Robot teaching device, appearance inspection system, and robot teaching method

Abstract

A robot teaching device (1) is used in a visual inspection system (100), the visual inspection system comprising: an imaging unit (2) for imaging a workpiece (W); an illumination unit (3) that irradiates the workpiece with illumination light; and a robot (4) that inspects the appearance of the workpiece by moving the imaging unit and the illumination unit, the robot teaching device comprising: a display unit (11); and a processing unit (13) that acquires the reflection state of the illumination light on the workpiece by simulation when teaching the operation of the robot on the display unit, and displays an image related to the acquired reflection state of the illumination light on the display unit.

Description

Technical Field

[0001] The present disclosure relates to a robot teaching device, an appearance inspection system, and a robot teaching method. Background Art

[0002] Conventionally, teaching devices are well known. For example, Japanese Patent No. 4266946 discloses such a teaching device.

[0003] The above-mentioned Patent Gazette No. 4266946 discloses an offline teaching device for a visual sensor. The offline teaching device includes: a workpiece; a storage device that stores the shape and size of a robot that operates on the workpiece and a visual sensor that measures the workpiece; and a display that displays images of the workpiece, the robot, and the visual sensor based on the data stored in the storage device. The offline teaching device is configured to be able to configure the workpiece, the robot, and the visual sensor on the display, and to teach and adjust the visual sensor offline. Specifically, the offline teaching device is configured to configure a camera on the display, photograph the measurement portion of the workpiece with the configured camera, and generate a camera image of the photographed measurement portion.

[0004] Prior art literature

[0005] Patent Literature

[0006] Patent Document 1: Japanese Patent No. 4266946 Summary of the invention

[0007] Problems to be solved by the invention

[0008] However, the technology of the offline teaching device described in the above-mentioned Japanese Patent No. 4266946 is a technology for teaching the visual sensor offline. Therefore, in the appearance inspection system that inspects the appearance of the workpiece by moving the camera unit or the workpiece by the robot, it is difficult to apply the teaching of the robot's movements to the offline purpose. Here, in such an appearance inspection system, at the stage of teaching the robot's movements offline, it is not possible to accurately know which part of the workpiece is inspected based on the image captured by the camera unit, so there is a problem of missing the inspection of the appearance of the workpiece. Therefore, there is a problem that it is difficult to teach the robot's movements when there is no omission or little omission in the inspection of the appearance of the workpiece.

[0009] The present disclosure is proposed to solve the above-mentioned problems, and its purpose is to provide a robot teaching device, an appearance inspection system and a robot teaching method, which can easily teach the robot's actions when there are no omissions or few omissions in the inspection of the appearance of the workpiece.

[0010] Technical solutions to solve problems

[0011] The first aspect of the present disclosure is a robot teaching device, which is used in an appearance inspection system, wherein the appearance inspection system comprises: a camera unit, which takes an image of a workpiece; an illumination unit, which illuminates the workpiece with illumination light; and a robot, which performs appearance inspection on the workpiece by moving the camera unit and the illumination unit or moving the workpiece, wherein the robot teaching device comprises: a display unit; and a processing unit, which, when teaching the movement of the robot on the display unit, obtains the reflection state of the illumination light on the workpiece through simulation, and causes the display unit to display an image related to the obtained reflection state of the illumination light.

[0012] In the robot teaching device of the first aspect of the present disclosure, as described above, a processing unit is provided, which, when teaching the action of the robot on the display unit, obtains an image related to the reflection state of the illumination light on the workpiece by simulation, and causes the display unit to display the obtained reflection state of the illumination light. Here, in the case of performing the appearance inspection of the workpiece, the entire range of the image captured by the camera unit does not contribute to the appearance inspection of the workpiece, but the range of the high brightness portion with a large reflection amount and high brightness in the image captured by the camera unit contributes to the appearance inspection of the workpiece. Therefore, if the high brightness portion is grasped, it is possible to accurately understand which part of the workpiece is being inspected, so that the action of the robot can be taught when there is no omission or little omission in the inspection of the appearance of the workpiece. Therefore, as described above, by displaying the image related to the reflection state of the illumination light on the display unit, it is possible to easily grasp the high brightness portion that actually contributes to the appearance inspection of the workpiece based on the image related to the reflection state of the illumination light displayed on the display unit, so it is possible to easily teach the action of the robot when there is no omission or little omission in the inspection of the appearance of the workpiece.

[0013] The appearance inspection system of the second aspect of the present disclosure comprises: a camera unit, which takes an image of a workpiece; a lighting unit, which illuminates the workpiece with illumination light; a robot, which performs appearance inspection on the workpiece by moving the camera unit and the lighting unit or moving the workpiece; and a robot teaching device, the robot teaching device comprising: a display unit; and a processing unit, which, when teaching the movement of the robot on the display unit, obtains the reflection state of the illumination light on the workpiece through simulation and causes the display unit to display an image related to the obtained reflection state of the illumination light.

[0014] In the appearance inspection system of the second aspect of the present disclosure, as described above, a processing unit is provided, which obtains the reflection state of the illumination light of the workpiece by simulation when teaching the action of the robot on the display unit, and causes the display unit to display an image related to the reflection state of the illumination light obtained. Thus, based on the image related to the reflection state of the illumination light displayed on the display unit, it is possible to easily grasp the high brightness portion that actually contributes to the appearance inspection of the workpiece, so that it is possible to provide an appearance inspection system that can easily teach the action of the robot when there is no omission or little omission in the inspection of the appearance of the workpiece.

[0015] The third aspect of the present disclosure is a robot teaching method, which is used in an appearance inspection system, wherein the appearance inspection system comprises: a camera unit, which takes an image of a workpiece; a lighting unit, which illuminates the workpiece with illumination light; and a robot, which performs appearance inspection on the workpiece by moving the camera unit and the lighting unit or moving the workpiece, wherein the robot teaching method includes: when teaching the movement of the robot on the display unit, obtaining the reflection state of the illumination light on the workpiece through simulation; and causing the display unit to display an image related to the obtained reflection state of the illumination light.

[0016] In the robot teaching method according to the third aspect of the present disclosure, as described above, when teaching the robot's actions on the display unit, the reflection state of the illumination light on the workpiece is obtained by simulation, and the display unit is made to display an image related to the obtained reflection state of the illumination light. Thus, based on the image related to the reflection state of the illumination light displayed on the display unit, it is possible to easily grasp the high-brightness portion that actually contributes to the appearance inspection of the workpiece, and thus it is possible to provide a robot teaching method that can easily teach the robot's actions when there are no omissions or few omissions in the inspection of the appearance of the workpiece.

[0017] Effects of the Invention

[0018] According to the present invention, as described above, it is possible to easily teach the operation of the robot with no or few omissions in the inspection of the appearance of the workpiece. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a diagram showing a visual inspection system according to one embodiment.

[0020] Figure 2 It is a diagram for explaining the setting of teaching points and movement paths of a robot teaching device according to one embodiment.

[0021] Figure 3 It is a diagram for explaining the reflection state of illumination light of the robot teaching device according to one embodiment.

[0022] Figure 4 This is a diagram for explaining a state in which a lighting unit is reflected in a captured image when the robot according to one embodiment is in a predetermined posture.

[0023] Figure 5 This is a diagram for explaining a state in which the lighting unit is reflected in a captured image when the imaging unit and the lighting unit according to one embodiment are moved by a robot.

[0024] Figure 6 It is a diagram for explaining superimposed display of inspection areas according to one embodiment.

[0025] Figure 7 It is a diagram for explaining the superimposed display of all inspection areas according to one embodiment.

[0026] Figure 8 This is a diagram for explaining superimposed display of arbitrary multiple inspection areas according to one embodiment.

[0027] Fig. 9 This is a flowchart for explaining the process of off-line teaching using a robot teaching device according to one embodiment. DETAILED DESCRIPTION

[0028] Hereinafter, embodiments embodying the present disclosure will be described based on the drawings.

[0029] (Structure of the appearance inspection system)

[0030] Reference Figures 1 to 8 , the structure of a visual inspection system 100 according to one embodiment is described. Figure 1 As shown, the appearance inspection system 100 is a system for inspecting the appearance of a workpiece W as an inspection object. In this embodiment, the workpiece W has a curved surface. The appearance inspection system 100 includes a robot teaching device 1, an imaging unit 2, an illumination unit 3, and a robot 4.

[0031] The robot teaching device 1 is a device for teaching the actions of the robot 4 for performing the appearance inspection of the workpiece W offline. The robot teaching device 1 performs offline teaching by teaching the actions of the robot 4 on the display screen through simulation without using a real machine. The robot teaching device 1 is, for example, a personal computer. The robot teaching device 1 includes a display unit 11, an operating unit 12, a processing unit 13, and a storage unit 14. The display unit 11 includes a monitor such as a liquid crystal monitor, which displays a screen. The operating unit 12 includes input devices such as a mouse and a keyboard, which accept user input operations. The processing unit 13 includes a processor, which performs various processes in the robot teaching device 1. The storage unit 14 includes a non-volatile memory, which stores a model M1 of the camera unit 2, a model M2 of the lighting unit 3, a model M3 of the robot 4, and a model M4 of the workpiece W, etc. for simulation. In addition, the detailed structure of the offline teaching of the robot teaching device 1 will be described later.

[0032] The imaging unit 2, the lighting unit 3, and the robot 4 are devices that actually perform the appearance inspection of the workpiece W based on the teaching results of the actions of the robot 4 of the robot teaching device 1. The imaging unit 2 is a camera that takes an image of the workpiece W. The lighting unit 3 irradiates the workpiece W with illumination light. The robot 4 moves the imaging unit 2 and the lighting unit 3 to perform the appearance inspection of the workpiece W. The robot 4 is a vertical multi-joint robot, including an arm 41. The arm 41 has a plurality of joints. In addition, the arm 41 integrally holds the imaging unit 2 and the lighting unit 3 at the front end. The robot 4 moves the imaging unit 2 and the lighting unit 3 relative to the workpiece W by driving the plurality of joints of the arm 41.

[0033] During the appearance inspection of the workpiece W, the lighting unit 3 irradiates the workpiece W with illumination light, while the imaging unit 2 captures the surface of the workpiece W. In addition, the imaging unit 2 and the lighting unit 3 move relative to the workpiece W via the robot 4, and the imaging unit 2 captures the surface of the workpiece W. Since it is unknown where the abnormality on the surface of the workpiece W, such as foreign matter, scratches, and dents, exists, the workpiece W is basically captured multiple times in a manner that covers the entire surface of the workpiece W. Then, based on the result of capturing the workpiece W by the imaging unit 2, it is checked whether the surface of the workpiece W has abnormalities such as foreign matter, scratches, and dents.

[0034] (Offline teaching)

[0035] The processing unit 13 performs offline teaching based on simulation based on the model M1 of the imaging unit 2, the model M2 of the lighting unit 3, the model M3 of the robot 4, and the model M4 of the workpiece W stored in the storage unit 14. The processing unit 13 causes the display unit 11 to display at least one of the imaging unit 2, the lighting unit 3, the robot 4, and the workpiece W, and performs offline teaching based on simulation. In offline teaching, as shown in FIG. Figure 2As shown, the processing unit 13 causes the display unit 11 to display the teaching point P of the operation of the robot 4 and the movement path PA defined by the teaching point P in accordance with the input operation of the user using the operation unit 12 .

[0036] Furthermore, in the present embodiment, the processing unit 13 obtains a movement path PA of the robot 4 that is substantially orthogonal to the curved surface of the workpiece W and along the curved surface of the workpiece W, and displays the obtained movement path PA on the display unit 11. Specifically, when a line L is input by a user to the surface of the workpiece W displayed on the display unit 11, the processing unit 13 generates a normal vector V that is substantially orthogonal to the surface of the workpiece W at a location through which the line L passes. The front end of the normal vector V is the teaching point P. Thus, the processing unit 13 obtains a plurality of teaching points P that are substantially orthogonal to the curved surface of the workpiece W and along the curved surface of the workpiece W. Furthermore, based on the plurality of teaching points P obtained, the processing unit 13 obtains a movement path PA that is substantially orthogonal to the curved surface of the workpiece W and along the curved surface of the workpiece W. Furthermore, in Figure 2 Only one movement path PA is shown in FIG.

[0037] Here, in this embodiment, if Figure 3 to Figure 7 As shown, when the processing unit 13 teaches the operation of the robot 4 on the display unit 11, it obtains the reflection state of the illumination light on the workpiece W through simulation, and causes the display unit 11 to display an image related to the obtained reflection state of the illumination light. Figure 3 As shown, for example, the processing unit 13 displays an image showing a state of reflection of illumination light on the workpiece W displayed on the display unit 11. In addition, for example, the processing unit 13 changes the image showing a state of reflection of illumination light on the workpiece W displayed on the display unit 11 according to the movement of the imaging unit 2 and the illumination unit 3 of the robot 4.

[0038] In addition, in this embodiment, if Figure 4 and Figure 5 As shown, the processing unit 13 obtains the reflection state of the lighting unit 3 in the captured image IM of the workpiece W of the imaging unit 2, and as the state of reflection of the illumination light, causes the display unit 11 to display the captured image IM of the workpiece W including the obtained reflection state of the lighting unit 3. The captured image IM is an example of an image related to the state of reflection of the illumination light.

[0039] Specifically, if Figure 4As shown, the processing unit 13 causes the display unit 11 to display the camera image IM of the workpiece W, and the camera image IM of the workpiece W includes the projection state of the lighting unit 3 when the robot 4 is in a specified posture. That is, the processing unit 13 displays the camera image IM of the workpiece W on the display unit 11, and the camera image IM of the workpiece W includes the projection state of the lighting unit 3 at the specified teaching point P. In addition, the processing unit 13 can display the camera image IM of the workpiece W including the projection state of the lighting unit 3 on the display unit 11 regardless of which teaching point P is used. The processing unit 13 displays the camera image IM based on the input operation of the user using the operation unit 12. The camera image IM includes a high-brightness portion HB with a large reflection amount of illumination light and a high brightness. The high-brightness portion HB can also be said to be a portion in the camera image IM where the lighting unit 3 is projected.

[0040] Here, when there are abnormalities such as foreign matter, scratches, and dents on the surface of the workpiece W, changes such as deformation occur in the high brightness portion HB. Therefore, in the appearance inspection system 100, the appearance of the workpiece W is inspected based on the changes in the high brightness portion HB with a large amount of reflection of the illumination light and a high brightness in the image captured by the imaging unit 2. That is, when the appearance inspection of the workpiece W is performed, the entire range of the image captured by the imaging unit 2 does not contribute to the appearance inspection of the workpiece W, and the range of the high brightness portion HB with a large amount of reflection of the illumination light and a high brightness in the image captured by the imaging unit 2 contributes to the appearance inspection of the workpiece W.

[0041] In addition, in this embodiment, if Figure 5 As shown, the processing unit 13 displays the image IM of the workpiece W on the display unit 11, the image IM of the workpiece W including the state of the illumination unit 3 being reflected when the imaging unit 2 and the illumination unit 3 are moved by the robot 4 along the moving path PA. Specifically, the processing unit 13 displays the image IM of the workpiece W on the display unit 11 while the imaging unit 2 and the illumination unit 3 are moved by the robot 4 along the moving path PA. The image IM of the workpiece W including the state of the illumination unit 3 being reflected when the imaging unit 2 scans and photographs the workpiece W. In addition, the processing unit 13 can display the image IM of the workpiece W including the state of the illumination unit 3 being reflected on the display unit 11 regardless of the moving path PA. The processing unit 13 displays the image IM based on the input operation of the user using the operation unit 12. The image IM includes a strip-shaped highlight portion HB corresponding to the moving path PA. The width of the highlight portion HB changes in accordance with the change of the curved surface of the workpiece W. Specifically, the width of the high brightness portion HB is reduced in a portion where the curvature of the curved surface of the workpiece W is large, and the width of the high brightness portion HB is increased in a portion where the curvature of the curved surface of the workpiece W is small. In addition, the camera image IM corresponds to an image when the inspection operation is actually performed by the robot 4. That is, when the appearance inspection of the workpiece W is actually performed, the appearance of the workpiece W is inspected based on the strip-shaped high brightness portion HB.

[0042] In addition, in this embodiment, if Figure 6 to Figure 8 As shown, the processing unit 13 obtains the reflection state of the lighting unit 3 in the workpiece W camera image IM of the camera unit 2 as the reflection state of the illumination light, and obtains the inspection area AR that can inspect the workpiece W based on the obtained reflection state of the lighting unit 3, and displays the obtained inspection area AR in a superimposed manner on the workpiece W displayed on the display unit 11. At this time, the processing unit 13 obtains the area within the field of view of the camera unit 2 and observed from the camera unit 2 where the reflection state of the illumination unit 3 is appropriate, that is, the area corresponding to the high brightness portion HB, as the inspection area AR. In addition, the processing unit 13 displays the obtained inspection area AR in a superimposed manner on the workpiece W displayed on the display unit 11 in a color different from that of the workpiece W. That is, the processing unit 13 color-maps the obtained inspection area AR onto the workpiece W displayed on the display unit 11. As a result, the area AR can be easily visually inspected. In addition, the inspection area AR is an example of an image related to the state of reflection of the illumination light.

[0043] In addition, in this embodiment, if Figure 6 As shown, the processing unit 13 obtains the strip-shaped inspection area AR when the imaging unit 2 and the lighting unit 3 are moved along the moving path PA by the robot 4, and displays the obtained strip-shaped inspection area AR in a superimposed manner on the workpiece W displayed on the display unit 11. More specifically, the processing unit 13 obtains the strip-shaped inspection area AR when the imaging unit 2 scans and photographs the workpiece W while the imaging unit 2 and the lighting unit 3 are moved along the moving path PA by the robot 4, and displays the obtained strip-shaped inspection area AR in a superimposed manner on the workpiece W displayed on the display unit 11.

[0044] In addition, in this embodiment, if Figure 7 and Figure 8 As shown in FIG. 1 , the processing unit 13 obtains a plurality of strip-shaped inspection areas AR corresponding to a plurality of moving paths PA, and displays the obtained plurality of strip-shaped inspection areas AR in a superimposed manner on the workpiece W displayed on the display unit 11. Specifically, based on the input operation of the user using the operation unit 12, the processing unit 13 displays one or more strip-shaped inspection areas AR corresponding to one or more moving paths PA specified by the user in a superimposed manner on the workpiece W displayed on the display unit 11. For example, Figure 7 As shown in FIG. 1 , when all the moving paths PA are specified by the user, the processing unit 13 displays a plurality of strip-shaped inspection areas AR corresponding to all the moving paths PA in a superimposed manner on the workpiece W displayed on the display unit 11. Figure 8As shown, when the user specifies any multiple movement paths PA, the processing unit 13 displays a plurality of strip-shaped inspection areas AR corresponding to the arbitrary multiple movement paths PA in a superimposed manner on the workpiece W displayed on the display unit 11. In addition, when the processing unit 13 displays a plurality of strip-shaped inspection areas AR corresponding to the arbitrary multiple movement paths PA on the display unit 11, the plurality of strip-shaped inspection areas AR are displayed on the display unit 11 in different colors.

[0045] For example, first, a plurality of strip-shaped inspection areas AR corresponding to all the movement paths PA are displayed on the display unit 11 (see FIG. Figure 7 ), the user confirms whether there is an uninspected portion in the current moving path PA. In a case where there is a strip-shaped inspection area AR that does not overlap with the workpiece W but allows visual confirmation of the surface of the workpiece W, the user determines that an uninspected portion exists in the current moving path PA. Furthermore, in a case where an uninspected portion exists in the current moving path PA, the user specifies a moving path PA close to the uninspected portion as the moving path PA related to the uninspected portion, and superimposes the strip-shaped inspection area AR corresponding to the specified moving path PA on the workpiece W displayed on the display unit 11, and displays it on the display unit 11 (refer to Figure 8 ). Thus, the state of the uninspected portion and the inspection area AR related to the uninspected portion in the current moving path PA can be easily recognized by naked eyes. Then, based on the state of the uninspected portion and the inspection area AR related to the uninspected portion in the current moving path PA, the user corrects the teaching point P so that the uninspected portion does not exist. In addition, after the correction of the teaching point P, if the inspection area AR is displayed again on the display unit 11, it can be confirmed whether the uninspected portion does not exist.

[0046] (Models of the camera unit, lighting unit, robot, and workpiece)

[0047] Furthermore, in the present embodiment, the storage unit 14 stores a model M2 of a plurality of lighting units 3. The processing unit 13 obtains the state of reflection of the illumination light by simulation based on the illumination unit 3 of the model selected based on the input operation of the user using the operation unit 12 among the models M2 of the plurality of lighting units 3 stored in the storage unit 14. The model M2 of the illumination unit 3 includes information such as the size of the illumination unit 3, the shape of the illumination unit 3, the type of the light source of the illumination unit 3, the arrangement of the light source of the illumination unit 3, and the color of the illumination light. Specifically, the model M2 of the plurality of lighting units 3 includes a model of linear illumination and a model of pattern illumination. The so-called model of linear illumination refers to a model of an illumination unit 3 in which the light source is arranged in a linear shape and irradiates the illumination light in a linear shape. The linear illumination is used in combination with a line array camera, for example. Furthermore, the so-called model of pattern illumination refers to a model of an illumination unit 3 in which the light source is arranged in two dimensions and irradiates the illumination light of a predetermined pattern such as a grid pattern. The pattern illumination is used in combination with an area array camera, for example.

[0048] In addition, in the present embodiment, the storage unit 14 stores a plurality of models M1 of the imaging units 2. The processing unit 13 obtains the camera image IM of the workpiece W photographed by the imaging unit 2, based on the imaging unit 2 of the model selected based on the input operation of the user using the operation unit 12 among the models M1 of the imaging units 2 stored in the storage unit 14. The model M1 of the imaging unit 2 includes information such as the size of the imaging unit 2, the shape of the imaging unit 2, the viewing angle of the imaging unit 2, the working distance indicating the distance from the lens of the imaging unit 2 to the focal position where the focal point is in focus, and the type of the image sensor of the imaging unit 2. Specifically, the model M1 of the plurality of imaging units 2 includes a model of a line scan camera and a model of an area scan camera. The so-called model of the line scan camera is a model of the imaging unit 2 that has a linear image sensor and photographs the workpiece W in a linear shape. In the appearance inspection of the workpiece W using the line scan camera, for example, scanning imaging is performed in which the imaging unit 2 is moved relative to the workpiece W while continuously photographing the workpiece W. The model of the area array camera is a model of an imaging unit 2 that has a two-dimensional image sensor and captures images of the workpiece W in a two-dimensional predetermined area. In the appearance inspection of the workpiece W using the area array camera, for example, intermittent imaging is performed while the imaging unit 2 is moved relative to the workpiece W. Figure 3 to Figure 8 In the figure, the case where the model of the linear array camera is selected and the scanning image is taken is shown. In addition, when the model of the area array camera is selected and the intermittent image is taken, the display unit 11 can also display the image. Figure 3 to Figure 8 An image related to the reflection state of the illumination light as shown.

[0049] In addition, the storage unit 14 stores a model M3 of the robot 4 and a model M4 of the workpiece W. The model M3 of the robot 4 includes information such as the size of the robot 4 and the shape of the robot 4. In addition, the model M4 of the workpiece W includes information such as the size of the workpiece W, the shape of the workpiece W, the color of the surface of the workpiece W, and the reflectivity of the surface of the workpiece W. In the present embodiment, the processing unit 13 obtains the state of reflection of the illumination light through simulation based on the color and reflectivity of the surface of the workpiece W. That is, the processing unit 13 considers the absorption of the illumination light by the color of the surface of the workpiece W, and obtains the state of reflection of the illumination light through simulation. In addition, the processing unit 13 may also display a user interface for changing the color and reflectivity of the surface of the workpiece W on the display unit 11.

[0050] (Offline teaching process using a robot teaching device)

[0051] Reference Fig. 9 , the process of off-line teaching using the robot teaching device 1 according to the present embodiment will be described based on a flowchart.

[0052] like Fig. 9 As shown, first, in step S1, based on the input operation of the user using the operation unit 12, the movement path PA of the robot 4 when performing the appearance inspection of the workpiece W is set. Then, in step S2, based on the input operation of the user using the operation unit 12, the reflection state of the illumination light is obtained. Then, in step S3, based on the input operation of the user using the operation unit 12, the camera image IM is displayed on the display unit 11.

[0053] In step S3, for example, the image IM of the workpiece W is displayed on the display unit 11 (see Figure 4 ), the camera image IM of the workpiece W includes the reflection state of the lighting unit 3 when the robot 4 is in a predetermined posture. Figure 4 The user compares the captured image IM shown in the figure to determine the validity of the model M1 of the imaging unit 2, the model M2 of the lighting unit 3, and the model M4 of the workpiece W used for the simulation. Figure 4 The high brightness portion HB in the camera image IM based on the simulation and the high brightness portion in the actual camera image such as the conventional camera image are compared to determine whether the high brightness portion HB in the camera image IM based on the simulation is appropriate. If the user determines that the high brightness portion HB in the camera image IM based on the simulation is inappropriate, the user corrects at least one of the model M1 of the camera unit 2, the model M2 of the lighting unit 3, and the model M4 of the workpiece W so that the high brightness portion HB in the camera image IM based on the simulation is appropriate.

[0054] In step S3, for example, the image IM of the workpiece W is displayed on the display unit 11 (see Figure 5), the camera image IM of the workpiece W includes the reflection state of the lighting unit 3 when the camera unit 2 and the lighting unit 3 are moved along the moving path PA by the robot 4. Figure 5 The captured image IM shown is used to check the state of the highlight portion HB in the captured image IM when the robot 4 performs the inspection operation. The user can check, for example, how the width of the highlight portion HB changes in accordance with changes in the curved surface of the workpiece W.

[0055] Then, in step S4, based on the input operation of the user using the operation unit 12, the inspection area AR is displayed on the display unit 11 in a manner superimposed on the workpiece W. In step S4, for example, a plurality of strip-shaped inspection areas AR (see FIG. 1 ) corresponding to all the movement paths PA are displayed. Figure 7 ) is displayed on the display unit 11 in a manner superimposed on the workpiece W. The user can Figure 7 The inspection area AR shown in the figure is used to check whether there is an uninspected portion in the current moving path PA. In addition, if there is an uninspected portion in the current moving path PA, the user specifies, for example, a moving path PA close to the uninspected portion. Then, a strip-shaped inspection area AR (see FIG. 1 ) corresponding to the specified moving path PA is selected. Figure 8 ) is displayed on the display unit 11 in a manner superimposed on the workpiece W. The user can Figure 8 The inspection area AR shown in the figure determines which teaching point P to correct. Then, based on the input operation of the user using the operation unit 12, the teaching point P is corrected and the moving path PA is corrected so that there is no uninspected portion. In addition, as needed, Figure 6 One inspection area AR shown is displayed on the display unit 11 .

[0056] As described above, off-line teaching is performed using the robot teaching device 1. Then, the robot teaching device 1 creates an action program for the robot 4 including the corrected movement path PA. When the appearance inspection of the workpiece W is actually performed, the imaging unit 2, the lighting unit 3, and the robot 4 are operated according to the action program created by the robot teaching device 1.

[0057] (Effects of this embodiment)

[0058] In the present embodiment, as described above, the robot teaching device 1 is a robot teaching device 1 for an appearance inspection system 100, which includes: an imaging unit 2 for imaging a workpiece W, an illumination unit 3 for irradiating the workpiece W with illumination light, and a robot 4 for moving the imaging unit 2 and the illumination unit 3 to perform appearance inspection of the workpiece W. The robot teaching device 1 includes: a display unit 11; and a processing unit 13, which obtains a reflection state of the illumination light on the workpiece W through simulation when teaching the movement of the robot 4 on the display unit 11, and displays an image related to the obtained reflection state of the illumination light on the display unit 11.

[0059] Here, when the appearance inspection of the workpiece W is performed, the entire range of the image captured by the imaging unit 2 does not contribute to the appearance inspection of the workpiece W, and the high-brightness portion HB in which the amount of reflection of the illumination light is large and the brightness is high in the image captured by the imaging unit 2 contributes to the appearance inspection of the workpiece W. Therefore, if the high-brightness portion HB is grasped, it is possible to accurately know which part of the workpiece W is inspected, so the operation of the robot 4 can be taught when there is no omission or little omission in the appearance inspection of the workpiece W. Therefore, as described above, by displaying an image related to the reflection state of the illumination light on the display unit 11, it is possible to easily grasp the high-brightness portion HB that actually contributes to the appearance inspection of the workpiece W based on the image related to the reflection state of the illumination light displayed on the display unit 11, so it is possible to easily teach the operation of the robot 4 when there is no omission or little omission in the appearance inspection of the workpiece W.

[0060] Furthermore, in the present embodiment, as described above, the processing unit 13 acquires the reflection state of the illumination unit 3 in the photographic image IM of the workpiece W captured by the imaging unit 2 as the reflection state of the illumination light, and causes the display unit 11 to display the photographic image IM of the workpiece W including the acquired reflection state of the illumination unit 3. Thus, the high-brightness portion HB in the photographic image IM can be easily grasped by the photographic image IM of the workpiece W including the reflection state of the illumination unit 3 displayed on the display unit 11. As a result, the operation of the robot 4 can be easily taught with no omissions or few omissions in the inspection of the appearance of the workpiece W.

[0061] Furthermore, in the present embodiment, as described above, the processing unit 13 displays the camera image IM of the workpiece W on the display unit 11, the camera image IM of the workpiece W including the projection state of the lighting unit 3 when the robot 4 is in the prescribed posture. Thus, by including the camera image IM of the workpiece W displayed on the display unit 11, which includes the projection state of the lighting unit 3 when the robot 4 is in the prescribed posture, the high brightness portion HB in the camera image IM when the robot 4 is in the prescribed posture can be grasped. Furthermore, by comparing the high brightness portion HB in the camera image IM when the robot 4 is in the prescribed posture with the high brightness portion HB in the actual camera image IM such as the previous camera image IM, it is possible to easily confirm whether there is a problem with the high brightness portion HB in the camera image IM based on the simulation. Thus, the appropriateness of the simulation can be confirmed.

[0062] Furthermore, in the present embodiment, as described above, the processing unit 13 displays the camera image IM of the workpiece W on the display unit 11, the camera image IM of the workpiece W including the projection state of the lighting unit 3 when the camera unit 2 and the lighting unit 3 are moved along the moving path PA by the robot 4. Thus, by including the camera image IM of the workpiece W including the projection state of the lighting unit 3 when the camera unit 2 and the lighting unit 3 displayed on the display unit 11 are moved along the moving path PA by the robot 4, it is possible to grasp the high brightness portion HB in the camera image IM when the robot 4 performs the inspection operation.

[0063] Furthermore, in the present embodiment, as described above, the processing unit 13 obtains the reflection state of the illumination unit 3 in the captured image IM of the workpiece W captured by the imaging unit 2 as the reflection state of the illumination light, and obtains the inspection area AR where the workpiece W can be inspected based on the obtained reflection state of the illumination unit 3, and displays the obtained inspection area AR in a superimposed manner on the workpiece W displayed on the display unit 11. Thus, the inspection area AR where the workpiece W can be inspected can be displayed in a superimposed manner on the workpiece W, so that the inspectable portion of the workpiece W can be visually easily confirmed. As a result, the operation of the robot 4 can be taught more easily with no omission or little omission of the inspection of the appearance of the workpiece W.

[0064] Furthermore, in the present embodiment, as described above, the processing unit 13 obtains the strip-shaped inspection area AR when the robot 4 moves the imaging unit 2 and the lighting unit 3 along the movement path PA, and displays the obtained strip-shaped inspection area AR in a superimposed manner on the workpiece W displayed on the display unit 11. Thus, the strip-shaped inspection area AR that can be inspected when the robot 4 performs the inspection operation can be displayed in a superimposed manner on the workpiece W, so that the part of the workpiece W that can be inspected when the robot 4 performs the inspection operation can be visually easily confirmed. As a result, the operation of the robot 4 can be taught more easily with no omission or little omission of the inspection of the appearance of the workpiece W.

[0065] Furthermore, in the present embodiment, as described above, the processing unit 13 obtains a plurality of strip-shaped inspection areas AR corresponding to a plurality of moving paths PA, and displays the obtained plurality of strip-shaped inspection areas AR in a superimposed manner on the workpiece W displayed on the display unit 11. Thus, the plurality of strip-shaped inspection areas AR that can be inspected when the robot 4 performs a plurality of inspection actions can be displayed in a superimposed manner on the workpiece W, so that the portion of the workpiece W that can be inspected when the robot 4 performs a plurality of inspection actions can be visually easily confirmed. Furthermore, when the robot 4 performs a plurality of inspection actions, the uninspected portion of the workpiece W can be visually easily confirmed. Thus, the operation of the robot 4 can be taught more easily when there is no omission or only a small omission in the inspection of the appearance of the workpiece W.

[0066] Furthermore, in the present embodiment, as described above, the robot teaching device 1 further includes the storage unit 14 storing the models M2 of the plurality of lighting units 3, and the processing unit 13 obtains the reflection state of the illumination light by simulation based on the lighting unit 3 of the model selected from the models M2 of the plurality of lighting units 3 stored in the storage unit 14. Thus, the model M2 of the lighting unit 3 based on the simulation can be used respectively according to the type of the lighting unit 3 actually used in the appearance inspection of the workpiece W. Thus, even when the type of the lighting unit 3 actually used for the appearance inspection of the workpiece W is different, the simulation can be flexibly processed.

[0067] Furthermore, in the present embodiment, as described above, the robot teaching device 1 further includes the storage unit 14 storing the models M1 of the plurality of imaging units 2, and the processing unit 13 obtains the camera image IM of the workpiece W captured by the imaging unit 2, based on the imaging unit 2 of the model selected from the models M1 of the plurality of imaging units 2 stored in the storage unit 14. Thus, the model M1 of the imaging unit 2 based on the simulation can be used respectively according to the type of the imaging unit 2 actually used in the appearance inspection of the workpiece W. Thus, even when the type of the imaging unit 2 actually used for the appearance inspection of the workpiece W is different, the simulation can be flexibly processed.

[0068] In this embodiment, as described above, the models M1 of the plurality of imaging units 2 include models of line scan cameras and area scan cameras. This allows simulation to be performed flexibly corresponding to line scan cameras or area scan cameras that are often used for visual inspection of workpieces W.

[0069] In addition, in the present embodiment, as described above, the processing unit 13 obtains the reflection state of the illumination light by simulation based on the color and reflectivity of the surface of the workpiece W. Thus, the reflection state of the illumination light can be correctly obtained based on the color and reflectivity of the surface of the workpiece W. In addition, when the reflection state of the illumination light is obtained by simulation based on the color of the surface of the workpiece W, the reflection state of the illumination light can be correctly obtained by considering the compatibility between the color of the surface of the workpiece W and the color of the illumination light.

[0070] In addition, in the present embodiment, as described above, the workpiece W has a curved surface, and the processing unit 13 obtains the movement path PA of the robot 4 that is substantially orthogonal to the curved surface of the workpiece W and along the curved surface of the workpiece W, and displays the obtained movement path PA on the display unit 11. As a result, the movement path PA of the robot 4 that is substantially orthogonal to the curved surface of the workpiece W that is difficult to teach when visually and along the curved surface of the workpiece W, which can be photographed with high accuracy, can be displayed on the display unit 11, so that the movement of the robot 4 that can photograph with high accuracy can be easily taught. In addition, in the case where the workpiece W has a curved surface, the shape of the high brightness portion HB when the camera unit 2 and the lighting unit 3 are moved by the robot 4 is likely to change significantly, so the effect of being able to grasp the high brightness portion HB is good. Moreover, in the case where the curved surface of the workpiece W is a curved surface with a changing curvature, the shape of the high brightness portion HB is likely to change significantly, so the effect of being able to grasp the high brightness portion HB is better.

[0071] (Variation Example)

[0072] The embodiments disclosed herein are to be considered in all respects as illustrative rather than restrictive. The scope of the present disclosure is indicated by the claims rather than the description of the embodiments described above, and includes all modifications (variations) within the meaning and scope equivalent to the claims.

[0073] For example, in the above-mentioned embodiment, an example in which the robot is a vertical multi-joint robot is shown, but the present disclosure is not limited thereto. In the present disclosure, the robot may be a robot other than a vertical multi-joint robot.

[0074] Furthermore, in the above-mentioned embodiment, an example is shown in which the robot moves the imaging unit and the lighting unit, but the present disclosure is not limited thereto. In the present disclosure, the robot may also move the workpiece.

[0075] In addition, in the above embodiment, an example is shown in which a captured image including the reflection state of the lighting unit is displayed on the display unit, but the present disclosure is not limited thereto. In the present disclosure, a captured image including the reflection state of the lighting unit may not be displayed on the display unit.

[0076] Furthermore, in the above-described embodiment, an example in which the present disclosure is applied to a workpiece having a curved surface is shown, but the present disclosure is not limited thereto. The present disclosure can be applied to a workpiece having a flat plate shape or the like that does not have a curved surface.

[0077] In addition, in the above-mentioned embodiment, an example of obtaining a moving path along the curved surface of the workpiece substantially orthogonal to the curved surface of the workpiece is shown, but the present disclosure is not limited to this. In the present disclosure, a moving path that is not substantially orthogonal to the curved surface of the workpiece can also be obtained. In other words, a moving path that is not perpendicular to the curved surface of the workpiece can also be obtained.

[0078] Furthermore, in the above-mentioned embodiment, an example is shown in which the storage unit stores models of a plurality of lighting units, but the present disclosure is not limited thereto. In the present disclosure, the storage unit may also store a model of one lighting unit.

[0079] In addition, in the above embodiment, an example is shown in which the models of the plurality of lighting units include a model of linear lighting and a model of patterned lighting, but the present disclosure is not limited thereto. In the present disclosure, the models of the plurality of lighting units may include a model of linear lighting, a model of patterned lighting, a model of ring lighting, a model of regional lighting, a model of strip lighting, etc., without particular limitation.

[0080] In addition, in the above-mentioned embodiment, an example is shown in which the storage unit stores models of a plurality of imaging units, but the present disclosure is not limited thereto. In the present disclosure, the storage unit may store a model of one imaging unit.

[0081] In addition, in the above-mentioned embodiment, an example is shown in which the models of the plurality of imaging units include the models of the line scan cameras and the models of the area scan cameras, but the present disclosure is not limited thereto. In the present disclosure, the models of the plurality of imaging units may include only one of the models of the line scan cameras and the models of the pattern cameras. In addition, the models of the plurality of imaging units may also include models other than the models of the line scan cameras and the models of the pattern cameras.

[0082] In addition, in the above-mentioned embodiment, an example of obtaining the reflection state of the illumination light by simulation based on the color and reflectivity of the surface of the workpiece is shown, but the present disclosure is not limited to this. In the present disclosure, the reflection state of the illumination light can be obtained by simulation based on only one of the color and reflectivity of the surface of the workpiece. In addition, the reflection state of the illumination light can also be obtained by simulation based on other than the color and reflectivity of the surface of the workpiece.

[0083] The functions of the elements disclosed in this specification can be performed using circuits or processing circuits, which include general-purpose processors, special-purpose processors, integrated circuits, ASICs (Application Specific Integrated Circuits), conventional circuits, and / or combinations thereof configured or programmed to perform the disclosed functions. A processor is considered a processing circuit or circuit because it includes transistors or other circuits. In the present disclosure, a circuit, unit, or device is hardware that performs the functions or is programmed to perform the functions listed. The hardware may be hardware disclosed in this specification, or it may be other known hardware that is programmed or configured to perform the functions listed. If the hardware is a processor that is considered to be a type of circuit, the circuit, device, or unit is a combination of hardware and software, and the software is used for the structure of the hardware and / or processor.

[0084] [Way]

[0085] It should be understood by those skilled in the art that the above exemplary embodiments are specific examples of the following manners.

[0086] (Item 1)

[0087] A robot teaching device is used in a visual inspection system, wherein the visual inspection system comprises: an imaging unit that images a workpiece; an illumination unit that illuminates the workpiece with illumination light; and a robot that performs visual inspection on the workpiece by moving the imaging unit and the illumination unit or by moving the workpiece, wherein:

[0088] The robot teaching device comprises:

[0089] a display unit; and

[0090] A processing unit that obtains a reflection state of the illumination light on the workpiece by simulation when teaching the operation of the robot on the display unit, and causes the display unit to display an image related to the obtained reflection state of the illumination light.

[0091] (Item 2)

[0092] A robot teaching device according to Item 1, wherein the processing unit obtains the reflection state of the lighting unit in the camera image of the workpiece taken by the camera unit as the reflection state of the illumination light, and causes the display unit to display the camera image of the workpiece including the obtained reflection state of the lighting unit.

[0093] (Item 3)

[0094] The robot teaching device according to item 2, wherein the processing unit causes the display unit to display the captured image of the workpiece, the captured image of the workpiece including a reflection state of the lighting unit when the robot is in a predetermined posture.

[0095] (Item 4)

[0096] A robot teaching device according to item 2 or 3, wherein the processing unit causes the display unit to display a camera image of the workpiece, the camera image of the workpiece including a reflection state of the lighting unit when the robot moves the camera unit and the lighting unit or the workpiece along a moving path.

[0097] (Item 5)

[0098] A robot teaching device according to any one of items 1 to 4, wherein the processing unit obtains the reflection state of the lighting unit in the camera image of the workpiece taken by the camera unit as the reflection state of the illumination light, and obtains an inspection area capable of inspecting the workpiece based on the obtained reflection state of the lighting unit, and displays the obtained inspection area in a superimposed manner on the workpiece displayed on the display unit.

[0099] (Item 6)

[0100] A robot teaching device according to Item 5, wherein the processing unit obtains the strip-shaped inspection area when the robot moves the imaging unit and the lighting unit or the workpiece along a moving path, and displays the obtained strip-shaped inspection area in a superimposed manner on the workpiece displayed on the display unit.

[0101] (Item 7)

[0102] The robot teaching device according to Item 6, wherein the processing unit obtains a plurality of strip-shaped inspection areas corresponding to a plurality of the movement paths, and displays the obtained plurality of strip-shaped inspection areas in a superimposed manner on the workpiece displayed on the display unit.

[0103] (Item 8)

[0104] The robot teaching device according to any one of items 1 to 7, wherein:

[0105] further comprising a storage unit for storing a plurality of models of the lighting unit,

[0106] The processing unit acquires the reflection state of the illumination light through simulation based on the illumination unit of a model selected from a plurality of models of the illumination unit stored in the storage unit.

[0107] (Item 9)

[0108] The robot teaching device according to any one of items 1 to 8, wherein:

[0109] further comprising a storage unit for storing a plurality of models of the camera unit,

[0110] The processing unit acquires a captured image of the workpiece captured by the imaging unit based on the imaging unit of a model selected from a plurality of models of the imaging units stored in the storage unit.

[0111] (Item 10)

[0112] The robot teaching device according to Item 9, wherein the plurality of models of the imaging unit include at least one of a model of a line array camera and a model of an area array camera.

[0113] (Item 11)

[0114] The robot teaching device according to any one of items 1 to 10, wherein the processing unit acquires the reflection state of the illumination light through simulation based on at least one of the color and the reflectivity of the surface of the workpiece.

[0115] (Item 12)

[0116] The robot teaching device according to any one of items 1 to 11, wherein:

[0117] The workpiece has a curved surface,

[0118] The processing unit acquires a movement path of the robot along the curved surface of the workpiece substantially orthogonal to the curved surface of the workpiece, and causes the display unit to display the acquired movement path.

[0119] (Item 13)

[0120] A visual inspection system, comprising:

[0121] A camera unit for taking a picture of the workpiece;

[0122] an illumination unit for irradiating the workpiece with illumination light;

[0123] a robot that performs appearance inspection on the workpiece by moving the imaging unit and the lighting unit or moving the workpiece; and

[0124] Robot teaching device,

[0125] The robot teaching device comprises:

[0126] a display unit; and

[0127] A processing unit that obtains a reflection state of the illumination light on the workpiece by simulation when teaching the operation of the robot on the display unit, and causes the display unit to display an image related to the obtained reflection state of the illumination light.

[0128] (Item 14)

[0129] A robot teaching method is used in a visual inspection system, wherein the visual inspection system comprises: an imaging unit that images a workpiece; an illumination unit that illuminates the workpiece with illumination light; and a robot that performs visual inspection on the workpiece by moving the imaging unit and the illumination unit or by moving the workpiece, wherein:

[0130] The robot teaching method comprises:

[0131] When teaching the movement of the robot on the display unit, a reflection state of the illumination light on the workpiece is obtained by simulation; and

[0132] The display unit is caused to display an image related to the acquired reflection state of the illumination light.

[0133] Description of Reference Numerals

[0134] 1Robot teaching device

[0135] 2Camera Department

[0136] 3Lighting Department

[0137] 4. Robots

[0138] 11Display unit

[0139] 13 Processing Department

[0140] 14 Storage

[0141] 100 Visual inspection system

[0142] AR inspection area (image related to the reflection state of illumination light)

[0143] IM camera image (image related to the reflection state of illumination light)

[0144] PA movement path

[0145] M1 camera unit model

[0146] M2 Lighting Model

[0147] W workpiece

Claims

1. A robot teaching device, which is used in an appearance inspection system, characterized in that: The appearance inspection system comprises: an imaging unit that captures an image of a workpiece; an illumination unit that illuminates the workpiece with illumination light; and a robot that performs appearance inspection on the workpiece by moving the imaging unit and the illumination unit or by moving the workpiece. The robot teaching device comprises: a display unit; and A processing unit that obtains a reflection state of the illumination light on the workpiece by simulation when teaching the operation of the robot on the display unit, and causes the display unit to display an image related to the obtained reflection state of the illumination light.

2. The robot teaching device according to claim 1, characterized in that: The processing unit acquires a reflection state of the illumination unit in the captured image of the workpiece captured by the imaging unit as a reflection state of the illumination light, and causes the display unit to display the captured image of the workpiece including the acquired reflection state of the illumination unit.

3. The robot teaching device according to claim 2, characterized in that: The processing unit causes the display unit to display a captured image of the workpiece, wherein the captured image of the workpiece includes a reflection state of the lighting unit when the robot is in a predetermined posture.

4. The robot teaching device according to claim 2, characterized in that: The processing unit causes the display unit to display a captured image of the workpiece, the captured image of the workpiece including a reflection state of the illumination unit when the robot moves the imaging unit and the illumination unit or the workpiece along a movement path.

5. The robot teaching device according to claim 1, characterized in that: The processing unit obtains the reflection state of the lighting unit in the camera image of the workpiece taken by the camera unit as the reflection state of the illumination light, and obtains an inspection area capable of inspecting the workpiece based on the obtained reflection state of the lighting unit, and displays the obtained inspection area in a superimposed manner on the workpiece displayed by the display unit.

6. The robot teaching device according to claim 5, characterized in that: The processing unit obtains the strip-shaped inspection area when the robot moves the imaging unit and the lighting unit or the workpiece along a movement path, and displays the obtained strip-shaped inspection area in a superimposed manner on the workpiece displayed on the display unit.

7. The robot teaching device according to claim 6, characterized in that: The processing unit acquires a plurality of the strip-shaped inspection regions corresponding to the plurality of the movement paths, and displays the acquired plurality of strip-shaped inspection regions in a superimposed manner on the workpiece displayed on the display unit.

8. The robot teaching device according to claim 1, characterized in that: further comprising a storage unit for storing a plurality of models of the lighting unit, The processing unit acquires the reflection state of the illumination light through simulation based on the illumination unit of a model selected from the plurality of models of the illumination unit stored in the storage unit.

9. The robot teaching device according to claim 1, characterized in that: further comprising a storage unit for storing a plurality of models of the camera unit, The processing unit acquires a captured image of the workpiece captured by the imaging unit based on the imaging unit of a model selected from a plurality of models of the imaging units stored in the storage unit.

10. The robot teaching device according to claim 9, characterized in that: The plurality of imaging unit models include at least one of a model of a line scan camera and a model of an area scan camera.

11. The robot teaching device according to claim 1, characterized in that: The processing unit acquires the reflection state of the illumination light through simulation based on at least one of the color and the reflectance of the surface of the workpiece.

12. The robot teaching device according to claim 1, characterized in that: The workpiece has a curved surface, The processing unit acquires a movement path of the robot along the curved surface of the workpiece substantially orthogonal to the curved surface of the workpiece, and causes the display unit to display the acquired movement path.

13. A visual inspection system, characterized in that: have: A camera unit for taking a picture of the workpiece; an illumination unit for irradiating the workpiece with illumination light; a robot that performs appearance inspection on the workpiece by moving the imaging unit and the lighting unit or moving the workpiece; as well as Robot teaching device, The robot teaching device comprises: Display unit; as well as A processing unit that obtains a reflection state of the illumination light on the workpiece by simulation when teaching the operation of the robot on the display unit, and causes the display unit to display an image related to the obtained reflection state of the illumination light.

14. A robot teaching method, which is used in a visual inspection system, the visual inspection system comprising: a camera unit that captures an image of a workpiece; an illumination unit that illuminates the workpiece with illumination light; and a robot that performs visual inspection on the workpiece by moving the camera unit and the illumination unit or by moving the workpiece. The robot teaching method is characterized by comprising: When teaching the movement of the robot on the display unit, a reflection state of the illumination light on the workpiece is obtained by simulation; as well as The display unit is caused to display an image related to the acquired reflection state of the illumination light.

Images