Binding system and binding program

Abstract

To enable the shape of a reinforcing bar to be properly detected.SOLUTION: A binding system 1 for binding using a binding device on the basis of signal information relating to a plurality of arranged reinforcing bars is provided with a second camera 51 for acquiring image data relating to the reinforcing bars S, and a control unit 77. The control unit 77 detects the shape of the reinforcing bars S on the basis of contrast information included in the image data of the reinforcing bars S.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present invention relates to a bundling system and a bundling program for bundling reinforcing bars. [Background technology]

[0002] Conventionally, there is a known bundling system that automatically ties the intersections of intersecting rebars with wire in order for a workpiece made up of multiple rebars. In this type of bundling system, information on the bundling points, which are the intersections of the rebars, may be obtained using sensors or cameras. For example, the technology described in Patent Document 1 is applied to a self-propelled binding device that binds rebars while running over them laid on a flat surface. It uses a distance sensor to acquire point cloud information in the vertical direction, and converts this point cloud information into a straight line model to detect the intersections of the rebars. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2022-110556 Summary of the Invention [Problem to be solved by the invention]

[0004] However, the technology described in Patent Document 1 has low accuracy in detecting intersections, making it difficult to grasp the shape of the reinforcing bar, such as the diameter of the reinforcing bar.

[0005] The present invention has been made in view of the above circumstances, and has an object to suitably detect the shape of a reinforcing bar. [Means for solving the problem]

[0006] In order to solve the above-mentioned problems, the present invention provides: A bundling system for bundling reinforcing bars with a bundling device based on signal information relating to a plurality of installed reinforcing bars, an information acquisition unit that acquires the signal information; a detection unit that detects the shape of the reinforcing bar based on contrast information included in the signal information; Equipped with. [Effects of the Invention]

[0007] According to the present invention, the outline of the reinforcing bar is extracted based on the contrast information contained in the signal information of the reinforcing bar. Then, the shape of the reinforcing bar, such as its diameter, can be determined from the position of this outline. Therefore, the shape of the reinforcing bar can be suitably detected. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 2 is a perspective view of the device body of the binding system according to the embodiment. [Figure 2] FIG. 2 is a block diagram showing a schematic control configuration of the binding system according to the embodiment. [Figure 3] FIG. 2 is a side view of the binding device according to the embodiment. [Figure 4] 10 is a flowchart illustrating a procedure of a binding process according to the embodiment. [Figure 5] 10 is a flowchart illustrating a procedure of a binding process according to the embodiment. [Figure 6] FIG. 2 is a diagram showing an example of image data acquired by a first camera. [Figure 7] FIG. 10 is a perspective view of the device main body in a state where the workpiece has been moved to the binding area. [Figure 8A] FIG. 10 is a diagram showing an example of image data acquired by the second camera. [Figure 8B] 8B is a diagram showing an example of image data in which height information of reinforcing bars and other positions is added to the image data of FIG. 8A. FIG. [Figure 9] 10A and 10B are diagrams for explaining the shape of a reinforcing bar detected from image data. [Figure 10] 10 is a flowchart showing the procedure of a modified example of the bundling process according to the embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0010] [Binding system configuration] FIG. 1 is a perspective view of an apparatus main body 10 provided in a binding system 1 according to this embodiment, and FIG. 2 is a block diagram showing a schematic control configuration of the binding system 1. As shown in FIG. As shown in these figures, the bundling system 1 binds a work B, which is made up of a plurality of reinforcing bars S arranged in a lattice pattern, at the intersections where the plurality of reinforcing bars S intersect. Specifically, the binding system 1 includes a device main body 10 and a control device 7.

[0011] The device main body 10 includes a workpiece holding unit 2, an overall photographing unit 3, a robot arm 4, an individual photographing unit 5, and a binding device 6. Of these, the workpiece holding unit 2 is disposed inside a stand 11 of the device main body 10, and the overall photographing unit 3, the robot arm 4, the individual photographing unit 5, and the binding device 6 are mounted on the stand 11. In the following description, the X, Y and Z directions refer to the directions shown in Fig. 1. The X, Y and Z directions are perpendicular to each other, the XY plane is a substantially horizontal plane, and the Z direction is a direction substantially along the vertical.

[0012] The mount 11 is formed in the shape of a rectangular parallelepiped that is long in the X direction, and includes four pillars 12 erected at the four corners in the X and Y directions, and four beams 13 that span the upper ends of the pillars 12 in the X and Y directions. Of the area inside the stand 11, approximately half on one side in the X direction (the right side in Figure 1) is the photography area E1 where photography is performed by the overall photography unit 3, and the half on the other side (the left side in Figure 1) is the binding area E2 where binding work is performed by the robot arm 4 and the binding device 6.

[0013] <Work holding part> The workpiece holding unit 2 holds the workpiece B and moves the held workpiece B between the photography area E1 and the binding area E2. Specifically, the workpiece holding unit 2 includes a holding table 21 that holds the workpiece B, rails 22 that movably support the holding table 21, and a drive motor 23 that drives the rails 22. The holder 21 is formed in the shape of a rectangular plate with four sides aligned along the X and Y directions. Support plates 211 that support a plurality of reinforcing bars S that constitute the workpiece B are erected on the four sides of the holder 21. The support plates 211 have a plurality of U-shaped grooves 211a that open upward, and the reinforcing bars S are inserted into the U-shaped grooves 211a. The multiple reinforcing bars S are arranged in a lattice pattern along the X and Y directions with their ends inserted into the U-shaped grooves 211a of the support plates 211. The rails 22 are laid along the X direction and guide the holder 21 in the X direction. In this embodiment, the rails 22 are laid so that the holder 21 (work B) can move at least between the photography area E1 and the binding area E2. However, the rails 22 may be configured to extend to the outside of the stand 11 so that the work B can be moved to a work process before or after binding. The drive motor 23 is a drive source that moves the holder 21. Based on a drive command from the control device 7, the drive motor 23 moves the holder 21 to the photographing area E1 and the binding area E2. It is sufficient that the workpiece holder 2 is capable of at least moving the holder 21 (workpiece B) from the photographing area E1 to the binding area E2.

[0014] <Overall Photography Department> The overall photographing unit 3 photographs the entire workpiece B in the photographing area E1. Specifically, the overall photographing unit 3 includes a first camera 31 arranged above the photographing area E1, and a moving mechanism 32 that movably supports the first camera 31. The first camera 31 is disposed facing downward and photographs the workpiece B held by the workpiece holder 2 from above in the photographing area E1. The first camera 31 of this embodiment is a compound eye (for example, four-eye) stereo camera that acquires image information (monochrome image) in the XY plane as well as distance information in the depth direction (up and down direction), and outputs this to the control device 7. The first camera 31 is an example of an information acquisition unit according to the present invention. Note that the sensor type of the first camera 31 is not particularly limited as long as it can acquire distance information (depth information) along with image information, and may be, for example, a TOF (Time of Flight) sensor. The movement mechanism 32 includes a Y-direction slider 33 that extends along the Y direction. The Y-direction slider 33 is hung on a beam 13 that extends along the X direction and is supported by the beam 13 so as to be movable in the X direction. A first camera 31 is suspended from the Y-direction slider 33 so as to be movable in the Y direction. The movement mechanism 32 drives a drive source (not shown) based on a control command from the control device 7, and moves the first camera 31 to a predetermined position (XY coordinates). As will be described later, the moving mechanism 32 is used to photograph the entire workpiece B multiple times in order to obtain an image of the workpiece B with a desired resolution. Therefore, depending on the performance of the first camera 31 and the shape of the workpiece B, the moving mechanism 32 may move the first camera 31 in only one of the X and Y directions, or may not be provided at all.

[0015] <Robot arm> The robot arm 4 is equipped with an individual photographing unit 5 and a binding device 6, and moves the individual photographing unit 5 and the binding device 6 to desired positions in the binding area E2. The robot arm 4 of this embodiment includes a movement mechanism 46, a robot arm main body 40, and a controller 49.

[0016] The movement mechanism 46 moves the robot arm body 40. The movement mechanism 46 of this embodiment includes a Y-direction slider 461 that is hung on the beam 13 of the base 11. The Y-direction slider 461 moves the robot arm body 40 in the Y direction. However, the specific configuration of the moving mechanism 46 is not particularly limited, and may include, for example, a mechanism for moving the robot arm body 40 in the X direction. Furthermore, if the operating range of the robot arm body 40 can cover the entire binding area E2 without relying on the moving mechanism 46, the moving mechanism 46 may not be provided.

[0017] The robot arm body 40 is a ceiling-suspended vertical articulated robot, and is installed facing downward on a Y-direction slider 461 suspended on the beam 13 in the binding area E2. Specifically, the robot arm body 40 includes a base 41, a plurality of arms 42, an end effector 43, and a plurality of joints 44. The robot arm body 40 is not limited to a vertical articulated robot, as long as it can move the individual photographing unit 5 and binding device 6 mounted thereon.

[0018] The arms 42 are connected in series with the base portion 41 as the base end. The base portion 41 is mounted on a Y-direction slider 461 of the movement mechanism 46 and is supported so as to be movable in the Y direction. The plurality of joints 44 rotatably connect the base 41, the plurality of arms 42, and the end effector 43. Each joint 44 is provided with a motor 441 that drives the arm 42 (or the end effector 43) connected to the tip side of the joint 44, and an encoder 442 that detects the position (speed) of the motor 441 and outputs the position (speed) to the controller 49. The end effector 43 is connected to the tip of the multiple arms 42. The end effector 43 is equipped with an individual photographing unit 5 and a binding device 6. Note that the specific configuration is not particularly limited as long as the tip of the robot arm main body 40 is equipped with the individual photographing unit 5 and the binding device 6. For example, the individual photographing unit 5 may be fixed to the joint unit 44 on the tip side, and the binding device 6 may be connected as an end effector via a tool changer.

[0019] The controller 49 controls the operation of each part of the robot arm 4 based on a control command from the control device 7. Specifically, the controller 49 operates each motor 441 and the moving mechanism 46, and outputs information acquired by each encoder 442 to the control device 7. The controller 49 may locally control the operations of the individual photographing unit 5 and the binding device 6 mounted thereon based on a control command from the control device 7.

[0020] <Individual Photography Department> The individual photographing unit 5 is mounted on the tip of the robot arm main body 40, and individually photographs the intersections P of the rebars S to be bundled in the binding area E2 with a higher resolution than that of the overall photographing unit 3. Specifically, the individual photographing unit 5 includes a second camera 51, an elevation motor 52, and a lighting unit 53. The second camera 51 is attached to the end effector 43 of the robot arm 4 facing the tip (downward) and captures an image of the intersection P of the rebar S to be bundled from above. The second camera 51 is provided so as to be movable toward the tip (up and down) relative to the end effector 43. The second camera 51 in this embodiment is, for example, an RGB camera, and acquires image information (color image) of the intersection P to be bundled and outputs it to the control device 7. The second camera 51 is an example of an information acquisition unit according to the present invention. Note that the sensor type of the second camera 51 is not particularly limited as long as it can acquire an image (signal information) of at least one intersection P. The lifting motor 52 is a drive source that moves (lifts) the second camera 51 toward the tip (up and down) relative to the end effector 43. The lighting unit 53 is disposed slightly in front of the second camera 51 and around the shooting range, and illuminates the subject to be shot by the second camera 51. The lighting unit 53 of this embodiment has a plurality of light sources (projectors, not shown) that can illuminate the subject to be shot by the second camera 51 from different angles.

[0021] <Binding device> FIG. 3 is a side view of the binding device 6. As shown in this figure, the binding device 6 is mounted on the tip of the robot arm main body 40. The binding device 6 includes a rebar binding machine 61 that binds the intersections P of the rebars S that make up the workpiece B with wire W, a slack forming unit 62 that pulls out the wire W from a reel 63 and forms slack in the wire W between the binding machine 61 and the reel 63, and a control unit 64 (see FIG. 2) that causes the rebar binding machine 61 to perform the binding operation and the slack forming unit 62 to perform the operation of forming slack in the wire W in accordance with operation commands from the control device 7.

[0022] The rebar binding machine 61 has an entrance section 611 through which two wires W are fed from outside the housing along the feed direction F shown in the figure, and the two wires W fed into the interior from the entrance section 611 are wound around the rebar S, and the two wires W wound around the rebar S are fed in the reverse feed direction R to wrap around the rebar S and cut it, and then the wires W are twisted and the rebar S is bound with the wires W.

[0023] For this reason, the binding machine 61 is equipped with a wire feeding section that feeds the wire W, a wire guide 612 that guides the wire W, a curl guide 613 and a guide guide 614 that wind the wire W around the reinforcing bar S, a cutting section that cuts the wire W wound around the reinforcing bar S, and a binding section that twists the wire W wound around the reinforcing bar S.

[0024] The wire guide 612 is provided in front of the entrance 611 and guides the two wires W so that they enter the entrance 611 along the feeding direction F.

[0025] The wire feeding unit is located inside the entrance 611, and clamps two wires W between a pair of feed gears and feeds them in a feed direction F. The wire feeding unit is equipped with a feed motor 615 (see FIG. 2) that serves as a drive source. This feed motor 615 is driven in a forward rotation to feed the two wires W in the feed direction F, allowing the wires W to be wound around the reinforcing bar S by the curl guide 613 and the induction guide 614 located at the end of the wires. In addition, the feed motor 615 is driven in a reverse rotation to feed the two wires W in the reverse feed direction R, allowing the reinforcing bar S to be tightened by the wires W.

[0026] The cutting unit is located inside the entrance 611, further back than the wire feeding unit. The cutting unit has a movable blade and a fixed blade (not shown), and the movable blade shares a drive source with the binding unit. The movable blade can be moved toward the fixed blade by a torsion motor 616 (see Figure 2), which is the drive source for the binding unit, to cut the two wires. The drive source for the cutting unit may be provided separately and independently.

[0027] 3 is supported by an end effector 43 at the tip of the robot arm 4, and performs binding operations with the rotation axis Zr of the end effector 43 parallel to the Z direction (vertical up-down direction) described above. The binding device 6 is set so that the position where the wire W is bound to the reinforcing bar S is located on the axis of the rotation axis Zr, and during binding, the robot arm 4 positions the binding device 6 so that the intersection P of the reinforcing bar S is located on the axis of the rotation axis Zr.

[0028] The curl guide 613 and the induction guide 614 are located at the tip end of the binding machine 61 (the lower end during binding operation), and are disposed on both sides of the above-mentioned rotation axis Zr. The curl guide 613 has its base end positioned at the end of the entrance 611 in the feed direction F, and a guide path is formed inside to curl the wire W as it moves from the base end to the tip end of the curl guide 613.

[0029] The induction guide 614 is positioned opposite the curl guide 613, and has a guide path formed inside that receives the wire W curled by the curl guide 613 from the tip end and guides the wire W to the base end while maintaining the curled state. By cooperation of the curl guide 613 and the induction guide 614, the wire W can be deformed into a loop and wound around the reinforcing bar S.

[0030] The bundling unit has a locking member that captures the wire W while it is wound around the reinforcing bar S between the base end of the guiding guide 614 and the base end of the curl guide 613. The locking member is rotatably supported inside the bundling machine 611 about a rotation axis that is concentric with the aforementioned pivot axis Zr, and torque for rotational drive is applied to the locking member by the aforementioned torsion motor 616. After the wire W is cut by the cutting unit, the locking member is rotationally driven by the torsion motor 616, and can twist both ends of the wire W to bind the reinforcing bar S.

[0031] Two reels 63 of the wire W are rotatably supported side by side on one side in the direction along the rotation axis Zr of the binding machine 61 (the upper side during binding operation). The two reels 63 are each rotatable around an axis extending perpendicular to the paper surface in FIG. 3, and are arranged side by side on the axis.

[0032] The slack forming unit 62 is disposed on one side of the binding machine 61 and the two reels 63 in the orthogonal direction Xw that is orthogonal to the rotation axis Zr. The slack forming section 62 has a first slack forming section 621 and a second slack forming section 622 that move past each other, and a slack forming motor 623 that serves as a drive source for these moving past each other.

[0033] The aforementioned feed direction F of the wire W is generally parallel to a plane parallel to the pivot axis Zr and the orthogonal direction Xw. Furthermore, the upstream side of the feed direction F of the wire W is slightly inclined upward in the plane of the paper in FIG. 3 with respect to the orthogonal direction Xw. The first slack forming portion 621 and the second slack forming portion 622 each hold a roller around which two wires W are wound.

[0034] The first slack forming unit 621 and the second slack forming unit 622 perform a passing operation generally along the feed direction F, thereby extending the path length of the wire W from the reel 63 to the inlet 611 of the binding machine 61 and pulling out the wire W from the reel 63. Furthermore, the first slack forming unit 621 and the second slack forming unit 622 perform a returning operation after the passing operation, thereby providing slack to the wire W by the amount pulled out from the reel 63. The slack forming portion 62 does not necessarily have to be provided.

[0035] Incidentally, the two wires W are required to be fed into the inlet 611 of the binding machine 61 from a direction close to the feeding direction F (i.e., at an incident angle close to the feeding direction F). The feeding direction F is a direction suitable for deforming the wire W into an appropriate loop shape by the curl guide 613 and the induction guide 614 located at the end of the feeding direction. In order to supply the wire W to the entrance 611 of the binding machine 61 along the feed direction F, the slack forming unit 62 is arranged so that the path from the downstream second slack forming unit 622 to the entrance 611 of the binding machine 61 follows the feed direction F. During passing operations, the second slack forming unit 622 moves away from the entrance 611 of the binding machine 61 along the feed direction F.

[0036] For this reason, the binding device 6 is disposed so that the slack forming portion 62 protrudes largely on one side (the right side of the paper in FIG. 3) in the direction Xw perpendicular to the binding machine 61 (swivel axis Zr). 3, the second camera 51 and the lighting unit 53 of the individual photographing section 5 are disposed on the left side of the binding machine 61 of the binding device 6 in FIG.

[0037] <Control device> 2, the control device 7 is a computer that comprehensively controls the binding system 1. Specifically, the control device 7 includes an operation unit 72, a display unit 73, a storage unit 76, and a control unit 77. The operation unit 72 is an operation means by which the user performs various operations to operate the control device 7, and includes, for example, a pointing device such as a mouse and a keyboard. The display unit 73 is configured with, for example, a liquid crystal display, an organic EL display, or other display, and displays various information based on a display signal from the control unit 77. The display unit 73 may be a touch panel that also serves as part of the operation unit 72, or may output audio.

[0038] The storage unit 76 is a memory configured by a RAM (Random Access Memory), a ROM (Read Only Memory), etc., and stores various programs and data, and also functions as a work area for the control unit 77. The memory unit 76 of this embodiment pre-stores a bundling program 761 and a rebar arrangement model 764 for executing the bundling process described below, as well as image data 762 and work information 763 acquired during the bundling process.

[0039] The image data 762 is image information of the workpiece B (reinforcing bar S) acquired by the first camera 31 and the second camera 51 during the execution of the bundling process, which will be described later. The work information 763 is various information related to the bundling work. Specific contents of the work information 763 will be described later. The reinforcing bar arrangement model 764 is arrangement information of multiple reinforcing bars S in the workpiece B to be worked on, and includes, for example, information on the number of reinforcing bars S arranged in each of the X, Y, and Z directions. In addition, it may include information such as the spacing between the reinforcing bars S in each of the X, Y, and Z directions, and, if the reinforcing bars S are inclined, information on the angle of the inclination. The storage unit 76 may also store various data other than those described above, which are acquired during the execution of the bundling process described below.

[0040] The control unit 77 is configured by, for example, a CPU (Central Processing Unit) and controls the operation of each unit of the control device 7. Specifically, the control unit 77 operates each unit of the control device 7 based on the operation content of the operation unit 72, deploys a program stored in advance in the storage unit 76, and executes various processes in cooperation with the deployed program.

[0041] [Bundling system operation] Next, the operation of the bundling system 1 when performing the bundling process for bundling the workpiece B will be described. Figures 4 and 5 are flowcharts showing the steps of the bundling process, and Figures 6 to 9 are figures for explaining the bundling process, where Figure 6 is an example of image data of work B acquired by the first camera 31, Figure 7 is an oblique view of the device main body 10 after work B has been moved to the bundling area E2, Figure 8A is an example of image data of the target intersection Pa acquired by the second camera 51, Figure 8B is an example of image data in which height information of the reinforcing bar S and other positions has been added to Figure 8A, and Figure 9 is a figure for explaining the shape of the reinforcing bar S detected from the image data.

[0042] In the bundling process, a plurality of reinforcing bars S arranged in a lattice pattern along each of the X and Y directions are bundled at intersections P (see FIG. 6) where the plurality of reinforcing bars S intersect. This bundling process is executed by the control unit 77 of the control device 7 reading and developing the bundling program 761 from the storage unit 76. Here, it is assumed that the work B is placed in advance on the support table 21 and placed in the photographing area E1 (see FIG. 1). In the following description, each step is assumed to be executed solely by the control device 7 (controller 77 thereof), but the entity that controls the bundling process is not particularly limited. For example, each component of the bundling system 1 (controller) may execute the steps, or the control device 7 and each component may execute the steps in cooperation with each other.

[0043] As shown in FIG. 4, when the bundling process is executed, first, the control unit 77 of the control device 7 photographs the workpiece B in the photographing area E1 with the first camera 31 of the whole photographing unit 3 (step S1). Here, the control unit 77 acquires image data (monochrome image) of the XY plane including distance information for the entire workpiece B using the first camera 31, which is a stereo camera, and stores the image data in the storage unit . More specifically, the control unit 77 controls the movement mechanism 32 to move the first camera 31 within the XY plane according to the size of the work B, the angle of view of the first camera 31, etc., and photographs the entire work B by dividing it into multiple parts with some overlapping (for example, dividing it into four parts, 2 x 2 in each of the X and Y directions).The control unit 77 then combines the multiple acquired images to generate an image of the entire work B, and stores it in the storage unit 76. As a result, image data 762a including the entire workpiece B, as shown in FIG. 6, for example, is acquired.

[0044] In step S1, it is sufficient to acquire signal information related to the multiple reinforcing bars S to be bundled. Here, "signal information related to the reinforcing bars S" is data including at least one of position information of the reinforcing bars S and position information of obstacles that may hinder the bundling of the reinforcing bars S. Furthermore, the data format of the signal information is not limited to image data, but broadly includes electromagnetic data including optical signals.

[0045] Next, the control unit 77 calculates the positions of all intersections P included in the workpiece B based on the image data acquired in step S1 (step S2). Here, the control unit 77 calculates three-dimensional position information including each of the X, Y and Z coordinates for each intersection point P. In this step, it is sufficient to calculate the positions of a plurality of intersections P among all the intersections P that the workpiece B has. Here, the position of the intersection point P may be calculated using a rebar arrangement model (the intersection shape of intersecting rebars). In this case, when the shape matches the rebar arrangement model, it is regarded as the intersection point P, making it easier to calculate the position.

[0046] Next, as shown in FIG. 7, the control unit 77 drives the drive motor 23 of the workpiece holder 2 to operate the holder 21, thereby moving the workpiece B to the bundling area E2 (step S3).

[0047] Next, the control unit 77 selects an intersection P to be bound from among the plurality of intersections P included in the work B (step S4). Here, the control unit 77 selects one intersection P to be bound next from among a plurality of intersections P excluding intersections P that have already been bound (or that have been recognized as having been bound), for example, based on a predetermined binding order. Hereinafter, the intersection P selected here as the next target for binding will be referred to as the "target intersection Pa."

[0048] Next, the control unit 77 causes the second camera 51 of the individual photographing unit 5 mounted on the robot arm 4 to approach the target intersection Pa selected in step S4 in the bundling area E2 (step S5). Here, the control unit 77 controls the operation of the robot arm 4 based on the position information of the target intersection Pa calculated in step S2 and the amount of movement in the X direction of the workpiece B moved in step S3, and moves the second camera 51 to directly above the target intersection Pa. Then, the control unit 77 controls the operation of the lift motor 52 to lower the second camera 51 and bring it within a predetermined distance from the target intersection Pa. As a result, the target intersection Pa is positioned immediately in front of the second camera 51 facing downward, and, for example, only the target intersection Pa falls within the angle of view of the second camera 51 (intersections P other than the target intersection Pa are outside the angle of view).

[0049] Next, the control unit 77 causes the second camera 51, which has been brought close in step S5, to photograph the target intersection Pa and acquire its image data (step S6). Here, the control unit 77 acquires image data (color image) of the target intersection Pa by the second camera 51, and stores it in the storage unit . As a result, as shown in FIG. 8A, for example, image data 762b of the target intersection point Pa is obtained, which has a higher resolution than the image data acquired by the first camera 31 in step S1. In this step, it is sufficient to acquire signal information for at least one of the multiple intersections P. More specifically, it is sufficient to acquire signal information for a smaller number of intersections P than the multiple intersections P for which signal information was acquired by the first camera 31 in step S1. In this step, the control unit 77 may also control the lighting unit 53 to capture images of the target intersection Pa using a plurality of different lighting patterns, thereby generating a three-dimensional image based on changes in the patterns of projected and reflected light, and acquiring distance information.

[0050] Next, the control unit 77 calculates the position of the target intersection Pa based on the image data acquired in step S6 (step S7).

[0051] 5, in calculating the target intersection Pa, the control unit 77 first detects the edge of the reinforcing bar S, which is the contour in the image of the reinforcing bar S, based on contrast information included in the image data of the reinforcing bar S (step S71). Here, the contour (edge) refers to the boundary between the target reinforcing bar S and other parts in the target image. At this time, the control unit 77 binarizes the image data and performs edge detection by scanning from the white side (bright part) to the black side (dark part) (i.e., from the part with a weak signal to the part with a strong signal). However, the image data may not be completely binarized, but may be grayscaled at a predetermined number of gradations. Specifically, in the case of the example of image data 762d shown in FIG. 9, the control unit 77 checks the contrast value, for example, from one side to the other in the X direction. Then, it detects (extracts) a portion where the contrast changes more than a predetermined threshold as an edge Se of the reinforcing bar S. Next, the control unit 77 similarly detects edges Se from the other side to the one side in the X direction. At this time, it confirms that they are both ends of the same reinforcing bar S based on the difference in contrast change from the previously detected edge Se. This detects two edges Se along the Y direction. In the same way, the control unit 77 then detects edges Se along the Y direction and detects two edges Se along the X direction.

[0052] Next, the control unit 77 calculates the reinforcing bar diameter (diameter of the reinforcing bar S) and the reinforcing bar center (central axis along the longitudinal direction of the reinforcing bar S) based on the position information of the edge Se (step S72). Here, since the reinforcing bar S is approximately cylindrical, the control unit 77 determines the distance between the edges Se as the reinforcing bar diameter D, and determines the line passing through the center of two edges Se in the same direction as the reinforcing bar center Ax. Here, detailed dimensions of the reinforcing bar S in the height direction (Z direction) can also be obtained.

[0053] Next, the control unit 77 calculates the position of the target intersection Pa (step S73). Here, the control unit 77 determines the position (coordinates) of the target intersection point Pa as, for example, the intersection point of two reinforcing bar centers Ax. Here, the dimensions of the target intersection point Pa can also be obtained from the dimensions of the reinforcing bar S in each of the X and Y directions. In this way, based on the high-resolution image data acquired by the second camera 51, position information of the target intersection Pa with higher accuracy than the position information calculated in step S2 is obtained.

[0054] Next, the control unit 77 calculates the distance from the second camera 51 to the target intersection Pa of the reinforcing bar S (step S74). Here, the control unit 77 acquires height information along the Z direction based on the image data, and determines the distance between the second camera 51 and the target intersection Pa. Regarding distance, image data 762c in FIG. 8B is shown, in which height information of the rebars and other positions, including the target intersection Pa, is added to image data 762b in FIG. 8A. In this way, the acquired height information can determine the distance at which the binding device 6 can approach the target intersection Pa. Here, the amount of gap in the Z direction between the two rebars S at the target intersection Pa can also be acquired.

[0055] Next, the control unit 77 compares the shape information of the reinforcing bars S obtained in the steps up to this point with the reinforcing bar arrangement model 764 of the workpiece B (step S75). Here, the control unit 77 reads out the rebar arrangement model 764 of the work B stored in advance in the storage unit 76 and compares it with the calculated shape information of the rebar S. This allows the control unit 77 to identify the target intersection Pa that is the binding target and confirm the type of rebar combination. In addition to the above, the information on the target intersection Pa may be compared with the information on other intersections P acquired in step S1 or step S6 to identify the target intersection Pa. For example, at an intersection formed by two rebars S along each of the X and Y directions, there is a risk that the image data may mistakenly recognize it as an intersection P where one thick rebar S intersects with another thick rebar S, but by comparing it with the results of other intersections P next to the target intersection Pa or other intersections P present in the same work B, the target intersection Pa can be identified and the type of rebar combination confirmed.

[0056] Next, the control unit 77 determines whether or not the target intersection Pa can be bound (step S76). Here, the control unit 77 determines whether or not a key part of the binding device 6 (such as the curl guide 613) can be inserted between the two rebars S from above, for example, based on the intersection angle of the two rebars S. If it determines that insertion is possible, it determines that binding is possible. If it determines that binding is not possible, the control unit 77 proceeds to other processing, such as suspending the work or issuing a warning. Alternatively, the robot arm 4 and the binding device 6 may be configured to be detachable, and multiple binding devices 6 with different sized insertion sections (portions to be inserted between the rebars S) may be prepared, and the binding device 6 corresponding to the target intersection Pa may be selected. That is, in this case, the control unit 77 selects one of the multiple binding devices 6 that can bind the target intersection Pa of the binding target. In this case, multiple binding devices 6 may be arranged at predetermined positions within the movement range of the robot arm 4, and the robot arm 4 may automatically replace the binding device 6. Here, the control unit 77 determines the binding direction based on the position, posture, etc. of the binding device 6 that can insert a main part between the two reinforcing bars S.

[0057] Next, the control unit 77 calculates the wire length required for bundling the target intersection Pa (step S77). Here, the control unit 77 calculates the length of the wire W (including the pull-back length) required for bundling the two reinforcing bars S that make up the target intersection Pa based on the reinforcing bar diameter D, the intersection angle, etc. Here, the control unit 77 may also set the rotation amount of the wire feed unit (the operation amount of the feed motor 615) when the wire W is bundled (pulled back) by the binding device 6.

[0058] Next, as shown in FIG. 4, the control unit 77 moves the binding device 6 closer to the target intersection Pa based on the position information of the target intersection Pa calculated in step S7 (S73) (step S8). Here, the control unit 77 controls the operation of the robot arm 4, and brings the binding device 6 mounted on the end effector 43, instead of the second camera 51, closer to the target intersection Pa. At this time, the control unit 77 can position the relevant part of the binding device 6 to face the target intersection Pa with high positional accuracy based on the more accurate positional information of the target intersection Pa obtained in step S7.

[0059] Next, the control unit 77 operates the binding device 6 to bind the target intersection Pa with the wire W (step S9). At this time, the binding device 6 is disposed opposite the target intersection Pa with sufficiently high positional accuracy, and therefore the target intersection Pa can be bound suitably. At this time, the amount of wire W used to bind the target intersection Pa may be calculated and stored in the storage unit 76. The amount of wire W used may be estimated from the actual wire feed amount (not including the amount of retraction) in the wire feed unit. The wire length required for binding, estimated prior to binding in step S77 above, may also be used as the amount of wire W used.

[0060] Next, the control unit 77 determines whether or not to end the bundling process (step S10), and if it determines not to end the bundling process (step S10; No), the process proceeds to step S4 described above. As a result, the processing of steps S4 to S10 is repeated until, for example, all the necessary intersections P are bound. That is, the selection of the next intersection P to be bound (changing the target intersection Pa), and the photographing and binding of the target intersection Pa are sequentially executed. Then, in step S10, when it is determined that the bundling process should be ended because, for example, all the necessary intersections P have been bundled (step S10; Yes), the control unit 77 ends the bundling process.

[0061] [Technical effect of this embodiment] As described above, according to this embodiment, the shape of the reinforcing bar S is detected based on the contrast information contained in the image data (signal information) of the reinforcing bar S. This allows the position of the reinforcing bar S to be determined based on the change in contrast, and shape information of the reinforcing bar S, such as the reinforcing bar diameter D and the reinforcing bar center Ax, to be obtained. Therefore, it is possible to suitably detect the shape of the reinforcing bar S. Furthermore, it is also possible to select an optimum binding device 6 based on the reinforcing bar diameter D, for example.

[0062] Furthermore, according to this embodiment, the edges (contours) Se of the reinforcing bars S are detected based on the contrast information of the image data. Therefore, the shape of the reinforcing bar S can be suitably detected from the image data of the reinforcing bar S. However, if the shape of the reinforcing bar S can be detected based on the contrast information, a portion other than the edge Se may be used.

[0063] Furthermore, according to this embodiment, the distance from the second camera 51 to the reinforcing bar S is calculated based on the image data of the reinforcing bar S. This makes it possible to confirm the amount of movement of the binding device 6 required for binding the rebar S (target intersection Pa). Also, compared to using a 3D sensor, distance information (height information) can be obtained by simple processing of two-dimensional image data. Furthermore, the gap in the height direction between the two rebars S at the target intersection Pa can also be confirmed.

[0064] Furthermore, according to this embodiment, the length of the wire W required for bundling is calculated (estimated) based on the image data. This makes it possible to detect a shortage of wire W in advance of the actual bundling work, for example, by comparing the remaining amount of wire.

[0065] Furthermore, according to this embodiment, the detection of the edge Se of the reinforcing bar S is performed from the light portion to the dark portion (from the portion with a weak signal to the portion with a strong signal) in the image data (signal information) of the reinforcing bar S. This makes it easy to detect the intersection point P even when the types of reinforcement are different (for example, differences in thickness, number of reinforcements, etc.).

[0066] Furthermore, according to this embodiment, the amount of wire W used to bind the target intersection Pa may be calculated and stored. This allows the remaining amount of wire in the binding device 6 to be known.

[0067] Furthermore, according to this embodiment, image data (signal information) of the reinforcing bar S (target intersection Pa) after binding may be acquired, and the binding state may be determined based on the image data. The image may be taken by either the second camera 51 or the first camera 31. Specifically, the wire W protruding from the edge Se of the target intersection Pa may be detected, and if the protruding wire W protrudes longer than a predetermined threshold, it may be determined that the binding state of the target intersection Pa is not good. This allows the binding state to be determined easily.

[0068] [Variations] Although the embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments. For example, in the above embodiment, the shape of the reinforcing bar S is determined based on image data acquired by the second camera 51. However, if the target is image data of the reinforcing bar S, image data acquired by the first camera 31 may be used, and even in this case, the bundling process (steps S71 to S77) can be performed in substantially the same manner as in the above embodiment. However, in this case, unlike the above embodiment, the image data contains multiple intersection points P, and based mainly on this point, the following processing may be further executed after step S77, as shown in Fig. 10. In this case, the processing of steps S71 to S77 is executed for each intersection point P. In addition, in the processing of steps S71 to S77 in this case, the "target intersection point Pa" is simply read as "intersection point P."

[0069] Specifically, after executing step S77, the control unit 77 acquires position information of multiple intersections P (step S78a), and detects the ends of the work B (multiple reinforcing bars S) based on the position information (step S78b). Here, the control unit 77 determines whether or not the intersections P are continuous (whether or not adjacent intersections P exist), thereby detecting the intersections P that are located at the ends among the plurality of intersections P. This makes it possible to grasp the overall shape and size of the workpiece B, and determine the range of the work target. As a result, it is possible to plan the movement path of the robot arm 4, for example.

[0070] Next, the control unit 77 detects an obstacle that may hinder bundling based on the image data of the reinforcing bar S (step S79a). Here, the control unit 77 determines that an obstacle exists at each intersection P if the height position of the intersection P differs from other intersections P by a predetermined threshold or more based on the height (Z direction) position of the intersection P. This allows the worker to continue working while avoiding contact with the obstacle, for example, by moving around the obstacle or by changing the binding direction so as not to interfere with the obstacle.

[0071] Next, the control unit 77 selects one of the intersections P based on predetermined selection conditions (step S80a). Here, the control unit 77 selects the intersection P that best matches the selection conditions, such as the shape of the intersection P that can be bound or the arrangement pattern of multiple intersections P, which are stored in advance in the storage unit 76. The selected intersection P may be the target intersection Pa. This allows the intersections P to be bound to be bound in a suitable manner even if they have various patterns. Here, it may be determined based on the above selection conditions whether or not the intersection P can be bound. In other words, an intersection P that does not meet the selection conditions may be determined as not being able to be bound. This allows intersections P that are difficult to bundle to be selected in advance, and reduces the occurrence of errors that make bundling impossible during actual work.

[0072] If the image data includes multiple intersections P, the comparison with the rebar array model 764 in step S75 identifies the approximate positions of the intersections P for comparison and determination, thereby shortening the determination time. Also, by comparing with the rebar array model 764, it is easier to identify the actual intersection locations.

[0073] [Other variations] Furthermore, in the above embodiment, work information related to the binding work performed by the binding device 6 may be stored in the storage unit 76. Here, "work information" refers to information related to the binding work performed in the binding area E2, and includes, for example, position information (XYZ coordinates), whether binding is possible, the binding direction (angle), the number of times binding is performed, the binding strength, the binding order, etc. Furthermore, the "work information" may include work log information such as the operation details of the robot arm 4 and the binding device 6 in each binding operation. This allows work information relating to the bundling work to be recorded at any time and output as appropriate.

[0074] In the above embodiment, the photographing area E1 (first area) and the bundling area E2 (second area) are different from each other. However, the photographing area E1 and the bundling area E2 may partially overlap or may be integrated (identical).

[0075] Furthermore, it is preferable that the position of an obstacle can be grasped and the insertion direction of the binding device 6 (access route to the intersection P) can be set taking the obstacle into consideration, regardless of whether the signal information is acquired by the first camera 31 or the second camera 51. Furthermore, the data format of the signal information acquired by first camera 31 and second camera 51 is not particularly limited, but if it is image data, it is preferable that one is a monochrome image and the other is a color image. Furthermore, it is preferable that the position information of the obstacle can be acquired in any of the X, Y, and Z directions. In other words, by grasping the position of the obstacle three-dimensionally, the robot arm 4 can perform the task without coming into contact with the obstacle.

[0076] Furthermore, in the above embodiment, the workpiece holder 2 moves the workpiece B in the X direction, but it may also be possible to move or rotate the workpiece B in other directions. For example, if the workpiece holder 2 can rotate the workpiece B around a horizontal axis to invert the top and bottom surfaces, it can be used effectively for workpieces B with double reinforcement on the top and bottom.

[0077] Furthermore, the image information according to the present invention is not particularly limited to a particular data type (data format) as long as it is essentially image data having contrast information of the reinforcing bars that are the subject of imaging.

[0078] In the above embodiment, an example in which the present invention is applied to a robot arm system using a robot arm has been described. However, the present invention can also be suitably applied to binding methods other than the robot arm method, such as a work transport method in which the work is transported, a gantry method in which the device is moved by a gantry, and a self-propelled method in which the entire device including the binding device is self-propelled above the work. However, the present invention is more suitable for use in a system in which the entire device is installed (fixed) indoors and the workpiece is moved, as in the above embodiment. In the case of a freely moving mobile object such as a self-propelled robot or in outdoor work, applying the structure of the above embodiment can cause problems such as an increased risk of collision with the information acquisition unit, disruption of the acquired signal (camera image) due to a collision, an increase in the size of the entire device, and the need to waterproof the information acquisition unit.

[0079] In addition, the details shown in the above embodiment can be modified as appropriate without departing from the spirit of the invention. [Explanation of symbols]

[0080] 1. Binding System 2 Work holding part 3 Overall Photography Section 31 First camera (information acquisition unit) 4. Robotic Arm 40 Robot arm body 5 Individual Photography Section 51 Second camera (information acquisition unit) 6 Binding device 61 Rebar tying machine 611 Entrance 613 Curl Guide 7 Control Device 76 Memory section 761 Unity Program 762 Image data (image information) 764 Rebar arrangement model (arrangement information) 77 control unit (detection unit, calculation unit, comparison unit, second comparison unit, selection unit, judgment unit) E1 Photo Area E2 Binding Area B Work S rebar Se Edge Ax Rebar center D Rebar diameter P intersection Pa Target intersection W Wire

Claims

1. A bundling system for bundling reinforcing bars with a bundling device based on signal information relating to a plurality of installed reinforcing bars, an information acquisition unit that acquires the signal information; a detection unit that detects the shape of the reinforcing bar based on contrast information included in the signal information; A bundling system comprising:

2. The detection unit detects the outline of the reinforcing bar based on the contrast information. The bundling system of claim 1 .

3. The information acquisition unit calculates the distance to the reinforcing bar based on the signal information. The bundling system of claim 1 .

4. a calculation unit that calculates a wire length required for bundling based on the signal information; The bundling system of claim 1 .

5. The detection unit detects position information of a plurality of intersections of the plurality of intersecting reinforcing bars based on the signal information. The bundling system of claim 1 .

6. the detection unit detects an obstacle that may hinder bundling based on the signal information. The bundling system of claim 1 .

7. A storage unit that stores arrangement information of the plurality of reinforcing bars in advance; a comparison unit that compares the signal information with the sequence information stored in the storage unit; Equipped with The bundling system of claim 1 .

8. The detection unit detects the outline of the reinforcing bar from a weak signal portion to a strong signal portion in the signal information. The bundling system of claim 2 .

9. A second comparison unit is provided that compares the signal information at the intersections of the plurality of intersecting reinforcing bars with the signal information at the intersections. The bundling system of claim 1 .

10. A plurality of binding devices are provided, and a selection unit is provided that selects one of the plurality of binding devices for a binding object. The bundling system of claim 1 .

11. the selection unit determines whether or not the bundling targets can be bundled based on the signal information. The bundling system of claim 10.

12. a binding device that binds the reinforcing bars with wire; a storage unit for storing the amount of wire used; Equipped with The bundling system of claim 1 .

13. the information acquisition unit acquires the signal information after bundling, a determination unit that determines a bundling state based on the signal information after bundling; The bundling system of claim 1 .

14. a computer for controlling the bundling system, the bundling system including an information acquisition unit for acquiring signal information relating to a plurality of installed reinforcing bars; a detection unit that detects the shape of the reinforcing bar based on contrast information included in the signal information; A cohesion program that functions as a

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