing imaging with the vision sensor 12 facing downward.

[0055] In addition, by providing the side marker L2b on the side surface 71s of the post 71, the marker L2 (side marker L2b) can be imaged by the vision sensor 12 even at a place away from the post 71 member. Accordingly, even in a case where the carriage 2 deviates from the route, the marker L2 is easily detected.

[0056] In addition, the manipulator 11 is provided on the support table 15 provided to protrude outward of the top plate 2t of the carriage 2 in a plan view. Therefore, compared to a case where the manipulator 11 is provided on the top plate 2t, a range in which the distal end 11a of the manipulator 11 reaches the side of the top plate 2t on which the support table 15 is provided is widened. Therefore, even in a case where the marker member 7 is separated from the traveling route of the carriage 2, the vision sensor 12 easily detects marker L2 of the marker member 7. As a result, the degree of freedom of the installation position of the marker member 7 is increased.

[0057] In addition, the height of the marker member 7 from the floor surface F is smaller than the height of the support table 15 from the floor surface F. Accordingly, even in a case where the carriage 2 deviates from the route, the support table 15 can be prevented from colliding with the marker member 7.

[0058] In addition, since the marker member 7 is provided to be detectable by the obstacle detection sensor 16, it is possible to prevent the carriage 2 from colliding with the marker member 7.

[0059] In addition, the robot control device 10 detects, based on the marker L2 included in the image captured by the vision sensor 12, the deviation amount of the carriage 2 with respect to the designated route, and corrects, based on the deviation amount, the traveling position or the traveling orientation of the carriage 2. As a result, the carriage 2 can be accurately moved along the route.

[0060] In the marker member 7 for the work robot system 100 as described above, the marker L2 is provided at the upper end portion of the post 71 that stands upward from the floor surface F. Therefore, compared to a case where the marker L2 is provided on the floor surface F, the marker L2 is less likely to be contaminated or damaged. Therefore, when the marker L2 is captured by the vision sensor 12 attached to the distal end 11a of the manipulator 11 of the work robot 1, the vision sensor 12 can be easily brought close to the marker L2. As a result, the marker L2 can be easily and satisfactorily captured, and the traveling control of the carriage 2 can be efficiently performed. In addition, in a case where the carriage 2 deviates from the route, the post 71 also functions as a protective member that prevents the carriage 2 from colliding with surrounding workers.

[0061] According to the control method of the work robot system 100 as described above, the marker L2 can be easily and satisfactorily captured, and the traveling control of the carriage 2 can be efficiently performed.

[0062] <Hardware Configuration> FIG. 8 is a diagram showing an example of a hardware configuration of the robot control device and the travel control device. A computer 900 includes a CPU 901, a main storage device 902, an auxiliary storage device 903, an input / output interface 904, and a communication interface 905.

[0063] The robot control device 10 and the travel control device 20 are each mounted on the computer 900. Each of the functions mentioned above is stored in the auxiliary storage device 903 in the form of a program. The CPU 901 reads the program from the auxiliary storage device 903, loads the program into the main storage device 902, and executes the above-described processing in accordance with the program. In addition, the CPU 901 secures a storage area in the main storage device 902 according to the program. In addition, the CPU 901 secures a storage area that stores currently processed data in the auxiliary storage device 903 in accordance with the program.

[0064] A program for realizing all or some of the functions of the robot control device 10 and the travel control device 20 may be recorded on a computer-readable recording medium, and the program recorded on the recording medium may be read by a computer system and executed to perform processing by each functional unit. The term "computer system" as used herein includes an OS and hardware such as peripheral devices. In addition, the term "computer system" also includes a homepage-providing environment (or a display environment) in a case where a WWW system is used. In addition, the term "computer-readable recording medium" refers to portable media such as a CD, a DVD, or a USB, or a storage device such as a hard disk built into the computer system. In addition, in a case where the program is distributed to the computer 900 by a communication line, the computer 900 receiving the distribution may expand the program to the main storage device 902, and may perform the above-described processes. In addition, the above-described program may be for implementing a part of the above-mentioned functions, or may also be capable of implementing the above-mentioned functions in combination with a program already recorded in the computer system.

[0065] <Second Embodiment> Next, a second embodiment will be described in detail with reference to FIGS. 9 to 12. The same components as those in the above embodiment are denoted by the same reference numerals, and detailed description thereof will be omitted.

[0066] (Functional Configuration of Travel Program Generation Device) FIG. 9 is a block diagram showing a functional configuration of a travel program generation device and a robot control device according to the second embodiment. In the present embodiment, an example in which the operation PC 3 functions as a travel program generation device 30 will be described. In another embodiment, the travel program generation device 30 may be hardware different from the operation PC 3. As shown in FIG. 9, the travel program generation device 30 includes a route generation unit 301, a travel program generation unit 302, and a transmission processing unit 303.

[0067] The route generation unit 301 generates route information D5 including the coordinates of the designated position and the passing position of the work robot 1 and the target orientation of the work robot 1 at the designated position and the passing position. The designated position is a destination of the work robot 1. The passing position is a waypoint that the work robot 1 passes through from the current position to the designated position. The route generation unit 301 generates the route information D5 by receiving, for example, an input operation of the coordinates and the orientation of each position from the operator of the work robot 1.

[0068] The travel program generation unit 302 calculates the movement amount between respective positions and the turning position at which the work robot 1 changes the traveling direction, based on the route information D5, and generates a travel program D6 in which operations including an operation of moving the work robot 1 between the respective positions, an operation of turning at the turning position, and an operation of correcting the position and the orientation of the work robot 1 based on the marker L2 included in the image D2 captured by the vision sensor 12 of the work robot 1 at the turning position are sequentially combined.

[0069] The transmission processing unit 303 transmits the travel program D6 generated by the travel program generation unit 302 to the work robot 1.

[0070] (Functional Configuration of Robot Control Device) The robot control device 10 of the present embodiment controls the operation of the work robot 1 in accordance with the travel program D6 generated by the travel program generation device 30.

[0071] As shown in FIG. 9, the robot control device 10 according to the present embodiment includes a travel program acquisition unit 106 instead of the route acquisition unit 101.

[0072] The travel program acquisition unit 106 acquires the travel program D6 from the travel program generation device 30.

[0073] The travel instruction unit 104 outputs the travel instruction D4 to the travel control device 20 in accordance with the travel program D6 acquired by the travel program acquisition unit 106. In addition, in a case where the travel program D6 includes the position and orientation correction operation, the travel instruction unit 104 outputs a detection instruction D7 of the marker L2 to the manipulator control unit 105.

[0074] In a case where the detection instruction D7 is input, the manipulator control unit 105 controls the orientation of the manipulator 11 such that the vision sensor 12 can capture the marker L2 (the upper marker L2a or the side marker L2b), and controls the vision sensor 12 to perform capturing.

[0075] In the first embodiment, the robot control device 10 constantly executes the capturing of the landmark L by the vision sensor 12 and the correction of the travel position and the traveling direction based on the image captured by the vision sensor 12. On the other hand, in the second embodiment, the robot control device 10 performs the capturing of the marker L2 by the vision sensor 12 and corrects the position and the orientation of the work robot 1 (carriage 2) based on the image D2 captured by the vision sensor 12 only when the position and orientation correction operation is instructed in the travel program D6.

[0076] (Travel Program Generation Process) FIG. 10 is a flowchart showing an example of a process of the travel program generation device according to the second embodiment. FIG. 11 is a diagram for describing a process of the travel program generation device according to the second embodiment. Here, a flow of a process in which the travel program generation device 30 generates the travel program D6 of the work robot 1 (carriage 2) will be described with reference to FIGS. 10 and 11.

[0077] The route generation unit 301 generates the route information D5 in accordance with the content input by the operator (step S201). As shown in FIG. 11, the route information D5 includes the coordinates (X, Y, Z) of each of the start position (current position), the passing position (waypoint), and the designated position (destination) of the work robot 1, and the orientation (R) of the work robot 1 at each position. The coordinates of the start position, the passing position, and the designated position are absolute coordinates in the travel area of the work robot 1.

[0078] The operator inputs the coordinates (X, Y, Z) of the passing position and the designated position in the movement order of the work robot 1, and inputs the target orientation (R) of the work robot 1 at the passing position and the designated position. For example, the operator inputs the coordinates of the passing positions P2 to P4 and the designated position P5 in the movement order. Then, the route generation unit 301 generates the route information D5 in which the coordinates of the positions P1 to P5 from the start position P1 to the designated position P5 are arranged in the movement order. The coordinates and the orientation (R) of the start position P1 may be automatically acquired from the current position and orientation of the work robot 1, or may be input by the operator by confirming the state of the work robot 1.

[0079] In addition, in a case where the operator wants to change the traveling direction of the work robot 1 at the passing position P2, the operator inputs the traveling direction (target orientation) of the work robot 1 at the passing position P2. Then, the route generation unit 301 generates the route information D5 including a step of changing (turning) the traveling direction without changing the position (coordinates) of the work robot 1 at the passing position P2.

[0080] Further, the operator may input an instruction for the work robot 1 to temporarily wait after the traveling direction is changed at the passing position P2. In this case, the route generation unit 301 generates the route information D5 including a step indicating a state (waiting) in which the position (coordinates) and the orientation of the work robot 1 are not changed at the passing position P2.

[0081] The travel program generation unit 302 calculates the movement amount (relative movement amount) between respective positions of the work robot 1, the turning position at which the work robot 1 changes the traveling direction, the waiting position, and the like, based on the route information D5 generated by the route generation unit 301, and generates the travel sequence of the work robot 1 (step S202).

[0082] In the example of FIG. 11, the travel program generation unit 302 generates a travel sequence including the following operations (1) to (6) based on the route information D5.

[0083] (1) The travel program generation unit 302 generates an operation (1) in which the work robot 1 moves straight (forward) by 1950 mm and laterally moves to the right by 40 mm, based on the movement amount calculated from the coordinates of the start position P1 and the passing position P2 of the route information D5. The wheels 23 of the carriage 2 of the work robot 1 are Mecanum wheels, and can move in all directions. Therefore, the travel program generation unit 302 may generate an operation of moving the work robot 1 in all directions including the left-right direction and the oblique direction without limiting the movement of the work robot 1 to only the front-rear direction.

[0084] (2) Since the orientation (R) is changed from the previous step at the passing position P2 of the route information D5, the passing position P2 is calculated as the turning position. In the present embodiment, the travel program generation unit 302 automatically adds an operation of correcting the position and the orientation of the work robot 1 at the turning position to the travel sequence. Therefore, in the example of FIG. 11, the travel program generation unit 302 generates an operation (2) of moving to the passing position P2 by the operation (1), correcting the position and the orientation of the work robot 1 based on the image D2 obtained by capturing the marker L2 provided in the vicinity of the passing position P2, and then turning the work robot 1 by 90° in the left direction. The operation (2) may be an operation of correcting the position and the orientation of the work robot 1 based on the marker L2 after the work robot 1 turns by 90° in the left direction.

[0085] (3) Since both the position (coordinates) and the orientation are not changed from the previous step at the passing position P2 of the route information D5, the passing position P2 is calculated as the waiting position. Therefore, the travel program generation unit 302 generates an operation (3) of causing the work robot 1 to wait (stop) for a predetermined waiting time at the passing position P2. The waiting time may be determined in advance, or the waiting time input by the operator in step S201 may be used.

[0086] (4) The travel program generation unit 302 generates an operation (4) in which the work robot 1 moves straight (backward) by 700 mm, based on the movement amount calculated from the coordinates of the passing position P2 and the next passing position P3 of the route information D5.

[0087] (5) The travel program generation unit 302 generates an operation (5) in which the work robot 1 laterally moves to the right by 400 mm, based on the movement amount calculated from the coordinates of the passing position P3 and the next passing position P4 of the route information D5.

[0088] (6) The travel program generation unit 302 generates an operation (6) in which the work robot 1 moves straight (forward) by 10 mm and laterally moves to the left by 10 mm, based on the movement amount calculated from the coordinates of the passing position P4 and the next designated position P5.

[0089] In addition, the travel program generation unit 302 may further add an operation of correcting the position and the orientation of the work robot 1 based on the image obtained by capturing the marker L2 provided in the vicinity of the designated position P5 after the work robot 1 reaches the designated position P5 (after the operation (6) is executed). Accordingly, when the work robot 1 reaches the designated position P5, the positional relationship between the work robot 1 and the working target can be appropriately corrected.

[0090] Upon completion of the generation of the travel sequence, the travel program generation unit 302 generates the travel program D6 obtained by converting the travel sequence into a program code for the robot control device 10 (step S203).

[0091] The transmission processing unit 303 transmits the travel program D6 generated by the travel program generation unit 302 to the robot control device 10 (step S204). The transmission processing unit 303 transmits the travel program D6 to the robot control device 10, for example, via an FTP server. In addition, in another embodiment, the transmission processing unit 303 may transmit the travel program D6 to a portable recording medium (not shown), and the robot control device 10 may read the travel program D6 from the recording medium.

[0092] (Traveling Processing of Carriage by Robot) FIG. 12 is a flowchart showing an example of traveling processing of a carriage by the robot system according to the second embodiment. A flow of the traveling processing of the carriage 2 by the robot control device 10 of the work robot 1 will be described with reference to FIG. 12.

[0093] The travel program acquisition unit 106 acquires the travel program D6 from the travel program generation device 30 (or from the recording medium) (step S301).

[0094] The travel instruction unit 104 repeatedly executes steps S302 to S308 to sequentially execute the instructions included in the acquired travel program D6, and controls the travel control device 20 of the carriage 2, the manipulator 11, and the vision sensor 12.

[0095] For example, in a case where the control commanded by the travel program D6 is the position and orientation correction (step S302; YES), the travel instruction unit 104 outputs the detection instruction D7 to the manipulator control unit 105 (step S303). Then, the manipulator control unit 105 outputs a control command to the manipulator 11 to take an orientation (for example, the first orientation) in which the marker L2 can be read, and outputs a control command to the vision sensor 12 to capture the marker L2.

[0096] The detection unit 103 acquires the image D2 captured by the vision sensor 12 (step S304). In a case where the detection unit 103 cannot detect the marker L2 from the image D2 captured in the current orientation (step S305; NO), the manipulator control unit 105 changes the orientation of the manipulator 11. For example, the manipulator control unit 105 outputs a control command to the manipulator 11 to change the current orientation to another orientation (for example, from the first orientation to the second orientation) or to shift the position and the orientation (angle) of the vision sensor 12 by a predetermined amount from the current orientation (the first orientation or the second orientation). Thereafter, the detection unit 103 acquires the image D2 captured in the new orientation (step S304).

[0097] In a case where the detection unit 103 detects the marker L2 from the image D2 (step S305; YES), the detection unit 103 detects the deviation amount of the position and the orientation (traveling direction) of the carriage 2 based on the coordinates and the angle of the detection position of the marker L2 in the image D2 (step S306), and outputs the detection information D3 including the deviation amount to the travel instruction unit 104. The travel instruction unit 104 outputs the travel instruction D4 such that the deviation amount of the carriage 2 is reduced based on the deviation amount and the traveling position included in the detection information D3 (step S307). The wheels 23 of the carriage 2 are Mecanum wheels, and can move in all directions. Therefore, the travel instruction unit 104 moves the carriage 2 in any direction including the front-rear direction, the left-right direction, and the oblique direction to correct the position and the orientation of the carriage 2. The processing of steps S304 to S307 is the same as the processing of steps S103 to S106 of the first embodiment (FIG. 5).

[0098] In addition, in a case where the control commanded by the travel program D6 is a content other than the position and orientation correction (step S302; NO), the travel instruction unit 104 outputs the travel instruction D4 (instruction of straight travel, lateral movement, turning, waiting, or the like) corresponding to the control commanded by the travel program D6 to the carriage 2 (travel control device 20) (step S310).

[0099] Thereafter, the travel instruction unit 104 determines whether or not the travel program D6 is completely executed (step S308). In a case where the travel program D6 is not executed to the end (step S308; NO), the travel instruction unit 104 returns to step S302 and continues the traveling processing (steps S302 to S307 and S310) of the carriage 2.

[0100] In a case where the travel program D6 is executed to the end (step S308; YES), the work robot 1 reads the marker L2 with the vision sensor 12 (step S309). The work robot 1 executes a predetermined process such as self-localization or interlock before the next operation, for example, based on the information included in the read marker L2. This process is the same as the process of step S108 of the first embodiment (FIG. 5).

[0101] (Operations and Effects) As described above, the travel program generation device 30 according to the present embodiment includes the route generation unit 301 that receives the input operation of the operator and generates the route information D5 including the coordinates of the designated position that is the destination of the work robot 1 and the passing position that is passed through to the designated position, and the target orientation indicating the traveling direction of the work robot 1 at each of the designated position and the passing position, and the travel program generation unit 302 that calculates the movement amount between respective positions and the turning position at which the work robot 1 changes the traveling direction, based on the route information D5, and generates the travel program D6 in which operations including an operation of moving the work robot 1 between the respective positions, an operation of turning at the turning position, and an operation of correcting the position and the orientation of the work robot 1 based on the marker L2 included in the image D2 captured by the vision sensor 12 of the work robot 1 at the turning position are sequentially combined.

[0102] In this manner, by generating the travel program D6 including the position and orientation correction at the turning position, the travel program generation device 30 can automatically correct the position and the orientation each time the work robot 1 reaches the turning position. Accordingly, the travel program generation device 30 can improve the reliability of the autonomous movement of the work robot 1 to the designated position (destination), and thus can reduce the work such as monitoring or operating the work robot 1 during the movement by the operator. In addition, the operator only needs to designate the coordinates of the designated position and the passing position and the orientation of the work robot 1 at each position as the preparation for the movement of the work robot 1, and it is possible to eliminate the need for complicated work such as calculating the movement amount between respective positions from the route of the work robot and creating the travel program. That is, it is possible to reduce the work load and the work time of the operator required for generating the travel program.

[0103] <Third Embodiment> Next, a third embodiment will be described in detail with reference to FIG. 13. The same components as those in the above embodiment are denoted by the same reference numerals, and detailed description thereof will be omitted.

[0104] FIG. 13 is a diagram for describing processing of a travel program generation device according to a third embodiment. In the present embodiment, the route generation unit 301 of the travel program generation device 30 presents the travel area screen shown in FIG. 13 to the operator in step S201 of FIG. 10, and generates and acquires the route information D5 based on the position and the orientation of the work robot 1 set by the operator on the travel area screen. The travel area screen includes the position of the work area where the work robot 1 performs the work, the map information of the travel area including the installation position of the marker L2, and the start position information indicating the current position and orientation of the work robot 1. In addition, the travel area screen may further include passage information indicating a passage in which the work robot 1 can travel.

[0105] The operator sets the designated position and the passing position of the work robot 1 by performing an operation (tap, click, or the like) of selecting any position on the travel area screen. The route generation unit 301 displays an icon of the work robot 1 at the position selected by the operator. In addition, the operator operates the icon to change the designated position and the passing position or to change the orientation (traveling direction) of the work robot 1 at the designated position and the passing position. Upon the operator performing an operation of setting completion, the route generation unit 301 generates and acquires the route information D5 including the coordinates of the start position, the designated position, and the passing position and the orientation of the work robot 1 at each position, based on the position and the orientation of each icon on the travel area screen.

[0106] In this manner, the travel program generation device 30 can automatically generate the route information D5 based on the position set by the operator on the travel area screen or the orientation (orientation of the icon) of the work robot 1. Accordingly, the operator does not need to manually input the coordinates of the designated position and the passing position or the numerical value indicating the orientation of the work robot 1, and can easily designate the movement route of the work robot 1.

[0107] In addition, the route generation unit 301 may display a travel area screen including passage information indicating a passage in which the work robot 1 can travel. At this time, in a case where the operator selects a position other than the passage in which the work robot 1 can travel, the route generation unit 301 displays a warning message indicating that "movement to the selected position is not possible" on the travel area screen. Alternatively, the route generation unit 301 may restrict a position other than the passage along which the work robot 1 can travel from being selected on the travel area screen.

[0108] In this manner, the travel program generation device 30 can enable, for example, even an inexperienced operator who is not familiar with the travel area to easily create a route plan of the work robot 1. Accordingly, it is possible to reduce a possibility that the work robot 1 travels on an inappropriate route, for example, a route approaching the surrounding environmental objects.

[0109] In addition, the route generation unit 301 may display a travel area screen indicating the installation position of the marker L2. At this time, in a case where the operator designates a position separated from the installation of the marker L2 by a predetermined distance as the turning position of the work robot 1, the route generation unit 301 displays a warning indicating that "the direction change is not possible at the selected position" on the travel area screen. Alternatively, the route generation unit 301 may restrict the orientation of the work robot 1 from being changed at a position separated from the installation position of the marker L2 by a predetermined distance on the travel area screen.

[0110] In this manner, the travel program generation device 30 can generate the route information D5 and the travel program D6 in which the position and orientation correction by the marker L2 can be more reliably executed when the work robot 1 changes the direction. Accordingly, it is possible to suppress the work robot 1 after the direction change from greatly deviating from the movement route due to the accumulation of the errors in the position and the orientation. Accordingly, the reliability of the autonomous movement to the designated position (destination) can be further improved.

[0111] <Fourth Embodiment> Next, a fourth embodiment will be described in detail with reference to FIG. 14. The same components as those in the above embodiment are denoted by the same reference numerals, and detailed description thereof will be omitted.

[0112] FIGS. 14 and 15 are diagrams for describing processing of a travel program generation device according to the fourth embodiment. In the present embodiment, in step S202 of FIG. 10, in a case where the movement amount of the linear path for causing the work robot 1 to move in one direction between the passing position set by the operator and the other position is equal to or greater than the threshold value, or in a case where the marker L2 is provided on the linear path, the travel program generation unit 302 of the travel program generation device 30 generates the travel program D6 to which the operation of correcting the position and the orientation of the work robot 1 at the installation position of the marker L2 on the linear path is added.

[0113] As shown in FIGS. 14 and 15, it is assumed that, in response to an input operation by the operator, the route generation unit 301 generates the route information D5 in which the work robot 1 moves straight from the start position P21 to the passing position P22 and further moves straight from the passing position P22 to the passing position P23. Here, in a case where the movement amount of the route 1, along which the work robot moves straight from the start position P21 to the passing position P22, is equal to or less than the threshold value, or in a case where the marker L2 is not installed on the route 1, the travel program generation unit 302 does not add the position and orientation correction operation on the route 1.

[0114] In addition, for example, as shown in FIG. 14, it is assumed that the markers L2 (L2-1, L2-2, L3, ...) are installed at equal intervals. Here, in a case where the movement amount of the route 2, along which the work robot moves straight from the passing position P22 to the passing position P23, is equal to or greater than the threshold value, the travel program generation unit 302 sets an intermediate passing position for each unit distance on the route 2. The unit distance is an installation interval of the marker L2. Therefore, the intermediate passing position is set to the installation position of the marker L2. Then, the travel program generation unit 302 generates a travel sequence for correcting the position and the orientation based on the marker L2 for each intermediate passing position. In the example of FIG. 14, the route 2 is divided into a divided route 2A from the passing position P22 to the intermediate passing position P22A and a divided route 2B from the intermediate passing position P22A to the passing position P23. Then, the travel program generation unit 302 generates a travel sequence including an operation of moving from the passing position P22 to the intermediate passing position P22A, an operation of correcting the position and the orientation based on the marker L2-2 at the intermediate passing position P22A, and an operation of moving from the intermediate passing position P22A to the passing position P23 after the correction is completed.

[0115] In addition, as in the example of FIG. 15, it is assumed that a plurality of markers L2 (L2-1, L2-3, L2-4, L3) are installed at unequal intervals between the passing position P22 and the passing position P23. Here, in a case where the movement amount of the route 2, along which the work robot moves straight from the passing position P22 to the passing position P23, is equal to or greater than the threshold value, the travel program generation unit 302 sets the intermediate passing position corresponding to the installation position of the marker L2 on the route 2. Then, the travel program generation unit 302 generates a travel sequence for correcting the position and the orientation based on the marker L2 for each intermediate passing position. In the example of FIG. 15, the route 2 is divided into a divided route 2C from the passing position P22 to the intermediate passing position P22B, a divided route 2D from the intermediate passing position P22B to the intermediate passing position P22C, and a divided route 2E from the intermediate passing position P22C to the passing position P23. Then, the travel program generation unit 302 generates a travel sequence including an operation of moving from the passing position P22 to the intermediate passing position P22B, an operation of correcting the position and the orientation based on the marker L2-3 at the intermediate passing position P22B, an operation of moving from the intermediate passing position P22B to the intermediate passing position P22C after the correction is completed, an operation of correcting the position and the orientation based on the marker L2-4 at the intermediate passing position P22C, and an operation of moving from the intermediate passing position P22C to the passing position P23 after the correction is completed.

[0116] In the example of FIG. 15, the travel program generation unit 302 may generate a travel sequence for performing the position and orientation correction at each of the intermediate passing positions P22B and P22C regardless of whether or not the movement amount of the route 2 is equal to or greater than the threshold value.

[0117] In step S203 of FIG. 10, the travel program generation unit 302 generates the travel program D6 based on the travel sequence in which the route is divided as described above.

[0118] In this way, the travel program generation device 30 can automatically generate a travel program to which an operation of correcting the position and the orientation of the work robot 1 at the installation position of the marker L2 is added, for example, in a case where the distance of the linear movement between the passing positions set by the operator is long. Accordingly, it is possible to reduce a risk that the work robot 1 loses the self-position due to accumulation of errors while moving a long distance or a risk that the work robot 1 comes into contact with the surrounding environmental objects by deviating from the assumed route.

[0119] <Other Embodiments> Although the embodiments have been described in detail with reference to the drawings, a specific configuration is not limited to the above-described configuration, and various design modifications and the like can be made. That is, in another embodiment, the order of the above processes may be changed as appropriate. Further, some of the processes may be executed in parallel.

[0120] <Supplementary Notes> The work robot system 100 and the control method of the work robot system 100 described in the embodiment are understood as follows, for example.

[0121] (1) A work robot system 100 according to a first aspect includes a work robot 1 including a carriage 2 configured to travel on a floor surface F, a manipulator 11 mounted on the carriage 2 and configured to freely change a position and an orientation of a distal end 11a of the manipulator 11, and a vision sensor 12 attached to the distal end 11a of the manipulator 11, and a marker member 7 provided at a predetermined position on the floor surface F, in which the marker member 7 includes a post 71 that stands upward from the floor surface F, and a marker L2 that is provided at an upper end portion of the post 71 and includes information related to a position on the floor surface F, and the work robot 1 includes a control device 10 that controls traveling of the carriage 2 based on the marker L2 included in an image captured by the vision sensor 12.

[0122] By guiding the carriage 2 using the vision sensor 12 attached to the manipulator 11, the work robot system 100 eliminates the need to separately provide a mechanism for guiding the carriage 2, and can realize both the configuration of the carriage 2 with a minimum amount of equipment and cost and the accurate movement of the carriage 2 along the route. In addition, the marker L2 is provided at the upper end portion of the post 71 that stands upward from the floor surface F. Therefore, compared to a case where the marker L2 is provided on the floor surface F, the marker L2 is less likely to be contaminated or damaged. Therefore, when the marker L2 is captured by the vision sensor 12 attached to the distal end 11a of the manipulator 11 of the work robot 1, the vision sensor 12 can be easily brought close to the marker L2. As a result, the marker L2 can be easily and satisfactorily captured, and the traveling control of the carriage 2 can be efficiently performed. In addition, the post 71 also functions as a protective member that prevents the carriage 2 from colliding with surrounding workers in a case where the carriage 2 deviates from the route.

[0123] (2) The work robot system 100 according to a second aspect is the work robot system 100 of (1), in which the post 71 has an upward-facing surface 71t facing upward, and the marker L2 has an upper marker L2a provided on the upward-facing surface 71t.

[0124] Accordingly, during the traveling of the carriage 2, the upper marker L2a provided on the upward-facing surface 71t of the post 71 can be easily imaged by performing capturing with the vision sensor 12 facing downward.

[0125] (3) The work robot system 100 according to a third aspect is the work robot system 100 of (1) or (2), in which the post 71 has a side surface 71s facing a side, and the marker L2 has a side marker L2b provided on the side surface 71s.

[0126] Accordingly, by providing the side marker L2b on the side surface 71s of the post 71, the marker L2 (side marker L2b) can be captured by the vision sensor 12 even at a place away from the post 71 member. Accordingly, even in a case where the carriage 2 deviates from the route, the marker L2 is easily detected.

[0127] (4) The work robot system 100 according to a fourth aspect is the work robot system 100 of any one of (1) to (3), in which the work robot 1 further includes a support table 15 provided to protrude outward of a top plate 2t of the carriage 2 in a plan view, and the manipulator 11 is provided on the support table 15.

[0128] Accordingly, the manipulator 11 is provided on the support table 15 provided to protrude outward of the top plate 2t of the carriage 2 in a plan view. Therefore, compared to a case where the manipulator 11 is provided on the top plate 2t, a range in which the distal end 11a of the manipulator 11 reaches the side of the top plate 2t on which the support table 15 is provided is widened. Therefore, even in a case where the marker member 7 is separated from the traveling route of the carriage 2, the vision sensor 12 easily detects the marker L2 of the marker member 7. As a result, the degree of freedom of the installation position of the marker member 7 is increased.

[0129] (5) The work robot system 100 according to a fifth aspect is the work robot system 100 of (4), in which a height of the marker member 7 from the floor surface F is smaller than a height of the support table 15 from the floor surface F.

[0130] Accordingly, even in a case where the carriage 2 deviates from the route, the support table 15 can be prevented from colliding with the marker member 7.

[0131] (6) The work robot system 100 according to a sixth aspect is the work robot system 100 of any one of (1) to (5), in which the work robot 1 further includes an obstacle detection sensor 16 that detects an obstacle around the carriage 2, and the marker member 7 is provided to be detectable by the obstacle detection sensor 16.

[0132] Accordingly, since the marker member 7 is provided to be detectable by the obstacle detection sensor 16, the carriage 2 can be prevented from colliding with the marker member 7.

[0133] (7) The work robot system 100 according to a seventh aspect is the work robot system 100 of any one of (1) to (6), in which the control device 10 includes a detection unit 103 that detects a deviation amount of the carriage 2 with respect to a designated route based on the marker L2 included in the image captured by the vision sensor 12, and a travel instruction unit 104 that instructs the carriage 2 to correct a travel position or a traveling orientation of the carriage 2 based on the deviation amount.

[0134] Accordingly, by detecting the deviation amount of the carriage 2 with respect to the designated route based on the marker L2 included in the image captured by the vision sensor 12, and correcting the travel position or the traveling orientation of the carriage 2 based on the deviation amount, the carriage 2 can be accurately moved along the route.

[0135] (8) A marker member 7 for a work robot system 100 according to an eighth aspect is a marker member 7 used in a work robot system 100 including a work robot 1 including a carriage 2 configured to travel on a floor surface F, a manipulator 11 mounted on the carriage 2 and configured to freely change a position and an orientation of a distal end of the manipulator 11, and a vision sensor 12 attached to the distal end 11a of the manipulator 11, the marker member 7 including: a post 71 that is provided at a predetermined position on the floor surface F and stands upward from the floor surface F; and a marker L2 that is provided at an upper end portion of the post 71 and includes information related to a position on the floor surface F.

[0136] In the marker member 7 for the work robot system 100, the marker L2 is provided at the upper end portion of the post 71 that stands upward from the floor surface F. Therefore, compared to a case where the marker L2 is provided on the floor surface F, the marker L2 is less likely to be contaminated or damaged. Therefore, when the marker L2 is captured by the vision sensor 12 attached to the distal end 11a of the manipulator 11 of the work robot 1, the vision sensor 12 can be easily brought close to the marker L2. As a result, the marker L2 can be easily and satisfactorily captured, and the traveling control of the carriage 2 can be efficiently performed. In addition, the post 71 also functions as a protective member that prevents the carriage 2 from colliding with surrounding workers in a case where the carriage 2 deviates from the route.

[0137] (9) A control method of a work robot system 100 according to a ninth aspect is a control method of the work robot system 100 according to any one of (1) to (7), the method including: step S101 of causing the carriage 2 to travel along a designated route; step S102 of capturing the marker L2 by the vision sensor 12; and step S106 of controlling traveling of the carriage 2 based on the marker L2 included in an image captured by the vision sensor 12.

[0138] (10) A travel program generation device 30 according to a tenth aspect includes: a route generation unit 301 that receives an input operation of an operator and generates route information D5 including coordinates of each of a designated position that is a destination of a work robot 1 and a passing position that is passed through to the designated position, and a target orientation indicating a traveling direction of the work robot 1 at each of the designated position and the passing position; and a travel program generation unit 302 that calculates a movement amount between respective positions and a turning position at which the work robot 1 changes the traveling direction, based on the route information D5, and generates a travel program D6 in which operations including an operation of moving the work robot 1 between the respective positions, an operation of turning at the turning position, and an operation of correcting a position and an orientation of the work robot 1 based on a marker L2 included in an image D2 captured by a vision sensor 12 of the work robot 1 at the turning position are sequentially combined.

[0139] In this manner, by generating the travel program D6 including the position and orientation correction at the turning position, the travel program generation device 30 can automatically correct the position and the orientation each time the work robot 1 reaches the turning position. Accordingly, the travel program generation device 30 can improve the reliability of the autonomous movement of the work robot 1 to the designated position (destination), and thus can reduce the work such as monitoring or operating the work robot 1 during the movement by the operator. In addition, the operator only needs to designate the coordinates of the designated position and the passing position and the orientation of the work robot 1 at each position as the preparation for the movement of the work robot 1, and it is possible to eliminate the need for complicated work such as calculating the movement amount between respective positions from the route of the work robot and creating the travel program. That is, it is possible to reduce the workload and the work time of the operator required for generating the travel program.

[0140] (11) The travel program generation device 30 according to an eleventh aspect is the travel program generation device 30 of (10), in which the route generation unit 301 displays a travel area screen including map information of a travel area of the work robot 1 and start position information indicating a current position and an orientation of the work robot 1 in the travel area, and generates the route information D5 including the coordinates of each of the passing position and the designated position of the work robot 1 and the target orientation at each of the passing position and the designated position, based on the position and the orientation of the work robot 1 set by the operator on the travel area screen.

[0141] In this manner, the travel program generation device 30 can automatically generate the route information D5 based on the position set by the operator on the travel area screen and the orientation of the work robot 1. Accordingly, the operator does not need to manually input the coordinates of the designated position and the passing position or the numerical value indicating the orientation of the work robot 1, and can easily designate the movement route of the work robot 1.

[0142] (12) The travel program generation device 30 according to a twelfth aspect is the travel program generation device 30 of (11), in which the travel area screen further includes passage information indicating a passage in which the work robot 1 is able to travel in the travel area.

[0143] In this manner, the travel program generation device 30 can enable, for example, even an inexperienced operator who is not familiar with the travel area to easily create a route plan of the work robot 1. Accordingly, it is possible to reduce a possibility that the work robot 1 travels on an inappropriate route, for example, a route approaching the surrounding environmental objects.

[0144] (13) The travel program generation device 30 according to a thirteenth aspect is the travel program generation device 30 of (11), in which the travel area screen further includes information indicating an installation position of the marker L2 in the travel area.

[0145] In this manner, the travel program generation device 30 can generate the route information D5 and the travel program D6 in which the position and orientation correction by the marker L2 can be more reliably executed when the work robot 1 changes the direction. Accordingly, it is possible to suppress the work robot 1 after the direction change from greatly deviating from the movement route due to the accumulation of the errors in the position and the orientation. Accordingly, the reliability of the autonomous movement to the designated position (destination) can be further improved.

[0146] (14) The travel program generation device 30 according to a fourteenth aspect is the travel program generation device 30 of any one of (10) to (13), in which in a case where a movement amount of a linear path for moving the work robot 1 in one direction between the passing position and another position is equal to or greater than a threshold value, the travel program generation unit 302 sets an intermediate passing position at an installation position of the marker L2 on the linear path, and generates the travel program D6 to which an operation of correcting the position and the orientation of the work robot 1 at the intermediate passing position is added.

[0147] In this way, the travel program generation device 30 can automatically generate a travel program to which an operation of correcting the position and the orientation of the work robot 1 at the installation position of the marker L2 is added, for example, in a case where the distance of the linear movement between the passing positions set by the operator is long. Accordingly, it is possible to reduce a risk that the work robot 1 loses the self-position due to accumulation of errors while moving a long distance or a risk that the work robot 1 comes into contact with the surrounding environmental objects by deviating from the assumed route.

[0148] (15) The travel program generation device 30 according to a fifteenth aspect is the travel program generation device 30 of any one of (10) to (13), in which in a case where the marker L2 is installed on a linear path for moving the work robot 1 in one direction between the passing position and another position, the travel program generation unit 302 sets an intermediate passing position at an installation position of the marker L2 on the linear path, and generates the travel program D6 to which an operation of correcting the position and the orientation of the work robot 1 at the intermediate passing position is added.

[0149] In this manner, the travel program generation device 30 can automatically generate a travel program to which an operation of correcting the position and the orientation of the work robot 1 at the installation position of the marker L2 is added. Accordingly, it is possible to reduce a risk that the work robot 1 loses the self-position due to accumulation of errors while moving or a risk that the work robot 1 comes into contact with the surrounding environmental objects by deviating from the assumed route.

[0150] (16) A travel program generation method according to a sixteenth aspect includes a step of receiving an input operation of an operator and generating route information D5 including coordinates of each of a designated position that is a destination of a work robot 1 and a passing position that is passed through to the designated position, and a target orientation indicating a traveling direction of the work robot 1 at each of the designated position and the passing position, and a step of calculating a movement amount between respective positions and a turning position at which the work robot 1 changes the traveling direction, based on the route information D5, and generating a travel program D6 in which operations including an operation of moving the work robot 1 between the respective positions, an operation of turning at the turning position, and an operation of correcting a position and an orientation of the work robot 1 based on a marker L2 included in an image D2 captured by a vision sensor 12 of the work robot 1 at the turning position are sequentially combined.

[0151] (17) A program according to a seventeenth aspect causes a travel program generation device 30 to execute a step of receiving an input operation of an operator and generating route information D5 including coordinates of each of a designated position that is a destination of a work robot 1 and a passing position that is passed through to the designated position, and a target orientation indicating a traveling direction of the work robot 1 at each of the designated position and the passing position, and a step of calculating a movement amount between respective positions and a turning position at which the work robot 1 changes the traveling direction, based on the route information D5, and generating a travel program D6 in which operations including an operation of moving the work robot 1 between the respective positions, an operation of turning at the turning position, and an operation of correcting a position and an orientation of the work robot 1 based on a marker L2 included in an image D2 captured by a vision sensor 12 of the work robot 1 at the turning position are sequentially combined. Industrial Applicability

[0152] According to the work robot system, the marker member for the work robot system, and the control method for the work robot system of the present disclosure, the work robot can be moved with a simple and low-cost configuration. Reference Signs List

[0153] 1: Work robot 2: Carriage 2s: Side surface 2t: Top plate 7: Marker member 10: Robot control device (control device) 11: Manipulator 11a: Distal end 12: Vision sensor 15: Support table 16: Obstacle detection sensor 26: Obstacle detection sensor 71: Post 71s: Side surface 71t: Upward-facing surface L2: Marker L2a: Upper marker L2b: Side marker 100: Work robot system 103: Detection unit 104: Travel instruction unit 30: Travel program generation device 301: Route generation unit 302: Travel program generation unit 303: Transmission processing unit F: Floor surface

Claims

1. A work robot system comprising:a work robot including a carriage configured to travel on a floor surface, a manipulator mounted on the carriage and configured to freely change a position and an orientation of a distal end of the manipulator, and a vision sensor attached to the distal end of the manipulator; anda marker member provided at a predetermined position on the floor surface,wherein the marker member includesa post that stands upward from the floor surface, anda marker that is provided at an upper end portion of the post and includes information related to a position on the floor surface, andthe work robot includes a control device that controls traveling of the carriage based on the marker included in an image captured by the vision sensor.

2. The work robot system according to Claim 1,wherein the post has an upward-facing surface facing upward, andthe marker includes an upper marker provided on the upward-facing surface.

3. The work robot system according to Claim 1 or 2,wherein the post has a side surface facing a side, andthe marker includes a side marker provided on the side surface.

4. The work robot system according to Claim 1 or 2,wherein the work robot further includes a support table provided to protrude outward of a top plate of the carriage in a plan view, andthe manipulator is provided on the support table.

5. The work robot system according to Claim 4,wherein a height of the marker member from the floor surface is smaller than a height of the support table from the floor surface.

6. The work robot system according to Claim 1 or 2,wherein the work robot further includes an obstacle detection sensor that detects an obstacle around the carriage, andthe marker member is provided to be detectable by the obstacle detection sensor.

7. The work robot system according to Claim 1 or 2,wherein the control device includesa detection unit that detects, based on the marker included in the image captured by the vision sensor, a deviation amount of the carriage with respect to a designated route, anda travel instruction unit that instructs the carriage to correct a traveling position or a traveling orientation of the carriage based on the deviation amount.

8. A marker member for a work robot system including a work robot including a carriage configured to travel on a floor surface, a manipulator mounted on the carriage and configured to freely change a position and an orientation of a distal end of the manipulator, and a vision sensor attached to the distal end of the manipulator, the marker member comprising:a post that is provided at a predetermined position on the floor surface and stands upward from the floor surface; anda marker that is provided at an upper end portion of the post and includes information related to a position on the floor surface.

9. A control method for the work robot system according to Claim 1 or 2, the control method comprising:a step of causing the carriage to travel along a designated route;a step of capturing the marker by the vision sensor; anda step of controlling traveling of the carriage based on the marker included in the image captured by the vision sensor.

10. A travel program generation device comprising:a route generation unit that receives an input operation of an operator andgenerates route information including coordinates of each of a designated position that is a destination of a work robot and a passing position through which the work robot passes before reaching the designated position, and a target orientation indicating a traveling direction of the work robot at each of the designated position and the passing position; anda travel program generation unit that calculates a movement amount between respective positions and a turning position at which the work robot changes the traveling direction, based on the route information, and generates a travel program in which operations including an operation of moving the work robot between the respective positions, an operation of turning at the turning position, and an operation of correcting a position and an orientation of the work robot based on a marker included in an image captured by a vision sensor of the work robot at the turning position are sequentially combined.

11. The travel program generation device according to Claim 10,wherein the route generation unitdisplays a travel area screen including map information of a travel area of the work robot and start position information indicating a current position and an orientation of the work robot in the travel area, andgenerates the route information including the coordinates of each of the passing position and the designated position of the work robot and the target orientation at each of the passing position and the designated position, based on the position and the orientation of the work robot set by the operator on the travel area screen.

12. The travel program generation device according to Claim 11, wherein the travel area screen further includes passage information indicating a passage along which the work robot is able to travel within the travel area.

13. The travel program generation device according to Claim 11,wherein the travel area screen further includes information indicating an installation position of the marker in the travel area.

14. The travel program generation device according to any one of Claims 10 to 13, wherein in a case where a movement amount along a linear path for causing the work robot to move in one direction between the passing position and another position is equal to or greater than a threshold value, the travel program generation unit sets an intermediate passing position at an installation position of the marker on the linear path, and generates the travel program to which an operation of correcting the position and the orientation of the work robot at the intermediate passing position is added.

15. The travel program generation device according to any one of Claims 10 to 13, wherein in a case where the marker is installed on a linear path for causing the work robot to move in one direction between the passing position and another position,the travel program generation unit sets an intermediate passing position at an installation position of the marker on the linear path, and generates the travel program to which an operation of correcting the position and the orientation of the work robot at the intermediate passing position is added.

16. A travel program generation method comprising:a step of receiving an input operation of an operator and generating route information including coordinates of each of a designated position that is a destination of a work robot and a passing position through which the work robot passes before reaching the designated position, and a target orientation indicating a traveling direction of the work robot at each of the designated position and the passing position; anda step of calculating a movement amount between respective positions and a turning position at which the work robot changes the traveling direction, based on the route information, and generating a travel program in which operations including an operation of moving the work robot between the respective positions, an operation of turning at the turning position, and an operation of correcting a position and an orientation of the work robot based on a marker included in an image captured by a vision sensor of the work robot at the turning position are sequentially combined.

17. A program causing a travel program generation device to execute:a step of receiving an input operation of an operator and generating route information including coordinates of each of a designated position that is a destinationof a work robot and a passing position through which the work robot passes before reaching the designated position, and a target orientation indicating a traveling direction of the work robot at each of the designated position and the passing position; anda step of calculating a movement amount between respective positions and a turning position at which the work robot changes the traveling direction, based on the route information, and generating a travel program in which operations including an operation of moving the work robot between the respective positions, an operation of turning at the turning position, and an operation of correcting a position and an orientation of the work robot based on a marker included in an image captured by a vision sensor of the work robot at the turning position are sequentially combined.

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