Control device, inspection system, control method, and storage medium

Abstract

A control device of an embodiment receives first posture data indicating a posture of a first robot. The first robot includes a first manipulator and a first end effector. The control device also sets a posture of the first robot based on the first posture data, so that the first robot performs a first work with respect to a first member. The first posture data is generated based on second posture data. The second posture data indicates a posture of a second robot including a second manipulator and a second end effector when the second robot performs a second work with respect to the first member.

Description

[0001] This invention is a divisional application of the following application, the original application information of which is as follows: International Application Number: PCT / JP2021 / 005498 Application Number: 202180021121.2 Application date: February 15, 2021 Invention Title: Control Device, Inspection System, Control Method, Program, and Storage Medium Technical Field

[0002] Embodiments of the present invention relate to control devices, inspection systems, control methods, programs, and storage media. Background Technology

[0003] Various industrial robots are used on the production floor. Before deploying a robot on the production line, its posture during operation is taught. The goal is to reduce the teaching time required.

[0004] Existing technical documents Patent documents Patent Document 1: Japanese Patent Application Publication No. 2019-90727 Summary of the Invention

[0005] The problem the invention aims to solve The problem to be solved by the present invention is to provide a control device, inspection system, control method, program and storage medium that can shorten the teaching time.

[0006] Methods for solving problems The control device in this embodiment receives first posture data representing the posture of a first robot. The first robot includes a first manipulator and a first end effector. The control device also sets the posture of the first robot based on the first posture data, causing the first robot to perform a first task relative to a first component. The first posture data is generated based on second posture data. The second posture data represents the posture of a second robot, including a second manipulator and a second end effector, when performing a second task on the first component. Attached Figure Description

[0007] Figure 1 This is a schematic diagram of a production system that illustrates the application and implementation of a robot system.

[0008] Figure 2 This is a 3D diagram illustrating the first robot.

[0009] Figure 3 This is a schematic diagram illustrating the second robot.

[0010] Figure 4This is a schematic diagram illustrating the operation of the production system in the implementation method.

[0011] Figure 5 This is an example of data stored in a storage device.

[0012] Figure 6 This is a flowchart illustrating the processing in the production system of the implementation method.

[0013] Figure 7 It is a three-dimensional diagram showing the internal structure of the detector front end.

[0014] Figure 8 This is a schematic diagram used to illustrate the inspection method.

[0015] Figure 9 This is a flowchart representing a specific example of the first assignment.

[0016] Figure 10 This is a diagram illustrating how the tilt angle of the detector is calculated.

[0017] Figure 11 This is an example of an image representing the detected information.

[0018] Figure 12 This is an example of an image representing the detected information.

[0019] Figure 13 This is a diagram showing an example of the structure of the processing device and the control device. Detailed Implementation

[0020] Hereinafter, various embodiments of the present invention will be described with reference to the accompanying drawings.

[0021] The accompanying drawings are schematic or conceptual, and the relationship between the thickness and width of each part, as well as the proportions between the parts, may not be the same as in reality. Even when representing the same part, there may be cases where the dimensions and proportions of each part are represented differently depending on the accompanying drawings.

[0022] In this application specification and figures, elements that are the same as those already described are labeled with the same reference numerals and detailed descriptions are omitted where appropriate.

[0023] Figure 1 This is a schematic diagram of a production system that illustrates the application and implementation of a robot system.

[0024] The robot system 100 of the embodiment includes a first robot 110, a control device 120, and a processing device 130. The production system 300 includes robot system 100 and robot system 200. Robot system 200 includes a second robot 210, a control device 220, and a processing device 230. In this example, production system 300 also includes a storage device 310, a teaching device 320, and a storage device 330.

[0025] The first robot 110 includes a first manipulator 111 and a first end effector 112. The first end effector 112 is mounted, for example, at the front end of the first manipulator 111. The first manipulator 111 is, for example, a vertically articulated type, a horizontally articulated type, or a parallel link type. The first manipulator 111 can also be a combination of two or more manipulators selected from vertically articulated, horizontally articulated, and parallel link types. The first robot 110 performs a first task corresponding to the function of the first end effector 112.

[0026] The control device 120 sends instructions to the first robot 110 to control the first robot 110. For example, the control device 120 causes the drive unit included in the first manipulator 111 to move, controlling the posture of the first robot 110. Alternatively, the control device 120 causes the first end effector 112 to move, causing the first robot 110 to perform a first task.

[0027] Here, pose refers to the position and orientation corresponding to the robot's degrees of freedom. For example, the pose of a robot with 6 degrees of freedom is represented by the position in each of three mutually orthogonal directions (X, Y, and Z) and the angles (rolling, pitching, and yaw) around each direction.

[0028] The processing unit 130 sends data for controlling the first robot 110 to the control unit 120. Alternatively, the processing unit 130 receives data from the control unit 120 based on information acquired by the first robot 110. The processing unit 130 processes the various data appropriately.

[0029] The second robot 210 includes a second manipulator 211 and a second end effector 212. The second end effector 212 is mounted, for example, at the front end of the second manipulator 211. The second manipulator 211 is, for example, a vertically articulated type, a horizontally articulated type, or a parallel-linked type. The second manipulator 211 may also be a combination of two or more manipulators selected from vertically articulated, horizontally articulated, and parallel-linked types.

[0030] The second robot 210 performs a second task corresponding to the function of the second end effector 212. The function of the second end effector 212 is different from the function of the first end effector 112. Therefore, the second task performed by the second robot 210 is different from the first task.

[0031] The control device 220 sends instructions to the second robot 210 to control the second robot 210. For example, the control device 220 causes the drive unit included in the second manipulator 211 to move, controlling the posture of the second robot 210. Alternatively, the control device 220 causes the second end effector 212 to move, causing the second robot 210 to perform the first task.

[0032] The processing unit 230 sends data for controlling the second robot 210 to the control unit 220. Alternatively, the processing unit 230 receives data acquired by the second robot 210 from the control unit 220. The processing unit 230 processes the various data appropriately.

[0033] Storage device 310 stores data related to robot systems 100 and 200. For example, processing device 130 accesses storage device 310 to obtain data related to the first task, data of the components that are the objects of the first task, etc. Similarly, processing device 230 accesses storage device 310 to obtain data related to the second task, data of the components that are the objects of the second task, etc. Processing device 130 saves data related to the first robot 110 and the first task sent from control device 120 to storage device 310. Processing device 230 saves data related to the second robot 210 and the second task sent from control device 220 to storage device 310.

[0034] The first robot 110 and the second robot 210 perform the first task and the second task respectively on the same component. For example, the second robot 210 performs the second task on the first component. Then, the first robot 110 performs the first task on the same first component.

[0035] Storage device 330 stores design data related to the first component. The design data may include, for example, computer-aided design (CAD) data. For instance, teaching device 320 generates a motion program for the second robot 210 based on the design data. Teaching device 320 then performs the generated motion program on a simulator to verify robot actions, interference checks, etc.

[0036] The motion program contains data related to the posture of the second robot 210. This data represents the posture of the control points of the second robot 210 when it performs the second task. Hereinafter, the data representing the posture of the control points of the second robot 210 generated based on the design data will be referred to as design posture data. The teaching pendant 320 saves the generated design posture data in the storage device 310.

[0037] When the second robot 210 performs the second task, the processing device 230 accesses the storage device 310 to obtain second posture data representing the posture of the second robot 210. For example, posture data is designed for the second posture data. Alternatively, the second posture data may also be data representing the posture taught using the second robot 210.

[0038] For example, in the actual execution of the second task, the operator, having set the posture of the second robot 210 based on the designed posture data, verifies whether any problems arise on-site. Specifically, when setting the posture of the second robot 210 based on the designed posture data, it is confirmed whether the second robot 210 might interfere with objects on-site or come into contact with the operator. If a problem is likely to occur, the operator uses the second robot 210 to teach its posture to eliminate the problem. In this case, the taught posture is saved as second posture data in the storage device 310.

[0039] Processing device 130 acquires second posture data and generates first posture data. The first posture data represents the posture of the first robot 110 when performing the first task. Processing device 130 saves the generated first posture data in storage device 310. Alternatively, processing device 130 sends the generated first posture data to control device 120. Control device 120 sets the posture of the first robot 110 based on the first posture data, causing the first robot 110 to perform the first task.

[0040] The generation of the first pose data can also be performed by the processing device 230. In this case, the processing device 230 saves the generated first pose data in the storage device 310, or sends the generated first pose data to the processing device 130.

[0041] When performing a first operation and a second operation on a first component at multiple locations, multiple first posture data and multiple second posture data corresponding to the multiple locations are prepared. The multiple first posture data are generated separately based on the multiple second posture data. At least a portion of the multiple second posture data is generated separately based on design posture data. At least a portion of the multiple second posture data can also be generated separately based on actual teaching, in addition to the design posture data. For example, a portion of the multiple second posture data is generated separately based on design posture data, and another portion is generated separately based on actual teaching.

[0042] The components of the production system 300 are interconnected via wired communication, wireless communication, or a network.

[0043] The effects of the implementation method are explained.

[0044] In the robot system 100 of this embodiment, the control device 120 receives first posture data. Then, the control device 120 sets the posture of the first robot 110 based on the first posture data, causing the first robot 110 to perform a first task. The first posture data is automatically generated by the processing device 130 or 230 based on second posture data representing the posture of the second robot 210 when performing a second task. Therefore, a human does not need to teach the first robot 110 its posture when performing the first task. According to the control device 120, the time required for a human to teach the first robot 110 can be reduced.

[0045] For example, in a production line, a product is manufactured through multiple processes. In a production line using robots, different types of robots are used for each process. Depending on the production line, sometimes in one process, a robot performs a task on a specific part of a component, and then in another process, a different robot performs a task on the same part of the same component. By applying the invention of the implementation method to such a production line, it is unnecessary to teach the other robots their postures during operation. For example, the teaching time can be reduced, and the operation of the production line can be accelerated.

[0046] As a reference example, there is a method for generating first posture data based on design data. For example, the teaching pendant 320 generates a motion program for the first robot 110 based on design data. This method is effective when the second posture data corresponds to the design posture data. By using the first posture data based on the design data, the other robot can perform operations on the same parts as the parts where the first robot performed the operation.

[0047] However, in practice, as mentioned above, there are also cases where the posture is taught on-site without using the designed posture data. In this case, when the first posture data is also generated based on the designed posture data, the other robots cannot perform operations on the same parts as those worked on by the first robot. Therefore, it is preferable to generate the first posture data based on the second posture data. According to the embodiment, even when using the second posture data, which is different from the designed posture data, the other robots are still able to perform operations on the same parts as those worked on by the first robot.

[0048] The following describes specific examples of the implementation methods.

[0049] Figure 2 This is a 3D diagram illustrating the first robot. Figure 3 This is a schematic diagram illustrating the second robot.

[0050] Here, we will explain the case where the first robotic arm 111 and the second robotic arm 211 are vertical multi-joint types with 6 degrees of freedom.

[0051] like Figure 2 As shown, the first robotic arm 111 includes six alternately connected joints J1a-J1f and six links L1a-L1f. Joints J1a-J1f are each driven by a drive unit (not shown). The control device 120 drives joints J1a-J1f, thereby adjusting the posture of the control points of the first robot 110.

[0052] like Figure 3 As shown, the second robotic arm 211 includes six alternately connected joints J2a-J2f and six links L1a-L1f. Joints J2a-J2f are each driven by a drive unit (not shown). The control device 220 drives joints J2a-J2f, thereby adjusting the posture of the control points of the second robot 210.

[0053] The control point is the point whose posture is controlled by the control device 120 or 220. The control point may be set at any point on each end effector, for example. When the workpiece or tool is held by the end effector, the control point may also be set at any point on the workpiece or tool. Hereinafter, the "posture of the control point of the first robot 110" will be simply referred to as the "posture of the first robot 110". Similarly, the "posture of the control point of the second robot 210" will be referred to as the "posture of the second robot 210".

[0054] As a specific example, such as Figure 2 As shown, the first end effector 112 includes a detector 112a and a coating device 112b. The second end effector 212 includes a welding device. Figure 3As shown, the welding device includes a welding torch 212a, an upper electrode 212b, a lifting part 212c, a lower electrode 212d, and a current supply part 212e.

[0055] The second end effector 212 performs spot welding on the first component. That is, the second operation is spot welding. The first end effector 112 sends ultrasonic waves to the spot-welded part and detects its reflected waves. That is, the first operation is to acquire information related to the welded part.

[0056] Figure 4 (a) and Figure 4 (b) is a schematic diagram showing the operation of the production system in the implementation method.

[0057] For example, through robot systems 100 and 200, for Figure 4 The first component 10 shown in (a) performs the first operation and the second operation. The first component 10 includes steel plates 11 and 12.

[0058] For example, such as Figure 4 As shown in (a), the conveying device T transports the first component 10 to the position where the second robot 210 is located. The conveying device T stops at a position pre-set for the second operation. The second robot 210 performs spot welding on the first part P1 and the second part P2 of the first component 10. Specifically, the second manipulator 211 moves such that the first part P1 or the second part P2 is positioned between the upper electrode 212b and the lower electrode 212d. The lifting unit 212c moves the upper electrode 212b toward the lower electrode 212d. The first component 10 is sandwiched between the upper electrode 212b and the lower electrode 212d. The current supply unit 212e intermittently supplies current between the upper electrode 212b and the lower electrode 212d. Steel plates 11 and 12 partially melt, mix, and join together.

[0059] The posture of the second robot 210 during spot welding is set based on the second posture data. For example, the second posture data includes coordinates (P) representing the portion of the second robot 210 that is being spot welded. X2 P Y2 P Z2 ) and the angles (α) of joints J2a~J2f respectively. J2a α J2b α J2c α J2d α J2e α J2fWhen spot welding the first part P1, the control device 220 refers to second posture data indicating the posture when spot welding the first part P1. When spot welding the second part P2, the control device 220 refers to second posture data indicating the posture when spot welding the second part P2. In each spot welding operation, the control device 220 sets the posture of the second robot 210 based on the referenced second posture data.

[0060] When spot welding is completed, the conveyor T transports the first component 10 to the position where the first robot 110 is located. The conveyor T stops at a position pre-set for the first operation. Figure 4 As shown in (b), the first robot 110 acquires information related to the first part P1 and the second part P2 of the first component 10. Specifically, the first manipulator 111 moves to bring the coating device 112b opposite to the first part P1. The coating device 112b applies a coupling agent to the first part P1. Then, the first manipulator 111 moves to bring the tip of the detector 112a into contact with the first part P1. The detector 112a sends an ultrasonic wave and detects its reflected wave. For example, three-dimensional data representing the intensity distribution of the reflected wave is acquired. This data reflects the state of the first part P1. The first robot 110 performs the same action on the second part P2.

[0061] The pose of the first robot 110 when acquiring data is set based on the first pose data. Like the second pose data, the first pose data includes coordinates (P) representing the portion of the data acquired by the first robot 110. X1 P Y1 P Z1 ) and the angles (α) of joints J1a~J1f respectively. J1a α J1b α J1c α J1d α J1e α J1f ).

[0062] When the first end effector 112 includes multiple devices, first posture data is prepared for each device. For example, when acquiring information about the first part P1, the control device 120 refers to the first posture data indicating the posture when the coupling agent is applied to the first part P1 and the first posture data indicating the posture when acquiring information about the first part P1. The same applies when acquiring information about the second part P2. During the acquisition of information about each part, the control device 120 sets the posture of the first robot 110 based on the referenced first posture data.

[0063] The first pose data is generated using the second pose data. For example, the first pose data is generated by the processing device 230. When generating the first pose data, the processing device 230 refers to the second pose data, the first construction data, and the second construction data.

[0064] The first construction data includes data representing the construction of the first manipulator 111. The first construction data also includes data representing the relationship between the posture of the first robot 110 and the posture of the front end of the first manipulator 111. The data representing the construction of the first manipulator 111 represents the length (β) of each of the links L1a~L1f included in the first manipulator 111. L1a β L1b β L1c β L1d β L1e β L1f The front end of the first robotic arm 111 corresponds to the angle (α) at ​​the first robotic arm 111 according to the respective angles of joints J1a to J1f. J1a α J1b α J1c α J1d α J1e α J1f The lengths (β) of the connecting rods L1a to L1f respectively. L1a β L1b β L1c β L1d β L1e β L1f The posture portion was calculated.

[0065] Positional relationships are represented, for example, by the displacement of the pose of the control point of the first robot 110 relative to the pose of the front end of the first manipulator 111. Specifically, the positional relationship is represented by the displacement (D) of the position in the X, Y, and Z directions. X1 D Y1 D Z1 ) and displacement of angles in each direction ( )express.

[0066] The second construction data includes data representing the positional relationship between the control points of the second robot 210 and the front end of the second manipulator 211.

[0067] The second construction data includes data representing the construction of the second manipulator 211. The second construction data also includes data representing the relationship between the posture of the second robot 210 and the posture of the front end of the second manipulator 211. The data representing the construction of the second manipulator 211 indicates the length (β) of each of the links L2a~L2f included in the second manipulator 211. L2a β L2b β L2c βL2d β L2e β L2f The front end of the second manipulator 211 corresponds to the angle (α) of each joint J2a~J2f in the second manipulator 211. J2a α J2b α J2c α J2d α J2e α J2f The lengths (β) of the connecting rods L2a~L2f respectively. L2a β L2b β L2c β L2d β L2e β L2f (This is used to calculate the posture part.)

[0068] Positional relationships can be represented, for example, by the displacement of the orientation of the front end of the second manipulator 211 relative to the orientation of the control point of the second robot 210. Specifically, the positional relationship is represented by the displacement of the positions in the X, Y, and Z directions (D). X2 D Y2 D Z2 ) and displacement of angles in each direction (D) θ2 , D ψ2 )express.

[0069] First, the processing device 230 uses the second posture data and the second configuration data to calculate the posture of the second robot 210 when spot welding a specific part. Next, the processing device 230 uses the calculated posture and the first configuration data to calculate the posture of the front end of the first manipulator 111 when the front end of the first end effector 112 is positioned at the part to be spot welded. The processing device 230 uses the calculated posture of the front end of the first manipulator 111 and the lengths (β) of each of the links L1a to L1f. L1a β L1b β L1c β L1d β L1e β L1f The angles (α) of joints J1a to J1f are calculated using inverse kinematics. J1a α J1b α J1c α J1d α J1e α J1f As described above, first posture data is generated. The first posture data includes the angles of joints J1a to J1f when information about the spot-welded portion is acquired. The processing device 230 saves the generated first posture data to the storage device 310.

[0070] The coordinates contained in the first pose data and the coordinates contained in the second pose data can be contained in different coordinate systems or in the same coordinate system. When generating the coordinates of the second pose data based on the coordinates of the first pose data, appropriate corrections can be applied according to the different coordinate systems.

[0071] Furthermore, the above calculations can be omitted when the following conditions are met: The first condition is that the lengths of links L1a to L1f of the first robotic arm 111 are the same as the lengths of links L2a to L2f of the second robotic arm 211. The second condition is that the positional relationship between the first robot 110 and the first component 10 during the first operation is the same as the positional relationship between the second robot 210 and the first component 10 during the second operation. The third condition is that the relationship between the posture of the first robot 110 and the posture of the front end of the first robotic arm 111 is the same as the relationship between the posture of the second robot 210 and the posture of the front end of the second robotic arm 211. When these conditions are met, the processing device 230 can directly generate the second posture data as the first posture data and save it in the storage device 310.

[0072] In the case where the first end effector 112 includes multiple devices, first configuration data is prepared for each device. Using the first configuration data, first posture data is generated for operation using each device.

[0073] The conveying device T includes, for example, at least one of a belt conveyor, a roller conveyor, an automated guided vehicle (AGV), and a lifting device. The conveying device T may also include multiple conveying mechanisms. For example, it may also include a conveying mechanism for transporting components to the position where the first robot 110 is located and other conveying mechanisms for transporting components to the position where the second robot 210 is located.

[0074] The operation of the conveying device T can also be controlled by the processing device 130 or 230, or by other processing devices. Alternatively, a higher-level processing device can be set up to manage the processing devices 130 and 230, and the conveying device T can be controlled through this higher-level processing device.

[0075] Figure 5 This is an example of data stored in a storage device.

[0076] Storage device 310, for example, stores Figure 5 (a) and Figure 5 The table shown in (b) is as follows. Figure 5 (a) represents the table (Table 1) containing data related to the first task. Figure 5 (b) represents the table containing data related to the second task (Table 2).

[0077] Each table contains process ID, process name, previous process ID, component ID, component name, robot ID, robot name, coordinates, and joint angles. Coordinates represent the coordinates of the robot's control points when performing the process. Joint angles represent the angles of each joint of the robot when performing the process. Figure 5 In the table shown in (a), a combination of a coordinate and a joint angle corresponds to a first pose data point. Figure 5 In the table shown in (b), a combination of a coordinate and a joint angle corresponds to a second pose data.

[0078] When generating the first pose data, the processing device 230 refers to the first table. The processing device 230 extracts the preceding process ID for each process and refers to the second table. The processing device 230 retrieves the process ID corresponding to the extracted preceding process ID from the second table and extracts the second pose data associated with that process ID. The processing device 230 generates the first pose data based on the extracted second pose data. The processing device 230 associates the generated first pose data with the process ID corresponding to the extracted preceding process ID in the first table and saves it.

[0079] When the first robot 110 performs the first task, the processing device 130 appropriately retrieves the first posture data from the storage device 310 and sends it to the control device 120. The control device 120 sets the posture of the first robot 110 based on the received first posture data, so that it performs the first task.

[0080] Figure 6 (a) and Figure 6 (b) is a flowchart illustrating the processing in the production system of the implementation method.

[0081] Figure 6 (a) indicates the processing performed before the production line starts operating. Figure 6 (b) indicates the processing performed during the operation of the production line.

[0082] like Figure 6 As shown in (a), the teaching device 320 generates design posture data for the second robot 210 to perform the second task based on the design data (step S1). Based on the design posture data, the second posture data is generated (step S2). As mentioned above, the second posture data can be generated either based on the design posture data or generated separately from the design posture data.

[0083] like Figure 6As shown in (b), the second robot 210 performs the second task in the posture shown by the second posture data (step S3). The processing device 230 generates the first posture data based on the second posture data (step S4). The first robot 110 performs the first task in the posture shown by the first posture data (step S5). Alternatively, step S4 can also be performed after step S2 before the production line starts operating.

[0084] Figure 7 It is a three-dimensional diagram showing the internal structure of the detector front end.

[0085] The operation of the robot system 100 will be described in detail. Here, an example of the robot system 100 being used as an inspection system for inspecting spot-welded welded parts will be described.

[0086] An internal structure is provided at the front end of detector 112a. Figure 7 The matrix sensor 401 is shown. The matrix sensor 401 includes multiple ultrasonic sensors 402. Each ultrasonic sensor 402 is, for example, a transducer. The multiple ultrasonic sensors 402 are arranged along two intersecting directions (X-direction and Y-direction). In this example, the X-direction and Y-direction are orthogonal. Furthermore, the X-direction and Y-direction of the arrangement of the multiple ultrasonic sensors 402 may or may not correspond to the X-direction and Y-direction of a coordinate system representing the position of the control point.

[0087] Figure 7 This indicates the inspection of the first component 10. The first component 10 is manufactured by spot welding steel plates 11 and 12 at a welding section 13. At the welding section 13, a solidified section 14 is formed by melting and mixing a portion of steel plate 11 and a portion of steel plate 12 and solidifying. Each ultrasonic sensor 402 sends ultrasonic waves US to the first component 10, which is coated with coupling agent 15, and detects (receives) the reflected waves RW from the first component 10.

[0088] As a more specific example, such as Figure 7 As shown, an ultrasonic sensor 402 sends an ultrasonic wave US to the weld 13. A portion of the ultrasonic wave US is reflected from the upper or lower surface of the first component 10. Multiple ultrasonic sensors 402 detect the reflected wave RW respectively. Each ultrasonic sensor 402 sequentially sends an ultrasonic wave US, and each reflected wave RW is detected by the multiple ultrasonic sensors 402.

[0089] When each ultrasonic sensor 402 detects a reflected wave, it sends a signal (current) to the control device 120. The signal strength corresponds to the strength of the reflected wave. The control device 120 sends data representing the received signal strength to the processing device 130. The processing device 130 inspects the weld 13 based on the received data.

[0090] Figure 8 This is a schematic diagram used to illustrate the inspection method.

[0091] like Figure 8 As shown in (a), a portion of the ultrasonic wave US is reflected on the upper surface 10a of the steel plate 11 or the upper surface 10b of the weld 13. Another portion of the ultrasonic wave US is incident on the first member 10 and reflected on the lower surface 10c of the steel plate 11 or the lower surface 10d of the weld 13.

[0092] The upper surface 10a, upper surface 10b, lower surface 10c, and lower surface 10d are positioned differently in the Z direction. That is, the distances in the Z direction between these surfaces and the ultrasonic sensor 402 are different. When the ultrasonic sensor 402 receives reflected waves from these surfaces, it detects the peak values ​​of the reflected wave intensity. After transmitting the ultrasonic wave US, by calculating the time until each peak value is detected, it is possible to investigate which surface the ultrasonic wave US is reflected from.

[0093] Figure 8 (b) and Figure 8 (c) is a graph illustrating the relationship between the time after the transmission of the ultrasonic wave US and the intensity of the reflected wave RW. Here, the intensity of the reflected wave RW is expressed in absolute value. Figure 8 The graph in (b) illustrates the reception results of the reflected wave RW from the upper surface 10a and lower surface 10c of the steel plate 11. Figure 8 The graph in (c) illustrates the reception results of the reflected wave RW from the upper surface 10b and lower surface 10d of the welded part 13.

[0094] exist Figure 8 In the curve diagram (b), the first peak Pe1 is based on the reflected wave RW from the upper surface 10a. The second peak Pe2 is based on the reflected wave RW from the lower surface 10c. The times at which peaks Pe1 and Pe2 are detected correspond to the positions of the upper surface 10a and lower surface 10c of the steel plate 11 in the Z direction, respectively. The time difference TD1 between the times at which peaks Pe1 and Pe2 are detected corresponds to the distance Di1 in the Z direction between the upper surface 10a and the lower surface 10c.

[0095] Similarly, in Figure 8 In the curve (c), the first peak Pe3 is based on the reflected wave RW from the upper surface 10b. The second peak Pe4 is based on the reflected wave RW from the lower surface 10d. The times at which peaks Pe3 and Pe4 are detected correspond to the Z-direction positions of the upper surface 10b and lower surface 10d of the welded part 13, respectively. The time difference TD2 between the times at which peaks Pe3 and Pe4 are detected corresponds to the Z-direction distance Di2 between the upper surface 10b and the lower surface 10d.

[0096] The processing device 130 checks whether points near the welded portion 13 have been welded based on the time difference between adjacent peak values. The upper surface 10b and lower surface 10d of the welded portion 13 are sometimes inclined relative to the upper surface 10a of the steel plate 11. This is based on the fact that the welded portion 13 includes a solidified portion 14, and that the shape deforms during the welding process. In this case, it is preferable to transmit ultrasonic waves US in a direction that is evenly perpendicular to the upper surface 10b or the lower surface 10d. This results in stronger reflection of ultrasonic waves on the upper surface 10b and the lower surface 10d, improving the accuracy of the inspection.

[0097] Figure 9 This is a flowchart representing a specific example of the first assignment.

[0098] First, the control device 120 refers to first posture data indicating the posture of the first robot 110 when applying coupling agent using the application device 112b. The control device 120 sets the posture of the first robot 110 based on this first posture data (step S41). The control device 120 applies coupling agent to the first component 10 from the application device 112b (step S42). The control device 120 refers to the first posture data indicating the posture of the first robot 110 when acquiring information using the detector 112a. The control device 120 sets the posture of the first robot 110 based on this first posture data (step S43). The control device 120 uses the detector 112a to acquire information about the spot-welded portion (step S44).

[0099] The control device 120 sends the acquired information to the processing device 130. The processing device 130 processes the information and calculates the tilt angle of the detector 112a relative to the first component 10 (step S45). The processing device 130 determines whether the tilt angle is less than a predetermined threshold (step S46). If the tilt angle is greater than the threshold, the control device 120 adjusts the posture of the first robot 110 to reduce the tilt angle (step S47). After the posture adjustment, step S44 is executed again.

[0100] When the tilt angle is less than a threshold, the processing device 130 uses the information obtained in the previous step S44 to inspect the weld (step S48). Specifically, at the weld, it is determined whether the first component 10 has been properly welded. For example, the processing device 130 stores the inspection result in the storage device 310.

[0101] The following is a specific example illustrating the method for calculating the inclination.

[0102] Figure 10 This is a diagram illustrating how the tilt angle of the detector is calculated.

[0103] Figure 11 and Figure 12This is an example of an image representing the detected information.

[0104] Figure 11 It is a three-dimensional volume data depicted based on the detection results of reflected waves. Figure 12 (a) represents Figure 11 The surface of the welded part 13 in the body data shown. Figure 12 (b) indicates Figure 11 The YZ section near weld 13 in the volume data shown. Figure 12 (c) represents Figure 11 The XZ section near weld 13 in the volume data shown. Figure 12 (b) and Figure 12 In (c), the upper side is the surface of the welded part 13, and the data in the depth direction is shown downwards. The brighter parts are those with high ultrasonic wave reflection intensity. Ultrasonic waves are strongly reflected at the bottom surface of the welded part 13, the surfaces between unjoined components, etc.

[0105] The tilt of detector 112a corresponds to Figure 10 The angle shown is between direction D1, which is perpendicular to the weld 13, and direction D2, which is perpendicular to the detector 112a. This angle is represented by the angle θx around the X direction and the angle θy around the Y direction. Direction D2 is perpendicular to the arrangement direction of the ultrasonic sensors 402.

[0106] Angle θx Figure 12 As shown in (b), the angle θy is calculated based on the detection results in the YZ profile. Figure 12 As shown in (c), the calculation is based on the detection results in the XZ profile. For each profile, the processing device 130 calculates the average of the three-dimensional brightness gradient as angles θx and θy. The processing device 130 stores the calculated angles θx and θy as the tilt of the detector 112a in the storage device 310.

[0107] Figure 13 This is a diagram showing an example of the structure of the processing device and the control device.

[0108] For example, such as Figure 13 As shown, each of the control device 120, processing device 130, control device 220, and processing device 230 includes a central processing unit (CPU) 501, a main memory 502, a non-volatile memory 503, an I / O interface 504, and a bus 505.

[0109] Bus 505 connects CPU 501, main memory 502, non-volatile memory 503 and I / O interface 504 to each other.

[0110] Main memory 502 can be accessed at a higher speed than non-volatile memory 503. Main memory 502 includes, for example, random access memory (RAM). Non-volatile memory 503 serves as a storage area for various types of data. Non-volatile memory 503 includes, for example, read-only memory (ROM), flash memory, optical disk, magnetic disk, removable memory device, or combinations thereof. I / O interface 504 is an interface device for connecting to other devices.

[0111] The non-volatile memory 503 stores the programs required for processing in the control unit 120, processing unit 130, control unit 220, or processing unit 230. For example, the control unit 120 or 220 stores firmware programs and robot programs for causing the first robot 110 or the second robot 210 to move. The robot program describes the sequence of actions for each robot. For example, in the control unit 120 or 220, the CPU 501 loads the firmware program from the non-volatile memory 503 into the main memory 502. The CPU 501 executes the robot program based on the loaded firmware program. The CPU 501 interprets the robot program and calculates drive instructions for each drive unit of the first robot 110 or the second robot 210 based on the results. The calculated drive instructions are sent to each robot via the I / O interface 504.

[0112] Each of the control device 120, processing device 130, control device 220, and processing device 230 may also have Figure 13 The structure shown has Figure 13 The device shown in the diagram can also function as two or more devices selected from control device 120, processing device 130, control device 220, and processing device 230. For example, a control device can function as control devices 120 and 220. A processing device can function as processing devices 130 and 230.

[0113] Figure 13 The structure shown can also be applied to the teaching device 320.

[0114] By using the control method executed by the control device 120, robot system 100, inspection system, production system 300, or control device 120 as described above, the time required for a human to teach the first robot can be shortened. The same effect can be achieved by using a program that causes the robot system's control device to execute the aforementioned control method.

[0115] The processing of the various data described above can also be recorded as programs that can be executed by a computer on a disk (floppy disk and hard disk, etc.), optical disk (CD-ROM, CD-R, CD-RW, DVD-ROM, DVD±R, DVD±RW, etc.), semiconductor memory or other recording media.

[0116] For example, data recorded on a recording medium can be read by a computer (or embedded system). The recording format (storage format) on the recording medium is arbitrary. For example, a computer reads a program from the recording medium, and based on that program, causes the CPU to execute the instructions described in the program. In a computer, program retrieval (or reading) can also be performed via a network.

[0117] The above embodiments of the present invention have been illustrated, but these embodiments are merely examples and are not intended to limit the scope of the invention. These new embodiments can be implemented in various other ways, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments or variations thereof are included in the scope or spirit of the invention, and are included within the scope of the invention as described in the claims and their equivalents. The above embodiments can be combined with each other for implementation.

Claims

1. A control device that receives first posture data representing the posture of a first robot including a first manipulator and a first end effector, and sets the posture of the first robot based on the first posture data to cause the first robot to perform a first task relative to a first component. In this control device, The first posture data is generated based on the second posture data, which represents the posture of the second robot, including the second manipulator and the second end effector, when performing the second task on the first component. The first component is transported after the second operation of the second robot, and the first robot performs the first operation on the transported first component. In the generation of the first pose data, the second pose data is corrected accordingly to the difference between the coordinate system of the first pose data and the coordinate system of the second pose data. The position where the first end effector of the first robot, whose posture was set based on the first posture data, contacts the first component during the first operation; and the position where the second end effector of the second robot, whose posture was set based on the second posture data, contacts the first component during the second operation. The first end effector includes a detector equipped with ultrasonic sensors, wherein the ultrasonic sensors are arranged along a first direction and a second direction that intersect each other. The second end effector includes a welding device for performing welding. In the first operation, the first robot uses the detector to obtain information about the welded parts. The information includes the intensity of the reflected ultrasonic waves from the welded portion. The information is used to calculate the gradient of the three-dimensional reflected wave intensity. The tilt angle of the detector relative to a direction perpendicular to the weld is calculated using the average of the gradient, the tilt angle including tilt angle about the first direction and tilt angle about the second direction. The tilt angle is compared with a threshold. If the tilt angle is greater than the threshold, the posture of the first robot is adjusted to reduce the tilt angle.

2. The control device according to claim 1, wherein, Receive multiple sets of the first pose data, The posture of the first robot is sequentially set based on the plurality of first posture data. The first robot performs the first task in each of the aforementioned postures.

3. The control device according to claim 2, wherein, The plurality of first pose data are generated based on the plurality of second pose data respectively. A portion of the plurality of second posture data is generated based on design posture data generated according to the design data of the first component. Another portion of the plurality of second pose data is generated based on teaching the second robot.

4. The control device according to claim 1, wherein, The first pose data is generated using the second pose data, the first construction data, and the second construction data. The first construction data represents the construction of the first manipulator and the relationship between the posture of the front end of the first manipulator and the posture of the first robot. The second construction data represents the construction of the second manipulator and the relationship between the posture of the front end of the second manipulator and the posture of the second robot.

5. The control device according to any one of claims 1 to 4, wherein, The welding device of the second end effector performs spot welding. In the first operation, the first robot uses the detector to obtain information about the spot-welded welded parts.

6. An inspection system comprising: The control device according to any one of claims 1 to 4; and Processing device, The processing device uses the information to perform an inspection of the weld or to calculate the tilt of the detector relative to the weld.

7. The inspection system according to claim 6, wherein, It also has the first robot.

8. A control method comprising receiving first posture data representing the posture of a first robot including a first manipulator and a first end effector, and setting the posture of the first robot based on the first posture data to cause the first robot to perform a first task relative to a first component. In this control method, The first posture data is generated based on the second posture data, which represents the posture of the second robot, including the second manipulator and the second end effector, when performing the second task on the first component. The first component is transported after the second operation of the second robot, and the first robot performs the first operation on the transported first component. In the generation of the first pose data, the second pose data is corrected accordingly to the difference between the coordinate system of the first pose data and the coordinate system of the second pose data. The position where the first end effector of the first robot, whose posture was set based on the first posture data, contacts the first component during the first operation; and the position where the second end effector of the second robot, whose posture was set based on the second posture data, contacts the first component during the second operation. The first end effector includes a detector equipped with ultrasonic sensors, wherein the ultrasonic sensors are arranged along a first direction and a second direction that intersect each other. The second end effector includes a welding device for performing welding. In the first operation, the first robot uses the detector to obtain information about the welded parts. The information includes the intensity of the reflected ultrasonic waves from the welded portion. The information is used to calculate the gradient of the three-dimensional reflected wave intensity. The tilt angle of the detector relative to a direction perpendicular to the weld is calculated using the average of the gradient, the tilt angle including tilt angle about the first direction and tilt angle about the second direction. The tilt angle is compared with a threshold. If the tilt angle is greater than the threshold, the posture of the first robot is adjusted to reduce the tilt angle.

9. The control method according to claim 8, wherein, The welding device of the second end effector performs spot welding. In the first operation, the first robot uses the detector to obtain information about the spot-welded welded parts.

10. A storage medium storing a program, The program enables a computer to function as a control device, which receives first posture data representing the posture of a first robot including a first manipulator and a first end effector, and sets the posture of the first robot based on the first posture data, causing the first robot to perform a first task relative to a first component. In this program, The first posture data is generated based on the second posture data, which represents the posture of the second robot, including the second manipulator and the second end effector, when performing the second task on the first component. The first component is transported after the second operation of the second robot, and the first robot performs the first operation on the transported first component. In the generation of the first pose data, the second pose data is corrected accordingly to the difference between the coordinate system of the first pose data and the coordinate system of the second pose data. The position where the first end effector of the first robot, whose posture was set based on the first posture data, contacts the first component during the first operation; and the position where the second end effector of the second robot, whose posture was set based on the second posture data, contacts the first component during the second operation. The first end effector includes a detector equipped with ultrasonic sensors, wherein the ultrasonic sensors are arranged along a first direction and a second direction that intersect each other. The second end effector includes a welding device for performing welding. In the first operation, the control device enables the first robot to use the detector to acquire information about the welded portion. The information includes the intensity of the reflected ultrasonic waves from the welded portion. The control device uses the information to calculate the gradient of the three-dimensional reflected wave intensity. The tilt angle of the detector relative to a direction perpendicular to the weld is calculated using the average of the gradient, the tilt angle including tilt angle about the first direction and tilt angle about the second direction. The tilt angle is compared with a threshold. If the tilt angle is greater than the threshold, the posture of the first robot is adjusted to reduce the tilt angle.

11. The storage medium according to claim 10, wherein, The welding device of the second end effector performs spot welding. In the first operation, the control device enables the first robot to use the detector to obtain information about the spot-welded welded parts.

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