Repair section detection method and repair section detection device

Abstract

A repair welding section detection method in which: input data and master data of a non-defective workpiece are used to generate shape inconsistency data in which a position of a shape inconsistency of a weld bead is extracted; the shape inconsistency data is divided into N (where N is an integer of 2 or more) equal windows in a direction perpendicular to a welding direction; a shift region formed of i (where i is an integer of 1 or more) consecutive windows is set; the volume of each of (N-i+1) shift regions obtained by shifting the i windows forming the shift region one by one is calculated; and a shift region having a volume equal to or greater than a prescribed value is determined to be a weld bead defective section.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to a repair welding section detection method and a repair welding section detection device. BACKGROUND

[0002] Patent Literature 1 discloses a shape inspection device that projects a slit light onto a weld bead, images shape lines sequentially formed on the weld bead by scanning the weld bead with the slit light, and acquires a three-dimensional shape of the weld bead as point cloud data, based on the imaging data of the sequentially formed shape lines. On the weld bead displayed based on the point cloud data, the shape inspection device sets an optional cutting line different from the shape lines (the shape lines are formed by scanning the weld bead with the slit light) in accordance with an input, and calculates a cross-sectional shape of the weld bead at the cutting line based on the point cloud data corresponding to the cutting line. Further, the shape inspection device compares various characteristic amounts calculated in accordance with the calculated cross-sectional shape with an allowable range of various characteristic amounts registered in advance, and determines whether the characteristic amounts are good or bad.

[0003] LIST OF CITATIONS

[0004] PATENT LITERATURE

[0005] Patent Literature 1: JP 2012-37487 A SUMMARY

[0006] TECHNICAL PROBLEM

[0007] The present disclosure provides a repair welding section detection method and a repair welding section detection device that more accurately detect a repair welding section of a workpiece produced by main welding.

[0008] SOLUTION TO PROBLEM

[0009] The present disclosure provides a repair welding section detection method including: inputting input data related to a weld bead of a workpiece produced by welding; performing a check determination related to a shape of the weld bead using the input data and main data of a non-defective workpiece; generating shape mismatch data obtained by extracting a shape mismatch portion of the weld bead, based on a result of the check determination; dividing the shape mismatch data into N equal windows in a direction perpendicular to a welding direction of the weld bead, where N is an integer of 2 or more; setting a shift region formed by i consecutive windows among the N windows, where i is an integer of 1 or more; calculating volumes of (N-i+1) shift regions obtained by shifting the i windows forming the shift region one by one in the welding direction, respectively; and determining that a shift region having a volume of a predetermined value or more among the calculated volumes of the (N-i+1) respective shift regions is a defective section of the weld bead.

[0010] Further, the present disclosure provides a repair welding section detection device including: an input unit configured to input input data related to a weld bead of a workpiece produced by welding; a determination unit configured to perform a check determination related to a shape of the weld bead using the input data and master data of a non-defective workpiece; a data generation unit configured to generate shape mismatch data obtained by extracting a shape mismatch portion of the weld bead based on a check determination result obtained by the determination unit; a calculation unit configured to divide the shape mismatch data into N equal windows in a direction perpendicular to a welding direction of the weld bead, where N is an integer of 2 or more, set a shift region formed by i consecutive windows in the respective windows, where i is an integer of 1 or more, and calculate a volume of (N-i+1) respective shift regions obtained by shifting the i windows forming the shift region one by one in the welding direction; and a generation unit configured to determine that a shift region having a volume of a predetermined value or more among the calculated (N-i+1) shift regions is a defective section of the weld bead, and generate information related to the defective section.

[0011] Advantages of the Invention

[0012] According to the present disclosure, a repair welding section of a workpiece produced by main welding can be more accurately detected. BRIEF DESCRIPTION OF DRAWINGS

[0013] Figure 1 is a diagram illustrating an example of a system configuration of a welding system.

[0014] Figure 2 is a diagram illustrating an example of an internal configuration of a check control device, a robot control device, and a host device according to an embodiment.

[0015] Figure 3 is a sequence diagram illustrating an example of a series of processes including main welding and a weld bead appearance check performed by a welding system according to an embodiment.

[0016] Figure 4 is a flowchart illustrating an example of a process of defect determination and defective section determination (detection) according to an embodiment.

[0017] Figure 5 is a diagram illustrating an example of a shape mismatch portion between a weld bead and master data.

[0018] Figure 6 is a diagram illustrating an example of a window when shape mismatch data is divided into N portions.

[0019] Figure 7FIG. 1 is a diagram showing an example of a cross-sectional view of shape mismatch data in a direction perpendicular to a welding direction of the shape mismatch data.

[0020] Figure 8 FIG. 2 is a diagram showing an example of a shift region and a shift operation of the shift region.

[0021] Figure 9 FIG. 3 is a diagram showing a determination example of a defect determination and determination of a start point and an end point of a defect section according to an embodiment.

[0022] Figure 10 FIG. 4 is a diagram showing an example of volume data of a defect mismatch portion of a weld bead and a defect section.

[0023] Figure 11 FIG. 5 is a diagram showing a process of a modified defect determination and defect section determination according to an embodiment.

[0024] Figure 12 FIG. 6 is a diagram showing a determination example of a process of a modified defect determination and defect section determination according to an embodiment.

[0025] Figure 13 FIG. 7 is a diagram showing a determination example of a process of a modified defect determination and defect section determination according to an embodiment.

[0026] Figure 14 FIG. 8 is a diagram showing an example of calculating coordinates of a start point and an end point in a defect section according to a modification.

[0027] Figure 15 FIG. 9 is a diagram showing an example of calculating coordinates of a start point and an end point in a defect section according to a modification.

[0028] Figure 16 FIG. 10 is a diagram showing an example of calculating coordinates of a start point and an end point in a defect section according to a modification. DETAILED DESCRIPTION

[0029] (BACKGROUND OF THE DISCLOSURE)

[0030] In related art, a device configuration is known that automatically performs appearance shape inspection of a weld bead, and for example, when a calculated value of a feature amount (for example, a weld bead width and a weld bead height) related to a weld bead shape of a workpiece is within an allowable range as in Patent Literature 1, it is determined that the workpiece produced by main welding is defect-free.

[0031] However, the shape of the weld bead can fluctuate due to a change in the working environment, deterioration of consumables for welding, dirt adhering to the surface of the workpiece, or the like. The fluctuation in the appearance shape of the weld bead does not necessarily affect the welding quality, and repair welding can be unnecessary. However, when the necessity of repair welding is determined based on the feature quantity of the shape mismatch portion (calculated by comparing the shape of the defect-free workpiece with the shape of the workpiece to be inspected, as in the appearance shape inspection of the weld bead in the related art) based on the shape of the entire weld bead, it can be determined that repair welding is necessary. For example, in the appearance shape inspection of the weld bead in the related art, when the area of the shape mismatch portion is large and the fluctuation in the shape is small (specifically, when the reinforcement height is slightly insufficient over the entire weld bead length, when the position of the weld bead is slightly shifted over the entire length, and the like), repair welding can be determined to be necessary although the welding quality standard is satisfied, and unnecessary repair welding can be performed.

[0032] Therefore, in the following embodiments, an example of a repair bead detection method and a repair bead detection device that more accurately detect a repair bead section of a workpiece produced by main welding will be described.

[0033] Hereinafter, embodiments in which a repair bead detection method and a repair bead detection device according to the present disclosure are specifically disclosed will be described in detail with appropriate reference to the accompanying drawings. However, unnecessary detailed descriptions can be omitted. For example, detailed descriptions of well-known matters or redundant descriptions of substantially the same configurations can be omitted. This is to avoid unnecessary redundancy of the following description and to facilitate understanding by those skilled in the art. It should be noted that the accompanying drawings and the following description are provided in order for those skilled in the art to sufficiently understand the present disclosure, and are not intended to limit the subject matter described in the claims.

[0034] According to the embodiments, the repair bead detection device inputs input data related to a weld bead of a workpiece produced by main welding, and performs a weld bead appearance inspection related to the shape of the weld bead based on a comparison between the input data and master data of a defect-free workpiece by using the input data and the master data. The repair program creation system determines a defect section (i.e., a repair bead section that needs repair welding) for each welding defect portion determined to need repair welding as a result of the weld bead appearance inspection.

[0035] Hereinafter, an object (e.g., metal) subjected to main welding is defined as an "original workpiece", and an object produced (manufactured) by main welding is defined as a "workpiece". It should be noted that the "workpiece" can be defined to include a "repaired workpiece" in which a welding defect portion detected by the appearance inspection is repaired. In addition, the "workpiece" is not limited to a workpiece produced by performing main welding once, and can be a composite workpiece produced by performing main welding two or more times.

[0036] The process of joining one raw workpiece to another raw workpiece by a welding robot or the like to produce a workpiece is defined as "main welding", and the process of performing correction (such as repair) to a defective portion of a workpiece by a welding robot is defined as "repair welding".

[0037] (Configuration of welding system)

[0038] Figure 1 is a schematic diagram showing a system configuration example of a welding system 100. The welding system 100 is a configuration including a host device 1 connected with each of an external storage ST, an input interface UI1, and a monitor MN1, a robot control device 2, an inspection control device 3, a sensor 4, a welding robot MC1, and a monitor MN2. In Figure 1 , the sensor 4 is shown as a main body separate from the welding robot MC1, but can also be provided integrally with the welding robot MC1 (see Figure 2 ). Note that the monitor MN2 is not a necessary component, and can be omitted.

[0039] The host device 1 performs overall control of the start and completion of the main welding performed by the welding robot MC1 via the robot control device 2. For example, the host device 1 reads out welding-related information that a user (for example, a welding operator or a system administrator. The same applies hereinafter.) has previously input or set from the external storage ST, generates a main welding execution command including the content of the welding-related information by using the welding-related information, and transmits the main welding execution command to the corresponding robot control device 2. When the main welding performed by the welding robot MC1 is completed, the host device 1 receives a main welding completion report indicating that the main welding performed by the welding robot MC1 is completed from the robot control device 2, updates the state indicating that the corresponding main welding is completed, and records the state in the external storage ST.

[0040] Note that the above-mentioned main welding execution command is not limited to being generated by the host device 1, and can be generated, for example, by an operation panel (for example, a PLC: Programmable Logic Controller) of equipment in a factory or the like where the main welding is performed, or an operation panel (for example, a TP: Teach Pendant) of the robot control device 2. Note that the Teach Pendant (TP) is a device for operating the welding robot MC1 connected to the robot control device 2.

[0041] Further, the host device 1 performs overall control of the start and completion of the bead appearance inspection using the robot control device 2, the inspection control device 3, and the sensor 4. For example, when the host device 1 receives a main welding completion report from the robot control device 2, the host device 1 generates a bead appearance inspection execution command for the workpiece produced by the welding robot MC1, and transmits the bead appearance inspection execution command to each of the robot control device 2 and the inspection control device 3. When the bead appearance inspection is completed, the host device 1 receives an appearance inspection report indicating the completion of the bead appearance inspection from the inspection control device 3, updates the state indicating that the corresponding bead appearance inspection is completed, and records the state in the external storage ST.

[0042] Here, the welding-related information is information indicating the content of the main welding performed by the welding robot MC1, and is generated in advance and registered in the external storage ST for each process of the main welding. For example, the welding-related information includes the number of raw workpieces used in the main welding, workpiece information (including the ID, name, and welding portion of the raw workpiece used in the main welding), a scheduled execution date of performing the main welding, the number of welding workpieces to be produced, and various welding conditions during the main welding. Note that the welding-related information is not limited to the data of the above items, and can include, for example, data related to the welding direction at the time of performing the main welding (i.e., data indicating position information of the operation trajectory of the welding robot MC1). Further, the data related to the welding direction can be included in the teaching program of the welding robot MC1. In addition, the welding direction data of the welding robot MC1 can be generated in advance as the welding direction data by inputting the welding line information together with the main data by user operation, and can be stored in the memory 32 in the inspection control device 3.

[0043] Based on the main welding execution command transmitted from the host device 1, the robot control device 2 causes the welding robot MC1 to perform the main welding using the raw workpiece specified by the execution command. Note that the above-described welding-related information is not limited to being managed by the host device 1 with reference to the external storage ST, and can also be managed, for example, by the robot control device 2. In this case, since the robot control device 2 can be aware of the state of the completion of the main welding, the actual execution date can be managed instead of the scheduled execution date scheduled to perform the welding process in the welding-related information. Further, note that although the type of the main welding is not limited in the present specification, a process of joining a plurality of raw workpieces to produce a workpiece is described as an example for ease of understanding the description.

[0044] The host device 1 is connected to the monitor MN1, the input interface UI1, and the external storage ST, respectively, so that the host device 1 can input and output data to and from each of the monitor MN1, the input interface UI1, and the external storage ST, and the host device 1 is further connected to the robot control device 2 so that data can be transmitted between the host device 1 and the robot control device 2. The host device 1 can be a terminal device P1 that integrally includes the monitor MN1 and the input interface UI1, and can further integrally include the external storage ST. In this case, the terminal device P1 is a personal computer (PC) that a user uses before performing main welding. Note that the terminal device P1 is not limited to the above-described PC, and can be a computer device having a communication function such as a smartphone or a tablet terminal.

[0045] The monitor MN1 can be formed using a display device such as a liquid crystal display (LCD) or an organic electroluminescence (EL). For example, the monitor MN1 can display a screen that shows a notification indicating completion of main welding or a notification indicating completion of a bead appearance inspection, which are output from the host device 1. Further, instead of or together with the monitor MN1, a speaker (not shown) can be connected to the host device 1, and the host device 1 can output a sound indicating content of completion of main welding or content of completion of a bead appearance inspection via the speaker.

[0046] The input interface UI1 is a user interface that detects an input operation of a user and outputs the input operation to the host device 1, and can be formed using, for example, a mouse, a keyboard, or a touch panel. For example, the input interface UI1 receives an input operation when a user creates welding-related information or when a main welding execution command is sent to the robot control device 2.

[0047] The external storage ST is formed using, for example, a hard disk drive or a solid state drive. For example, the external storage ST stores data of welding-related information created for each main welding, a state (production state) of a workpiece produced by main welding, and workpiece information of the workpiece (see the above description).

[0048] The robot control device 2 is connected to the host device 1 so that data can be transmitted between the robot control device 2 and the host device 1, and to the welding robot MC1 so that data can be transmitted between the robot control device 2 and the welding robot MC1. When the robot control device 2 receives a main welding execution command transmitted from the host device 1, the robot control device 2 controls the corresponding welding robot MC1 based on the execution command to execute the main welding. When the robot control device 2 detects completion of the main welding, the robot control device 2 generates a main welding completion report indicating completion of the main welding, and notifies the host device 1 of the main welding completion report. Thus, the host device 1 can appropriately detect completion of the main welding by the robot control device 2. It should be noted that the method of detecting completion of the main welding by the robot control device 2 can be, for example, a method of determining completion of the main welding based on a signal indicating completion of the main welding from a sensor (not shown) provided in the wire feeding device 300, or can be a known method, and the content of the method of detecting completion of the main welding is not limited.

[0049] Further, when the robot control device 2 receives a bead appearance inspection execution command transmitted from the host device 1, the robot control device 2 controls the welding robot MC1 to which the sensor 4 is attached (see Figure 2 ) according to an appearance inspection program created or prepared in advance by the robot control device 2, and performs a bead appearance inspection of the corresponding workpiece based on the execution command. It should be noted that although an appearance inspection report indicating completion of the bead appearance inspection is transmitted from the inspection control device 3 to the host device 1, the appearance inspection report can also be transmitted from the robot control device 2 itself to the host device 1, or from the robot control device 2 that received the instruction from the inspection control device 3 to the host device 1. Thus, the host device 1 is able to appropriately detect completion of the bead appearance inspection.

[0050] The welding robot MC1 is connected to the robot control device 2 so that data can be transmitted between the welding robot MC1 and the robot control device 2. The welding robot MC1 performs the main welding commanded from the host device 1 under the control of the corresponding robot control device 2. Further, when the sensor 4 is integrally attached to the welding robot MC1, the welding robot MC1 moves the sensor 4 according to the appearance inspection program, thereby assisting in the execution of the bead appearance inspection commanded from the host device 1.

[0051] The inspection control device 3, which is an example of the repair section inspection device, is connected to the host device 1, the robot control device 2, and the sensor 4, respectively, so that data can be transmitted between the inspection control device 3, the host device 1, the robot control device 2, and the sensor 4. When the inspection control device 3 receives a bead appearance inspection execution command transmitted from the host device 1, the inspection control device 3 cooperates with the sensor 4 to perform a bead appearance inspection (for example, to check whether a weld bead formed in a workpiece satisfies a predetermined welding standard) on a welded portion of the workpiece produced by the welding robot MC1. Note that although details of the bead appearance inspection will be described later, for example, the inspection control device 3 uses input data (for example, point cloud data that can specify a three-dimensional shape of a weld bead) acquired by the sensor 4 on the shape of the weld bead based on the welded portion information of the workpiece included in the bead appearance inspection execution command, thereby performing the bead appearance inspection based on a comparison with master data of a defect-free workpiece determined in advance for each workpiece. Figures 4 to 10 Details of the bead appearance inspection are described, but for example, the inspection control device 3 uses input data (for example, point cloud data that can specify a three-dimensional shape of a weld bead) acquired by the sensor 4 on the shape of the weld bead based on the welded portion information of the workpiece included in the bead appearance inspection execution command, thereby performing the bead appearance inspection based on a comparison with master data of a defect-free workpiece determined in advance for each workpiece.

[0052] The inspection control device 3 performs the bead appearance inspection, generates an appearance inspection report including an inspection determination result of the bead appearance inspection and a notification indicating completion of the bead appearance inspection, transmits the appearance inspection report to the host device 1, and outputs the appearance inspection report to the monitor MN2. Note that when the inspection control device 3 determines that a defect is detected in the bead appearance inspection of the workpiece, the inspection control device 3 generates an appearance inspection report including an appearance inspection result including information on a repair section for repair of the defect, and transmits the appearance inspection report to the host device 1 and the robot control device 2.

[0053] Further, when the inspection control device 3 determines that a defect is detected by the bead appearance inspection of the workpiece, the inspection control device 3 generates a repair program for performing correction (such as repair) on the defective portion by using the appearance inspection result including information on the defective section. The inspection control device 3 transmits the repair program and the appearance inspection result to the host device 1 or the robot control device 2 in association with each other.

[0054] The sensor 4 is connected to the inspection control device 3 so that data can be transmitted between the sensor 4 and the inspection control device 3. When the sensor 4 is attached to the welding robot MC1 (see Figure 2 ), the sensor 4 can be operated to perform a three-dimensional scan on the mounting table on which the workpiece Wk is placed under the control of the robot control device 2 according to driving of the manipulator 200. The sensor 4 acquires data (for example, point cloud data) that can specify a three-dimensional shape of the workpiece Wk placed on the mounting table (see Figure 2 ) under the control of the robot control device 2 according to driving of the manipulator 200, and transmits the data to the inspection control device 3.

[0055] The monitor MN2 can be formed using a display device such as an LED or an organic EL. The monitor MN2 displays a screen, for example, showing a notification indicating that the bead appearance inspection is completed, which is output from the inspection control device 3, or a notification and an appearance inspection result (information indicating whether there is a defect, information relating to a defective section, volume data of a bead missing in a defective section, and the like) output from the inspection control device 3. Further, instead of or together with the monitor MN2, a speaker (not shown) can be connected to the inspection control device 3, and the inspection control device 3 can output a sound indicating a notification indicating that the bead appearance inspection is completed or a content of a notification and an appearance inspection result (for example, the above-described inspection determination result) via the speaker.

[0056] Figure 2 is a diagram showing an internal configuration example of the inspection control device 3, the robot control device 2, and the host device 1 according to the embodiment. In order to make the description easy to understand, Figure 2 In the configuration example shown in FIG. 1, the monitor MN1 and the monitor MN2 and the input interface UI1 are omitted. Note that, Figure 2 The workpiece Wk shown in FIG. 1 is a workpiece to be subjected to the bead appearance inspection. The workpiece Wk can be a workpiece produced by main welding, or a so-called repaired workpiece that has been repaired one or more times by repair welding.

[0057] Under the control of the robot control device 2, the welding robot MC1 performs various processes such as main welding instructed from the host device 1 and movement of the sensor 4 during the bead appearance inspection. For example, the welding robot MC1 performs arc welding in the process of the main welding. However, the welding robot MC1 can perform welding other than arc welding (for example, laser welding or gas welding). In this case, although not shown, a laser head can be connected to a laser oscillator via an optical fiber instead of the welding torch 400. The welding robot MC1 is a configuration including at least the manipulator 200, the wire feeding device 300, the welding wire 301, and the welding torch 400.

[0058] The manipulator 200 includes joint arms, and moves each arm based on a control signal from the robot control unit 24 of the robot control device 2. Thus, the manipulator 200 can change a positional relationship (for example, an angle of the welding torch 400 with respect to the workpiece Wk) between the workpiece Wk and the welding torch 400 by driving the arms.

[0059] The wire feeding device 300 controls a feeding speed of the welding wire 301 based on a control signal from the robot control device 2. Note that the wire feeding device 300 can include a sensor (not shown) that can detect a remaining amount of the welding wire 301. Based on an output of the sensor, the robot control device 2 can detect that the process of the main welding is completed.

[0060] The welding wire 301 is held by the welding torch 400. When power is supplied from the power supply device 500 to the welding torch 400, an arc is generated between the tip of the welding wire 301 and the workpiece Wk, and arc welding is performed. Note that illustration and description of a configuration and the like for supplying a shielding gas to the welding torch 400 are omitted for ease of description.

[0061] The host device 1 generates execution commands of various processes of main welding or bead appearance inspection by using welding-related information that is input or set by a user in advance, and transmits the execution commands to the robot control device 2. Note that, as described above, when the sensor 4 is integrally attached to the welding robot MC1, the bead appearance inspection execution commands are transmitted to both the robot control device 2 and the inspection control device 3. The host device 1 is a configuration including at least a communication unit 10, a processor 11, and a memory 12.

[0062] The communication unit 10 is connected to the robot control device 2 and the external storage ST, respectively, so that data can be transferred between the communication unit 10, the robot control device 2, and the external storage ST. The communication unit 10 transmits execution commands of various processes of main welding or bead appearance inspection generated by the processor 11 to the robot control device 2. The communication unit 10 receives a main welding completion report and an appearance inspection report transmitted from the robot control device 2, and outputs the main welding completion report and the appearance inspection report to the processor 11. Note that the main welding execution commands can include, for example, control signals for controlling each of the manipulator 200, the welding wire feeding device, and the power supply device 500 included in the welding robot MC1.

[0063] The processor 11 is configured by using, for example, a central processing unit (CPU) or a field programmable gate array (FPGA), and performs various processing and control in cooperation with the memory 12. Specifically, the processor 11 realizes the functions of a cell control unit 13 by referring to a program stored in the memory 12 and executing the program.

[0064] The memory 12 includes, for example, a random access memory (RAM) as a work memory used when processing by the processor 11 is performed, and a read only memory (ROM) that stores a program defining the processing by the processor 11. Data generated or acquired by the processor 11 is temporarily stored in the RAM. The program defining the processing by the processor 11 is written in the ROM. Further, the memory 12 stores data of welding-related information read out from the external storage ST, the state of the workpiece, and data of workpiece information of the workpiece (see the above description) transmitted from the robot control device 2, respectively.

[0065] The cell control unit 13 generates execution commands for performing main welding, bead appearance inspection of the workpiece, or repair welding based on the welding-related information stored in the external storage ST. Further, based on the welding-related information stored in the external storage ST, the cell control unit 13 creates an appearance inspection program related to driving of the welding robot MC1 during the bead appearance inspection after performing the main welding or performing the repair welding one or more times, and also creates an appearance inspection program execution command including the appearance inspection program. Note that the appearance inspection program can be created in advance and stored in the external storage ST, and in this case, the cell control unit 13 only reads out and acquires the appearance inspection program from the external storage ST. The cell control unit 13 can generate different execution commands for various processes of the main welding performed by the welding robot MC1. The main welding execution command generated by the cell control unit 13 or the appearance inspection program execution command including the appearance inspection program is transmitted to the corresponding robot control device 2 via the communication unit 10 or to each of the robot control device 2 and the inspection control device 3.

[0066] The robot control device 2 controls processing of the corresponding welding robot MC1 (for example, the sensor 4, the manipulator 200, the wire feeding device 300, and the power supply device 500) based on the main welding execution command or the bead appearance inspection execution command transmitted from the host device 1. The robot control device 2 is a configuration including at least a communication unit 20, a processor 21, and a memory 22.

[0067] The communication unit 20 is connected to the host device 1, the inspection control device 3, and the welding robot MC1 so that data can be transmitted between the communication unit 20, the host device 1, the inspection control device 3, and the welding robot MC1. Note that although the illustration is simplified in Figure 2 The communication unit 20 receives the main welding execution command or the bead appearance inspection execution command transmitted from the host device 1. The communication unit 20 transmits workpiece information of the workpiece produced by the main welding to the host device 1.

[0068] Here, the workpiece information includes not only the ID of the workpiece but also at least the ID, name, and welding portion of the original workpiece used in the main welding, and the welding conditions at the time of performing the main welding. In addition, the workpiece information can include, as the position information indicating the defective portion of the workpiece, for example, position information indicating a defective section of each defective portion and position information indicating a start point and an end point of each defective section. Further, the welding conditions include, for example, the material and thickness of the original workpiece, the material and wire diameter of the welding wire 301, the type of the shielding gas, the flow rate of the shielding gas, the set average value of the welding current, the set average value of the welding voltage, the feeding speed and the feeding amount of the welding wire 301, the number of welds, and the welding time. In addition, the welding conditions can include, in addition to the above, for example, information indicating the type of the main welding (for example, TIG welding, MAG welding, and pulse welding), and the moving speed and moving time of the manipulator 200.

[0069] The processor 21 is formed using, for example, a CPU or an FPGA, and performs various processing and control in cooperation with the memory 22. Specifically, the processor 21 realizes the functions of the main welding program creation unit 23, the robot control unit 24, and the power supply control unit 25 by referring to and executing the program stored in the memory 22. Further, the processor 21 performs the calculation of the parameters for controlling the welding robot MC1 (specifically, each of the manipulator 200, the welding wire feeding device, and the power supply device 500) controlled by the robot control unit 24, based on the main welding program generated by the main welding program creation unit 23.

[0070] The memory 22 includes, for example, a RAM as a work memory used when the processing of the processor 21 is performed, and a ROM that stores a program defining the processing of the processor 21. Data generated or acquired by the processor 21 is temporarily stored in the RAM. The program defining the processing of the processor 21 is written in the ROM. Further, the memory 22 stores data of the main welding execution command or the bead appearance inspection execution command transmitted from the host device 1, and data of the workpiece information of the workpiece produced by the main welding, respectively. Further, the memory 22 stores the main welding program of the main welding to be performed by the welding robot MC1. This main welding program is a program defining the specific procedure (process) of the main welding in which a plurality of original workpieces are joined using the welding conditions of the main welding.

[0071] Based on the main welding execution command transmitted from the host device 1 via the communication unit 20, the main welding program creation unit 23 generates a main welding program of the main welding to be executed by the welding robot MC1 using the workpiece information (for example, the ID, name, and welding portion of the original workpiece) of each of the plurality of original workpieces included in the execution command. The main welding program can include various parameters for controlling the power source device 500, the manipulator 200, the wire feeding device 300, the welding torch 400, and the like during execution of the main welding, such as welding current, welding voltage, offset amount, welding speed, and posture of the welding torch 400. Note that the main welding program can be stored in the processor 21, or can be stored in the RAM of the memory 22.

[0072] The robot control unit 24 generates a control signal for driving the welding robot MC1 (specifically, the manipulator 200, the wire feeding device 300, and the power source device 500) based on the main welding program generated by the main welding program creation unit 23. The robot control unit 24 transmits the generated control signal to the welding robot MC1. In addition, the robot control unit 24 drives the manipulator 200 of the welding robot MC1 during the bead appearance inspection based on the appearance inspection program transmitted from the host device 1 so as to cover the operation range of the welding robot MC1 defined by the main welding program. Thus, the sensor 4 (see FIG. 1) attached to the welding robot MC1 can move in accordance with the operation of the welding robot MC1, and can acquire input data related to the shape of the bead of the workpiece Wk (for example, point cloud data that can specify the three-dimensional shape of the bead). Figure 2 ) can move in accordance with the operation of the welding robot MC1, and can acquire input data related to the shape of the bead of the workpiece Wk (for example, point cloud data that can specify the three-dimensional shape of the bead).

[0073] The power source control unit 25 drives the power source device 500 based on the calculation result of the main welding program generated by the main welding program creation unit 23.

[0074] The inspection control device 3 controls the processing of the bead appearance inspection on the workpiece produced by the main welding executed by the welding robot MC1 or the workpiece repaired by performing one or more times of repair welding based on the bead appearance inspection execution command transmitted from the host device 1. The bead appearance inspection is, for example, an inspection of whether the bead formed in the workpiece satisfies a predetermined welding standard (for example, a welding quality standard required by each user), and is formed by the above-described inspection determination. The inspection control device 3 determines (inspects) whether the appearance shape of the bead formed in the workpiece Wk satisfies the predetermined welding standard based on the input data related to the shape of the bead (for example, point cloud data that can specify the three-dimensional shape of the bead) acquired by the sensor 4. The inspection control device 3 is a configuration including at least a communication unit 30, a processor 31, a memory 32, and an inspection result storage unit 33.

[0075] The communication unit 30 is connected to the host device 1, the robot control device 2, and the sensor 4 so that data can be transmitted between the communication unit 30, the host device 1, the robot control device 2, and the sensor 4. Note that, although Figure 2 Although the illustration is simplified in the middle, data is transmitted and received between the shape detection control unit 35 and the sensor 4 via the communication unit 30. The communication unit 30 receives a bead appearance inspection execution command transmitted from the host device 1. The communication unit 30 transmits a check determination result of the bead appearance inspection performed by the sensor 4 (for example, whether there is a defect of a bead in the workpiece, position information related to a defect section of each defect portion, and volume data of the bead missing in the defect section) to the host device 1.

[0076] The processor 31 is formed using, for example, a CPU or an FPGA, and performs various processing and control in cooperation with the memory 32. Specifically, the processor 31 realizes the functions of the determination threshold storage unit 34, the shape detection control unit 35, the data processing unit 36, and the repair welding program creation unit 37 by referring to a program stored in the memory 32 and executing the program.

[0077] The memory 32 includes, for example, a RAM as a work memory used when the processor 31 performs processing, and a ROM that stores a program that defines the processing of the processor 31. Data generated or acquired by the processor 31 is temporarily stored in the RAM. The program that defines the processing of the processor 31 is written in the ROM. Further, the memory 32 stores data of a bead appearance inspection execution command of a workpiece transmitted from the host device 1, and data of workpiece information of the workpiece, respectively.

[0078] The check result storage unit 33 is formed using, for example, a hard disk or a solid state drive. The check result storage unit 33 stores data indicating a check determination result of a bead appearance inspection of a welding portion of a workpiece Wk (for example, a workpiece), as an example of data generated or acquired by the processor 31. The data indicating the check determination result of the bead appearance inspection is generated by the data processing unit 36, for example.

[0079] The determination threshold storage unit 34 stores set values used in the bead appearance inspection processing according to the welding portion (for example, various set values used to perform a defect determination described later) and thresholds (for example, a threshold related to a volume of a bead used in the defect determination, information related to a blind area width for detecting an end point of a defect section, and the like). Further, as each threshold during the bead appearance inspection, the determination threshold storage unit 34 can store an allowable range (for example, a minimum allowable value, a maximum allowable value, and the like) that satisfies a minimum welding standard (quality) required by a customer or the like.

[0080] Based on the bead appearance inspection execution command of the welding portion of the workpiece Wk transmitted from the host device 1, the shape detection control unit 35 as an example of the input unit acquires input data related to the shape of the bead (for example, point cloud data in which the three-dimensional shape of the bead can be specified) transmitted from the sensor 4 while the robot control device 2 operates the welding robot MC1 to which the sensor 4 is attached. When the sensor 4 reaches a position at which the sensor 4 can image the bead (in other words, can detect the three-dimensional shape of the welding portion) according to the driving of the manipulator 200 by the above-described robot control device 2, the shape detection control unit 35 causes the sensor 4 to emit, for example, a laser beam to acquire input data related to the shape of the bead (for example, point cloud data in which the three-dimensional shape of the bead can be specified). When the shape detection control unit 35 receives the input data acquired by the sensor 4, the shape detection control unit 35 transmits the input data to the data processing unit 36.

[0081] When the data processing unit 36 as an example of the determination unit, the data generation unit, the calculation unit, and the generation unit acquires the input data related to the shape of the bead from the shape detection control unit 35 (see the above description), the data processing unit 36 converts the acquired input data into a data format suitable for the bead appearance inspection. It should be noted that the data processing unit 36 can count the number of times the bead appearance inspection is performed for each defect portion determined to be a defect, and even when the number of times of the bead appearance inspection exceeds the number of times stored in advance in the storage 32, it is determined that it is difficult or unlikely to correct the defect portion by repair welding when the welding inspection result is poor. In this case, the data processing unit 36 generates an alarm screen including workpiece information in which it is determined that it is difficult or unlikely to correct the defect portion by repair welding, data related to the position of a repair welding section for the defect portion, and the type of the defect (for example, a hole, a crater, an undercut, and a protrusion), and transmits the generated alarm screen to the host device 1 via the communication unit 30. The alarm screen transmitted to the host device 1 is displayed on the monitor MN1. It should be noted that the alarm screen can be displayed on the monitor MN2.

[0082] Based on a comparison between the input data related to the shape of the weld bead acquired by the sensor 4 and the master data of the defect-free workpiece predetermined for each workpiece, the data processing unit 36 performs the weld bead appearance inspection using the threshold values for the weld bead appearance inspection stored in the determination threshold storage unit 34. Specifically, the data processing unit 36 performs a comparison (so-called image processing) between the data converted by the data processing unit 36 (for example, image data generated based on point cloud data) and the master data of the defect-free workpiece, and extracts a shape mismatch portion in which the shape of the weld bead indicated by the input data is determined to be mismatched. The data processing unit 36 generates shape mismatch data based on the extracted shape mismatch portion of the input data, and determines a defect determination regarding whether there is a defect portion for which repair welding is required for each shape mismatch portion included in the generated shape mismatch data, and the position of the defect section of the defect portion.

[0083] The data processing unit 36 creates an appearance inspection report (including a defect determination result (i.e., information indicating whether there is a defect requiring repair welding) as a result of the inspection determination and information regarding the defect section of each defect portion) and stores the appearance inspection report in the inspection result storage unit 33, and transmits the appearance inspection report to the host device 1 or the robot control device 2 via the communication unit 30. Furthermore, when the data processing unit 36 determines that there is no defect portion requiring repair welding in the workpiece Wk to be inspected, the data processing unit 36 creates an appearance inspection report including an inspection determination result indicating that the result of the weld bead appearance inspection is successful, and stores the appearance inspection report in the inspection result storage unit 33, and transmits the appearance inspection report to the host device 1 via the communication unit 30.

[0084] The repair welding program creation unit 37 generates a repair welding program of the workpiece Wk to be executed by the welding robot MC1 by using the appearance inspection report of the workpiece Wk created by the data processing unit 36. The repair welding program can include various parameters for controlling the power source device 500, the manipulator 200, the wire feeding device 300, the welding torch 400, and the like during execution of repair welding, such as welding current, welding voltage, offset amount, welding speed, and posture of the welding torch 400. Note that the generated repair welding program can be stored in the processor 31, can be stored in the RAM of the memory 32, or can be transmitted to the host device 1 or the robot control device 2 in association with the appearance inspection report via the communication unit 30.

[0085] The sensor 4 is, for example, a three-dimensional shape sensor attached to the tip of the welding robot MC1, can acquire a plurality of point cloud data capable of specifying the shape of the welding portion of the workpiece Wk (e.g., a workpiece), and generate point cloud data capable of specifying the three-dimensional shape of the welding portion based on the point cloud data, and transmit the point cloud data to the inspection control device 3. It should be noted that when the sensor 4 is not attached to the tip of the welding robot MC1 and is provided separately from the welding robot MC1, the sensor 4 can include a laser source (not shown) configured to scan the welding portion of the workpiece Wk (e.g., a workpiece or a repaired workpiece) based on the welding portion position information transmitted from the inspection control device 3, and a camera (not shown) provided in a manner capable of imaging an imaging region including the periphery of the welding portion, and image the reflection trajectory of the reflected laser light (i.e., the shape line of the welding portion) among the laser light emitted onto the welding portion. In this case, the sensor 4 transmits the shape data of the welding portion based on the laser light imaged by the camera (in other words, the image data of the bead) to the inspection control device 3. It should be noted that the above-mentioned camera includes at least a lens (not shown) and an image sensor (not shown). The image sensor is, for example, a solid-state imaging element such as a charge-coupled device (CCD) or a complementary metal-oxide semiconductor (CMOS), and converts an optical image formed on an imaging surface into an electric signal.

[0086] (Operation of the welding system)

[0087] Next, a series of operation processes of the main welding and the bead appearance inspection performed by the welding system 100 according to the embodiment will be described with reference to Figure 3 Figure 3 is a sequence diagram illustrating an example of a series of processes including the main welding and the bead appearance inspection performed by the welding system 100 according to the embodiment. In the description of Figure 3

[0088] In the description of Figure 3 ​​In the present embodiment, the host device 1 acquires workpiece information of the original workpiece to be subjected to main welding (e.g., the ID, name, and welding portion of the original workpiece) (St1), respectively, and generates a main welding execution command including the workpiece information of the original workpiece. The host device 1 transmits the main welding execution command including the workpiece information of the original workpiece to the robot control device 2 (St2). Note that the robot control device 2 can perform the processes of steps St1 and St2 without going through the host device 1. In this case, it is preferable that the same data as the data stored in the external storage ST be stored in the memory 22 of the robot control device 2, or that the robot control device 2 be connected to the external storage ST so that the robot control device 2 can acquire the data from the external storage ST.

[0089] When the robot control device 2 receives the main welding execution command transmitted from the host device 1, the robot control device 2 creates a main welding program of the main welding to be performed by the welding robot MC1 using the workpiece information of each of the plurality of original workpieces included in the execution command, and causes the welding robot MC1 to perform the main welding according to the main welding program (St3). When the robot control device 2 determines that the main welding performed by the welding robot MC1 is completed by various known methods, the robot control device 2 generates a main welding completion notification indicating that the main welding is completed and transmits the main welding completion notification to the host device 1 (St4). When the host device 1 receives the main welding completion notification, the host device 1 generates an appearance inspection program execution command including an appearance inspection program of the workpiece and transmits the appearance inspection program execution command to the robot control device 2 (St5), and generates a bead appearance inspection execution command of the workpiece and transmits the bead appearance inspection execution command to the inspection control device 3 (St6). The robot control device 2 executes the appearance inspection program received from the host device 1 along with the start of the bead appearance inspection, and moves the sensor 4 attached to the welding robot MC1 along the welding line (St7). The sensor 4 acquires point cloud data that can specify the three-dimensional shape of the workpiece while the robot control device 2 moves the sensor 4 so as to be able to scan the welding portion of the workpiece (St7).

[0090] The inspection control device 3 uses the point cloud data that can specify the three-dimensional shape of the bead acquired by the sensor 4 as input data, and performs the above-described bead appearance inspection (St8). The inspection control device 3 acquires the main welding program from the robot control device 2, and performs inspection determination (i.e., defect determination and defect segment determination) in the bead appearance inspection of the bead of the workpiece (St8). Note that details of the processing in step St8 will be described later with reference to Figures 4 to 10 Details of the processing in step St8 will be described later with reference to

[0091] When the inspection control device 3 determines that there is a defect in the workpiece by the defect determination (as the inspection determination result of Step St8) (St8), the inspection control device 3 determines (detects) the defect section for each defect portion for which repair welding of the defect portion is performed based on the information related to the welding direction in which the workpiece is produced, and generates an appearance inspection report including the defect determination result and information related to the position of the defect section of each defect portion (St9). On the other hand, when the inspection control device 3 determines that there is no defect in the workpiece by the defect determination (as the inspection determination result of Step St8) (St8), the inspection control device 3 generates an appearance inspection report including the inspection determination result indicating that the result of the bead appearance inspection is successful (St9).

[0092] Accordingly, the inspection control device 3 can acquire the information related to the welding direction at the time of performing the main welding. The inspection control device 3 generates the appearance inspection report including the inspection determination result performed in Step St8, and transmits the appearance inspection report to the robot control device 2 (St10). Further, the inspection control device 3 also transmits the appearance inspection report generated in the same manner to the host device 1 (St11).

[0093] Next, details of the process of the defect determination and the defect section determination (detection) that performs the inspection determination as performed in Step St8 of the embodiment will be described with reference to Figures 4 to 10 Figure 3 the flowchart shown in FIG. 10. Figure 4 is a flowchart showing an example of the process of the defect determination and the defect section determination (detection) according to the embodiment.

[0094] The point cloud data acquired by the sensor 4, which can specify the three-dimensional shape of the bead B1, is used for the bead appearance inspection. The data processing unit 36 converts the point cloud data from the sensor 4 into a data format suitable for the bead appearance inspection (for example, image data representing the ideal three-dimensional shape of the bead) and passes the converted data to the data processing unit 36. The data processing unit 36 reads out and acquires the main data MD1 of the defect-free workpiece (for example, image data representing the ideal three-dimensional shape of the bead of the defect-free workpiece) stored in the storage 32 (St8-1).

[0095] The data processing unit 36 compares the image data RT1 from the data processing unit 36 (data to be inspected) with the main data MD1 and extracts a shape mismatch portion in which the shapes do not match (for example, each of the shape mismatch portions ED1, ED2, and ED3 shown in Figure 5 Figure 6 )(St8-2). It should be noted that, for simplicity of explanation, the shape mismatch data EDD1 of the bead B1 is generated based on each of the shape mismatch portions ED1 to ED3 extracted in Step St8-2. Figure 6 ​​The shape mismatch data EDD1 shown in FIG. 6 is an example of the generated shape mismatch data including each of the plurality of shape mismatch portions ED1 to ED3. However, the shape mismatch data EDD1 is not limited to the above example, and for example, one piece of shape mismatch data can be generated for each shape mismatch portion.

[0096] Here, an example of the shape mismatch data EDD1 will be described with reference to Figure 5 to FIG. 6. Figure 5 is a diagram showing an example of the shape mismatch portions ED1, ED2, and ED3 between the weld bead B1 and the main data MD1. In Figure 5 , the main data MD1 is indicated by a solid line, the weld bead B1 is indicated by a broken line, and a shape mismatch region ED in which the shape of the weld bead B1 does not match the shape in the main data MD1 is indicated by a diagonal line. As Figure 5 indicated, the data processing unit 36 compares the shape of the weld bead B1 with the main data MD1 and extracts the shape mismatch portions ED1, ED2, and ED3, respectively. Note that, Figure 5 The weld bead B1, the main data MD1, and the shape mismatch portions ED1 to ED3 shown in FIG. 6 are examples, and needless to say, the present application is not limited thereto.

[0097] Next, an example of the shape mismatch data and the window used for the defect determination processing in the present embodiment will be described with reference to Figure 6 and Figure 7 Figure 6 is a diagram showing an example of the windows AV[1], AV[2],..., AV[m],..., AV[N] when the shape mismatch data EDD1 is equally divided into N portions. Figure 7 is a diagram showing an example of a cross-sectional view of the shape mismatch data EDD2 in a direction perpendicular to the welding direction of the shape mismatch data EDD2. Note that, Figure 6 The shape mismatch data EDD1 shown in FIG. 6 is shape mismatch data generated on the basis of Figure 5 the shape mismatch portions ED1 to ED3 shown in FIG. 6, and is a view from the Z direction. Further, Figure 7 shows a cross section SS1 when the shape mismatch data EDD2 is cut along a cutting surface CS1 in a direction perpendicular to the welding direction M2 and a cross section SS2 when the shape mismatch data EDD2 is cut along a cutting surface CS2.

[0098] ​The data processing unit 36 acquires information about the welding direction Ml in which the bead B1 is generated, and sets N windows AV[l], AV[2],..., AV[m],..., AV[N] (N: an integer of 2 or more) obtained by equally dividing the shape mismatch data EDDl in a direction perpendicular to the welding direction Ml at intervals ΔD (St8-3). Here, the window AV[k] shows a volume calculated by multiplying the cross-sectional area S[k] of the k-th (k: an integer of 1 or more) of the N divided windows of the shape mismatch data EDDl by the interval ΔD.

[0099] Note that, although an example in which the cross-sectional area S[k] shown in FIG. 8 is calculated by approximating the cross section of the shape mismatch data EDDl with a rectangle is shown, the present application is not limited thereto. For example, the cross-sectional area S[k] can be calculated by calculating the area of each of the cross sections SS1 and SS2 shown in FIG. 9, and can be calculated based on an approximate shape obtained by approximating each of the cross sections SS1 and SS2 as any polygon. Figure 6 Figure 7

[0100] Further, here, the interval ΔD or the number N of windows (i.e., the number of windows) obtained by cutting the shape mismatch data EDDl can be set to a fixed value. Note that, regarding the length of the interval ΔD, any length preset based on a quality standard required by a user can be set by an operator, and a length based on the total length of the shape mismatch data EDDl in the welding direction Ml can be set (e.g., ΔD = 5 mm when the total length of the shape mismatch data EDDl is 50 mm or more, or ΔD = 10 mm when the total length is 100 mm or more). Similarly, regarding the number N of windows, any number based on a quality standard required by a user can be set by an operator, and a number preset based on the total length of the shape mismatch data EDDl in the welding direction Ml can be set (e.g., N = 5 when the total length of the shape mismatch data EDDl is 50 mm or more, or N = 10 when the total length is 100 mm or more).

[0101] The data processing unit 36 sets (N-i+l) (i: an integer of 1 or more) shift regions PS1, PS2,..., PS(N-i+l) formed by i consecutive windows of the N respective windows AV[l],..., AV[N] (see FIG. 10) (St8-4). Here, the shift regions PS1, PS2,..., PS(N-i+l) will be described with reference to FIG. 11. Figure 8 Figure 8 Figure 8 is a diagram showing an example of the shift regions PS1, PS2,..., PS(N-i+l) and a shift operation of the shift regions.​​​​

[0102] As Figure 8 indicated, each of the shift regions PS1, PS2,..., PS(N-i+1) is formed by i windows. Since the windows are shifted one by one in the welding direction M1 by the number k, the i windows forming each of the shift regions PS1, PS2,..., PS(N-i+1) are different. Specifically, the shift region PS1 is formed by i windows from the window AV[1] to the window AV[i]. By shifting the i windows forming the shift region PS1 one by one in the welding direction M1, the shift region PS2 is formed by i windows from the window AV[2] to the window AV[i+1]. Further, similarly, the shift region PS(N-i+1) is formed by i windows from the window AV[N-i] to the window AV[N]. It should be noted that, regarding the number i of windows forming one shift region, any value of 1 or more can be set by the operator based on the quality standard of each user.

[0103] The data processing unit 36 calculates the volume of each shift region and determines whether the calculated volume of the shift region is equal to or greater than the threshold value stored in the determination threshold storage unit 34 (St8-4). When the data processing unit 36 determines that the volume of the shift region is equal to or greater than the threshold value, the data processing unit 36 determines that the shift region is a defective portion requiring repair welding (St8-4). From the first shift region PS1 to the (N-i+1)th shift region among the (N-i+1) shift regions PS1, PS2,..., PS(N-i+1), the data processing unit 36 sequentially performs the calculation of the volume of the (N-i+1) corresponding shift regions and the above-described defective determination, and based on the result of the defective determination, sequentially determines the start point and the end point of the defective section (St8-4). Thus, the data processing unit 36 can more accurately determine whether there is a defect that does not satisfy the quality standard of the user and is to be repaired for each shift region based on the volume of the shape mismatch portion per reference length (i.e., the interval AD), and based on the shift region determined to be a defective portion, determine the start point and the end point of the defective section to be repaired (St8-4). The determination processing method of the start point and the end point will be described hereinafter.

[0104] When the data processing unit 36 determines that the volume of the calculated kth shift region is defective, the data processing unit 36 determines whether the previous (i.e., (k-1)th) shift region is non-defective. When the data processing unit 36 determines that the previous shift region is non-defective and the volume of the kth shift region is defective, the data processing unit 36 determines any position in the kth shift region as the starting point of the defective section. It should be noted that when the data processing unit 36 determines that the first (i.e., k = 1) shift region is defective, the data processing unit 36 determines any position in the first shift region as the starting point of the defective section.

[0105] Further, after the data processing unit 36 determines the starting point, when the data processing unit 36 determines that the volume of the calculated kth shift region is defective and the (k+1)th shift region is non-defective, the data processing unit 36 determines any position in the kth shift region as the ending point of the defective section. It should be noted that when the data processing unit 36 determines that the (N-1)th (i.e., k = N-1) shift region is defective and the Nth (i.e., k+1 = N) shift region is defective, the data processing unit 36 determines any position in the Nth shift region as the ending point of the defective section.

[0106] It should be noted that when the data processing unit 36 determines that one discontinuous shift region is a defective portion, the data processing unit 36 can determine the first window of the i windows forming the shift region as the starting point of the defective section and can determine the ith window of the i windows as the ending point of the defective section.

[0107] In addition, when the center of one discontinuous shift region is used, the data processing unit 36 can determine that the starting point and the ending point of the defective section are the same point. Therefore, when the starting point and the ending point of the defective section are the same point, the repair welding program creation unit 37 generates a repair welding program for repairing the defective section (the same point) by, for example, spot welding, and causes the welding robot MC1 to perform repair welding by spot welding.

[0108] Further, another determination processing method of the start point and the end point will be described. When the data processing unit 36 determines that two or more continuous shift regions are defective portions, the data processing unit 36 can determine the first window among i windows forming a shift region which is a shift region first determined as a defective portion among the two or more continuous shift regions or the center of the shift region as the start point of the defective section. Further, similarly, when the data processing unit 36 determines that two or more continuous shift regions are defective portions, the data processing unit 36 can determine the i-th window among i windows forming a shift region which is a shift region last determined as a defective portion among the two or more continuous shift regions or the center of the shift region as the end point of the defective section. Note that the center of the shift region can be the center position of the shift region, or can be the i / 2-th window among i windows.

[0109] Further, when the shift region first determined as a defective portion among the two or more continuous shift regions is the first shift region PS1, the data processing unit 36 can determine the first window among i windows as the start point of the defective section. Further, when the shift region last determined as a defective portion among the two or more continuous shift regions is the (N-i+1)-th shift region PS(N-i+1), the data processing unit 36 can determine the i-th window among i windows as the end point of the defective section. Thus, in the defect determination based on the volume of the shape mismatch portion per reference length (i.e., the interval ΔD), the data processing unit 36 can determine (detect) the defective section, which can prevent an oversight in the repair welding of the defects in the first shift region PS1 and the (N-i+1)-th shift region PS(N-i+1) where it is difficult to specify the position of the defects to be repaired.

[0110] The data processing unit 36 specifies (detects) the defective section of each defective portion based on the determined start point and end point (St8-5). Note that, regarding the defective portion referred to herein, a plurality of continuous defective portions is regarded as one defective portion.

[0111] Here, the processing performed in steps St8-4 and St8-5 will be described in detail by using specific examples with reference to Figure 9 Figure 9 is a diagram showing a determination example of the defect determination and the defective section determination according to the embodiment. Note that, Figure 9 shows a determination example when the shape mismatch data is equally divided into 7 portions (i.e., N = 7), the number of windows i = 3, and the volume threshold T = 4.0 mm 3

[0112] Further, in the determination Figure 9 ​​Although two examples are shown, including: a first determination example in which a first window of the three windows forming the first shift region determined to be defective is determined as the start point of the defect segment, and a third window of the three windows forming the last shift region is determined as the end point of the defect segment; and a second determination example in which a first window of the three windows forming the first shift region determined to be defective as a center position of the three windows (i.e., an integer subscript of i = 3 / 2) is determined as the start point of the defect segment, and a first window of the three windows forming the last shift region as a center position of the three windows (i.e., an integer subscript of i = 3 / 2) is determined as the end point of the defect segment, it is needless to say that the present application is not limited thereto. For example, with respect to the center position in the second determination example, the data processing unit 36 can determine a second window of the three windows as the center position.

[0113] The volume of the kth shift region V[k] is the total value of the volume of the window ΔV[k], the volume of the window ΔV[k+1], and the volume of the window ΔV[k+2]. The data processing unit 36 calculates the volume of the first shift region V[1], and determines that the first shift region V[1] is a non-defective portion because the calculated volume of the first shift region V[1] 3.5 mm 3 is equal to or greater than the threshold value T = 4.0 mm 3 .

[0114] The data processing unit 36 calculates the volume of the second shift region V[2], and determines that the second shift region V[2] is a defective portion because the calculated volume of the second shift region V[2] 4.5 mm 3 is equal to or greater than the threshold value T = 4.0 mm 3 Since the previous shift region (i.e., the first shift region V[1]) is a non-defective portion, the data processing unit 36 performs determination of the start point of the defect segment in the second shift region V[2]. Specifically, in the first determination example, the data processing unit 36 determines a first window ΔV[2] of the three windows forming the second shift region V[2] as the start point RCA1 of the defect segment RCA in the defective portion, and in the second determination example, the data processing unit 36 determines a window ΔV[2] at a center position of the three windows forming the second shift region V[2] as the start point RCB1 of the defect segment RCB in the defective portion.

[0115] The data processing unit 36 calculates the volume of the third shift region V[3], and determines that the third shift region V[3] is a defective portion because the calculated volume of the third shift region V[3] 4.8 mm 3 is equal to or greater than the threshold value T = 4.0 mm 3. Since the previous shift region (i.e., the second shift region V[2]) is a defective portion, the data processing unit 36 omits the determination of the end point of the defective section. Similarly, the data processing unit 36 calculates the volume of the fourth shift region V[4], and determines that the fourth shift region V[4] is a defective portion because the calculated volume 4.8 mm 3 of the fourth shift region V[4] is equal to or greater than the threshold value T = 4.0 mm 3 . Since the previous shift region (i.e., the third shift region V[3]) is a defective portion, the data processing unit 36 omits the determination of the end point of the defective section.

[0116] The data processing unit 36 calculates the volume of the fifth shift region V[5], and determines that the fifth shift region V[5] is a non-defective portion because the calculated volume 3.3 mm 3 of the fifth shift region V[5] is less than the threshold value T = 4.0 mm 3 . Since the previous shift region (i.e., the fourth shift region V[4]) is a defective portion and the fifth shift region V[5] is a non-defective portion, the data processing unit 36 performs the determination of the end point of the defective section in the fourth shift region V[4]. Specifically, in the first determination example, the data processing unit 36 determines the third window AV[6] of the three windows forming the fourth shift region V[4] as the end point RCA2 of the defective section RCA in the defective portion, and in the second determination example, the data processing unit 36 determines the window AV[4] at the center position of the three windows forming the fourth shift region V[4] as the end point RCB2 of the defective section RCB in the defective portion.

[0117] As described above, in the first determination example, Figure 9 the data processing unit 36 determines the section from the position of the start point RCA1 (i.e., the window AV[2]) to the position of the end point RCA2 (i.e., the window AV[6]) as the defective section RCA, and in the second determination example, the data processing unit 36 determines the section from the position of the start point RCB1 (i.e., the window AV[2]) to the position of the end point RCB2 (i.e., the window AV[4]) as the defective section RCB.

[0118] The data processing unit 36 repeatedly performs the repetitive processing RP1 from the step St8-3 to the step St8-5 for each shape mismatched portion, and generates the volume data of the missing weld bead in each defective section (see Figure 10 ) (St8-6). Note that the processing of the step St8-6 is not essential, and can be omitted.

[0119] Here, the volume data VD1 will be described with reference to Figure 10 .Figure 10 is a graph showing an example of the volume data VD1 showing the shape mismatched portions ED2 and ED3 and the defect sections RC2 and RC3 of the weld bead B1. Note that the following example is shown: Figure 10 The weld bead B1 shown in (B) has three respective shape mismatched portions ED1, ED2 and ED3, and two of the three respective shape mismatched portions ED2 and ED3 are determined by the data processing unit 36 to be defective. Further, in the example shown in (B), Figure 10 In the example shown in (B), the data processing unit 36 determines the section from the start point RC21 to the end point RC22 as the defect section RC2 of the shape mismatched portion ED2, and determines the section from the start point RC31 to the end point RC32 as the defect section RC3 of the shape mismatched portion ED3.

[0120] The data processing unit 36 generates the volume data VD1 obtained by extracting the volume of the weld bead missing in the defect section RC2 and the defect section RC3 in the weld bead direction M1 from shape mismatched data (not shown) generated by extracting the shape mismatched region ED from the total length of the weld bead B1. Here, the data processing unit 36 can generate repair condition data VD2 obtained by plotting the volume value at a position corresponding to the respective positions of the plurality of windows included in the respective defect sections RC2 and RC3 in the volume data VD1 generated, note that the repair condition data VD2 is not limited to data obtained by approximating the volume value, and the data processing unit 36 can generate, for example, data indicating the amount of feed of the welding wire 301 for repair of the respective defect sections RC2 and RC3, data indicating the welding current value or the welding voltage value of the power supply device 500 for controlling the welding torch 400 to perform repair of the respective defect sections RC2 and RC3, as examples of the welding conditions, based on the volume data VD1.

[0121] The data processing unit 36 generates notification information indicating whether there is a defect as a result of the inspection determination, i.e., whether repair is necessary, and an appearance inspection report including at least information on the defect section of each shape mismatched portion (St8-7). Note that when the volume data or the repair condition data is generated in step St8-6, the data processing unit 36 generates the appearance inspection report further including the generated volume data or repair condition data.

[0122] As described above, the inspection control device 3 according to the embodiment can more accurately determine whether there is a shape mismatch (defect) that needs to be repaired at a shape mismatch portion based on a comparison between the weld bead's appearance shape and the master data of a defect-free workpiece, and can more appropriately determine (detect) the repair weld segment (defect segment) that needs repair, thus effectively reducing unnecessary repair welding. Furthermore, since the inspection control device 3 can set the shift area for defect determination based on the welding quality standards required by the user, its usability in determining whether there is a defect that needs repair welding and in determining (detecting) the repair weld segment (defect segment) can be improved.

[0123] For example, when the number of windows i forming the displacement region is set to a smaller value, the operator can more accurately determine whether there are defects requiring re-welding and can shorten the re-welding segment (defect segment) obtained through determination. On the other hand, when the number of windows i forming the displacement region is set to a value equal to or greater than i=2, the operator can further prevent erroneous defect determination due to the influence of noise included in the weld appearance shape acquired by sensor 4, and can reduce the processing load caused by defect determination and defect segment determination. Furthermore, this effect can be similarly achieved by adjusting not only the value of the number of windows i forming the displacement region, but also the value of the interval ΔD indicating the window width in the welding direction.

[0124] (Modification of the Implementation Example)

[0125] An example according to the above embodiment is shown, wherein the inspection control device 3 performs defect determination and defect segment determination (detection) for each defect based on a threshold stored in any volume of the determination threshold storage unit 34. A modified example according to the embodiment is described, wherein the inspection control device 3 performs defect determination and defect segment determination (detection) for each defect based on a first threshold stored in any volume of the determination threshold storage unit 34 and a second threshold based on the first threshold.

[0126] It should be noted that the defect determination and defect segment determination (detection) process according to the modified embodiment is different in step St8-4. Figure 4 The example of defect determination and defect segment determination (detection) processes in the illustrated embodiment differs from the example. Therefore, in the following description relating to the modified defect determination and defect segment determination (detection) processes according to the embodiment, the processing of step St8-4 will be described, and descriptions of other processing procedures will be omitted.

[0127] According to the modification of the embodiment, the inspection control device 3 stores, in the threshold value storage unit 34, a first threshold value T1 for defect determination (the first threshold value T1 referred to herein is the same as the threshold value for defect determination in the embodiment) and a blind zone width Z (0 < Z < 1) for calculating a second threshold value T2 for determining the end point of the defect section. The second threshold value T2 is calculated by multiplying the first threshold value T1 by (1-Z). Note that the blind zone width Z can be a value expressed in percentage.

[0128] Note that, as the blind zone width Z, a predetermined relative value can be set with respect to the first threshold value, or a specified value (constant value) can be set. For example, when the first threshold value ≥ 10.0 mm 3 , the blind zone width Z can be set to Z = 2.0 mm 3 , when the first threshold value < 10.0 mm 3 , Z = 1.0 mm 3 and so on, and the blind zone width Z can be set to Z = 2.0 mm 3 as the specified value regardless of the value of the first threshold value.

[0129] As described above, according to the modification of the embodiment, the inspection control device 3 changes the threshold value for determining the start point of the defect section (the first threshold value T1) and the threshold value for determining the end point of the defect section (the second threshold value T2). Here, the second threshold value T2 is a volume value smaller than the first threshold value T1. Therefore, according to the modification of the embodiment, when the start point is determined in the determination of the defect section to be repaired (the repair section), the inspection control device 3 can tighten the standard for determining as defect-free (end of defect) in the defect determination of the continuously shifted area. That is, since the inspection control device 3 determines that the defect section does not end when the volume of the shifted area (in other words, the volume difference between the appearance shape of the bead and the master data) is not equal to or smaller than the changed second threshold value T2, the inspection control device 3 can determine (detect) the defect section, which can further prevent repair omissions in the repair performed based on the generated information on the defect section.

[0130] The process of defect determination and defect section determination (detection) according to the modification of the embodiment will be described with reference to Figure 11 FIG. 10. Figure 11 is a graph showing the determination of the start point and the end point of the defect section according to the modification of the embodiment. Figure 11 The volume graph V3 shown in FIG. 10 is a graph obtained by plotting the respective volumes of the plurality of shifted areas calculated by the data processing unit 36.

[0131] The first threshold value T1 is a threshold value for determining the starting point of a defective section according to the modification of the embodiment. The second threshold value T2 is a threshold value for determining the ending point of a defective section according to the modification of the embodiment. The difference between the first threshold value T1 and the second threshold value T2 is a value obtained by multiplying the blind zone width Z by the first threshold value T1.

[0132] The data processing unit 36 calculates the volume of the shifted region, and determines whether the calculated volume of the shifted region is equal to or greater than the first threshold value T1 of the volume stored in the storage 32 (i.e., determines the starting point of the defective section RCC). When the data processing unit 36 determines that the calculated volume of the shifted region is equal to or greater than the first threshold value T1 (e.g., the point RCC1 shown in FIG. 12), the data processing unit 36 determines that the shifted region is a defective portion requiring repair welding, and performs determination of the starting point of the defective portion. Figure 11

[0133] After the data processing unit 36 determines that the starting point of the defective portion is the position indicated by the point RCC1, the data processing unit 36 changes the threshold value for performing defect determination on the shifted region continuous in the welding direction (i.e., determines the ending point of the defective section RCC) from the first threshold value T1 to the second threshold value T2.

[0134] When the data processing unit 36 determines that the calculated volume of the shifted region is equal to or less than the second threshold value T2 (e.g., the point RCC2 shown in FIG. 12), the data processing unit 36 determines that the shifted region is a non-defective portion, and performs determination of the ending point of the defective section from the shifted region determined to be the non-defective portion. Figure 11

[0135] After the data processing unit 36 determines that the ending point of the defective section is the position indicated by the point RCC2, the data processing unit 36 changes the threshold value for performing defect determination on the shifted region continuous in the welding direction (i.e., determines the starting point of the defective section RCD) from the second threshold value T2 to the first threshold value T1, and performs defect determination for each of the shifted regions one by one along the welding direction and in order.

[0136] When the data processing unit 36 determines that the calculated volume of the shifted region is equal to or greater than the first threshold value T1 (e.g., the point RCD1 shown in FIG. 12), the data processing unit 36 determines that the shifted region is a defective portion requiring repair welding, and performs determination of the starting point of the defective portion. After the data processing unit 36 determines that the starting point of the defective portion is the position indicated by the point RCD1, the data processing unit 36 changes the threshold value for performing defect determination on the shifted region continuous in the welding direction (i.e., determines the ending point of the defective section RCD) from the first threshold value T1 to the second threshold value T2. Note that the subsequent illustration of the volume graph V3 and the description of the various determination processes will be omitted in FIG. 13. Figure 11 Figure 11 After the data processing unit 36 determines that the ending point of the defective section is the position indicated by the point RCD2, the data processing unit 36 changes the threshold value for performing defect determination on the shifted region continuous in the welding direction (i.e., determines the starting point of the defective section RCD) from the second threshold value T2 to the first threshold value T1, and performs defect determination for each of the shifted regions one by one along the welding direction and in order.​​​

[0137] In this way, in the modification of the embodiment, the data processing unit 36 changes the volume threshold for defect determination from the first threshold value T1 to the second threshold value T2 after determining the start point of the defect section, changes the volume threshold for defect determination from the second threshold value T2 to the first threshold value T1 after determining the end point of the defect section, and sequentially executes the determination of the start point and the end point of the defect section based on the above-described results of defect determination and defect determination from the first shifted region PS1 to the (N-i+1)th shifted region PS(N-i+1) among the (N-i+1) shifted regions PS1, PS2, …, PS(N-i+1) (St8-4).

[0138] Note that since the determination method of the start point in the first shifted region determined to be defective and the determination method of the end point in the last shifted region determined to be defective are the same as the determination methods shown in the embodiment, the description thereof is omitted.

[0139] Here, the processing examples of defect determination and defect section determination and the processing examples of determination of the repair welding start point and the repair welding end point executed in Step St8-4 and Step St8-5 will be described with reference to Figures 12 to 14 Figs. 10 to 13. Figure 12 Fig. 10 is a diagram showing an example of determination of the start point and the end point of the defect section according to the modification of the embodiment. Figure 13 Fig. 11 is a diagram showing an example of determination of the start point and the end point of the defect section according to the modification of the embodiment. Figure 14 Fig. 12 is a diagram showing an example of calculation of the coordinates of the start point and the end point in the defect section according to the modification of the embodiment. Note that in the determination example of defect determination and determination of the start point and the end point of the defect section shown in Figure 12 Fig. 13 is a diagram showing an example of determination of the start point and the end point of the defect section according to the modification of the embodiment. Figure 13 In the determination example of defect determination and determination of the start point and the end point of the defect section shown in Figure 12 Fig. 10, the shape mismatch data ED4 shown in Fig. 9 is equally divided into 10 parts (i.e., N = 10), the number of windows i = 3, the blind zone width Z = 0.2, and the first threshold value T1 = 4.0 mm 3 . Note that the second threshold value T2 shown in Fig. 10 is calculated as T2 = 3.2 mm 3 based on the first threshold value T1 and the blind zone width Z.

[0140] Further, in the determination of the start point and the end point of the defect section shown in Figure 12 Fig. 10, although an example is shown in which the first window (i.e., the integer subscript i = 3 / 2) that is the center position of the three windows forming the first shifted region determined to be defective is determined to be the start point, and the first window (i.e., the integer subscript i = 3 / 2) that is the center position of the three windows forming the last shifted region determined to be defective is determined to be the end point, it goes without saying that the present application is not limited thereto.

[0141] The volume of the kth shift region V[k] is the total value of the volume of the window AV[k], the volume of the window AV[k+1], and the volume of the window AV[k+2]. The data processing unit 36 calculates the volume of the first shift region V[1], and determines that the first shift region V[1] is non-defective because the calculated volume of the first shift region V[1] is 3.0 mm 3 equal to or less than the first threshold value T1 = 4.0 mm 3 .

[0142] The data processing unit 36 calculates the volume of the second shift region V[2], and determines that the second shift region V[2] is non-defective because the calculated volume of the second shift region V[2] is 3.5 mm 3 equal to or less than the first threshold value T1 = 4.0 mm 3 .

[0143] The data processing unit 36 calculates the volume of the third shift region V[3], determines that the third shift region V[3] is defective because the calculated volume of the third shift region V[3] is 4.3 mm 3 equal to or greater than the first threshold value T1 = 4.0 mm 3 , and since the previous shift region (i.e., the second shift region V[2]) is a non-defective portion, the determination (detection) of the starting point of the defective section is performed in the third shift region V[3]. Specifically, the data processing unit 36 determines the window AV[4] at the center position of the three windows forming the third shift region V[3] as the starting point RCE1 of the defective section RCE in the defect. After the data processing unit 36 determines the starting point RCE1 of the defective section RCE, the data processing unit 36 changes the threshold value for defect determination from the first threshold value T1 to the second threshold value T2.

[0144] The data processing unit 36 calculates the volume of the fourth shift region V[4], and determines that the fourth shift region V[4] is defective because the calculated volume of the fourth shift region V[4] is 3.5 mm 3 not equal to or less than the second threshold value T2 = 3.2 mm 3 .

[0145] The data processing unit 36 calculates the volume of the fifth shift region V[5], determines that the fifth shift region V[5] is non-defective because the calculated volume of the fifth shift region V[5] is 2.5 mm 3 equal to or less than the second threshold value T2 = 3.2 mm 3and since the previous shift region (i.e., the fourth shift region V[4]) is defective, the determination (detection) of the end point of the defective segment is performed from the fifth shift region V[5]. Specifically, the data processing unit 36 determines the window AV[6] at the center position of the three windows forming the fifth shift region V[5] as the end point RCE2 of the defective segment RCE in the defect. After the data processing unit 36 determines the end point RCE2 of the defective segment RCE, the data processing unit 36 changes the threshold value for the defect determination from the second threshold value T2 to the first threshold value T1.

[0146] The data processing unit 36 calculates the volume of the sixth shift region V[6] and determines that the sixth shift region V[6] is non-defective because the calculated volume 1.7 mm 3 is equal to or less than the first threshold value T1 = 4.0 mm 3 .

[0147] The data processing unit 36 calculates the volume of the seventh shift region V[7] and determines that the seventh shift region V[7] is defective because the calculated volume 8.5 mm 3 is equal to or greater than the first threshold value T1 = 4.0 mm 3 and since the previous shift region (i.e., the sixth shift region V[6]) is non-defective, the determination (detection) of the start point of the defective segment is performed from the seventh shift region V[7]. Specifically, the data processing unit 36 determines the window AV[8] at the center position of the three windows forming the seventh shift region V[7] as the start point RCF1 of the defective segment RCF in the defect. After the data processing unit 36 determines the start point RCF1 of the defective segment RCF, the data processing unit 36 changes the threshold value for the defect determination from the first threshold value T1 to the second threshold value T2.

[0148] The data processing unit 36 calculates the volume of the eighth shift region V[8] and determines that the eighth shift region V[8] is defective because the calculated volume 9.0 mm 3 is not equal to or less than the second threshold value T2 = 3.2 mm 3 In addition, since there is no next shift region after the defect determination of the eighth shift region V[8], the data processing unit 36 performs the determination (detection) of the end point of the defective segment from the eighth shift region V[8]. Specifically, the data processing unit 36 determines the window AV[9] at the center position of the three windows forming the eighth shift region V[8] as the end point RCF2 of the defective segment RCF in the defect.

[0149] As Figure 13Based on the results of the defect determination and the defect segment determination (detection) of the shape mismatch data ED4 shown in FIG. 6, the data processing unit 36 generates an appearance inspection report including information on the first defect segment RCE (i.e., position information of the start point RCE1 and the end point RCE2) and information on the second defect segment RCF (i.e., position information of the start point RCF1 and the end point RCF2), and ends the processing. Figure 13 The processing of the defect determination and the defect segment determination (detection) of the shape mismatch data ED4 shown in FIG. 6.

[0150] After the processing of the defect determination and the defect segment determination (detection), the data processing unit 36 performs processing of calculating the coordinates of the start point and the end point of the defect segment as a repair welding segment, so that the welding robot MC1 actually performs repair welding. The data processing unit 36 extracts point cloud data of each window AV[k] including each position of each start point and each end point obtained as a result of determination from the shape mismatch data ED4, respectively. In the example shown in FIG. 7, the data processing unit 36 extracts point cloud data ED41 of the window AV[4] including the position of the start point RCE1 in the defect segment RCE, point cloud data ED42 of the window AV[6] including the position of the end point RCE2 in the defect segment RCE, point cloud data ED43 of the window AV[9] including the position of the start point RCF1 in the defect segment RCF, and point cloud data ED44 of the window AV

[10] including the position of the end point RCF2 in the defect segment RCF. Figure 14

[0151] The data processing unit 36 calculates the center-of-gravity coordinates of each of the extracted point cloud data ED41 to ED44, and outputs the calculated center-of-gravity coordinates as coordinates for the welding robot MC1 to perform repair welding. Specifically, in the example shown in FIG. 8, the data processing unit 36 calculates the coordinates (X1, Y1, Z1) of the start point RCE1 in the defect segment RCE, the coordinates (X2, Y2, Z2) of the end point RCE2 in the defect segment RCE, the coordinates (X3, Y3, Z3) of the start point RCF1 in the defect segment RCF, and the coordinates (X4, Y4, Z4) of the end point RCF2 in the defect segment RCF based on each of the extracted point cloud data. Figure 14

[0152] ​​​Note that the center-of-gravity coordinates of each of the point cloud data ED41 to ED44 calculated here are not limited to the center-of-gravity coordinates calculated based on each of the point cloud data ED41 to ED44, and can be center-of-gravity coordinates calculated based on a part of each of the point cloud data ED41 to ED44. For example, when the data processing unit 36 calculates the coordinates of the starting point in the defect section, the data processing unit 36 can calculate the center-of-gravity coordinates of the point cloud data in a section (i.e., a part) of ΔD / 2 or ΔD / 3 in the same direction as the welding direction M3 from a position having a cross-sectional area S[k] corresponding to the kth window ΔV[k] including the position of the starting point. Further, in the cutting surface for calculating the coordinates of the ending point of the defect section, the center-of-gravity coordinates of the point cloud data in a section (i.e., a part) of ΔD / 2 or ΔD / 3 in the direction opposite to the welding direction M3 can be calculated from a position having a cross-sectional area S[k+1] corresponding to the (k+1)th window ΔV[k+1] continuous to the kth window ΔV[k] including the position of the ending point.

[0153] As a result of the defect determination and the defect section determination (detection) of the shape mismatch data ED4, the data processing unit 36 generates an appearance inspection report including information on the first defect section RCE (i.e., position (coordinate) information of the starting point RCE1 and the ending point RCE2) and information on the second defect section RCF (i.e., position (coordinate) information of the starting point RCF1 and the ending point RCF2), and ends the process of calculating the coordinates of the starting point and the ending point of the defect section of the shape mismatch data ED4 shown in Figure 13

[0154] Note that the method of calculating the coordinates of the starting point and the ending point of the defect section is not limited to the above-described example. Hereinafter, another method of calculating the coordinates of the starting point and the ending point of the defect section performed by the data processing unit 36 will be described with reference to Figure 15 Figure 16 Figure 15 is a diagram showing an example of calculating the coordinates of the starting point and the ending point in the defect section according to a modification of the embodiment.

[0155] In the example shown in Figure 15 , the data processing unit 36 extracts the point closest to the welding direction M3 (i.e., the operation trajectory of the welding robot MC1) and the point farthest from the welding direction M3 from each of the extracted point cloud data ED41 to ED44, and calculates the coordinates of the intermediate point between the two extracted points as the coordinates of the starting point and the ending point in the defect section.

[0156] ​​​Specifically, the data processing unit 36 extracts the point SP11 closest to the welding direction M3 and the point SP12 farthest from the welding direction M3 from the extracted point cloud data ED41, calculates the coordinates of the intermediate point between the two extracted points as the coordinates (X5, Y5, Z5) of the starting point RCE3 in the defective section RCE, extracts the point SP21 closest to the welding direction M3 and the point SP22 farthest from the welding direction M3 from the extracted point cloud data ED42, and calculates the coordinates of the intermediate point between the two extracted points as the coordinates (X6, Y6, Z6) of the ending point RCE4 in the defective section RCE. Further, similarly, the data processing unit 36 extracts the point SP31 closest to the welding direction M3 and the point SP32 farthest from the welding direction M3 from the extracted point cloud data ED43, calculates the coordinates of the intermediate point between the two extracted points as the coordinates (X7, Y7, Z7) of the starting point RCF3 in the defective section RCF, extracts the point SP41 closest to the welding direction M3 and the point SP42 farthest from the welding direction M3 from the extracted point cloud data ED44, and calculates the coordinates of the intermediate point between the two extracted points as the coordinates (X8, Y8, Z8) of the ending point RCF4 in the defective section RCF.

[0157] As a result of the defect determination and the defective section determination (detection) as the shape mismatch data ED4, the data processing unit 36 generates the appearance inspection report including the information on the first defective section RCE (i.e., the position (coordinates) information of the starting point RCE3 and the ending point RCE4) and the information on the second defective section RCF (i.e., the position (coordinates) information of the starting point RCF3 and the ending point RCF4).

[0158] Figure 16 is a diagram showing an example of calculating the coordinates of the starting point and the ending point in the defective section according to a modification of the embodiment. Note that, in Figure 16 the method of calculating the coordinates will be described in detail with reference to the enlarged view EX, which is obtained by enlarging the point cloud data ED41 including the window AV[4] of the starting point RCE5 of the defective section RCE, and the illustration of the enlarged views of the other point cloud data ED42, ED43, and ED44 is omitted.

[0159] In Figure 16In the example shown in FIG. 6, the data processing unit 36 extracts the point cloud data of each window AV[k] including each position of each start point and each end point obtained as a result of the determination from the shape mismatch data ED4, respectively. When the extracted point cloud data of the window AV[k] includes the position of the start point in the defective section, the data processing unit 36 calculates the coordinates of the point closest to the cutting surface (i.e., the cutting surface (plane) that forms the sectional area S[k] used to calculate the volume of the window AV[k]) among the points included in the point cloud data, as the coordinates of the start point in the defective section. Further, when the point cloud data of the window AV[k] includes the position of the end point in the defective section, the data processing unit 36 calculates the coordinates of the point closest to the cutting surface (i.e., the cutting surface (plane) that forms the sectional area S[k+1] used to calculate the volume of the window AV[k+1]) of the next window AV[k+1] of the extracted window AV[k], as the coordinates of the end point in the defective section. In other words, in the calculation of the coordinates of the end point in the defective section, when the point cloud data of the window AV[k] includes the position of the end point in the defective section, the data processing unit calculates the coordinates of the point farthest from the cutting surface (i.e., the cutting surface (plane) that forms the sectional area S[k] used to calculate the volume of the window AV[k]) among the points included in the point cloud data, as the coordinates of the end point in the defective section.

[0160] In Figure 16 In the example shown in FIG. 6, an equation for calculating the coordinates of the point that is the start point or the end point of the defective section is shown in (Equation 1). (Equation 1) is an equation that shows the cutting surface (plane). (Equation 2) is an equation for calculating the distance D0 between the cutting surface and the point that is the start point or the end point. Note that here, the normal vector of the cutting surface (plane) is (A, B, C). The coordinates of the point that is the start point and the end point of the defective section are assumed to be coordinates (X0, Y0, Z0).

[0161] [Equation 1]

[0162]

[0163] [Equation 2]

[0164]

[0165] Specifically, the data processing unit 36 calculates the distance Dll, D12, D13, D14, D15 between each of the plurality of points EDD included in the extracted point cloud data ED41 and the cutting surface CS41 of the window AV[4] corresponding to the start point RCE5 of the defect section RCE, and calculates the coordinates of the point closest to the cutting surface CS41 among the respective distances Dll to D15 of the plurality of points calculated, as the coordinates (X9, Y9, Z9) of the start point RCE5 of the defect section RCE. Note that, in the example shown in FIG. 9, the distance Dll is the minimum value. Figure 16 In the example shown in FIG. 9, the reference sign of the point EDD in the point cloud data ED41 is shown only for some of the points, and can be omitted for other points and the start point RCE5. Similarly, the reference sign indicating the distance between each of the plurality of points EDD and the cutting surface CS41 is shown only for some of the points EDD, and can be omitted for other points. Figure 16

[0166] The data processing unit 36 calculates the distance between each of the plurality of points (not shown) included in the extracted point cloud data ED42 and the cutting surface CS42 of the next window AV[7] corresponding to the window AV[6] including the end point RCE6 of the defect section RCE, and calculates the coordinates of the point closest to the cutting surface CS42 among the distances between each of the plurality of points calculated and the cutting surface CS42, as the coordinates (X10, Y10, Z10) of the end point RCE6 of the defect section RCE. Note that the data processing unit 36 can calculate the distance between each of the plurality of points (not shown) included in the extracted point cloud data ED42 and the cutting surface of the window AV[6] including the end point RCE6 of the defect section RCE, and can calculate the coordinates of the point farthest from the cutting surface among the distances between each of the plurality of points calculated and the cutting surface, as the coordinates (X10, Y10, Z10) of the end point RCE6 of the defect section RCE.

[0167] ​Similarly, the data processing unit 36 calculates a distance between each of a plurality of points (not shown) included in the extracted point cloud data ED43 and the cutting surface CS43 of the window AV[8] corresponding to the start point RCF5 of the defective section RCF, and calculates coordinates of a point that is farthest from the cutting surface CS43 among the calculated distances between each of the plurality of points and the cutting surface CS43, as the coordinates (X11, Y11, Z11) of the start point RCF5 of the defective section RCF. Further, the data processing unit 36 calculates a distance between each of a plurality of points (not shown) included in the extracted point cloud data ED44 and the cutting surface CS44 of the next window AV

[10] adjacent to the window AV[9] corresponding to the end point RCF6 of the defective section RCF, and calculates coordinates of a point that is closest to the cutting surface CS44 among the calculated distances between each of the plurality of points and the cutting surface CS44, as the coordinates (X12, Y12, Z12) of the end point RCF6 of the defective section RCF.

[0168] As a result of the defect determination and the defective section determination (detection) of the shape mismatch data ED4, the data processing unit 36 generates an appearance inspection report including information on the first defective section RCE (i.e., position (coordinates) information of the start point RCE5 and the end point RCE6) and information on the second defective section RCF (i.e., position (coordinates) information of the start point RCF5 and the end point RCF6).

[0169] As described above, according to the embodiment and the modification of the embodiment, the inspection control device 3 as an example of the repair section detection device: inputs input data (e.g., point cloud data) on a weld bead of a workpiece Wk produced by welding; performs a check determination on a shape of the weld bead by using the input data and master data of a non-defective workpiece; generates shape mismatch data obtained by extracting a shape mismatch portion of the weld bead, based on a result of the check determination; divides the shape mismatch data into N (N: an integer of 2 or more) equal windows in a direction perpendicular to a welding direction of the weld bead; sets a shift region formed of i (i: an integer of 1 or more) consecutive windows among the N windows; calculates volumes of (N-i+1) shift regions obtained by shifting the i windows forming the shift region one by one in the welding direction, respectively; and determines that a shift region having a volume of a predetermined value or more among the calculated volumes of the (N-i+1) respective shift regions is a defective section of the weld bead.

[0170] According to the embodiment and the modification of the embodiment, therefore, the inspection control device 3 can more accurately determine whether or not there is a defective portion that does not satisfy the quality standard of the user and that is to be repaired by welding, based on the volume of the shape-mismatched portion per reference length (i.e., the interval ΔD), and determine the start point and the end point of the defective section to be repaired by welding based on the shifted region determined as the defective portion.

[0171] Further, as described above, according to the embodiment and the modification of the embodiment, the inspection control device 3 sequentially executes the process of calculating the volume of (N-i+1) respective shifted regions and determining the defective section (N-i+1) times in the welding direction. According to the embodiment and the modification of the embodiment, therefore, the inspection control device 3 can perform the determination of the defective portion of the shifted region while shifting at the interval ΔD, and thus, the inspection control device 3 can more accurately detect the position of the defective portion (i.e., the defective section) that does not satisfy the quality standard of the user and that is to be repaired by welding.

[0172] Further, as described above, according to the embodiment and the modification of the embodiment, the inspection control device 3 determines the first window among the i windows included in the one or more shifted regions determined as the defective section as the start point of the defective section, and determines the i-th window as the end point of the defective section. In the determination method, for example, when one discontinuous shifted region is determined as defective, the inspection control device 3 determines (detects) the entire region of the shifted region as the defective section, and when two or more continuous shifted regions are determined as defective, the inspection control device 3 detects the entire region of the two or more shifted regions as the defective section. According to the embodiment and the modification of the embodiment, therefore, the inspection control device 3 can more accurately determine the position of the defective portion (i.e., the defective section) in the shape-mismatched portion that is to be repaired by welding, and can prevent an oversight in the detection of the defective section.

[0173] Further, as described above, according to the embodiment and the modification of the embodiment, when two or more continuous shifted regions are determined as the defective section, the inspection control device 3 determines the first window among the i windows of the shifted region that is first determined as the defective section among the two or more continuous shifted regions as the start point of the defective section, and determines the i-th window among the i windows included in the shifted region that is last determined as the defective section as the end point of the defective section. According to the embodiment and the modification of the embodiment, therefore, the inspection control device 3 can more accurately detect the defective section in the shape-mismatched portion that is to be repaired by welding.

[0174] Further, as described above, according to the embodiment and the modification of the embodiment, when the first of the (N-i+1) shifted regions is determined to be the defective section, the inspection control device 3 determines the first of the i windows forming the first shifted region as the starting point of the defective section. Thus, according to the embodiment and the modification of the embodiment, in the first shifted region PS1 in which it is difficult to specify the position of the defect for which repair welding is to be performed, the inspection control device 3 can detect the defective section for repair welding for all defects in the first shifted region PS1.

[0175] Further, as described above, according to the embodiment and the modification of the embodiment, when the (N-i+1)th of the (N-i+1) shifted regions is determined to be the defective section, the inspection control device 3 determines the i-th of the i windows forming the (N-i+1)th shifted region as the end point of the defective section. Thus, according to the embodiment and the modification of the embodiment, the inspection control device 3 can detect the defective section for repair welding for all defects in the (N-i+1)th shifted region PS(N-i+1) in which it is difficult to specify the position of the defect for which repair welding is to be performed.

[0176] Further, as described above, according to the embodiment and the modification of the embodiment, when two or more consecutive shifted regions are determined to be the defective section, the inspection control device 3 determines the center position of the shifted region that is first determined to be the defective section as the starting point of the defective section, and determines the center position of the shifted region that is last determined to be the defective section as the end point. Thus, according to the embodiment and the modification of the embodiment, the inspection control device 3 can more accurately detect the defective section in the shape mismatching portion for which repair welding is to be performed.

[0177] Further, as described above, according to the modification of the embodiment, when any k-th shift region among the (N-i+1) shift regions is determined to be a defective section, the inspection control device 3 sets any window included in the shift region as a start point of the defective section, and determines whether or not a volume of a (k+1)-th shift region continuous to the shift region is equal to or smaller than a second threshold value (an example of a second predetermined value) smaller than the first threshold value (an example of a predetermined value), and when the volume of the (k+1)-th shift region is equal to or smaller than the second predetermined value, the inspection control device 3 determines any window forming the (k+1)-th shift region as an end point of the defective section. Thus, according to the modification of the embodiment, when the start of the defect is determined in the determination of the defective section (the repair welding section) to be repair welded, the inspection control device 3 can tighten the standard for determining as non-defective (the end of the defect) in the determination of the defect in the continuous shift regions. That is, since the inspection control device 3 determines that the defective section is not ended when the volume of the shift region (in other words, the volume difference between the appearance shape of the weld and the master data) is not equal to or smaller than the second threshold value, the inspection control device 3 can determine (detect) the defective section, which can further prevent the repair omission in the repair welding performed based on the generated information on the defective section.

[0178] Further, as described above, according to the modification of the embodiment, when the volume of the (k+1)-th shift region is not equal to or smaller than the second threshold value (an example of a second predetermined value), the inspection control device 3 determines whether or not a volume of a (k+2)-th shift region continuous to the (k+1)-th shift region is equal to or smaller than the second threshold value, and repeatedly performs the determination until any one of the calculated volumes of the shift regions is determined to be equal to or smaller than the second threshold value, and determines any window forming the shift region having the volume determined to be equal to or smaller than the second threshold value as the end point of the defective section. Thus, according to the modification of the embodiment, the inspection control device 3 can continue the determination of the defect while setting the standard for determining as non-defective (the end of the defect) to be the second threshold value which is more strict, until any one of the continuous shift regions is determined to be non-defective.

[0179] Further, as described above, according to the modification of the embodiment, when the volume of the (N-i+1)-th shift region is determined not to be equal to or smaller than the second threshold value (an example of a second predetermined value) by the determination, the inspection control device 3 determines any window forming the (N-i+1)-th shift region as the end point of the defective section. Thus, according to the modification of the embodiment, even when the (N-i+1)-th shift region is determined to be defective, the inspection control device 3 can detect the defective section for repair welding of all defects in the (N-i+1)-th shift region PS(N-i+1).

[0180] Further, as described above, according to the modification of the embodiment, the inspection control device 3 determines the coordinate of the start point (for example, the coordinate (X1, Y1, Z1) shown in FIG. 12) as the coordinate of the start point (for example, the start point RCE1 shown in FIG. 12) in the window (for example, the window AV[4] including the start point RCE1 shown in FIG. 12) including the start point of the defective section. Thus, according to the modification of the embodiment, the inspection control device 3 can calculate the coordinate of the start point for welding each defective section in the repair welding of each defective section to be performed by the welding robot MC1. Further, since the inspection control device 3 calculates the coordinate based on the barycentric coordinate of the shape mismatch data (point cloud data) in each window, the inspection control device 3 can arrange the welding torch 400 at a more appropriate position. Figure 14 Figure 14 Figure 14

[0181] Further, as described above, according to the modification of the embodiment, the inspection control device 3 determines the coordinate of the start point (for example, the coordinate (X5, Y5, Z5) shown in FIG. 13) as the coordinate of the start point (for example, the start point RCE3 shown in FIG. 13) in the window (for example, the window AV[5] including the start point RCE3 shown in FIG. 13) including the start point of the defective section. Thus, according to the modification of the embodiment, the inspection control device 3 can calculate the coordinate of the start point for welding each defective section in the repair welding of each defective section to be performed by the welding robot MC1, and therefore, the inspection control device 3 can arrange the welding torch 400 at a more appropriate position. Figure 15 Figure 15 Figure 15 Figure 15 Figure 15

[0182] Further, as described above, according to the modification of the embodiment, the inspection control device 3 determines the coordinate of the end point (for example, the coordinate (X2, Y2, Z2) shown in FIG. 14) as the coordinate of the end point (for example, the end point RCE2 shown in FIG. 14) in the window (for example, the window AV[6] including the end point RCE2 shown in FIG. 14) including the end point of the defective section. Thus, according to the modification of the embodiment, the inspection control device 3 can calculate the coordinate of the end point for welding each defective section in the repair welding of each defective section to be performed by the welding robot MC1. Further, since the inspection control device 3 calculates the coordinate based on the barycentric coordinate of the shape mismatch data (point cloud data) in each window, the inspection control device 3 can arrange the welding torch 400 at a more appropriate position. Figure 14 Figure 14 Figure 14

[0183] ​​​​​​​​​​​Furthermore, as described above, according to the modification of the embodiment, the inspection control device 3 will include an end point (e.g., Figure 15 The distance from the weld bead in the window of the end point RCE4 shown (e.g., Figure 15 The nearest point (e.g., the operating trajectory of welding robot MC1 indicated by welding direction M3 shown in the figure) to the welding direction M3 shown in the figure. Figure 15 Point SP21 shown is the point furthest from the welding trajectory (e.g., Figure 15 The coordinates of the midpoint between points SP22 shown in the figure (e.g., Figure 15 The coordinates (X6, Y6, Z6) shown are determined as the coordinates of the end point. Therefore, according to the modification of the embodiment, the inspection control device 3 can calculate the coordinates of the end point used for welding each defect segment in the repair welding of each defect segment to be performed by the welding robot MC1, and thus, the inspection control device 3 can arrange the welding torch 400 in a more appropriate position.

[0184] Furthermore, as described above, according to the modification of the embodiment, the inspection control device 3 corresponds the distance shape mismatch data to the starting point including the defect segment (e.g., Figure 16 The cutting surface of the window (e.g., corresponding to the starting point RCE5 shown) Figure 16 The coordinates of the nearest point to the cut surface CS41 of the window ΔV[4] shown in the figure (e.g., Figure 16 The coordinates (X9, Y9, Z9) shown are determined as the coordinates of the starting point. Therefore, according to the modification of the embodiment, the inspection control device 3 can calculate the coordinates of the starting point for welding each defect segment in the repair welding of each defect segment to be performed by the welding robot MC1, and thus, the inspection control device 3 can arrange the welding torch 400 in a more appropriate position.

[0185] Furthermore, as described above, according to the modification of the embodiment, the inspection control device 3 will correspond the distance to the shape mismatch data to the nearest end point including the defective segment (e.g., Figure 16 The cutting surface of the next window of the window shown at the end point RCE6) (e.g., corresponding to the end point RCE6) Figure 16 The coordinates of the nearest point (e.g., the cutting surface CS42 of the window ΔV[6] shown in the figure) are shown. Figure 16 The coordinates (X10, Y10, Z10) shown are determined as the coordinates of the end point. Therefore, according to the modification of the embodiment, the inspection control device 3 can calculate the coordinates of the end point used for welding each defect segment in the repair welding of each defect segment to be performed by the welding robot MC1, and thus, the inspection control device 3 can arrange the welding torch 400 in a more appropriate position.

[0186] Furthermore, as described above, according to the embodiments and modifications thereof, the inspection control device 3 outputs repair welding conditions in association with the defective segment and information related to the volume within the defective segment. Therefore, according to the embodiments and modifications thereof, the inspection control device 3 can output repair welding conditions, such as the feed rate of the welding wire 300 or control parameters (welding current value or welding voltage value) of the power supply device 500 necessary for creating the repair welding procedure, in association with information about the defective segment. Thus, the inspection control device 3 can assist in generating a repair welding procedure that achieves more accurate repair welding of the detected defective segment.

[0187] Although various embodiments have been described above with reference to the accompanying drawings, it goes without saying that this disclosure is not limited to such examples. It will be apparent to those skilled in the art that various changes, corrections, substitutions, additions, deletions, and equivalents are contemplated within the scope of the claims, and it should be understood that such changes, corrections, substitutions, additions, deletions, and equivalents also fall within the technical scope of this disclosure. Furthermore, the components in the various embodiments described above can be freely combined without departing from the spirit of the invention.

[0188] It should be noted that this application is based on Japanese patent application (Japanese Patent Application No. 2020-180663) filed on October 28, 2020, the contents of which are incorporated herein by reference.

[0189] Industrial applicability

[0190] This disclosure is useful as a method and apparatus for more accurately detecting weld repair sections in workpieces produced by main welding.

[0191] List of reference numerals

[0192] 1: Main unit

[0193] 2: Robot control device

[0194] 3: Inspect the control device

[0195] 4: Sensors

[0196] 10, 20, 30: Communication Units

[0197] 11, 21, 31: Processor

[0198] 12, 22, 32: Memory

[0199] 23: Main Welding Program Creation Unit

[0200] 24: Robot Control Unit

[0201] 25: Power Control Unit

[0202] 33: inspection result storage unit

[0203] 34: determination threshold storage unit

[0204] 35: determination threshold storage unit

[0205] 36: data processing unit

[0206] 37: repair welding program creation unit

[0207] 100: welding system

[0208] 200: manipulator

[0209] 300: wire feeder

[0210] 301: welding wire

[0211] 400: torch

[0212] 500: power supply device

[0213] CS1, CS2, CS41, CS42, CS43, CS44: cutting surface

[0214] MC1: welding robot

[0215] MN1, MN2: monitor

[0216] M1, M2, M3: welding direction

[0217] RC2, RC3, RCA, RCB, RCC, RCD, RCE, RCF: defective section

[0218] RC21, RC31, RCA1, RCB1, RCE1, RCE3, RCE5, RCF1, RCF3, RCF5: start point

[0219] RC22, RC32, RCA2, RCB2, RCE2, RCE4, RCE6, RCF2, RCF4, RCF6: end point

[0220] ST: external storage device

[0221] UI1: input interface

Claims

1. A repair section detection method, comprising: inputting input data related to a weld bead of a workpiece produced by welding; performing a check determination related to a shape of the weld bead using the input data and master data of a non-defective workpiece; generating shape mismatch data obtained by extracting a shape mismatch portion of the weld bead based on a result of the check determination; dividing the shape mismatch data into N equal windows in a direction perpendicular to a welding direction of the weld bead, where N is an integer of 2 or more; setting a shift region formed by i consecutive windows among the N windows, where i is an integer of 1 or more; calculating volumes of (N-i+1) shift regions obtained by shifting the i windows forming the shift region one by one in the welding direction, respectively; and determining that a shift region having a volume of a predetermined value or more among the calculated volumes of the (N-i+1) respective shift regions is a defective section of the weld bead.

2. The repair section detection method according to claim 1, wherein the process of calculating the volumes of the (N-i+1) respective shift regions and determining the defective section is performed (N-i+1) times in order along the welding direction.

3. The repair section detection method according to claim 1, further comprising: determining a first window among the i windows included in the shift region determined as the defective section as a starting point of the defective section, and determining an i-th window as an end point of the defective section.

4. The repair section detection method according to claim 2, further comprising: in a case where two or more consecutive shift regions are determined as the defective section, determining a first window among the i windows forming a shift region that is first determined as the defective section among the two or more consecutive shift regions as a starting point of the defective section, and determining an i-th window among the i windows included in a shift region that is last determined as the defective section as an end point of the defective section.

5. The repair section detection method according to claim 2, further comprising: in a case where a first shift region among the (N-i+1) shift regions is determined as the defective section, determining a first window among the i windows forming the first shift region as a starting point of the defective section.

6. The repair section detection method according to claim 2, further comprising: in a case where an (N-i+1)-th shift region among the (N-i+1) shift regions is determined as the defective section, determining an i-th window among the i windows forming the (N-i+1)-th shift region as an end point of the defective section.

7. The repair section detection method according to claim 2, further comprising: in a case where two or more consecutive shift regions are determined as the defective section, determining a center position of a shift region that is first determined as the defective section as a starting point of the defective section, and determining a center position of a shift region that is last determined as the defective section as an end point.

8. The repair section detection method according to claim 2, further comprising: in the case where any k-th shift region among the (N-i+1) shift regions is determined as the defective section, where k is an integer of 1 or more, setting any window included in the shift region as a start point of the defective section, and determining whether or not a volume of a (k+1)-th shift region continuous to the shift region is equal to or smaller than a second predetermined value which is smaller than the predetermined value; and in the case where the volume of the (k+1)-th shift region is equal to or smaller than the second predetermined value, determining any window forming the (k+1)-th shift region as an end point of the defective section.

9. The repair welding section detection method according to claim 8, further comprising: in the case where the volume of the (k+1)-th shift region is not equal to or smaller than the second predetermined value, determining whether or not a volume of a (k+2)-th shift region continuous to the (k+1)-th shift region is equal to or smaller than the second predetermined value; and repeatedly performing the determination until any one of the calculated volumes of the shift regions is determined to be equal to or smaller than the second predetermined value, and determining any window forming a shift region having a volume determined to be equal to or smaller than the second predetermined value as the end point of the defective section.

10. The repair welding section detection method according to claim 9, further comprising: in the case where the volume of the (N-i+1)-th shift region is determined not to be equal to or smaller than the second predetermined value by the determination, determining any window forming the (N-i+1)-th shift region as the end point of the defective section.

11. The repair welding section detection method according to any one of claims 3 to 5 and 7, further comprising: determining a center of gravity coordinate of a window including the start point of the defective section as a coordinate of the start point.

12. The repair welding section detection method according to claim 11, further comprising: determining a coordinate of an intermediate point between a point closest to a welding trajectory of the weld bead and a point farthest from the welding trajectory in the window including the start point as the coordinate of the start point.

13. The repair welding section detection method according to any one of claims 3 to 4 and 6 to 10, further comprising: determining a center of gravity coordinate of a window including the end point of the defective section as a coordinate of the end point.

14. The repair welding section detection method according to claim 13, further comprising: determining a coordinate of an intermediate point between a point closest to a welding trajectory of the weld bead and a point farthest from the welding trajectory in the window including the end point as the coordinate of the end point.

15. The repair welding section detection method according to any one of claims 3 to 5 and 7, further comprising: determining a coordinate of a point closest to a cutting surface of the shape mismatch data corresponding to a window including the start point of the defective section as the coordinate of the start point.

16. The repair welding section detection method according to any one of claims 3 to 4 and 7 to 10, further comprising: The coordinates of a point closest to a cutting surface corresponding to a next window adjacent to the window including the end point of the defective section are determined as the coordinates of the end point.

17. The repair welding section detection method according to claim 1, further comprising: outputting the defective section and information about a volume in the defective section as a repair welding condition in association with each other.

18. A repair welding section inspection apparatus comprising: an input unit configured to input input data about a weld bead of a workpiece produced by welding; a determination unit configured to perform an inspection determination about a shape of the weld bead using the input data and master data of a defect-free workpiece; a data generation unit configured to generate shape mismatch data obtained by extracting a shape mismatch portion of the weld bead based on an inspection determination result obtained by the determination unit; a calculation unit configured to divide the shape mismatch data into N equal windows in a direction perpendicular to a welding direction of the weld bead, where N is an integer of 2 or more, set a shift region formed by i consecutive windows in the respective windows, where i is an integer of 1 or more, and calculate volumes of (N-i+1) respective shift regions obtained by shifting the i windows forming the shift region one by one in the welding direction; and a generation unit configured to determine that a shift region having a volume of a predetermined value or more among the calculated (N-i+1) shift regions is a defective section of the weld bead, and generate position information of a start point and an end point of the defective section.

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