Picking system, picking method and program

Abstract

To suitably pick and kit a plurality of kinds of workpieces.SOLUTION: There is provided a picking system for picking and kitting a plurality of kinds of workpieces, and including: a picking hand having a gripping part for gripping the workpieces piled in bulk and performing picking and kitting; an imaging unit for imaging the workpieces; and an identification unit for identifying shapes of the workpieces from an imaged image; and a control part for discriminating a gripping position for the gripping part to grip, of the workpiece and an attitude at a time of kitting, causing the gripping part to grip the workpiece at the gripping position, and causing the picking hand to kit the workpiece in the attitude at the time of kitting.SELECTED DRAWING: Figure 9

Description

[Technical field]

[0001] The present disclosure relates to a picking system, a picking method, and a program. [Background technology]

[0002] In recent years, there has been a demand for parts supply systems that can handle variable-mix, variable-volume production to meet diversifying market needs. In response to this, development of picking systems that recognize bulk-stacked workpieces with vision sensors and pick them out with robots is progressing widely.

[0003] For example, Patent Document 1 discloses a robot system that uses the fingers of a robot hand to pick and kit a specified number of workpieces from a pile of workpieces. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2022-45771 A Summary of the Invention [Problem to be solved by the invention]

[0005] However, the robot system described in Patent Document 1 manages only the number of workpieces of a single type, and therefore cannot be used when picking and kitting multiple types of workpieces. In addition, this robot system identifies the location of the workpiece using an imaging unit, but attempts to hold the workpiece using the fingers of the robot hand without identifying the position and orientation of the workpiece, which may result in failure to hold the workpiece.

[0006] The present disclosure has been made in consideration of the above-mentioned situation, and aims to provide a picking system, a picking method, and a program that are suitable for picking and kitting multiple types of work. [Means for solving the problem]

[0007] In order to achieve the above-mentioned objective, the picking system disclosed herein is a picking system that picks and kits multiple types of workpieces, and is equipped with a picking hand that has a gripping part that grips bulk stacked workpieces and performs the picking and kitting, an imaging part that images the workpieces, and a control part that identifies the shape of the workpiece from the captured image, determines the gripping position of the workpiece by the gripping part and the posture at the time of kitting, and controls the gripping part to grip the workpiece at the gripping position and the picking hand to kit the work in the posture at the time of kitting. Effect of the Invention

[0008] According to the present disclosure, by identifying the shape of the workpiece from the captured image, it is possible to determine the gripping position of the workpiece by the gripping unit and the posture at the time of kitting, and to control the gripping unit to grip the workpiece at the gripping position and the picking hand to kit the workpiece in the posture at the time of kitting. Therefore, it is possible to provide a picking system, a picking method, and a program suitable for picking and kitting multiple types of workpieces. [Brief description of the drawings]

[0009] [Figure 1A] FIG. 1 is a plan view illustrating a state during picking of a picking system according to a first embodiment of the present disclosure. [Figure 1B] Side view of Figure 1A [Figure 2A] FIG. 1 is a plan view illustrating a state during kitting of the picking system according to the first embodiment. [Figure 2B] Side view of Figure 2A [Diagram 3] Block diagram of a picking system according to the first embodiment [Figure 4A] FIG. 1 is a front view of the picking hand in a state where the gripping portion is closed according to the first embodiment; [Figure 4B]FIG. 1 is a front view of a state in which the gripping portion of the picking hand according to the first embodiment is open; [Diagram 5] FIG. 1 is a front view of a posture-changing device according to a first embodiment; [Figure 6A] FIG. 1 is a front view showing an initial position of a three-dimensional vision sensor according to a first embodiment; [Figure 6B] FIG. 1 is a front view showing a state in which the three-dimensional vision sensor according to the first embodiment has been moved downward; [Figure 7] FIG. 1 is a diagram for explaining an example of a worklist according to the first embodiment. [Figure 8] Flowchart of main flow 1 according to embodiment 1 [Figure 9] Flowchart of picking and kitting process according to the first embodiment [Figure 10] FIG. 13 is a diagram illustrating a container in which a plurality of types of workpieces are mixed according to a second embodiment of the present disclosure; [Figure 11] FIG. 11 is a plan view illustrating a state during picking of the picking system according to the second embodiment. [Figure 12] Flowchart of main flow 2 according to the second embodiment DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Hereinafter, a picking system according to the present disclosure will be described with reference to the drawings. In the drawings, the same or equivalent parts are denoted by the same reference numerals.

[0011] For ease of understanding, an orthogonal coordinate system XYZ is set. In the orthogonal coordinate system XYZ shown in each drawing, the long axis direction of the three-dimensional vision sensor moving axis 42 is the Z axis direction, the direction in which the container 60 arranged at the picking position P and the kitting tray 65 are aligned is the Y axis direction, and the direction perpendicular to the Z axis direction and the Y axis direction is the X axis direction. Each embodiment will be described below with reference to this coordinate system as appropriate.

[0012] [Embodiment 1] In the picking system 1 according to the first embodiment, as shown in, for example, FIG. 1A, which is a plan view, and FIG. 1B, which is a side view, three types of workpieces 100A, 100B, and 100C, which are piled up in three containers 60 according to type, are picked up by a picking hand 20 attached to the tip of a robot 10. After that, the picking hand 20 and the posture changing device 30 are used to change the workpieces 100A, 100B, and 100C, and the workpieces 100A, 100B, and 100C are kitted in a posture suitable for the work of a worker or a working robot in the next process. Hereinafter, when there is no distinction between the workpieces 100A, 100B, and 100C, they are called the workpieces 100.

[0013] As shown in Figures 1A and 1B showing the picking process and Figures 2A and 2B showing the kitting process, the picking system 1 includes a robot 10 having an arm 11 and a joint 12, a picking hand 20 for picking up the workpieces 100 piled up in a container 60, a posture changing device 30 for changing the posture of the picked workpieces 100, an imaging unit 40 for imaging the posture of the workpieces 100, and a control unit 50 for controlling the robot 10, the picking hand 20, the posture changing device 30, and the imaging unit 40. The picking system 1 also includes a kitting table 66 on which a kitting tray 65 for kitting the picked workpieces 100 is placed, a vibration generating device 70 for vibrating the container 60, a conveyor 90 for transporting the container 60, an input unit 95 for inputting information about the workpieces 100, and a control device 5 including the control unit 50, the input unit 95, and the like.

[0014] The workpieces 100 are parts to be picked and kitted. There are a plurality of types of workpieces 100, such as workpieces 100A, 100B, and 100C, and as shown in Fig. 1A and Fig. 2A, each type of workpiece is bulk loaded into a separate container 60.

[0015] The robot 10 is a single-arm robot having six rotation axes of a vertical articulated system, which can handle the task of picking up workpieces 100 stacked in various postures and changing the posture of the workpieces 100 using a posture changing device 30.

[0016] The picking hand 20 is attached to the tip of the arm 11 of the robot 10. The picking hand 20 picks the workpiece 100 from the container 60 in which the workpieces 100 are piled up in bulk. As shown in FIG. 4A and FIG. 4B, the picking hand 20 has gripping claws 21, 21 that hold the workpiece 100, and a gripping claw drive unit 22 that adjusts the claw opening width W, which is the distance between the gripping claws 21, 21. The gripping claw drive unit 22 moves one of the gripping claws 21 by an air chuck using an electric cylinder 25. The electric cylinder 25 is connected to one of the gripping claws 21 via a cylinder mounting member 26. This allows one of the gripping claws 21 to move between the other gripping claw 21, which is fixed, and the restraining member 27. The gripping claws 21, 21 are an example of a gripping unit that grips the workpiece 100.

[0017] As shown in FIG. 5, the posture changing device 30 has a parallel chuck 31 for receiving the work 100 gripped by the robot 10, and a rotation mechanism 32 for rotating the parallel chuck 31. The posture changing device 30 receives the work 100 from the picking hand 20, changes the posture of the work 100, and transfers it to the picking hand 20 in a state in which the gripping position of the gripping jaws 21, 21 can be changed. The parallel chuck 31 adjusts the jaw opening width L, which is the distance between the jaws, by an electric chuck (not shown), in the same way as the gripping jaw driving unit 22. The rotation mechanism 32 rotates the work 100 to a preset posture after picking up the work 100 from the robot 10 in order to transfer the work 100 to the robot 10 in a state in which the work 100 can be kitted in the same posture no matter what posture the robot 10 picks up the work 100 in. The rotation mechanism 32 has one or more rotation axes, and each axis can rotate 360° or more.

[0018] As shown in FIG. 6A and FIG. 6B, the imaging unit 40 has a three-dimensional vision sensor 41 that images the workpiece 100 and a three-dimensional vision sensor moving axis 42 that moves the three-dimensional vision sensor 41. The three-dimensional vision sensor 41 acquires shape data and positional relationship of the subject in three dimensions in order to acquire information for determining the type of the workpiece 100, selecting the position to hold the workpiece 100, and calculating the amount of change in the attitude of the workpiece 100 by the attitude change device 30. The three-dimensional vision sensor moving axis 42 is provided to change the distance from the bulk workpieces 100 to the three-dimensional vision sensor 41. As the picking and kitting work progresses, the bulk of the bulk workpieces 100 decreases, and the work distance from the workpieces 100 to the three-dimensional vision sensor 41 changes. If this happens, the three-dimensional vision sensor 41 will not be able to focus, resulting in failure to capture the image, or a clear image will not be obtained, making it impossible to obtain accurate shape data of the workpieces 100, resulting in failure to pick the workpiece. By using the three-dimensional vision sensor movement axis 42 to bring the three-dimensional vision sensor 41 closer to the bulk-stacked workpieces 100 and adjust the work distance to a value suitable for imaging, it becomes possible to capture an image of the workpieces 100 in focus. Furthermore, when the workpieces 100 are small, the three-dimensional vision sensor 41 is brought closer to the workpieces 100 by the three-dimensional vision sensor movement axis 42 so that imaging can be performed with sufficient resolution.

[0019] The container 60 is a box with an open top for storing the workpieces 100 to be picked by the picking hand 20 in a bulk manner inside the container. The containers 60 are prepared in the same number as the types of the workpieces 100.

[0020] A required number of workpieces 100 are placed on the kitting tray 65 in an orientation suitable for the next process.

[0021] A kitting tray 65 is placed on the kitting table 66. The kitting table 66 is disposed at a kitting position K adjacent to the picking position P shown in FIG.

[0022] 1B and 2B, the container 60 is placed on the upper portion of the vibration generator 70, and vibrates the container 60 as necessary. When the three-dimensional vision sensor 41 fails to capture an image of the bulk-stacked workpieces 100, when picking up the workpieces 100 fails consecutively, or when the vibration generator 70 applies vibrations to the container 60 in the horizontal and / or vertical directions to change the posture of the workpieces 100 in the container 60.

[0023] An installation position for the container 60 is preset on the conveyor 90, which is a transport device. A vibration generating device 70 is placed at the installation position. As shown in Fig. 1A and Fig. 2A, the conveyor 90 is disposed surrounding the robot 10. The conveyor 90 places the container 60, in which the workpieces 100 to be picked are piled up in bulk, at a picking position P in front of the robot 10.

[0024] The control device 5 includes a control unit 50 that controls the robot 10, the picking hand 20, the posture changing device 30, etc., a memory unit 80, an input unit 95, and a notification unit 96.

[0025] A work list WL, which will be described later, is input to the input unit 95. The kitting quantities of the workpieces 100A, 100B, and 100C are input to the input unit 95. In addition, information regarding the positions and required postures of the workpieces 100A, 100B, and 100C on the kitting tray 65 during kitting is input to the input unit 95.

[0026] When the picking and kitting process is completed, or when an empty kitting tray 65 is not set on the kitting table 66, the notification unit 96 notifies the user by sound, light, etc.

[0027] The storage unit 80 is composed of a ROM (Read Only Memory), a RAM (Random Access Memory), etc., and includes a work shape storage unit 81 that stores the shape of the workpiece 100 to be picked, a gripping pattern storage unit 82 that stores the pattern of the position at which the workpiece 100 is gripped by the picking hand 20, and a work list storage unit 83 that stores a work list WL described later, as shown in Fig. 3. The ROM stores the program executed by the control unit 50, data required in advance to execute the program, etc. The RAM stores the program and data created or changed during program execution.

[0028] The work shape storage unit 81 stores the shape of the work 100 to be picked by the picking hand 20 as three-dimensional data.

[0029] 7, the gripping pattern storage unit 82 stores information on the position at which the workpiece 100 is gripped by the gripping jaws 21 for each type of workpiece 100. The picking system 1 grips the workpiece 100 at the position indicated by the arrow with the gripping jaws 21 according to the type of workpiece 100 and its posture when bulk stacked.

[0030] The work list storage unit 83 stores a work list WL, as exemplified in Fig. 7. The work list WL specifies the types and priorities of the workpieces 100 to be picked and kitted, and further specifies, for each type of workpiece 100, the priorities of the positions preferred for gripping the workpieces 100 by the gripping jaws 21.

[0031] The opening width table storage unit 84 stores the optimal claw opening width W for each combination of the type of workpiece 100 and the gripping position by the picking hand 20. S Memorize.

[0032] The setting storage unit 85 stores, for example, the number of picking attempts n that are allowed for failure in picking the workpiece 100 by the picking hand 20. MAX, the optimal posture of the work 100 during kitting, picking position P, kitting position K, a picking list listing the number of kittings by type of work 100, and the maximum jaw opening width W MAX , the optimal value of the work distance, etc. are stored.

[0033] As shown in Figure 3, the control unit 50 is composed of, for example, a CPU (Central Processing Unit), and by executing a program stored in the memory unit 80, it realizes a work shape identification unit 51 that identifies the shape of the work 100, a gripping pattern consideration unit 52 that considers the priority of the positions for gripping the work 100, a discrimination unit 53 that determines the positions for gripping the work 100, a calculation unit 54 that calculates the opening width of the gripping jaws 21, and an operation control unit 55 that controls the operation of each unit.

[0034] The workpiece shape identification unit 51 identifies the shape of the workpiece 100 from the image captured by the three-dimensional vision sensor 41 , and stores the identified shape of the workpiece 100 in the workpiece shape storage unit 81 .

[0035] The gripping pattern review unit 52 prioritizes the gripping positions of the workpiece 100 by the picking hand 20 according to the shape and posture of the workpiece 100 .

[0036] The discrimination unit 53 discriminates which workpiece 100 in the container 60 is to be picked according to the picking list stored in the setting storage unit 85. The discrimination unit 53 discriminates at which position the workpiece 100 to be picked is to be held. The discrimination unit 53 discriminates whether the required number of workpieces 100 have been kitted.

[0037] The calculation unit 54 calculates the jaw opening width W. Furthermore, the calculation unit 54 calculates the amount of posture change for the angle and gripping position of the workpiece 100 to be changed based on the captured image and the information input to the input unit 95 in order to put the workpiece 100 in a posture required for kitting the workpiece 100.

[0038] The operation control unit 55 controls the operation of the robot 10 and the picking hand 20. The operation control unit 55 drives the electric cylinder 25 to adjust the jaw opening width W. The operation control unit 55 controls the posture changing device 30 to change the posture of the workpiece 100 handed over from the picking hand 20. The operation control unit 55 controls the three-dimensional vision sensor 41 to move along the three-dimensional vision sensor movement axis 42. The operation control unit 55 controls the vibration generating device 70 to vibrate. The operation control unit 55 controls the conveyor 90 to operate.

[0039] A main flow 1 performed by the picking system 1 having the above configuration will be described below with reference to Fig. 8, taking as an example the picking and kitting of three types of workpieces 100A, 100B, and 100C that are piled up in bulk and are required for the manufacture of a certain product X. The work list WL of the workpieces 100A, 100B, and 100C input to the input unit 95 is as shown in Fig. 7.

[0040] First, the power supply of the picking system 1 is turned on by a user. A work list of the workpieces 100 to be picked and kitted and information about the workpieces 100 at the time of kitting are inputted via the input unit 95. In the example of FIG. 7, a work list WL of the workpieces 100A, 100B, 100C and information about the positions to be arranged of the workpieces 100A, 100B, 100C at the time of kitting, and the required posture and number of the workpieces are inputted via the input unit 95, and the picking system 1 reads this (step S1). In addition, the containers 60 in which the workpieces 100A, 100B, 100C are respectively piled up in the container arrangement positions of the conveyor 90, and each container arrangement position and the type of the workpieces arranged at that position are inputted via the input unit 95. The control unit 50 controls the conveyor 90 according to the work list WL so that the container 60 in which the workpieces with the highest picking priority are piled up in the bulk is positioned in front of the kitting table 66.

[0041] The discrimination unit 53 uses a presence sensor (not shown) to confirm that an empty kitting tray 65 is set on the kitting table 66 (step S2). If it is set (step S2: Yes), the process proceeds to step S3. If it is not set (step S2: No), the notification unit 96 issues a warning (step S4), and after a preset time has elapsed, the discrimination unit 53 reconfirms that the kitting tray 65 is set (step S2).

[0042] In step S3, the discrimination unit 53 determines the order of picking and kitting. In the example of Fig. 7, the discrimination unit 53 determines that picking and kitting are performed in the order of the arrows shown in the column of the priority order for picking and kitting the work 100 in the work list WL illustrated in Fig. 7, that is, in the order of the work 100A, 100B, and 100C.

[0043] Proceeding to step S5, the operation control unit 55 controls the conveyor 90 to move the container 60 containing the workpiece 100 that is the first in the order determined by the discrimination unit 53 in step S3 among those that have not been picked and kitted, to the picking position P shown in Fig. 1A. In the example of Fig. 7, the operation control unit 55 controls the conveyor 90 to move the container 60 containing the workpiece 100A to the picking position P. The discrimination unit 53 verifies the captured image against the data of the workpieces 100A, 100B, and 100C in the work list WL, thereby confirming that the container 60 that has been moved is the container 60 containing the workpiece 100A.

[0044] Proceeding to step S6, picking and kitting processing, which will be described later, is performed on the workpiece 100 that has the earliest order among the workpieces 100 for which picking and kitting have not yet been performed. In this description, picking and kitting processing, which will be described later, is performed on the workpiece 100A.

[0045] When the required number of workpieces 100 that have not been picked and kitted are picked and kitted, the process proceeds to step S7, where the discrimination unit 53 discriminates whether all types of workpieces 100 have been kitted in the kitting tray 65. If all types of workpieces 100 have been kitted (step S7: Yes), the notification unit 96 notifies the user that kitting has been completed (step S8), and ends the process. If kitting of all types of workpieces 100 has not been completed (step S7: No), the process returns to step S5, and steps S5 to S7 are similarly performed for the workpiece 100 that has the earliest order in the order determined by the discrimination unit 53 in step S3, among the workpieces 100 excluding the workpieces 100 that have been picked and kitted. Thereafter, steps S5 to S7 are repeated in order for the workpieces 100 that have not been picked and kitted. 7, when the discrimination unit 53 finishes picking and kitting the required number of workpieces 100A, the process proceeds to step S7, where the discrimination unit 53 checks via the imaging unit 40 whether all types of workpieces 100 listed in the work list WL have been kitted onto the kitting tray 65. If all types of workpieces 100 have not been kitted (step S7: No), the process returns to step S5, and steps S5 to S7 are performed on the workpiece 100B that is the earliest in the order determined by the discrimination unit 53 in step S3 among the workpieces 100 excluding the workpiece 100A that has been picked and kitted, in the same manner as for the above-mentioned workpiece 100A.

[0046] In the example of FIG. 7, after picking and kitting of the workpiece 100B is completed, the process proceeds to step S7, but since picking and kitting of the workpiece 100C remains, the process returns to step S5 again.

[0047] In the example of Figure 7, among the works 100, excluding works 100A and 100B that have been picked and kitted, steps S5 to S7 are performed for work 100C, which is the first in the order determined by discrimination unit 53 in step S3, in the same manner as for work 100A described above.

[0048] 7, after picking and kitting of the workpiece 100C is completed, the process proceeds to step S7, and since picking and kitting of all types of workpieces 100 is completed (step S7: Yes), the process proceeds to step S8 and then ends. If there are m types of workpieces 100 to be picked and kitted, steps S5 to S7 are repeated m times.

[0049] Next, the picking and kitting process performed in the above-mentioned step S6 will be described with reference to Fig. 9. In this process, the workpiece 100 picked by the picking hand 20 is once handed over to the posture changing device 30 to change the posture of the workpiece 100, and the posture-changed workpiece 100 is then handed over to the picking hand 20, after which kitting is performed.

[0050] First, the operation control unit 55 controls the three-dimensional vision sensor 41 of the imaging unit 40 to capture an image of the workpiece 100 in the container 60 (step S101). When capturing an image, the position of the three-dimensional vision sensor 41 is adjusted so that the image is in focus.

[0051] The work shape identification unit 51 identifies the shape of the work 100 from the captured image. The discrimination unit 53 checks whether the work shape identification unit 51 has been able to identify one or more workpieces 100 from the image (step S102). If the work shape identification unit 51 has been able to identify one or more workpieces 100 from the image (step S102: Yes), the discrimination unit 53 selects a gripping posture of each workpiece 100 from the gripping postures in the work list WL based on the postures of all the identified workpieces 100, determines the picking order of the workpieces 100 based on the priority order of the work list WL, and sets the number of picking attempts n=1 (step S103). If the work shape identification unit 51 has not been able to identify any workpieces 100 from the image (step S102: No), the operation control unit 55 controls the posture changing device 30 to vibrate the container 60, changes the posture of the workpieces 100 in the container 60 (step S104), and returns to step S101. In addition, when the workpiece 100 is identified, this means that the discrimination unit 53 compares the point cloud data of the workpiece 100 that the workpiece shape identification unit 51 identified in the image captured by the three-dimensional vision sensor 41 with the data in the worklist WL, for example, by pattern matching technology, and as a result of the comparison, the workpiece 100 corresponding to the point cloud data is confirmed in the worklist WL.

[0052] In order to grip the workpiece 100 that is the earliest in the picking order, the operation control unit 55 determines the opening width W of the gripping jaws 21 corresponding to the gripping posture of the workpiece 100. S The operation control unit 55 controls the robot 10 and the picking hand 20 to grip and pick up the workpiece 100 (step S105).

[0053] In step S106, the discrimination unit 53 determines whether the number of picking attempts n is equal to the set number n MAX Whether or not the workpiece 100 has been picked up is determined by checking whether or not the workpiece 100 is being held by the gripping jaws 21 in an image of the gripping jaws 21 captured by the three-dimensional vision sensor 41. n is the set number of times n MAXIf the number of times is equal to or less than the set number of times n and the workpiece 100 has been picked (step S106: Yes), the process proceeds to step S107. If the number of times is not equal to or less than the set number of times n, the process proceeds to step S108. MAX Determine whether n is equal to or less than the set number of times n MAX If the number of times is equal to or less than the set number of times (step S108: Yes), n is set to n+1 (step S109), and the process returns to step S105 to try picking the same workpiece 100 again. MAX If it exceeds (step S108: No), the process returns to step S104.

[0054] In step S107, the calculation unit 54 calculates the amount of attitude change for the rotation angle and gripping position of the work 100 required to put the work 100 into the attitude required for kitting from the captured image, and the position of the gripping jaws 21 when in that attitude, based on the information input in step S1 and the attitude of the work 100 in the captured image.

[0055] In step S110, the discrimination unit 53 discriminates whether or not it is necessary to change the gripping position of the workpiece 100 by the gripping jaws 21 in order to achieve the requested kitting, based on the calculation result in step S107. Whether or not it is necessary to change the gripping position is determined based on whether or not the gripping jaws 21 can be in the position and posture required for kitting the workpiece 100 in the current state in which they grip the workpiece 100. For example, if the gripping jaws 21 are in the posture required for kitting the workpiece 100, it is determined that it is necessary to change the gripping position because the position and posture required for kitting the workpiece 100 cannot be achieved if any of the gripping jaws 21 is below the workpiece 100 when the workpiece 100 is in the posture required. In addition, it is also determined that it is necessary to change the gripping position if any of the gripping jaws 21 comes into contact with the workpiece 100 that is already placed when placing the workpiece 100 at the kitting position.

[0056] If there is no need to change the gripping position (step S110: No), picking and kitting are possible by controlling the six axes of the robot 10, so the process proceeds to step S116, which will be described later.

[0057] On the other hand, if it is necessary to change the gripping position of the workpiece 100 by the gripping jaws 21 (step S110: Yes), the parallel chuck 31 of the posture changing device 30 is adjusted to a posture that allows it to receive the workpiece 100 from the picking hand 20 (step S111), and then the process proceeds to step S112.

[0058] In step S112, the operation control unit 55 controls the picking hand 20 to transfer the workpiece 100 to the posture changing device 30.

[0059] Next, the discrimination unit 53 discriminates whether or not it is necessary to change the angle of the workpiece 100 in order to kit the workpiece 100 at the required position and posture based on the posture change amount calculated in step S107 (step S113). Whether or not it is necessary to change the angle of the workpiece 100 is determined based on whether or not the workpiece 100 can be kitted at the required position and posture at the time of kitting while maintaining the posture of the workpiece 100 held by the gripping jaws 21.

[0060] If it is necessary to change the angle of the workpiece 100 (step S113: Yes), the operation control unit 55 controls the posture changing device 30 to rotate the rotation mechanism 32 to change the posture of the handed over workpiece 100 by the posture change amount in terms of angle (step S114), and proceeds to step S115. On the other hand, if it is not necessary to change the angle of the workpiece 100 (step S113: No), step S114 is skipped and the process proceeds to step S115.

[0061] In step S115, the operation control unit 55 controls the posture changing device 30 to transfer the workpiece 100 to the picking hand 20.

[0062] If it is determined as No in step S110, or following step S115, the operation control unit 55 controls the picking hand 20 to kit the workpiece 100 onto the kitting tray 65 in a requested attitude (step S116).

[0063] The discrimination unit 53 discriminates whether or not the requested number of workpieces 100 have been kitted in step S1 (step S117). If the requested number of workpieces 100 have been kitted (step S117: Yes), the process ends. If the requested number of workpieces 100 have not been kitted (step S117: No), the process proceeds to step S118.

[0064] In step S118, the discrimination unit 53 discriminates whether or not the workpieces 100 remain in the container 60 based on an image of the inside of the container 60 captured by the three-dimensional vision sensor 41. If the workpieces 100 remain in the container 60 (step S118: Yes), the process proceeds to step S119. If the workpieces 100 do not remain in the container 60 (step S118: No), the notification unit 96 notifies the user that there is a shortage of the workpieces 100 (step S120), and the process proceeds to step S121.

[0065] In step S119, it is determined whether or not there are any workpieces 100 remaining in the container 60 that can be gripped by the gripping jaws 21, based on an image of the inside of the container 60 captured by the three-dimensional vision sensor 41. If there are any workpieces 100 remaining in the container 60 that can be gripped by the gripping jaws 21 (step S119: Yes), the process returns to step S105. If there are no workpieces 100 remaining in the container 60 that can be gripped by the gripping jaws 21 (step S119: No), the process returns to step S104 and then to step S101.

[0066] In step S121, the discrimination unit 53 discriminates whether or not the missing workpieces 100 have been replenished in the container 60 based on an image of the inside of the container 60 captured by the three-dimensional vision sensor 41. If the missing workpieces 100 have been replenished in the container 60 (step S121: Yes), the process returns to step S119. If the missing workpieces 100 have not been replenished in the container 60 (step S121: No), the process returns to step S120.

[0067] As described above, the picking system 1 according to the first embodiment can adjust the interval between the gripping jaws 21 gripping the work 100 according to the posture of the work 100 shown in the captured image, and change the posture of the work 100 using the posture changing device 30 to make the work 100 have the required posture at the time of kitting. In addition, the order of picking the work 100 is determined according to the posture of the work 100 shown in the captured image and the priority order of the work list WL. Furthermore, if picking of the work 100 fails more than a set number of times, the vibration generating device 70 can vibrate the container 60 to change the posture of the bulk-stacked work 100, thereby improving the probability of successful picking. In addition, as picking and kitting progress, when the bulk pile of the work 100 becomes smaller, the three-dimensional vision sensor 41 can be brought closer to the work 100 along the three-dimensional vision sensor moving axis 42, and the bulk-stacked work 100 can be suitably imaged. In this way, the picking system 1 is suitable for automatically picking and kitting multiple types of workpieces 100 without changing the equipment configuration, equipment usage, etc.

[0068] [Embodiment 2] In the first embodiment, one type of workpiece 100 is bulk-stacked in one container 60, but in the second embodiment, as illustrated in FIG. 10, a plurality of types of workpieces 100, that is, workpieces 100D, 100E, 100F, and 100G, are mixed in one container 60. The picking system 2 picks and kits the workpieces 100 from the container 60 in which two or more types of workpieces 100 are mixed. The configuration of the picking system 2 is the same as that of the first embodiment, and differs from the first embodiment in that the type of the workpiece 100 is identified by comparing the shape of the workpiece 100 to be picked during picking with each of the workpieces 100D, 100E, 100F, and 100G registered in the work list WL.

[0069] As shown in FIG. 11, the picking system 2 has a configuration in which the conveyor 90 is omitted from the configuration of the picking system 1, and the number of containers 60 is reduced to one.

[0070] A main flow 2 performed by the picking system 2 having the above configuration will be described below using as an example the picking and kitting of four types of bulk-stacked workpieces 100, namely workpieces 100D, 100E, 100F, and 100G, which are required for the manufacture of a certain product Y. Note that steps similar to those in the main flow 1 performed by the picking system 1 will be omitted as appropriate.

[0071] 12, in the picking system 2, steps S1 and S2 are performed in the same manner as in the picking system 1. The power of the picking system 1 is turned on by a user, and a work list of the workpieces 100 to be picked and kitted and information about the workpieces 100 at the time of kitting are input via the input unit 95. The discrimination unit 53 confirms that an empty kitting tray 65 is set on the kitting table 66.

[0072] Thereafter, the process proceeds to step S3, where the discrimination unit 53 determines the order in which the workpieces 100 are to be picked and kitted based on the information input to the input unit 95.

[0073] After that, picking and kitting processing is performed (step S6) without performing step S5 in Fig. 8. After picking and kitting of all types of works 100 is performed as required, step S7 in Fig. 8 is not performed and the notification unit 96 notifies the user that kitting is completed (step S8), and the process ends.

[0074] Next, the picking and kitting process performed in step S6 will be described with reference to FIG.

[0075] As in the first embodiment, the operation control unit 55 controls the three-dimensional vision sensor 41 of the imaging unit 40 to capture the workpiece 100 in the container 60 (step S101), and the workpiece shape identification unit 51 identifies the shape of the workpiece 100 from the captured image (step S102). In step S103, the discrimination unit 53 selects the type and gripping posture of each workpiece 100 from the gripping postures in the work list WL based on the postures of all the identified workpieces 100, and determines the picking order of the workpieces 100 based on the priority of the work list WL without distinguishing the type of the workpieces 100, and sets the number of picking attempts n=1. From this point on, up to step S116, the process is the same as in the first embodiment. In step S117, the discrimination unit 53 determines whether all types of the workpieces 100 requested in step S1 have been kitted (step S117). If all types of the requested number of workpieces 100 have been kitted (step S117: Yes), the process ends. If the requested number of works 100 have not been kitted for all alcoholic beverages (step S117: No), the process proceeds to step S118. Steps S118-S121 are also similar to those in the first embodiment.

[0076] As described above, the picking system 2 according to the second embodiment requires only one container 60, regardless of the type of workpiece 100. In addition, the cost of installing the conveyor 90 can be reduced, and space can be saved. In this way, the picking system 2 is suitable for automatically picking and kitting a plurality of types of workpieces 100 without changing the equipment configuration, equipment usage, etc.

[0077] [Variations] In each of the above-described embodiments, the gripping jaw driving unit 22 opens and closes the gripping jaws 21 by using an air chuck, but the gripping jaws 21 may be opened and closed by using an electric chuck. The parallel chuck 31 may also be opened and closed by using an electric chuck.

[0078] In the above embodiments, the grip portion is the grip claws 21, 21, but the grip portion may be composed of three or more grip claws. Alternatively, the grip portion may be composed of, for example, about five fingers having joints.

[0079] In each of the above embodiments, the posture of the workpiece 100 is changed via the posture changing device 30, but the posture change amount may be calculated before the picking hand 20 grips the workpiece 100, and the posture may be changed by the picking hand 20 without using the posture changing device. In other words, the workpiece 100 may be gripped at a position where there is no change in the gripping position, and the picking hand 20 may simply rotate the gripping part to kit the workpiece 100 at the required position and posture. Alternatively, the picking system may include two picking hands 20, and when one picking hand 20 picks the workpiece 100, the other picking hand 20 may function as the posture changing device, and when the other picking hand 20 picks the workpiece 100, the one picking hand 20 may function as the posture changing device.

[0080] In addition, in the above embodiment 1, when the work 100 to be picked and kitted is changed, the container 60 in which the work 100 to be picked and kitted is bulk-stacked is moved by the conveyor 90. However, for example, the picking position P of the picking hand 20 may be changed to the position of the container 60 in which the target work 100 is bulk-stacked when the work 100 to be picked and kitted is changed.

[0081] In the above embodiment 1, the method of confirming that the moved container 60 contains the work 100 to be picked and kitted was performed by comparing the captured image with the data of the works 100A, 100B, 100C in the work list WL, but it is also possible to attach a data code, such as a barcode or QR code (registered trademark), that stores information indicating the type of work 100 to the container 60, and read this with a code reader to identify the work.

[0082] In each of the above embodiments, the posture of the bulk-stacked workpieces 100 is changed by the vibration generating device 70. However, for example, the posture of the bulk-stacked workpieces 100 may be changed by stirring the bulk-stacked workpieces 100 with the picking hand 20 or by tilting the container 60.

[0083] 9, the posture of the bulk workpieces 100 is changed by the vibration generator 70, but for example, the three-dimensional vision sensor 41 may be moved in the -Z direction to approach the bulk workpieces 100 and check the workpieces 100 again. Alternatively, the posture of the bulk workpieces 100 may be changed by the vibration generator 70 while moving the three-dimensional vision sensor 41 in the -Z direction, or one of the movement of the three-dimensional vision sensor 41 in the -Z direction and the vibration by the vibration generator 70 may be selected according to the situation.

[0084] In the above-mentioned first embodiment, there are three types of workpieces 100, and in the second embodiment, there are four types of workpieces 100, but the number of types of workpieces 100 may be any number of types greater than or equal to two.

[0085] In the above-mentioned first embodiment, the order of picking and kitting the workpieces 100 is determined based on the work list WL, but for example, picking and kitting may be performed in the order starting from the workpieces 100 bulk-stacked in the container 60 closest to the picking position P. Alternatively, the order of picking and kitting may be arbitrarily designated by the user via the input unit, and the workpieces 100 may be picked and kitted in order of size, either largest or smallest.

[0086] The picking system 1 can be realized by using a normal computer system, not by a dedicated device. For example, a program for realizing each function in the picking system 1 may be stored in a computer-readable recording medium such as a flexible disk, a CD-ROM (Compact Disc Read Only Memory), a DVD-ROM (Digital Versatile Disc Read Only Memory), or an MO (Magneto-Optical Disc) and distributed, and the program may be installed in a computer to configure a computer capable of realizing each of the above-mentioned functions. In addition, when each function is realized by sharing between an OS (Operating System) and an application, or by cooperation between an OS and an application, only the application may be stored in the recording medium.

[0087] Various embodiments and modifications of the present disclosure are possible without departing from the broad spirit and scope of the present disclosure. The above-described embodiments are for explaining the present disclosure and do not limit the scope of the present disclosure. In other words, the scope of the present disclosure is indicated by the claims, not the embodiments. Various modifications made within the scope of the claims and the scope of the disclosure equivalent thereto are considered to be within the scope of the present disclosure.

[0088] (Additional Note) The present disclosure can be realized in the following forms.

[0089] (Appendix 1) A picking system for picking and kitting a plurality of types of work, A picking hand having a gripping part for gripping the bulk-stacked workpieces and performing picking and kitting; An imaging unit that images the workpiece; a control unit that identifies a shape of the workpiece from a captured image, determines a gripping position of the workpiece by the gripping unit and an attitude at the time of kitting, and controls the gripping unit to grip the workpiece at the gripping position and the picking hand to kit the workpiece in the attitude at the time of kitting; Equipped with Picking system. (Appendix 2) Further comprising a conveying device, The workpieces are bulk-stacked in containers according to type, The container is placed on the conveying device, When the type of the workpiece to be picked and kitted is changed, the control unit operates the transport device to change the workpiece to be picked and kitted by the picking hand, determines the gripping position of the workpiece by the gripping unit according to the type of the workpiece and the posture at the time of kitting, controls the gripping unit to grip the workpiece at the gripping position, and controls the picking hand to kit the workpiece in the posture at the time of kitting. 2. A picking system as described in appendix 1. (Appendix 3) The control unit identifies the type of the workpiece from the captured image, determines the gripping position of the workpiece by the gripping unit according to the type of the workpiece and the posture at the time of kitting, and controls the gripping unit to grip the workpiece at the gripping position and the picking hand to kit the workpiece in the posture at the time of kitting. 3. A picking system according to claim 1 or 2. (Appendix 4) The robot further includes a posture changing device for changing the gripping position and posture of the picked workpiece, The posture changing device changes the posture of the workpiece after receiving the workpiece from the picking hand, and transfers the workpiece to the picking hand again. 4. A picking system according to any one of claims 1 to 3. (Appendix 5) The gripping portion grips the workpiece with a plurality of gripping jaws, Adjusting the distance between the gripping jaws according to the gripping position of the workpiece. 5. A picking system according to any one of claims 1 to 4. (Appendix 6) The workpiece is further provided with a vibration generating device that changes the posture of the bulk-stacked workpieces by vibrating the workpieces. 6. A picking system according to any one of claims 1 to 5. (Appendix 7) The imaging unit can be moved in a direction approaching the bulk workpieces, When the picking hand fails to pick up the workpiece within a preset number of times, the imaging unit is moved in a direction approaching the bulk piled workpieces. 7. A picking system according to any one of claims 1 to 6. (Appendix 8) A picking method for picking and kitting a plurality of types of workpieces, comprising: Taking an image of the workpieces stacked in bulk; By identifying the shape of the workpiece from the captured image, a gripping position of the workpiece by a gripping part of a picking hand and a posture at the time of kitting are determined; The gripping unit grips the workpiece at the gripping position, and the picking hand kits the workpiece in the kitting posture. Picking method. (Appendix 9) On the computer, Taking an image of the bulk workpieces, By identifying the shape of the workpiece from the captured image, a gripping position of the workpiece by a gripping part of a picking hand and a posture at the time of kitting are determined; The gripping unit grips the workpiece at the gripping position, and the picking hand kits the workpiece in the kitting posture. A program that executes a process. [Explanation of symbols]

[0090] 1,2 Picking system, 5 Control device, 10 Robot, 11 Arm, 12 Joint, 20 Picking hand, 21 Grip claw, 22 Grip claw drive unit, 25 Electric cylinder, 26 Cylinder mounting member, 27 Restraint member, 30 Posture change device, 31 Parallel chuck, 32 Rotation mechanism, 40 Imaging unit, 41 Three-dimensional vision sensor, 42 Three-dimensional vision sensor moving axis, 50 Control unit, 51 Work shape identification unit, 52 Grip pattern consideration unit, 53 Discrimination unit, 54 Calculation unit, 55 Operation control unit, 60 Container, 65 Kitting tray, 66 Kitting table, 70 Vibration generator, 80 Memory unit, 81 Work shape memory unit, 82 Grip pattern memory unit, 83 Work list memory unit, 84 Opening width table memory unit, 85 Setting memory unit, 90 Conveyor, 95 Input unit, 96 Notification unit, 100, 100A, 100B, 100C, 100D, 100E, 100F, 100G work, n number of picking attempts, K kitting position, L, W jaw opening width, P picking position, WL work list, X, Y product

Claims

1. A picking system for picking and kitting a plurality of types of work, A picking hand having a gripping part for gripping the bulk-stacked workpieces and performing picking and kitting; An imaging unit that images the workpiece; a control unit that identifies a shape of the workpiece from a captured image, determines a gripping position of the workpiece by the gripping unit and an attitude at the time of kitting, and controls the gripping unit to grip the workpiece at the gripping position and the picking hand to kit the workpiece in the attitude at the time of kitting; Equipped with Picking system.

2. Further comprising a conveying device, The workpieces are bulk-stacked in containers according to type, The container is placed on the conveying device, When the type of the workpiece to be picked and kitted is changed, the control unit operates the transport device to change the workpiece to be picked and kitted by the picking hand, determines the gripping position of the workpiece by the gripping unit according to the type of the workpiece and the posture at the time of kitting, controls the gripping unit to grip the workpiece at the gripping position, and controls the picking hand to kit the workpiece in the posture at the time of kitting. The picking system according to claim 1 .

3. The control unit identifies the type of the workpiece from the captured image, determines the gripping position of the workpiece by the gripping unit according to the type of the workpiece and the posture at the time of kitting, and controls the gripping unit to grip the workpiece at the gripping position and the picking hand to kit the workpiece in the posture at the time of kitting. The picking system according to claim 1 .

4. The robot further includes a posture changing device for changing the gripping position and posture of the picked workpiece, The posture changing device changes the posture of the workpiece after receiving the workpiece from the picking hand, and transfers the workpiece to the picking hand again. The picking system according to claim 1 .

5. The gripping portion grips the workpiece with a plurality of gripping jaws, Adjusting the distance between the gripping jaws according to the gripping position of the workpiece. The picking system according to claim 1 .

6. The workpiece is further provided with a vibration generating device that changes the posture of the bulk-stacked workpieces by vibrating the workpieces. The picking system according to claim 1 .

7. The imaging unit can be moved in a direction approaching the bulk workpieces, When the picking hand fails to pick up the workpiece within a preset number of times, the imaging unit is moved in a direction approaching the bulk piled workpieces. The picking system according to claim 1 .

8. A picking method for picking and kitting a plurality of types of workpieces, comprising: Taking an image of the workpieces stacked in bulk; By identifying the shape of the workpiece from the captured image, a gripping position of the workpiece by a gripping part of a picking hand and a posture at the time of kitting are determined; The gripping unit grips the workpiece at the gripping position, and the picking hand kits the workpiece in the kitting posture. Picking method.

9. On the computer, Taking an image of the bulk workpieces, By identifying the shape of the workpiece from the captured image, a gripping position of the workpiece by a gripping part of a picking hand and a posture at the time of kitting are determined; The gripping unit grips the workpiece at the gripping position, and the picking hand kits the workpiece in the kitting posture. A program that executes a process.

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