Method and system for measuring the three-dimensional shape of a fitting

Abstract

This invention provides a method and system for measuring the three-dimensional shape dimensions of an accessory before starting work, a method for determining the usability of an accessory using the method, and a method for teaching a molded part removal machine or adjusting a mold for production changeover. With the removal head (60) mounted on the lifting frame (59B) of a molded part removal machine (53) which is an orthogonal three-axis robot, before the removal head (60) starts working, the maximum dimensions of the removal head (60) in the X direction, the maximum dimensions in the Y direction, and the maximum dimensions in the Z direction are measured based on images of the removal head (60) captured by at least the imaging devices (C11) and (C12).

Description

Technical Field

[0001] This invention relates to a method and system for measuring the three-dimensional shape and size of accessories mounted on the working frame of an orthogonal three-axis robot, a method for determining the usability of accessories using the method, and a method for teaching a molded product take-off machine or adjusting a mold for production changeover. Background Technology

[0002] For example, Japanese Patent Application Publication No. 2002-120175 (Patent Document 1) discloses an invention relating to teaching a molded article removal machine, which is an example of an orthogonal three-axis robot. Conventionally, when removing a molded article from the mold of a molding machine, the operator observes the relationship between the removal head and the mold, and while moving the removal head, sets a teaching program to prevent the removal head (part) from colliding with the mold. This removal head is mounted on the entry frame of the molded article removal machine. Furthermore, when reusing a removal head and mold with existing usage history (in the case of production changeover adjustments), a confirmation process is performed to determine whether the previously used teaching program can be directly used.

[0003] Prior art literature

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2002-120175

[0006] During the aforementioned operations, a problem arose where the take-up head collided with the mold, damaging the mold. This problem stemmed from the operator's perception that the mold's setup on the forming machine and the installation state of the take-up head's structural components should remain constant. However, in reality, the take-up head's installation state is not always consistent, and the shapes of its components change due to maintenance, replacement, or repair. Under these circumstances, performing the teaching operation to prevent the mold and take-up head from colliding requires a high level of operator skill and keen observation.

[0007] Collision problems like those described above also occur in orthogonal three-axis robots other than those used in molded product removal machines. Summary of the Invention

[0008] The purpose of this invention is to provide a method that measures the three-dimensional shape and size of the accessory mounted on the working frame of an orthogonal three-axis robot before the accessory begins operation, so that appropriate measures can be taken before the robot's operation begins even if the size and installation state of the accessory are different.

[0009] Another object of the present invention is to provide a method for determining the usability of an accessory and a method for teaching a molded product take-off machine or adjusting a mold for production changeover. The usability determination method determines whether the installed accessory is usable based on the three-dimensional shape and size of the accessory measured by the method of the present invention. The production changeover adjustment method stops teaching or production changeover adjustment when an alarm is issued by the usability determination method of the accessory.

[0010] This invention addresses the method for measuring the three-dimensional shape dimensions of accessories mounted on the working frame of an orthogonal triaxial robot, which has motion axes in the X, Y, and Z directions. In this invention, before the accessory begins operation, while mounted on the working frame of the orthogonal triaxial robot, the maximum dimensions of the accessory in the X, Y, and Z directions are measured based on images of the accessory captured by at least one imaging device. Accessories mounted on the working frame of an orthogonal triaxial robot are often replaced with components whose design specifications differ from the installed components due to repairs, or the configuration of the installed components changes due to maintenance. For example, in the case where the working frame is the entry frame of a molded product removal machine, the accessory mounted on the entry frame is configured to include auxiliary components such as air hoses that provide power to the accessory, or wiring that provides control signals or electricity. Therefore, the position and orientation of these air hoses or wiring sometimes change each time the accessory is replaced. Furthermore, there are also cases where operators incorrectly install accessories on the working frame. In this situation, by measuring the maximum dimensions of the actual component in the X, Y, and Z directions while it is installed on the work frame, it is possible to determine any changes in the shape of the component to be used before actually using it and starting work. As a result, it is possible to detect in advance collisions between the component and other parts in the movement path, as well as situations where incorrect components are installed.

[0011] Furthermore, image-based methods for determining the maximum size only require well-known measurement techniques, minimizing measurement errors caused by differences in operator skill. Additionally, if image data is used, the maximum size can be automatically determined by comparing images of standard components with the captured images, utilizing AI technology adept at image recognition. The result is automated measurement.

[0012] Preferably, the three-dimensional position coordinates of the shooting device, the three-dimensional position coordinates of the part being photographed, the viewing angle of the shooting device, and the mounting posture of the part on the work frame are determined when taking pictures by at least one shooting device, so that the image includes the information needed to determine the three-dimensional shape and size of the part. The more coordinate information, viewing angle of the shooting device, mounting posture, etc., that is available in advance, the easier it is to calculate the maximum size based on the image, thereby reducing the correction calculations of image data based on differences in the mounting position and posture of the shooting device.

[0013] An orthogonal three-axis robot can be used as a part removal machine, with the working frame being an entry frame that mounts parts at the front end and enters the mold of the molding machine. In this case, the extraction direction of the mold mounted on the molding machine is defined as the Y-direction, the up-down direction orthogonal to the extraction direction is defined as the Z-direction, and the direction orthogonal to both the Y and Z directions is defined as the X-direction. Furthermore, when the part is mounted on the entry frame, before inserting it into the mold, the maximum dimensions of the part in the Y-direction, Z-direction, and X-direction are determined based on imaging data of the part captured by at least one imaging device.

[0014] For example, the maximum size can be measured by the following method. In this method, in order to measure the maximum size through operator operation, a shooting system including one or more shooting devices is used: a first shooting device for acquiring a first image of the accessory in a posture in which the maximum size in the X direction and the maximum size in the Z direction of the accessory can be measured; a second shooting device for acquiring a second image of the accessory in a posture in which the maximum size in the Y direction and the maximum size in the Z direction of the accessory can be measured; and an image display device equipped with a screen with orthogonal coordinate axis indicators displaying the first image or the second image. Here, the so-called screen with orthogonal coordinate axis indicators is a screen having images of two dimension gauges along two orthogonal axes.

[0015] In this method, the orthogonal three-axis robot uses: a Y-direction drive source and a Y-direction movement measuring device to move the working frame in the Y direction; a Z-direction drive source and a Z-direction movement measuring device to move the working frame in the Z direction; and an X-direction drive source and an X-direction movement measuring device to move the working frame in the X direction. Furthermore, while driving the Z-direction drive source to move the accessory in the Z direction, during the period from the outermost end of one direction of the Z-direction in the first image crossing the reference line on the screen to the outermost end of the other direction of the Z-direction crossing the reference line, the maximum dimension in the Z-direction is determined based on the distance measured by the movement measuring device. Furthermore, while driving the X-direction drive source to move the component in the X-direction with the orthogonal coordinate axis indicator on the screen aligned with the X and Z directions in the first image, the maximum dimension in the X-direction is determined based on the distance measured by the X-direction movement measuring device during the period from when the outermost end of one direction of the X-direction in the first image crosses the reference line on the screen to when the outermost end of the other direction of the X-direction crosses the reference line. Further, while driving the Y-direction drive source to move the component in the Y-direction with the orthogonal coordinate axis indicator on the screen aligned with the Y and Z directions in the second image, the maximum dimension in the Y-direction is determined based on the distance measured by the Y-direction movement measuring device during the period from when the outermost end of one direction of the Y-direction in the second image crosses the reference line on the screen to when the outermost end of the other direction of the Y-direction crosses the reference line. According to this method, the maximum dimension can be determined using a simple device and through simple operation.

[0016] Furthermore, regarding the maximum size, a 3D imaging device is used for measurement. This device measures the surface of the object and outputs a set of point data with multiple points having three-dimensional coordinates. In this case, the 3D imaging device acquires a first set of point data that allows for the measurement of the maximum size of the accessory in the X and Z directions. Additionally, it acquires a second set of point data that allows for the measurement of the maximum size of the accessory in the Y and Z directions. Then, based on the first set of point data, the maximum size in the Z direction is measured using the coordinates of one outermost point and the other outermost point in the Z direction. Similarly, based on the first set of point data, the maximum size in the X direction is measured using the coordinates of one outermost point and the other outermost point in the X direction. Furthermore, based on the second set of point data, the maximum size in the Y direction is measured using the coordinates of one outermost point and the other outermost point in the Y direction.

[0017] The maximum size measured can be used arbitrarily. A usability determination method can also be constructed that determines whether the part is suitable for use in operation based on its three-dimensional shape and size information, and generates an alarm if it is unusable. Furthermore, suitability can be determined, for example, based on the likelihood of the part colliding with surrounding objects during movement or differences from previous dimensional information. This invention can also be applied to methods for teaching a molded part removal machine or adjusting a mold if an alarm is issued by the part's usability determination method.

[0018] The three-dimensional shape and size measurement system for accessories of the present invention includes a processor. This processor constitutes a size measurement unit that, with the accessory mounted on the working frame of an orthogonal three-axis robot, measures the maximum dimensions of the accessory in the X, Y, and Z directions based on images of the accessory captured by at least one imaging device before the accessory begins operation. Furthermore, the orthogonal three-axis robot is a molded product removal robot, and the working frame is configured as an entry frame with the accessory mounted at its front end and inserted into the mold of a molding machine. Moreover, the extraction direction of the mold while mounted on the molding machine is defined as the Y direction, the vertical direction orthogonal to the extraction direction is defined as the Z direction, and the direction orthogonal to both the Y and Z directions is defined as the X direction. In this case, the size measurement unit includes a size calculation unit that, with the accessory mounted on the entry frame, calculates the maximum dimensions of the accessory in the Y, Z, and X directions based on image data of the accessory captured by at least one imaging device before the accessory is inserted into the mold.

[0019] Furthermore, in the three-dimensional shape and size measurement system for accessories, the imaging system including one or more imaging devices may also include: a first imaging device for acquiring a first image of the accessory in a posture capable of measuring the maximum size in the X direction and the maximum size in the Z direction; a second imaging device for acquiring a second image of the accessory in a posture capable of measuring the maximum size in the Y direction and the maximum size in the Z direction; and an image display device equipped with a screen displaying the first image or the second image with orthogonal coordinate axis indicators. In this case, the orthogonal three-axis robot includes: a Y-direction drive source and a Y-direction motion measuring device for moving the working frame in the Y direction; a Z-direction drive source and a Z-direction motion measuring device for moving the working frame in the Z direction; and an X-direction drive source and an X-direction motion measuring device for moving the working frame in the X direction. Furthermore, while the orthogonal coordinate axis with the orthogonal coordinate axis indicator on the screen extends in the same direction as the X and Z directions in the first image, and the dimension calculation unit drives the Z-direction drive source to move the component in the Z direction, the maximum dimension in the Z direction is calculated based on the distance measured by the Z-direction movement measuring device during the period from when the outermost end of one direction of the Z direction in the first image crosses the reference line on the screen to when the outermost end of the other direction of the Z direction crosses the reference line. Additionally, while the orthogonal coordinate axis with the orthogonal coordinate axis indicator on the screen extends in the same direction as the X and Z directions in the first image, and the dimension measurement unit drives the X-direction drive source to move the component in the X direction, the maximum dimension in the X direction is calculated based on the distance measured by the X-direction movement measuring device during the period from when the outermost end of one direction of the X direction in the first image crosses the reference line on the screen to when the outermost end of the other direction of the X direction crosses the reference line. Furthermore, while the direction of the orthogonal coordinate axis with the orthogonal coordinate axis indicator on the screen is aligned with the Y and Z directions in the second image, the dimension measuring unit drives the Y-direction drive source to move the accessory in the Y direction. During this period, from the outermost end of one direction of the Y direction in the second image passing through the reference line on the screen to the outermost end of the other direction of the Y direction passing through the reference line, the maximum dimension in the Y direction is determined by calculation based on the distance measured by the Y-direction movement measuring device.

[0020] Furthermore, in the three-dimensional shape and size measurement system for accessories, a three-dimensional imaging device can also be used as the imaging device. The three-dimensional imaging device measures the surface of the object and outputs it as point group data of multiple points with three-dimensional coordinates. In this case, it also includes: a first point group data acquisition unit, which acquires a first point group data capable of measuring the maximum size of the accessory in the X direction and the maximum size in the Z direction using the three-dimensional imaging device; and a second point group data acquisition unit, which acquires a second point group data capable of measuring the maximum size of the accessory in the Y direction and the maximum size in the Z direction. Moreover, the size calculation unit is configured to include a maximum size determination unit, which calculates the maximum size in the Z direction based on the first point group data, using the coordinates of one outermost point in the Z direction and the coordinates of another outermost point. In addition, it calculates the maximum size in the X direction based on the first point group data, using the coordinates of one outermost point in the X direction and the coordinates of another outermost point. Furthermore, it calculates the maximum size in the Y direction based on the second point group data, using the coordinates of one outermost point in the Y direction and the coordinates of another outermost point. Attached Figure Description

[0021] Figure 1 This is a perspective view of a molding manufacturing system, which includes an orthogonal three-axis robot that applies the three-dimensional shape and size measurement method for accessories of the present invention, the orthogonal three-axis robot having motion axes in the X, Y and Z directions.

[0022] Figure 2 This is a left-side view of the molding manufacturing system.

[0023] Figure 3 This is the front view of the molded product manufacturing system.

[0024] Figure 4 This is a top view of the molding manufacturing system.

[0025] Figure 5 This is a block diagram showing the structure of a measurement system built within the control system of a molded part removal machine for applying a method to measure the three-dimensional shape and size of parts.

[0026] Figure 6 This is a diagram showing the maximum size of the removed head.

[0027] Figure 7 Images (A) to (H) are images used to illustrate the method of implementation.

[0028] Figure 8 Images (A) to (E) are images used to illustrate the method of implementation.

[0029] Figure 9This is a block diagram showing the structure of a measurement system used when using a single 3D imaging device to measure the maximum size.

[0030] Figure 10 Figures (A) to (D) are used to illustrate the use of point set data to determine the maximum dimensions in the X and Z directions.

[0031] Figure 11 This is a diagram used to illustrate the use of point set data to determine the maximum dimension in the Y direction.

[0032] Explanation of reference numerals in the attached figures

[0033] 1: Molded product manufacturing system;

[0034] 3: Forming machine;

[0035] 5: Molded product removal machine;

[0036] 71: Filming device system;

[0037] 72: Image display device;

[0038] 73: Screen;

[0039] 74: X-axis direction drive source;

[0040] 75: X-axis displacement measuring device;

[0041] 76: Y-axis direction drive source;

[0042] 77: Y-axis displacement measuring device;

[0043] 78: Z-axis drive source;

[0044] 79: Z-axis displacement measuring device;

[0045] C11: First camera device;

[0046] C12: Second camera device;

[0047] 90: Control device;

[0048] 91: Teaching Department;

[0049] 92: Data Storage Department;

[0050] 93: Usability Determination Section;

[0051] 94: Drive control unit;

[0052] 95: Dimension Calculation Unit;

[0053] 96: Image Control Unit;

[0054] 97: Operations Department. Detailed Implementation

[0055] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. Figures 1 to 4 These are perspective views, left side views, front views, and top views of a molding manufacturing system 1. The molding manufacturing system 1 includes an orthogonal three-axis robot that applies the three-dimensional shape and size measurement method for accessories according to the present invention. This orthogonal three-axis robot has motion axes in the X, Y, and Z directions. Figure 1 The X, Y, and Z directions used in this embodiment are shown in the diagram. The molded article manufacturing system 1 is configured to combine a molding machine 3, which acts as an orthogonal three-axis robot for manufacturing resin molded articles, and a molded article extraction machine 5. The molded article extraction machine 5 is a sloping sliding type molded article extraction machine, and its base is supported by the fixed plate 30 of the resin molding machine 3.

[0056] A fixed mold 31 and an intermediate mold 32 are fixed on the fixed shelf 30 of the forming machine 3, and a movable mold 34 is fixed on the movable shelf 33. Furthermore, four guide rods 35A to 35D are arranged between the fixed shelf 30 and the movable shelf 33 to guide the movement of the movable shelf 33. The four guide rods 35A to 35D are arranged at equal intervals, and an imaginary center line passing through the center of the four guide rods 35A to 35D passes through the center of the fixed mold 31 and the center of the movable mold 34 (the center of the suction nozzle). In addition, the fixed mold 31, the intermediate mold 32, and the movable mold 34 are guided by guide pins 36A to 36D. The four guide pins 36A to 36D are also arranged at equal intervals, and an imaginary center line passing through the center of the four guide pins 36A to 36D also passes through the center of the fixed mold 31 and the center of the movable mold 34 (the center of the suction nozzle).

[0057] The molded product extraction machine 5 includes a traverse shaft 53, a first traveling body 55, an extraction shaft 57, a flow channel lifting unit 58, and a molded product adsorption lifting unit 59. The traverse shaft 53 has a cantilever beam structure extending in the X-axis direction, horizontally orthogonal to the length direction of the molding machine 3. The first traveling body 55 is supported by the traverse shaft 53 and moves forward and backward in the X-axis direction along the traverse shaft 53, driven by an AC servo motor included in the servo mechanism. The extraction shaft 57 is provided on the first traveling body 55 and extends in the Y-axis direction, parallel to the length direction of the molding machine. The flow channel lifting unit 58 and the molded product adsorption lifting unit 59 are supported by the extraction shaft 57 and are movable in the Y-direction, driven by an AC servo motor included in the servo mechanism. The flow channel lifting unit 58 has the following structure: a lifting frame 58B that moves in the Z-direction is provided on the traveling body 58A, which is movably supported by the extraction shaft 57. The traveling body 59A is driven by an AC servo motor, thereby moving in the Y-direction. The lifting frame 58B is raised and lowered in the vertical direction (Z direction) by a drive source. The lifting frame 58B is equipped with a clamp 58C as an accessory to hold discarded flow channels.

[0058] Furthermore, the walking body 59A included in the molding article adsorption lifting unit 59 is driven by an AC servo motor, thereby moving along the Y direction on the extraction shaft 57. The molding article adsorption lifting unit 59 includes a lifting frame 59B that moves up and down in the vertical direction (Z direction) by a drive source, a flipping unit 59C that serves as a posture control device and rotates around the axis of the lifting frame 59B, and an extraction head 60 provided in the flipping unit 59C. In this embodiment, the extraction head 60 is used as an accessory, and its maximum size is measured.

[0059] In this embodiment, to experimentally explore preferred installation locations, eight imaging devices C1 to C8 are installed on various parts of the molded product extraction machine 5 and the molding machine 3, and on a platform 7 placed to the side of the molding machine 3. Two-dimensional or three-dimensional cameras are used as these imaging devices C1 to C8. In this embodiment, it is possible to select an imaging device from among these imaging devices C1 to C8 that can obtain preferred images, thereby obtaining the desired image.

[0060] Figure 5 This is a block diagram showing the structure of the measurement system built within the control system 1 of the molded article take-out machine 5 for applying the three-dimensional shape and size measurement method for the accessory according to this embodiment. Furthermore, Figure 6 This is a diagram showing the maximum size of the removed head 60. Figure 7 as well as Figure 8 These are images used to illustrate the method of this embodiment.

[0061] In this embodiment, with the extraction head 60, which is an accessory, mounted on the lifting frame 59B, which serves as the working frame of the molded product extraction machine 5, before the extraction head 60 begins operation, the maximum dimensions of the extraction head 60 in the X direction, Y direction, and Z direction are determined based on images of the extraction head 60 captured by at least one imaging device (G1 to C8). This molded product extraction machine is an orthogonal three-axis robot. While this also depends on the measurement method used, it is preferable to determine the three-dimensional position coordinates of the imaging devices when the images are captured by at least one imaging device, the three-dimensional position coordinates of the extracted head 60 being photographed, the viewing angle of the imaging devices, and the mounting posture of the extraction head 60 towards the lifting frame 59B (working frame), so that the images obtained by the imaging devices include the information necessary for measuring the three-dimensional shape and dimensions of the extraction head 60. The more coordinate information, the viewing angle of the imaging devices, the mounting posture, etc., that is available beforehand, the easier the calculation becomes when determining the maximum dimension based on the image, thereby reducing the need for correction calculations of image data based on differences in the mounting position and posture of the imaging devices.

[0062] In use Figure 5 In the case of measuring using the system shown in the block diagram, in order to measure the maximum size through operator operation, the imaging system 71, which includes one or more imaging devices, uses: a first imaging device C11 for acquiring a first image of the extraction head 60 in an orientation capable of measuring the maximum size in the X and Z directions; a second imaging device C12 for acquiring a second image of the extraction head 60 in an orientation capable of measuring the maximum size in the Y and Z directions; and an image display device 72 equipped with a screen 73 with an orthogonal coordinate axis indicator that displays the first or second image. Here, the screen 73 with the orthogonal coordinate axis indicator is a gauge screen with two orthogonal axes (GZ-GX, GZ-GY).

[0063] In this embodiment, an X-direction drive source 74 and an X-direction movement measuring device 75 are used to move the lifting frame 59B in the X direction; a Y-direction drive source 76 and a Y-direction movement measuring device 77 are used to move the lifting frame 59B in the Y direction; and a Z-direction drive source 78 and a Z-direction movement measuring device 79 are used to move the lifting frame 59B in the Z direction. The operator performs the following operations using an operation unit 97, including operation switches, provided in the controller. Furthermore, in the following operations, the image display of the screen 73 on the image display device 72 is performed by an image control unit 96 within a control device 90, which is configured within the control unit of the molded product take-off machine 5. In addition, the control device 90 includes a processor for implementing a size calculation unit 95, which constitutes the size measuring unit. The maximum size calculation is performed by the size calculation unit 95, which is the size measuring unit, based on the outputs of the X-direction movement measuring device 75 to the Z-direction movement measuring device 79. Moreover, based on the operation from the operation unit 97, operation commands for the X-direction drive source 74 to the Z-direction drive source 78 are output from the drive control unit 94. Furthermore, the control device 90 includes a teaching unit 91 for operating the teaching described later, a data storage unit 92 for storing teaching data, and a usability determination unit 93.

[0064] Specifically, as the first imaging device C11, it can be used as long as the posture of the head 60 is not changed. Figures 1 to 4 The shown imaging devices are C1 or C2. For the first imaging device C11, it takes a picture of the extraction head 60, which is an accessory, from the front. Furthermore, as the second imaging device C12, it can be used as long as the posture of the extraction head 60 is not changed. Figures 1 to 4 The shooting devices C6 to C8 are shown. They can be used as long as the posture of removing the head 60 is not changed. Figures 1 to 4 The imaging devices C1 to C5 are shown. The first imaging device C11 takes a picture of the extraction head 60, which is an accessory, from the front. The second imaging device C12 takes a picture of the extraction head 60 from the side.

[0065] Specifically, such as Figure 7 As shown, the orientation of the orthogonal coordinate axes GZ and GX on the screen 73, which have orthogonal coordinate axis indicators G, is aligned with the X and Z directions in the first image from the first imaging device C11. This is achieved by observing the image on the screen 73 and the image on the indicator G. Then, during the period when the Z-direction drive source 78, including a servo motor, moves the extraction head 60 in the Z-direction, the time from when the outermost end 60A of the extraction head 60 in one direction of the Z-direction in the first image crosses the reference line on the screen (in this example, GX) (assuming the measured value at this time is Zs), to when the outermost end 60B in the other direction of the Z-direction crosses the reference line (in this example, GX) (assuming the measured value at this time is Ze), is […]. Figure 7 (A) to Figure 7 [D], the distance measured by the Z-direction movement measuring device 79, including the encoder, etc. [refer to] Figure 6 [Zs-Ze] is used to calculate the maximum dimension in the Z direction.

[0066] Furthermore, during the period when the orthogonal coordinate axes GZ and GY on the screen 73 with orthogonal coordinate axis indicators G extend in directions consistent with the X and Z directions in the first image, the distance measured by the X-direction drive source 74 to move the extraction head 60 in the X direction is as follows: from the outermost end 60C of one direction in the X direction of the first image passing through the reference line on the screen (GZ in this example) (let's assume the measured value at this time is Xs) to the outermost end 60D of the other direction in the X direction passing through the reference line (GZ) (let's assume the measured value at this time is Xe). [Ref] Figure 6 [Xs-Xe], the maximum dimension in the X direction is determined.

[0067] Furthermore, such as Figure 8 As shown, during the period when the orthogonal coordinate axis GZ-GY on screen 73, with orthogonal coordinate axis indicator G, extends in the same direction as the Y and Z directions in the second image (side view), the distance measured by the Y-direction drive source 76 to move the extraction head 60 in the Y direction is as follows: from the outermost end 60E of one direction in the Y direction of the second image crossing the reference line on the screen (GZ in this example) (let's assume the measured value at this time is Ys) to the outermost end 60F of the other direction in the Y direction crossing the reference line (GZ) (let's assume the measured value at this time is Ye), the distance measured by the Y-direction movement measuring device [refer to...] Figure 6 [Ys-Ye], to determine the maximum dimension in the Y direction.

[0068] According to this method, the maximum dimensions in the X, Y, and Z directions can be measured using simple equipment and through simple operation. Regarding the take-up head 60 mounted on the lifting frame 59B of the forming machine 5, the installed components are often replaced with components different from the design specifications due to repairs, or the configuration of the installed components changes due to maintenance. For example, the take-up head 60, when mounted on the lifting frame 59B as the working frame, is configured with an accessory assembly including an air pipe or wiring that provides power to the take-up head 60. Therefore, the position and orientation of these air pipes or wiring sometimes change each time the take-up head 60 is replaced. Furthermore, there are also cases where the operator incorrectly installs the take-up head on the lifting frame 59B. Even in such cases, by measuring the maximum dimensions of the take-up head 60 in the X, Y, and Z directions while it is mounted on the lifting frame 59B, changes in the shape of the take-up head 60 that are actually intended to be used can be determined before actually using the take-up head 60 and starting the take-up operation. As a result, it is possible to detect in advance situations where the take-up head 60 collides with components in the movement path or where an incorrect take-up head is installed.

[0069] (Other measurement systems)

[0070] Figure 9 This is a block diagram showing the structure of a measurement system used to measure the maximum size when using a single 3D imaging device C13 as the imaging device. In this measurement system, the 3D imaging device C13 is used as the imaging device to measure the maximum size. The 3D imaging device C13 measures the surface of an object and outputs point group data of multiple points with three-dimensional coordinates. The first point group data acquisition unit 101A acquires first point group data capable of measuring the maximum size of the extraction head 60 in the X direction and the maximum size in the Z direction based on image data captured by the 3D imaging device C13 from the front. Furthermore, the second point group data acquisition unit 101B acquires second point group data capable of measuring the maximum size of the extraction head 60 in the Y direction and the maximum size in the Z direction based on image data captured by the 3D imaging device C13 from the side. When using a single 3D imaging device, only one point group data is needed... Figure 1 The imaging device C1, as a 3D imaging device, after capturing a frontal image, uses the flipping unit 59C, which functions as a pose-changing device, to rotate the extraction head 60 by 90 degrees, thereby acquiring a side image. Alternatively, it is also possible to use two 3D imaging devices to obtain both the frontal and side images.

[0071] The maximum size determination unit 98, which is a size measurement calculation unit composed of a processor in the control device 90', determines the maximum size in the Z direction based on the coordinates of one outermost point and another outermost point in the Z direction, according to the first set of data. Furthermore, it determines the maximum size in the X direction based on the coordinates of one outermost point and another outermost point in the X direction, according to the first set of data. Further, it determines the maximum size in the Y direction based on the coordinates of one outermost point and another outermost point in the Y direction, according to the second set of data.

[0072] Point group data obtained by a 3D imaging device is data that automatically measures the surface of an object and sets up a data file with the 3D coordinates of multiple points as point groups. That is, each point constituting a point group includes 3D coordinate information. Therefore, if a 3D imaging device... Figure 10 If the head is removed 60 as shown in (A) and photographed, the following can be obtained: Figure 10 The data consists of a set of points as shown in (B). Each point includes information about its three-dimensional coordinates. Therefore, as... Figure 10 As shown in (C), the maximum size determination unit 98 calculates the coordinates of the point with the largest and smallest X-direction coordinates among points with the same depth (same Y-coordinate value) in the X-direction from the point set data, and uses the difference between these coordinate values ​​as the maximum size Xm in the X-direction. Furthermore, it calculates the coordinates of the point with the largest and smallest Z-direction coordinates among points with the same depth (same Y-coordinate value) in the Z-direction from the point set data, and uses the difference between these coordinate values ​​as the maximum size Zm in the Z-direction. Next, as... Figure 11 As shown, from the point group data acquired by the second point group data acquisition unit 101B, the coordinate values ​​of the point with the largest and smallest Y-direction coordinates among points with the same depth (same X-coordinate value) in the Y-direction are obtained, and the difference between these coordinate values ​​is taken as the maximum dimension Ym in the Y-direction. In this way, the maximum three-dimensional dimensions Xm, Ym, and Zm of the extraction head 60 can be obtained based on the point group data. After obtaining the maximum dimensions, they can be used in the same way as in the original embodiment. In addition, of course, if the part that is the maximum dimension is determined by prior observation based on the shape characteristics of the extraction head, even if data of points with the same depth are not collected as described above, the coordinate values ​​can be accurately obtained based on specific point group data, thereby obtaining the maximum dimension.

[0073] Furthermore, image-based methods for determining the maximum size can utilize well-known measurement techniques, minimizing measurement errors caused by differences in operator skill, as illustrated in the example above. Alternatively, if image data is used, the maximum size can be automatically determined by comparing a standard image of the removed head (accessory) with the captured image, or by employing AI technology adept at image recognition. The result is automated measurement.

[0074] (Usability, teaching, and production changeover adjustments)

[0075] The method for determining the maximum size as described above is arbitrary. In the above embodiment, before teaching is performed using the teaching unit 91, the suitability of using the extraction head 60 in operation is determined based on the three-dimensional shape and size information of the extraction head 60. If it is unusable, an alarm is output from the usability determination unit 93. That is, if teaching is performed, the possibility of collision with surrounding objects during the movement of the extraction head 60 is determined in advance. If the extraction head 60 is not usable, an alarm is issued.

[0076] Furthermore, when changing molds, if the maximum size of the replacement part is measured using the method of this invention, it is possible to know before starting work whether the new part is the correct part to be replaced, or whether the shape and size of the part have not changed due to repairs, etc. As a result, the possibility of damaging the teaching or changeover adjustments, molds, removal heads, etc., can be eliminated.

[0077] In addition, the data storage unit 92 stores information such as the gap size between the fixed mold and the movable mold, the protrusion size of the mold protrusion inside the mold, and the maximum size of the mold measured before the previous operation. In the usability determination unit 93, based on this information and the measured maximum size, a usability determination is made as to whether the accessory can be used in this operation.

[0078] (other)

[0079] Furthermore, in the above embodiments, the method of the present invention is set as an example of a formed product extraction machine for an orthogonal three-axis robot, but the present invention can of course also be applied to orthogonal three-axis robots used for other purposes.

[0080] -Industrial Applicability-

[0081] According to the present invention, before the accessory begins operation, the three-dimensional shape and size of the accessory mounted on the working frame of the orthogonal three-axis robot are measured. Therefore, even if the size and installation state of the accessory are different, appropriate measures can be taken before the robot's operation begins.

Claims

1. A method for measuring the three-dimensional shape and dimensions of an accessory, wherein the three-dimensional shape and dimensions of the accessory are measured on the working frame of an orthogonal triaxial robot. The orthogonal three-axis robot has motion axes in the X, Y, and Z directions. The method for measuring the three-dimensional shape and dimensions of the accessory is characterized in that, With the accessory mounted on the working frame of the orthogonal triaxial robot, before the accessory begins operation, based on images of the accessory captured by one or more imaging devices, the maximum dimensions of the accessory in the X direction, Y direction, and Z direction are determined. A shooting system including one or more shooting devices comprises: a first shooting device for acquiring a first image of the accessory in an orientation capable of measuring its maximum size in the X direction and its maximum size in the Z direction; a second shooting device for acquiring a second image of the accessory in an orientation capable of measuring its maximum size in the Y direction and its maximum size in the Z direction; and an image display device comprising a screen with orthogonal coordinate axis indicators for displaying the first image or the second image. The orthogonal three-axis robot comprises: a Y-direction drive source and a Y-direction motion measuring device for moving the working frame in the Y direction; a Z-direction drive source and a Z-direction motion measuring device for moving the working frame in the Z direction; and an X-direction drive source and an X-direction motion measuring device for moving the working frame in the X direction. In the method, While driving the Z-direction drive source to move the accessory in the Z-direction with the orthogonal coordinate axis indicator on the screen extending in the same direction as the X and Z directions in the first image, the maximum dimension in the Z-direction is determined based on the distance measured by the Z-direction movement measuring device from the time the outermost end of one direction of the Z-direction in the first image passes through the reference line on the screen to the time the outermost end of the other direction of the Z-direction passes through the reference line. While driving the X-direction drive source to move the accessory in the X-direction with the orthogonal coordinate axis indicator on the screen in a state where the direction of extension of the orthogonal coordinate axis on the screen is consistent with the X-direction and the Z-direction in the first image, the maximum dimension in the X-direction is determined based on the distance measured by the X-direction movement measuring device from the time the outermost end of one direction of the X-direction in the first image passes through the reference line on the screen to the time the outermost end of the other direction of the X-direction passes through the reference line. While driving the Y-direction drive source to move the accessory in the Y-direction with the orthogonal coordinate axis indicator on the screen in a state where the direction of extension of the orthogonal coordinate axis on the screen is consistent with the Y-direction and the Z-direction in the second image, the maximum dimension in the Y-direction is determined based on the distance measured by the Y-direction movement measuring device during the period from when the outermost end of one direction of the Y-direction in the second image passes through the reference line on the screen to when the outermost end of the other direction of the Y-direction passes through the reference line.

2. The method for measuring the three-dimensional shape and dimensions of accessories according to claim 1, characterized in that, The three-dimensional position coordinates of the shooting device, the three-dimensional position coordinates of the accessory being photographed, the viewing angle of the shooting device, and the mounting posture of the accessory toward the working frame are determined when the accessory is photographed by one or more shooting devices, so that the image includes the information needed to determine the three-dimensional shape and size of the accessory.

3. The method for measuring the three-dimensional shape and dimensions of accessories according to claim 1, characterized in that, The orthogonal three-axis robot is a robot for removing shaped products. The working frame is an entry frame in which the accessory is installed at the front end and enters the mold of the forming machine. The extraction direction of the mold installed on the forming machine is defined as the Y direction, the up-down direction orthogonal to the extraction direction is defined as the Z direction, and the direction orthogonal to both the Y and Z directions is defined as the X direction. With the accessory installed in the entry frame, before inserting the accessory into the mold, the maximum dimensions of the accessory in the Y direction, the maximum dimensions in the Z direction, and the maximum dimensions in the X direction are determined based on the imaging data of the accessory captured by one or more imaging devices.

4. A method for determining the usability of an accessory, characterized in that, The method described in claim 1 is used to determine the three-dimensional shape and dimensions of the accessory. Based on the information of the three-dimensional shape and size, it is determined whether the accessory is suitable for use in the operation. If it is unusable, an alarm is generated.

5. A method for measuring the three-dimensional shape and dimensions of an accessory, wherein the three-dimensional shape and dimensions of the accessory are measured on the working frame of an orthogonal three-axis robot. The orthogonal three-axis robot has motion axes in the X, Y, and Z directions. The method for measuring the three-dimensional shape and dimensions of the accessory is characterized in that, With the accessory mounted on the working frame of the orthogonal triaxial robot, before the accessory begins operation, based on images of the accessory captured by one or more imaging devices, the maximum dimensions of the accessory in the X direction, Y direction, and Z direction are determined. The imaging device is a three-dimensional imaging device. It measures the surface of an object and outputs the data as a set of point data containing multiple points with three-dimensional coordinates. In the method described above, further, The three-dimensional imaging device acquires a first set of data capable of measuring the maximum dimensions of the accessory in the X and Z directions, and a second set of data capable of measuring the maximum dimensions of the accessory in the Y and Z directions. Based on the data from the first set of points, and using the coordinates of the outermost point in the Z direction and the coordinates of the other outermost point, the maximum dimension in the Z direction is determined. Furthermore, based on the data from the first set of points, and using the coordinates of the outermost point located in the X direction and the coordinates of the other outermost point, the maximum dimension in the X direction is determined. Furthermore, based on the second set of data, the maximum dimension in the Y direction is determined using the coordinates of a point located at one of the outermost ends and the coordinates of a point located at the other outermost end.

6. A method for determining the usability of an accessory, characterized in that, The method described in claim 5 is used to determine the three-dimensional shape and dimensions of the accessory. Based on the information of the three-dimensional shape and size, it is determined whether the accessory is suitable for use in the operation. If it is unusable, an alarm is generated.

7. The method for determining the usability of accessories according to claim 6, characterized in that, Whether the accessory is suitable for use is determined based on the likelihood of the accessory colliding with surrounding objects during its movement, or the difference in size information compared to the previous one.

8. The method for determining the usability of accessories according to claim 7, characterized in that, The accessory, when installed on the working frame, is configured as an assembly including an air hose that provides power to the accessory, or wiring that provides control signals or electricity.

9. A method for teaching or adjusting a mold for taking out a molded product, characterized in that, Whether the accessory is suitable for use is determined based on the likelihood of it colliding with surrounding objects during its movement, or the difference in size information compared to the previous measurement. If the alarm is issued using the usability determination method for the accessory as described in claim 6, then the teaching or production change adjustment is suspended.

10. A three-dimensional shape and size measurement system for an accessory, used to measure the three-dimensional shape and size of an accessory mounted on the working frame of an orthogonal three-axis robot, wherein the orthogonal three-axis robot has motion axes in the X, Y, and Z directions. The three-dimensional shape and size measurement system for the accessory is characterized in that, Including processors, The processor constitutes a dimension measuring unit. With the accessory mounted on the working frame of the orthogonal triaxial robot, before the accessory begins operation, the dimension measuring unit measures the maximum dimension of the accessory in the X direction, the maximum dimension in the Y direction, and the maximum dimension in the Z direction based on images of the accessory captured by one or more imaging devices. A shooting system including one or more shooting devices comprises: a first shooting device for acquiring a first image of the accessory in a posture capable of measuring its maximum size in the X direction and its maximum size in the Z direction; a second shooting device for acquiring a second image of the accessory in a posture capable of measuring its maximum size in the Y direction and its maximum size in the Z direction; and an image display device comprising a screen with orthogonal coordinate axis indicators for displaying the first image or the second image. The orthogonal three-axis robot includes: a Y-direction drive source and a Y-direction motion measuring device for moving the working frame in the Y direction; a Z-direction drive source and a Z-direction motion measuring device for moving the working frame in the Z direction; and an X-direction drive source and an X-direction motion measuring device for moving the working frame in the X direction. The dimension measuring unit is configured as follows: While driving the Z-direction drive source to move the accessory in the Z-direction, with the orthogonal coordinate axis indicator on the screen extending in the same direction as the X and Z directions in the first image, the maximum dimension in the Z-direction is determined by calculation based on the distance measured by the Z-direction movement measuring device from the time the outermost end of one direction of the Z-direction in the first image crosses the reference line on the screen to the time the outermost end of the other direction of the Z-direction crosses the reference line. While driving the X-direction drive source to move the accessory in the X-direction with the orthogonal coordinate axis indicator on the screen in a state where the direction of extension of the orthogonal coordinate axis on the screen is consistent with the X-direction and the Z-direction in the first image, the maximum dimension in the X-direction is determined by calculation based on the distance measured by the X-direction movement measuring device from the time the outermost end of one direction of the X-direction in the first image crosses the reference line on the screen to the time the outermost end of the other direction of the X-direction crosses the reference line. While driving the Y-direction drive source to move the accessory in the Y-direction with the orthogonal coordinate axis indicator on the screen in a state where the direction of the orthogonal coordinate axis on the screen is consistent with the Y-direction and the Z-direction in the second image, the maximum dimension in the Y-direction is determined by calculation based on the distance measured by the Y-direction movement measuring device from the time the outermost end of one direction of the Y-direction in the second image passes through the reference line on the screen to the time the outermost end of the other direction of the Y-direction passes through the reference line.

11. A three-dimensional shape and size measurement system for an accessory, used to measure the three-dimensional shape and size of an accessory mounted on the working frame of an orthogonal three-axis robot, wherein the orthogonal three-axis robot has motion axes in the X, Y, and Z directions. The three-dimensional shape and size measurement system for the accessory is characterized in that, Including processors, The processor constitutes a dimension measuring unit. With the accessory mounted on the working frame of the orthogonal triaxial robot, before the accessory begins operation, the dimension measuring unit measures the maximum dimension of the accessory in the X direction, the maximum dimension in the Y direction, and the maximum dimension in the Z direction based on images of the accessory captured by one or more imaging devices. The imaging device is a three-dimensional imaging device. It measures the surface of an object and outputs the data as a set of point data containing multiple points with three-dimensional coordinates. The three-dimensional shape and size measurement system for the accessory also includes: The first point group data acquisition unit acquires first point group data through the three-dimensional imaging device, which can measure the maximum size of the accessory in the X direction and the maximum size in the Z direction. and The second set of data acquisition unit acquires second set of data capable of measuring the maximum dimension in the Y direction and the maximum dimension in the Z direction of the accessory. The size measuring unit includes a maximum size determination unit. The maximum size determining part is configured as follows: Based on the data of the first set of points, the maximum dimension in the Z direction is obtained by taking into account the coordinates of the outermost point located in the Z direction and the coordinates of the other outermost point. Furthermore, based on the data from the first set of points, the maximum dimension in the X direction is obtained using the coordinates of the outermost point located in the X direction and the coordinates of the other outermost point. Furthermore, based on the second set of data, the maximum dimension in the Y direction is obtained by considering the coordinates of the outermost point in the Y direction and the coordinates of the other outermost point.

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