Processing device, handling system, processing method, program, and storage medium

Abstract

To provide a processing device, a handling system, a processing method, a program, and a storage medium that can further increase a utilization rate of a handling robot.SOLUTION: A processing device according to an embodiment is capable of communicating with a handling device including a handling robot for conveying an article and an inspection unit for inspecting the article that has been conveyed. The processing device detects an occurrence of an error in the handling device. The processing device determines a process in which the error occurred and a cause of the error occurred. The processing device uses a result of the determination of the process and a result of the cause to determine whether a change in management information on the article is caused by the error.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] Embodiments of the present invention relate to a processing device, a handling system, a processing method, a program, and a storage medium.

Background Art

[0002] In warehouses and the like, handling robots capable of automatically transporting articles are used. Regarding the transport process using a handling robot, there is a need for a technology that can increase the operating rate of the handling robot.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The problem to be solved by the present invention is to provide a processing device, a handling system, a processing method, a program, and a storage medium that can increase the operating rate of a handling robot.

Means for Solving the Problems

[0005] The processing device according to the embodiment is communicable with a handling device including a handling robot that transports an article and an inspection unit that inspects the transported article. The processing device detects the occurrence of an error in the handling device. The processing device determines the process in which the error occurred and the cause of the error. The processing device determines the change in the management information of the article due to the error using the determination result of the process and the determination result of the cause.

Brief Description of the Drawings

[0006]

Figure 1

Figure 2

Figure 3

Figure 4

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Figure 7

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Figure 9

[0007] Hereinafter, each embodiment of the present invention will be described with reference to the drawings. The drawings are schematic or conceptual, and the relationship between the thickness and width of each part, the ratio of the sizes between parts, etc. are not necessarily the same as those in reality. Also, even when representing the same part, the dimensions and ratios may be represented differently depending on the drawings. In the present specification and each figure, the same reference numerals are given to the same elements as those already described, and the detailed description is omitted as appropriate.

[0008] FIG. 1 is a perspective view showing a handling device according to an embodiment. As shown in FIG. 1, the handling device 100 according to the embodiment includes a handling robot 110, an inspection unit 120, a first measuring instrument 130, a second measuring instrument 140, and a photographing device 150.

[0009] The handling robot 110 includes a gripping part 115 for gripping an article, and conveys the article using the gripping part 115. The gripping part 115 grips the article by suction or clamping, etc. For example, the handling robot 110 is a picking robot that performs a picking operation.

[0010] In the illustrated example, the handling robot 110 is a vertically articulated robot and grips the article by suction. The handling robot 110 includes a plurality of links 111 and a plurality of rotating shafts 112. The links 111 are connected to each other by the rotating shafts 112. The gripping part 115 is attached to the tip of the handling robot 110. By operating each rotating shaft 112, the position and angle of the tip of the handling robot 110 change.

[0011] In addition to the vertically articulated robot, the handling robot 110 may be a horizontally articulated robot, a Cartesian robot, a parallel link robot, etc. It is preferable that the tip of the handling robot 110 has at least six degrees of freedom so as to be able to handle various articles.

[0012] Also, the handling robot 110 is provided with a sensor 114 for detecting the force applied to the gripping part 115. For example, the sensor 114 includes at least one selected from a force sensor and an acceleration sensor. From the force detection result by the force sensor, it is possible to detect the contact between the gripping part 115 and the object to be gripped, the contact between the gripping part 115 and an unintended object, etc. From the acceleration detection result by the acceleration sensor, it is possible to detect the conveyance speed by the gripping part 115, the fall of the article during conveyance, etc.

[0013] Near the handling robot 110, a container containing an article is arranged by a person or another conveyance device. The handling robot 110 conveys the designated article from the container to another location.

[0014] The inspection unit 120 inspects whether the articles conveyed by the handling robot 110 and their quantity are correct. In the illustrated example, the inspection unit 120 includes a conveyor 121, a weight sensor 122, and a guide 123.

[0015] An article A conveyed by the handling robot 110 is placed on the conveyor 121. The conveyor 121 conveys the article A in the horizontal direction. The weight sensor 122 is provided at a part of the conveyance path of the conveyor 121 and measures the weight of the article being conveyed by the conveyor 121. Further, the weight sensor 122 inspects the article A based on the measured weight.

[0016] An outgoing container C2 and a discharge container C3 are provided adjacent to the conveyor 121. The guide 123 is provided in the middle of the conveyance path of the conveyor 121 and guides the article conveyed by the conveyor 121 to the outgoing container C2 or the discharge container C3. One end of the guide 123 is rotatably fixed along a horizontal plane. By the rotation of the guide 123, the state in which the guide 123 guides the article to the outgoing container C2 and the state in which the guide 123 guides the article to the discharge container C3 are switched.

[0017] For example, the weight sensor 122 determines whether the conveyed article matches the indicated article. When it is determined by the weight sensor 122 that the conveyed article matches the indicated article, the guide 123 guides the article being conveyed by the conveyor 121 to the outgoing container C2. When it is determined that the conveyed article does not match the indicated article, the guide 123 guides the article being conveyed by the conveyor 121 to the discharge container C3.

[0018] The weight sensor 122 may further determine whether the article is damaged. Even when the conveyed article matches the indicated article, if it is determined that the conveyed article is damaged, the article is guided to the discharge container C3 by the guide 123.

[0019] The articles conveyed to the discharge container C3 are then inspected by an operator for any problems and then stored (restocked) in their original storage location within the warehouse.

[0020] The first measuring device 130 measures the position and orientation of each article contained in the container C1 from above. For example, the first measuring device 130 includes an image sensor and a distance measuring sensor.

[0021] The second measuring device 140 measures the size of the article being conveyed by the handling robot 110 from the side. For example, the second measuring device 140 includes one or more selected from an optical sensor and a distance measuring sensor. An article passing by the side of the second measuring device 140 is detected from the detection result of the optical sensor or the distance measuring sensor. The second measuring device 140 measures the size (height) of the article in the vertical direction from the speed of upward conveyance and the time when the article was detected.

[0022] The imaging device 150 images the handling robot 110. The imaging device 150 transmits the captured image to an external terminal device. By displaying the image captured by the imaging device 150 on the terminal device, the user of the terminal device can remotely check the state of the handling robot 110.

[0023] FIG. 2 is a schematic diagram showing a configuration example of the handling system according to the embodiment. As shown in FIG. 2, the handling system 10 according to the embodiment includes a handling device 100 and a processing device 200.

[0024] The processing device 200 can communicate with each element of the handling device 100. For example, when the processing device 200 receives a conveyance instruction, it generates an operation plan. The operation plan includes the article to be conveyed, the gripping position, the route position, the release position, the gripping force for the article, the gripping method for the article, the conveyance speed of the article, and the like.

[0025] The processing device 200 transmits the generated operation plan to the handling robot 110. When the robot controller of the handling robot 110 receives the operation plan, it operates the handling robot 110 according to the operation plan.

[0026] The "grasping position" is the position of the grasping part 115 when the article is grasped. The "passing position" is the position through which the grasping part 115 passes during the operation of the handling robot 110. The "release position" is the position where the article grasped by the grasping part 115 is released. The "grasping force" is the force required to grasp the article to be conveyed. The "grasping method" indicates which method is used to grasp the article when the grasping part 115 has a plurality of methods for grasping the article. The "conveying speed" is the speed of the grasping part 115 when the handling robot 110 conveys the article.

[0027] In generating the operation plan, the measurement results of the first measuring device 130 and the measurement results of the second measuring device 140 are used. For example, using the measurement results of the first measuring device 130, the posture of the grasping part 115 for stably grasping the article is estimated. Using the measurement results of the first measuring device 130 and the measurement results of the second measuring device 140, the posture of the grasping part 115 for safely placing the article is estimated. The "posture" is represented by the respective positions in three mutually orthogonal directions and the respective angles around the three directions.

[0028] In addition, the processing device 200 communicates with the handling robot 110 during the operation of the handling robot 110. When the grasping part 115 of the handling robot 110 passes through the grasping position, the passing position, or the release position, the handling robot 110 transmits that information to the processing device 200. When an error occurs in the handling robot 110, the handling robot 110 transmits the details of the error to the processing device 200. The errors transmitted from the handling robot 110 include defects in the software of the handling robot 110, contact between the handling robot 110 and an unintended object, and dropping of the article during conveyance.

[0029] The "unintended object" refers to an object that is not planned to come into contact with the handling robot 110 in the operation plan. Since the article to be transported is planned to be contacted and grasped by the handling robot 110 in the operation plan, it is not included in the unintended objects. For example, the side wall of a container, an article different from the article to be transported, other robots, etc. may be included in the unintended objects. Here, the contact between the handling robot 110 and an unintended object is referred to as "interference".

[0030] The inspection unit 120 (weight sensor 122) transmits the inspection result to the processing device 200. The inspection result is determined based on the relationship between the measured weight of the transported article and the weight of the instructed article. For example, based on the relationship between the measured weight and the weight of the instructed article, it is determined whether the transported article matches the instructed article, whether the transported quantity matches the instructed quantity, whether the transported article is damaged, etc.

[0031] For example, when the transported content such as the transported article or its quantity matches the instructed content such as the instructed article or its quantity and the article is not damaged, the inspection unit 120 transmits an inspection result of "qualified" to the processing device 200. When the transported article is different from the instructed article, the inspection unit 120 transmits an inspection result of "article difference" to the processing device 200. When the transported quantity is different from the instructed quantity, the inspection unit 120 transmits an inspection result of "quantity difference" to the processing device 200. When the transported article is damaged, the inspection unit 120 transmits an inspection result of "article damaged" to the processing device 200.

[0032] An example of the inspection method by the inspection unit 120 will be described. Before the conveyance of articles starts, the processing device 200 receives article information from a higher-level device. The information includes the size, weight, etc. of the articles to be conveyed. When the handling robot 110 conveys articles one by one, the weight sensor 122 compares the measured weight of each article with the weight in the pre-acquired data. If the difference between the measured weight and the weight in the data is less than the first threshold value, the weight sensor 122 determines that the conveyed article matches the designated article. The method of setting the first threshold value is arbitrary. For example, any value between 5% and 50% of the weight in the data is set as the first threshold value.

[0033] If the measured weight is greater than the weight in the data and the difference is equal to or greater than the first threshold value and less than the second threshold value, the weight sensor 122 determines that multiple articles are being conveyed. The second threshold value is greater than the first threshold value. For example, any value between 2.2 times and 3.0 times the weight in the data is set as the second threshold value. When it is determined that multiple articles are being conveyed, the conveyed articles are guided to the discharge container C3 and recovered. Also, this case is processed as "quantity discrepancy".

[0034] If the measured weight is greater than the weight in the data and the difference is equal to or greater than the second threshold value, the weight sensor 122 determines that an article different from the designated article is being conveyed. In that case, the conveyed article is guided to the discharge container C3 and recovered. This case is processed as "article discrepancy".

[0035] If the measured weight is less than the weight in the data, the difference is equal to or greater than the first threshold value, and the measured weight is equal to or greater than the minimum measured value, the weight sensor 122 determines that the conveyed article is damaged. In that case, the conveyed article is guided to the discharge container C3 and recovered. The "minimum measured value" is the lowest value of the measurable weight and is set considering the error of the weighing scale. This case is processed as "article damage".

[0036] If the measured weight is less than the minimum measurable value, the weight sensor 122 determines that the number of conveyed articles is zero. In this case, the conveyed article may be caught by the handling robot 110 or may have fallen during conveyance. This case is processed as a "quantity discrepancy".

[0037] The inspection unit 120 may further include an image sensor. The image sensor includes an imaging device that captures an article from above. For example, the image sensor uses the image acquired by the imaging device to determine whether the conveyed article matches the designated article and whether the conveyed article is damaged. Technologies such as template matching can be used for these determinations.

[0038] Based on the information received from the handling robot 110 or the inspection unit 120, the processing device 200 detects the occurrence of an error. When detecting the occurrence of an error, the processing device 200 determines the process in which the error occurred and the cause of the error. Then, based on the determination results of the process and the cause, the processing device 200 determines the change in the article management information due to the error. The management information is, for example, the inventory quantity. In other words, the processing device 200 determines whether articles that cannot be shipped have occurred due to the error. And when articles that cannot be shipped occur, the processing device 200 determines the number of articles that cannot be shipped. Or the management information is other information related to the inventory of articles.

[0039] The processing device 200 outputs a determination result regarding the change in the inventory quantity of articles due to the error. For example, based on the determination result by the processing device 200, the inventory quantity information of the article is corrected. Thereafter, based on the corrected inventory quantity, a conveyance instruction is generated.

[0040] The handling system according to the embodiment is applicable to a site where articles are stored, such as a warehouse. The processing device 200 receives a conveyance instruction from a higher-level system that manages the inventory of articles in the warehouse and generates an operation plan according to the instruction.

[0041] Figure 3 is a schematic diagram showing a specific configuration example of the handling system according to the embodiment. As shown in FIG. 3, the handling system 10 according to the embodiment may further include a management device 300 and a storage device 400.

[0042] The management device 300 is a higher-level system that manages the entire handling system 10. For example, the management device 300 functions as a warehouse management system (WMS). The management device 300 manages the inventory of articles in real time, such as inventory management and history management. When the management device 300 receives a conveyance instruction from a higher-level system, it transmits a shipping request to the storage device 400. The shipping request specifies an article and its quantity, and requests to take out the container containing the article and convey it to the location of the handling robot 110 or the operator. Further, the management device 300 accesses the article database 310 and transmits information on the instructed article to the processing device 200.

[0043] The storage device 400 manages articles stored in the warehouse. In response to a shipping request, the storage device 400 transmits a conveyance instruction to the processing device 200 or the terminal device 410. The conveyance instruction instructs to take out a specified number of articles from the shipped container. The processing device 200 generates an operation plan in response to the conveyance instruction and operates the handling robot 110. By the operation of the handling robot 110, the instructed articles are conveyed by the instructed quantity. The inspection unit 120 inspects the conveyed articles based on the information on the articles transmitted from the management device 300. The articles that pass the inspection are accommodated in the shipping container.

[0044] When the terminal device 410 receives a conveyance instruction, it displays the conveyance instruction on the monitor. The operator picks the instructed articles in the instructed quantity according to the displayed conveyance instruction. The operator inspects the picked articles and accommodates the articles without problems in the shipping container.

[0045] The processing device 200 and the terminal device 410 transmit the conveyance result to the storage device 400. The conveyance result indicates whether the conveyance operation by the handling robot 110 has been completed, and includes a determination result of either "conveyance successful" or "conveyance failed". Further, the processing device 200 transmits the conveyance result and the inspection result to the management device 300. The storage device 400 transmits the result for the shipping request to the management device 300 based on the conveyance result received from the processing device 200 and the terminal device 410.

[0046] When an error occurs, the processing device 200 also transmits the determination result of the inventory quantity change and the error information to the management device 300. When the management device 300 receives a conveyance result indicating "conveyance successful", it decreases the inventory quantity in the article database 310 regardless of the inspection result. Further, the management device 300 issues a notification to the operator to correct the inventory quantity based on the determination result of the inventory quantity change. The operator who receives the notification checks the inventory status of the article that is the target of the error and corrects the inventory quantity registered in the article database 310.

[0047] For example, when it is determined that "conveyance successful", the management device 300 decreases the inventory quantity in the article database 310. And when it is determined in the inspection that there is "article difference", "quantity difference", or "article damage", and the article conveyed by the operator is restocked, the operator increases the inventory quantity in the article database 310. Further, the management device 300 resends the shipping request for the article that failed to be conveyed to the storage device 400 based on the error information.

[0048] The handling system 10 may further include another management device that functions as a warehouse execution system (WES). The management device 300 communicates with the other management device and receives a conveyance instruction from the other management device.

[0049] FIG. 4 is a table showing an example of an article database. As shown in FIG. 4, the article database 310 includes columns for article identification information 311, box shape 312, deformability 313, size (X) 314, size (Y) 315, size (Z) 316, weight 317, robot handling 318, and stock quantity 319.

[0050] The data of the identification information 311 indicates the identification information (ID) for each article. The data of the box shape 312 indicates whether each article is in a box shape. "True" indicates that the article is in a box shape. "False" indicates that the article is not in a box shape. The data of the deformability 313 indicates whether each article can be deformed. "True" indicates that the article can be deformed during transportation. "False" indicates that the article cannot be deformed during transportation.

[0051] The data of the size (X) 314, the data of the size (Y) 315, and the data of the size (Z) 316 indicate the width, depth, and height of the article, respectively. For example, the unit is millimeters. The data of the weight 317 indicates the weight of each article. For example, the unit is grams.

[0052] The data of the robot handling 318 indicates the feasibility of handling by the handling device 100. "True" indicates that the handling robot 110 can transport the article. "False" indicates that the handling robot 110 cannot transport the article. When an article with the data of the robot handling 318 being "True" is transported, an instruction is sent from the storage device 400 to the processing device 200. When an article with the data of the robot handling 318 being "False" is transported, an instruction is sent from the storage device 400 to the terminal device 410. The data of the stock quantity 319 indicates the stock quantity of each article.

[0053] The management device 300 transmits article information to the processing device 200 and sends a shipping request to the storage device 400 based on the data in the article database 310. Further, when the management device 300 receives the determination result of the change in the stock quantity from the processing device 200, it issues a notification requesting confirmation of the stock status according to the determination result. The worker who receives the notification appropriately corrects the stock quantity registered in the article database 310. For example, when the determination result indicates that there is no change in the stock quantity due to an error, the management device 300 does not issue a notification to the worker. When the determination result indicates a decrease in the stock quantity due to an error, the management device 300 issues a notification to the worker.

[0054] As shown in FIG. 3, the handling system 10 may further include a terminal device 210 for remotely operating the handling robot 110. The terminal device 210 is connected to the handling robot 110 via a network.

[0055] When an error occurs in the handling robot 110 and it is difficult for the handling robot 110 or the processing device 200 to automatically recover, the operator operates the handling robot 110 using the terminal device 210. Thereby, the operator can recover the handling robot 110 from the error without going to the site of the handling robot 110. The period during which the handling robot 110 stops when an error occurs can be made shorter, and the operating rate of the handling device 100 can be increased.

[0056] When an error occurs, the processing device 200 may determine the necessity of remote operation and send a notification to the terminal device 210. By determining the necessity of remote operation and sending the notification, the operator does not need to monitor the handling robot 110. For example, the operator can be responsible for a plurality of handling robots 110.

[0057] FIG. 5 is a schematic diagram showing the overall processing flow of the handling system according to the embodiment. First, the management device 300 receives a transfer instruction from a higher-level management device. The management device 300 allocates the instructed transfer work to an operator or the handling robot 110. A storage device 400 (not shown) transports the container storing the articles to the allocation destination. When the transfer work is allocated to an operator, the operator transports the articles according to the instruction content and inspects the articles and the quantity. When the articles and their quantity are correct, the instructed transfer work is completed.

[0058] When the transfer work is allocated to the handling robot 110, the processing device 200 receives a transfer instruction from the management device 300 and causes the handling robot 110 to execute the transfer. When the transfer operation by the handling robot 110 is completed, regardless of whether the articles are actually transferred normally, the processing device 200 processes the case as "transfer successful". When the transfer operation by the handling robot 110 is not completed, the processing device 200 processes the case as "transfer failed".

[0059] After the transfer operation by the handling robot 110 is completed, the inspection unit 120 performs an inspection. When the inspection result is qualified, the instructed transfer is completed. As described above, based on the information transmitted from the handling robot 110, errors such as dropping of articles can be detected. However, in the transfer work, errors that are difficult to detect by the handling robot 110, such as a mismatch between the transferred articles and the instructed articles, a mismatch in quantity, and damage to the articles, may also occur. According to the inspection unit 120, such errors that are difficult to detect by the handling robot 110 can be detected. By providing the inspection unit 120, the accuracy of the transfer process executed by the handling device 100 can be improved.

[0060] When the transfer by the handling robot 110 fails, or when the inspection by the inspection unit 120 is unqualified, the processing device 200 detects these errors. When an error is detected, the processing device 200 attempts a recovery process.

[0061] For example, when it is determined that a software defect has occurred in the handling robot 110, the processing device 200 resets the software of the handling robot 110. When it is determined that an article has fallen during conveyance, the processing device 200 causes the handling robot 110 to convey the article again. When it is determined in the inspection that the conveyed content does not match the instructed content, the processing device 200 causes the handling robot 110 to convey the article again. By the return process, the handling by the handling device 100 is automatically restarted, and the operation rate of the handling device 100 can be increased.

[0062] When it is determined that automatic return processing is difficult and remote operation is required, the processing device 200 notifies the terminal device 210 of the necessity of remote operation for return. When the terminal device 210 receives the notification, the operator executes the return process by remote operation.

[0063] In addition to the return process, the processing device 200 determines the process in which an error has occurred and the cause of the error. Based on those determination results, the processing device 200 determines the change in the inventory number of articles due to the error. For example, in different cases where it is determined as "article difference", "quantity difference", or "article damage" in the inspection, the processing device 200 outputs a determination result to decrease the inventory number of that article by the number being conveyed. When an error occurs during conveyance and the handling robot 110 is gripping an article, the processing device 200 outputs a determination result to decrease the inventory number of that article by the number being conveyed. When the error is the dropping of an article during conveyance, the processing device 200 outputs a determination result to decrease the inventory number of that article by the number that was being conveyed.

[0064] Further, when an error occurs, the processing device 200 generates error information indicating the content of the error based on the determination result of the process and the determination result of the cause. Also, when re-conveyance of an article is required due to an error, the processing device 200 transmits a re-execution request for conveyance to the management device 300.

[0065] When an article is conveyed to the discharge container C3, the processing device 200 transmits a notification to a predetermined terminal device. Articles stored in the discharge container C3 when an error occurs, articles that have fallen during conveyance, etc. are collected by an operator at an arbitrary timing. Normal articles without damage, deformation, deterioration, etc. are restocked in the storage location of the warehouse. At this time, the inventory number registered in the article database is increased by the number of restocked articles.

[0066] FIG. 6 is a flowchart showing the return process when an error occurs. By executing the return process shown in FIG. 6, the handling device 100 returns from the error state and conveyance is restarted. First, when an error occurs during conveyance or inspection, the processing device 200 detects the error and confirms the process in which the error has occurred (step S1). Subsequently, the processing device 200 determines the process in which the error has occurred (step S2). That is, it is determined whether the error has occurred during conveyance or inspection.

[0067] When an error occurs during conveyance, the processing device 200 determines whether the cause of the error is a software defect (step S3). If the determination result in step S3 is "No", the processing device 200 determines whether the cause of the error is related to before gripping the article (step S4). Errors that occur before gripping the article include failures in recognition or planning. More specifically, there may be cases where the recognition of the article by the first measuring instrument 130 is not completed normally, cases where the generation of the operation plan by the processing device 200 is not completed normally, etc.

[0068] If the determination result in step S4 is "No", the processing device 200 determines whether the cause of the error is the detection of a collision by the handling robot 110 (step S5). When interference of the handling robot 110 occurs, a collision is detected by the sensor 114 of the handling robot 110. The handling robot 110 transmits information indicating that a collision has been detected to the processing device 200. When the processing device 200 has received that information, the cause of the error is determined to be the detection of a collision.

[0069] When the determination result in step S5 is "Yes", the processing device 200 notifies the terminal device 210 that remote operation is necessary (step S6). The operator of the terminal device 210 remotely operates the handling robot 110 using the terminal device 210 (step S7). For example, the operator moves the handling robot 110 to a position where it does not interfere with the object. Thereafter, the processing device 200 regenerates the operation plan based on the position after the movement. As a result, the conveyance by the handling robot 110 is restarted and the return process ends.

[0070] If it is determined in step S2 that an error has occurred during the inspection, the processing device 200 counts the change in the inventory quantity (step S8). Thereafter, the processing device 200 generates error information (step S9). When step S9 is completed, the processing at the time of error occurrence ends.

[0071] When the determination result in step S3 is "Yes", the processing device 200 executes a software reset (step S11). As a result, the software defect of the handling robot 110 is eliminated. Thereafter, the processing device 200 determines whether the handling robot 110 is gripping an article (step S12). If the handling robot 110 is gripping an article, the processing device 200 operates the handling robot 110 so as to convey the gripped article to the discharge container C3 (step S13). Thereafter, step S8 is executed. In this case, the number conveyed to the discharge container C3 is counted as a decrease in the inventory quantity.

[0072] If the determination result in step S4 is "Yes", the processing device 200 notifies the terminal device 210 that remote operation is required (step S21). For example, the operator uses the terminal device 210 to teach the position for the handling robot 110 to grasp an object. After step S21, the handling robot 110 determines whether remote teaching has been executed (step S22). If remote teaching is not executed, the handling robot 110 determines whether a predetermined time has elapsed since the execution of step S21 (step S23). If the predetermined time has not elapsed, step S22 is executed again.

[0073] If the determination result in step S23 is "Yes", step S9 is executed. If the determination result in step S22 is "Yes", the handling robot 110 operates to grasp the object at the taught position. Thus, the recovery process from the error ends. In any case, since the error occurs before the article is grasped, the inventory number of the article does not change.

[0074] If the determination result in step S5 is "No", the processing device 200 determines whether the cause of the error is the dropping of the article during conveyance (step S14). If the determination result in step S14 is "Yes", step S8 is executed. In this case, the number of dropped articles is counted as a decrease in the inventory number.

[0075] If the determination result in step S14 is "No", step S12 is executed. As an error determined as "No" in step S14, there may be a measurement error by the second measuring instrument 140. If the height of the article cannot be measured normally by the second measuring instrument 140, the processing device 200 attempts to generate an operation plan assuming that the article with the maximum size that can be handled is being grasped. And if an operation plan capable of conveying the article with the maximum size cannot be generated, the processing device 200 issues an error indicating that conveyance is impossible.

[0076] FIG. 7 and FIG. 8 are schematic diagrams showing a graphical user interface during remote operation. When performing remote operation, the terminal device 210 displays a graphical user interface (GUI) for remote operation of the handling robot 110 on the monitor.

[0077] When the remote operation in step S7 is executed, the terminal device 210 displays, for example, the GUI 500 shown in FIG. 7. The GUI 500 includes a display area 501, icons 503 to 506, and icons 511 to 516.

[0078] An image captured by the imaging device is displayed in the display area 501. For example, when the imaging device acquires an image, the image is displayed in the display area 501 in real time. The icon 503 is an icon for switching the image displayed in the display area 501. In the illustrated example, an image captured by the imaging device 150 is displayed. When a plurality of imaging devices are provided around the handling robot 110, the icon 503 can be used to select which imaging device's acquired image is to be displayed in the display area 501.

[0079] The icon 504 is an icon for releasing an error of the handling robot 110. By releasing the error, the handling robot 110 becomes operable. The icon 505 is an icon for acquiring the right to control remote operation. When the operator clicks the icon 505, the operator can acquire the right to remotely operate the handling robot 110. The icon 506 is an icon for returning the handling robot 110 and the processing device 200 to autonomous operation.

[0080] Icons 511 to 516 are icons for remotely operating the handling robot 110. Icons 511 to 514 are icons for operating the handling robot 110 in two horizontal directions (X direction and Y direction). Icons 515 and 516 are icons for operating the handling robot 110 in the vertical direction (Z direction).

[0081] When the operator clicks any one of the icons 511 to 516, the gripping part 115 moves in either the X direction, the Y direction, or the Z direction according to the operation. After the operator moves the gripping part 115 to a position where no interference occurs, the operator clicks the icon 506. In response to this operation, the processing device 200 regenerates an operation plan based on the position moved by the operator. Then, the handling robot 110 operates according to the generated operation plan.

[0082] When remote operation is executed after step S21, the terminal device 210 displays, for example, the GUI 600 shown in FIG. 8. The GUI 600 includes a display area 601 and icons 603 to 606.

[0083] A real-time image captured by the imaging device is displayed in the display area 601. The icon 603 is an icon for switching the image displayed in the display area 601. In the illustrated example, an image captured by the imaging device of the first measuring instrument 130 is displayed. An imaging device for acquiring an image to be displayed on the GUI 600 may be provided around the handling robot 110.

[0084] The icon 604 is an icon for canceling an error of the handling robot 110. The icon 605 is an icon for acquiring the leading right of remote operation. The icon 606 is an icon for returning the handling robot 110 and the processing device 200 to autonomous operation.

[0085] Message 608 indicates an instruction to the operator. After obtaining the remote operation leadership by clicking on icon 605, the operator uses the pointing device (such as a mouse) of terminal device 210 to move cursor 610. The operator moves cursor 610 to the gripping point by the gripping part 115 according to the instruction of message 608 and designates the gripping point. After moving cursor 610 to the gripping point, the operator clicks on icon 606. The processing device 200 generates an operation plan to grip the article at the designated point. Then, handling robot 110 operates according to the generated operation plan.

[0086] While cursor 610 exists on the display area 601, auxiliary lines 611 and 612 may be displayed. Auxiliary lines 611 and 612 are straight lines extending in the horizontal and vertical directions respectively. By displaying auxiliary lines 611 and 612, it becomes easier for the operator to confirm the point selected by cursor 610.

[0087] The advantages of the embodiments of the present invention will be described. When an article is transported using handling robot 110, various errors may occur. As described above, the errors are software defects, interference, dropping of the article, failure of recognition or planning, mismatch between the transported content and the instructed content, etc. Conventionally, when these errors occurred, the operator checked the presence or absence of changes in the inventory count and appropriately corrected the inventory count in the article database 310.

[0088] In the conventional method, every time an error occurs, it is necessary for the operator to check the presence or absence of changes in the inventory count. That is, the transportation by handling robot 110 stops until the change in the inventory count is confirmed and the information in the article database 310 is corrected. Also, a method of restarting the transportation by handling robot 110 without checking the change in the inventory count regardless of the occurrence of an error is conceivable. However, in that case, there is no information such as from which container the article was being transported when the error occurred, when the error occurred, and where to check to confirm the inventory count. Therefore, it takes a lot of time for the operator to make the confirmation.

[0089] Regarding this problem, according to an embodiment of the present invention, the processing device 200 detects the occurrence of an error in the handling device 100. The processing device 200 determines the process in which the error occurred and the cause of the error. Then, the processing device 200 uses the determination result of the process and the determination result of the cause to determine the change in the inventory quantity of the article due to the error. As a result, the operator can collectively confirm the change in the inventory quantity after the occurrence of a plurality of errors according to the determination result of the change in the inventory quantity for each error.

[0090] For example, for an error determined by the processing device 200 that the inventory quantity has not changed, it is not necessary for the operator to check the inventory quantity. Also, regarding an error determined that the inventory quantity has not changed, from the time when the error is detected, the operator can grasp the occurrence time of the error. Further, from the process of the error and the cause of the error, the operator can grasp the range where the article should be searched.

[0091] According to an embodiment of the present invention, the time for the handling robot 110 to stop for inventory confirmation can be shortened, and it is possible to improve the operation rate of the handling robot.

[0092] In the determination of the process, the processing device 200 determines in which process, either the conveyance by the handling robot 110 or the inspection by the inspection unit 120, the error occurred. When an error occurs during the inspection, the processing device 200 outputs a determination result to decrease the inventory quantity of the article.

[0093] When an error occurs during the conveyance by the handling robot 110 and it is determined that the cause of the error is the dropping of the article, the processing device 200 outputs a determination result to decrease the inventory quantity of the article.

[0094] In this case, the management device 300 may modify the approval information indicating the approval or disapproval of the handling by the handling robot 110 for the dropped article. For example, when an article drops, the management device 300 changes the data of the robot processing 318 of that article from "True" to "False" in the article database 310. As a result, for the dropped article, the conveyance work is thereafter executed by an operator. Consequently, the occurrence of an error by the handling robot 110 is suppressed, and it becomes possible to further increase the operation rate of the handling robot 110.

[0095] When an error occurs during conveyance by the handling robot 110, the processing device 200 appropriately determines whether an article is being gripped by the handling robot. For example, when the cause of the error is a software defect, or when the cause of the error is not related to before gripping of the article and is not an article drop, the processing device 200 determines whether the article is being gripped. When it is determined that the article is being gripped by the handling robot 110, the processing device 200 outputs a determination result to decrease the inventory count of the article.

[0096] When an error occurs during conveyance by the handling robot 110 and the cause of the error is related to before the handling robot 110 grips the article, a determination result is output not to change the inventory count of the article.

[0097] As in the above example, by determining the change in the inventory count using the determination result of the process and the determination result of the cause, an operator can more quickly and accurately confirm the change in the inventory count due to a plurality of errors later.

[0098] In addition, when an error occurs during the transfer by the handling robot 110, the processing device 200 may determine the necessity of remotely operating the handling robot 110. When it is determined that remote operation is necessary, the processing device 200 issues a notification. For example, the notification is transmitted to the terminal device 210, and in response to the notification, the operator of the terminal device 210 remotely operates the handling robot 110. The operator can return the handling robot 110 from the error without going to the site where the handling robot 110 is installed. Therefore, the period during which the handling robot 110 stops can be made shorter, and the operating rate of the handling device 100 can be increased more.

[0099] FIG. 9 is a schematic diagram showing a hardware configuration. The processing device 200, the management device 300, the storage device 400, etc. include, for example, the computer 90 shown in FIG. 9. The computer 90 includes a CPU 91, a ROM 92, a RAM 93, a storage device 94, an input interface 95, an output interface 96, and a communication interface 97.

[0100] The ROM 92 stores a program for controlling the operation of the computer 90. The ROM 92 stores programs necessary for causing the computer 90 to implement each of the above-described processes. The RAM 93 functions as a storage area in which the programs stored in the ROM 92 are expanded.

[0101] The CPU 91 includes a processing circuit. The CPU 91 executes a program stored in at least one of the ROM 92 or the storage device 94, using the RAM 93 as a work memory. During the execution of the program, the CPU 91 controls each component via the system bus 98 and executes various processes.

[0102] The storage device 94 stores data necessary for the execution of the program and data obtained by the execution of the program.

[0103] The input interface (I / F) 95 can connect the computer 90 and the input device 95a. The input I / F 95 is, for example, a serial bus interface such as USB. The CPU 91 can read various data from the input device 95a via the input I / F 95.

[0104] The output interface (I / F) 96 can connect the computer 90 and the output device 96a. The output I / F 96 is, for example, a video output interface such as Digital Visual Interface (DVI) or High-Definition Multimedia Interface (HPMI (registered trademark)). The CPU 91 can transmit data to the output device 96a via the output I / F 96 and cause the output device 96a to output the data.

[0105] The communication interface (I / F) 97 can connect the computer 90 and a server 97a outside the computer 90. The communication I / F 97 is, for example, a network card such as a LAN card. The CPU 91 can read various data from the server 97a via the communication I / F 97.

[0106] The storage device 94 includes one or more selected from a Hard Disk Drive (HDD) and a Solid State Drive (SSD). The input device 95a includes one or more selected from a mouse, a keyboard, a microphone (voice input), and a touch pad. The output device 96a includes one or more selected from a monitor, a projector, a printer, and a speaker. A device having both functions of the input device 95a and the output device 96a, such as a touch panel, may be used.

[0107] Each process executed by the processing device 200, the management device 300, or the storage device 400 may be realized by one computer 90 or may be realized by the cooperation of a plurality of computers 90. One computer 90 may function as two or more selected from the processing device 200, the management device 300, and the storage device 400.

[0108] The processing of the various data described above can be recorded as a program executable by a computer on a magnetic disk (such as a flexible disk and a hard disk), an optical disk (such as a CD-ROM, CD-R, CD-RW, DVD-ROM, DVD±R, DVD±RW), a semiconductor memory, or other non-transitory computer-readable storage media (non-transitory computer-readable storage medium).

[0109] For example, the information recorded on the recording medium can be read by a computer (or an embedded system). In the recording medium, the recording format (storage format) is arbitrary. For example, the computer reads a program from the recording medium and causes the CPU to execute the instructions described in the program based on this program. In the computer, the acquisition (or reading) of the program may be performed through a network.

[0110] According to the embodiments described above, a processing device, a handling system, a processing method, a program, and a storage medium that can further increase the operating rate of the handling robot are provided.

[0111] In this specification, "or" indicates that "at least one or more" of the items listed in the sentence can be adopted.

[0112] As described above, some embodiments of the present invention have been illustrated. However, these embodiments are presented as examples and are not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, replacements, changes, etc. can be made without departing from the gist of the invention. These embodiments and their modifications are included in the scope and gist of the invention, and are included in the invention described in the claims and its equivalent scope. In addition, the above-described embodiments can be implemented in combination with each other.

Description of Reference Numerals

[0113] 10: Handling system, 100: Handling device, 110: Handling robot, 111: Link, 112: Rotation axis, 114: Sensor, 115: Gripping part, 120: Inspection unit, 121: Conveyor, 122: Weight sensor, 123: Guide, 130: First measuring instrument, 140: Second measuring instrument, 150: Imaging device, 200: Processing device, 210: Terminal device, 300: Management device, 310: Article database, 400: Storage device, 410: Terminal device, 500, 600: Graphical user interface, A: Article, C1: Container, C2: Shipping container, C3: Discharge container

Claims

1. A processing device capable of communicating with a handling device including a handling robot for transporting an article and an inspection unit for inspecting the transported article, detecting the occurrence of an error in the handling device, determining the process in which the error occurred and the cause of the error, A processing device that determines a change in the management information of the article due to the error using the determination result of the process and the determination result of the cause.

2. The processing device according to claim 1, wherein in the determination of the process, it is determined in which process of the transport by the handling robot and the inspection by the inspection unit the error occurred.

3. The processing device according to claim 2, wherein the management information includes the inventory quantity of the article.

4. The processing device according to claim 3, wherein when an error occurs in the inspection by the inspection unit, a determination result for reducing the inventory quantity of the article is output.

5. The processing device according to claim 3, wherein when an error occurs in the transport by the handling robot and it is determined that the cause of the error is the dropping of the article, a determination result for reducing the inventory quantity of the article is output.

6. When an error occurs in the transport by the handling robot, it is determined whether the article is being held by the handling robot, The processing device according to claim 3, wherein when it is determined that the article is being held by the handling robot, a determination result for reducing the inventory quantity of the article is output.

7. When the error occurs during the transfer by the handling robot and the cause of the error relates to before the handling robot grips the article, the processing device according to claim 3 outputs a determination result not to change the inventory number of the article.

8. When the error occurs during the transfer by the handling robot, determine the necessity of remote operation of the handling robot, When it is determined that the remote operation is necessary, issue a notification, the processing device according to claim 1.

9. The processing device according to any one of claims 1 to 8, and The handling device and the handling system.

10. Further comprising a management device communicable with the processing device, The processing device transmits a transfer result indicating success or failure of the transfer of the article and a determination result of change of the management information of the article to the management device, the handling system according to claim 9.

11. The management device accesses an article database including availability information indicating the availability of transfer by the handling robot for each article, and when the article drops by the handling robot, modifies the availability information for the dropped article, the handling system according to claim 10.

12. Further comprising a terminal device communicable with the handling robot via a network and capable of remotely operating the handling robot, the handling system according to claim 11.

13. Communicate with a handling device including a handling robot that transports an article and an inspection unit that inspects the transported article, Detect the occurrence of an error in the handling device, Determine the process in which the error occurred and the cause of the error, A processing method for determining a change in management information of the article due to the error by using the determination result of the process and the determination result of the cause.

14. A program for causing a computer to execute the processing method according to claim 13.

15. A storage medium storing the program according to claim 14.

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