Reinforcement binding robot

Abstract

To provide a technology capable of controlling an operation of a reinforcement binding robot depending on a state of a reinforcement binding device.SOLUTION: A reinforcement binding robot can repeat, with respect to a plurality of first reinforcements and a plurality of second reinforcements intersecting with the plurality of first reinforcements, an operation of moving over the plurality of first reinforcements and the plurality of second reinforcements and an operation of binding reinforcement intersection points where the plurality of first reinforcements and the plurality of second reinforcements intersect. The reinforcement binding robot comprises: a robot control unit controlling the operation of the reinforcement binding robot; and a reinforcement binding device performing reinforcement binding work using wires. The reinforcement binding device includes a device control unit controlling the operation of the reinforcement binding device. The device control unit is configured to send a first signal to the robot control unit. The robot control unit is configured to control the operation of the reinforcement binding robot based on the first signal sent from the device control unit.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The technology disclosed in this specification relates to a rebar tying robot. [Background technology]

[0002] Patent Document 1 discloses a rebar tying robot that can repeatedly perform the following operations: moving over a plurality of first rebars and a plurality of second rebars that intersect with the plurality of first rebars; and tying the rebar intersections where the plurality of first rebars intersect with the plurality of second rebars. The rebar tying robot includes a robot control unit that controls the operation of the rebar tying robot and a rebar tying device that performs rebar tying work using a wire. The robot control unit is configured to send a trigger signal to the rebar tying device. The rebar tying device is configured to perform the rebar tying work in response to the trigger signal. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2019-39174 Summary of the Invention [Problem to be solved by the invention]

[0004] With a rebar bundling robot, there are cases where it is desirable to control the operation of the rebar bundling robot depending on the state of the rebar bundling device, such as stopping the operation of the rebar bundling robot depending on the state of the rebar bundling device. However, with the rebar bundling robot of Patent Document 1, the robot control unit cannot grasp the state of the rebar bundling device (for example, whether there is a wire shortage or an operational malfunction). Therefore, it is not possible to control the operation of the rebar bundling robot depending on the state of the rebar bundling device. This specification provides a technology that makes it possible to control the operation of the rebar bundling robot depending on the state of the rebar bundling device. [Means for solving the problem]

[0005] The rebar tying robot disclosed in this specification can repeatedly perform the following operations: moving over a plurality of first rebars and a plurality of second rebars that intersect with the plurality of first rebars; and tying rebar intersections where the plurality of first rebars intersect with the plurality of second rebars. The rebar tying robot includes a robot control unit that controls the operation of the rebar tying robot and a rebar tying device that performs rebar tying work using a wire. The rebar tying device includes an equipment control unit that controls the operation of the rebar tying device. The equipment control unit is configured to send a first signal to the robot control unit. The robot control unit is configured to control the operation of the rebar tying robot based on the first signal sent from the equipment control unit. Note that in this specification, "the work of tying rebar intersections where a plurality of first rebars and a plurality of second rebars intersect" may be referred to as "rebar tying work."

[0006] According to the above configuration, the device control unit can transmit the state of the rebar tying device to the robot control unit through the first signal. The robot control unit can grasp the state of the rebar tying device based on the first signal. Therefore, the robot control unit can control the operation of the rebar tying robot according to the state of the rebar tying device. [Brief explanation of the drawings]

[0007] [Figure 1] 1 is a diagram showing a reinforcing bar binding robot 1 according to an embodiment as viewed from above. [Figure 2] 1 is a perspective view of a reinforcing bar binding robot 1 according to an embodiment, viewed from the front right below. [Figure 3] 1 is a perspective view of a reinforcing bar binding device 2 according to an embodiment, viewed from above and behind the left. [Figure 4] 1 is a perspective view of the internal structure of a reinforcing bar binding device 2 according to an embodiment, seen from above and to the right of the rear. [Figure 5] 1 is a perspective view of the internal structure of a reinforcing bar binding device 2 according to an embodiment, viewed from above on the front left. [Figure 6] 3 is a cross-sectional view of a reel holding mechanism 36 of the reinforcing bar binding device 2 according to the embodiment. FIG. [Figure 7] 1 is a perspective view of a release lever 82 and a lock lever 86 of a reinforcing bar binding device 2 according to an embodiment, as viewed from the upper left front. [Figure 8] 1 is a perspective view of an upper curl guide 90 of a reinforcing bar binding device 2 according to an embodiment, viewed from the upper left rear. [Figure 9] 1 is a perspective view of an upper curl guide 90 of a reinforcing bar binding device 2 according to an embodiment, viewed from the upper right rear. [Figure 10] 1 is a perspective view of the internal structure of a first guide passage 94 of an upper curl guide 90 of a reinforcing bar binding device 2 according to an embodiment, viewed from the upper left rear. [Figure 11] 10 is a perspective view of the internal structure of the second guide passage 96 of the upper curl guide 90 of the reinforcing bar binding device 2 according to the embodiment, as seen from the upper left rear. FIG. [Figure 12] 1 is a perspective view of the internal structure of the reinforcing bar binding device 2 according to the embodiment when the lower curl guide 92 is closed, as seen from the lower right front. [Figure 13] 1 is a perspective view of the internal structure of the reinforcing bar binding device 2 according to the embodiment when the lower curl guide 92 is open, as seen from the lower front right side. [Figure 14]10 is a perspective view of the wire reel WR and the brake mechanism 40 seen from the upper right rear when the pull solenoid 146 is not energized in the reinforcing bar binding device 2 according to the embodiment. FIG. [Figure 15] 10 is a perspective view of the wire reel WR and the brake mechanism 40 seen from the upper right rear when the pull solenoid 146 is energized in the reinforcing bar binding device 2 according to the embodiment. FIG. [Figure 16] FIG. 2 is a block diagram showing an example of an electrical system of a device control unit 50 according to the embodiment. [Figure 17] 10 is a flowchart showing an example of device main processing executed by a device control unit 50 according to the embodiment. [Figure 18] 10 is a flowchart showing an example of a feeding operation state determination process executed by the device control unit 50 according to the embodiment. [Figure 19] 10 is a flowchart showing an example of a plate state determination process executed by the device control unit 50 according to the embodiment. [Figure 20] 10 is a flowchart illustrating an example of a supply voltage state determination process executed by the device control unit 50 according to the embodiment. [Figure 21] 10 is a flowchart showing an example of a temperature state determination process executed by a device control unit 50 according to the embodiment. [Figure 22] 10 is a flowchart showing an example of a twisting operation state determination process executed by a device control unit 50 according to the embodiment. [Figure 23] 10 is a flowchart illustrating an example of a hardware state determination process executed by a device control unit 50 according to the embodiment. [Figure 24] 1 is a perspective view of a side stepper 196 of a reinforcing bar binding robot 1 according to an embodiment, viewed from above and to the rear right. FIG. [Figure 25] 10 is a cross-sectional view of the front crank mechanism 276 of the reinforcing bar binding robot 1 according to the embodiment, as seen from behind. FIG. [Figure 26] 1 is a perspective view of the rear portion of a side stepper 196 of a reinforcing bar binding robot 1 according to an embodiment, viewed from above on the front right. [Figure 27]1 is a front view of the reinforcing bar binding robot 1 according to the embodiment, showing the state in which the step bars 272, 274 are raised. [Figure 28] FIG. 2 is a front view of the reinforcing bar binding robot 1 according to the embodiment, showing the state in which the step bars 272, 274 are lowered. [Figure 29] 1 is a perspective view of the internal structure of a power transmission mechanism 402 in a reinforcing bar binding robot 1 according to an embodiment, as viewed from the front upper right. [Figure 30] 10 is a perspective view of the lifting device 6 seen from above and in front when the slider crank mechanism 638 is at the top dead center position in the rebar binding robot 1 according to the embodiment. FIG. [Figure 31] 10 is a perspective view of the lifting device 6 seen from above and in front when the slider crank mechanism 638 is at the bottom dead center position in the rebar binding robot 1 according to the embodiment. FIG. [Figure 32] 10 is a diagram showing the positional relationship between a cam 666, a first photosensor 668, and a second photosensor 670 provided in the lifting device 6 in the rebar binding robot 1 according to the embodiment. FIG. [Figure 33] 5 is a flowchart showing an example of a robot main process executed by the robot control unit 10 according to the embodiment. [Figure 34] 1A to 1C are top views showing an example of the operation of the reinforcing bar binding robot 1 according to the embodiment. [Figure 35] 10 is a top view showing another example of the operation of the reinforcing bar binding robot 1 according to the embodiment. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0008] Representative, non-limiting examples of the present invention are described in detail below with reference to the drawings. This detailed description is intended simply to provide those skilled in the art with details for implementing preferred examples of the present invention, and is not intended to limit the scope of the present invention. Additionally, the additional features and inventions disclosed can be used separately or in conjunction with other features and inventions to provide further improved rebar tying robots.

[0009] Furthermore, the combinations of features and steps disclosed in the following detailed description are not essential to practicing the invention in its broadest sense, but are described solely to specifically illustrate exemplary embodiments of the invention. Furthermore, the various features of the following exemplary embodiments and those described in the claims do not necessarily have to be combined in the exact embodiments described herein or in the exact order listed to provide additional and useful embodiments of the invention.

[0010] All features described in this specification and / or claims are intended to be disclosed individually and independently of one another as limitations to the specific features described in the original disclosure and claims, apart from the configuration of features described in the examples and / or claims. Furthermore, all numerical ranges and group or aggregate descriptions are intended to disclose intermediate configurations thereof as limitations to the specific features described in the original disclosure and claims.

[0011] In a first aspect of the present technology, a rebar tying robot is capable of repeatedly performing the following operations for a plurality of first rebars and a plurality of second rebars that intersect with the plurality of first rebars: moving over the plurality of first rebars and the plurality of second rebars; and tying rebar intersections where the plurality of first rebars and the plurality of second rebars intersect. The rebar tying robot may include a robot control unit that controls the operation of the rebar tying robot, and a rebar tying device that performs rebar tying work using a wire. The rebar tying device may include an equipment control unit that controls the operation of the rebar tying device. The equipment control unit may be configured to send a first signal to the robot control unit. The robot control unit may be configured to control the operation of the rebar tying robot based on the first signal sent from the equipment control unit.

[0012] According to the above configuration, the device control unit can transmit the state of the rebar tying device to the robot control unit through the first signal. The robot control unit can grasp the state of the rebar tying device based on the first signal. Therefore, the robot control unit can control the operation of the rebar tying robot according to the state of the rebar tying device.

[0013] In a second aspect, the reinforcing bar binding device in the first aspect may be configured to be able to execute the operation of feeding the wire. The reinforcing bar binding device may further include a first state detection unit that detects a state related to the operation of feeding the wire. The first signal may include information related to the detection result of the first state detection unit. Note that the "state related to the operation of feeding the wire" here includes not only the state of the feeding mechanism, but also the presence or absence of the wire and the state of the braking mechanism described below.

[0014] The wire feeding operation is a main operation of the rebar binding device. Therefore, there are cases where the robot control unit needs to know the status of the wire feeding operation of the rebar binding device. With the above configuration, the robot control unit can know the status of the wire feeding operation based on the first signal.

[0015] In a third aspect, in the second aspect, the first state detection unit may include a wire detection unit that detects the presence or absence of the wire, and the first signal may include information regarding a detection result of the wire detection unit.

[0016] If the rebar tying device runs out of wire, the device will be unable to perform the rebar tying work. In order to control the operation of the rebar tying robot in response to such a situation, the robot control unit needs to know whether or not there is wire. With the above configuration, the robot control unit can know whether or not there is wire based on the first signal.

[0017] In a fourth aspect, the reinforcing bar binding device of the third aspect may further include a wire reel on which the wire is wound and a housing that rotatably holds the wire reel. The wire detection unit may detect the presence or absence of the wire wound on the wire reel.

[0018] According to the above configuration, when the wire is wound around the wire reel, the wire reel rotates in accordance with the operation of feeding the wire of the rebar binding device. When the wire wound around the wire reel runs out, the wire reel stops rotating in accordance with the operation of feeding the wire of the rebar binding device. Therefore, the wire detection unit can indirectly detect the presence or absence of the wire by detecting whether the wire reel rotates in accordance with the operation of feeding the wire of the rebar binding device.

[0019] In a fifth aspect, in any one of the second to fourth aspects, the rebar binding device may further include a feed motor and a feed mechanism capable of feeding the wire. The first state detection unit may include a feed mechanism state detection unit that detects the state of the feed mechanism. The first signal may include information regarding the detection result of the feed mechanism state detection unit.

[0020] For example, there are cases where the wires in the feeding mechanism become tangled, rendering the feeding mechanism inoperable. To control the operation of the rebar binding robot in response to such a situation, the robot control unit needs to grasp the state of the feeding mechanism (for example, whether the feeding mechanism is operating smoothly, etc.). With the above configuration, the robot control unit can grasp the state of the feeding mechanism based on the first signal.

[0021] In a sixth aspect, in any one of the second to fifth aspects, the reinforcing bar binding device may further include a wire reel on which the wire is wound, a housing that rotatably holds the wire reel, and a braking mechanism that includes a braking actuator and is capable of braking the rotational movement of the wire reel. The first state detection unit may include a braking mechanism state detection unit that detects the state of the braking mechanism. The first signal may include information regarding the detection result of the braking mechanism state detection unit.

[0022] For example, the braking mechanism may become inoperable due to an electrical disconnection between the power supply and the braking actuator. In order to control the operation of the rebar binding robot in response to such a situation, the robot control unit needs to grasp the state of the braking mechanism (e.g., whether the electrical connection between the power supply and the braking actuator is secure). With the above configuration, the robot control unit can grasp the state of the braking mechanism based on the first signal.

[0023] In a seventh aspect, in any one of the first to sixth aspects, the reinforcing bar binding device may be configured to be able to perform an operation of twisting the wire wound around the reinforcing bar intersection. The reinforcing bar binding device may further include a second state detection unit that detects a state related to the operation of twisting the wire. The first signal may include information related to the detection result of the second state detection unit.

[0024] The wire twisting operation is a main operation of the rebar binding device. Therefore, the robot control unit may need to grasp the status of the wire twisting operation of the rebar binding device. With the above configuration, the robot control unit can grasp the status of the wire twisting operation based on the first signal.

[0025] In an eighth aspect, the reinforcing bar binding device of the seventh aspect may further include a twisting mechanism that includes a twisting motor and is capable of twisting the wire wound around the reinforcing bar intersection. The second state detection unit may include a twisting mechanism state detection unit that detects the state of the twisting mechanism. The first signal may include information regarding the detection result of the twisting mechanism state detection unit.

[0026] For example, there are cases where the twisting mechanism becomes inoperable due to wires getting tangled in the twisting mechanism. In order to control the operation of the rebar binding robot in accordance with such a situation, the robot control unit needs to grasp the state of the twisting mechanism (e.g., whether the twisting mechanism is operating smoothly, etc.). With the above configuration, the robot control unit can grasp the state of the twisting mechanism (e.g., whether the twisting mechanism is operating smoothly, etc.) based on the first signal.

[0027] In a ninth aspect, in any one of the first to eighth aspects, the reinforcing bar binding device may further include a wire reel around which the wire is wound or which guides the wire, a reel holding unit that detachably holds the wire reel, and a reel detection unit that detects whether the wire reel is held by the reel holding unit. The first signal may include information regarding a detection result of the reel detection unit.

[0028] When the reel holding portion does not hold a wire reel, this is essentially equivalent to a wire shortage, and the rebar binding device cannot perform rebar binding work. In order to control the operation of the rebar binding robot in accordance with this situation, the robot control unit needs to determine whether or not a wire reel is held in the reel holding portion. With the above configuration, the robot control unit can determine whether or not a wire reel is held in the reel holding portion based on the first signal.

[0029] In a tenth aspect, in any one of the first to ninth aspects, the reinforcing bar binding device may further include a feed mechanism having a feed motor and capable of feeding the wire, a housing accommodating the feed motor, a guide member attached to the housing and movable between a first position where the wire fed by the feed mechanism is guided onto a substantially annular guide track and wound around the reinforcing bar intersection, and a second position where the guide member is moved outward from the first position, and a guide member position detector for detecting the position of the guide member relative to the housing. The first signal may include information regarding the detection result of the guide member position detector.

[0030] In a rebar tying device, a guide member may be provided that is movable relative to the housing to improve the maintenance performance of parts installed around the guide track. However, if rebar tying work is performed with the guide member moved to the second position, it is not possible to properly tie the rebar intersections. For this reason, in a rebar tying robot, it may be necessary to perform control (e.g., switching between allowing and prohibiting rebar tying work) according to the position of the guide member. In this case, the robot control unit needs to know the position of the guide member relative to the housing. With the above configuration, the robot control unit can know the position of the guide member relative to the housing based on the first signal.

[0031] In an eleventh aspect, in any one of the first to tenth aspects, the reinforcing bar binding device may further include a temperature detection unit that detects the temperature of the device control unit. The first signal may include information regarding the detection result of the temperature detection unit.

[0032] If the temperature of the device control unit becomes too high, it may lead to a malfunction of the device control unit. For this reason, the rebar tying robot may want to perform control according to the temperature of the device control unit (for example, suspending the rebar tying work when the temperature of the device control unit becomes too high). In this case, the robot control unit needs to know the temperature of the device control unit. With the above configuration, the robot control unit can know the temperature of the device control unit based on the first signal.

[0033] In a twelfth aspect, in any one of the first to eleventh aspects, the rebar tying robot may further include a power supply device for supplying power to the rebar tying device. The rebar tying device may further include a supply voltage detection unit that detects a voltage value of power supplied from the power supply device to the rebar tying device. The first signal may include information regarding a detection result of the supply voltage detection unit.

[0034] If the voltage value of the power supplied from the power supply device to the rebar binding device drops and becomes insufficient, there is a possibility that the rebar binding work will be forcibly interrupted due to insufficient power. For this reason, in the rebar binding robot, it may be desirable to perform control according to the voltage value of the power supplied to the device control unit (for example, to notify the user when the voltage value drops and becomes insufficient). In this case, the robot control unit needs to know the voltage value of the power supplied from the power supply device to the rebar binding device. With the above configuration, the robot control unit can know the voltage value of the power supplied from the power supply device to the rebar binding device based on the first signal.

[0035] In a thirteenth aspect, in any one of the first to twelfth aspects, the reinforcing bar binding device may further include a contact member arranged at a position where it can contact the first reinforcing bar or the second reinforcing bar during the reinforcing bar binding work, a housing that swingably holds the contact member, and a contact member position detection unit that detects the position of the contact member relative to the housing. The first signal may include information related to the detection result of the contact member position detection unit.

[0036] In order to reliably perform rebar tying work, the robot control unit may want to detect that the rebar tying device has been set at a rebar intersection. With the above configuration, the robot control unit can detect that the rebar tying device has been set at a rebar intersection by determining whether the contact member has been swung based on the first signal.

[0037] In a fourteenth aspect, in any one of the first to thirteenth aspects, the first signal may include information indicating that an abnormality has occurred in the reinforcing bar binding device.

[0038] According to the above configuration, the robot control unit can recognize that an abnormality has occurred in the reinforcing bar binding device based on the first signal. Therefore, the robot control unit can stop the operation of the reinforcing bar binding robot in response to the occurrence of an abnormality in the reinforcing bar binding device, or notify the user of that fact.

[0039] In a fifteenth aspect, in any one of the first to fourteenth aspects, the robot control unit may be configured to transmit a call signal to the device control unit, and the device control unit may be configured to transmit the first signal to the robot control unit upon receiving the call signal.

[0040] According to the above configuration, the device control unit does not need to execute a process for identifying the timing of transmitting the first signal. Therefore, the device control unit can have a simple configuration. Furthermore, according to the above configuration, the robot control unit can grasp the state of the reinforcing bar binding device at a desired timing.

[0041] In a sixteenth aspect, in any one of the first to fifteenth aspects, the robot control unit may be configured to transmit a bundling instruction signal to the device control unit. The device control unit may be configured to cause the rebar tying device to perform the rebar tying task upon receiving the bundling instruction signal. The robot control unit may be configured to transmit the call signal to the device control unit prior to transmitting the bundling instruction signal.

[0042] If the state of the reinforcing bar binding device can be grasped at the timing when the reinforcing bar binding work is started, the robot control unit can determine whether or not to continue the reinforcing bar binding work based on the state of the reinforcing bar binding device. According to the above configuration, the robot control unit can grasp the state of the reinforcing bar binding device at the timing when the reinforcing bar binding work is started. Therefore, the robot control unit can determine whether or not to continue the reinforcing bar binding work based on the state of the reinforcing bar binding device.

[0043] (Example) As shown in FIG. 1 , the rebar binding robot 1 of this embodiment moves over a plurality of first rebars R1 arranged parallel to one another along the horizontal direction and a plurality of second rebars R2 arranged parallel to one another along the horizontal direction, and uses a rebar binding device 2 to bind the intersections of the first rebars R1 and the second rebars R2. When viewed from above, the extension direction of the second rebars R2 is perpendicular to the extension direction of the first rebars R1. The second rebars R2 are also arranged above the first rebars R1. The first rebars R1 are arranged at intervals of, for example, 100 mm to 300 mm, and the second rebars R2 are arranged at intervals of, for example, 100 mm to 300 mm. The rebar binding robot 1 has a front-to-rear dimension of, for example, approximately 900 mm and a left-to-right dimension of, for example, approximately 600 mm.

[0044] The reinforcing bar binding robot 1 mainly includes a reinforcing bar binding device 2, a transport device 4, a lifting device 6, a power supply device 8, a robot control unit 10, an independent reel 500, and a wire relay mechanism 550.

[0045] The rebar binding robot 1 is also provided with a patrol lamp 183, a buzzer (not shown), an operation panel (not shown), and multiple rebar detection sensors (not shown). The patrol lamp 183 can alert the user to abnormalities in the rebar binding robot 1 by emitting light. The buzzer can alert the user to abnormalities in the rebar binding robot 1 by emitting sound. The operation panel is provided with a power switch (not shown) for turning on the power to the rebar binding robot 1, setting switches (not shown) for setting the number of turns of wire W around the rebar R and the torsional torque when twisting the wire W, an emergency stop button (not shown) for emergency stopping the rebar binding robot 1, and a display LED (not shown) for displaying the current settings. The multiple rebar detection sensors are, for example, time-of-flight (TOF) sensors that can acquire range image data that measures the distance to a subject for each pixel. The multiple reinforcing bar detection sensors include a reinforcing bar detection sensor provided on the front connecting frame 215 (see Figure 2), a reinforcing bar detection sensor provided on the rear connecting frame 216 (see Figure 2), and a reinforcing bar detection sensor provided in the central portion of the base plate 204.

[0046] (Configuration of robot control unit 10) The robot control unit 10 includes a CPU, memory, a communication interface, and the like. The robot control unit 10 is configured to control the operation of the transport device 4 and the lifting device 6. The robot control unit 10 can determine the relative positions of the first rebars R1 and the second rebars R2 with respect to the multiple rebar detection sensors based on range image data acquired by the multiple rebar detection sensors. For example, the memory of the robot control unit 10 stores map information (referred to herein as a "rebar map") indicating the positional relationship between the multiple first rebars R1 and the multiple second rebars R2. This allows the robot control unit 10 to determine the position of the rebar tying robot 1 with respect to the multiple first rebars R1 and the multiple second rebars R2. The robot control unit 10 can also store information related to the binding status of rebar intersections in the memory as needed. This allows the robot control unit 10 to distinguish between bound rebar intersections and unbound rebar intersections in the rebar map.

[0047] (Configuration of power supply unit 8) The power supply device 8 includes a right battery case 802, a left battery case 804, a transformer 806, and a power control board 808. Three battery packs B are detachably mounted in the right battery case 802. Two battery packs B are detachably mounted in the left battery case 804. In this specification, these five battery packs B are collectively referred to as "plurality of battery packs B." The plural battery packs B are, for example, lithium ion batteries that can be charged by a charger (not shown). The right battery case 802 is provided with a right battery remaining capacity indicator 812 that displays the remaining battery capacity of each battery pack B mounted in the right battery case 802. The left battery case 804 is provided with a left battery remaining capacity indicator 814 that displays the remaining battery capacity of each battery pack B mounted in the left battery case 804. The plural battery packs B are electrically connected to the power control board 808 via the transformer 806. The power control board 808 is electrically connected to the rebar binding device 2, the transport device 4, and the robot control unit 10. Therefore, the power supply device 8 (specifically, the power control board 808) can supply power from multiple battery packs B to the rebar binding device 2, the transport device 4, and the robot control unit 10. Note that in Figure 2 and subsequent figures, the power supply device 8 and the robot control unit 10 are not shown to simplify the explanation.

[0048] (Configuration of the independent reel 500 and the wire relay mechanism 550) The independent reel 500 is fixed to the base plate 204. The wire W used for rebar binding work is wound on the independent reel 500 in advance. In this embodiment, the maximum length of the wire W that can be wound on the independent reel 500 is within a range of 600 m to 1,000 m, for example, 800 m. The wire relay mechanism 550 includes a base 552, a guide roller 554, feed rollers 556 and 557, and an insertion member 558. The wire relay mechanism 550 is fixed to the base plate 204 via the base 552. The wire W unwound from the independent reel 500 passes through the insertion member 558, is clamped between the feed rollers 556 and 557, and is guided by the guide roller 554 toward the rebar binding device 2. The independent reel 500 can be said to be a supply source of wire W for the rebar binding robot 1.

[0049] (Configuration of rebar binding device 2) The following describes the configuration of the reinforcing bar binding device 2. Note that the front-rear direction, left-right direction, and up-down direction in the descriptions of Figures 3 to 15 do not refer to the front-rear direction, left-right direction, and up-down direction relative to the reinforcing bar binding robot 1, but rather refer to the front-rear direction, left-right direction, and up-down direction relative to the reinforcing bar binding device 2.

[0050] As shown in FIG. 3, the reinforcing bar binding device 2 binds mutually intersecting reinforcing bars R (for example, a first reinforcing bar R1 and a second reinforcing bar R2) with a wire W. The reinforcing bar binding device 2 includes a housing 12. The housing 12 includes a fitting portion 12a for fitting with a base member 654 (see FIG. 30) of the lifting device 6. As shown in FIG. 4, a through-hole 12b is provided at the rear of the housing 12 for receiving the wire W drawn out from the independent reel 500. As shown in FIG. 1, the through-hole 12b opens toward the wire relay mechanism 550.

[0051] As shown in Figures 4 and 5, the rebar binding device 2 mainly includes a reel holding mechanism 36, a feed mechanism 38, a brake mechanism 40, a guide mechanism 42, a cutting mechanism 44, a twisting mechanism 46, and a device control unit 50.

[0052] (Configuration of reel holding mechanism 36) As shown in FIG. 6, the reel holding mechanism 36 includes a cam member 54, a shaft member 56, and a compression spring 58. The cam member 54 is rotatably held by the housing 12. The shaft member 56 is biased to the right (i.e., toward the inside of the housing 12) by the compression spring 58 held in the housing 12. Normally, the biasing force of the compression spring 58 causes the shaft member 56 to move to the right (i.e., toward the inside of the housing 12) relative to the housing 12. In this state, the right end of the shaft member 56 slides relatively into the shaft receiving groove WRa of the wire reel WR. At this time, the wire reel WR is held rotatably relative to the shaft member 56. From this state, when the user moves the pivot lever 54a (see FIG. 3) of the cam member 54 from the front to the rear, the shaft member 56 moves to the left (i.e., toward the outside of the housing 12) against the biasing force of the compression spring 58, in the manner of a so-called cylindrical cam mechanism. As a result, the shaft member 56 comes out of the shaft receiving groove WRa of the wire reel WR. In this state, the user can insert or remove the wire reel WR into or from the housing 12.

[0053] The reel holding mechanism 36 further includes a rotating base 60, an inner bearing 62, an outer bearing 64, and a reel rotation detection sensor 66 (see FIG. 4). The rotating base 60 is rotatably held in the housing 12 via the inner bearing 62 and the outer bearing 64. The rotating base 60 engages with the wire reel WR so that the rotating base 60 is relatively non-rotatable. Therefore, when the wire reel WR rotates, the rotating base 60 also rotates integrally with the wire reel WR. As shown in FIG. 4, the reel rotation detection sensor 66 is fixed to the housing 12. The reel rotation detection sensor 66 is a Hall sensor equipped with a Hall IC (not shown). The reel rotation detection sensor 66 can detect the rotation of the wire reel WR from fluctuations in magnetism from multiple magnets (not shown) provided on the rotating base 60.

[0054] As described above, the reel holding mechanism 36 detachably and rotatably holds the wire reel WR. In this embodiment, the wire W pulled out from the independent reel 500 is passed through the through hole 12b, wound around the wire reel WR, and then supplied to the feeding mechanism 38. Therefore, when the wire W is fed out by the feeding mechanism 38, the wire W slides along the outer peripheral surface of the wire reel WR. At this time, sliding friction between the wire reel WR and the wire W generates a force that rotates the wire reel WR. As a result, the wire reel WR is configured to rotate as the wire W is fed out.

[0055] (Configuration of the feeding mechanism 38) As shown in FIG. 4, the feed mechanism 38 feeds the wire W supplied from the wire reel WR of the reel holding mechanism 36 to the guide mechanism 42 at the front of the rebar binding device 2. The feed mechanism 38 includes a guide member 68, a feed motor 72, a driving gear 78, a driven gear 80, a release lever 82, a compression spring 84 (see FIG. 7), and a lock lever 86. The wire W passes through the guide member 68 and is clamped between the driving gear 78 and the driven gear 80. The driving gear 78 is connected to the feed motor 72 via a reduction mechanism (not shown). The feed motor 72 is a DC brushed motor.

[0056] As shown in FIG. 7 , a V-shaped groove 78a extending radially is formed in the center of the height direction on the side surface of the drive gear 78. A V-shaped groove 80a extending radially is formed in the center of the height direction on the side surface of the driven gear 80. The driven gear 80 is rotatably supported by a gear arm 82a of a release lever 82. The release lever 82 is a substantially L-shaped member including a gear arm 82a and an operating arm 82b. The release lever 82 is swingably supported on the housing 12 via a swing shaft 82c. The operating arm 82b of the release lever 82 is biased leftward, i.e., outward, by a compression spring 84 held in the housing 12. Under normal circumstances, the biasing force of the compression spring 84 applies torque to the release lever 82 in a direction that moves the driven gear 80 toward the drive gear 78, pressing the driven gear 80 against the drive gear 78. As a result, teeth (not shown) on the side surface of the driven gear 80 engage with teeth (not shown) on the side surface of the drive gear 78, and the wire W is sandwiched between the V-shaped groove 78a of the drive gear 78 and the V-shaped groove 80a of the driven gear 80. In this state, when the feed motor 72 (see FIG. 4) rotates the drive gear 78, the driven gear 80 rotates in the reverse direction, and the wire W sandwiched between the drive gear 78 and the driven gear 80 is fed to the guide mechanism 42 (see FIG. 4), and the wire W is pulled out from the wire reel WR. The drive gear 78 and the driven gear 80 can be said to be feed gears that feed out the wire W. The feed mechanism 38 has a built-in gear rotation detection sensor 79 (see FIG. 16) that detects the rotation angle of the drive gear 78.

[0057] The lock lever 86 is a substantially L-shaped member that includes a lock arm 86a and a spring receiving arm (not shown). The lock lever 86 is swingably supported on the housing 12 via a swing shaft 86c. The spring receiving arm of the lock lever 86 is biased rightward by a compression spring (not shown) that is held in the housing 12. The biasing force of the compression spring applies torque to the lock lever 86 in a direction that moves the lock arm 86a toward the operating arm 82b of the release lever 82. An engaging protrusion 86d is formed on the lock arm 86a of the lock lever 86, and an engaging recess 82d that engages with the engaging protrusion 86d is formed on the operating arm 82b of the release lever 82.

[0058] When the user pushes in the operating arm 82b against the biasing force of the compression spring 84, the release lever 82 swings around the swing shaft 82c, and the driven gear 80 moves away from the drive gear 78. At this time, when the operating arm 82b is pushed in to a position where the engaging recess 82d of the operating arm 82b faces the engaging protrusion 86d of the locking arm 86a, the locking lever 86 swings around the swing shaft 86c, and the engaging protrusion 86d of the locking arm 86a engages with the engaging recess 82d of the operating arm 82b. This holds the operating arm 82b in the pushed-in state. When setting the wire W extending from the wire reel WR in the feed mechanism 38, the user pushes in the operation arm 82b to move the driven gear 80 away from the drive gear 78, and in this state, places the tip of the wire W pulled out from the wire reel WR between the drive gear 78 and the driven gear 80 through the insertion hole 68a of the guide member 68. Then, when the user swings the lock arm 86a of the lock lever 86 in a direction away from the operation arm 82b against the biasing force of the compression spring, the engagement between the engaging protrusion 86d of the lock arm 86a and the engaging recess 82d of the operation arm 82b is released, and the biasing force of the compression spring 84 causes the release lever 82 to swing around the swing shaft 82c, so that the driven gear 80 engages with the drive gear 78 and the wire W is clamped between the V-shaped groove 78a of the drive gear 78 and the V-shaped groove 80a of the driven gear 80.

[0059] (Configuration of guide mechanism 42) As shown in FIG. 5, the guide mechanism 42 is disposed at the front of the rebar binding device 2 and guides the wire W fed from the feed mechanism 38 along a substantially circular guide track (see FIG. 3). As shown in FIG. 4, the guide mechanism 42 includes a guide pipe 88, an upper curl guide 90, and a lower curl guide 92. The rear end of the guide pipe 88 opens toward the space between the drive gear 78 and the driven gear 80 of the feed mechanism 38. The wire W fed from the feed mechanism 38 is fed into the guide pipe 88. As shown in FIG. 10, the front end of the guide pipe 88 opens toward the interior of the upper curl guide 90. The upper curl guide 90 is provided with a first guide passage 94 for guiding the wire W fed from the guide pipe 88 and a second guide passage 96 (see FIG. 11) for guiding the wire W fed from the lower curl guide 92.

[0060] As shown in Figures 8 and 9, the upper curl guide 90 includes a lead holder 98, a guide arm 100, a contact plate 102, a left guide plate 104, an inner guide plate 106, a right guide plate 108, a guide member 110, and a top plate 112 (see Figure 10).

[0061] The lead holder 98 holds the guide pipe 88 (see FIG. 10 ) so that the front opening of the guide pipe 88 faces the first guide passage 94 formed by the guide member 110, the right guide plate 108, the inner guide plate 106, and the top plate 112. As shown in FIG. 10 , the guide member 110 is a metal member, and a wire passage 110a through which the wire W passes is formed therein. A first guide pin 114 is disposed below the front end of the wire passage 110a. The first guide pin 114 is a member made of a highly wear-resistant metal such as tungsten, and is press-fit into the right guide plate 108. The wire W fed out from the guide pipe 88 is guided toward the cutter 116 by the wire passage 110a and the first guide pin 114.

[0062] The cutter 116 includes a fixed member 118 and a swingable member 120. The fixed member 118 is a metallic member having a cylindrical outer shape, and has a wire passage 118a formed therein through which the wire W passes. The fixed member 118 is fitted to the inner guide plate 106 and is sandwiched between the right guide plate 108 and the inner guide plate 106. The swingable member 120 is a metallic member having a through hole 120a through which the fixed member 118 passes and a cutting piece 120b that cuts the wire W, and is swingably held by the inner guide plate 106 and the right guide plate 108 via the fixed member 118. The cutting piece 120b cuts the wire W by shearing when the swingable member 120 swings. The top plate 112 is a metallic member and is fixed to the right guide plate 108. The wire W that has passed through the cutter 116 is further guided downward by the protrusion 112a of the top plate 112 and the second guide pin 122. The second guide pin 122 is a member made of a highly wear-resistant metal such as tungsten, and is press-fit into the right guide plate 108. As the wire W passes through the first guide passage 94, it is fed toward the lower curl guide 92 while being curled by the inner upper surface of the wire passage 110a, the first guide pin 114, and the second guide pin 122.

[0063] The lower curl guide 92 is provided with a third guide passage 124 and a guard plate 126. The third guide passage 124 has a left guide wall 124a and a right guide wall 124b that guide the wire W fed from the front end of the upper curl guide 90. The guard plates 126 are formed in a shape that extends upward on both sides of the third guide passage 124, preventing multiple reinforcing bars R from interfering with the twisting mechanism 46 and preventing foreign matter from entering the interior of the reinforcing bar binding device 2. The guard plates 126 also prevent the wire W from moving wildly from side to side when the twisting mechanism 46 twists the wire W, which is wound in a substantially circular shape. The wire W guided by the lower curl guide 92 is fed toward the second guide passage 96 of the upper curl guide 90.

[0064] The wire W fed from the rear of the lower curl guide 92 to the rear of the upper curl guide 90 is fed into a second guide passage 96 formed by a guide arm 100, a left guide plate 104, and an inner guide plate 106. As shown in FIG. 11 , an arc-shaped upper guide wall 100a that guides the wire W is formed on the lower surface of the front of the guide arm 100. The wire W fed from the lower curl guide 92 to the upper curl guide 90 is guided by the second guide passage 96, and is again fed from the front of the upper curl guide 90 toward the front of the lower curl guide 92.

[0065] As shown in FIGS. 8 and 9, the contact plate 102 is a generally U-shaped member and is disposed so as to straddle the lead holder 98 and the guide arm 100. The contact plate 102 includes a contact portion 102a, a swing shaft 102b, and a connecting portion 102c. The contact plate 102 is swingably supported by the lead holder 98 via the swing shaft 102b. The connecting portion 102c of the contact plate 102 is biased upward by a compression spring 128 held by the lead holder 98. As shown in FIG. 9, the contact plate 102 includes a magnet arm 132 to which a sensor magnet 130 is attached. The sensor magnet 130 is made of a magnet with strong magnetic force, such as a neodymium magnet. As shown in FIG. 4, a plate position detection sensor 134 is attached to the housing 12. Normally, the sensor magnet 130 of the contact plate 102 is positioned facing the plate position detection sensor 134. When the reinforcing bar binding device 2 is set on a plurality of reinforcing bars R, and the plurality of reinforcing bars R are pressed against the contact portion 102a, the contact plate 102 swings against the biasing force of the compression spring 128, and the sensor magnet 130 of the magnet arm 132 is positioned away from the plate position detection sensor 134. The plate position detection sensor 134 can detect whether or not the plurality of reinforcing bars R are pressed against the contact portion 102a.

[0066] As shown in FIG. 5, the lower curl guide 92 is supported on the housing 12 via a swing shaft 92a so as to be able to swing. The lower curl guide 92 can swing between a closed state shown in FIG. 12 and an open state shown in FIG. 13. In the open state, the lower curl guide 92 swings outward relative to the guide track of the wire W. As shown in FIG. 5, the lower curl guide 92 is biased in the closing direction by a torsion spring 92b. The rebar binding device 2 is usually used with the lower curl guide 92 closed. If the wire W becomes tangled in the twisting mechanism 46, the user can remove the wire W tangled in the twisting mechanism 46 by opening the lower curl guide 92 against the biasing force of the torsion spring 92b.

[0067] As shown in Figures 12 and 13, a guide position detection mechanism 136 that detects the open / closed state of the lower curl guide 92 is provided at the front lower part of the rebar binding device 2. The guide position detection mechanism 136 is attached to the housing 12. The guide position detection mechanism 136 includes a guide position detection member 138, a compression spring 140, and a guide position detection sensor 142. The guide position detection member 138 includes a contact arm 138a and a support arm 138c. The guide position detection member 138 is swingably supported on the housing 12 via a swing shaft 138b. The guide position detection member 138 is biased in the swing direction of the contact arm 138a upward by the compression spring 140 held by the housing 12. A sensor magnet 144 (see Figure 13) is attached to the support arm 138c of the guide position detection member 138. The sensor magnet 144 is made of a magnet with strong magnetic force, such as a neodymium magnet. The guide position detection sensor 142 is fixed to the housing 12. A contact portion 92c that protrudes rearward is formed on the lower rear portion of the lower curl guide 92. As shown in FIG. 12, when the lower curl guide 92 is closed by the biasing force of the torsion spring 92b, the contact portion 92c of the lower curl guide 92 presses down on the contact arm 138a of the guide position detection member 138, and the sensor magnet 144 of the support arm 138c is positioned opposite the guide position detection sensor 142. As shown in FIG. 13, when a user opens the lower curl guide 92 against the biasing force of the torsion spring 92b, the contact portion 92c of the lower curl guide 92 moves away from the contact arm 138a of the guide position detection member 138. As a result, the biasing force of the compression spring 140 causes the guide position detection member 138 to swing, and the sensor magnet 144 of the support arm 138c is positioned away from the guide position detection sensor 142. The guide position detection sensor 142 can detect whether the lower curl guide 92 is open or closed.

[0068] 3, the upper curl guide 90 feeds the wire W downward from above and in front of the plurality of reinforcing bars R, and the lower curl guide 92 feeds the wire W fed from the upper curl guide 90 upward from below and behind the plurality of reinforcing bars R. As a result, the wire W fed from the feeding mechanism 38 is wound in a substantially circular shape around the plurality of reinforcing bars R. When the feeding mechanism 38 has fed the wire W by the feed amount of wire W set by the user, it stops the feed motor 72 and stops feeding the wire W.

[0069] (Configuration of brake mechanism 40) The brake mechanism 40 shown in FIG. 4 stops rotation of the wire reel WR in conjunction with the feed mechanism 38 stopping the payout of the wire W. As shown in FIGS. 14 and 15, the brake mechanism 40 includes a pull solenoid 146, a compression spring 148, and a brake member 150. The brake member 150 is a single member including a drive arm 150a and a brake arm 150c. The brake member 150 is swingably attached to the housing 12 via a swing shaft 150b. The drive arm 150a of the brake member 150 is connected to the output shaft of the pull solenoid 146, which moves back and forth in the vertical direction. The brake member 150 is biased by the compression spring 148 in a swing direction in which the brake arm 150c moves away from the wire reel WR. The brake arm 150c of the brake member 150 includes a wide plate portion 150d, a tip rib 150e that protrudes toward the wire reel WR from the tip of the plate portion 150d, and side end ribs 150f that protrude toward the wire reel WR from both ends of the plate portion 150d. Engagement portions WRc that engage with the tip ribs 150e of the brake arm 150c are formed on the wire reel WR at predetermined angular intervals in the circumferential direction. As shown in FIG. 14, when the pull solenoid 146 is not energized, the biasing force of the compression spring 148 causes the brake arm 150c to move away from the engagement portion WRc of the wire reel WR. In this state, the wire reel WR can rotate freely, allowing the feed mechanism 38 to pull out the wire W from the wire reel WR. As shown in Figure 15, when the pull solenoid 146 is energized, the pull solenoid 146 drives the drive arm 150a, and torque acts on the brake member 150 about the pivot shaft 150b, causing the brake member 150 to pivot about the pivot shaft 150b, and the tip rib 150e of the brake arm 150c engages with the engagement portion WRc of the wire reel WR. In this state, rotation of the wire reel WR is prohibited. This prevents the wire reel WR from continuing to rotate due to inertia even after the feed mechanism 38 has stopped feeding the wire W, which would otherwise cause the wire W to become loose between the wire reel WR and the feed mechanism 38.

[0070] In this specification, the operation of using the feed mechanism 38, the brake mechanism 40, and the guide mechanism 42 to feed out the wire W so that the wire W is wound around a plurality of reinforcing bars R may be simply referred to as the "feed operation." The feed operation is started by driving the feed motor 72 and ended by stopping the pull solenoid 146.

[0071] (Configuration of cutting mechanism 44) As shown in FIG. 5, the cutting mechanism 44 is disposed at the front of the reinforcing bar binding device 2 and cuts the wire W while it is wound around multiple reinforcing bars R. As shown in FIG. 10, the cutting mechanism 44 is unitized with the upper curl guide 90 of the guide mechanism 42. The cutting mechanism 44 includes a push plate 152, a pull plate 154, a first link arm 156, a second link arm 158, and a cutter 116. The push plate 152, the pull plate 154, and the first link arm 156 are pivotally connected to each other via a pivot shaft 160. The push plate 152 and the pull plate 154 are pivotally supported by the guide arm 100 via a pivot shaft 162. The first link arm 156 is biased forward by a torsion spring 164. The first link arm 156 and the second link arm 158 are pivotally connected to each other via a pivot shaft 166. The second link arm 158 is pivotally connected to the pivot member 120 of the cutter 116 via a pivot shaft 168.

[0072] When the lower part of the push plate 152 is pushed forward by the operation of the torsion mechanism 46, which will be described later, the first link arm 156 and the second link arm 158 move rearward, causing the swinging member 120 of the cutter 116 to swing around the fixed member 118. As a result, the wire W is cut by shearing with the cutting piece 120b of the swinging member 120 at the front end of the wire passage 118a of the fixed member 118. From this state, when the lower part of the pull plate 154 is pushed rearward by the operation of the torsion mechanism 46, the first link arm 156 and the second link arm 158 move forward, causing the swinging member 120 of the cutter 116 to swing around the fixed member 118, and the cutter 116 returns to its initial state.

[0073] (Configuration of twisting mechanism 46) 5 binds a plurality of reinforcing bars R with the wire W by twisting the wire W wound around the plurality of reinforcing bars R. The twisting mechanism 46 includes a twisting motor 170, a speed reducing mechanism 172, a sleeve 174, a screw shaft (not shown) disposed inside the sleeve 174, a pusher 176, a sleeve position detection sensor 177, and a hook 178.

[0074] The torsion motor 170 is a DC brushless motor. The torsion motor 170 is equipped with a torsion motor rotation detection sensor 55 (see FIG. 16 ) that detects the rotation angle of a rotor (not shown). The rotation of the torsion motor 170 is transmitted to the screw shaft via a reduction gear mechanism 172. The torsion motor 170 is rotatable in both forward and reverse directions, and the screw shaft is also rotatable in both forward and reverse directions accordingly. The sleeve 174 is disposed to cover the periphery of the screw shaft. When the rotation of the sleeve 174 is prohibited, the sleeve 174 moves forward when the screw shaft rotates in the forward direction, and moves backward when the screw shaft rotates in the reverse direction. When the rotation of the sleeve 174 is permitted, the sleeve 174 rotates together with the screw shaft. The pusher 176 moves forward when the sleeve 174 moves forward, and moves backward when the sleeve 174 moves backward. As shown in FIG. 10 , when the sleeve 174 advances from the initial position to a predetermined position, the pusher 176 presses the lower part of the push plate 152 of the cutting mechanism 44 forward, causing the swinging member 120 of the cutter 116 to swing around the fixed member 118. Conversely, when the sleeve 174 retreats from the advanced position to the predetermined position, the pusher 176 presses the lower part of the pull plate 154 of the cutting mechanism 44 rearward, causing the swinging member 120 of the cutter 116 to swing around the fixed member 118. A hook 178 is provided at the front end of the sleeve 174 and opens and closes depending on the position of the sleeve 174 in the front-to-rear direction. When the sleeve 174 moves forward, the hook 178 closes and grips the wire W. Conversely, when the sleeve 174 moves rearward, the hook 178 opens and releases the wire W. As shown in FIG. 5, the sleeve position detection sensor 177 is fixed in its front-to-rear position relative to the housing 12, and can detect whether the sleeve 174 is in its initial position by detecting the magnetic field from a magnet (not shown) provided on the pusher 176.

[0075] When the twisting motor 170 is rotated with the wire W wound around multiple rebars R, the rotation of the screw shaft moves the sleeve 174 forward, and the pusher 176 and hook 178 also move forward, causing the cutting mechanism 44 to cut the wire W and the hook 178 to close and grip the wire W. Thereafter, when the sleeve 174 is allowed to rotate, the rotation of the screw shaft rotates the sleeve 174 and also rotates the hook 178. As a result, the wire W is twisted to the set twisting torque, and multiple rebars R are bound together. From this state, when the twisting motor 170 is rotated in the reverse direction, the rotation of the screw shaft moves the sleeve 174 backward, and the hook 178 moves backward while opening, releasing the wire W. Furthermore, the sleeve 174 moves backward, and the pusher 176 moves backward, returning the cutting mechanism 44 to its initial state. Thereafter, the pusher 176 and the hook 178 are retracted to their initial positions, and the sleeve 174 is allowed to rotate, so that the hook 178 returns to its initial angle.

[0076] In this specification, the operation of cutting the wire W and twisting the wire W wound around a plurality of reinforcing bars R using the cutting mechanism 44 and the twisting mechanism 46 may be simply referred to as the "twisting operation." The twisting operation is started by driving the twisting motor 170 and is ended by stopping the twisting motor 170.

[0077] (Configuration of device control unit 50) As shown in FIG. 16, the device control unit 50 includes a control power supply circuit 20, a main microcomputer 21, driver circuits 22, 23, and 24, voltage detection circuits 25, 26, and 27, a current detection circuit 28, and the like. The main microcomputer 21 includes a CPU, memory, a communication interface, and the like. The main microcomputer 21 is configured to be able to communicate with the robot control unit 10. The communication method between the main microcomputer 21 and the robot control unit 10 is, for example, a wired serial communication method. This allows the robot control unit 10 and the device control unit 50 to communicate with each other. The device control unit 50 also includes a temperature detection sensor 32 that can detect the temperature of the device control unit 50.

[0078] The control power supply circuit 20 adjusts the power supplied from the power control board 808 of the power supply device 8 to a predetermined voltage and supplies the power to the main microcomputer 21 .

[0079] The driver circuit 22 drives the pull solenoid 146 in response to instructions from the main microcomputer 21. Although not shown, the driver circuit 22 has a built-in FET as a switching element. The main microcomputer 21 can control the operation of the pull solenoid 146 via the driver circuit 22.

[0080] The voltage detection circuit 25 is provided corresponding to the driver circuit 22. The voltage detection circuit 25 is capable of detecting the voltage applied to the driver circuit 22 and the potential of the driver circuit 22.

[0081] The driver circuit 23 drives the feed motor 72 in response to instructions from the main microcomputer 21. Although not shown, the driver circuit 23 has a built-in FET as a switching element. The main microcomputer 21 can control the operation of the feed motor 72 via the driver circuit 23.

[0082] The voltage detection circuit 26 is provided corresponding to the driver circuit 23. The voltage detection circuit 26 is capable of detecting the voltage applied to the driver circuit 23 and the potential of the driver circuit 23.

[0083] The driver circuit 24 drives the torsion motor 170 in response to instructions from the main microcomputer 21. Although not shown, the driver circuit 24 has a built-in FET as a switching element. The main microcomputer 21 can control the operation of the torsion motor 170 via the driver circuit 24.

[0084] The voltage detection circuit 27 detects the voltage of the power supplied from the power control board 808. The main microcomputer 21 can obtain the voltage of the power supplied from the power control board 808 from the signal received from the voltage detection circuit 27.

[0085] Current detection circuit 28 detects the current supplied to driver circuits 22, 23, 24, etc. from power control board 808. From the signal received from current detection circuit 28, main microcomputer 21 can obtain the current supplied from power control board 808 to driver circuits 22, 23, 24, etc., i.e., the current supplied from power control board 808 to torsion motor 170, feed motor 72, pull solenoid 146, etc.

[0086] A protective FET 31 is provided in the path for supplying power from the power control board 808 to the driver circuits 22, 23, and 24. When the protective FET 31 is turned on, power is supplied from the power control board 808 to the driver circuits 22, 23, and 24. When the protective FET 31 is turned off, power supply from the power control board 808 to the driver circuits 22, 23, and 24 is cut off. The main microcomputer 21 can switch the protective FET 31 between an on state and an off state.

[0087] The following describes various processes executed by the device control unit 50 (specifically, processes executed by the main microcomputer 21).

[0088] (Main processing of the device) When the power control board 808 starts supplying power to the rebar binding device 2, the device control unit 50 executes the device main processing shown in FIG.

[0089] In S102, the device control unit 50 executes a hardware status determination process. The hardware status determination process will be described in detail later. After S102, the process proceeds to S104.

[0090] In S104, the device control unit 50 determines whether or not an abnormality has occurred in the reinforcing bar binding device 2. Specifically, the device control unit 50 determines whether or not a binding device abnormality determination flag, which will be described later, is stored in memory. If no abnormality has occurred in the reinforcing bar binding device 2 (NO), the process proceeds to S106.

[0091] In S106, the device control unit 50 executes a device initialization process. When the device initialization process starts, the device control unit 50 turns on the protection FET 31. Thereafter, the device control unit 50 rotates the torsion motor 170 in the forward and reverse directions to check operation and return the sleeve 174 to its initial position. Thereafter, the device control unit 50 turns off the protection FET 31 and ends the device initialization process. After S106, the process proceeds to S108.

[0092] In S108, the device control unit 50 determines whether or not it has received a status call signal transmitted from the robot control unit 10. If it has not received a status call signal (NO), the process repeats S108. If it has received a status call signal (YES), the process proceeds to S110.

[0093] In S110, the device control unit 50 transmits a status notification signal to the robot control unit 10. The status notification signal includes, for example, various flags stored in memory. After S110, the process proceeds to S112.

[0094] In S112, the device control unit 50 determines whether or not it has received a bundling instruction signal transmitted from the robot control unit 10. If it has not received a bundling instruction signal (NO), the process repeats S112. If it has received a bundling instruction signal (YES), the process proceeds to S114.

[0095] In S114, the device control unit 50 executes a hardware status determination process. The hardware status determination process will be described in detail later. After S114, the process proceeds to S116.

[0096] In S116, the device control unit 50 determines whether or not an abnormality has occurred in the reinforcing bar binding device 2. Specifically, the device control unit 50 determines whether or not a binding device abnormality determination flag is stored in memory. If no abnormality has occurred in the reinforcing bar binding device 2 (NO), the process proceeds to S118.

[0097] In S118, the device control unit 50 starts the rebar binding work. The device control unit 50 stores a binding work in progress flag in memory, which indicates that the rebar binding device 2 is performing the rebar binding work, and turns on the protection FET 31. After S118, the process proceeds to S120.

[0098] In S120, the device control unit 50 instructs the driver circuit 23 to start driving the feed motor 72. That is, the device control unit 50 instructs the start of the feed operation. After S120, the process proceeds to S122.

[0099] In S122, the device control unit 50 executes a feed operation state determination process. The feed operation state determination process will be described in detail later. After S122, the process proceeds to S124.

[0100] In S124, the device control unit 50 determines whether or not an abnormality has occurred in the reinforcing bar binding device 2. Specifically, the device control unit 50 determines whether or not a binding device abnormality determination flag is stored in memory. If no abnormality has occurred in the reinforcing bar binding device 2 (NO), the process proceeds to S126.

[0101] In S126, the device control unit 50 determines whether the feeding operation has ended. If the feeding operation has not ended (NO), the process returns to S122. If the feeding operation has ended (YES), the process proceeds to S128.

[0102] In S128, the device control unit 50 instructs the driver circuit 24 to start driving the torsion motor 170. That is, the device control unit 50 instructs the start of the torsion operation. After S128, the process proceeds to S130.

[0103] In S130, the device control unit 50 executes a twisting operation state determination process. The twisting operation state determination process will be described in detail later. After S130, the process proceeds to S132.

[0104] In S132, the device control unit 50 determines whether or not an abnormality has occurred in the reinforcing bar binding device 2. Specifically, the device control unit 50 determines whether or not a binding device abnormality determination flag is stored in memory. If no abnormality has occurred in the reinforcing bar binding device 2 (NO), the process proceeds to S134.

[0105] In S134, the device control unit 50 determines whether the twisting operation has ended. If the twisting operation has not ended (NO), the process returns to S130. If the twisting operation has ended (YES), the process proceeds to S136.

[0106] In S136, the device control unit 50 ends the rebar binding work. The device control unit 50 turns off the protection FET 31 and erases the binding work in progress flag stored in the memory. After S136, the process returns to S108.

[0107] If it is determined in S104, S116, S124, or S132 that an abnormality has occurred in the rebar binding device 2 (if YES), the process proceeds to S138. In S138, the device control unit 50 determines whether or not a status call signal transmitted from the robot control unit 10 has been received. If a status call signal has not been received (if NO), the process executes S138 again. If a status call signal has been received (if YES), the process proceeds to S140.

[0108] In S140, the device control unit 50 transmits a status notification signal to the robot control unit 10. The status notification signal includes, for example, various flags stored in memory. After S140, the processing shown in FIG. 17 ends.

[0109] (Feed operation status determination process) The device control unit 50 executes a feed operation state determination process shown in FIG. 18 in S122 of the device main process (see FIG. 17).

[0110] In S2, the device control unit 50 determines whether or not the wire reel WR is held by the reel holding mechanism 36. Specifically, if the reel rotation detection sensor 66 has never detected rotation of the wire reel WR after S118 of the device main processing (see FIG. 17) has ended, the device control unit 50 determines that the wire reel WR is not held by the reel holding mechanism 36. If the reel rotation detection sensor 66 has detected rotation of the wire reel WR even once after S118 of the device main processing (see FIG. 17) has ended, the device control unit 50 determines that the wire reel WR is held by the reel holding mechanism 36. If the wire reel WR is held by the reel holding mechanism 36 (if YES), the process proceeds to S3.

[0111] In S3, the device control unit 50 determines whether the feed motor FET (FET of the driver circuit 23) has an open circuit failure. Specifically, if no current has flowed through the driver circuit 23 even once during the period from the end of S118 of the device main processing (see FIG. 17) until a predetermined time has elapsed, the device control unit 50 determines that the feed motor FET has an open circuit failure. If current has flowed through the driver circuit 23 even once during the period from the end of S118 of the device main processing (see FIG. 17) until a predetermined time has elapsed, the device control unit 50 determines that the feed motor FET has not had an open circuit failure. If the feed motor FET has not had an open circuit failure (NO), the process proceeds to S4.

[0112] In S4, the device control unit 50 determines whether an overload has been detected in the feed motor 72. Specifically, if the current value detected by the current detection circuit 28 continues to exceed a predetermined first upper current limit for a predetermined time or more, the device control unit 50 determines that an overload has been detected in the feed motor 72. If an overload has not been detected in the feed motor 72 (NO), the process proceeds to S6.

[0113] In S6, the device control unit 50 determines whether an abnormality has occurred in the feed gear (the drive gear 78 and the driven gear 80). The device control unit 50 of this embodiment calculates the amount of rotation of the drive gear 78 after S118 of the device main processing (see FIG. 17) is completed, based on the gear rotation detection sensor 79. Then, if the amount of rotation of the drive gear 78 does not reach a predetermined value (for example, an amount of rotation corresponding to the amount of wire W to be fed set by the user) even after a predetermined time has elapsed since S118 of the device main processing (see FIG. 17) was completed, the device control unit 50 determines that an abnormality has occurred in the feed gear. If no abnormality has occurred in the feed gear (NO), the process proceeds to S8.

[0114] In S8, the device control unit 50 determines whether a wire shortage has occurred. The device control unit 50 of this embodiment calculates the amount of rotation of the wire reel WR after S118 of the device main processing (see FIG. 17) is completed based on the reel rotation detection sensor 66. Then, if the amount of rotation of the wire reel WR has not reached a predetermined value (for example, an amount of rotation corresponding to the amount of wire W fed out set by the user) even after a predetermined time has elapsed since S118 of the device main processing (see FIG. 17) was completed, the device control unit 50 determines that a wire shortage has occurred. If it is determined that a wire shortage has not occurred (NO), the process proceeds to S9.

[0115] In S9, the device control unit 50 determines whether the solenoid FET (FET of the driver circuit 22) has an open circuit failure. Specifically, if no current has flowed through the driver circuit 22 even once during the predetermined time period since S118 of the device main processing (see FIG. 17) ended, the device control unit 50 determines that the solenoid FET has an open circuit failure. If current has flowed through the driver circuit 22 even once during the predetermined time period since S118 of the device main processing (see FIG. 17) ended, the device control unit 50 determines that the solenoid FET has not had an open circuit failure. If the solenoid FET has not had an open circuit failure (NO), the process proceeds to S10.

[0116] In S10, the device control unit 50 stores in memory a feeding operation normality determination flag indicating that the feeding operation is being performed normally. After S10, the processing of FIG. 18 ends.

[0117] If it is determined in S2 that the wire reel WR is not held by the reel holding mechanism 36 (if NO), if it is determined in S3 that the feed motor FET has an open-circuit failure (if YES), if it is determined in S4 that an overload has been detected in the feed motor 72 (if YES), if it is determined in S6 that an abnormality has occurred in the feed gear (if YES), if it is determined that a wire shortage has occurred (if YES), or if it is determined in S9 that the solenoid FET has an open-circuit failure (if YES), the process proceeds to S12. In S12, which is executed if the result in S2 is NO, the device control unit 50 stores in memory a reel dropout determination flag indicating that the wire reel WR is not held by the reel holding mechanism 36. In S12, which is executed if the result in S3 is YES, the device control unit 50 stores in memory a feed motor FET open-circuit failure determination flag indicating that the feed motor FET has an open-circuit failure. In S12, which is executed if the result in S4 is YES, the device control unit 50 stores in memory a feed motor overload determination flag indicating that an overload has been detected in the feed motor 72. In S12, which is executed if the result of S6 is YES, the device control unit 50 stores in memory a feed gear abnormality determination flag indicating that an abnormality has occurred in the feed gear. In S12, which is executed if the result of S8 is YES, the device control unit 50 stores in memory a wire shortage determination flag indicating that a wire shortage has occurred. In S12, which is executed if the result of S9 is YES, the device control unit 50 stores in memory a solenoid FET open failure determination flag indicating that an open failure has occurred in the solenoid FET. After S12, the process proceeds to S14.

[0118] In S14, the device control unit 50 suspends the ongoing rebar binding work. Specifically, the device control unit 50 turns off the protection FET 31. This cuts off the power supply from the power control board 808 to the driver circuits 22, 23, and 24. After S14, the processing in FIG. 18 ends.

[0119] The feed operation normality determination flag stored in memory in S10 and the reel dropout determination flag, feed motor FET open failure determination flag, feed motor overload determination flag, feed gear abnormality determination flag, wire shortage determination flag, and solenoid FET open failure determination flag stored in memory in S12 are held in memory until the next time the feed operation state determination process is started, and are erased from memory when the next time the feed operation state determination process is started. These determination flags are also erased from memory when the power supply from the power control board 808 to the device control unit 50 is cut off.

[0120] (Plate status determination process) While power is being supplied from the power control board 808, the device control unit 50 repeatedly executes the plate position state determination process shown in FIG.

[0121] In S32, the device control unit 50 determines whether or not a rebar contact state has been detected using the plate position detection sensor 134. The rebar contact state here refers to a state in which multiple rebars R are pressed against the contact plate 102. If a rebar contact state has been detected (YES), the process proceeds to S34. If a rebar contact state has not been detected (NO), the process executes S32 again.

[0122] In S34, the device control unit 50 determines whether the rebar contact state has continued for a predetermined time (e.g., 5 seconds) or more. The device control unit 50 makes the determination in S34 by continuing to monitor the plate position detection sensor 134 until the predetermined time has passed since the determination in the processing of S32 was YES. If the rebar contact state has not continued for the predetermined time or more (if the determination is NO), the processing proceeds to S36.

[0123] In S36, the device control unit 50 stores in memory a plate normality determination flag indicating that the contact plate 102 is operating normally. After S36, the processing of FIG. 19 ends.

[0124] If it is determined in S34 that the rebar contact state has continued for a predetermined time or longer (YES), the process proceeds to S38. In S38, the device control unit 50 stores in memory a plate abnormality determination flag indicating that an abnormality has occurred in the operation of the contact plate 102. After S38, the process of FIG. 19 ends.

[0125] The plate normality determination flag stored in memory in S36 or the plate abnormality determination flag stored in memory in S38 is held in memory until the next start of the plate state determination process, and is erased from memory when the next plate state determination process is started. These determination flags are also erased from memory when the power supply from the power control board 808 to the device control unit 50 is cut off.

[0126] (Supply voltage status determination process) While power is being supplied from the power control board 808, the device control unit 50 repeatedly executes the supply voltage status determination process shown in FIG.

[0127] In S42, the device control unit 50 determines whether the voltage value detected by the voltage detection circuit 27 is below a predetermined lower voltage limit. If the voltage value detected by the voltage detection circuit 27 is below the lower voltage limit (YES), the process proceeds to S44. If the voltage value detected by the voltage detection circuit 27 is equal to or greater than the lower voltage limit (NO), the process proceeds to S46.

[0128] In S44, the device control unit 50 stores in memory a low voltage determination flag indicating that the voltage value of the power supplied from the power control board 808 to the device control unit 50 is insufficient. After S44, the processing in FIG. 20 ends.

[0129] In S46, the device control unit 50 stores in memory a supply voltage normality determination flag indicating that the voltage value of the power supplied from the power control board 808 to the device control unit 50 is sufficient. After S46, the processing in FIG. 20 ends.

[0130] The low voltage determination flag stored in memory in S44 or the normal supply voltage determination flag stored in memory in S46 is held in memory until the next start of the supply voltage status determination process, and is erased from memory when the next supply voltage status determination process is started. These determination flags are also erased from memory when the power supply from power control board 808 to device control unit 50 is cut off.

[0131] (Temperature state determination process) While power is being supplied from the power control board 808, the device control unit 50 repeatedly executes the temperature state determination process shown in FIG.

[0132] In S52, the device control unit 50 determines whether the device control unit 50 is overheating. Specifically, the device control unit 50 determines whether the temperature of the device control unit 50 detected by the temperature detection sensor 32 has been detected to be above a predetermined upper temperature limit for a predetermined period of time or more. If the device control unit 50 is overheating (YES), the process proceeds to S54.

[0133] In S54, the device control unit 50 stores in memory a temperature abnormality determination flag indicating that the device control unit 50 is overheating. After S54, the process proceeds to S56.

[0134] In S56, if the device control unit 50 is currently performing rebar tying work, it suspends the ongoing rebar tying work. Specifically, the device control unit 50 turns off the protection FET 31. This cuts off the power supply from the power control board 808 to the driver circuits 22, 23, and 24. After S56, the processing in FIG. 21 ends.

[0135] If it is determined in S52 that the device control unit 50 is not overheated (NO), the process proceeds to S58. In S58, the device control unit 50 stores a temperature normality determination flag in memory, which indicates that the device control unit 50 is not overheated (i.e., the temperature of the device control unit 50 is normal). After S58, the process of FIG. 21 ends.

[0136] The temperature abnormality determination flag stored in memory in S54 or the temperature normality determination flag stored in memory in S58 is held in memory until the next start of the temperature status determination process, and is erased from memory when the next temperature status determination process is started. These determination flags are also erased from memory when the power supply from the power control board 808 to the device control unit 50 is cut off.

[0137] (Twisting operation state determination process) The device control unit 50 executes the twisting operation state determination process shown in FIG. 22 in S130 of the device main process (see FIG. 17).

[0138] In S62, the device control unit 50 determines whether the torsion motor 170 is locked based on the detection result of the torsion motor rotation detection sensor 55. In this embodiment, the torsion motor rotation detection sensor 55 is a Hall sensor, and is configured to switch the signal output to the device control unit 50 between an H signal and an L signal each time the rotor of the torsion motor 170 rotates a predetermined angle. The device control unit 50 detects the rotation of the torsion motor 170 based on the number of times the signal output from the torsion motor rotation detection sensor 55 switches. Therefore, if the signal output from the torsion motor rotation detection sensor 55 does not switch even once a predetermined time has passed since the end of S128 of the device main processing (see FIG. 17), the device control unit 50 determines that the torsion motor 170 is locked. If the torsion motor 170 is not locked (NO), the process proceeds to S64.

[0139] In S64, the device control unit 50 determines whether or not a rotation abnormality has been detected in the torsion motor 170. Specifically, the device control unit 50 determines whether or not a rotation abnormality has been detected in the torsion motor 170 by comparing the change pattern of the rotation angle of the torsion motor 170 detected by the torsion motor rotation detection sensor 55 with the ideal change pattern stored in memory. If a rotation abnormality in the torsion motor 170 has not been detected (NO), the process proceeds to S66.

[0140] In S66, the device control unit 50 determines whether an overload has been detected in the torsion motor 170. Specifically, the device control unit 50 determines whether a state in which the current value detected by the current detection circuit 28 exceeds a predetermined second upper current limit has been detected for a predetermined time or longer. If an overload has not been detected in the torsion motor 170 (NO), the process proceeds to S68.

[0141] In S68, the device control unit 50 determines whether an abnormality has occurred in the torsion motor rotation detection sensor 55. Specifically, the device control unit 50 continues to monitor the control output from the torsion motor rotation detection sensor 55 from the time the torsion motor 170 is driven until the torsion motor 170 is stopped. Then, if the signal (H signal or L signal) output from the torsion motor rotation detection sensor 55 never switches, the device control unit 50 determines that an abnormality has occurred in the torsion motor rotation detection sensor 55. If no abnormality has occurred in the torsion motor rotation detection sensor 55 (if NO), the process proceeds to S70.

[0142] In S70, the device control unit 50 determines whether an abnormality has occurred in the torsion arm (sleeve 174 and hook 178). Specifically, the device control unit 50 determines that an abnormality has occurred in the torsion arm if the sleeve 174 is not in its initial position after a predetermined time has elapsed since S128 of the device main processing (see FIG. 17) ended. If no abnormality has occurred in the torsion arm (NO), the processing proceeds to S72.

[0143] In S72, the device control unit 50 determines whether an overcurrent has been detected in the current detection circuit 28 during the execution of the twisting operation. In this embodiment, the current detection circuit 28 is provided with an overcurrent detection circuit (not shown) that transmits an overcurrent detection signal to the device control unit 50 when the value of the current flowing through the current detection circuit 28 exceeds a predetermined third current upper limit. Therefore, the device control unit 50 determines whether an overcurrent detection signal has been received from the overcurrent detection circuit. The third current upper limit is set to a value greater than the first current upper limit in S4 of FIG. 18 and the second current upper limit in S66 of FIG. 22. If an overcurrent is not detected (NO), the process proceeds to S74.

[0144] In S74, the device control unit 50 stores in memory a twisting operation normality determination flag indicating that the twisting operation is being performed normally. After S74, the processing of FIG. 22 ends.

[0145] If it is determined in S62 that a locked state of the torsion motor 170 has been detected (if YES), if it is determined in S64 that an abnormal rotation of the torsion motor 170 has been detected (if YES), if it is determined in S66 that an overload has been detected in the torsion motor 170 (if YES), if it is determined in S68 that an abnormality has occurred in the torsion motor rotation detection sensor 55 (if YES), if it is determined that an abnormality has occurred in the torsion arm (if YES), or if it is determined that an overcurrent has been detected (if YES) in S72, the process proceeds to S76. In S76, which is executed if the result in S62 is YES, the device control unit 50 stores in memory a torsion motor lock determination flag indicating that the torsion motor 170 is in a locked state. In S76, which is executed if the result in S64 is YES, the device control unit 50 stores in memory a torsion motor rotation abnormality determination flag indicating that the torsion motor 170 is rotating abnormally. In S76, which is executed if S66 returns YES, the device control unit 50 stores in memory a torsion motor overload determination flag indicating that an overload has been detected in the torsion motor 170. In S76, which is executed if S68 returns YES, the device control unit 50 stores in memory a torsion motor rotation detection sensor abnormality determination flag indicating that an abnormality has occurred in the torsion motor rotation detection sensor 55. In S76, which is executed if S70 returns YES, the device control unit 50 stores in memory a torsion arm abnormality determination flag indicating that an abnormality has occurred in the torsion arm. In S76, which is executed if S72 returns YES, the device control unit 50 stores in memory an overcurrent determination flag indicating that an overcurrent has been detected. After S76, the process proceeds to S78.

[0146] In S78, the device control unit 50 suspends the ongoing rebar binding work. Specifically, the device control unit 50 turns off the protection FET 31. This cuts off the power supply from the power control board 808 to the driver circuits 22, 23, and 24. After S78, the processing in FIG. 22 ends.

[0147] The torsion operation normality determination flag stored in memory in S74 and the torsion motor lock determination flag, torsion motor rotation abnormality determination flag, torsion motor overload determination flag, torsion motor rotation detection sensor abnormality determination flag, torsion arm abnormality determination flag, and overcurrent determination flag stored in memory in S76 are held in memory until the next time the torsion operation state determination process is started, and are erased from memory the next time the torsion operation state determination process is started. These determination flags are also erased from memory when the power supply from power control board 808 to device control unit 50 is cut off.

[0148] (Hardware status determination process) The device control unit 50 executes the hardware state determination process shown in FIG. 23 in S102 and S114 of the device main process (see FIG. 17).

[0149] In S82, the device control unit 50 determines whether the lower curl guide 92 is in the open state based on the guide position detection sensor 142. If it is determined that the lower curl guide 92 is not in the open state (i.e., in the closed state) (NO), the process proceeds to S84.

[0150] In S84, the device control unit 50 identifies the voltage value of the protection FET 31 based on the detection values ​​of the voltage detection circuits 25, 26, and 27. Then, the device control unit 50 determines whether the voltage value of the protection FET 31 is an abnormal value. An abnormal value here is, for example, a value below the gate threshold value of the protection FET 31. If the voltage value of the protection FET 31 is a normal value (NO), the process proceeds to S86.

[0151] In S86, the device control unit 50 uses the voltage detection circuit 25 to determine whether the voltage value of the solenoid FET is abnormal. An abnormal value here is, for example, a value below the gate threshold value of the solenoid FET. If the voltage value of the solenoid FET is normal (NO), the process proceeds to S88.

[0152] In S88, the device control unit 50 uses the voltage detection circuit 26 to determine whether the voltage value of the feed motor FET is abnormal. An abnormal value here is, for example, a value below the gate threshold value of the feed motor FET. If the voltage value of the feed motor FET is normal (NO), the process proceeds to S90.

[0153] In S90, the device control unit 50 stores in memory a hardware normality determination flag indicating that the hardware status is normal. After S90, the processing of FIG.

[0154] If it is determined in S82 that the lower curl guide 92 is in the open state (YES), if it is determined in S84 that the voltage value of the protection FET 31 is abnormal (YES), if it is determined in S86 that the voltage value of the solenoid FET is abnormal (YES), or if it is determined in S88 that the voltage value of the feed motor FET is abnormal (YES), the process proceeds to S92. In S92, which is executed if the result in S82 is YES, the device control unit 50 stores in memory a guide position abnormality determination flag indicating that the lower curl guide 92 is not in an appropriate position. In S92, which is executed if the result in S84 is YES, the device control unit 50 stores in memory a protection FET voltage abnormality determination flag indicating that the voltage value of the protection FET 31 is abnormal. In S92, which is executed if the result in S86 is YES, the device control unit 50 stores in memory a solenoid FET voltage abnormality determination flag indicating that the voltage value of the solenoid FET is abnormal. In S92, which is executed if the result of S88 is YES, the device control unit 50 stores in memory a feed motor FET voltage abnormality determination flag indicating that the voltage value of the feed motor FET is abnormal. After S92, the processing of FIG. 23 ends.

[0155] The hardware normality determination flag stored in memory in S90 and the guide position abnormality determination flag, protection FET voltage abnormality determination flag, solenoid FET voltage abnormality determination flag, and feed motor FET voltage abnormality determination flag stored in memory in S92 are held in memory until the next time the hardware status determination process is started, and are erased from memory when the next hardware status determination process is started. These determination flags are also erased from memory when the power supply from the power control board 808 to the device control unit 50 is cut off.

[0156] (Classification of various judgment flags) In this specification, of the various determination flags mentioned above, the feed operation normal determination flag, plate normal determination flag, supply voltage normal determination flag, temperature normal determination flag, twisting operation normal determination flag, and hardware normal determination flag are collectively referred to as the “binding device normal determination flags.” Also, the reel dropout determination flag, feed motor FET open failure determination flag, feed motor overload determination flag, feed gear abnormality determination flag, wire shortage determination flag, solenoid FET open failure determination flag, plate abnormality determination flag, low voltage determination flag, temperature abnormality determination flag, torsion motor lock determination flag, torsion motor rotation abnormality determination flag, torsion motor overload determination flag, torsion motor rotation detection sensor abnormality determination flag, torsion arm abnormality determination flag, overcurrent determination flag, guide position abnormality determination flag, protection FET voltage abnormality determination flag, solenoid FET voltage abnormality determination flag, and feed motor FET voltage abnormality determination flag are collectively referred to as the “binding device abnormality determination flags.”

[0157] (Configuration of conveying device 4) 2, the transport device 4 includes a chassis 190, a right crawler 192, a left crawler 194, a side stepper 196, and a power transmission mechanism 402. The right crawler 192, the left crawler 194, the side stepper 196, and the power transmission mechanism 402 are each supported by the chassis 190.

[0158] (Chassis 190 configuration) As shown in FIG. 2, the chassis 190 includes a base plate 204, a right plate 210, a left plate 212, multiple base frames 214, a front connecting frame 215, and a rear connecting frame 216. The base plate 204 is arranged along the front-rear and left-right directions (i.e., the horizontal direction). The reinforcing bar binding robot 1 has a through hole 204a formed by penetrating the base plate 204 in the up-down direction at the center in the front-rear and left-right directions. The through hole 204a is sized to allow the reinforcing bar binding device 2 to pass through in the approximately up-down direction. The multiple base frames 214 are fixed to the underside of the base plate 204. The right plate 210 is fixed to the right surface of one of the multiple base frames 214 that extends in the front-rear direction along the right end of the base plate 204. The right plate 210 is arranged along the front-rear and up-down directions. The left plate 212 is fixed to the left surface of one of the multiple base frames 214 that extends in the front-rear direction along the left end of the base plate 204. The left plate 212 is arranged along the front-rear and up-down directions. In the up-down direction, the upper ends of the right plate 210 and the left plate 212 are at the same position as the lower surface of the base plate 204. In the front-rear direction, the front ends of the right plate 210 and the left plate 212 protrude forward from the front end of the base plate 204, and the rear ends of the right plate 210 and the left plate 212 protrude rearward from the rear end of the base plate 204. The front connecting frame 215 is forward of the front end of the base plate 204 and connects the vicinity of the front end of the right plate 210 to the vicinity of the front end of the left plate 212. The rear connecting frame 216 is rearward of the rear end of the base plate 204 and connects the vicinity of the rear end of the right plate 210 to the vicinity of the rear end of the left plate 212. The front connecting frame 215 and the rear connecting frame 216 extend in the left-right direction. In the up-down direction, the front connecting frame 215 and the rear connecting frame 216 are disposed lower than the plurality of base frames 214.

[0159] (Right crawler 192 configuration) The right crawler 192 includes a front pulley 218, a rear pulley 220, a plurality of auxiliary pulleys 222, a tensioner pulley 224, a rubber belt 226, a right crawler motor 228, and a gearbox 230. Teeth that mesh with the rubber belt 226 are formed on the outer surface of the front pulley 218, the outer surface of the rear pulley 220, the outer surfaces of the plurality of auxiliary pulleys 222, and the outer surface of the tensioner pulley 224. The rubber belt 226 is looped around the front pulley 218, the rear pulley 220, the plurality of auxiliary pulleys 222, and the tensioner pulley 224. The front pulley 218 is rotatably supported by the right plate 210 near the front end of the right plate 210 via a bearing 232. The rear pulley 220 is rotatably supported by the right plate 210 near the rear end of the right plate 210 via a bearing 234. The multiple auxiliary pulleys 222 are rotatably supported by the right plate 210 between the front pulley 218 and the rear pulley 220 via corresponding bearings 236. The multiple auxiliary pulleys 222 are arranged side by side in the front-to-rear direction. The outer diameters of the front pulley 218 and the rear pulley 220 are substantially the same, and the outer diameters of the multiple auxiliary pulleys 222 are smaller than the outer diameters of the front pulley 218 and the rear pulley 220. In the vertical direction, the lower end of the front pulley 218, the lower end of the rear pulley 220, and the lower ends of the multiple auxiliary pulleys 222 are located at substantially the same position. The tensioner pulley 224 is rotatably supported by a movable bearing 237. The movable bearing 237 is supported by the right plate 210 so as to be movable in the vertical direction. With the rubber belt 226 looped around the tensioner pulley 224, the tension of the rubber belt 226 can be adjusted by adjusting the vertical position of the movable bearing 237 relative to the right plate 210. The right crawler motor 228 is supported by the right plate 210 via a bearing 232 and a gear box 230. The right crawler motor 228 is, for example, a DC brushless motor. The right crawler motor 228 is connected to the front pulley 218 via a reduction gear (not shown) built into the gear box 230.When the right crawler motor 228 rotates in the forward or reverse direction, the front pulley 218 rotates in the forward or reverse direction, causing the rubber belt 226 to rotate in the forward or reverse direction around the front pulley 218, the rear pulley 220, the multiple auxiliary pulleys 222, and the tensioner pulley 224.

[0160] (Left crawler 194 configuration) The left crawler 194 includes a front pulley 244, a rear pulley 246, a plurality of auxiliary pulleys 248, a tensioner pulley 250, a rubber belt 252, a left crawler motor 254, and a gearbox 256. Teeth that mesh with the rubber belt 252 are formed on the outer surface of the front pulley 244, the outer surface of the rear pulley 246, the outer surfaces of the plurality of auxiliary pulleys 248, and the outer surface of the tensioner pulley 250. The rubber belt 252 is looped around the front pulley 244, the rear pulley 246, the plurality of auxiliary pulleys 248, and the tensioner pulley 250. The front pulley 244 is rotatably supported by the left plate 212 near the front end of the left plate 212 via a bearing 258. The rear pulley 246 is rotatably supported by the left plate 212 via a bearing 260 near the rear end of the left plate 212. The multiple auxiliary pulleys 248 are rotatably supported by the left plate 212 between the front pulley 244 and the rear pulley 246 via corresponding bearings 262. The multiple auxiliary pulleys 248 are arranged side by side in the front-to-rear direction. The outer diameters of the front pulley 244 and the rear pulley 246 are approximately the same, and the outer diameters of the multiple auxiliary pulleys 248 are smaller than the outer diameters of the front pulley 244 and the rear pulley 246. In the vertical direction, the lower end of the front pulley 244, the lower end of the rear pulley 246, and the lower ends of the multiple auxiliary pulleys 248 are located at approximately the same position. The tensioner pulley 250 is rotatably supported by a movable bearing 264. The movable bearing 264 is supported by the left plate 212 so as to be movable in the vertical direction. With the rubber belt 252 looped around the tensioner pulley 250, the tension of the rubber belt 252 can be adjusted by adjusting the vertical position of the movable bearing 264 relative to the left plate 212. The left crawler motor 254 is supported by the left plate 212 via a bearing 258 and a gear box 256. The left crawler motor 254 is, for example, a DC brushless motor. The left crawler motor 254 is connected to the front pulley 244 via a reduction gear (not shown) built into the gear box 256.When the left crawler motor 254 rotates in the forward or reverse direction, the front pulley 244 rotates in the forward or reverse direction, causing the rubber belt 252 to rotate in the forward or reverse direction around the front pulley 244, the rear pulley 246, the multiple auxiliary pulleys 248, and the tensioner pulley 250.

[0161] (Configuration of Side Stepper 196) As shown in Fig. 24, the side stepper 196 includes step bars 272 and 274, a front crank mechanism 276, and a rear crank mechanism 277. The step bars 272 and 274 are rod-shaped members with a substantially rectangular cross section, and extend in the front-rear direction. As shown in Fig. 2, in the left-right direction, the step bar 272 is disposed between the center and the right end of the base plate 204, and the step bar 274 is disposed between the center and the left end of the base plate 204.

[0162] As shown in FIG. 24 , the front crank mechanism 276 includes a support plate 278, pulleys 280 and 282, a tensioner pulley 283, a belt 284, crank arms 286 and 288, crank pins 290 and 292 (see FIG. 25 ), a crank plate 294, rollers 296 and 298, and a guide plate 300. The support plate 278 is fixed to the lower surface of the base plate 204 near the front end of the base plate 204. The support plate 278 is arranged along the left-right and up-down directions. The pulley 280 is arranged near the right end of the support plate 278 and rearward of the support plate 278. The pulley 282 is arranged near the left end of the support plate 278 and rearward of the support plate 278. The pulleys 280 and 282 are each rotatably supported by the support plate 278. The diameter of pulley 280 is approximately the same as the diameter of pulley 282. Belt 284 is stretched across pulleys 280 and 282. Therefore, when one of pulleys 280 and 282 rotates in the forward or reverse direction, the other also rotates in the forward or reverse direction at approximately the same rotation speed. Tensioner pulley 283 is rotatably supported on base plate 204 (see FIG. 2) via a movable bearing (not shown) that is movable in the vertical direction. Tensioner pulley 283 is disposed so as to abut against belt 284 from above. Therefore, the tension of belt 284 can be adjusted by adjusting the vertical position of the movable bearing that supports tensioner pulley 283 relative to base plate 204.

[0163] The crank arms 286, 288, crank pins 290, 292 (see FIG. 25), crank plate 294, rollers 296, 298, and guide plate 300 are disposed forward of the support plate 278. As shown in FIG. 25, the crank arms 286, 288 have fitting holes 286a, 288a into which shafts 280a, 282a of the pulleys 280, 282 are fitted, and elongated holes 286b, 288b extending in the longitudinal direction of the crank arms 286, 288. When the pulleys 280, 282 rotate, the crank arms 286, 288 rotate integrally with the pulleys 280, 282 around the shafts 280a, 282a. The crank pins 290, 292 are slidably inserted into the elongated holes 286b, 288b. The crank pins 290, 292 are fixed to the crank plate 294 while passing through it. The crank plate 294 is disposed forward of the crank arms 286, 288. The crank plate 294 extends in the left-right and up-down directions. The rollers 296, 298 (see FIG. 24) are attached to the crank pins 290, 292 forward of the crank plate 294. As shown in FIG. 24, the rollers 296, 298 fit into guide grooves 302, 304 formed in the rear surface of a guide plate 300. The guide plate 300 is fixed to the lower surface of the base plate 204 forward of the crank plate 294. The guide plate 300 extends in the left-right and up-down directions. As shown in FIG. 25, the guide grooves 302, 304 of the guide plate 300 are formed in a generally rectangular shape with rounded corners. Guide grooves 302 and 304 define a side step path S, which is shown by a dashed line in Fig. 25. The side step path S has a generally rectangular shape with rounded corners, and has upper and lower sides extending in the left-right direction and right and left sides extending in the up-down direction.

[0164] In the front crank mechanism 276, when the pulleys 280, 282 rotate, the crank arms 286, 288 rotate, causing the crank pins 290, 292 to move in the rotational direction of the crank arms 286, 288. At this time, because the rollers 296, 298 are fitted in the guide grooves 302, 304, the crank pins 290, 292 slide inside the elongated holes 286b, 288b and move along the side step trajectory S defined by the guide grooves 302, 304. As a result, the crank plate 294 to which the crank pins 290, 292 are fixed also moves along the side step trajectory S defined by the guide grooves 302, 304.

[0165] As shown in FIG. 26, the rear crank mechanism 277 includes a support plate 306, pulleys 308 and 310, a tensioner pulley 311, a belt 312, crank arms 314 and 316, crank pins 318 and 320 (see FIG. 25), a crank plate 322, rollers 324 and 326, and a guide plate 328. The support plate 306 is fixed to the lower surface of the base plate 204 (see FIG. 2) near the rear end of the base plate 204. The support plate 306 is disposed along the left-right and up-down directions. The pulley 308 is disposed near the right end of the support plate 306 and forward of the support plate 306. The pulley 310 is disposed near the left end of the support plate 306 and forward of the support plate 306. The pulleys 308 and 310 are each rotatably supported by the support plate 306. The diameter of pulley 308 is approximately the same as the diameter of pulley 310, which is also approximately the same as the diameter of pulleys 280, 282 of the front crank mechanism 276. Belt 312 is looped around pulleys 308, 310. Therefore, when one of pulleys 308, 310 rotates in the forward or reverse direction, the other also rotates in the forward or reverse direction at approximately the same rotation speed. Furthermore, tensioner pulley 311 is rotatably supported on base plate 204 via a movable bearing (not shown) that is movable in the vertical direction. Tensioner pulley 311 is positioned so as to abut against belt 312 from above. Therefore, the tension of belt 312 can be adjusted by adjusting the vertical position of the movable bearing that supports tensioner pulley 311 relative to base plate 204.

[0166] The crank arms 314, 316, crank pins 318, 320 (see FIG. 25), crank plate 322, rollers 324, 326, and guide plate 328 are disposed rearward of the support plate 306. As shown in FIG. 25, the crank arms 314, 316 have fitting holes 314a, 316a into which the shafts 308a, 310a of the pulleys 308, 310 are fitted, and elongated holes 314b, 316b extending in the longitudinal direction of the crank arms 314, 316. When the pulleys 308, 310 rotate, the crank arms 314, 316 rotate integrally with the pulleys 308, 310 around the shafts 308a, 310a. The crank pins 318, 320 are slidably inserted into the elongated holes 314b, 316b. The crank pins 318, 320 penetrate the crank plate 322 and are fixed to the crank plate 322. The crank plate 322 is disposed rearward of the crank arms 314, 316. The crank plate 322 extends in the left-right and up-down directions. The rollers 324, 326 (see FIG. 26) are attached to the crank pins 318, 320 rearward of the crank plate 322. As shown in FIG. 26, the rollers 324, 326 fit into guide grooves 330, 332 formed in the front surface of a guide plate 328. The guide plate 328 is fixed to the lower surface of the base plate 204 rearward of the crank plate 322. The guide plate 328 extends in the left-right and up-down directions. As shown in FIG. 25, the guide grooves 330, 332 of the guide plate 328 are formed in a generally rectangular shape with rounded corners. Guide grooves 330, 332 define a side step trajectory S, shown by the dashed line in Figure 25. Side step trajectory S has a generally rectangular shape with rounded corners, with upper and lower sides aligned in the left-right direction and right and left sides aligned in the up-down direction. The side step trajectory S defined by guide grooves 330, 332 is the same as the side step trajectory S defined by guide grooves 302, 304.

[0167] In the rear crank mechanism 277, when the pulleys 308, 310 rotate, the crank arms 314, 316 rotate, causing the crank pins 318, 320 to move in the rotational direction of the crank arms 314, 316. At this time, because the rollers 324, 326 are fitted in the guide grooves 330, 332, the crank pins 318, 320 slide inside the elongated holes 314b, 316b and move along the side step path S defined by the guide grooves 330, 332. As a result, the crank plate 322 to which the crank pins 318, 320 are fixed also moves along the side step path S defined by the guide grooves 330, 332.

[0168] 2, the step bars 272, 274 have their front ends fixed to the crank plate 294 of the front crank mechanism 276 and their rear ends fixed to the crank plate 322 of the rear crank mechanism 277. As shown in FIG. 24, the pulley 282 of the front crank mechanism 276 and the pulley 310 of the rear crank mechanism 277 are each connected to a rotation transmission shaft 428 of the power transmission mechanism 402. Therefore, when the rotation transmission shaft 428 rotates, the pulleys 280, 282 of the front crank mechanism 276 and the pulleys 308, 310 of the rear crank mechanism 277 rotate in synchronization with each other, and the crank plate 294 of the front crank mechanism 276 and the crank plate 322 of the rear crank mechanism 277 operate in synchronization with each other. That is, when the rotation transmission shaft 428 rotates in the forward or reverse direction, the pulleys 280, 282, 308, 310 rotate in the forward or reverse direction, which causes the crank plates 294, 322 to move clockwise or counterclockwise along the side step path S, and the step bars 272, 274 to also move clockwise or counterclockwise along the side step path S. A zero-point detection sensor (not shown) is provided in one of the front crank mechanism 276 and the rear crank mechanism 277 (e.g., the front crank mechanism 276). The zero-point detection sensor includes, for example, a permanent magnet (not shown) fixed to the crank plate 294 and a Hall element (not shown) fixed to the guide plate 300. The zero-point detection sensor can detect whether the crank plates 294, 322 are at the zero-point position, with the center of the upper edge of the side step path S in the left-right direction being the zero-point position.

[0169] As shown in Figure 27, when the crank plates 294, 322 are on the upper side of the side step track S (see Figure 25) and the step bars 272, 274 are moving upward, the crank plates 294, 322 and the step bars 272, 274 are separated from the first reinforcing bar R1 and the second reinforcing bar R2. In this state, the right crawler 192 and the left crawler 194 are in contact with the first reinforcing bar R1 and the second reinforcing bar R2, so the reinforcing bar binding robot 1 can drive the right crawler 192 and the left crawler 194 to move the chassis 190 in the front-to-rear direction. In addition, by imparting a speed difference between the right crawler 192 and the left crawler 194, the reinforcing bar binding robot 1 can also change the orientation of the chassis 190 with respect to the first reinforcing bar R1 and the second reinforcing bar R2.

[0170] When the rotation transmission shaft 428 (see FIG. 24) rotates from the state shown in FIG. 27, the crank plates 294, 322 move along the side step path S (see FIG. 25), and the step bars 272, 274 move downward accordingly, causing the crank plates 294, 322 and the step bars 272, 274 to come into contact with the second rebar R2. When the rotation transmission shaft 428 rotates further from this state, the crank plates 294, 322 and the step bars 272, 274 move further downward, causing the right crawler 192 and the left crawler 194 to move away from the second rebar R2, as shown in FIG. 28. As the rotation transmission shaft 428 continues to rotate, the chassis 190 moves to the right or left by a step width corresponding to the left-right width of the side step track S, and then the crank plates 294, 322 and step bars 272, 274 move upward, causing the right crawler 192 and left crawler 194 to again abut against the first rebar R1 and the second rebar R2, and the crank plates 294, 322 and step bars 272, 274 to move away from the second rebar R2. As described above, the rebar binding robot 1 can move the chassis 190 to the right or left by a predetermined step width by driving the side stepper 196.

[0171] The side step path S defined by the guide grooves 302, 304, 330, 332 is not limited to the generally rectangular shape described above and may have various other shapes. The side step path S may have any shape as long as, when the step bars 272, 274 move along the side step path S, the lower ends of the step bars 272, 274 move below the lower ends of the right crawler 192 and the left crawler 194, then the lower ends of the step bars 272, 274 move in the left-right direction, and then the lower ends of the step bars 272, 274 move above the lower ends of the right crawler 192 and the left crawler 194. For example, the side step path S may be circular, elliptical, triangular with a base at the bottom, or polygonal with pentagons or more sides.

[0172] (Configuration of power transmission mechanism 402) 29, the power transmission mechanism 402 includes a planetary gear mechanism 406, a first output shaft 414, a second output shaft 416, a first spur gear 418, a second spur gear 420, a third spur gear 422, a worm shaft 424, a worm wheel 426, a rotation transmission shaft 428, a universal joint 430, and a switching actuator 432. The planetary gear mechanism 406, the first output shaft 414, the second output shaft 416, the first spur gear 418, the second spur gear 420, the third spur gear 422, the worm shaft 424, and the worm wheel 426 are housed in a gear box 438 (see FIG. 24).

[0173] A dual-purpose motor 400 is connected to the planetary gear mechanism 406 from the left. The dual-purpose motor 400 is connected to a sun gear (not shown) of the planetary gear mechanism 406. The dual-purpose motor 400 is, for example, a DC brushless motor. A planetary carrier 410 of the planetary gear mechanism 406 is connected to a worm shaft 636 (see FIG. 30) of the lifting device 6 via a first output shaft 414 and a universal joint 430. An internal gear 412 of the planetary gear mechanism 406 is connected to the side stepper 196 via a first spur gear 418, a second output shaft 416, a second spur gear 420, a third spur gear 422, a worm shaft 424, a worm wheel 426, and a rotation transmission shaft 428 in this order.

[0174] An inner engagement recess 440 is formed on the outer surface of the planetary carrier 410. The inner engagement recess 440 is arranged in a row in the circumferential direction and has a plurality of inner recessed grooves 440a recessed from the radially outer side to the radially inner side. Furthermore, an outer recessed groove 442a is formed on the inner surface of the internal gear 412. The outer recessed grooves 442a are arranged in a row in the circumferential direction and have a plurality of outer recessed grooves 442a recessed from the radially inner side to the radially outer side.

[0175] The switching actuator 432 includes a locking member 434, a position detection mechanism 436, a pull solenoid 452, and a cap 456. The locking member 434 includes a locking pin 446 disposed near its front end so as to extend in the left-right direction. The locking member 434 is held by the cap 456 so as to be slidable in the front-rear direction. The locking member 434 is connected to the output shaft of the pull solenoid 452 within the cap 456. A compression spring (not shown) is also provided within the cap 456 to bias the output shaft of the pull solenoid 452 forward. The robot control unit 10 can switch the pull solenoid 452 between an energized state and a de-energized state.

[0176] In the state shown in FIG. 29, the pull solenoid 452 is energized. The output shaft of the pull solenoid 452 is moved rearward by the attractive force of the pull solenoid 452 against the biasing force of the compression spring. The locking member 434 is moved rearward in conjunction with the output shaft of the pull solenoid 452. At this time, the locking pin 446 of the locking member 434 engages with the outer engaging recess 442 of the internal gear 412, preventing the internal gear 412 from rotating. In this state, the power of the dual-purpose motor 400 is transmitted to the lifting device 6 (see FIG. 30) via the planetary gear mechanism 406, the first output shaft 414, and the universal joint 430 in this order. In this specification, the state in which the power of the dual-purpose motor 400 is transmitted to the lifting device 6 may be referred to as the "first transmission state."

[0177] When the pull solenoid 452 is switched from the state shown in FIG. 29 to a de-energized state, the locking member 434 is moved forward by the biasing force of the compression spring. The locking member 434 is moved forward in conjunction with the output shaft of the pull solenoid 452. As a result, the locking pin 446 of the locking member 434 engages with the inner engaging recess 440 of the planetary carrier 410. With the locking pin 446 engaged with the inner engaging recess 440, rotation of the internal gear 412 is prohibited. In this state, the power of the dual-purpose motor 400 is transmitted to the side stepper 196 via the planetary gear mechanism 406, the first spur gear 418, the second output shaft 416, the second spur gear 420, the third spur gear 422, the worm shaft 424, the worm wheel 426, and the rotation transmission shaft 428 in this order. In this specification, the state in which the power of the dual-purpose motor 400 is transmitted to the side stepper 196 may be referred to as the "second transmission state."

[0178] The position detection mechanism 436 is attached above the cap 456. The position detection mechanism 436 is a slide switch that moves in conjunction with the movement of the locking member 434, and is capable of detecting the position of the locking member 434. Therefore, based on the signal transmitted from the position detection mechanism 436, the robot control unit 10 can detect whether the power transmission mechanism 402 is in the first transmission state or the second transmission state.

[0179] (Configuration of lifting device 6) As shown in FIG. 30, the lifting device 6 includes a worm gear case 632, a lifting arm 634, and a slider crank mechanism 638. The worm gear case 632 is fixed to the base plate 204 (see FIG. 2). The lifting arm 634 is fixed to the worm gear case 632 with a screw. The lifting arm 634 extends from the worm gear case 632 toward the front, left, and upper side. The worm gear case 632 includes a worm shaft 636. The slider crank mechanism 638 includes a crank shaft 642, a crank arm 644, a crank pin 646, a crank rod 648, a slider pin 650, a slider 652, a rail 653, and a base member 654.

[0180] The crankshaft 642 is connected to the worm shaft 636 via a worm gear (not shown) built into the worm gear case 632. The crank arm 644 is fixed to the crankshaft 642. The crank pin 646 is rotatably held by both the crank arm 644 and the crank rod 648. The slider pin 650 is rotatably held by the crank rod 648. The slider pin 650 is fixed to a slider 652. The slider 652 is slidably held by a rail 653 provided on the lifting arm 634. The base member 654 is rotatably provided on the slider pin 650. The base member 654 is fitted into a fitting portion 12a (see FIG. 3) provided on the housing 12 of the rebar binding device 2, and is fixed to the housing 12 with a screw (not shown). That is, the lifting device 6 holds the reinforcing bar binding device 2 via the base member 654. As shown in FIG. 2, when the reinforcing bar binding device 2 is held by the lifting device 6, the front of the reinforcing bar binding device 2 faces downward toward the reinforcing bar binding robot 1, and the rear of the reinforcing bar binding device 2 faces upward toward the reinforcing bar tying robot 1.

[0181] In the state shown in FIG. 30, the slider-crank mechanism 638 is at the top dead center position. At this time, the reinforcing bar binding device 2 (see FIG. 3) is held at a position away from the first reinforcing bar R1 and the second reinforcing bar R2. In this specification, the position of the reinforcing bar binding device 2 in this state may be referred to as the "upper limit position." When the worm shaft 636 rotates forward or backward from the state shown in FIG. 30, the crankshaft 642 and crank arm 644 rotate forward or backward, and the crank pin 646 moves on a circumference centered on the rotation axis of the crankshaft 642. At this time, the slider pin 650 and slider 652, which are connected to the crank pin 646 via the crank rod 648, move downward along the rail 653 while maintaining a constant distance from the crank pin 646. At this time, the reinforcing bar binding device 2 fixed to the base member 654 descends relative to the chassis 190. In this embodiment, when the rebar binding device 2 is lowered, the crank arm 644 is rotated so that the crank pin 646 passes above the crankshaft 642 from the position shown in FIG. 30 to the position shown in FIG.

[0182] In the state shown in FIG. 31, the slider-crank mechanism 638 is at the bottom dead center position. At this time, the rebar binding device 2 (see FIG. 3) is held in a position that allows binding of the rebar intersections. In this specification, the position of the rebar binding device 2 in this state may be referred to as the "lower limit position." When the worm shaft 636 rotates forward or backward from the state shown in FIG. 31, the crankshaft 642 and crank arm 644 rotate forward or backward, and the crank pin 646 moves on a circle centered on the rotation axis of the crankshaft 642. At this time, the slider pin 650 and slider 652, which are connected to the crank pin 646 via the crank rod 648, move upward along the rail 653 while maintaining a constant distance from the crank pin 646. At this time, the rebar binding device 2, which is fixed to the base member 654, rises relative to the chassis 190. In this embodiment, when the rebar binding device 2 is raised, the crank arm 644 is rotated so that the crank pin 646 passes below the crankshaft 642 from the position shown in FIG. 31 to the position shown in FIG.

[0183] The slider 652 has a first interference pin 656 that protrudes toward the base member 654 along the rotation axis A1 of the slider pin 650, and an elongated hole 658 that is cut out along the circumferential direction of the rotation axis A1. The base member 654 has a second interference pin 660 that protrudes toward the slider 652 along the rotation axis A1 and is inserted into the elongated hole 658. The elongated hole 658 receives the second interference pin 660 so that it can slide in the circumferential direction of the rotation axis A1. A torsion spring 662 is attached to the slider pin 650 and is arranged to bias the second interference pin 660 in a first circumferential direction of the rotation axis A1 relative to the first interference pin 656. Therefore, the second interference pin 660 is held in contact with the side surface of the end of the elongated hole 658 from the first circumferential direction by the biasing force of the torsion spring 662, and is able to swing in a second circumferential direction, which is the opposite direction to the first circumferential direction, against the biasing force of the torsion spring 662. In other words, the reinforcing bar binding device 2 fixed to the base member 654 is held so as to be able to swing in the second circumferential direction about the rotation axis A1. As a result, for example, when the reinforcing bar binding device 2 collides with the first reinforcing bar R1, the second reinforcing bar R2, or another obstacle, the reinforcing bar binding device 2 swings in the second circumferential direction, thereby mitigating the impact on the reinforcing bar binding device 2 and the lifting device 6.

[0184] As shown in FIG. 32, the lifting device 6 is fixed to the crankshaft 642 (see FIG. 30) and further includes a cam 666 having a first fin 663 and a second fin 664 formed thereon and protruding radially outward from the crankshaft 642. One end of the first fin 663 and one end of the second fin 664 overlap each other in the circumferential direction of the rotation axis of the crankshaft 642. Meanwhile, the other end of the first fin 663 and the other end of the second fin 664 are spaced apart in the circumferential direction of the rotation axis of the crankshaft 642. Therefore, a gap having a width in the circumferential direction of the rotation axis of the crankshaft 642 is formed between the other end of the first fin 663 and the other end of the second fin 664. The lifting device 6 also includes a first photosensor 668 and a second photosensor 670, each of which has a light-emitting portion and a light-receiving portion. Each of the first photosensor 668 and the second photosensor 670 transmits an ON signal to the robot control unit 10 when there is no obstruction between the light-emitting portion and the light-receiving portion, and transmits an OFF signal to the robot control unit 10 when there is obstruction between the light-emitting portion and the light-receiving portion. The first photosensor 668 and the second photosensor 670 are fixed to the worm gear case 632 and aligned along the rotation axis of the crankshaft 642.

[0185] When the rebar binding device 2 is in a position between the lower limit position and the upper limit position, one of the first fin 663 or the second fin 664 is in a position that blocks the light-emitting portion and the light-receiving portion of either the first photosensor 668 or the second photosensor 670. The other of the first fin 663 or the second fin 664 is in a position that does not block the light-emitting portion and the light-receiving portion of either the first photosensor 668 or the second photosensor 670. When the rebar binding device 2 is moved from this state to the lower limit position, the overlapping portions of the first fin 663 and the second fin 664 are moved to approximately the same position as the first photosensor 668 and the second photosensor 670 in the circumferential direction of the rotation axis of the crankshaft 642. That is, when the reinforcing bar binding device 2 is at the lowermost position, the light emitting portion and the light receiving portion of the first photosensor 668 are blocked by the first fin 663, and the light emitting portion and the light receiving portion of the second photosensor 670 are blocked by the second fin 664. On the other hand, when the reinforcing bar binding device 2 is moved to the uppermost position, the portions of the first fin 663 and the second fin 664 that are separated from each other are moved to approximately the same positions as the first photosensor 668 and the second photosensor 670 in the circumferential direction of the rotation axis of the crankshaft 642. That is, when the reinforcing bar binding device 2 is at the uppermost position, the light emitting portion and the light receiving portion of the first photosensor 668 are not blocked, and the light emitting portion and the light receiving portion of the second photosensor 670 are not blocked either. Therefore, the robot control unit 10 can detect, based on the signals transmitted from the first photosensor 668 and the second photosensor 670, that the rebar binding device 2 has reached the upper limit position or the lower limit position.

[0186] (Robot initialization process) When the power switch is turned on to the rebar binding robot 1, the robot control unit 10 executes a robot initialization process. In this specification, "power on" refers to the start of power supply from the power control board 808 to the rebar binding device 2, the transport device 4, and the robot control unit 10. When the robot initialization process starts, the robot control unit 10 sends a status call signal to the device control unit 50. This causes the device control unit 50 to send a status notification signal to the robot control unit 10. The robot control unit 10 then determines whether an abnormality has occurred in the rebar binding device 2 based on the status notification signal. Specifically, the robot control unit 10 determines whether a binding device abnormality determination flag is included in the status notification signal. If it is determined that no abnormality has occurred in the rebar binding device 2, the robot control unit 10 terminates the robot initialization process. If it is determined that an abnormality has occurred in the rebar binding device 2, the robot control unit 10 executes the abnormality processing described below. Thereafter, the robot control unit 10 ends the robot initialization process.

[0187] (Robot main processing) When an instruction to execute an operation of the rebar binding robot 1 is given via an operation execution button (not shown) or the like, the robot control unit 10 executes the robot main processing shown in Fig. 33. In the following, for the sake of simplicity, the movement of the chassis 190 of the rebar binding robot 1 is considered to be the movement of the rebar binding robot 1.

[0188] In S202, the robot control unit 10 transmits a status call signal to the device control unit 50. As a result, a status notification signal is transmitted from the device control unit 50 to the robot control unit 10. After S202, the process proceeds to S204.

[0189] In S204, the robot control unit 10 determines whether or not an abnormality has occurred in the rebar binding device 2 based on the status notification signal sent from the device control unit 50. Specifically, the robot control unit 10 determines whether or not the status notification signal includes a binding device abnormality determination flag. If no abnormality has occurred in the rebar binding device 2 (YES), the process proceeds to S206.

[0190] In S206, the robot control unit 10 drives at least one of the right crawler 192, the left crawler 194, and the side stepper 196 to move the rebar binding robot 1 over the plurality of first rebars R1 and the plurality of second rebars R2. The robot control unit 10 moves the rebar binding robot 1 toward the rebar intersection RC', which is the target point for the rebar binding work. At this time, the robot control unit 10 controls the operation of the right crawler 192, the left crawler 194, and the side stepper 196 based on the relative positions of the first rebars R1 and the second rebars R2 detected by the plurality of rebar detection sensors and the rebar map. Note that if the pull solenoid 452 is energized at the start of S206, the robot control unit 10 switches the pull solenoid 452 to a de-energized state. As a result, the power transmission mechanism 402 is switched from the first transmission state to the second transmission state, and the side stepper 196 can be driven by the dual-purpose motor 400. After S206, the process proceeds to S208.

[0191] In S208, the robot control unit 10 determines whether the horizontal position of the rebar intersection RC' detected by the multiple rebar detection sensors is within a predetermined range from the reference position. The reference position here refers to the position where the rebar intersection RC' should be when the rebar binding device 2, located at its lowest position, performs rebar binding work. For example, the reference position is located at the center of the base plate 204 in the front-rear and left-right directions. The predetermined range here refers to the range within which it is determined that horizontal movement by the side stepper 196 is necessary if the horizontal position of the rebar intersection RC' is outside that range. If the position of the rebar intersection RC' is not within the predetermined range (NO), the process returns to S206. If the position of the rebar intersection RC' is within the predetermined range (YES), the process proceeds to S210.

[0192] In S210, the robot control unit 10 determines whether the angle of the first rebar R1 detected by the multiple rebar detection sensors at the rebar intersection RC' (hereinafter simply referred to as the "angle of the rebar intersection RC'") is within a predetermined angle range from the reference angle. The reference angle here refers to the angle that the first rebar R1 should take at the rebar intersection RC' when the rebar binding device 2 in the lowest position performs rebar binding work. For example, the reference angle is zero degrees. The predetermined angle range here refers to the range within which the rebar binding device 2 can perform rebar binding work if the angle of the rebar intersection RC' is within that range. If the angle of the rebar intersection RC' is not within the predetermined angle range (NO), the process proceeds to S212. If the angle of the rebar intersection RC' is within the predetermined angle range (YES), the process proceeds to S214.

[0193] In S212, the robot control unit 10 executes rebar tracing control. In rebar tracing control, the robot control unit 10 advances or retreats the rebar binding robot 1 while applying a speed difference between the right crawler 192 and the left crawler 194, thereby bringing the left-right position and angle of the rebar intersection point RC' closer to the reference position and reference angle. As shown in FIG. 34, when rebar tracing control is started, the robot control unit 10 first matches the angle of the rebar intersection point RC' to the reference angle. Then, as shown in FIG. 35, the robot control unit 10 matches the left-right position of the rebar intersection point RC' to the reference position. In FIGS. 34 and 35, the reference position and reference angle of the rebar binding robot 1 are represented by a cross cursor C. After S212, the process proceeds to S214.

[0194] In S214, the robot control unit 10 first switches the pull solenoid 452 to an energized state. This switches the power transmission mechanism 402 from the second transmission state to the first transmission state, enabling the lifting device 6 to be driven by the dual-purpose motor 400. The robot control unit 10 then drives the lifting device 6 to lower the rebar binding device 2 to its lowest position. This sets the rebar binding device 2 at the rebar intersection location RC'. After S214, the process proceeds to S216.

[0195] In S216, the robot control unit 10 transmits a status call signal to the device control unit 50. As a result, a status notification signal is transmitted from the device control unit 50 to the robot control unit 10. After S216, the process proceeds to S218.

[0196] In S218, the robot control unit 10 determines whether or not an abnormality has occurred in the rebar binding device 2 based on the status notification signal transmitted from the device control unit 50. Specifically, the robot control unit 10 determines whether or not the status notification signal includes a binding device abnormality determination flag. If no abnormality has occurred in the rebar binding device 2 (YES), the process proceeds to S220.

[0197] In S220, the robot control unit 10 transmits a bundling instruction signal to the device control unit 50. After S220, the process proceeds to S222.

[0198] In S222, the robot control unit 10 determines whether the rebar binding work has been completed in the rebar binding device 2. If the status notification signal received in S216 includes a binding work in progress flag, the robot control unit 10 determines that the rebar binding work has not been completed in the rebar binding device 2. If the status notification signal received in S216 does not include a binding work in progress flag, the robot control unit 10 determines that the rebar binding work has been completed in the rebar binding device 2. If the rebar binding work has not been completed in the rebar binding device 2 (in the case of NO), the process returns to S216. If the rebar binding work has been completed in the rebar binding device 2 (in the case of YES), the process proceeds to S224.

[0199] In S224, the robot control unit 10 drives the lifting device 6 to raise the rebar binding device 2 to the upper limit position. After S224, the process proceeds to S226.

[0200] In S226, the robot control unit 10 refers to the rebar map and determines whether the rebar tying work has been completed for all rebar intersections. If it is determined that the rebar tying work has been completed for all rebar intersections (YES), the processing in Figure 33 ends. If it is determined that the work has not yet been completed (NO), the processing proceeds to S228.

[0201] In S228, the robot control unit 10 changes the rebar intersection RC' that is the target of the rebar tying work to another rebar intersection where the rebar tying work has not yet been completed. After S228, the process returns to S206.

[0202] If it is determined in S204 or S218 that an abnormality has occurred in the rebar binding device 2 (NO), the process proceeds to S230. In S230, the robot control unit 10 executes the abnormality process described below. After S230, the process in FIG. 33 ends.

[0203] (Processing when an abnormality occurs) When the abnormality processing starts, the robot control unit 10 first stops driving the right crawler 192, the left crawler 194, and the side stepper 196. Then, the robot control unit 10 activates the patrol lamp 183 to notify that an abnormality has occurred in the rebar binding device 2. The robot control unit 10 also uses a buzzer to notify that an abnormality has occurred in the rebar binding device 2. If the rebar binding robot 1 is equipped with an external controller (not shown), the robot control unit 10 notifies the external controller that an abnormality has occurred in the rebar binding device 2. Then, the robot control unit 10 ends the abnormality processing. Note that the external controller here may be a controller dedicated to the rebar binding robot 1, or may be a general-purpose communication terminal such as a smartphone or tablet terminal.

[0204] (Variation) In the above embodiment, a configuration has been described in which the reinforcing bar tying robot 1 is equipped with the independent reel 500, and the independent reel 500 serves as a supply source of the wire W. In another embodiment, the reinforcing bar tying robot 1 does not have to be equipped with the independent reel 500. In this case, the reinforcing bar tying device 2 may be equipped with a wire reel WR on which the wire W is wound in advance, and the wire reel WR may serve as a supply source of the wire W.

[0205] In the above embodiment, a configuration has been described in which the wire W introduced into the housing 12 from the through hole 12b is wound around the wire reel WR and then supplied to the feeding mechanism 38. In another embodiment, the wire W introduced into the housing 12 from the through hole 12b may be wound around the wire reel WR, but may be stretched along the outer circumferential surface of the wire reel WR, and then supplied to the feeding mechanism 38. In this case, the wire reel WR may guide the wire W by rotating as the wire W is fed out.

[0206] In the above embodiment, the wire reel WR is detachably provided in the housing 12. In another embodiment, the wire reel WR may be non-detachably provided in the housing 12.

[0207] In the above embodiment, a configuration has been described in which the power supply device 8 is equipped with multiple battery packs B, and the power control board 808 of the power supply device 8 supplies power from the multiple battery packs B to the rebar binding device 2, the transport device 4, and the robot control unit 10. In another embodiment, the power supply device 8 may be equipped with a power cord that connects to an external power source instead of the multiple battery packs B. The power control board 808 may be configured to supply power from the external power source to the rebar binding device 2, the transport device 4, and the robot control unit 10.

[0208] In the above embodiment, a configuration has been described in which the communication method between the device control unit 50 and the robot control unit 10 is a wired serial communication method. In another embodiment, the communication method between the device control unit 50 and the robot control unit 10 may be a wired parallel communication method. In yet another embodiment, the communication method between the device control unit 50 and the robot control unit 10 may be a wireless communication method.

[0209] In the above embodiment, the device control unit 50 may further include a voltage detection circuit provided in correspondence with the driver circuit 24. The device control unit 50 may directly detect the voltage applied to the driver circuit 24 or the potential of the driver circuit 24 via this voltage detection circuit.

[0210] In the above embodiment, a configuration has been described in which the reel rotation detection sensor 66 (Hall sensor) detects the presence or absence of the wire W wound on the wire reel WR. In another embodiment, a sensor other than a Hall sensor (for example, a pressure sensor, a photoelectric sensor, or a microswitch) may detect the presence or absence of the wire W wound on the wire reel WR. For example, the pressure sensor may be provided to detect the pressure of the cylindrical portion of the wire reel WR (the portion around which the wire W is wound). The photoelectric sensor may include a light-emitting portion provided on one of a pair of flanges (portions that prevent the wire W from slipping out) of the wire reel WR, and a light-receiving portion provided on the other of the pair of flanges. The microswitch may be provided to be pressed by the wire W wound on the wire reel WR.

[0211] In the above embodiment, a configuration has been described in which the reel rotation detection sensor 66 (Hall sensor) detects whether or not the wire reel WR is held by the reel holding mechanism 36. In another embodiment, a sensor other than the Hall sensor (for example, a microswitch) may detect whether or not the wire reel WR is held by the reel holding mechanism 36. For example, the microswitch may be provided so as to be pressed when the wire reel WR is held by the reel holding mechanism 36.

[0212] In the above embodiment, a configuration has been described in which a dedicated rebar tying device 2 is attached to the rebar tying robot 1. In another embodiment, a commercially available handheld rebar tying machine (for example, TR180D sold by Makita Corporation) may be attached to the rebar tying robot 1 instead of the dedicated rebar tying device 2. In this case, the control unit built into the commercially available rebar tying machine may have a configuration similar to that of the device control unit 50. The control unit built into the commercially available rebar tying machine may be configured to be able to execute the various processes executed by the device control unit 50.

[0213] In the above embodiment, the robot control unit 10 may transmit a status call signal to the device control unit 50 every time a predetermined time has elapsed. The device control unit 50 may transmit a status notification signal to the robot control unit 10 in response to a status call signal periodically transmitted from the robot control unit 10. In this case, in S204 or S218 of the processing shown in FIG. 33, the robot control unit 10 may always determine whether or not an abnormality has occurred in the rebar binding device 2 based on the latest status notification signal.

[0214] In the above embodiment, a configuration has been described in which the robot control unit 10 determines that an abnormality has occurred in the rebar binding device 2 when a binding device abnormality determination is included in the status notification signal sent from the device control unit 50. In another embodiment, the robot control unit 10 may determine that an abnormality has occurred in the rebar binding device 2 when a predetermined time has passed without receiving a binding completion signal from the device control unit 50 after sending a binding instruction signal to the device control unit 50.

[0215] In the above embodiment, the device control unit 50 may store in memory, during the rebar tying operation, the transitions of the detected values ​​of the reel rotation detection sensor 66, the gear rotation detection sensor 79, the plate position detection sensor 134, the guide position detection sensor 142, the sleeve position detection sensor 177, the torsion motor rotation detection sensor 55, the voltage detection circuits 25, 26, 27, the current detection circuit 28, and the temperature detection sensor 32. Then, when the rebar tying operation by the rebar tying device 2 is successfully completed, the device control unit 50 may transmit a binding completion signal including the transitions of the above detected values ​​to the robot control unit 10. In this case, the robot control unit 10 may determine the quality of the rebar tying operation (for example, whether the wire W is loose) based on the transitions of the above detected values.

[0216] (Correspondence) As described above, in the first aspect of the present technology, the rebar tying robot 1 can repeatedly perform the following operations: moving over a plurality of first rebars R1 and a plurality of second rebars R2 that intersect with the plurality of first rebars R1; and tying rebar intersections where the plurality of first rebars R1 and the plurality of second rebars R2 intersect. The rebar tying robot 1 includes a robot control unit 10 that controls the operation of the rebar tying robot 1, and a rebar tying device 2 that performs rebar tying work using a wire W. The rebar tying device 2 includes an equipment control unit 50 that controls the operation of the rebar tying device 2. The equipment control unit 50 is configured to send a status notification signal (an example of a first signal) to the robot control unit 10. The robot control unit 10 is configured to control the operation of the rebar tying robot 1 based on the status notification signal sent from the equipment control unit 50.

[0217] According to the above configuration, the device control unit 50 can transmit the state of the rebar binding device 2 to the robot control unit 10 through a state notification signal. The robot control unit 10 can grasp the state of the rebar binding device 2 based on the state notification signal. Therefore, the robot control unit 10 can control the operation of the rebar binding robot 1 according to the state of the rebar binding device 2.

[0218] In the second aspect, the reinforcing bar binding device 2 in the first aspect is configured to be able to perform an operation of feeding the wire W. The reinforcing bar binding device 2 further includes a reel rotation detection sensor 66, a gear rotation detection sensor 79, a voltage detection circuit 25, a voltage detection circuit 26, and a current detection circuit 28 (examples of a first state detection unit) that detect a state related to the operation of feeding the wire W. The state notification signal includes a feed operation normal determination flag, a hardware normal determination flag, a wire shortage determination flag, a feed motor overload determination flag, a feed gear abnormality determination flag, a feed motor FET open failure determination flag, a feed motor FET voltage abnormality determination flag, a solenoid FET open failure determination flag, a solenoid FET voltage abnormality determination flag, and detection values ​​of the reel rotation detection sensor 66, the gear rotation detection sensor 79, the voltage detection circuit 25, the voltage detection circuit 26, and the current detection circuit 28 (examples of information related to the detection results of the first state detection unit).

[0219] The operation of feeding the wire W is a main operation of the rebar binding device 2. For this reason, there are cases where the robot control unit 10 wants to know the status of the operation of feeding the wire W of the rebar binding device 2. According to the above configuration, the robot control unit 10 can know the status of the operation of feeding the wire W based on the status notification signal.

[0220] In the third aspect, in the second aspect, the first state detection unit includes a reel rotation detection sensor 66 (an example of a wire detection unit) that detects the presence or absence of a wire W. The state notification signal includes a wire shortage determination flag and a detection value of the reel rotation detection sensor 66 (an example of information related to the detection result of the wire detection unit).

[0221] If there is a shortage of wire in the reinforcing bar binding device 2, the reinforcing bar binding device 2 will be unable to perform the reinforcing bar binding work. In order to control the operation of the reinforcing bar binding robot 1 in accordance with such a situation, the robot control unit 10 needs to know whether or not there is wire W. According to the above configuration, the robot control unit 10 can know whether or not there is wire W based on the status notification signal.

[0222] In a fourth aspect, the reinforcing bar binding device 2 in the third aspect further includes a wire reel WR around which the wire W is wound, and a housing 12 that rotatably holds the wire reel WR. A reel rotation detection sensor 66 detects whether or not the wire W is wound around the wire reel WR.

[0223] According to the above configuration, when the wire W is wound around the wire reel WR, the wire reel WR rotates in accordance with the operation of feeding the wire W of the reinforcing bar binding device 2. When the wire W wound around the wire reel WR runs out, the wire reel WR stops rotating in accordance with the operation of feeding the wire W of the reinforcing bar binding device 2. Therefore, the reel rotation detection sensor 66 can indirectly detect the presence or absence of the wire W by detecting whether the wire reel WR rotates in accordance with the operation of feeding the wire W of the reinforcing bar binding device 2.

[0224] In a fifth aspect, in any one of the second to fourth aspects, the rebar binding device 2 includes a feed motor 72, and further includes a feed mechanism 38 capable of feeding the wire W. The first state detection unit includes a gear rotation detection sensor 79, a voltage detection circuit 26, and a current detection circuit 28 (examples of a feed mechanism state detection unit) that detect the state of the feed mechanism 38. The state notification signal includes a feed motor overload determination flag, a feed gear abnormality determination flag, a feed motor FET open failure determination flag, a feed motor FET voltage abnormality determination flag, and detection values ​​of the gear rotation detection sensor 79, the voltage detection circuit 26, and the current detection circuit 28 (examples of information related to the detection results of the feed mechanism state detection unit).

[0225] For example, the wire W may become tangled in the feeding mechanism 38, rendering the feeding mechanism 38 inoperable. To control the operation of the rebar binding robot 1 in response to such a situation, the robot control unit 10 needs to know the state of the feeding mechanism 38. With the above configuration, the robot control unit 10 can know the state of the feeding mechanism 38 based on the state notification signal.

[0226] In a sixth aspect, in any one of the second to fifth aspects, the rebar binding device 2 further includes a wire reel WR around which the wire W is wound, a housing 12 that rotatably holds the wire reel WR, and a brake mechanism 40 (an example of a brake mechanism) that includes a pull solenoid 146 (an example of a brake actuator) and is capable of braking the rotational motion of the wire reel WR. The first state detection unit includes a voltage detection circuit 25 and a current detection circuit 28 (an example of a brake mechanism state detection unit) that detect the state of the brake mechanism 40. The state notification signal includes a solenoid FET open failure determination flag, a solenoid FET voltage abnormality determination flag, and detection values ​​of the voltage detection circuit 25 and the current detection circuit 28 (an example of information related to the detection results of the brake mechanism state detection unit).

[0227] For example, the brake mechanism 40 may become inoperable due to an open circuit failure of the solenoid FET (an example of which is when the electrical connection between the power supply and the braking actuator is cut off). In order to control the operation of the rebar binding robot 1 in accordance with such a situation, the robot control unit 10 needs to grasp the state of the brake mechanism 40. With the above configuration, the robot control unit 10 can grasp the state of the brake mechanism 40 based on the state notification signal.

[0228] In a seventh aspect, in any one of the above first to sixth aspects, the reinforcing bar binding device 2 is configured to be able to execute an operation of twisting the wire W wound around a reinforcing bar intersection point. The reinforcing bar binding device 2 further includes a twisting motor rotation detection sensor 55, a sleeve position detection sensor 177, and a current detection circuit 28 (an example of a second state detection unit) that detect states related to the operation of twisting the wire W. The state notification signal includes a twisting operation normal determination flag, a hardware normal determination flag, a twisting motor lock determination flag, a twisting motor rotation abnormal determination flag, a twisting motor overload determination flag, a twisting motor rotation detection sensor abnormal determination flag, a twisting arm abnormality determination flag, and detection values ​​of the twisting motor rotation detection sensor 55, the sleeve position detection sensor 177, and the current detection circuit 28 (an example of information related to the detection results of the second state detection unit).

[0229] The operation of twisting the wire W is a main operation of the rebar binding device 2. For this reason, there are cases where the robot control unit 10 wants to know the status of the operation of twisting the wire W of the rebar binding device 2. According to the above configuration, the robot control unit 10 can know the status of the operation of twisting the wire W based on the status notification signal.

[0230] In an eighth aspect, the rebar binding device 2 of the seventh aspect is equipped with a twisting motor 170 and further includes a twisting mechanism 46 that is capable of twisting the wire W wound around the rebar intersection. The second state detection unit includes a twisting motor rotation detection sensor 55, a sleeve position detection sensor 177, and a current detection circuit 28 (examples of a twisting mechanism state detection unit) that detect the state of the twisting mechanism 46. The state notification signal includes a twisting motor lock determination flag, a twisting motor rotation abnormality determination flag, a twisting motor overload determination flag, a twisting motor rotation detection sensor abnormality determination flag, a twisting arm abnormality determination flag, and detection values ​​of the twisting motor rotation detection sensor 55, the sleeve position detection sensor 177, and the current detection circuit 28 (examples of information related to the detection results of the twisting mechanism state detection unit).

[0231] For example, the wire W may become tangled in the twisting mechanism 46, rendering the twisting mechanism 46 inoperable. To control the operation of the rebar binding robot 1 in response to such a situation, the robot control unit 10 needs to grasp the state of the twisting mechanism 46. With the above configuration, the robot control unit 10 can grasp the state of the twisting mechanism 46 based on the state notification signal.

[0232] In a ninth aspect, in any one of the above first to eighth aspects, the rebar binding device 2 further includes a wire reel WR around which the wire W is wound or which guides the wire W, a reel holding mechanism 36 (an example of a reel holding section) which detachably holds the wire reel WR, and a reel rotation detection sensor 66 (an example of a reel detection section) which detects whether the wire reel WR is held by the reel holding mechanism 36. The state notification signal includes a reel detachment determination flag (an example of information relating to the detection result of the reel detection section).

[0233] If the wire reel WR is not held by the reel holding mechanism 36, this is essentially the same as a wire shortage, and the rebar binding device 2 cannot perform rebar binding work. In order to control the operation of the rebar binding robot 1 in accordance with such a situation, the robot control unit 10 needs to know whether or not the wire reel WR is held by the reel holding mechanism 36. With the above configuration, the robot control unit 10 can know whether or not the wire reel WR is held by the reel holding mechanism 36 based on the status notification signal.

[0234] In a tenth aspect, in any one of the first to ninth aspects, the rebar binding device 2 further includes a feed mechanism 38 equipped with a feed motor 72 and capable of feeding wire W, a housing 12 accommodating the feed motor 72, a lower curl guide 92 (an example of a guide member) attached to the housing 12 and movable between a closed position (an example of a first position) in which the wire W fed by the feed mechanism 38 is guided onto a substantially annular guide track and wound around a rebar intersection, and an open position (an example of a second position) in which the lower curl guide 92 is moved outward from the guide track relative to the closed position, and a guide position detection sensor 142 (an example of a guide member position detection unit) that detects the position of the lower curl guide 92 relative to the housing 12. The status notification signal includes a guide position abnormality determination flag and a detection value of the guide position detection sensor 142 (an example of information related to the detection result of the guide member position detection unit).

[0235] In the rebar binding device 2, the lower curl guide 92 may be provided to be movable relative to the housing 12 to improve the maintenance performance of parts provided around the guide track. However, if rebar binding work is performed with the lower curl guide 92 moved to the open position, the rebar intersections cannot be properly bound. For this reason, in the rebar binding robot 1, it may be desirable to perform control according to the position of the lower curl guide 92. In this case, the robot control unit 10 needs to know the position of the lower curl guide 92 relative to the housing 12. With the above configuration, the robot control unit 10 can know the position of the lower curl guide 92 relative to the housing 12 based on the status notification signal.

[0236] In an eleventh aspect, in any one of the first to tenth aspects, the reinforcing bar binding device 2 further includes a temperature detection sensor 32 (an example of a temperature detection unit) that detects the temperature of the device control unit 50. The status notification signal includes a temperature normality determination flag, a temperature abnormality determination flag, and a detection value of the temperature detection sensor 32 (an example of information related to the detection result of the temperature detection unit).

[0237] If the temperature of the device control unit 50 becomes very high, it may lead to a breakdown of the device control unit 50. For this reason, in the rebar binding robot 1, there are cases where it is desired to execute control according to the temperature of the device control unit 50. In this case, the robot control unit 10 needs to know the temperature of the device control unit 50. With the above configuration, the robot control unit 10 can know the temperature of the device control unit 50 based on the status notification signal.

[0238] In a twelfth aspect, in any one of the above first to eleventh aspects, the rebar binding robot 1 further includes a power supply device 8 for supplying power to the rebar binding device 2. The rebar binding device 2 further includes a voltage detection circuit 27 (an example of a supply voltage detection unit) that detects the voltage value of the power supplied from the power supply device 8 to the rebar binding device 2. The status notification signal includes a low voltage determination flag, a normal supply voltage determination flag, and a detection value of the voltage detection circuit 27 (an example of information relating to the detection result of the supply voltage detection unit).

[0239] If the voltage value of the power supplied from the power supply device 8 to the rebar binding device 2 drops and becomes insufficient, there is a possibility that the rebar binding work will be forcibly interrupted due to a lack of power. For this reason, there are cases where the rebar binding robot 1 needs to execute control according to the voltage value of the power supplied to the rebar binding device 2. In this case, the robot control unit 10 needs to know the voltage value of the power supplied from the power supply device 8 to the rebar binding device 2. With the above configuration, the robot control unit 10 can know the voltage value of the power supplied from the power supply device 8 to the rebar binding device 2 based on the status notification signal.

[0240] In a thirteenth aspect, in any one of the above first to twelfth aspects, the reinforcing bar binding device 2 further includes a contact plate 102 (an example of a contact member) arranged in a position where it can come into contact with the first reinforcing bar R1 or the second reinforcing bar R2 during reinforcing bar binding work, a housing 12 that swingably holds the contact plate 102, and a plate position detection sensor 134 (an example of a contact member position detection unit) that detects the position of the contact plate 102 relative to the housing 12. The status notification signal includes a plate normality determination flag, a plate abnormality determination flag, and a detection value of the plate position detection sensor 134 (an example of information related to the detection result of the contact member position detection unit).

[0241] In order to reliably perform rebar tying work, the robot control unit 10 may want to detect that the rebar tying device 2 has been set at a rebar intersection. According to the above configuration, the robot control unit 10 can detect that the rebar tying device 2 has been set at a rebar intersection by determining whether the contact plate 102 has been swung based on the status notification signal.

[0242] In a fourteenth aspect, in any one of the first to thirteenth aspects, the state notification signal includes a binding device abnormality determination flag (an example of information indicating that an abnormality has occurred in the reinforcing bar binding device).

[0243] According to the above configuration, the robot control unit 10 can grasp, based on the status notification signal, that an abnormality has occurred in the rebar binding device 2. Therefore, the robot control unit 10 can stop the operation of the rebar binding robot 1 in response to the occurrence of an abnormality in the rebar binding device 2, or notify the user of this fact.

[0244] In a fifteenth aspect, in any one of the first to fourteenth aspects, the robot control unit 10 is configured to transmit a status call signal (an example of a call signal) to the device control unit 50. The device control unit 50 is configured to transmit a status notification signal to the robot control unit 10 when the device control unit 50 receives the status call signal.

[0245] According to the above configuration, the device control unit 50 does not need to execute a process for identifying the timing for transmitting a status notification signal. This allows the device control unit 50 to have a simple configuration. Furthermore, according to the above configuration, the robot control unit 10 can grasp the status of the rebar binding device 2 at the desired timing.

[0246] In a sixteenth aspect, in any one of the first to fifteenth aspects, the robot control unit 10 is configured to transmit a bundling instruction signal to the device control unit 50. The device control unit 50 is configured to cause the rebar binding device 2 to perform a rebar binding operation when the device control unit 50 receives the bundling instruction signal. The robot control unit 10 is configured to transmit a status call signal to the device control unit 50 prior to transmitting the bundling instruction signal.

[0247] If the state of the reinforcing bar binding device 2 can be grasped at the timing when the reinforcing bar binding work is started, the robot control unit 10 can determine whether or not to continue the reinforcing bar binding work thereafter based on the state of the reinforcing bar binding device 2. According to the above configuration, the robot control unit 10 can grasp the state of the reinforcing bar binding device 2 at the timing when the reinforcing bar binding work is started. Therefore, the robot control unit 10 can determine whether or not to continue the reinforcing bar binding work based on the state of the reinforcing bar binding device 2. [Explanation of symbols]

[0248] 1: Rebar tying robot 2: Rebar binding device 4:Transportation device 6: Lifting device 8:Power supply 10: Robot control unit 12: Housing 12a: Fitting part 12b: Through hole 20: Control power circuit 21: Main microcomputer 22: Driver circuit 23: Driver circuit 24: Driver circuit 25: Voltage detection circuit 26: Voltage detection circuit 27: Voltage detection circuit 28: Current detection circuit 31:Protection FET 32: Temperature detection sensor 36: Reel holding mechanism 38: Feed mechanism 40: Brake mechanism 42: Guide mechanism 44: Cutting mechanism 46: Torsion mechanism 50: Device control unit 54: Cam member 54a: Rotating lever 55: Torsion motor rotation detection sensor 56: Shaft member 58: Compression spring 60: Rotating table 62: Inner bearing 64: Outer bearing 66: Reel rotation detection sensor 68: Guide member 68a: Insertion hole 72: Feed motor 78: Main gear 78a: V-shaped groove 79: Gear rotation detection sensor 80: Driven gear 80a: V-shaped groove 82: Release lever 82a: Gear arm 82b: Operating arm 82c: Oscillating shaft 82d: Engagement recess 84: Compression spring 86: Lock lever 86a: Lock arm 86c: Oscillating shaft 86d: Engagement convex part 88: Guide pipe 90: Upper curl guide 92: Lower curl guide 92a: Oscillating shaft 92b: Torsion spring 92c: Contact part 94: First guide aisle 96: Second guide aisle 98: Lead holder 100: Guide arm 100a: Upper guide wall 102: Contact plate 102a: Contact part 102b: Oscillating shaft 102c:Connection part 104: Left guide plate 106: Inner guide plate 108: Right guide plate 110: Guide member 110a: Wire passage 112: Top plate 112a:Protrusion 114: First guide pin 116: Cutter 118: Fixing member 118a: Wire passage 120: Swinging member 120a: Through hole 120b: Cut piece 122: Second guide pin 124: Third guide aisle 124a:Left guide wall 124b: Right guide wall 126: Guard plate 128: Compression spring 130: Sensor magnet 132:Magnetic arm 134: Plate position detection sensor 136: Guide position detection mechanism 138: Guide position detection member 138a: Contact arm 138b: Oscillating shaft 138c: Support arm 140: Compression spring 142: Guide position detection sensor 144: Sensor magnet 146: Pull solenoid 148: Compression spring 150: Brake member 150a: Drive arm 150b: Oscillating shaft 150c: Brake arm 150d: Plate section 150e: Tip rib 150f: Side edge rib 152: Push plate 154: Pull plate 156: First link arm 158: Second link arm 160: Oscillating shaft 162: Oscillating shaft 164: Torsion spring 166: Oscillating shaft 168: Oscillating shaft 170: Torsion motor 172: Reduction mechanism 174: Sleeve 176: Pusher 177: Sleeve position detection sensor 178: Hook 183: Patrol lamp 190: Chassis 192: Right crawler 194: Left crawler 196: Side Stepper 204: Base plate 204a: Through hole 210: Right side plate 212: Left side plate 214: Base frame 215: Front connecting frame 216: Rear connecting frame 218: Front pulley 220: Rear pulley 222: Auxiliary pulley 224: Tensioner pulley 226: Rubber belt 228: Right crawler motor 230: Gearbox 232: Bearing 234: Bearing 236: Bearing 237: Movable bearing 244: Front pulley 246: Rear pulley 248: Auxiliary pulley 250: Tensioner pulley 252: Rubber belt 254: Left crawler motor 256: Gearbox 258: Bearing 260: Bearing 262: Bearing 264: Movable bearing 272: Step bar 274: Step bar 276: Front crank mechanism 277: Rear crank mechanism 278: Support plate 280: Pulley 280a: Axis 282: Pulley 282a: Axis 283: Tensioner pulley 284: Belt 286: Crank arm 286a: Fitting hole 286b: Long hole 288: Crank arm 288a: Fitting hole 288b: Long hole 290: Crank pin 292: Crank pin 294: Crank plate 296: Laura 298: Laura 300: Guide plate 302: Guide groove 304: Guide groove 306: Support plate 308: Pulley 308a: Axis 310: Pulley 310a: Axis 311: Tensioner pulley 312: Belt 314: Crank arm 314a: Fitting hole 314b: Long hole 316: Crank arm 316a: Fitting hole 316b: Long hole 318: Crank pin 320: Crank pin 322: Crank plate 324: Laura 326: Laura 328: Guide plate 330: Guide groove 332: Guide groove 400: Dual-purpose motor 402: Power transmission mechanism 406: Planetary gear mechanism 410: Planetary carrier 412: Internal gear 414: 1st output shaft 416: Second output shaft 418: 1st spur gear 420: 2nd spur gear 422: 3rd spur gear 424: Worm shaft 426: Worm wheel 428: Rotation transmission shaft 430: Universal joint 432: Switching actuator 434:Locking member 436: Position detection mechanism 438: Gearbox 440: Inner engagement recess 440a: Internal recessed groove 442:Outer engagement recess 442a: Lateral recessed groove 446: Locking pin 452: Pull solenoid 456: Cap 500: Independent reel 550: Wire relay mechanism 552: Base 554: Guide roller 556: Feed roller 557: Feed roller 558: Insertion member 632: Worm gear case 634: Lifting arm 636: Worm shaft 638: Slider crank mechanism 642: Crankshaft 644: Crank arm 646: Crank pin 648: Crank rod 650: Slider pin 652: Slider 653: Rail 654: Base material 656: First interference pin 658: Long hole 660: Second interference pin 662: Spring 663: First Fin 664: Second Fin 666: Cam 668: First photosensor 670: Second photosensor 802: Right battery case 804: Left battery case 806: Transformer 808: Power control board 812: Right-side battery remaining capacity indicator 814: Left battery level indicator B: Multiple battery packs W: Wire WR: Wire reel WRa: Shaft receiving groove WRc: Engagement part

Claims

1. A rebar tying robot capable of repeatedly performing an action of moving over a plurality of first rebars and a plurality of second rebars intersecting with the plurality of first rebars, and an action of tying rebar intersections where the plurality of first rebars and the plurality of second rebars intersect, A robot control unit for controlling the operation of the rebar tying robot; A rebar tying device that performs rebar tying work using a wire, The reinforcing bar tying device includes a device control unit that controls the operation of the reinforcing bar tying device, the machine control unit is configured to send a first signal to the robot control unit; The robot control unit is configured to control an operation of the rebar tying robot based on the first signal transmitted from the machine control unit.

2. The reinforcing bar binding device is configured to be capable of performing an operation of feeding the wire, The reinforcing bar binding device further includes a first state detection unit that detects a state related to the operation of feeding the wire, The rebar tying robot according to claim 1 , wherein the first signal includes information regarding a detection result of the first state detection unit.

3. The first state detection unit includes a wire detection unit that detects the presence or absence of the wire, The rebar tying robot according to claim 2 , wherein the first signal includes information regarding a detection result of the wire detection unit.

4. The reinforcing bar binding device is a wire reel on which the wire is wound; The wire reel further includes a housing that rotatably holds the wire reel, The reinforcing bar binding robot according to claim 3 , wherein the wire detection unit detects the presence or absence of the wire wound around the wire reel.

5. The rebar binding device further includes a feed mechanism that includes a feed motor and is capable of feeding the wire; The first state detection unit includes a feed mechanism state detection unit that detects a state of the feed mechanism, The rebar tying robot according to claim 2 , wherein the first signal includes information regarding a detection result of the feed mechanism state detection unit.

6. The reinforcing bar binding device is a wire reel on which the wire is wound; a housing that rotatably holds the wire reel; The wire reel further includes a braking mechanism including a braking actuator and capable of braking the rotational motion of the wire reel, The first state detection unit includes a brake mechanism state detection unit that detects a state of the brake mechanism, The rebar tying robot according to claim 2 , wherein the first signal includes information regarding a detection result of the braking mechanism state detection unit.

7. The reinforcing bar binding device is configured to be capable of twisting the wire wound around the reinforcing bar intersection, The reinforcing bar binding device further includes a second state detection unit that detects a state related to the operation of twisting the wire, The rebar tying robot according to claim 1 , wherein the first signal includes information regarding a detection result of the second state detection unit.

8. The reinforcing bar tying device further includes a twisting motor and a twisting mechanism capable of twisting the wire wound around the reinforcing bar intersection, The second state detection unit includes a torsion mechanism state detection unit that detects a state of the torsion mechanism, The rebar tying robot according to claim 7 , wherein the first signal includes information regarding a detection result of the twisting mechanism state detection unit.

9. The reinforcing bar binding device is a wire reel on which the wire is wound or which guides the wire; a reel holding portion that detachably holds the wire reel; a reel detection unit that detects whether the wire reel is held by the reel holding unit, The rebar tying robot according to claim 1 , wherein the first signal includes information regarding a detection result of the reel detection unit.

10. The reinforcing bar binding device is a feed mechanism including a feed motor and capable of feeding the wire; a housing that accommodates the feed motor; a guide member attached to the housing and movable between a first position where the wire fed by the feeding mechanism is guided onto a substantially annular guide track and wound around the rebar intersection, and a second position where the guide track is moved outward relative to the first position; a guide member position detector that detects a position of the guide member relative to the housing, The rebar tying robot according to claim 1 , wherein the first signal includes information regarding a detection result of the guide member position detection unit.

11. The reinforcing bar binding device further includes a temperature detection unit that detects the temperature of the device control unit, The rebar tying robot according to claim 1 , wherein the first signal includes information regarding a detection result of the temperature detection unit.

12. The rebar tying robot further includes a power supply device for supplying power to the rebar tying device, The reinforcing bar binding device further includes a supply voltage detection unit that detects a voltage value of the power supplied from the power supply device to the reinforcing bar binding device, The rebar tying robot according to claim 1 , wherein the first signal includes information regarding a detection result of the supply voltage detection unit.

13. The reinforcing bar binding device is a contact member disposed at a position capable of contacting the first reinforcing bar or the second reinforcing bar during the reinforcing bar fastening operation; a housing that holds the contact member so as to be able to swing; a contact member position detector that detects a position of the contact member relative to the housing, The rebar tying robot according to claim 1 , wherein the first signal includes information regarding a detection result of the contact member position detection unit.

14. The rebar tying robot according to claim 1 , wherein the first signal includes information indicating that an abnormality has occurred in the rebar tying device.

15. the robot control unit is configured to send a call signal to the machine control unit; The rebar tying robot of claim 1 , wherein the machine control unit is configured to transmit the first signal to the robot control unit upon receiving the call signal.

16. the robot control unit is configured to send a bundling instruction signal to the machine control unit; The device control unit is configured to cause the reinforcing bar fastening device to perform the reinforcing bar fastening operation when the device control unit receives the fastening instruction signal, The rebar tying robot of claim 15 , wherein the robot control unit is configured to send the call signal to the machine control unit prior to sending the tying instruction signal.

Images