Robotic system and method of controlling a robotic system

Abstract

A robot system (100) includes a robot (1) having an end effector (6), an operation section (8), and a control section (3) that moves the end effector (6) based on an operation of the operation section (8) and causes the end effector (6) to perform processing in a non-contact manner with respect to a processed surface of a workpiece. The control section (3) performs at least one of a first control that fixes a distance between the end effector (6) and a control processed surface that is the processed surface of the workpiece or a virtual processed surface of the workpiece and a second control that fixes an angle of the end effector with respect to the control processed surface when moving the end effector (6) based on the operation of the operation section (8).

Description

[0001] Cross-reference of related applications

[0002] This application claims priority to Japan Patent Application No. 2020-167845, filed on October 2, 2020 with the Japan Patent Office, and is incorporated herein by reference in its entirety. Technical Field

[0003] This invention relates to robot systems and control methods for robot systems. Background Technology

[0004] Previously, it was known to mount a paint gun on a robot to paint the object to be painted. For example, in the tire inner surface painting apparatus disclosed in Patent Document 1, a technique was disclosed in which painting was performed while keeping the distance between the paint gun mounted on the robot and the surface to be painted on the tire fixed, based on data of the target path of the paint gun preset by teaching and the distance between the paint gun and the surface to be painted on the tire measured by a distance sensor.

[0005] Existing technical documents

[0006] Patent documents

[0007] Patent Document 1: Japanese Patent Application Publication No. 2015-047834 Summary of the Invention

[0008] The uniformity of coating thickness depends at least on the movement path of the coating gun. Therefore, it is preferable to determine the movement path of the coating gun while confirming the actual coating condition of the workpiece. For example, uniformity can be categorized by the amount of coating unevenness.

[0009] However, in the aforementioned tire inner surface coating apparatus, the movement path of the coating gun parallel to the coating surface direction is not actually determined while coating is performed with the coating gun while maintaining a fixed distance between the coating gun and the surface to be coated on the tire; rather, it is preset. Therefore, it cannot be guaranteed that the actual coating state will be the desired state.

[0010] Furthermore, when using a robot's paint gun for painting, it's considered to paint at a certain angle relative to the surface being painted. However, in this case, if the movement path of the paint gun is not determined while painting, it cannot be guaranteed that the actual painting result will be the desired one.

[0011] These problems also apply when robots are used to process the workpiece surface in a non-contact manner. For example, this could be seen in machining processes where the material or energy used for machining is released from an end effector onto the workpiece surface.

[0012] The present invention was made to solve the aforementioned problems, and its purpose is to provide a robot system and a control method for the robot system, which can improve the actual processing state when the workpiece surface is processed in a non-contact manner.

[0013] To achieve the above objectives, a robot system according to one aspect of the present invention comprises: a robot having an end effector; an operation unit; and a control unit that moves the end effector based on the operation of the operation unit and performs non-contact machining of the end effector relative to a workpiece surface, wherein the control unit, when moving the end effector based on the operation of the operation unit, executes at least one of a first control and a second control, wherein the first control fixes the distance between the end effector and a control machining surface that is either the workpiece surface or a virtual workpiece surface, and the second control fixes the angle of the end effector relative to the control machining surface as a fixed angle.

[0014] Another aspect of the present invention provides a control method for a robot system comprising a robot having an end effector and an operating unit. The end effector is moved according to the operation of the operating unit, and the end effector performs non-contact machining relative to the workpiece's machined surface. When the end effector is moved, at least one of a first control and a second control is executed. The first control fixes the distance between the end effector and a control machined surface, which is either the workpiece's machined surface or a virtual machined surface of the workpiece. The second control fixes the angle of the end effector relative to the control machined surface.

[0015] The effects of the invention

[0016] The present invention improves the actual processing condition when the workpiece surface is processed in a non-contact manner. Attached Figure Description

[0017] Figure 1 This is a schematic diagram illustrating an example of the structure of the painting robot system according to Embodiment 1 of the present invention.

[0018] Figure 2 It is a schematic representation Figure 1 A top view of the robot and its position / pose sensors configuration.

[0019] Figure 3 It means Figure 1 A functional block diagram illustrating an example of the structure of the control system of a painting robot system.

[0020] Figure 4 This is a three-dimensional diagram illustrating the general concept of fixed gun distance control.

[0021] Figure 5 This is a top view showing an overview of the vertical control of the gun surface.

[0022] Figure 6 This is a schematic diagram illustrating an example of setting up a robot coordinate system for the CAD data of a workpiece.

[0023] Figure 7 This is a flowchart illustrating an example of specific control measures for a robot.

[0024] Figure 8 This is a flowchart illustrating an example of fixed-distance control of a robot's gun.

[0025] Figure 9 It is a top view showing the fixed control of gun distance and the allowable range of correction positions related to the position of the painting gun.

[0026] Figure 10 This is a top view showing the range of permissible angles for correction related to the orientation of the paint gun.

[0027] Figure 11 This is a flowchart illustrating an example of vertical control of the robot's gun surface.

[0028] Figure 12 This is a top view showing an example of the specific control content of Variation 1.

[0029] Figure 13 This is a top view showing an example of the specific control content of Implementation Method 2.

[0030] Figure 14 This is a top view showing an example of the specific control content of Variation Example 2. Detailed Implementation

[0031] Hereinafter, specific embodiments of the present invention will be described with reference to the accompanying drawings. Furthermore, the same reference numerals will be used to label the same or corresponding components in all the drawings, and repeated descriptions will be omitted. Also, the following drawings are for illustrating the present invention; therefore, due to the omission of components unrelated to the present invention, there may be instances of incorrect dimensions due to exaggeration, simplification, or inconsistencies in the shapes of corresponding components in multiple drawings. Furthermore, the present invention is not limited to the following embodiments.

[0032] (Summary of the implementation method)

[0033] The robot system according to an embodiment of the present invention includes: a robot having an end effector; an operation unit; and a control unit that moves the end effector based on operations of the operation unit, and causes the end effector to process the workpiece surface in a non-contact manner. When the control unit moves the end effector according to the operation unit's operation, it executes at least one of a first control and a second control. The first control sets a fixed distance between the end effector and a controlled surface that is either the workpiece surface or a virtual workpiece surface. The second control sets a fixed angle between the end effector and the controlled surface. Here, the "fixed angle" in the second control is selected to be an angle suitable for processing using the end effector. For example, in painting using a paint gun, 90 degrees is selected. Of course, other angles can be selected in other processing methods.

[0034] The operation unit includes a position and posture indicator that indicates the position and posture of the end effector, a position and posture detection unit that detects the position and posture of the position and posture indicator, and a processing indicator for operating the processing.

[0035] Hereinafter, in Embodiment 1, we will describe the method in which the controlled machined surface in the first control and the second control is the actual machined surface of the workpiece, and in Embodiment 2, we will describe the method in which the controlled machined surface in the first control and the second control is the virtual machined surface of the workpiece.

[0036] (Implementation Method 1)

[0037] [structure]

[0038] {Hardware Structure}

[0039] Figure 1 This is a schematic diagram illustrating an example of the structure of the robot system according to Embodiment 1 of the present invention. Figure 2 It is a schematic representation Figure 1 A top view of the configuration of robot 1 and position / posture sensor 4.

[0040] Reference Figure 1 In this embodiment 1, the robot system is, for example, a painting robot system 100. The painting robot system 100 includes a robot 1, an indicator 2 (e.g., a position and posture indicator), a system controller 3 (e.g., a control unit), a position / posture sensor 4 (e.g., a position / posture detection unit), a specific control switch 5, and a memory 7 (e.g., a storage unit). A painting gun 6 (e.g., an end effector) is mounted on the EF mounting section 1a of the end effector mounting section of the robot 1. The indicator 2 and the position / posture sensor 4 constitute an operator 8 (e.g., an operation unit).

[0041] Here, the painting robot system 100 is an example of a robot system according to an embodiment of the present invention. In this robot system, the processing by the end effector is performed by releasing processing material or energy from the end effector onto the surface to be processed of the workpiece. Hereinafter, processing performed by releasing processing material or energy from the end effector onto the surface to be processed of the workpiece is described. In the following text, as a processing performed by releasing processing material or energy from the end effector onto the surface to be processed of the workpiece, i.e., release processing, painting performed by spraying paint from the painting gun 6 is exemplified. However, release processing can also be other types of release processing. Furthermore, by appropriately applying the following disclosure of painting based on spraying paint from the painting gun 6 to other types of release processing, a robot system capable of performing such release processing can be realized. This is because all robot systems share the common principle of processing by releasing material or energy from the end effector onto the surface to be processed of the workpiece.

[0042] Here, the term "matter or energy used for processing" is not specifically limited. Examples of "matter used for processing" include liquids, gases, powdered or granular solids, and flames. Examples of "energy used for processing" include electric current, electromagnetic waves, light, and sound waves. Examples of electromagnetic waves include radio waves and radiation. Light includes ultraviolet and infrared radiation. Examples of sound waves include ultrasound. "Processing" refers to causing at least a physical or chemical change to the surface being processed. Examples of physical changes include changes in the shape, hardness, color, and properties of the surface being processed. Examples of changes in the shape of the surface being processed include the formation of concave areas, peeling off of the surface, formation of coatings, and melting deformation. Melting deformation includes welding. Examples of changes in properties include changes in conductivity and magnetism. Examples of chemical changes include oxidation, reduction, compounding, polymerization, and decomposition. Examples of the "emission" of matter or energy include the radiation, spraying, ejection, and flow of matter or energy.

[0043] Additionally, "the direction of material or energy emission from the end effector" can be, for example, the main direction of material or energy emission, the direction of extension of the centerline of the material or energy emission port of the end effector, or the normal direction. In the following text, the paint gun 6 is the "end effector," the paint is the material used for processing, the spraying of the paint is the "emission of material," and the spraying direction of the paint from the paint gun 6 is the "emission direction of material from the end effector." For simplicity, the "spraying direction of the paint from the paint gun 6" will be referred to as the "direction of the paint gun 6."

[0044] Furthermore, in the following, “EF distance fixed control”, which is an example of the first control, will be referred to as “gun distance fixed control”, and “EF surface vertical control”, which is an example of the second control, will be referred to as “gun surface vertical control”.

[0045] Furthermore, in the following description, an operator 8 is shown in which the indicator part indicating the position and orientation of the paint gun 6 and the sensor part detecting the position and orientation of the paint gun 6 are separated into an indicator 2 and a position / orientation sensor 4, respectively. However, an operator 8 that integrates the indicator part and the sensor part can also be used.

[0046] Additionally, in the following text, the machining indicator for operating the end effector is a trigger 2a, which exemplifies the operator 8 mounted on the indicator 2. However, the machining indicator may also be mounted separately from the operator 8. The machining indicator may also be displayed on the display of the system controller 3, for example.

[0047] Next, the configuration of these components will be explained. (Refer to...) Figure 2 The robot 1 and the workpiece W to be coated are, for example, arranged inside a sealed coating chamber 13. Additionally, in Figure 2 In the figure, for ease of observation, the EF mounting part 1a, which serves as the wrist, is shown instead of the robot 1. Reference numeral 10 indicates paint sprayed from the paint gun 6. One side wall of the paint chamber 13 is formed by a transparent partition 12, and a control area is formed adjacent to the transparent partition 12.

[0048] Imagine an operating position where the workpiece W and the painting gun 6 are visible within the control area. A specific control switch 5 is positioned at this operating position, and multiple position / attitude sensors 4 are arranged around this position. Here, the number of position / attitude sensors 4 is three. The operator 11, positioned at this operating position, observes the workpiece W and the painting gun 6 while holding an indicator 2 in one hand and moving the indicator 2 to operate the painting gun 6. Here, one hand is, for example, the right hand. The position / attitude sensors 4 detect the position and attitude of the indicator 2. Additionally, the operator 11 uses their other hand to operate the specific control switch 5, instructing at least one of gun distance fixing control and gun surface vertical control. Here, the other hand is, for example, the left hand. Furthermore, in the following text, gun distance fixing control and gun surface vertical control are collectively referred to as "specific control".

[0049] The system controller 3 may be configured in a suitable location outside the painting chamber 13, for example. The system controller 3 may be configured, for example, close to the operating position of the control area. Alternatively, the system controller 3 may be miniaturized and integrated with… Figure 3 The robot controller 9 shown is integrated. Alternatively, the integrated system controller 3 can be configured inside the base of the robot 1.

[0050] The memory 7 can be configured in any location. Here, it is configured inside the system controller 3.

[0051] The following is a detailed description of these components.

[0052] <Robot 1>

[0053] Robot 1 is the component that moves the paint gun 6. Therefore, robot 1 only needs to be able to mount the paint gun 6. Examples of robot 1 include vertical joint robots, horizontal joint robots, parallel linkage robots, and vertical coordinate robots.

[0054] In the following description, the case where robot 1 is a 6-axis vertical articulated robot is illustrated. A paint gun 6 is mounted on the EF mounting section 1a of robot 1. The EF mounting section 1a is an example of a mounting section for the paint gun 6. If robot 1 is of another type, the name of the mounting section for the paint gun 6 may be changed.

[0055] For robot 1, the paint gun 6 is one type of end effector mounted on the EF mounting part 1a. Therefore, the position and orientation of the paint gun 6 are controlled by controlling the position and orientation of the EF mounting part 1a, which serves as the mounting part for the paint gun 6. Therefore, in the following description, the control of the position and orientation of the EF mounting part 1a will be explained, but controlling the position and orientation of the EF mounting part 1a is synonymous with controlling the position and orientation of the paint gun 6. Furthermore, "the orientation of the EF mounting part 1a" is synonymous with the orientation of the paint gun 6 mounted on the EF mounting part 1a.

[0056] <Indicator 2>

[0057] Indicator 2 indicates the position and orientation of the paint gun 6 and is a component used for spraying paint from the paint gun 6. Here, indicator 2 is shaped to simulate the shape of the paint gun 6. Therefore, the position and orientation of the paint gun 6 can be indicated based on the position and orientation of indicator 2. However, the shape of indicator 2 does not have to be a gun shape. For example, a mark can be set on indicator 2 of any shape, and the position and orientation of indicator 2 can be determined by detecting the mark using position / or orientation sensor 4.

[0058] Here, in indicator 2, a trigger 2a is provided for operating the spraying of paint from the paint gun 6. The trigger 2a is configured to be able to be pressed and returned to its original position by applying force. The operator 11 presses the trigger 2a with their finger, thereby spraying paint from the paint gun 6. When the operator 11 releases their finger from the trigger 2a, spraying from the paint gun 6 stops. Furthermore, the amount of paint sprayed increases or decreases depending on the amount of pressure applied to the trigger 2a. The amount of paint sprayed can, for example, be the amount sprayed per unit time.

[0059] <System Controller 3>

[0060] The system controller 3 controls the actions of the robot 1 to achieve basic position and posture control of the coating gun 6, corresponding to the position and posture of the indicator 2 detected by the position / posture sensor 4. Furthermore, it controls the spraying of paint from the coating gun 6 based on the operation of the indicator 2 related to the spraying of paint from the coating gun 6. In addition, the system controller 3 performs at least one of the following basic controls: gun distance fixing control, which fixes the distance between the coating gun 6 and the coating surface f of the workpiece W; and gun surface perpendicularity control, which ensures that the orientation of the coating gun 6 is perpendicular to the coating surface of the workpiece W. The coating surface f is an example of a surface being processed.

[0061] Specifically, the system controller 3 generates control signals for the robot 1 and the painting gun 6 based on the position and posture data of the indicator 2 detected by the position / posture sensor 4, the three-dimensional data of the workpiece W, and the position data of the workpiece W, and sends them to the robot 1. Figure 3 The robot controller 9 is shown. Position and pose data represent position / pose signals.

[0062] The three-dimensional data of workpiece W is pre-stored Figure 3 The memory 7 of the system controller 3 shown contains the 3D data of the workpiece W, including CAD data of the workpiece W, measured data of the workpiece W, etc.

[0063] System controller 3 consists of having Figure 3 The processor Pr and memory Me shown are composed of an arithmetic logic unit. Figure 3 The mode switching switch 31 is a functional module implemented in this arithmetic unit by the processor Pr executing the control program stored in the memory Me. Specifically, this arithmetic unit is composed of, for example, a microcontroller, MPU, FPGA (Field Programmable Gate Array), PLC (Programmable Logic Controller), etc. These can be composed of a single arithmetic unit for centralized control, or multiple arithmetic units for distributed control.

[0064] In this specification, the functions of the components disclosed herein may be performed using circuitry or processing circuitry, including general-purpose processors, special-purpose processors, integrated circuits, ASICs (Application Specific Integrated Circuits), conventional circuitry, or combinations thereof configured or programmed to perform the disclosed functions. A processor is considered a processing circuit or circuit because it includes transistors and other circuitry. In this invention, "device" and "component" are hardware that performs the exemplified functions, or hardware programmed to perform the exemplified functions. The hardware may be the hardware disclosed herein, or may be other known hardware programmed or configured to perform the exemplified functions. If the hardware is a processor considered a type of circuit, then "device" and "component" are combinations of hardware and software used in the construction of the hardware and / or processor.

[0065] Location / Posture sensor 4>

[0066] Location / The posture sensor 4 is a component that detects the position and posture of the manipulator. Therefore, position... / The posture sensor 4 can be any sensor that can detect the position and posture of the indicator 2.

[0067] As a position / Attitude sensor 4, for example, can be of type A which combines multiple distance sensors, type B which uses a 3D camera as an example of a stereo camera, type C which uses a depth camera, and type D which combines a three-axis accelerometer, a gyroscope sensor, and a geomagnetic sensor.

[0068] According to type A, for example, the position and orientation of indicator 2 can be obtained by combining and analyzing distance data detected by multiple infrared distance sensors.

[0069] According to type B, for example, the position and orientation of indicator 2 can be obtained by analyzing an image containing depth information captured by more than one 3D camera.

[0070] According to type C, for example, the position and pose of indicator 2 can be obtained by analyzing depth images captured by more than one TOF camera.

[0071] According to type D, the position and orientation of indicator 2 can be obtained using a three-axis accelerometer mounted on indicator 2. In addition to the three-axis accelerometer, a gyroscope sensor and a geomagnetic sensor are also mounted on indicator 2. By combining and analyzing their outputs, the position and orientation of indicator 2 can be obtained with high precision.

[0072] Here, as a location / The posture sensor 4 uses type B. In this case, for example, a marker can be attached to the indicator 2 to determine the position and posture of the indicator 2 from the image captured by the 3D camera.

[0073] <Specific Control Switch 5>

[0074] The specific control switch 5 includes a gun distance fixing switch 5a and a gun surface vertical switch 5b. For example, when the gun distance fixing switch 5a is rotated, a gun distance fixing control ON signal is output; when the gun distance fixing switch 5a is rotated back, the gun distance fixing control ON signal disappears. Similarly, when the gun surface vertical switch 5b is rotated, a gun surface vertical control ON signal is output; when the gun surface vertical switch 5b is rotated back, the gun surface vertical control ON signal disappears.

[0075] <Paint Gun 6>

[0076] The paint gun 6 is not particularly limited. Here, the paint gun 6 can change the amount of paint sprayed. The paint can be, for example, liquid, gas, powder, or a mixture of one or more of these.

[0077] <Memory 7>

[0078] The memory 7 stores the three-dimensional data of the workpiece W. Additionally, the memory 7 stores, in time sequence, the robot control signals and paint gun control signals output by the system controller 3 to the robot 1 and paint gun 6, respectively, for controlling the actions of the robot 1 and the spraying of paint by the paint gun 6. The memory 7 is composed of the memory Me that constitutes the system controller 3 and is built inside the system controller 3.

[0079] The memory 7 can be located outside the system controller 3 as a separate component. For example, the memory 7 can also be composed of a teach pendant.

[0080] {Structure of Control System}

[0081] Figure 3 It means Figure 1 A functional block diagram illustrating an example of the structure of the control system of a painting robot system 100.

[0082] Reference Figure 3 The painting robot system 100 also features a mode switching switch 31. The mode switching switch 31, for example, displays... Figure 1 The system controller 3 shown is equipped with a display. The mode switching switch 31 outputs a mode switching signal to the system controller 3 to switch between storage mode and playback mode.

[0083] Indicator 2 outputs a spray signal to system controller 3, indicating the amount of paint sprayed from the paint gun 6 corresponding to the amount of pressure applied by trigger 2a.

[0084] Location / The posture sensor 4 outputs a position and posture of the detected indicator 2 to the system controller 3. / Posture signals.

[0085] Based on the operation of the gun distance fixing switch 5a and the gun surface vertical switch 5b, the specific control switch 5 outputs the gun distance fixing control ON signal and the gun surface vertical control ON signal to the system controller 3, respectively.

[0086] Robot 1 has a robot controller 9, which controls the actions of robot 1 and paint gun 6 respectively according to the input robot control signal and paint gun control signal.

[0087] System controller 3 based on location / The position input by the posture sensor 4 / The posture signal outputs the robot control signal to the robot controller 9 of robot 1, and controls the position and posture of the painting gun 6 through the actions of robot 1.

[0088] In addition, the system controller 3 outputs the paint gun control signal to the robot controller 9 of the robot 1 based on the spray signal input from the indicator 2, and controls the ON / OFF of the paint spraying of the paint gun 6 and the spraying amount through the robot controller 9.

[0089] In addition, during the basic control of the robot 1's movements, when the system controller 3 inputs a gun distance fixed control ON signal or a gun surface vertical control ON signal from a specific control switch 5, it performs gun distance fixed control or gun surface vertical control, that is, sets the gun distance fixed control or gun surface vertical control to ON.

[0090] Furthermore, when a mode switching signal is input from the mode switching switch 31, the system controller 3 switches between the storage mode and the playback mode of the robot 1's actions. In storage mode, the system controller 3 stores its own output robot control signals and paint gun control signals in the memory 7 in a time sequence. In playback mode, the system controller 3 sequentially reads the time-series stored robot control signals and paint gun control signals from the memory 7 and outputs them to the robot 1 and the paint gun 6.

[0091] <Fixed Gun Distance Control>

[0092] Next, we will explain the fixed control of gun distance. Figure 4 This is a three-dimensional diagram illustrating the general concept of fixed gun distance control.

[0093] Reference Figure 4In the gun distance fixing control, the movement of robot 1 is controlled so that the EF mounting part 1a of robot 1 maintains a fixed distance from the coating surface f of workpiece W. As a result of maintaining a fixed distance between the EF mounting part 1a of robot 1 and the coating surface f of workpiece W, the coating gun 6 also maintains a fixed distance from the coating surface f of workpiece W. On the other hand, the EF mounting part 1a of the coating gun 6 on which robot 1 is mounted is controlled to move to a position corresponding to the position of indicator 2 in a direction perpendicular to the orientation of the EF mounting part 1a. Gun distance fixing control is performed during the period when the trigger 2a of indicator 2 is pressed.

[0094] <Gun Surface Vertical Control>

[0095] Next, the vertical control of the gun surface will be explained. Figure 5 This is a top view showing an overview of the vertical control of the gun surface. Figure 5 In the diagram, the dashed line in the EF mounting section 1a represents the posture of the paint gun 6 corresponding to the posture of the indicator 2, while the solid line represents the posture of the paint gun 6 controlled vertically by the gun surface. The posture of the paint gun 6 corresponding to the posture of the indicator 2 represents the posture in basic control.

[0096] Reference Figure 5 In the vertical control of the gun surface, the robot 1 is controlled to orient the painting gun 6 perpendicular to the coating surface f of the workpiece W. On the other hand, the position P0 of the EF mounting part 1a of the painting gun 6 is unrestricted, and the painting gun 6 can move in any direction. Vertical control of the gun surface is performed during the period when the trigger 2a of the indicator 2 is pressed.

[0097] <Setting the CAD data for workpiece W>

[0098] Figure 6 This is a schematic diagram illustrating an example of setting up the robot coordinate system for the CAD data of workpiece W.

[0099] Reference Figure 6 For example, the CAD data of workpiece W, as its three-dimensional data, is stored in the memory 7 of the system controller 3. At this time, the coordinates of workpiece W as observed from the origin O are set in the coordinate system of robot 1. The position of workpiece W as observed from this origin is measured, for example, using a ruler or similar tool.

[0100] [action]

[0101] Next, the operation of the painting robot system 100 configured as described above will be explained. The operation of the painting robot system 100 represents the control method of the painting robot system 100.

[0102] {Storage Mode}

[0103] First, the storage mode will be explained. In the storage mode, the system controller 3 stores the robot control signals and painting gun control signals it outputs in a time sequence in the memory 7 during the actions described below.

[0104] <Basic Control>

[0105] Reference Figure 2 and Figure 3 Operator 11 first operates the mode switch 31 displayed on the system controller 3's screen to set the robot 1's motion to the stored mode. Then, operator 11, positioned in the operating position, observes the workpiece W and the painting gun 6 while holding the indicator 2 in one hand, moving the indicator 2 to operate the painting gun 6. / The posture sensor 4 detects the position and posture of the indicator 2, and uses the position as the detection signal. / The system controller 3 controls the robot 1's movements using the posture signal, so that the position and posture of the EF mounting part 1a and the painting gun 6 correspond to the position and posture of the indicator 2.

[0106] Next, when operator 11 presses trigger 2a of indicator 2 with their finger, system controller 3 causes paint gun 6 to spray paint 10 in the amount corresponding to the spray signal from indicator 2. During the period when trigger 2a of indicator 2 is pressed, system controller 3 performs specific control as described below.

[0107] <Specific Control>

[0108] Figure 7 This is a flowchart illustrating an example of specific control operations for robot 1. (See attached diagram.) Figure 7 System controller 3 performs specific controls within the basic controls described above.

[0109] In a specific control, firstly, it is determined whether the vertical switch 5b on the gun surface outputs an ON signal (step S1). If the vertical switch 5b on the gun surface does not output an ON signal ("No" in step S1), proceed to step S3.

[0110] When the gun surface vertical switch 5b outputs an ON signal ("Yes" in step S1), the gun surface vertical processing (gun surface vertical control) is performed (step S2).

[0111] Next, the system controller 3 determines whether the gun distance fixing switch 5a outputs an ON signal (step S3). When the gun distance fixing switch 5a does not output an ON signal ("No" in step S3), the specific control ends.

[0112] When the gun distance fixing switch 5a outputs an ON signal ("Yes" in step S3), the gun distance fixing process (gun distance fixing control) is performed (step S4).

[0113] Then, system controller 3 terminates this specific control.

[0114] The system controller 3 repeats the specific control at a predetermined control interval.

[0115] <Fixed Gun Distance Control>

[0116] Figure 8 This is a flowchart illustrating an example of the fixed distance control of the gun in robot 1. Figure 9 This is a top view showing the gun distance fixing control and the allowable position range 21 of the correction related to the position of the painting gun 6. The gun distance fixing control of robot 1 indicates the gun distance fixing process of robot 1.

[0117] Reference Figure 8 and Figure 9 In fixed gun distance control, the system controller 3 first determines the position based on the input from the position / attitude sensor 4. / The position P0 and orientation of the EF mounting section 1a of robot 1 are obtained from the posture signal (step S11). Here, as already described, the orientation of the EF mounting section 1a is consistent with the orientation of the paint gun 6 mounted on the EF mounting section 1a. The orientation of the paint gun 6 is appropriately defined. The orientation of the paint gun 6 can be defined, for example, as the main spray direction of the paint, the extension direction of the center line of the paint nozzle, etc. The paint gun 6, as an end effector, is mounted in a manner in which its orientation is consistent with the axis representing the orientation of the end effector of the EF mounting section 1a. Here, the paint gun 6 is mounted in a manner consistent with the torsional rotation axis of the EF mounting section 1a. Therefore, the orientation of the EF mounting section 1a refers to the extension direction of the torsional rotation axis of the EF mounting section 1a.

[0118] Next, the system controller 3 determines the position of the intersection point P1 of the torsional rotation axis of the EF mounting part 1a and the coating surface f of the workpiece W (step S12). Thus, point P1 is determined as the reference point for the distance between the coating surface f and the EF mounting part 1a.

[0119] Next, the system controller 3 determines whether the calibration conditions are met (step S13). Here, "calibration" refers to the change in target position and target posture from the basic control of the coating gun 6 to the specific control of gun distance fixation and gun surface verticality control. When the coating gun 6, as the end effector, is located away from the coating surface f of the workpiece W, or is oriented in a direction away from the coating surface f of the workpiece W, it is assumed that the operator 11 does not intend to perform gun distance fixation control or gun surface verticality control. Therefore, in this embodiment, in order to comply with the operator 11's intention, calibration is limited to meeting the prescribed calibration conditions.

[0120] The calibration conditions include calibration conditions related to the position of the paint gun 6 and calibration conditions related to the posture of the paint gun 6.

[0121] Reference Figure 9 The system controller 3 sets a correction allowable position range 21 related to the position of the EF mounting part 1a. Here, "set" means stored in the memory 7. The correction allowable position range 21 is appropriately set. The correction allowable position range 21 is set here as a three-dimensional area within a specified distance range from the coated surface f of the workpiece W. The specified distance range includes a specified distance Lc. The three-dimensional area is here in the shape of a cuboid. The system controller 3 sets the correction allowable position range 21 in the memory 7. / The position input by the posture sensor 4 / If the position P0 of the EF mounting part 1a obtained by the attitude signal is within the allowable correction position range 21, it is determined that the correction condition related to the position of the EF mounting part 1a is met.

[0122] Figure 10 This is a top view showing the allowable range of correction angles related to the orientation of the EF mounting section 1a. (See reference...) Figure 10 The system controller 3 sets a correction allowable angle range 22 related to the orientation of the EF mounting part 1a. The correction allowable angle range 22 is appropriately set. Here, the correction allowable angle range 22 is set as a conical region within a specified angle range relative to the normal 23 of the coated surface f of the workpiece W. The system controller 3 calculates the difference angle θ between the intersection angle of the rotation axis of the EF mounting part 1a with the coated surface f at the intersection point P1 of the workpiece W and the normal 23. If this difference angle θ is within the correction allowable angle range, it is determined that the correction conditions related to the posture of the EF mounting part 1a are met.

[0123] When the system controller 3 determines that the correction conditions related to the position and the posture of the EF mounting part 1a are met, it determines that the correction conditions are met.

[0124] When the system controller 3 determines that the calibration conditions are not met ("No" in step S13), the gun distance fixing control ends.

[0125] On the other hand, when the system controller 3 determines that the correction condition is met ("Yes" in step S13), the position of the point P2 (hereinafter referred to as the fixed distance point) that is a distance away from the intersection point P1 on the rotation axis of the EF mounting part 1a from the specified distance Lc is determined (step S14). The specified distance Lc is the distance between the EF mounting part 1a and the surface to be coated f, which is a suitable distance for the coating gun 6 to coat the surface to be coated f, and is determined by the operator 11's experience, experiments, simulations, calculations, etc.

[0126] Next, the system controller 3 positions the EF mounting part 1a at a fixed distance point P2 (step S15).

[0127] Then, system controller 3 terminates the fixed gun distance control.

[0128] <Gun Surface Vertical Control>

[0129] Figure 11 This is a flowchart illustrating an example of vertical control of the robot's gun surface. Vertical control of the gun surface refers to vertical processing of the gun surface.

[0130] Reference Figure 11 In the vertical control of the gun surface, the system controller 3 first determines the position from the position. / The position input by the posture sensor 4 / The orientation signal is obtained to determine the orientation of the EF mounting part 1a as the posture of the EF mounting part 1a of the robot 1 (step S21).

[0131] Then, the system controller 3 determines whether the correction condition is met (step S22). Since the determination of whether the correction condition is met is the same as that in the case of fixed gun distance control described above, its explanation is omitted.

[0132] When the system controller 3 determines that the calibration conditions are not met ("No" in step S22), the vertical control of the gun surface ends.

[0133] On the other hand, when the system controller 3 determines that the correction condition is met ("Yes" in step S22), the posture of the EF mounting part 1a, which is perpendicular to the coating surface f of the workpiece W, is calculated (step S23). This process can be performed appropriately using the posture data of the EF mounting part 1a and the CAD data of the workpiece W. Here, for example, the normal vector of the coating surface f of the workpiece W is used as input, and the following process is performed. In addition, in the following process, vector

[010] represents the unit vector used as a reference.

[0134] A. Find the quaternion that makes vector

[010] face the EF mounting part 1a of robot 1.

[0135] B. Convert the quaternions obtained in the processing of A into rotation matrices.

[0136] C. Find the quaternion that makes vector

[010] point toward the normal vector of the painted surface f.

[0137] D. Convert the quaternion obtained in the processing of C into a rotation matrix.

[0138] E. Find the transformation matrix that converts the rotation matrix obtained in the process of B into the rotation matrix obtained in the process of D.

[0139] F. Multiply the transformation matrix obtained in the processing of E with the posture of the EF mounting part 1a of robot 1, and set it as the corrected posture of the EF mounting part 1a of robot 1, that is, the surface vertical posture.

[0140] Next, the system controller 3 determines whether the position and orientation of the EF mounting part 1a after correction meet the correction conditions (step S24). Since the determination of whether the correction conditions are met is the same as that in the case of fixed gun distance control described above, its explanation is omitted.

[0141] When the system controller 3 determines that the calibration conditions are not met ("No" in step S24), the vertical control of the gun surface ends.

[0142] On the other hand, when the system controller 3 determines that the correction conditions are met ("Yes" in step S24), the posture of the EF mounting part 1a is corrected to the surface vertical posture obtained above (step S25).

[0143] Then, system controller 3 terminates vertical control of the gun surface.

[0144] {Reproduction Mode}

[0145] Reference Figure 2 and Figure 3 Operator 11 operates the mode switch 31 displayed on the system controller 3's screen to set the robot 1's actions to playback mode. Then, the system controller 3 sequentially reads the robot control signals and painting gun control signals stored in time sequence from the memory 7 and outputs them to the robot 1 and the painting gun 6. Thus, in storage mode, the painting operation performed by a skilled operator on one workpiece is automatically performed on multiple workpieces of the same specifications.

[0146] As explained above, the coating robot system 100 according to this embodiment can determine the movement path of the coating gun 6 while performing coating, under at least one of the following conditions: controlling the distance between the coating gun 6 and the coating surface f of the workpiece W to be fixed, and controlling the orientation of the coating gun 6 to be perpendicular to the coating surface f of the workpiece W.

[0147] In addition, it can automatically perform painting operations on multiple workpieces of the same specifications, which would otherwise be done by a skilled operator on a single workpiece.

[0148] In addition, while operating the paint spraying of the paint gun 6 through the indicator 2, the operator 11 moves the indicator 2 to mimic the paint gun 6, thereby enabling the workpiece to be painted as if it were actually held in hand.

[0149] {Variation Example 1}

[0150] Figure 12 This is a top view showing an example of the specific control content of Variation 1. (See reference...) Figure 1 In modified example 1, the coating surface f of the workpiece W is, for example, a curved surface. Furthermore, as specific controls, the system controller 3 performs gun distance fixing control and gun surface vertical control. Otherwise, it is the same as in embodiment 1.

[0151] Through this variation 1, the same effect as in embodiment 1 can be obtained. Furthermore, as can be seen from embodiment 1 and variation 1, the shape of the coating surface f of the workpiece W is not particularly limited.

[0152] (Implementation Method 2)

[0153] Figure 13 This is a top view illustrating an example of the specific control content of Implementation Method 2. (See reference...) Figure 13 In Embodiment 2, a virtual workpiece Wv is defined for the actual workpiece Ws. The actual workpiece Ws has a rough coating surface fs. The virtual workpiece Wv has a virtual coating surface fv that homogenizes the coating surface fs of the actual workpiece Ws, and the portion other than the virtual coating surface fv is set to run along the surface of the actual workpiece Ws. Therefore, a "workpiece W" exists as a concept that includes both the actual workpiece Ws and the virtual workpiece Wv. The "coating surface" of this "workpiece W" is called the "control coating surface f". Therefore, in Embodiment 1 and Modification 1, the coating surface of the actual workpiece W is the control coating surface f.

[0154] The virtual workpiece Wv is determined, for example, by CAD data and stored as three-dimensional data in memory 7. Then, the system controller 3 uses the virtual coating surface fv as the control coating surface f to perform gun distance fixing control and gun surface vertical control as specific controls. Otherwise, it is the same as in embodiment 1.

[0155] If the actual surface to be coated, fs, of the workpiece Ws is rough, and the first or second control is performed based on the distance or angle of the coating gun 6 relative to the actual surface to be coated, the position and posture of the coating gun 6 will not follow the state of the actual surface to be coated and will become disordered, which may result in a poor coating condition.

[0156] According to Embodiment 2, a virtual coating surface fv is set in the workpiece W to homogenize the actual coating surface fs, and a first control or a second control is performed on the virtual coating surface fs. Therefore, the position and posture of the coating gun 6 follow the state of the virtual coating surface fs, and the position and posture of the coating gun 6 can be prevented from becoming disordered.

[0157] {Variation Example 2}

[0158] Figure 14 This is a top view illustrating an example of the specific control content of Variation 2. (See reference...) Figure 14 In Variation 2, the virtual coating surface fv of the virtual workpiece Wv is not only set to a shape that homogenizes the actual coating surface fs of the actual workpiece Ws, but also, in the second control, the virtual coating surface fv is set to be sprayed with paint from the coating gun 6 onto the actual coating surface fs from a desired orientation. Specifically, the virtual coating surface fv is set such that the normal of the virtual coating surface fv faces the desired orientation. Otherwise, it is the same as in Embodiment 2.

[0159] According to this variation 2, paint is sprayed from the desired direction onto the actual surface to be coated, fs, by the paint gun 6, thus achieving the desired coating condition.

[0160] (Other implementation methods)

[0161] In the above embodiments, in addition to omitting the storage mode and the reproduction mode, and not storing the robot control signal and the paint gun control signal, the paint robot system 100 can also be configured with only the same general operation mode as the storage mode.

[0162] In the above embodiments, the release process can also be a release process other than painting. Examples of such release processes include cleaning by spraying cleaning fluid from a cleaning nozzle, shot peening or shot peening hardening by spraying a mixture of projected material particles and air or water from a spray nozzle, arc welding by releasing current from an electrode, or scorching by releasing flame from a burner.

[0163] In the above embodiments, an operator 8 that integrates the indicator and sensor units can also be used. Examples of such an operator 8 include a joystick, a main robot arm with a shape similar to that of the robot 1, and a dedicated operator.

[0164] The system controller may be configured to perform at least one of the EF distance fixation control and the EF surface vertical control during the period when the manipulator is operated to cause the end effector to release the matter or energy.

[0165] According to this structure, the end effector can move in at least one of a free movement path and posture without releasing matter or energy.

[0166] (Effects of the implementation method)

[0167] As described above, in embodiments 1 and 2, a robot 1 is provided, which includes an end effector 6; an operation unit 8; and a control unit 3, which moves the end effector 6 based on the operation of the operation unit 8, so that the end effector 6 performs non-contact processing relative to the workpiece W's processing surface. When the control unit 3 moves the end effector 6 based on the operation of the operation unit 8, it executes at least one of a first control and a second control. The first control fixes the distance between the end effector 6 and a control processing surface f, which is either the processing surface fs of the workpiece W or a virtual processing surface fv of the workpiece W. The second control fixes the angle between the end effector 6 and the control processing surface f.

[0168] According to this structure, at least one of the first and second controls can be performed while the end effector 6 is moved based on the operation of the operating unit 8, and the end effector 6 can perform machining relative to the machined surface fs of the workpiece W in a non-contact manner. Therefore, the movement path of the end effector 6 can be determined while confirming the actual machining state of the workpiece W according to at least one of the first and second controls. As a result, since the machining state desired by the operator 11 can be obtained, the actual machining state can be improved compared to the case where at least one of the first and second controls is performed while moving the end effector 6 along a preset path.

[0169] The control unit 3 may also perform at least one of the first control and the second control during the period when the end effector 6 is machining the workpiece W's machined surface fs.

[0170] According to this structure, when the end effector 6 does not process the workpiece W's surface fs, the end effector 6 can move through at least one of a free movement path and posture.

[0171] The operation unit 8 may also include a position and posture indicator 2 that indicates the position and posture of the end effector 6, a position and posture detection unit 4 that detects the position and posture of the position and posture indicator 2, and a processing indicator 2a for operating the processing.

[0172] According to this structure, the position and posture of the end effector 6 become the position and posture corresponding to the position and posture of the position and posture indicator 2 detected by the position and posture detection unit 4, and the end effector 6 is processed according to the operation control of the processing instruction unit 2a. Therefore, the operator 11 can process the workpiece W by holding the actual end effector 6 by hand while operating the end effector 6 with the processing instruction unit 2a and making the position and posture indicator 2 move in the same way as the end effector 6.

[0173] The control unit 3 stores the three-dimensional data of the workpiece W. The control unit 3 performs the first control based on the three-dimensional data of the workpiece W and the position of the end effector 6, or performs the second control based on the three-dimensional data of the workpiece W and the posture of the end effector 6. Here, "three-dimensional data" can be, for example, CAD data, measured data, etc.

[0174] Based on this structure, first and second control can be performed by using calculations of the three-dimensional data of the workpiece W.

[0175] The position and posture of the end effector 6 used for the first control and the second control are respectively the position and posture of the position and posture indicator 2 detected by the position and posture detection unit 4. The control surface f in the first control and the second control can also be the virtual surface fv of the workpiece W.

[0176] If the actual machined surface fs of workpiece W is rough, and the first or second control is performed based on the distance or angle of the end effector 6 relative to the actual machined surface fs, the position and posture of the end effector 6 will not follow the state of the actual machined surface fs and will become disordered, potentially resulting in poor machining. According to this structure, for example, if a virtual machined surface fv is set for workpiece W to homogenize the actual machined surface fs, and the first or second control is performed on this virtual machined surface fs, then the position and posture of the end effector 6 will follow the state of the virtual machined surface fs, preventing the position and posture of the end effector 6 from becoming disordered.

[0177] The robot system 100 also includes a storage unit 7, which stores control signals that cause the end effector 6 to move and that the control unit 3 outputs to enable the end effector 6 to perform the processing. The control unit 3 has a storage mode and a playback mode. In the storage mode, the control unit 3 stores the control signals in the storage unit 7 in a time sequence, and in the playback mode, it outputs the control signals stored in the storage unit 7 to the robot 1 and the end effector 6.

[0178] According to this structure, in storage mode, a skilled operator 11 processes a workpiece W, and then in playback mode, multiple workpieces W of the same specifications can be processed automatically in the same way as the skilled operator 11.

[0179] The control unit 3 may also perform at least one of the first control and the second control when the end effector 6 is located within a specified distance from the controlled processing surface f and the orientation of the end effector 6 relative to the controlled processing surface f is within a specified orientation range.

[0180] When the end effector 6 is located away from the workpiece W's machined surface fs, or in a direction detached from the workpiece W's machined surface fs, it is assumed that the operator 11 has no intention of performing the first or second control. According to this configuration, in this situation, the operator 11's intention can be appropriately met.

[0181] The processing of the end effector 6 may be performed by releasing processing material or energy from the end effector 6 onto the surface of the workpiece to be processed.

[0182] According to this structure, in the processing performed by releasing processing material or energy from the end effector 6 onto the processing surface fs of the workpiece W, the processing state desired by the operator 11 can be obtained.

[0183] The processing performed by releasing the processing material or energy from the end effector 6 onto the processed surface fs of the workpiece W can be any one of the following: painting by spraying liquid or powder paint from a paint gun; cleaning by spraying cleaning fluid from a cleaning nozzle; shot peening or shot peening hardening by spraying a mixture of projected material particles and air or water from a nozzle; arc welding by releasing current from an electrode; and scorching processing by releasing flame from a burner.

[0184] According to this structure, the processing state desired by the operator 11 can be obtained in these processes.

[0185] Based on the above description, many modifications and other embodiments will be apparent to those skilled in the art. Therefore, the above description should be interpreted as illustrative only.

[0186] Label Explanation

[0187] 1 robot

[0188] 1a EF Installation Section

[0189] 2 indicators

[0190] 2a trigger

[0191] 3 System Controller

[0192] 4 position / attitude sensors

[0193] 5 Specific control switches

[0194] 6 Paint Guns

[0195] 7 Memory

[0196] 8 operators

[0197] 9 robot controllers 9

[0198] 10. Coatings

[0199] 21. Calibration Allowable Position Range

[0200] 22. Correction allowable angle range

[0201] 23 Normals

[0202] 31 Mode Switch

[0203] 100 Painting Robot System

[0204] f The surface to be coated, control the surface to be coated

[0205] Lc specifies a fixed distance

[0206] Me memory, memory

[0207] O origin

[0208] Location of P0 EF mounting section

[0209] P1 intersection

[0210] P2 Fixed distance point

[0211] Pr processor

[0212] W workpiece

[0213] θ difference angle

Claims

1. A robotic system, characterized by, Possessing: a robot having an end effector; an operation section including an instruction section that instructs a position and a posture of the end effector according to an operation of an operator; and a control section that moves the end effector based on an operation of the operation section and causes the end effector to perform a processing with respect to a processed surface of a workpiece in a non-contact manner, the control section executing at least one of a first control that fixes a distance between the end effector and a control processed surface that is the processed surface of the workpiece or a virtual processed surface of the workpiece and a second control that causes an angle of the end effector with respect to the control processed surface to be a fixed angle, while determining a movement path of the end effector based on the operation of the operation section.

2. The robot system according to claim 1, wherein the control section executes at least one of the first control and the second control during the end effector performs the processing with respect to the processed surface of the workpiece.

3. The robot system according to claim 1 or 2, wherein the operation section includes: a position-posture instruction section that indicates a position and a posture of the end effector; a position-posture detection section that detects the position and the posture of the position-posture instruction section; and a processing instruction section for operating the processing.

4. The robot system according to claim 1 or 2, wherein the control section stores three-dimensional data of the workpiece, the control section performs the first control according to the three-dimensional data of the workpiece and the position of the end effector or performs the second control according to the three-dimensional data of the workpiece and the posture of the end effector.

5. The robot system according to claim 3, wherein the position of the end effector and the posture of the end effector for the first control and the second control are the position and the posture of the position-posture instruction section detected by the position-posture detection section, respectively, the control processed surface in the first control and the second control is the virtual processed surface of the workpiece.

6. The robot system according to claim 1 or 2, wherein the robot system further has a storage section that stores a control signal output by the control section in order to move the end effector and cause the end effector to perform the processing, the control section has a storage mode and a reproduction mode, the control section stores the control signal in the storage section in a time series in the storage mode and outputs the control signal stored in the storage section to the robot and the end effector in the reproduction mode.

7. The robot system according to claim 1 or 2, wherein the control section executes at least one of the first control and the second control when the end effector is located within a prescribed distance range from the control processed surface and an orientation of the end effector with respect to the control processed surface is within a prescribed orientation range.

8. The robot system according to claim 1 or 2, wherein The processing of the end effector is processing performed by discharging a substance or energy for processing from the end effector toward a processed surface of the workpiece.

9. The robot system according to claim 8, characterized in that, The processing performed by discharging a substance or energy for processing from the end effector toward a processed surface of the workpiece is any one of painting performed by ejecting liquid or powder paint from a painting gun, washing performed by ejecting a washing liquid from a washing nozzle, shot blasting or shot peening performed by ejecting a mixture of shot particles and air or water from a jetting nozzle, electric arc welding performed by releasing electric current from an electrode, and torch processing performed by releasing a flame from a burner.

10. The robot system according to claim 1, characterized in that, Further comprising a specific control switch provided with a gun distance fixing switch and a gun surface perpendicular switch, A gun distance fixing control on signal and a gun surface perpendicular on signal are output by rotating the gun distance fixing switch and the gun surface perpendicular switch, respectively.

11. A control method of a robot system provided with a robot having an end effector and an operation section, characterized in that, The operation section includes an instruction section that instructs a position and a posture of the end effector according to an operation of an operator, The end effector is moved according to the operation of the operator on the operation section, and the end effector performs processing in a non-contact manner with respect to a processed surface of a workpiece, While the end effector is moved, at least one of a first control and a second control is executed while determining a movement path of the end effector based on the operation of the operation section, the first control fixing a distance between the end effector and a control processed surface that is the processed surface of the workpiece or a virtual processed surface of the workpiece, the second control fixing an angle of the end effector with respect to the control processed surface to a fixed angle.

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